Transmission DODGE RAM 2003 Service Repair Manual

(13) Reconnect the negative battery cable.
REAR MOUNT
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Using a suitable jack, support transmission.
(3) Remove the nuts from the transmission mount
(Fig. 24).
(4) Remove the two bolts that attach the transmis-
sion mount to the engine bracket.
(5) Raise the transmission enough to remove the
mount from the crossmember.
(6) Remove the mount.
INSTALLATION
NOTE: Threadlocking compound must be applied to
the bolts before installation.
(1) Install the two bolts that attach the transmis-
sion mount to the transmission bracket.
(2) Torque the bolts to 61N´m (45 ft.lbs.) torque.
Fig. 23 ENGINE INSULATOR MOUNTS 4X4
1 - RH INSULATOR TO AXLE BOLT
2 - NUT
3 - PINION SUPPORT MOUNT
4 - LH INSULATOR MOUNT5 - LH INSULATOR TO AXLE BOLT
6 - FRONT AXLE
7 - NUT
8 - RH INSULATOR MOUNT
Fig. 24 TRANSMISSION MOUNT
1 - MOUNT
2 - CROSSMEMBER
3 - NUT
4 - BOLT
DRENGINE - 5.7L 9 - 213
FRONT MOUNT (Continued)

(3) Lower the transmission so the transmission
mount rests on the crossmember, and the studs of
the transmission mount are aligned in the slots in
the crossmember.
(4) Install the nuts onto the transmission mount
studs through the crossmember access slot.
(5) Torque the nuts to 54N´m (40 ft. lbs.).
LUBRICATION
DESCRIPTION
The lubrication system (Fig. 25) is a full flow fil-
tration pressure feed type.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE
(1) Remove oil pressure sending unit and install
gauge assembly C-3292.
(2) Run engine until thermostat opens.
(3) Oil Pressure:
²Curb Idle±25 kPa (4 psi) minimum
²3000 rpm±170 - 758 kPa (25 - 110 psi)
(4) If oil pressure is 0 at idle, shut off engine.
Check for a clogged oil pick-up screen or a pressure
relief valve stuck open.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
Fig. 25 Engine Oil Lubrication System
9 - 214 ENGINE - 5.7LDR
REAR MOUNT (Continued)

STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtGASKET SEALANT
MopartGasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This mate-
rial is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will pre-
vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier than using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
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.
9 - 232 ENGINE - 5.9LDR
ENGINE - 5.9L (Continued)

(1) Perform the Fuel Pressure Release Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(7) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N´m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil. (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery.
(16) Start the engine and check for any leaks.
STANDARD PROCEDURE - CYLINDER BORE
HONING
Before honing, stuff plenty of clean shop towels
under the bores and over the crankshaft to keep
abrasive materials from entering the crankshaft
area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.
The hone marks should INTERSECT at 40É to 60É
for proper seating of rings (Fig. 3).
(4) A controlled hone motor speed between 200 and
300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 40É to 60É
angle. Faster up and down strokes increase the cross-
hatch angle.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
Fig. 3 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
DRENGINE - 5.9L 9 - 233
ENGINE - 5.9L (Continued)

(3) Recover refrigerant from a/c system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(4) Remove the a/c condenser, if equipped (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - REMOVAL).
(5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
(6) Remove the washer bottle from the fan shroud.
(7) Remove the viscous fan/drive (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(8) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(9) Remove the upper crossmember and top core
support.
(10) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(11) Remove the A/C compressor with the lines
attached. Secure compressor out of the way.
(12) Remove generator assembly (Refer to 8 -
ELECTRICAL/CHARGING/GENERATOR - REMOV-
AL).
(13) Remove the air cleaner resonator and duct
work as an assembly.
(14) Disconnect the throttle linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL).
(15) Remove throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(16) Remove the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(17) Remove the distributor cap and wiring.
(18) Disconnect the heater hoses.
(19) Disconnect the power steering hoses, if
equipped.
(20) Perform the Fuel System Pressure Release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).
(21) Disconnect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(22) On Manual Transmission vehicles, remove the
shift lever (Refer to 21 - TRANSMISSION/TRANS-
AXLE/MANUAL/SHIFT COVER - REMOVAL).
(23) Raise and support the vehicle on a hoist and
drain the engine oil.
(24) Remove engine front mount thru-bolt nuts.
(25) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(26) Disconnect exhaust pipe at manifolds.(27) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
(28) Remove the dust shield and transmission
inspection cover.
(29) Remove drive plate to converter bolts (Auto-
matic transmission equipped vehicles).
(30) Remove transmission bell housing to engine
block bolts.
(31) Lower the vehicle.
(32) Install an engine lifting fixture.
(33) Separate engine from transmission, remove
engine from vehicle, and install engine assembly on a
repair stand.
INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment. Position the thru-
bolt into the support cushion brackets.
(2) Install engine lifting device.
(3) Lower engine into compartment and align
engine with transmission:
²Manual Transmission: Align clutch disc assem-
bly (if disturbed). Install transmission input shaft
into clutch disc while mating engine and transmis-
sion surfaces. Install two transmission to engine
block mounting bolts finger tight.
²Automatic Transmission: Mate engine and trans-
mission and install two transmission to engine block
mounting bolts finger tight.
(4) Lower engine assembly until engine mount
through bolts rest in mount perches.
(5) Install remaining transmission to engine block
mounting bolts and tighten.
(6) Tighten engine mount through bolts.
(7) Install drive plate to torque converter bolts.
(Automatic transmission models)
(8) Install the dust shield and transmission cover.
(9) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(10) Install exhaust pipe to manifold.
(11) Install the transmission cooler line brackets to
the oil pan.
(12) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(13) Lower the vehicle.
(14) Remove engine lifting fixture.
(15) On Manual Transmission vehicles, install the
shift lever (Refer to 21 - TRANSMISSION/TRANS-
AXLE/MANUAL/SHIFT COVER - INSTALLATION).
(16) Connect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(17) Connect the power steering hoses, if equipped.
(18) Connect the heater hoses.
9 - 234 ENGINE - 5.9LDR
ENGINE - 5.9L (Continued)

(19) Install the distributor cap and wiring.
(20) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(21) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(22) Connect the throttle linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - INSTALLATION).
(23) Install the air cleaner resonator and duct
work..
(24) Install the generator and wire connections
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION).
(25) Install a/c compressor and lines (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION).
(26) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(27) Install upper radiator support crossmember.
(28) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(29) Connect the radiator lower hose.
(30) Connect the transmission oil cooler lines to
the radiator.
(31) Install the fan shroud.
(32) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(33) Connect the radiator upper hose.
(34) Install the washer bottle.
(35) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
(36) Connect the transmission cooler lines.
(37) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - INSTALLATION).
(38) Evacuate and charge the air conditioning sys-
tem, if equipped (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE).
(39) Add engine oil to crankcase (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES - SPEC-
IFICATIONS).
(40) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(41) Connect battery negative cable.
(42) Start engine and inspect for leaks.
(43) Road test vehicle.SPECIFICATIONS
5.9L ENGINE
ENGINE SPECIFICATIONS
DESCRIPTION SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type 90É V-8 OHV
Bore and Stroke 101.6 x 90.9 mm
(4.00 x 3.58 in.)
Displacement 5.9L (360 c.i.)
Compression Ratio 9.1:1
Firing Order 1±8±4±3±6±5±7±2
Lubrication Pressure Feed ± Full
Flow
Filtration
Cooling System Liquid Cooled ± Forced
Circulation
Cylinder Block Cast Iron
Cylinder Head Cast Iron
Crankshaft Nodular Iron
Camshaft Nodular Cast Iron
Pistons Aluminum Alloy w/strut
Connecting Rods Forged Steel
Compression Pressure 689.5 kPa (100 psi)
(Min.)
CAMSHAFT
Bearing Diameter
No. 1 50.800 ± 50.825 mm
(2.000 ± 2.001 in.)
No. 2 50.394 ± 50.419 mm
(1.984 ± 1.985 in.)
No. 3 50.013 ± 50.038 mm
(1.969 ± 1.970 in.)
No. 4 49.606 ± 49.632 mm
(1.953 ± 1.954 in.)
No. 5 39.688 ± 39.713 mm
(1.5625 ± 1.5635 in.)
DRENGINE - 5.9L 9 - 235
ENGINE - 5.9L (Continued)

OS-US Item Identification Location of
.127 mm adjacent to
two
(.005 in.) 3/89tapped
holes on
each
end of
cylinder
head.
TORQUE
TORQUE CHART 5.9L ENGINE
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Camshaft Sprocket Bolt 68 50 Ð
Camshaft Thrust Plate Bolts 24 Ð 210
Timing Chain Case Cover
Bolts41 30 Ð
Connecting Rod Cap Bolts 61 45 Ð
Main Bearing Cap Bolts 115 85 Ð
Crankshaft Pulley Bolts 24 Ð 210
Cylinder Head Bolts
Step 1 68 50 Ð
Step 2 143 105 Ð
Cylinder Head Cover Bolts 11 Ð 95
Engine Support Bracket to
Block Bolts (4WD)41 30 Ð
Exhaust Manifold to Cylinder
Head Bolts/Nuts34 25 Ð
Flywheel Bolts 75 55 Ð
Front Insulator Through
bolt/nut95 70 Ð
Front Insulator to Support
Bracket
Stud Nut (4WD) 41 30 Ð
Through Bolt/Nut (4WD) 102 75 Ð
Front Insulator to Block Bolts
(2WD)95 70 Ð
Generator Mounting Bolt 41 30 Ð
Intake Manifold Bolts Refer to Procedure
Oil Pan Bolts 24 Ð 215
Oil Pan Drain Plug 34 25 Ð
Oil Pump Attaching Bolts 41 30 Ð
Oil Pump Cover Bolts 11 Ð 95
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Rear Insulator to Bracket
Through-Bolt (2WD)68 50 Ð
Rear Insulator to
Crossmember Support
Bracket Nut (2WD)41 30 Ð
Rear Insulator to
Crossmember Nuts (4WD)68 50 Ð
Rear Insulator to
Transmission Bolts (4WD)68 50 Ð
Rear Insulator Bracket Bolts
(4WD Automatic)68 50 Ð
Rear Support Bracket to
Crossmember Flange Nuts41 30 Ð
Rear Support Plate to
Transfer Case Bolts41 30 Ð
Rocker Arm Bolts 28 21 Ð
Spark Plugs 41 30 Ð
Starter Motor Mounting Bolts 68 50 Ð
Thermostat Housing Bolts 25 Ð 225
Throttle Body Bolts 23 Ð 200
Torque Converter Drive Plate
Bolts31 Ð 270
Transfer Case to Insulator
Mounting Plate Nuts204 105 Ð
Transmission Support Bracket
Bolts (2WD)68 50 Ð
Vibration Damper Bolt 244 180 Ð
Water Pump to Timing Chain
Case Cover Bolts41 30 Ð
DRENGINE - 5.9L 9 - 239
ENGINE - 5.9L (Continued)

If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the air cleaner resonator and duct
work.
(4) Remove the intake manifold-to-generator
bracket support rod. Remove the generator.
(5) Remove closed crankcase ventilation system.
(6) Disconnect the evaporation control system.
(7) Perform the Fuel System Pressure Release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(9) Remove distributor cap and wires.
(10) Disconnect the coil wires.
(11) Disconnect heat indicator sending unit wire.
(12) Disconnect heater hoses and bypass hose.
(13) Remove the master cylinder and booster
assembly. Refer to section 5 brakes.
(14) Remove cylinder head covers and gaskets
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(15) Remove intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL) and throttle body as an assembly. Dis-
card the flange side gaskets and the front and rear
cross-over gaskets.(16) Remove exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
REMOVAL).
(17) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(18) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(19) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness
exceeds 0.00075mm/mm (0.0001in/in.) times the span
length in any direction, either replace head or lightly
machine the head surface.
FOR EXAMPLE:ÐA 305 mm (12 in.) span is
0.102 mm (0.004 in.) out-of-flat. The allowable out-of-
flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 mm
(0.009 in.). This amount of out-of-flat is acceptable.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
(1) Clean all surfaces of cylinder block and cylin-
der heads.
(2) Clean cylinder block front and rear gasket sur-
faces using a suitable solvent.
(3) Position new cylinder head gaskets onto the
cylinder block.
(4) Position cylinder heads onto head gaskets and
cylinder block.
(5) Starting at top center, tighten all cylinder head
bolts, in sequence (Fig. 8).
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(6) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 N´m
(21 ft. lbs.) torque.
(7) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION) and throttle body assembly.
(8) Install exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSTALLATION).
9 - 244 ENGINE - 5.9LDR
CYLINDER HEAD (Continued)

(9) If required, adjust spark plugs to specifications.
Install the plugs and tighten to 41 N´m (30 ft. lbs.)
torque.
(10) Install coil wire.
(11) Connect heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(15) Install the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(16) 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. Tighten the adjusting
strap bolt to 23 N´m (200 in. lbs.) torque.
(17) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(18) Place the cylinder head cover gaskets in posi-
tion and install cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(19) Install closed crankcase ventilation system.
(20) Connect the evaporation control system.
(21) Reinstall the master cylinder and booster
assembly. Refer to section 5 brakes.
(22) Install the air cleaner.
(23) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(24) Connect the negative cable to the battery.
(25) Start engine check for leaks.
CYLINDER HEAD COVER(S)
REMOVAL
NOTE: A steel backed silicon gasket is used with
the cylinder head cover (Fig. 9). This gasket can be
used again.
(1) Disconnect the negative cable from the battery.
(2) Disconnect the spark plug wires form the spark
plugs and set aside.
(3) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
(4) Remove cylinder head cover and gasket.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
INSTALLATION
(1) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas-
ket. Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(3) Install closed crankcase ventilation system and
evaporation control system.
(4) Connect the spark plug wires to the spark
plugs.
(5) Connect the negative cable to the battery.
Fig. 8 Cylinder Head Bolt Tightening Sequence
Fig. 9 Cylinder Head Cover Gasket
1 - CYLINDER HEAD COVER GASKET
DRENGINE - 5.9L 9 - 245
CYLINDER HEAD (Continued)

CRANKSHAFT
DESCRIPTION
The crankshaft (Fig. 23) is of a cast nodular steel
splayed type design, with five main bearing journal-
s.The crankshaft is located at the bottom of the
engine block and is held in place with five main bear-
ing caps. The number 3 counterweight is the location
for journal size identification.
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or
flexplate.
REMOVAL
NOTE: This procedure can be done in vehicle. How-
ever the transmission must be removed first.
(1) If crankshaft is to be removed while engine is
in vehicle remove the transmission. Refer to 21 -
TRANSMISSION/TRANSAXLE.
(2) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(3) Remove the oil pump from the rear main bear-
ing cap (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - REMOVAL).
(4) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(5) Remove the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(6) Identify rod bearing caps before removal.
Remove rod bearing caps with bearings.CAUTION: Support crankshaft before removing
main bearing caps. failure to do so will allow the
crankshaft to fall damaging the crankshaft.
(7) Using a suitable jack, support the crankshaft.
(8) Identify main bearing caps before removal.
Remove main bearing caps and bearings one at a
time.
(9) Lower the crankshaft out of the block.
(10) Remove and discard the crankshaft rear oil
seals.
(11) Remove and discard the front crankshaft oil
seal.
INSTALLATION
(1) Clean Gasket Maker residue and sealant from
the cylinder block and rear cap mating surface. Do
this before applying the MopartGasket Maker and
the installation of rear cap.
(2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine
oil.
(6) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of MopartGasket
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 24). DO NOT over apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application.
Fig. 23 Crankshaft with Journal Size Identification
Fig. 24 Sealant Application to Bearing Cap
1 - MOPARTGASKET MAKER 5 mm (0.20 IN.) ON BOTH SIDES
OF REAR MAIN CAP
9 - 252 ENGINE - 5.9LDR