DODGE RAM 2003 Service Repair Manual

Inspect the piston pin for nicks, gouges and exces-
sive wear. Measure the pin diameter (Fig. 93). The
minimum diameter is 39.990 mm (1.5744 inch), max-
imum 40.003 mm (1.5749 inch). If the diameter is out
of limits, replace the pin.
INSPECTIONÐCONNECTING ROD
Inspect the connecting rod for damage and wear.
The I-Beam section of the connecting rod cannot have
dents or other damage. Damage to this part can
cause stress risers which will progress to breakage.
Measure the connecting rod pin bore (Fig. 94). The
maximum diameter is 40.042 mm (1.5765 inch), min-
imum diameter is 40.019 mm (1.5756 inch). If out of
limits, replace the connecting rod.
INSTALLATION
(1) Lubricate the cylinder bores with clean engine
oil.
(2) Generously lubricate the rings and piston
skirts with clean engine oil.(3) Compress the rings using a piston ring com-
pressor tool (Fig. 95). If using a strap-type ring com-
pressor, make sure the inside end of the strap does
not hook on a ring gap and break the ring.
(4) Bar the crankshaft so the rod journal for the
piston to be installed is at BDC (Bottom Dead Cen-
ter) - (Fig. 96).
(5) Make sure the front of the piston is oriented
properly according to the marking on the top of the
piston and the numbers on the rod and cap are ori-
ented as illustrated.
(6) Position the piston and rod assembly into the
cylinder bore with the front of the piston oriented
properly according to the stamping in the top of the
piston. In this position the numbers on the connect-
ing rod should be facing the intake or camshaft side
of the engine, and the rod bolt hex heads toward the
oil cooler. Use care when you install the piston and
connecting rod so the cylinder bore is not damaged. If
a fractured split connecting rod is being installed, the
long side of the connecting rod must be installed on
the intake side of the engine.
(7) Push the piston into the bore until the top of
the piston is approximately 50 mm (2 inch) below the
top of the block. Carefully pull the connecting rod
onto the crankshaft journal.
Fig. 93 Piston Pin Diameter
1 - PISTON PIN
Fig. 94 Connecting Rod Pin Bore
1 - CONNECTING ROD
Fig. 95 Piston Ring Compressor Tool
1 - PISTON RING COMPRESSOR TOOL
Fig. 96 Piston/Rod Assembly at BDC
9 - 332 ENGINE 5.9L DIESELDR
PISTON & CONNECTING ROD (Continued)

(8) Use clean engine oil to lubricate the threads
and under the heads of the connecting rod bolts.
(9)For machined connecting rods,the number
stamped on the rod cap at the parting line must
match and be installed towards the intake or cam-
shaft side of the engine (Fig. 97).For fractured/
split type connecting rods,the long end of the rod
must be installed towards the intake side of the
engine.
(a) The connecting rod split/face must face
toward the same side as the piston notch feature
on the skirt. The split face will face toward the oil
cooler side of the engine if properly installed.
(10) Install the rod cap and bolts to the connecting
rod. Tighten the connecting rod bolts evenly in 3
steps.
²Tighten the bolts to 30 N´m (22 ft. lbs.) torque.
²Tighten the bolts to 60 N´m (44 ft. lbs.) torque.
²Rotate 60É clockwise.
(11) The crankshaft must rotate freely. Check for
freedom of rotation as the caps are installed. If the
crankshaft does not rotate freely, check the installa-
tion of the rod bearing and the bearing size.
(12) Measure the side clearance between the con-
necting rod and the crankshaft (Fig. 98). DO NOT
measure the clearance between the cap and crank-
shaft.
(13) Install J-jet piston cooling nozzles if equipped.
(14) Install block stiffener. Torque to 43 N´m (32 ft.
lbs.).
(15) Install the suction tube and oil pan (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).(16) Install the cylinder head onto the engine
(Refer to 9 - ENGINE/CYLINDER HEAD - INSTAL-
LATION).
(17) Install a new filter and fill the crankcase with
new engine oil.
(18) Connect the battery negative cables and start
engine.
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Determine the piston diameter and obtain the
appropriate ring set. The piston rings can be identi-
fied as shown in (Fig. 99).
Fig. 97 Correct Rod Cap Installation
Fig. 98 Side Clearance between Connecting
Rod/Crankshaft
1 - FEELER GAUGE
´Minimum 0.33 mm (.013 inch)
´MAX. 0.10mm (.004 inch)
Fig. 99 Piston Ring Identification
DRENGINE 5.9L DIESEL 9 - 333
PISTON & CONNECTING ROD (Continued)

(2) Position each ring in the cylinder and use a
piston to square it with the bore at a depth of 89.0
mm (3.5 inch) - (Fig. 100).
(3) Use a feeler gauge to measure the piston ring
gap.
PISTON RING GAP CHART
TOP RING 0.26 - 0.36 mm(0.010 - 0.014
in.)
INTERMEDIATE
RING0.85-1.15 mm(0.033 - 0.045
in.)
OIL CONTROL
RING0.25-0.55 mm(0.010 - 0.022
in.)
(4) The top surface of all of the rings are identified
with the word TOP or the supplier's MARK. Assem-
ble the rings with the word TOP or the supplier's
MARK up.
(5) Position the oil ring expander in the oil control
ring groove (bottom groove).
(6) Install the oil control ring with the end gap
OPPOSITE the ends on the expander (Fig. 101).
(7) Install the intermediate piston ring in the sec-
ond groove.
(8) Install the top piston ring in the top groove
(Fig. 102).
(9) Position the rings as shown in (Fig. 103).
Fig. 100 Position of Ring in Cylinder Bore
1 - PISTON
2 - CYLINDER BORE
3 - DEPTH
Fig. 101 Oil Control Ring/Expander Location in
Groove
1 - OIL CONTROL RING
2 - EXPANDER
3 - PISTON
Fig. 102 Piston Ring Installation Tool
1 - PISTON RING INSTALLATION TOOL
Fig. 103 Piston Ring Orientation
1 - TOP RING
2 - INTERMEDIATE RING
3 - OIL CONTROL RING
9 - 334 ENGINE 5.9L DIESELDR
PISTON RINGS (Continued)

VIBRATION DAMPER
REMOVAL
(1) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove the four (4) damper to crankshaft bolts
and remove damper and speed indicator ring.
INSPECTION
(1) Inspect the damper hub for cracks and replace
if any are found.
(2) Inspect the index lines on the damper hub and
the inertia member (Fig. 104). If the lines are more
than 1.59 mm (1/16 in.) out of alignment, replace the
damper.
(3) Inspect the rubber member for deterioration or
missing segments (Fig. 105).
INSTALLATION
(1) Install speed indicator ring.
NOTE: The speed indicator ring is located over a
dowel pin.
(2) Install the crankshaft damper and bolts.
Tighten bolts to 40 N´m (30 ft. lbs.) torque, plus an
additional 60É.
NOTE: The damper must be installed so the hole is
located over the dowel pin.
(3) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
FRONT MOUNT
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the viscous fan/drive assembly (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(3) Raise vehicle on hoist.
(4) Install engine support fixture tool# 8534 and
steel bracket tool # 8534A
(5) Loosen the thru-bolt and nut.
(6) Lift the engine SLIGHTLY and remove the
insulator to block bolts (Fig. 107) (Fig. 106).
(7) Remove the insulator from the vehicle.
INSTALLATION
(1) With engine raised SLIGHTLY, position the
insualtor to the mount (Fig. 108) (Fig. 109). Install
the bolts and torque to specification.
(2)
(3) Lower the engine using tool # 8534, while guid-
ing the mount and thru-bolt into the frame mounted
support cushion brackets.
(4) Install the thru-bolt nut and tighten the nut to
88 N´m (65 ft. lbs.) torque.
(5) Remove the engine support fixture tool #8534.
(6) Lower the vehicle.
(7) Install the viscous fan/drive assembly (Refer to
7 - COOLING/ENGINE/RADIATOR FAN - INSTAL-
LATION).
(8) Connect the battery negative cables.
Fig. 104 Inspect Index Lines for Alignment
1 - INDEX LINES
2 - HUB
3 - INERTIA MEMBER
Fig. 105 Inspect Damper Rubber Member
DRENGINE 5.9L DIESEL 9 - 335

Fig. 106 RH Insulator
1 - Mount
2 - Insulator
3 - Bolt
Fig. 107 LH Insulator
1 - Bolt
2 - Insulator
3 - Mount
Fig. 108 LH Insulator
1 - Bolt
2 - Insulator
3 - Mount
Fig. 109 RH Insulator
1 - Mount
2 - Insulator
3 - Bolt
9 - 336 ENGINE 5.9L DIESELDR
FRONT MOUNT (Continued)

REAR MOUNT
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Position a transmission jack in place.
(3) Remove support cushion stud nuts (Fig. 110).
(4) Raise rear of transmission and engine
SLIGHTLY.
(5) Remove the bolts holding the support cushion
to the transmission support bracket. Remove the sup-
port cushion.
(6) If necessary, remove the bolts holding the
transmission support bracket to the transmission.
INSTALLATION
(1) If removed, position the transmission support
bracket to the transmission. Install new attaching
bolts and tighten to 102 N´m (75 ft. lbs.) torque.
(2) Position support cushion to transmission sup-
port bracket. Install stud nuts and tighten to 47 N´m
(35 ft. lbs.) torque.
(3) Using the transmission jack, lower the trans-
mission and support cushion onto the crossmember
(Fig. 110).
(4) Install the support cushion bolts and tighten to
47 N´m (35 ft. lbs.) torque.
(5) Remove the transmission jack.
(6) Lower the vehicle.
LUBRICATION
DESCRIPTION
NOTE: Refer to (Fig. 111) and (Fig. 112) for circuit
illustrations.
A gear driven gerotor type oil pump is mounted
behind the front gear cover in the lower right portion
on the engine.
OPERATION
A gerotor style oil pump draws oil from the crank-
case through the suction tube and delivers it through
the block where it enters the oil cooler cover and
pressure regulator valve. When oil pressure exceeds
517 kPa (75 PSI), the valve opens exposing the dump
port, which routes excess oil back to the oil pump.
At the same time, oil is directed to a cast in pas-
sage in the oil cooler cover, leading to the oil cooler
element. As the oil travels through the element
plates, it is cooled by engine coolant traveling past
the outside of the plates. It is then routed to the oil
filter head and through a full flow oil filter. If a
plugged filter is encountered, the filter by-pass valve
opens, allowing unfiltered oil to lubricate the engine.
This condition can be avoided by frequent oil and fil-
ter changes, per the maintenance schedules found in
Fig. 110 Engine Rear Support Cushion Assembly
DRENGINE 5.9L DIESEL 9 - 337

the owners manual. The by-pass valve is calibrated
to open when it sees a pressure drop of more than
345 kPa (50 psi) across the oil filter.
The oil filter head then divides the oil between the
engine and the turbocharger. The turbocharger
receives filtered, cooled and pressurized oil through a
supply line from the filter head. The oil lubricates
the turbocharger and returns to the pan by way of a
drain tube connecting the bottom of the turbocharger
to a pressed in tube in the cylinder block.
Oil is then carried across the block to an angle
drilling which intersects the main oil rifle. The main
oil rifle runs the length of the block and delivers oil
to the crankshaft main journals and valve train. Oil
travels to the crankshaft through a series of transfer
drillings (one for each main bearing) and lubricates a
groove in the main bearing upper shell. From there
another drilling feeds the camshaft main journals.
The saddle jet piston cooling nozzles are also sup-
plied by the main bearing upper shell. J-jet piston
cooling nozzles are supplied by a separate oil rifle.
Plugs are used in place of saddle jets when J-jets are
used. J-jet hole locations are plugged when saddle jet
cooling nozzles are used. Crankshaft internal cross-
drillings supply oil to the connecting rod journals.
Another series of transfer drillings intersecting the
main oil rifle supply the valve train components. Oil
travels up the drilling, through a hole in the head
gasket, and through a drilling in the cylinder head
(one per cylinder), where it enters the rocker arm
pedestal and is divided between the intake and
exhaust rocker arm. Oil travels up and around therocker arm mounting bolt, and lubricates the rocker
shaft by cross drillings that intersect the mounting
bolt hole. Grooves at both ends of the rocker shaft
supply oil through the rocker arm where the oil trav-
els to the push rod and socket balls (Fig. 111) and
(Fig. 112).
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE
(1) Remove the 1/8 npt plug from the top of the oil
filter housing.
(2) Install Oil Pressure Line and Gauge Tool
C-3292 with a suitable adapter.
(3) Start engine and warm to operating tempera-
ture.
(4) Record engine oil pressure and compare with
engine oil pressure chart.
CAUTION: If engine oil pressure is zero at idle, DO
NOT RUN THE ENGINE.
Engine Oil Pressure (MIN)
At Idle 68.9 kPa (10 psi)
At 2500 rpm 206.9 kPa (30 psi)
If minimum engine oil pressure is below these
ranges, (Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
(5) Remove oil pressure gauge and install the 1/8
npt plug.
9 - 338 ENGINE 5.9L DIESELDR
LUBRICATION (Continued)

Fig. 111 Lubrication System Circulation
1 - TO FILTER
2 - FROM FILTER
3 - TO MAIN OIL RIFLE
4 - CLOSED
5 - OPEN
6 - TO COOLER7 - FROM PUMP
8 - CLOSED
9 - OPEN
10 - OIL DRAINS BACK TO THE PUMP
11 - OIL DRAIN
12 - OIL SUPPLY
DRENGINE 5.9L DIESEL 9 - 339
LUBRICATION (Continued)

Fig. 112 Lubrication System CirculationÐCont'd
9 - 340 ENGINE 5.9L DIESELDR
LUBRICATION (Continued)

OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL LEVEL
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
To ensure proper lubrication of an engine, the
engine oil must be maintained at an acceptable level.
The acceptable oil level is in the SAFE RANGE on
the engine oil dipstick (Fig. 113).
Unless the engine has exhibited loss of oil pres-
sure, run the engine for about five minutes before
checking oil level. Checking engine oil level of a cold
engine is not accurate.
(1) Position vehicle on level surface.
(2) With engine OFF, allow approximately ten min-
utes for oil to settle to bottom of crankcase, remove
engine oil dipstick.
(3) Wipe dipstick clean.
(4) Replace dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the SAFE RANGE
area on the dipstick.
(7) Replace dipstick
STANDARD PROCEDURE - ENGINE OIL
SERVICE
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
NOTE: Change engine oil and filter at intervals
specified in the owner's manual.
(1) Operate the engine until the water tempera-
ture reaches 60ÉC (140ÉF). Shut the engine off.
(2) Use a container that can hold at least 14 liters
(15 quarts) to hold the used oil. Remove the oil drain
plug and drain the used engine oil into the container.
(3) Always check the condition of the used oil. This
can give you an indication of engine problems that
might exist.
²Thin, black oil indicates fuel dilution.
²Milky discoloration indicates coolant dilution.
(4) Clean the area around the oil filter head.
Remove the filter (Refer to 9 - ENGINE/LUBRICA-
TION/OIL FILTER - REMOVAL).
(5) Install new oil filter (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION).
(6) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and seal-
ing surface on the oil pan and drain plug.
(7) Install the drain plug. Tighten the plug to 50
N´m (37 ft. lbs.) torque.
(8) Use only High-Quality Multi-Viscosity lubricat-
ing oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(9) Fill the engine with the correct grade of new oil
(Refer to LUBRICATION & MAINTENANCE/FLUID
CAPACITIES - SPECIFICATIONS).
(10) Start the engine and operate it at idle for sev-
eral minutes. Check for leaks at the filter and drain
plug.
(11) Stop engine. Wait several minutes to allow the
oil to drain back to the pan and check the level
again.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing of used
engine oil after it has been drained from a vehicle's
engine.
1 - ROCKER ARM
2 - ROCKER SHAFT
3 - PEDESTAL
4 - FROM MAIN OIL RIFLE
5 - TO VALVE TRAIN
6 - MAIN OIL RIFLE
7 - FROM MAIN OIL RIFLE8 - TO CAMSHAFT
9 - TO PISTON COOLING NOZZLE
10 - FROM OIL COOLER
11 - CRANKSHAFT MAIN JOURNAL
12 - ROD JOURNAL
13 - TO ROD BEARING
14 - MAIN OIL RIFLE
Fig. 113 Oil Level Indicator (Dipstick)
1 - ADD OIL MARK
2 - O-RING
3 - SAFE RANGE
DRENGINE 5.9L DIESEL 9 - 341
OIL (Continued)