clock DODGE TRUCK 1993 Service Service Manual

WIRING
DIAGRAMS
SW - 41

Wiring
Diagram Name _ Sheet Number

Illumination
Lamps-Instrument Panel ........... .12,14

Intermittent
Wiper ......................... .53

Key-In
. . . . . . . .49
Liftgate
Ajar
............................ .51

Park
Brake
.31,33

Power
Door Lock-Left ....................... .73

Power
Door Lock-Right .74

Power
Mirrors .75,76

Power
Window-Left 71
Power
Window-Right . .72

Seat
Belt
Warning
with
Diesel Engine 77
Seal
Belt
Warning
with
Gas Engine .78

Speed
Control
........... ,32,36,38

Standard
Windshield Wiper . .55
Stop
Lamp .32,34,36,38
Transfer
Case
Switch . 13
Transmission
Thermo ....................... .24
Turn Signal .56
Windshield Washer
Intermittent
Wiper . .53
Windshield Washer-Standard .55 Windshield
Wiper-Intermittent
53

Stereo
Radio-4 Speakers .61,62,63,64

Fuse
.61,63

Speaker-Left ......... ............ 62,64

Speaker-Right
. .62,64

Stereo
Radio-Dual Speakers .65
Temperature Sending
with
Diesel Engine . .27
Temperature Sending
Unit
with
Gas Engine .......... .28

Trailer
Tow Wiring 81

Transmission
Overdrive Solenoid ............... .12,14

Transmission
Overdrive System 12,14
Wiring
Diagram Name ^ Sheet Number

2-Speed
Wiper Motor 55
Washer
Pump
Motor
....................... .55
Switch 55
Turn
Signal
System
.......................... .56

Flasher
56
Fuse
.56

Lamps-Front
43,44,45,46

Lamps-Rear
. 79,80,81
Switch
Control
56

Underhood
Lamp 29

Valve
Hydraulic, Dual Solenoid .32,34
Vehicle
Speed
Control
(Diesel) .37,38
Clockspring 42 Connector .37
Fuse
................................. .38

Lamp
Switch . . .38

Resistor
.38

Servo
• .37
Vehicle
Speed
Control
(Gas) .35,36
Clockspring 36
Connector .35
Fuse
......... 36
Lamp
Switch .36

Resistor
.36

Servo
. 35
Vehicle
Speed
Sensor
.20,25,26 Wide Open
Throttle
Cutout Relay . .68,70
Windshield
Wiper-intermittent
...... ....... .53,54
Windshield Wiper-Standard 55

WIRING
DIAGRAMS
8W - 43

FUSIBLE
LINK
(18GY)

12BK/RD
FUSIBLE
LINK

(200R)

(LEFT
FRONT
WHEELHOUSE) HEATED

REAR
WINDOW
SH
39
FUSIBLE
LINK

(200R)

(LEFT
FRONT
WHEELHOUSE)
I—A22
12BK/0R

IT

1
30
AMPS
J CIRCUIT
,—h BREAKER —P CAVITY
#12
-A22
12BK/0R-

RUN ONLY
IGNITION

SWITCH
SH
10

A31

14BK/WT

RUN
AND ACC
F21
12TN

POWER WINDOW
SH
71
FUSE
#11
30 AMP

CI
12DG

A/C
AND
HEATER BLOWER MOTOR
SH
66.67.69

S
FUSE
#10

10*ZJ20
AMP
O

FUSE
#8
310 AMP
-A41
14YL-

ENGINE
STARTER
SYSTEM

SH
7.8.9

A21
14DB
FUSE
#1

3
2 AMP
RUN
AND
START

V34

20WT/RD
A2I
14DB
VEHICLE

SPEED
CONTROL (GAS)

SH
36

VEHICLE

SPEED
CONTROL (DIESEL)
SH
38
FUSE
#3
20 AMP

F20
18WT

BACK-UP
LAMP
SH
79.80

HEATER REAR WINDOW
SH
39
G5

20DB/WT

TO
4tART
D

FUSE
# 2

3
5 AMP

LAMP LOW

FUSE
#9
120 AMP

V6
18DB
WINDSHIELD WIPER

SYSTEM

SH
54.55
RADIO
AND
CLOCK

SH
61.63.65
L5
18RD

i

TURN SIGNAL FLASHER
SH
56

TACHOMETER

PROVISIONS

SH
48

REAR
WHEEL ANTI-LOCK
MODULE

SH
31.33
AUTOMATIC
SHUT DOWN
RELAY

SH
16.22

TRANSMISSION
OVERDRIVE

SOLENOIDS
SH
12.14

FUEL PUMP RELAY
SH
16

GENERATOR
SH
4

VACUUM SENSOR

SH
34

AIR SWITCHING
SOLENOIDS
SH
16

PMC

SH
16

AIR HEATER CONTROLLER

SH
21

WOT RELAY
SH
68.70
A/C

ELECTRONIC CYCLING SWITCH

SH
68.70

3.R.L.
MODULE
SH
46

EMCC
RELAY

SH
11

FUEL HEATER AND PUMP
SH
24
WAIT
TO
START

SH
57

FUEL LAMP
SH
57

GAUGES
SH
59

BRAKE
LAMP
SH
57.58

SEAT
BELT LAMP AND BUZZER
SH
77 78

WATER
IN
FUEL LAMP
SH
57

4
WHEEL DRIVE
INDICATOR LAMP
SH
13

LOW ENGINE
OIL
LAMP
SH
59

MALFUNCTION
INDICATOR LAMP

SH
59

ANTI-LOCK LAMP
SH
57 58

LIFTGATE OPEN LAMP
SH
58

TRANSMISSION

CONTROL MODULE
SH
12.14

SERVICE
REMINDER INDICATOR LAMP
SH
58

J938W-11
FUSE
APPLICATION
CHART

AD
2

WIRING DIAGRAMS
8W - 71

TO FUSIBLE
LINK

(SEE
SH 4,6)
:X2

SPLICE

(SEE
SH 47)
FUSE
#4
(20 AMP)

F33
18PK
RD

F33
18PK
RD
HORN RELAY

[ON
FUSE BLOCK)
(SEE
SH 82)

TO HEADLAMP SWITCH

(SEE
SH 47)
LOW NOTE)
HORN
(HIGH
NOTE)
HORN

(LEFT
SIDE
OF RADIATOR SUPPORT) (GAS)

(LEFT
SIDE
SHIELD (DIESEL)
BLACK X2 18DG/RD

(RIGHT
SIDE
OF RADIATOR SUPPORT) (GAS)

(LEFT
SIDE SHIELD
(DIESEL) BLACK
X2
18DG
RD
NOTE:

HORNS
ON
DIESEL

ARE
ON
LEFT SIDE
NEAR BATTERY

32

X2
18DG
RD
X3
20BK/RD
CLOCK SPRING
OR

HORN RING

(IN
COLUMN)
(IN
STEERING COLUMN)
HORN
SWITCH
STEERING
COLUMN
GROUND
(THROUGH CENTER SHAFT)

J938W-11
HORN
SYSTEM

AD
30

9
- 28 3.9L
ENGINE
•
accompanied by excessive clearance between the
valve stem and rocker arm as valve closes. In either
case,
tappet assembly should be removed for inspec­
tion and cleaning.
The valve train generates a noise very much like a
light tappet noise during normal operation. Care
must be taken to ensure that tappets are making the
noise. In general, if more than one tappet seems to
be noisy, its probably not the tappets.

REMOVAL
(1) Remove the air cleaner.
(2) Remove cylinder head cover.
(3) Remove rocker assembly and push rods. Iden­
tify push rods to ensure installation in original loca­
tion.
(4) Remove intake manifold.
(5) Remove yoke retainer and aligning yokes.
(6) Slide Hydraulic Tappet Remover/Installer Tool

C-4129-A
through opening in cylinder head and seat
tool firmly in the head of tappet.
(7) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed, identify tappets to
ensure installation in original location. (8) If the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to
next oversize. Replace with oversize tappet.

CAUTION:
The
plunger
and
tappet bodies
are not

interchangeable.
The
plunger
and
valve must
al­

ways
be fitted to the
original body.
It is
advisable
to

work
on one
tappet
at a
time
to
avoid mixing
of
parts.
Mixed parts
are not
compatible.
DO NOT
dis­

assemble
a
tappet
on a
dirty
work bench.

DISASSEMBLE (1) Pry out plunger retainer spring clip (Fig. 17).
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, check valve, check valve spring, check valve retainer and plunger spring (Fig. 17). Check valve
could be flat or ball.
ASSEMBLE (1) Clean all tappet parts in a solvent that will re­
move all varnish and carbon.
(2) Replace tappets that are unfit for further ser­
vice with new assemblies. (3) If plunger shows signs of scoring or wear, in­
stall a new tappet assembly. If valve is pitted, or
valve seat on end of plunger is prevented from seat­ ing, install a new tappet assembly.
(4) Assemble tappets (Fig. 17).

INSTALLATION
(1) Lubricate tappets.
PLUNGER
SPRING CHECK
BALL PLUNGER
RETAINER
SPRING CLIP
ROLLER

TAPPET
BODY RETAINER
I
PLUNGER
CHECK VALVE
SPRING PLUNGER
CAP
J9109-220
Fig.
17 Hydraulic
Tappet
Assembly

(2) Install tappets and push rods in their original
positions. Ensure that the oil feed hole in the side of
the tappet body faces up (away from the crankshaft).
(3) Install aligning yokes with ARROW toward
camshaft.
(4) Install yoke retainer. Tighten the bolts to 23
N*m (200 in. lbs.) torque. Install intake manifold.
(5) Install push rods in original positions. (6) Install rocker arms.
(7) Install cylinder head cover.
(8) Start and operate engine. Warm up to normal
operating temperature.

CAUTION:
To
prevent damage
to
valve mechanism,
engine must
not be run
above fast idle
until
all hy­
draulic tappets have
filled
with
oil and
have become
quiet.

VALVE
TIMING
(1) Turn crankshaft until the No.6 exhaust valve
is closing and No.6 intake valve is opening. (2) Insert a 6.350 mm (1/4 inch) spacer between
rocker arm pad and stem tip of No.l intake valve.
Allow spring load to bleed tappet down giving in ef­ fect a solid tappet. (3) Install a dial indicator so plunger contacts
valve spring retainer as nearly perpendicular as pos­ sible. Zero the indicator. (4) Rotate the crankshaft clockwise (normal run­
ning direction) until the valve has lifted 0.254 mm (0.010 inch). The timing of the crankshaft should
now read from 10° before top dead center to 2° after
top dead center. Remove spacer.

CAUTION:
DO NOT
turn
crankshaft
any
further

clockwise
as
valve spring might bottom
and
result in serious damage.

(5) If reading is not within specified limits: (a) Check sprocket index marks.
(b) Inspect timing chain for wear. (c) Check accuracy of DC mark on timing indica­
tor.

(5) Be sure the connecting rod and connecting rod
cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston and connecting rod assemblies from the engine, ro­
tate crankshaft so that the connecting rod is centered in cylinder bore and at BDC. Be careful not to nick
crankshaft journals.
(7) After removal, install bearing cap on the mat­
ing rod.

INSPECTION
Check the crankshaft connecting rod journal for ex­
cessive wear, taper and scoring. Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.
Check the pistons for taper and elliptical shape be­
fore they are fitted into the cylinder bore (Fig. 12).
DIAMETER
(D)

SHOULD BE

0.0000-0.0152
mm

(0.0000-0.0006
in.)
LARGER
THAN
(C).
98.704-98.831
mm

-(3.886-3.891
in.)-
98.577-98.704
mm-
(3.881-3.886
in.) (a) Measure piston ring gap 2 inches from bot­
tom of cylinder bore. An inverted piston can be used to push the rings down to ensure positioning
rings squarely in the cylinder bore before measur­ ing.
(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 inch). The second compression
ring gap should be between 0.508-0.762 mm (0.020- 0.030 inch). The oil ring gap should be 0.254-1.270
mm (0.010-0.050 inch).
(c) Rings with insufficient end gap may be prop­
erly filled to the correct dimension. Rings with ex­
cess 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.
(b) Install the compression rings using Installa­
tion Tool C-4184. The top compression may be in­ stalled with either side up. The second compression
ring must be installed with the identification mark
face up (toward top of piston) and the chamfer should face down. An identification mark on the
ring is a drill point, a stamped letter "O", an oval
depression or the word TOP.
(c) Measure side clearance between piston ring
and ring land (Fig. 13). Clearance should be 0.038-
0.076 mm (0.0015-0.0030 inch) for the compression

rings.
The steel rail oil ring should be free in groove, but should not exceed 0.203 mm (0.0080 inch) side clearance.
FEELER
GAUGE
ELLIPTICAL SHAPE
OF
THE PISTON

SKIRT
SHOULD
BE
0.254-0.304
mm

(0.010-0.012
in.)
LESS
AT DIAMETER
(A)
THAN
ACROSS
THE THRUST
FACES
AT DIAMETER
(B).

J9309-9
Fig.
12
Piston
Measurements

FITTING
PISTONS
Piston and cylinder wall must be clean and dry.
Specified clearance between the piston and the cylin­
der wall is 0.013-0.038 mm (0.0005-0.0015 inch). Piston diameter should be measured at the top of
skirt, 90° to piston pin axis. Cylinder bores should be
measured halfway down the cylinder bore and trans­
verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21°C (70°F).

FITTING
RINGS
(1) Measurement of end gaps: J9209-136

Fig.
13
Measuring
Piston
Ring Side
Clearance (d) Pistons with insufficient or excessive side
clearance should be replaced. (3) Orient the rings:
(a) Arrange top compression ring 90° counter­
clockwise from the oil ring rail gap (Fig. 14). (b) Arrange second compression ring 90° clock­
wise from the oil ring rail gap (Fig. 14).

S
- 40 3.9L
ENGINE
39 Fig.
18 Main Bearing identification
(2) Remove the oil pump from the rear main bear­
ing cap.
(3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 19).

(5)
Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.

Fig.
19 Upper Main Bearing Removal and installation with Tool
C-3059

INSTALLATION Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight­ ened. All bearing capbolts removed during service
procedures are to be cleaned and oiled before instal­ lation.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 19).
(2) Slowly rotate crankshaft counterclockwise slid­
ing the bearing into position. Remove Tool C-3059. (3) Install the bearing caps. Clean and oil the

bolts.
Tighten the capbolts to 115 N*m (85 ft. lbs.)
torque.
(4) Install the oil pump. (5) Install the oil pan.

CRANKSHAFT REAR
OIL
SEALS
The service seal is a 2 piece, viton seal. The upper
seal half can be installed with crankshaft removed
from engine or with crankshaft installed. When a
new upper seal is installed, install a new lower seal.
The lower seal half can only be installed with the
rear main bearing cap removed.
UPPER SEAL REPLACEMENT (CRANKSHAFT
REMOVED)
(1) Remove the crankshaft. Discard the old upper
seal.
(2) Lightly oil the new upper seal lips with engine

oil.

(3) Install the new upper rear bearing oil seal with
the yellow paint facing towards the rear of the en­

gine.

(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 yellow paint facing towards the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap (Fig. 16). Do not over apply sealant or allow the seal­
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica­
tion.
(8) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more
than 2 times for proper engagement. (9) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 N*m (85 ft. lbs.) torque. (10) Install oil pump.
(11) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­
ply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove. (12) Install new front crankshaft oil seal.
(13) Immediately install the oil pan.
UPPER SEAL REPLACEMENT (CRANKSHAFT
INSTALLED)
(1) Remove the oil pan. (2) Remove the oil pump from the rear main bear­
ing cap.

CAUTION:
Th© plunger and
tappet
bodies are not
interchangeable. The plunger and valve must al­

ways
be
fitted
to the
original
body. It is advisable to

work
on one
tappet
at a
time
to avoid
mixing
of parts. Mixed
parts
are not
compatible.
DO NOT
dis­

assemble
a
tappet
on a
dirty
work
bench,

DISASSEMBLE
(1) Pry out plunger retainer spring clip (Fig. 17).
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, check valve, check valve spring, check valve
retainer and plunger spring (Fig. 17). Check valve could be flat or ball.

ASSEMBLE

(1) Clean all tappet parts in a solvent that will re­
move all varnish and carbon.
(2) Replace tappets that are unfit for further ser­
vice with new assemblies.
(3) If plunger shows signs of scoring or wear, in­
stall a new tappet assembly. If valve is pitted, or
valve seat on end of plunger is prevented from seat­
ing, install a new tappet assembly. (4) Assemble tappets (Fig. 17).
PLUNGER
CHECK

BALL
PLUNGER
RETAINER
SPRING CLIP
ROLLER
TAPPET BODY RETAINER I PLUNGER
CHECK VALVE
SPRING PLUNGER
CAP
J9109-220
Fig.
17 Hydraulic
Tappet
Assembly

INSTALLATION
(1) Lubricate tappets.
(2) Install tappets and push rods in their original
positions. Ensure that the oil feed hole in the side of
the tappet body faces up (away from the crankshaft). (3) Install aligning yokes with ARROW toward
camshaft. (4) Install yoke retainer. Tighten the bolts to 23
N»m (200 in. lbs.) torque. Install intake manifold. (5) Install push rods in original positions.
(6) Install rocker arm.
(7) Install cylinder head cover.
(8) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To
prevent
damage to valve mechanism,
engine must not be run above
fast
idle
until
all hy­
draulic
tappets
have
filled
with
oil and have become
quiet.
VALVE
TIMING

(1) Turn crankshaft until the No.6 exhaust valve
is closing and No.6 intake valve is opening. (2) Insert a 6.350 mm (1/4 inch) spacer between
rocker arm pad and stem tip of No.l intake valve. Allow spring load to bleed tappet down giving in ef­
fect a solid tappet. (3) Install a dial indicator so plunger contacts
valve spring retainer as nearly perpendicular as pos­
sible.
Zero the indicator. (4) Rotate the crankshaft clockwise (normal run­
ning direction) until the valve has lifted 0.254 mm (0.010 inch). The timing of the crankshaft should
now read from 10° before top dead center to 2° after
top dead center. Remove spacer.

CAUTION:
DO NOT
turn
crankshaft any
further

clockwise as valve spring
might
bottom
and
result
in serious
damage.

(5) If reading is not within specified limits: (a) Check sprocket index marks.
(b) Inspect timing chain for wear.
(c) Check accuracy of DC mark on timing indica­
tor.

VIBRATION DAMPER
REMOVAL (1) Disconnect the negative cable from the battery.
(2) Remove fan shroud retainer bolts and set
shroud back over engine.
(3) Remove the cooling system fan.
(4) Remove the serpentine belt (refer to Group 7,
Cooling System).
(5) Remove the vibration damper pulley. (6) Remove vibration damper bolt and washer from
end of crankshaft. (7) Install bar and screw from Puller Tool Set
C-3688. Install 2 bolts with washers through the
puller tool and into the vibration damper (Fig. 1).
(8) Pull vibration damper off of the crankshaft.
J9209-81

Fig.
1
Vibration
Damper
Assembly

5.2L ENGINE
9 - 69

BEARING
CAP
J9309-72

Fig.
16 Sealant Application to Bearing Cap (7) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more
than 2 times for proper engagement.
(8) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 Nnn (85 ft. lbs.) torque.
(9) Install oil pump.
(10) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­
ply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove.
(11) Install new front crankshaft oil seal.
(12) Immediately install the oil pan.
MOPAR SILICONE SEALANT

RUBBER
ADHESIVE APPLIED
Fig.
17
Apply
Sealant to Bearing Cap to
Block
Joint

CRANKSHAFT
MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter­ changeable. Lower main bearing halves of No.2 and

4
are interchangeable. Upper and lower No.3 bearing halves are flanged
to carry the crankshaft thrust loads. They are NOT interchangeable with any other bearing halves in the
engine (Fig. 18). Bearing shells are available in stan­
dard and the following under
sizes:
0.25 mm (0.001

inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
Never install an undersize bearing that will reduce
clearance below specifications.

Fig.
18 Main Bearing
Identification

REMOVAL (1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap.
(3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 19).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
Fig.
19 Upper Main Bearing
Removal
and

Installation
with
Tool C-3059

INSTALLATION

Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight­ ened. All bearing capbolts removed during service
procedures are to be cleaned and oiled before instal­ lation. When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 19).
(2) Slowly rotate crankshaft counterclockwise slid­
ing the bearing into position. Remove Tool C-3059.
(3) Install the bearing cap. Clean and oil the bolts.
Tighten the capbolts to 115 N»m (85 ft. lbs.) torque.
(4) Install the oil pump.
(5) Install the oil pan.

CRANKSHAFT REAR
OIL
SEALS
The service seal is a 2 piece, viton seal. The upper
seal half can be installed with crankshaft removed
from engine or with crankshaft installed. When a
new upper seal is installed, install a new lower seal.
The lower seal half can only be installed with the rear main bearing cap removed.
UPPER SEAL REPLACEMENT (CRANKSHAFT
REMOVED) (1) Remove the crankshaft. (2) Lightly oil the new upper seal lips with engine

oil.

(3) Install the new upper rear bearing oil seal with
the yellow paint facing towards the rear of the en­
gine.

(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 yellow paint facing towards the rear of the engine. (7) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap (Fig. 16). Do not over apply sealant or allow the seal­
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica­
tion.
(8) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more
than 2 times for proper engagement.
(9) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately tighten to 115 N*m (85 ft. lbs.) torque. (10) Install oil pump.
(11) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­ ply enough sealant until a small amount is squeezed
out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove. (12) Install new front crankshaft oil seal.
(13) Immediately install the oil pan.

UPPER SEAL
REPLACEMENT (CRANKSHAFT

INSTALLED)
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap.
(3) Remove the rear main bearing cap. Remove
and discard the old lower oil seal.

(4)
Carefully remove and discard the old upper oil
seal.
(5)
Lightly oil the new upper seal lips with engine

oil.
To allow ease of installation of the seal, loosen at
least the 2 main bearing caps forward of the rear
bearing cap.
(6) Rotate the new upper seal into the cylinder
block being careful not to shave or cut the outer sur­ face of the seal. To assure proper installation, use the installation tool provided with the kit. Install the
new seal with the yellow paint facing towards the
rear of the engine.
(7) Install the new lower rear bearing oil seal into
the bearing cap with the yellow paint facing towards
the rear of the engine.
(8) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap (Fig. 16). Do not over apply sealant or allow the seal­
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica­
tion. Be sure the yellow paint faces toward the rear of the engine. (9) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more than 2 times for proper engagement. (10) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten ALL cap
bolts to 115 N*m (85 ft. lbs.) torque. (11) Install oil pump.
(12) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­
ply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove. (13) Immediately install the oil pan.
LOWER SEAL REPLACEMENT (1) Remove the oil pan.
(2)
Remove the oil pump from the rear main bear­
ing cap. (3) Remove the rear main bearing cap and discard
the old lower seal.

5.9L
ENGINE SERVICE PROCEDURES

INDEX

page
Camshaft
91

Crankshaft
98
Crankshaft Main Bearings
99

Crankshaft Rear
Oil
Seals
100

Cylinder
Block
101

Cylinder
Head Cover
81

Cylinder
Heads
82
Distributor
92

Engine Assembly
80

Engine
Front
Mounts
77

Engine Rear Mount
78

Front
Crankshaft
Oil
Seal Replacement
91
page
General
Information
77
Hydraulic
Tappets
87

Oil
Pan 93

Oil Pump
. 94

Piston
/
Connecting
Rod
Assembly
96

Rocker Arms
81

Specifications—5.9L
Engine
103

Timing
Chain Cover
89

Valve Stem Shield
/
Spring Replacement
86

Valve
Timing
. 88

Valves
/
Valve Springs
84

Vibration
Damper
88

GENERAL
INFORMATION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve en­
gine with hydraulic roller tappets (Fig. 1).
Engine Type .90° V-8 OHV
Bore and Stroke 101.6 x 90.9
mm
(4.00 x 3.58 in.)
Displacement 5.9L (360 cu. in.)
Compression Ratio 9.1:1
Torque 441 N-m (325 ft. lbs.) @ 3,200 rpm (Heavy Duty). 448 N-m (330 ft. lbs.)
@
2,800 rpm
Firing Order
1-8-4-3-6-5-7-2

Lubrication ...... Pressure Feed - Full Flow Filtration
Engine Oil Capacity .4.7L (5.0 Qts) w/filter
Cooling System . .
.
Liquid Cooled - Forced Circulation Cooling Capacity ..... . . 14.7L (15.5 Qts)
Ramcharger (4WD) 14.2L (15.0 Qts)
Cylinder Block Cast Iron Crankshaft
-
Nodular Iron
Cylinder Head • . Cast Iron Combustion Chambers Wedge-High Swirl Valve
Shrouding
Camshaft Nodular Cast Iron Pistons Cast Aluminum Alloy
Connecting Rods Forged Steel
J9309-99
Fig. 1
Engine
Description
This engine is designed for unleaded fuel.
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. 2).
The engine serial number is stamped into a ma­
chined pad located on the left, front corner of the cyl­
inder block. When component part replacement is
necessary, use the engine type and serial number for
reference (Fig. 3).
o
FRONT OF
ENGINE CLOCKWISE ROTATION

1-8-4-3-6-5-7-2
J908D-49

Fig. 2 Firing Order

X
M 5.9L T
XXXX
XXXXXXXX

X
= Last Digit of Model Year
M = Plant - M Mound Road S Saltillo
T Trenton K Toluca
5.9L = Engine Displacement

T
= Usage -
T
Truck
XXXX
= Month/Day

XXXXXXXX
= Serial Code - Last 8 Digits of
VIN
No.
J9209-74

Fig.
3
Engine
identification
Number

ENGINE
FRONT MOUNTS
REMOVAL (1) Raise hood and position fan to assure clearance
for radiator top tank and hose.