seats DODGE RAM 2003 Service Manual PDF

ENGINE 5.9L DIESEL
TABLE OF CONTENTS
page page
ENGINE 5.9L DIESEL
DESCRIPTION........................282
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - MECHANICAL............283
DIAGNOSIS AND TESTINGÐSMOKE
DIAGNOSIS CHARTS.................285
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION/LEAKAGE TESTS.......288
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS........289
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS........289
STANDARD PROCEDUREÐHYDROSTATIC
LOCK..............................290
REMOVAL
REMOVALÐENGINE..................290
REMOVALÐCRANKCASE BREATHER....291
INSTALLATION
INSTALLATIONÐENGINE..............291
INSTALLATIONÐCRANKCASE BREATHER . 292
SPECIFICATIONS
5.9L DIESEL........................293
TORQUE...........................294
SPECIAL TOOLS
5.9L DIESEL ENGINE.................294
ENGINE DATA PLATE
DESCRIPTION........................297
AIR CLEANER ELEMENT
REMOVAL............................297
INSTALLATION........................298
CYLINDER HEAD
DESCRIPTION........................298
REMOVAL............................298
CLEANING
CLEANINGÐCYLINDER HEAD..........300
CLEANINGÐCROSSHEADS............300
CLEANINGÐPUSHRODS..............301
INSPECTION
INSPECTION - CYLINDER HEAD.........301
INSPECTIONÐCROSSHEADS..........301
INSPECTIONÐPUSHRODS.............302
INSTALLATION........................302
CYLINDER HEAD COVER(S)
REMOVAL
REMOVALÐCYLINDER HEAD COVER....304
REMOVALÐROCKER HOUSING.........304
CLEANING...........................304INSPECTION.........................304
INSTALLATION
INSTALLATIONÐCYLINDER HEAD COVER . 304
INSTALLATIONÐROCKER HOUSING.....304
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................305
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVES,
GUIDES AND SPRINGS................305
STANDARD PROCEDURE - VALVE LASH
ADJUSTMENT AND VERIFICATION.......308
REMOVAL - VALVE SPRINGS AND SEALS . . . 308
INSTALLATION........................309
ROCKER ARM / ADJUSTER ASSY
DESCRIPTION........................310
REMOVAL............................310
CLEANING...........................310
INSPECTION..........................311
INSTALLATION........................312
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
BLOCK REFACING...................312
STANDARD PROCEDURE - CYLINDER
BORE - DE-GLAZE...................313
STANDARD PROCEDUREÐCYLINDER
BORE REPAIR.......................313
STANDARD PROCEDUREÐCAM BORE
REPAIR ............................315
INSPECTION.........................316
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS......317
REMOVAL - CAMSHAFT...............317
INSPECTION.........................318
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS . . 320
INSTALLATION - CAMSHAFT............320
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING AND CRANKSHAFT
JOURNAL CLEARANCE................321
CRANKSHAFT AND GEAR
DESCRIPTION........................322
REMOVALÐGEAR.....................322
INSTALLATION - GEAR..................322
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
CLEARANCE........................322
9 - 280 ENGINE 5.9L DIESELDR

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

INSPECTIONÐPUSHRODS
Inspect the push rod ball and socket for signs of
scoring. Check for cracks where the ball and the
socket are pressed into the tube (Fig. 16).
Roll the push rod on a flat work surface with the
socket end hanging off the edge (Fig. 17). Replace
any push rod that appears to be bent.
INSTALLATION
WARNING: THE OUTSIDE EDGE OF THE HEAD
GASKET IS VERY SHARP. WHEN HANDLING THE
NEW HEAD GASKET, USE CARE NOT TO INJURE
YOURSELF.
(1) Install a new gasket with the part number side
up, and locate the gasket over the dowel sleeves.
(2) Using an engine lifting crane, lower the cylin-
der head onto the engine.
(3) Lightly lubricate head bolts with engine oil and
install. Using the sequence shown in (Fig. 18),
tighten bolts in the following steps:
(a) Torque bolts to 70 N´m (52 ft. lbs.)(b) Back off 360 degrees in sequence
(c) Torque bolts to 105 N´m (77 ft. lbs.)
(d) Re-check all bolts to 105 N´m (77 ft. lbs.)
(e) Tighten all bolts an additional
1¤4turn (90É)
(4) Install push rods into their original locations
(Fig. 19).Verify that they are seated in the tap-
pets.
(5) Lubricate valve stem tips and install the cross-
heads in their original locations.
(6) Lubricate the rocker arms and pedestals and
install them in their original locations (Fig. 20).
Install the bolts and torque them to 36 N´m (27 ft.
lbs.).
(7) Verify that the valve lash settings are main-
tained (Refer to 9 - ENGINE/CYLINDER HEAD/IN-
TAKE/EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
(8) Inspect rocker housing gasket for cuts and
proper installation into groove. Replace if damaged.
Fig. 16 Inspecting Push Rod for Cracks
Fig. 17 Inspecting Push Rod for Flatness
Fig. 18 Cylinder Head Bolt Torque Sequence
Fig. 19 Push Rod Installation
9 - 302 ENGINE 5.9L DIESELDR
CYLINDER HEAD (Continued)

INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves are made of heat resistant steel, and
have chrome plated stems to prevent scuffing. The
intake and exhaust valves are both similar in head
diameter and overall length, but they have unique
face angles which makes them non-interchangeable.
The valves are distinguished by unique dimples on
the exhaust valve head (Fig. 21).
The exhaust valve springs are made from high
strength, chrome silicon steel. The exhaust valve
springs are also exhaust brake compatible.
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVES, GUIDES
AND SPRINGS
REMOVAL
(1) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(2) Support cylinder head on stands, or install
head bolts upside down (through combustion surface
side) to protect injector tips from damage from work
bench.
(3) Install the valve spring compressor mounting
base as shown in (Fig. 22).
(4) Install the compressor top plate, washer, and
nut. Using a suitable wrench, tighten the nut (clock-
wise) to compress the valve springs (Fig. 23) and
remove the locks.
(5) Rotate the compressor nut counter-clockwise to
relieve tension on the springs. Remove the spring
compressor.(6) Remove the retainers, springs, valve seals (if
necessary), and valves (Fig. 24). Arrange or number
all components so they can be installed in their orig-
inal locations.
(7) Repeat the procedure on all cylinders to be ser-
viced.
CLEANING
Clean the valve stems with crocus cloth or a
Scotch-BriteŸ pad. Remove carbon with a soft wire
brush. Clean valves, springs, retainers, and valve
retaining locks in a suitable solvent. Rinse in hot
water and blow dry with compressed air.
Fig. 21 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
Fig. 22 Spring Compressor Mounting BaseÐPart of
Tool 8319±A
1 - COMPRESSOR MOUNTING BASE
Fig. 23 Compressing Valve Springs with Tool
8319±A
1 - SPECIAL TOOL 8319
DRENGINE 5.9L DIESEL 9 - 305

INSPECTION
Visually inspect the valves for abnormal wear on
the heads, stems, and tips. Replace any valve that is
worn out or bent (Fig. 25).Measure the valve stem diameter in three places
as shown in (Fig. 26).
Measure the cylinder head valve guide bore (Fig. 27).
VALVE GUIDE BORE SPECIFICATIONS
VALVE GUIDE BORE SPECIFICATIONS
Valve guide bore
diameter
Min. 7.027 mm (0.2767 in.)
Max. 7.077 mm (0.2786 in.)
Installed valve guide
depth
Intake
Min. 0.584 mm ( 0.023 in.)
Max. 1.092 mm ( 0.043 in.)
Exhaust
Min. 0.965 mm ( 0.028 in.)
Max. 1.473 mm (0.058 in.)
Fig. 24 Valve Spring, Seal, and Retainers
1 - VALVE RETAINING LOCKS
2 - VALVE
3 - SEAL
4 - SPRING
5 - RETAINER
Fig. 25 Visually Inspect Valves for Abnormal Wear
Fig. 26 Measure Valve Stem Diameter
VALVE STEM DIAMETER
6.96 mm (0.2740 in.) MIN
7.010 mm (0.2760 in.) MAX
Fig. 27 Measure Valve Guide Bore
9 - 306 ENGINE 5.9L DIESELDR
INTAKE/EXHAUST VALVES & SEATS (Continued)

Measure valve margin (rim thickness) (Fig. 28).
Measure the valve spring free length and maxi-
mum inclination (Fig. 29).
Test valve spring force with tool C-647 (Fig. 30).
Specification 72.0 Ð 80.7 lbs. when compressed to
35.33 mm (1.39 in.).
INSTALLATION
(1) Install new valve seals. The yellow seals are for
the intake valves and the green seals are for the
exhaust valves.
(2) Install the valves in their original postion. The
exhaust valves are identified by a dimple on the
valve head (Fig. 31).
(3) Install the valve springs and retainer.
(4) Install the valve spring compressor tool 8319±A
as shown in (Fig. 22) and (Fig. 23).(5) Compress the valve springs and install the
valve retaining locks (Fig. 24).
(6) Remove the compressor and repeat the proce-
dure on the remaining cylinders.
(7) Install new o-ring and sealing washer on injec-
tor.
(8) Lubricate o-ring and injector bore.
(9) Verify sealing washer (shim) was removed with
old injector.
(10) Install injector with fuel injector connector
port facing intake manifold.
(11) Install hold-down bolt. Torque to 10 Nm (89
in. lbs.).
(12) Install fuel injector connector and connector
nut. Torque nut to 50 Nm (36.8 ft. lbs.).
(13) Install the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION).
Fig. 28 Measure Valve Margin (Rim Thickness)
VALVE MARGIN (RIM THICKNESS)
0.79 mm (0.031 in.) MIN.
Fig. 29 Measure Valve Spring Free Length and Max.
Inclination
APPROXIMATE VALVE SPRING FREE LENGTH
47.75 mm (1.88 in.)
MAX INCLINATION
1.5 mm (.059 in.)
Fig. 30 Testing Valve Spring with Tool C-647
1 - SPECIAL TOOL C-647
Fig. 31 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
DRENGINE 5.9L DIESEL 9 - 307
INTAKE/EXHAUST VALVES & SEATS (Continued)

STANDARD PROCEDURE - VALVE LASH
ADJUSTMENT AND VERIFICATION
NOTE: To obtain accurate readings, valve lash mea-
surements AND adjustments should only be per-
formed when the engine coolant temperature is less
than 60É C (140É F).
The 24±valve overhead system is a ªlow-mainte-
nanceº design. Routine adjustments are no longer
necessary, however, measurement should still take
place when trouble-shooting performance problems,
or upon completion of a repair that includes removal
and installation of the valve train components or
injectors.
(1) Disconnect battery negative cables.
(2) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Using the crankshaft barring tool #7471±B,
rotate crankshaft to align damper TDC mark to
12:00 o'clock position.
(a) If both number one cylinder rocker levers are
loose, continue to next step.
(b) If both number one clylinder rocker levers
are not loose, rotate crankshaft 360 degrees.
(4) With the engine in this position, valve lash can
be measured at the following rocker arms:INTAKE
1±2±4 / EXHAUST 1±3±5. Measure the valve lash by
inserting a feeler gauge between the rocker arm
socket and crosshead (Fig. 32). Refer to VALVE
LASH LIMIT CHART for the correct specifications. If
the measurement fallswithinthe limits, adjust-
ment/resettingis notnecessary. If measurement
finds the lashoutsideof the limits, adjustment/re-
settingisrequired.
VALVE LASH LIMIT CHART
INTAKE EXHAUST
0.152 mm ( 0.006 in.)
MIN.0.381 mm (0.015 in.)
MIN.
0.381 mm (0.015 in.)
MAX.0.762 mm (0.030 in.)
MAX.
note:
If measured valve lash falls within these
specifications, no adjustment/reset is necessary.
Engine operation within these ranges has no adverse
affect on performance, emissions, fuel economy or
level of engine noise.(5) If adjustment/resetting is required, loosen the
lock nut on rocker arms and turn the adjusting screw
until the desired lash is obtained:
²INTAKE0.254 mm (0.010 in.)
²EXHAUST0.508 mm (0.020 in.) Tighten the
lock nut to 24 Nm (18 ft. lbs.) and re-check the valve
lash.
(6) Using the crankshaft barring tool, rotate the
crankshaftone revolution (360É) to align the
damper TDC mark to the 12 o'clock position.
(7) With the engine in this position, valve lash can
be measured at the remaining rocker arms:INTAKE
3±5±6 / EXHAUST 2±4±6. Use the same method as
above for determining whether adjustment is neces-
sary, and adjust those that are found to be outside of
the limits.
(8) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(9) Connect the battery negative cables.
REMOVAL - VALVE SPRINGS AND SEALS
(1) Disconnect the battery negative cables.
(2) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Disconnect rocker housing injector harness con-
nector. Remove all injector harness solenoid nuts.
(4) Remove injector(s) for cylinder(s) to be serviced.
Refer to Group 14 for injector removal.
(5) Remove the rocker housing.
(6) Remove the rocker arms and crossheads from
the cylinder(s) to be serviced. Mark each component
so they can be installed in their original position.
(7) Using the crankshaft barring tool #7471±B
(Fig. 33), rotate the engine to position the damper
Fig. 32 Measuring Valve Lash - Typical
1 - INTAKE
2 - FEELER GAUGE
3 - EXHAUST
9 - 308 ENGINE 5.9L DIESELDR
INTAKE/EXHAUST VALVES & SEATS (Continued)

mark in the 12 o'clock position.At this engine posi-
tion, cylinders #1 and #6 can be serviced.
(8) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(9) With the damper TDC mark in the 12 o'clock
position, add a paint mark anywhere on the gear
housing cover next to the crankshaft damper. Place
another mark on the vibration damper in alignment
with the mark you just made on the cover.
(10) Divide the crankshaft damper into three
equally sized segments as follows:
(a) Using a tape measure, measure the circum-
ference of the crankshaft damper and divide the
measurement by three (3).
(b) Measure that distance in a counter-clockwise
direction from the first balancer mark and place
another mark on the balancer.
(c) From the second damper mark, again mea-
sure in a counter-clockwise direction and place a
mark on the damper at the same distance you
measured when placing the second damper mark.
The damper should now be marked in three
equally spaced locations and the damper TDC
mark should be in the 12 o'clock position.
(d) Remove injectors, fuel lines, and high pres-
sure connectors for every cylinder that requires
repair.
(11) Compress the valve springs at cyls. #1 and #6
as follows:
(a) Remove bolts and injector hold-down clamp.
(b) Using miller special tool #9010, remove injec-
tor.
(c) Install the valve spring compressor mounting
base as shown in (Fig. 34).
(d) Install the top plate, washer, and nut. Using
a suitable wrench tighten the nut (clock-wise) (Fig.35) to compress the valve springs and remove the
collets.
(e) Rotate the compressor nut counter-clockwise
to relieve tension on springs. Remove spring com-
pressor.
(f) Remove and replace retainers, springs, and
seals as necessary.
(g)Do not rotate the engine until the
springs and retainers are re-installed.
(h) Install seals, springs and retainers. Install
spring compressor, compress valve springs and
install the collets.
(i) Release the spring tension and remove the
compressor. Verify that the collets are seated by
tapping on the valve stem with a plastic hammer.
(12) Using the crankshaft barring tool, rotate the
engine until the next crankshaft damper paint mark
aligns with the mark you placed on the cover.In this
position, cylinders #2 and #5 can be serviced.
(13) Repeat the valve spring compressing proce-
dure previously performed and service the retainers,
springs, and seals as necessary.
(14) Using the crankshaft barring tool, rotate the
engine until the next crankshaft damper paint mark
aligns with the mark you placed on the cover.In this
position, cylinders #3 and #4 can be serviced.
(15) Repeat the spring compressing procedure pre-
viously performed and service the retainers, springs,
and seals as necessary.
INSTALLATION
(1) Install rocker housing.
(2) Install fuel injectors and high pressure fuel
lines.
(3) Lubricate the valve tips and install the cross-
heads in their original locations.
Fig. 33 Rotating Engine with Barring Tool - Typical
1 - REAR FLANGE
2 - BARRING TOOLFig. 34 Spring Compressor Mounting BaseÐPart of
Tool 8319±A
1 - COMPRESSOR MOUNTING BASE
DRENGINE 5.9L DIESEL 9 - 309
INTAKE/EXHAUST VALVES & SEATS (Continued)

(4) Lubricate the crossheads and push rod sockets
and install the rocker arms and pedestals in their
original locations. Tighten bolts to 36 N´m (27 ft. lbs.)
torque.
(5)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
(6) Install cylinder head cover and reusable gasket
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - INSTALLATION).
(7) Connect battery negative cables.
ROCKER ARM / ADJUSTER
ASSY
DESCRIPTION
The unique intake and exhaust rocker arms have
their own rocker shafts and are lubricated by pas-
sages intersecting the cylinder block main oil rifle.
Crossheads are used, which allow each rocker arm to
operate two valves.
The solid push rods are hardened at the rocker
arm and tappet contact areas for superior strength
and durability.
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Remove the rocker arm/pedestal fasteners (Fig.
36) and remove rocker arm and pedestal from cylin-der head. Mark the arms and pedestals so they can
be installed in their original position.
CAUTION: When removing the rocker arms, the
sockets (Fig. 37) may come loose and fall into the
engine. Make sure they stay with the arm upon
removal/installation.
(4) Lift the push rod(s) up and out of the engine
(Fig. 38). Mark them so they can be installed in their
original position.
NOTE: The #5 cyl. intake and exhaust and #6 cyl.
intake and exhaust push rods must be raised
through the provided cowl panel access holes.
(5) Lift the crosshead(s) off of the valve stems.
Mark them so they can be installed in their original
position.
CLEANING
Clean all components in a suitable solvent. If nec-
essary, use a wire brush or wheel to remove stubborn
deposits. Rinse in hot water and blow dry with com-
pressed air. Inspect oil passages in rocker arms and
pedestals. Apply compressed air to lubrication orifices
to purge contaminants.
Fig. 35 Compressing Valve Springs with Tool
8319±A
1 - SPECIAL TOOL 8319
Fig. 36 Rocker Arm and Pedestal Removal
1 - ROCKER ARM
2 - PEDESTAL
9 - 310 ENGINE 5.9L DIESELDR
INTAKE/EXHAUST VALVES & SEATS (Continued)

Crossheads
Inspect the crossheads for cracks and/or excessive
wear on rocker lever and valve tip mating surfaces
(Fig. 43).
INSTALLATION
(1) If previously removed, install the push rods in
their original location.Verify that they are seated
in the tappets.
(2) Lubricate the valve tips and install the cross-
heads in their original locations.
(3) Lubricate the crossheads and push rod sockets
and install the rocker arms and pedestals in their
original locations. Tighten bolts to 36 N´m (27 ft. lbs.)
torque.
(4)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
(5) Install cylinder head cover and reusable gasket
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - INSTALLATION).
(6) Connect battery negative cables.
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER BLOCK
REFACING
(1) The combustion deck can be refaced twice. The
first reface should be 0.25 mm (0.0098 inch). If addi-
tional refacing is required, an additional 0.25 mm
(0.0098 inch) can be removed. Total allowed refacing
is 0.50 mm (0.0197 inch) - (Fig. 44).
(2) The upper right corner of the rear face of the
block must be stamped with a X when the block is
refaced to 0.25 mm (0.0098 inch). A second X must be
stamped beside the first when the block is refaced to
0.50 mm (0.0197 inch) - (Fig. 45).
Fig. 42 Inspecting Push Rod for Flatness
Fig. 43 Inspecting Crosshead for Cracks
Fig. 44 Refacing Dimensions of the Cylinder Block
CYLINDER BLOCK REFACING DIMENSIONS
DIMENSION(A(
1st Reface 0.25mm (0.0098 in.)
2nd Reface 0.25mm (0.0098 in.)
Dim (A) Total 0.50 mm (0.0197 in.)
DIMENSION(B(
Dim.9B9(STD.)323.00 mm   0.10
mm(12.7165 in.  
0.0039 in.)
1st Reface322.75 mm   0.10
mm(12.7067 in.  
0.0039 in.)
2nd Reface322.50 mm   0.10
mm(12.6968 in.  
0.0039 in.)
9 - 312 ENGINE 5.9L DIESELDR
ROCKER ARM / ADJUSTER ASSY (Continued)