fuel DODGE RAM 2003 Service Repair Manual

WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPMs occur, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL).
(4) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner.
(7) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel lines (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect the accelerator linkage (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL) and if so equipped,
the speed control and transmission kickdown cables.
(9) Remove the return spring.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the heat indicator sending unit
wire.
(13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear end seals.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 68). Dis-
card the gasket.
(19) If required, remove the plenum pan and gas-
ket. Discard gasket.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.Clean cylinder block gasket surfaces using a suit-
able solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) If removed, position new plenum gasket and
install plenum pan (Fig. 69).
(2) Tighten plenum pan mounting bolts as follows:
²Step 1. Tighten bolts to 5.4 N´m (48 in. lbs.)
²Step 2. Tighten bolts to 9.5 N´m (84 in. lbs.)
²Step 3. Check all bolts are at 9.5 N´m (84 in.
lbs.)
(3) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 71). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(4) Apply MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, to the four corner joints.
An excessive amount of sealant is not required to
ensure a leak proof seal. However, an excessive
amount of sealant may reduce the effectiveness of
the flange gasket. The sealant should be approxi-
mately 5 mm (0.2 in) in diameter and 15 mm (0.6 in.)
long.
Fig. 68 Throttle Body Assembly
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
DRENGINE - 5.9L 9 - 275
INTAKE MANIFOLD (Continued)

(5)Install the front and rear end seals (Fig. 70) Make
sure the molded dowel pins on the end seals fully enter the
corresponding holes in the cylinder block.
(6)Carefully lower intake manifold into position on
the cylinder block and cylinder heads. After intake man-
ifold is in place, inspect to make sure seals are in place.
(7) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N´m
(200 in. lbs.) torque.(8) Install the intake manifold bolts and tighten as
follows (Fig. 72):
²Step 1. Tighten bolts 1 through 4 to 8 N´m (72
in. lbs.) Tighten in alternating steps 1.4 N´m (12 in.
lbs.) at a time
²Step 2. Tighten bolts 5 through 12 to 8 N´m (72
in. lbs.)
²Step 3. Check all bolts are torqued to 8 N´m (72
in. lbs.)
²Step 4. Tighten all bolts in sequence to 16 N´m
(12 ft. lbs.)
²Step 5. Check all bolts are torqued to 16 N´m
(12 ft. lbs.)
(9) Install closed crankcase ventilation and evapo-
ration control systems.
(10) Connect the coil wires.
(11) Connect the heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Hook up the return spring.
(15) Connect the accelerator linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - INSTALLATION) and if so
Fig. 69 Plenum Pan Bolt Tightening Sequence
Fig. 70 Front and Rear End Seals
1 - FRONT CROSS-OVER GASKET
2 - REAR CROSS-OVER GASKET
Fig. 71 Intake Manifold Flange Gasket Alignment
1 - FLANGE GASKET
2 - ALIGNMENT TABS
3 - CYLINDER HEAD GASKET
9 - 276 ENGINE - 5.9LDR
INTAKE MANIFOLD (Continued)

equipped, the speed control and transmission kick-
down cables.
(16) Install the fuel lines (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(17) Install the accessory drive bracket and A/C
compressor (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
INSTALLATION).
(18) Install the generator and drive belt (Refer to 7
- COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION). Tighten generator mounting bolt
to 41 N´m (30 ft. lbs.) torque.
(19) Install the air cleaner.
(20) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(21) Connect the negative cable to the battery.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds (Fig. 73) are constructed of
cast iron and are LOG type with balanced flow. One
exhaust manifold is attached to each cylinder head.
OPERATION
The exhaust manifolds collect the engine exhaust
exiting the combustion chambers, then channels the
exhaust gases to the exhaust pipes attached to the
manifolds.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise and support the vehicle.
(3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold.
(4) Lower the vehicle.
(5) Remove the exhaust heat shields.(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold from the cylinder head.
CLEANING
Clean mating surfaces on cylinder head and mani-
fold. Wash with solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straight edge. Gasket surfaces must be flat
within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
CAUTION: If the studs came out with the nuts when
removing the engine exhaust manifold, install new
studs. Apply sealer on the coarse thread ends.
Water leaks may develop at the studs if this precau-
tion is not taken.
(1) Position the engine exhaust manifolds on the
two studs located on the cylinder head. Install coni-
cal washers and nuts on these studs (Fig. 74).
(2) Install two bolts and conical washers at the
inner ends of the engine exhaust manifold outboard
arms. Install two bolts WITHOUT washers on the
center arm of engine exhaust manifold (Fig. 74).
Starting at the center arm and working outward,
tighten the bolts and nuts to 34 N´m (25 ft. lbs.)
torque.
(3) Install the exhaust heat shields.
(4) Raise and support the vehicle.
Fig. 72 Intake Manifold Bolt Tightening SequenceFig. 73 Exhaust ManifoldsÐV-8 Gas Engines Typical
1 - EXHAUST MANIFOLD (LEFT)
2 - BOLTS & WASHERS
3 - NUTS & WASHERS
4 - EXHAUST MANIFOLD (RIGHT)
5 - BOLTS & WASHERS
DRENGINE - 5.9L 9 - 277
INTAKE MANIFOLD (Continued)

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL
PRESSURE LOW1. Low oil level. 1. (a) Check and fill with clean engine oil.
(b) Check for a severe external oil leak that
could reduce the pressure.
2. Oil viscosity thin, diluted or wrong
specification.2. (a) Verify the correct engine oil is being
used. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
2. (b) Look for reduced viscosity from fuel
dilution.
3. Improperly operating pressure
switch/gauge.3. Verify the pressure switch is functioning
correctly. If not, replace switch/gauge.
4. Relief valve stuck open. 4. Check/replace valve.
6. If cooler was replaced, shipping
plugs may have been left in cooler6. Check/remove shipping plugs.
7. Worn oil pump. 7. Check and replace oil pump.
8. Suction tube loose or seal leaking. 8. Check and replace seal.
9. Loose main bearing cap. 9. Check and install new bearing. Tighten
cap to proper torque.
10. Worn bearings or wrong bearings
installed.10. Inspect and replace connecting rod or
main bearings. Check and replace directed
piston cooling nozzles.
11. Directed piston cooling nozzles
under piston, bad fit into main
carrier.11. Check directed piston cooling nozzles
position.
12. Loose oil rifle plug with saddle-jet
style nozzles12.Tighten oil rifle plug.
13. Loose directed piston cooling
nozzle.13. Tighten directed piston cooling nozzle.
14. Both J-jet and saddle jet style
cooling nozzle installed.14. Install correct style jet.
LUBRICATING OIL
PRESSURE TOO HIGH1. Pressure switch/gauge not
operating properly.1. Verify pressure switch is functioning
correctly. If not, replace switch/gauge.
2. Engine running too cold. 2. Refer to Coolant Temperature Below
Normal (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
3. Oil viscosity too thick. 3. Make sure the correct oil is being used.
(Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
4. Oil pressure relief valve stuck
closed or binding4. Check and replace valve.
DRENGINE 5.9L DIESEL 9 - 283
ENGINE 5.9L DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as
required.
2. Crankcase being overfilled. 2. Verify that the correct dipstick is being
used.
3. Incorrect oil specification or
viscosity.3. (a) Make sure the correct oil is being
used (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(b) Look for reduced viscosity from dilution
with fuel.
(c) Review/reduce oil change intervals.
4. Oil cooler leak 4. Check and replace the oil cooler.
5. High blow-by forcing oil out the
breather.5. Check the breather tube area for signs of
oil loss. Perform the required repairs.
6. Turbocharger leaking oil to the air
intake.6. Inspect the air ducts for evidence of oil
transfer. Repair as required.
COMPRESSION KNOCKS 1. Air in the fuel system. 1. Identify location of air leak and repair. Do
not bleed high pressure fuel system.
2. Poor quality fuel or water/gasoline
contaminated fuel.2. Verify by operating from a temporary
tank with good fuel. Clean and flush the
fuel tank. Replace fuel/water separator filter.
3. Engine overloaded. 3. Verify the engine load rating is not being
exceeded.
4. Improperly operating injectors. 5. Check and replace misfiring/inoperative
injectors.
EXCESSIVE VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts.
2. Damaged fan or improperly
operating accessories.2. Check and replace the vibrating
components.
3. Improperly operating vibration
damper3. Inspect/replace vibration damper.
4. Improperly operating electronically
controlled viscous fan drive.4. Inspect/replace fan drive.
5. Worn or damaged generator
bearing.5. Check/replace generator.
6. Flywheel housing misaligned. 6. Check/correct flywheel alignment.
7. Loose or broken power
component.7. Inspect the crankshaft and rods for
damage that causes an unbalance
condition. Repair/replace as required.
8. Worn or unbalanced driveline
components.8. Check/repair driveline components.
EXCESSIVE ENGINE
NOISES1. Drive belt squeal, insufficient
tension or abnormally high loading.1. Check the automatic tensioner and
inspect the drive belt. Make sure water
pump, tensioner pulley, fan hub, generator
and power steering pump turn freely.
2. Intake air or exhaust leaks. 2. Refer to Excessive Exhaust Smoke
(Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
9 - 284 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
3. Excessive valve lash. 3. Adjust valves. Make sure the push rods
are not bent and rocker arms, adjusting
screws, crossheads, are not severely worn.
Replace bent or severely worn components.
4. Turbocharger noise. 4. Check turbocharger impeller and turbine
wheel for housing contact. Repair/replace
as required.
5. Gear train noise. 5. Visually inspect and measure gear
backlash. Replace gears as required.
6. Power function knock. 6. Check/replace rod and main bearings.
DIAGNOSIS AND TESTINGÐSMOKE
DIAGNOSIS CHARTS
The following charts include possible causes and
corrections forexcess or abnormalexhaust smoke.Small amounts of exhaust smoke (at certain times)
are to be considered normal for a diesel powered
engine.
EXCESSIVE BLACK SMOKE
POSSIBLE CAUSE CORRECTION
Air filter dirty or plugged. Check Filter MinderTat air filter (Refer to 9 - ENGINE/
AIR INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
Air intake system restricted. Check entire air intake system including all hoses and
tubes for restrictions, collapsed parts or damage.
Repair/replace as necessary.
Air Leak in Intake System. Check entire air intake system including all hoses and
tubes for cracks, loose clamps and/or holes in rubber
ducts. Also check intake manifold for loose mounting
hardware.
Diagnostic Trouble Codes (DTC's) active or multiple,
intermittent DTC's.Refer to Powertrain Diagnostic Procedures Information.
Engine Control Module (ECM) not calibrated or ECM
has incorrect calibration.Refer to Powertrain Diagnostic Procedures Information.
Exhaust system restriction is above specifications. Check exhaust pipes for damage/restrictions. Repair as
necessary.
Fuel grade is not correct or fuel quality is poor. Temporarily change fuel brands and note condition.
Change brand if necessary.
Fuel injection pump malfunctioning. A DTC may have been set. If so, refer to Powertrain
Diagnostic Procedures Information.
Fuel injector malfunctioning. A DTC may have been set. Perform9Cylinder Cutout
Test9using DRB scan tool to isolate individual
cylinders. Also refer to Powertrain Diagnostic
Procedures Information and, to (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
DIAGNOSIS AND TESTING).
Fuel return system restricted. Check fuel return lines for restriction (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Intake manifold restricted. Remove restriction.
DRENGINE 5.9L DIESEL 9 - 285
ENGINE 5.9L DIESEL (Continued)

EXCESSIVE BLACK SMOKE
POSSIBLE CAUSE CORRECTION
Manifold Air Pressure (Boost) Sensor or sensor circuit
malfunctioning.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Raw fuel in intake manifold. Fuel injectors leaking on engine shutdown. Do Fuel
Injector Test (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - DIAGNOSIS AND
TESTING).
Turbocharger air intake restriction. Remove restriction.
Turbocharger damaged. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
Turbocharger has excess build up on compressor
wheel and/or diffuser vanes.(Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - CLEANING).
Turbocharger wheel clearance out of specification. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Air in fuel supply: Possible leak in fuel supply side
(between transfer pump and fuel tank module).(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL
TRANSFER PUMP - DIAGNOSIS AND TESTING).
Coolant leaking into combustion chamber. Do pressure test of cooling system (Refer to 7 -
COOLING - DIAGNOSIS AND TESTING).
Diagnostic Trouble Codes (DTC's) active or multiple,
intermittent DTC's.Refer to Powertrain Diagnostic Procedures Information.
In very cold ambient temperatures, engine block heater
is malfunctioning (if equipped).(Refer to 7 - COOLING/ENGINE/ENGINE BLOCK
HEATER - REMOVAL).
Engine coolant temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check
thermostat operation (Refer to 7 - COOLING/ENGINE/
ENGINE COOLANT THERMOSTAT - DIAGNOSIS AND
TESTING).
Engine Control Module (ECM) not calibrated or has
incorrect calibration.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel filter plugged. Refer to Powertrain Diagnostic Manual for fuel system
testing.
Fuel grade not correct or fuel quality is poor. Temporarily change fuel brands and note condition.
Change brand if necessary.
Fuel heater element or fuel heater temperature sensor
malfunctioning. This will cause wax type build-up in fuel
filter.Refer to Fuel Heater Testing (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL HEATER -
DIAGNOSIS AND TESTING).
Fuel injector malfunctioning. A DTC should have been set. Perform9Cylinder cutout
Test9using DRB scan tool to isolate individual
cylinders. Also refer to Powertrain Diagnostic
Procedures Information and, (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
DIAGNOSIS AND TESTING).
Fuel injector hold-downs loose. Torque to specifications.
9 - 286 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Fuel injector protrusion not correct. Check washer (shim) at bottom of fuel injector for
correct thickness. (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - INSTALLATION)
Fuel injection pump malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel supply side restriction to transfer pump. Refer to Powertrain Diagnostic Manual for fuel system
testing.
Fuel transfer (lift) pump malfunctioning. A DTC may have been set. Refer to Powertrain
Diagnostic Procedures Information.
Intake/Exhaust valve adjustments not correct (too tight). (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/
EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
Intake manifold air temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Intake manifold heater circuit not functioning correctly in
cold weather.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check heater
elements for correct operation.
Intake manifold heater elements not functioning
correctly in cold weather.A DTC should have been set if heater elements are
malfunctioning. Refer to Powertrain Diagnostic
Procedures Information.
Internal engine damage (scuffed cylinder). Analyze engine oil and inspect oil filter to locate area of
probable damage.
Restriction in fuel supply side of fuel system. Refer to Powertrain Diagnostic Manual for fuel system
testing.
EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Dirty air cleaner or restricted turbocharger intake duct. Check Filter MinderTat air filter housing. (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
ELEMENT - REMOVAL).
Air leak in boost system between turbocharger
compressor outlet and intake manifold.Service air charge system..
Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - REMOVAL).
Restricted turbocharger drain tube. Remove turbocharger drain tube and remove
obstruction.
Crankcase ventilation system plugged. Inspect crankcase ventilation system for function
Valve seals are worn, brittle, or improperly installed. Replace valve stem oil seals (Refer to 9 - ENGINE/
CYLINDER HEAD/INTAKE/EXHAUST VALVES &
SEATS - REMOVAL).
Valve stems and/or guides are worn. Remove valves and inspect valves and guides. (Refer
to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
Broken or Improperly installed piston rings. Tear down engine and inspect piston rings.
DRENGINE 5.9L DIESEL 9 - 287
ENGINE 5.9L DIESEL (Continued)

EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Excessive piston ring end gap. Remove pistons and measure piston ring end gap
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS
- STANDARD PROCEDURE).
Excessive cylinder bore wear and taper. Remove pistons and measure cylinder bore wear and
taper (Refer to 9 - ENGINE/ENGINE BLOCK -
STANDARD PROCEDURE).
Cylinder damage. Remove pistons and inspect cylinder bore for cracks or
porosity. Repair with cylinder liner if necessary. (Refer
to 9 - ENGINE/ENGINE BLOCK - STANDARD
PROCEDURE).
Piston damage. Remove pistons and inspect for cracks, holes. Measure
piston for out-of-round and taper (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECTING
ROD - INSPECTION).
Turbocharger failure. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION/LEAKAGE TESTS
CYLINDER COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure batteries are completely charged and the
engine starter motor is in good operating condition.
Otherwise, the indicated compression pressures may
not be valid for diagnostic purposes.
(1) Disconnect the fuel inlet line to the fuel trans-
fer pump. Plug the fuel line from the fuel tank.
(2) Start the engine and idle until the engine stalls
(runs out of fuel).
(3) Disconnect all three injector wire harness con-
nectors at the rocker housing.
(4) Remove the breather cover and cylinder head
cover.
(5) Remove the high pressure fuel line between the
cylinder head and fuel rail for the cylinder to be
tested.
(6) Remove the exhaust rocker lever.
(7) Use Tool 9010 to remove the injector and cop-
per sealing washer.
(8) Install the exhaust rocker lever and torque to
43 N´m (32 ft. lbs.).
(9) Cover the remaining rocker levers with clean
shop towels to prevent any oil splatter under the
hood.
(10) Place a rag over the compression test tool fit-
ting. Crank the engine for 2±3 seconds to purge any
fuel that may have drained into the cylinder when
the injector was removed.(11) Connect the compression test gauge.
(12) Crank the engine for 5 seconds and record the
pressure reading. Repeat this step three times and
calculate the average of the three readings.
(13) Combustion pressure leakage can be checked
if cylinder pressure is below the specification. Per-
form the leakage test procedure on each cylinder
according to the tester manufacturer instructions.
(14) Upon completion of the test check an erase
any engine related fault codes.
CYLINDER COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss
(1) Start and operate the engine until it attains
normal operating temperature.
(2) Remove the breather cover and cylinder head
cover.
(3) Disconnect all three injector wire harness con-
nectors at the rocker housing.
(4) Bring the cylinder to be tested to TDC.
(5) Remove the high pressure fuel line between the
cylinder head and the fuel rail for the cylinder to be
tested.
(6) Install capping Tool 9011 onto the rail.
(7) Remove the high pressure connector nut and
high pressure connector with Tool 9015.
(8) Remove the exhaust and intake rocker lever.
9 - 288 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Disconnect the negative cable(s) from the bat-
tery.
(2) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(3) Place a shop towel around the fuel injectors to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the fuel injectors (Refer
to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL
INJECTOR - REMOVAL).
(4) With all injectors removed, rotate the crank-
shaft using the crankshaft barring tool (PN 7471±B).
(5) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(6) Be sure all fluid has been removed from the
cylinders.
(7) Repair engine or components as necessary to
prevent this problem from occurring again.
(8) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(9) Install fuel injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
(10) Drain engine oil. Remove and discard the oil
filter (Refer to 9 - ENGINE/LUBRICATION/OIL FIL-
TER - REMOVAL).
(11) Install the drain plug. Tighten the plug to 50
N´m (37 ft. lbs.) torque.
(12) Install a new oil filter (Refer to 9 - ENGINE/
LUBRICATION/OIL FILTER - INSTALLATION).
(13) Fill engine crankcase with the specified
amount and grade of oil (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES - SPECIFICA-
TIONS).
(14) Connect the negative cable(s) to the battery.
(15) Start the engine and check for any leaks.
REMOVAL
REMOVALÐENGINE
(1) Disconnect both battery negative cables.
(2) Disconnect engine grid heater harness at grid
heater relays.(3) Disconnect electrical connections from rear of
alternator.
(4) Recover A/C refrigerant. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
(5) Raise vehicle on a hoist.
(6) Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(7) Remove engine oil drain plug and drain engine
oil.
(8) Remove fan/drive assembly. Refer to Section 7
± Fan/Drive Removal
(9) Remove radiator upper hose.
(10) Remove upper fan shroud mounting bolts.
(11) Disconnect the coolant recovery bottle hose
from the radiator fill neck and remove bottle.
(12) Using a 36mm wrench, remove viscous fan/
drive assembly. (Refer to 7 - COOLING/ENGINE/RA-
DIATOR FAN - REMOVAL).
(13) Remove cooling fan and shroud together.
(14) Disconnect heater core supply and return
hoses from the cylinder head fitting and coolant pipe.
(15) Raise vehicle on a hoist.
(16) Remove transmission and transfer case (if
equipped).
(17) Disconnect exhaust pipe from turbocharger
extension pipe.
(18) Disconnect engine harness to vehicle harness
connectors.
(19) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(20) Remove flywheel/flexplate.
(21) Remove transmission adapter
(22) Disconnect A/C suction/discharge hose from
the rear of the A/C compressor.
(23) Lower vehicle.
(24) Disconnect lower radiator hose from radiator
outlet.
(25) Automatic transmission models:
(26) Disconnect transmission oil cooler lines from
in front of radiator using special tool #6931
(27) Remove radiator. (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(28) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(29) Disconnect charge air cooler piping.
(30) Remove charge air cooler mounting bolts.
(31) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(32) Remove damper and speed indicator ring from
front of engine.
(33) Disconnect engine block heater connector.
(34) Disconnect A/C compressor and pressure sen-
sor electrical connectors.
9 - 290 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)