lock DODGE RAM 2003 Service Repair Manual

(3) Immerse the piston head and rings in clean
engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench
(part of Tool C-385).Be sure position of rings
does not change during this operation.
(4) Install connecting rod bolt protectors on rod
bolts. The long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal.
(7) The notch, or groove, on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, con-
necting rod cap, and cylinder bore number are the
same. Install nuts on cleaned and oiled rod bolts and
tighten nuts to 61 N´m (45 ft. lbs.) torque.
(9) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(10) Install the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION).
(11) Install the engine into the vehicle (Refer to 9 -
ENGINE - INSTALLATION).
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Measurement of end gaps:
(a) Measure piston ring gap 2 in. from bottom of
cylinder bore. An inverted piston can be used to
push the rings down to ensure positioning rings
squarely in the cylinder bore before measuring.
(b) Insert feeler gauge in the gap. The top com-
pression ring gap should be between 0.254-0.508
mm (0.010-0.020 in.). The second compression ring
gap should be between 0.508-0.762 mm
(0.020-0.030 in.). The oil ring gap should be 0.254-
1.270 mm (0.010-0.050 in.).
(c) Rings with insufficient end gap may be prop-
erly filed to the correct dimension. Rings with
excess gaps should not be used.
(2) Install rings, and confirm ring side clearance:
(a)
Install oil rings being careful not to nick or
scratch the piston. Install the oil control rings accord-
ing to instructions in the package. It is not necessary
to use a tool to install the upper and lower rails.
Insert oil rail spacer first, then side rails.
(b) Install the second compression rings using
Installation Tool C-4184. The compression rings
must be installed with the identification mark face
up (toward top of piston) and chamfer facing down.
An identification mark on the ring is a drill point,
a stamped letter ªOº, an oval depression, or the
word ªTOPº (Fig. 40) (Fig. 42).
(c) Using a ring installer, install the top com-
pression ring with the chamfer facing up (Fig. 41)
(Fig. 42). An identification mark on the ring is a
drill point, a stamped letter ªOº, an oval depression
or the word ªTOPº facing up.
(d) M
easure side clearance between piston ring
and ring land. Clearance should be 0.074-0.097 mm
(0.0029-0.0038 in.) for the compression rings. The
steel rail oil ring should be free in groove, but should
not exceed 0.246 mm (0.0097 in.) side clearance.
(e) Pistons with insufficient, or excessive, side
clearance should be replaced.
(3) Orient the rings:
(a) Arrange top compression ring 90É counter-
clockwise from the oil ring rail gap (Fig. 43).
Fig. 40 Second Compression Ring Identification
(Typical)
1 - SECOND COMPRESSION RING (BLACK CAST IRON)
2 - CHAMFER
3 - TWO DOTS
Fig. 41 Top Compression Ring Identification (Typical)
1 - TOP COMPRESSION RING (GRAY IN COLOR)
2 - CHAMFER
3 - ONE DOT
9 - 262 ENGINE - 5.9LDR
PISTON & CONNECTING ROD (Continued)

(b) Arrange second compression ring 90É clock-
wise from the oil ring rail gap (Fig. 43).
VIBRATION DAMPER
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove the cooling system fan (Refer to 7 -
COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL).
(3) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove vibration damper bolt and washer from
end of crankshaft.
(5) Position Special Tool 8513 Insert into the
crankshaft nose.(6) Install Special Tool 1026 Three Jaw Puller onto
the vibration damper (Fig. 44).
(7) Pull vibration damper off of the crankshaft.
INSTALLATION
CAUTION: Thoroughly remove any contaminants
from the crankshaft nose and the vibration damper
bore. Failure to do so can cause sever damage to
the crankshaft.
(1)
Position the vibration damper onto the crankshaft.
(2) Place installing tool, part of Puller Tool Set
C-3688 in position and press the vibration damper
onto the crankshaft (Fig. 45).
(3) Install the crankshaft bolt and washer. Tighten
the bolt to 244 N´m (180 ft. lbs.) torque.
(4) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(5)
Position the fan shroud and install the bolts.
Tighten the retainer bolts to 11 N´m (95 in. lbs.) torque.
(6) Install the cooling fan (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS CLUTCH -
INSTALLATION).
(7) Connect the battery negative cable.
Fig. 42 Compression Ring Chamfer Location (Typical)
1 - CHAMFER
2 - TOP COMPRESSION RING
3 - SECOND COMPRESSION RING
4 - PISTON
5 - CHAMFER
Fig. 43 Proper Ring Installation
1 - OIL RING SPACER GAP
2 - SECOND COMPRESSION RING GAP OIL RING RAIL GAP
(TOP)
3 - OIL RING RAIL GAP (BOTTOM)
4 - TOP COMPRESSION RING GAP
Fig. 44 Vibration Damper Removal
1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026
Fig. 45 Vibration Damper Installation
1 - SPECIAL TOOL C-3688
DRENGINE - 5.9L 9 - 263
PISTON RINGS (Continued)

FRONT MOUNT
REMOVAL
2WD
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the viscous fan before raising
engine. Failure to do so may cause damage to the
fan blade, fan clutch and fan shroud.
(2) Remove the viscous fan (Refer to 7 - COOL-
ING/ENGINE/FAN DRIVE VISCOUS CLUTCH -
REMOVAL).
(3) Raise the vehicle.
(4) Remove the engine oil filter.
(5) Remove the oil drain trough.
(6)
Support the engine with a suitable jack and a
block of wood across the full width of the engine oil pan.
(7) Support the front axle with a suitable jack.
(8) Remove the (4) bolts that attach the engine
mounts to the front axle.
(9) Remove the (3) bolts that attach the front axle
to the left engine bracket.
(10) Lower the front axle.
(11) Remove the through bolts(12) Raise the engine far enough to be able to
remove the left and right engine mounts.
(13)
Remove the (8) mount to engine attaching bolts
(14) Remove the engine mounts.
4WD
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the viscous fan before raising
engine. Failure to do so may cause damage to the
fan blade, fan clutch and fan shroud.
(2) Remove the viscous fan (Refer to 7 - COOL-
ING/ENGINE/FAN DRIVE VISCOUS CLUTCH -
REMOVAL).
(3) Raise the vehicle.
(4) Remove the skid plate.
(5) Remove the front crossmember.
(6) Remove the engine oil filter.
(7) Remove the oil drain trough.
(8) Support the engine with a suitable jack and a
block of wood across the full width of the engine oil
pan.
(9) Support the front axle with a suitable jack.
(10) Remove the (4) bolts that attach the engine
mounts to the front axle (Fig. 46).
Fig. 46 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
9 - 264 ENGINE - 5.9LDR

(11) Remove the (3) bolts that attach the front axle
to the left engine bracket.
(12) Lower the front axle.
(13) Remove the (6) through bolts
(14) Raise the engine far enough to be able to
remove the left (Fig. 47) and right (Fig. 48) engine
mounts.
(15) Remove the engine mounts.
INSTALLATION
2WD
NOTE: For mount to engine block and left engine
bracket to front axle bolts, apply MoparTLock and
Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to
the engine block with (8) bolts. Torque bolts to 54
N´m (40 ft. lbs.).
(2) Insert the (2) through bolts into the right and
left side engine mounts and loose assemble the two
nuts onto the through bolts.
(3) Lower the engine until the through bolts rest
onto the slots in the frame brackets.(4) Tighten the through bolt nuts to 94 N´m (70 ft.
lbs.).
(5) Install the oil drain trough.
(6) Install the engine oil filter.
(7) Lower the vehicle.
(8) Install the viscous fan (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS CLUTCH -
REMOVAL).
(9) Reconnect the negative battery cable.
4WD
NOTE: For mount to engine block and left engine
bracket to front axle bolts, apply MoparTLock and
Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to
the front axle. Torque nuts to 94 N´m (70 ft. lbs.).
(2) Raise the front axle into the frame and install
the left and right side through bolts. Torque nuts to
94 N´m (70 ft. lbs.).
(3) Insert the two upper through bolts into the
right and left side engine mounts and loose assemble
the two nuts onto the through bolts.
(4) Lower the engine until the left and right side
engine brackets rest on the through bolts, and the
lower engine bracket through holes align with the
engine mounts, and the left engine bracket holes
align with the front axle slots (Fig. 49).
(5) Loose assemble the (3) bolts that attach the
front axle to the left engine bracket.
Fig. 47 ENGINE SUPPORT BRACKET 5.9L
1 - ENGINE SUPPORT BRACKET
2 - BOLT
3 - BOLT
Fig. 48 ENGINE SUPPORT RH 4X4
1 - BOLT
2 - ENGINE SUPPORT
DRENGINE - 5.9L 9 - 265
FRONT MOUNT (Continued)

(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.
(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
A gear-type positive displacement pump (Fig. 51) is
mounted at the underside of the rear main bearing
cap. The pump uses a pick-up tube and screen
assembly to gather engine oil from the oil pan.
OPERATION
The pump draws oil through the screen and inlet
tube from the sump at the rear of the oil pan. The oil
is driven between the drive and idler gears and
pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
the inlet side of the full flow oil filter. After passing
through the filter element, the oil passes from the
center outlet of the filter through an oil gallery that
channels the oil up to the main gallery, which
extends the entire length on the right side of the
block. The oil then goes down to the No. 1 main bear-
ing, back up to the left side of the block, and into the
oil gallery on the left side of the engine.
Galleries extend downward from the main oil gal-
lery to the upper shell of each main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Each connecting rod bearing has half a hole in it, oil
passes through the hole when the rods rotate and the
hole lines up, oil is then thrown off as the rod
rotates. This oil throwoff lubricates the camshaft
lobes, distributor drive gear, cylinder walls, and pis-
ton pins.
The hydraulic valve tappets receive oil directly
from the main oil gallery. The camshaft bearings
receive oil from the main bearing galleries. The front
camshaft bearing journal passes oil through the cam-
shaft sprocket to the timing chain. Oil drains back to
the oil pan under the No. 1 main bearing cap.
The oil supply for the rocker arms and bridged
pivot assemblies is provided by the hydraulic valve
tappets, which pass oil through hollow push rods to a
hole in the corresponding rocker arm. Oil from the
rocker arm lubricates the valve train components.
The oil then passes down through the push rod guide
holes and the oil drain-back passages in the cylinder
head, past the valve tappet area, and then returns to
the oil pan (Fig. 52).
Fig. 51 Positive Displacement Oil PumpÐTypical
1 - INNER ROTOR AND SHAFT
2 - BODY
3 - DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 - COTTER PIN
5 - RETAINER CAP
6 - SPRING
7 - RELIEF VALVE
8 - LARGE CHAMFERED EDGE
9 - BOLT
10 - COVER
11 - OUTER ROTOR
DRENGINE - 5.9L 9 - 267
REAR MOUNT (Continued)

(6) Add oil only if level is below the ADD mark on
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. This infor-
mation can be found in the owner's manual.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist vehicle.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Install drain plug in crankcase.
(7) Change oil filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL).
(8) Lower vehicle and fill crankcase with specified
type (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION) and amount of
engine oil (Refer to LUBRICATION & MAINTE-
NANCE - SPECIFICATIONS).
(9) Install oil fill cap.
(10) Start engine and inspect for leaks.
(11) Stop engine and inspect oil level.
OIL FILTER
REMOVAL
All engines are equipped with a high quality full-
flow, disposable type oil filter. DaimlerChrysler Cor-
poration recommends a Mopartor equivalent oil
filter be used.
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
(3) Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss (Fig. 54).
(4) When filter separates from adapter nipple, tip
gasket end upward to minimize oil spill. Remove fil-
ter from vehicle.
(5) With a wiping cloth, clean the gasket sealing
surface (Fig. 55) of oil and grime.
(6) Install new filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - INSTALLATION).
INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, (Fig. 55) hand
tighten filter one full turn, do not over tighten.
(3) Add oil (Refer to 9 - ENGINE/LUBRICATION/
OIL - STANDARD PROCEDURE).
OIL PAN
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
(5) Remove exhaust pipe.
(6) Remove left engine to transmission strut.
(7) Loosen the right side engine support bracket
cushion thru-bolt nut and raise the engine slightly.
Remove oil pan by sliding backward and out.
(8) Remove the one-piece gasket.
CLEANING
Clean the block and pan gasket surfaces.
Fig. 54 Oil Filter RemovalÐTypical
1 - ENGINE OIL FILTER
2 - OIL FILTER WRENCH
Fig. 55 Oil Filter Sealing SurfaceÐTypical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
9 - 270 ENGINE - 5.9LDR
OIL (Continued)

Trim or remove excess sealant film in the rear
main cap oil pan gasket groove.DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the
engine.
Clean oil pan in solvent and wipe dry with a clean
cloth.
Clean oil screen and pipe thoroughly in clean sol-
vent. Inspect condition of screen.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor-
tion. Straighten flange, if necessary.
INSTALLATION
(1) Clean the block and pan gasket surfaces.
(2) Trim or remove excess sealant film in the rear
main cap oil pan gasket groove.DO NOT remove
the sealant inside the rear main cap slots.
(3) If present, trim excess sealant from inside the
engine.
(4)
Fabricate 4 alignment dowels from 5/16x11/2
inch bolts. Cut the head off the bolts and cut a slot into
the top of the dowel. This will allow easier installation
and removal with a screwdriver (Fig. 56).
(5) Install the dowels in the cylinder block (Fig.
57).
(6) Apply small amount of MopartSilicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
(7) Slide the one-piece gasket over the dowels and
onto the block.
(8) Position the oil pan over the dowels and onto
the gasket.
(9) Install the oil pan bolts. Tighten the bolts to 24
N´m (215 in. lbs.) torque.(10) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 N´m (215 in. lbs.)
torque.
(11) Lower the engine into the support cushion
brackets and tighten the thru bolt nut to the proper
torque.
(12) Install the drain plug. Tighten drain plug to
34 N´m (25 ft. lbs.) torque.
(13) Install the engine to transmission strut.
(14) Install exhaust pipe.
(15) Lower vehicle.
(16) Install dipstick.
(17) Connect the negative cable to the battery.
(18) Fill crankcase with oil to proper level.
Fig. 56 Fabrication of Alignment Dowels
1 - 5/16º X 11¤2º BOLT
2 - DOWEL
3 - SLOT
Fig. 57 Position of Dowels in Cylinder Block
1 - DOWEL
2 - DOWEL
3 - DOWEL
4 - DOWEL
DRENGINE - 5.9L 9 - 271
OIL PAN (Continued)

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)

(5) Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and
nuts to 34 N´m (25 ft. lbs.) torque.
(6) Lower the vehicle.
(7) Connect the negative cable to the battery.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(3) Remove power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(4) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(5) Loosen oil pan bolts and remove the front bolt
at each side.
(6) Remove the cover bolts.
(7) Remove chain case cover and gasket using
extreme caution to avoid damaging oil pan gasket.
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
(2) The water pump mounting surface must be
cleaned.
(3) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of MopartSilicone Rubber Adhe-
sive Sealant, or equivalent, at the joint between tim-
ing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.NOTE: Special Tool 6635 must be used to align the
front cover and seal with the crankshaft.
(4) Position the special tool 6635 onto the crank-
shaft (Fig. 75).
(5) Tighten chain case cover bolts to 41 N´m (30
ft.lbs.) torque. Tighten oil pan bolts to 24 N´m (215
in. lbs.) torque.
(6) Remove special tool 6635.
(7)
Inspect the seal flange on the vibration damper.
(8) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(9) Install water pump and housing assembly
using new gaskets (Refer to 7 - COOLING/ENGINE/
WATER PUMP - INSTALLATION).
(10) Install power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(11) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(12) Install the cooling system fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(13) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(14) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(15) Connect the negative cable to the battery.
(16) Start engine check for leaks.
Fig. 74 Engine Exhaust Manifold Installation - 5.9L
Engines
1 - EXHAUST MANIFOLD (LEFT)
2 - BOLTS & WASHERS
3 - NUTS & WASHERS
4 - EXHAUST MANIFOLD (RIGHT)
5 - BOLTS & WASHERS
Fig. 75 Position Special Tool 6635 onto Crankshaft
1 - SPECIAL TOOL 6635
2 - OIL SEAL
3 - TIMING CHAIN COVER
9 - 278 ENGINE - 5.9LDR
EXHAUST MANIFOLD (Continued)