app DODGE RAM 2003 Service Repair Manual

HYDRAULIC LIFTERS
DIAGNOSIS AND TESTINGÐHYDRAULIC
TAPPETS...........................258
REMOVAL............................259
CLEANING...........................260
INSTALLATION........................260
PISTON & CONNECTING ROD
DESCRIPTION........................260
STANDARD PROCEDURE - PISTON FITTING . 260
REMOVAL............................261
CLEANING...........................261
INSPECTION.........................261
INSTALLATION........................261
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................262
VIBRATION DAMPER
REMOVAL............................263
INSTALLATION........................263
FRONT MOUNT
REMOVAL............................264
INSTALLATION........................265
REAR MOUNT
REMOVAL............................266
INSTALLATION........................267
LUBRICATION
DESCRIPTION........................267
OPERATION..........................267
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE OIL
LEAKS.............................269
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE.........................269
OIL
STANDARD PROCEDURE - ENGINE OIL....269
OIL FILTER
REMOVAL............................270INSTALLATION........................270
OIL PAN
REMOVAL............................270
CLEANING...........................270
INSPECTION.........................271
INSTALLATION........................271
OIL PUMP
REMOVAL............................272
DISASSEMBLY........................272
INSPECTION.........................272
ASSEMBLY...........................274
INSTALLATION........................274
INTAKE MANIFOLD
DESCRIPTION........................274
OPERATION..........................274
DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE.................274
REMOVAL............................275
CLEANING...........................275
INSPECTION.........................275
INSTALLATION........................275
EXHAUST MANIFOLD
DESCRIPTION........................277
OPERATION..........................277
REMOVAL............................277
CLEANING...........................277
INSPECTION.........................277
INSTALLATION........................277
TIMING BELT / CHAIN COVER(S)
REMOVAL............................278
INSTALLATION........................278
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL............................279
INSPECTIONÐMEASURING TIMING CHAIN
STRETCH..........................279
INSTALLATION........................279
ENGINE - 5.9L
DESCRIPTION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
The engine lubrication system consists of a rotor
type oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 1).
Fig. 1 Firing Order
9 - 224 ENGINE - 5.9LDR

The engine serial number is stamped into a
machined pad located on the left, front corner of the
cylinder block. When component part replacement is
necessary, use the engine type and serial number for
reference (Fig. 2).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING - Preformance) or (Refer to 9 - ENGINE - DIAG-
NOSIS AND TESTING - Mechanical). Refer to 14 -
FUEL SYSTEM for fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING)
²Cylinder Combustion Pressure Leakage Test
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
²Cylinder Head Gasket Failure Diagnosis (Refer
to 9 - ENGINE/CYLINDER HEAD - DIAGNOSIS
AND TESTING)
²Intake Manifold Leakage Diagnosis (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING)
²Lash Adjuster (Tappet) Noise Diagnosis (Refer to
9 - ENGINE/ENGINE BLOCK/HYDRAULIC LIFT-
ERS (CAM IN BLOCK) - DIAGNOSIS AND TEST-
ING)
²Engine Oil Leak Inspection (Refer to 9 -
ENGINE/LUBRICATION - DIAGNOSIS AND TEST-
ING)
Fig. 2 Engine Identification Number
DRENGINE - 5.9L 9 - 225
ENGINE - 5.9L (Continued)

DIAGNOSIS AND TESTINGÐENGINE DIAGNOSIS - PERFORMANCE
PERFORMANCE DIAGNOSIS CHARTÐGASOLINE ENGINES
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/
BATTERY - STANDARD PROCEDURE).
Check charging system. (Refer to 8 -
ELECTRICAL/CHARGING - DIAGNOSIS
AND TESTING).
2. Corroded or loose battery connections 2. Clean/tighten suspect battery/starter
connections
3. Faulty starter or related circuit(s) 3. Check starting system. (Refer to 8 -
ELECTRICAL/STARTING - DIAGNOSIS
AND TESTING)
4. Seized accessory drive component 4. Remove accessory drive belt and
attempt to start engine. If engine starts,
repair/replace seized component.
5. Engine internal mechanical failure or
hydro-static lock5. Refer to (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
ENGINE CRANKS BUT
WILL NOT START1. No spark 1. Check for spark. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL -
DESCRIPTION)
2. No fuel 2. Perform fuel pressure test, and if
necessary, inspect fuel injector(s) and
driver circuits. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL PUMP -
DIAGNOSIS AND TESTING).
3. Low or no engine compression 3. Perform cylinder compression pressure
test. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING).
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor (Refer to
8 - ELECTRICAL/IGNITION CONTROL/
DISTRIBUTOR - REMOVAL).
3. Worn or incorrect gapped spark plugs 3. Clean plugs and set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
SPARK PLUG - CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING).
9. Burned, warped, or pitted valves 9. Install/Reface valves as necessary
10. Plugged or restricted exhaust system 10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted cables
9 - 226 ENGINE - 5.9LDR
ENGINE - 5.9L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
12. Faulty ignition coil 12. Test and replace, as necessary (Refer
to 8 - ELECTRICAL/IGNITION CONTROL/
IGNITION COIL - REMOVAL).
ENGINE STALLS OR
ROUGH IDLE1. Carbon build-up on throttle plate 1. Remove throttle body and de-carbon.
(Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/THROTTLE BODY -
REMOVAL).
2. Engine idle speed too low 2. Check Idle Air Control circuit. (Refer to
14 - FUEL SYSTEM/FUEL INJECTION/
IDLE AIR CONTROL MOTOR -
DESCRIPTION)
3. Worn or incorrectly gapped spark plugs 3. Replace or clean and re-gap spark
plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or crossed 5. Check for correct firing order or replace
spark plug cables. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
SPARK PLUG CABLE - DIAGNOSIS AND
TESTING)
6. Faulty coil 6. Test and replace, if necessary (Refer to
8 - ELECTRICAL/IGNITION CONTROL/
IGNITION COIL - REMOVAL)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket and
vacuum hoses (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING).
ENGINE MISSES ON
ACCELERATION1. Worn or incorrectly gapped spark plugs 1. Replace spark plugs or clean and set
gap. (Refer to 8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG - CLEANING)
2. Spark plug cables defective or crossed 2. Replace or rewire secondary ignition
cables. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
CABLE - REMOVAL)
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary (Refer to
8 - ELECTRICAL/IGNITION CONTROL/
IGNITION COIL - REMOVAL)
DRENGINE - 5.9L 9 - 227
ENGINE - 5.9L (Continued)

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil. (Refer to 9 - ENGINE/
LUBRICATION/OIL - STANDARD
PROCEDURE)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. (Refer to 9 -
ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) for
engine oil pressure test/specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic tappets/
lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats or
valve faces9. Grind valves and seats
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level.
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. (Refer to 9 -
ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) engine
oil pressure test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
(Refer to 9 - ENGINE/LUBRICATION/
OIL - STANDARD PROCEDURE) for
correct procedure/engine oil
specifications
4. Excessive connecting rod bearing
clearance4. Measure bearings for correct
clearance with plasti-gage. Repair as
necessary
5. Connecting rod journal out of
round5. Replace crankshaft or grind
journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level.
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. (Refer to 9 -
ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING)
3. Thin or diluted oil 3. Change oil to correct viscosity.
9 - 228 ENGINE - 5.9LDR
ENGINE - 5.9L (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)

DESCRIPTION SPECIFICATION
Intake 47.752 mm (1.88 in.)
Exhaust 41.072 (1.617 in.)
Length (Overall)
Intake 126.21 ± 126.85 mm
(4.969 ± 4.994 in.)
Exhaust 126.44 ± 127.30 mm
(4.978 ± 5.012 in.)
Lift (@ zero lash)
Intake 10.414 mm (0.410 in.)
Exhaust 10.592 mm (0.417 in.)
Stem Diameter
Intake 9.449 - 9.474 mm
(0.372 - 0.373 in.)
Exhaust 9.423 - 9.449 mm
(0.371 - 0.372 in.)
Guide Bore 9.500 - 9.525 mm
(0.374 - 0.375 on.)
Stem to Guide Clearance
Intake 0.0254 - 0.0762 mm
(0.001 - 0.003 in.)
Exhaust 0.0508 - 0.1016 mm
(0.002 - 0.004 in.)
Service Limit 0.4318 - (0.017 in.)
Valve Springs
Free Length 49.962 mm (1.967 in.)
Spring Tension
Valve closed 378 N @ 41.66 mm
(85 lbs. @ 1.64 in.)
Valve open 890 N @ 30.89 mm
(200 lbs. @ 1.212 in.)
Number of Coils 6.8
Installed Height 41.66 mm (1.64 in.)
Wire Diameter 4.50 mm (0.177 in.)
HYDRAULIC TAPPETS
Body Diameter 22.949 - 22.962 mm
(0.9035 - 0.9040 in.)
Clearance (to bore) 0.0279 - 0.0610 mmDESCRIPTION SPECIFICATION
(0.0011 - 0.0024 in.)
Dry Lash 1.524 - 5.334 mm
(0.060 - 0.210 in.)
Push Rod Length 175.64 - 176.15 mm
(6.915 - 6.935 in.)
OIL PRESSURE
Curb Idle (Min.*) 41.4 kPa (6 psi)
@ 3000 rpm 207 - 552 kPa (30 - 80
psi)
Oil Pressure Bypass
Valve Setting 62 - 103 kPa (9 - 15 psi)
Switch Actuating
Pressure34.5 - 48.3 kPa (5 - 7
psi)
* If oil pressure is zero at curb idle, DO NOT RUN
ENGINE.
OIL PUMP
Clearance over Rotors
(Max.)0.1016 mm (0.004 in.)
Cover Out of Flat (Max.) 0.0381 mm (0.0015 in.)
Inner Rotor Thickness
(Min.)20.955 mm (0.825 in.)
Outer Rotor
Clearance (Max.) 0.3556 mm (0.014 in.)
Diameter (Min.) 62.7126 mm (2.469 in.)
Thickness (Min.) 20.955 mm (0.825 in.)
Tip Clearance between
Rotors (Max.) 0.2032 mm (0.008 in.)
PISTONS
Clearance at Top of Skirt 0.013 - 0.038 mm
(0.0005 - 0.0015 in.)
Land Clearance (Diam.) 0.508 - 0.660 mm
(0.020 - 0.026 in.)
Piston Length 81.03 mm (3.19 in.)
Piston Ring Groove
Depth
Groove #1 and 2 4.761 - 4.912 mm
DRENGINE - 5.9L 9 - 237
ENGINE - 5.9L (Continued)

DESCRIPTION SPECIFICATION
(0.187 - 0.193 in.)
Groove #3 3.996 - 4.177 mm
(0.157 - 0.164 in.)
Weight 582 - 586 grams
(20.53 - 20.67 oz.)
PISTON PINS
Clearance in Piston 0.006 - 0.019 mm
(0.00023 - 0.00074 in.)
Diameter 25.007 - 25.015 mm
(0.9845 - 0.9848 in.)
End Play NONE
Length 67.8 - 68.3 mm
(2.67 - 2.69 in.)
PISTON RINGS
Ring Gap
Compression Ring (Top) 0.30 - 0.55 mm
(0.012 - 0.022 in.)
Compression Ring (2nd) 0.55 - 0.80 mm
(0.022 - 0.031 in.)
Oil Control (Steel Rails) 0.381 - 1.397 mm
(0.015 - 0.055 in.)
Ring Side Clearance
Compression Rings 0.040 - 0.085 mm
(0.0016 - 0.0033 in.)
Oil Ring (Steel Rails) 0.05 - 0.21 mm
MAX (0.002 - 0.008 in.)
Ring Width
Compression rings 1.530 - 1.555 mm
(0.060 - 0.061 in.)
Oil Ring (Steel Rails)
Max.0.447 - 0.473 mm
(0.018 - 0.019 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) 33É
Opens (BBDC) 56É
Duration 269ÉDESCRIPTION SPECIFICATION
Intake Valve
Closes (ATDC) 62É
Opens (BBDC) 7É
Duration 249É
Valve Overlap 41É
OVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
OS-US Item Identification Location of
Identification
U/S Crankshaft R or M M-2-3
ect.Milled flat on
.025 MM (indicating No.
2 andNo. three
(.001 in.) 3 main bearing crankshaft
journal) and/or counter-
weight.
R-1-4 ect.
(indicating No.
1 and
4 connecting
rod
journal)
O/S Cylinder A Following
.508 mm Bores engine serial
(.020 in.) number.
O/S TappetsL3/89
.203 mm diamond
(.008 in.) -shaped
stamp Top
pad
Ð Front of
engine and
flat
ground on
outside
surface
of each O/S
tappet bore.
O/S Valve
StemsX Milled pad
9 - 238 ENGINE - 5.9LDR
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)

CYLINDER HEAD
DESCRIPTION
DESCRIPTIONÐCYLINDER HEAD
The cast iron cylinder heads (Fig. 6) are mounted
to the cylinder block using ten bolts. The spark plugs
are located in the peak of the wedge between the
valves.
DESCRIPTION - CYLINDER HEAD COVER
GASKET
The cylinder head cover gasket (Fig. 7) is a steel-
backed silicone gasket, designed for long life usage.
OPERATION
OPERATIONÐCYLINDER HEAD
The cylinder head closes the combustion chamber
allowing the pistons to compress the air fuel mixture
to the correct ratio for ignition. The valves located in
the cylinder head open and close to either allow clean
air into the combustion chamber or to allow the
exhaust gases out, depending on the stroke of the
engine.
OPERATION - CYLINDER HEAD COVER
GASKET
The steel-backed silicone gasket is designed to seal
the cylinder head cover for long periods of time
through extensive heat and cold, without failure. The
gasket is designed to be reusable.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
²Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
þ Loss of engine power
þ Engine misfiring
þ Poor fuel economy
²Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
þ Engine overheating
þ Loss of coolant
þ Excessive steam (white smoke) emitting from
exhaust
þ Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test in this
section. An engine cylinder head gasket leaking
between adjacent cylinders will result in approxi-
mately a 50±70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
Fig. 6 Cylinder Head AssemblyÐV-8 Gas Engines
1 - EXHAUST VALVE
2 - SPARK PLUGS
3 - EXHAUST VALVES
4 - SPARK PLUGS
5 - EXHAUST VALVE
6 - INTAKE VALVES
7 - INTAKE VALVES
Fig. 7 Cylinder Head Cover Gasket V-8 Gas Engines
1 - CYLINDER HEAD COVER GASKET
DRENGINE - 5.9L 9 - 243