DODGE TRUCK 1993 Service Repair Manual

9
- 116 5.9L
(DIESEL) ENGINE

•

CYLINDER HEAD

Fig. 11 Cylinder Head/Gasket Alignment J9109-36
Fig. 12 Cylinder Head Tightening Sequence
(7) Be sure to lubricate the push rod sockets with
clean engine oil.
(8) Install the rocker lever pedestal bolts and
tighten to 24 N*m (18 ft. lbs.) torque. (9) Adjust the valve clearance.
(10) Install the valve covers. Tighten the bolts to
24 N*m (18 ft. lbs.) torque.
(11) Install the injector nozzles and fuel lines (refer
to Group 14, Fuel System).
(12) Install the fuel filter (refer to Group 14, Fuel
System for the proper procedures). (13) Install the exhaust manifold (refer to Group

11,
Exhaust System and Intake Manifold).
(14) Install the turbocharger.
(15) Connect the radiator and heater hoses. (16) Fill the engine with new coolant or the clean
drained coolant (refer to Group 7, Cooling System for
the proper procedure). (17) Fill the engine with clean lubricating oil (re­
fer to Group 0, Lubrication and Maintenance).
VALVES
AND VALVE
SPRINGS

REMOWAL
(1) Remove the cylinder head.
(2) Mark the valves to identify their position.
(3) Compress the valve spring and remove the
valve stem collets (Fig. 1). (4) Release valve spring and remove the retainer
and spring (Fig. 1).
(5) Remove the remaining collets, retainers,
springs and valves. Keep the valves in a labeled
rack.
(6) Remove the valve stem seals (Fig. 1). -38
Fig. 1 Valve Removal
WALVES

CLEANING AND INSPECTION
Before cleaning, note the valve number. Clean the
valve heads with a soft wire wheel. Mark the valve
with the numbet* noted above.
Polish the valve stems with crocus cloth.
Inspect for abnormal wear on the valve heads and

stems.
Replace badly worn valves. Check for bent valves. Replace bent valves.
Measure the valve stem diameter (Fig. 2). The
valve stem diameter should be 7.935-7.960 mm (0.3126-0.3134 inch). If out of limits, replace the
valve. Mark the new valves with the replacement lo­ cation. Ik 1

MEASURE
AT THESE POINTS
Fig. 2 Measure Valve Stem Diameter

•
5.9L
(DIESEL)
ENGINE
9 - 117 Inspect the end of the valve stem for flatness.
If required, resurface the valve end.

VALVE
GRINDING
The valve seat angle should be 30° (Intake Valve)
and 45° (Exhaust Valve) - (Fig. 3). INTAKE
EXHAUST

J9109-41
^ 00 ^

Fig.
3
Valve
Seat
Angle
Measure the rim thickness (Fig. 4). The minimum
valve rim thickness is 0.79 mm (0.031 inch).

VALVE
RIM

THICKNESS

J9109-146

Fig.
4
Valve
Rim
Thickness

Grind the face of valves to be reused.
Check the valve stem tip for flatness. If required,
re-surface the tip.

VALWE
GUIDES

INSPECTION
Inspect the valve guides for scuffing or scoring.
Measure the valve guide bore (Fig. 5). The bore di­
ameter should be 8.019-8.089 mm (0.3157-0.3185

inch).

If the valve guide bores are larger than the worn
limit, the cylinder head must be machined for service
valve guides. New valve guides must be reamed to size after they are installed.
If the cylinder head needs service valve guides and
valve seat inserts, the valve guides should be in­ stalled first.
NEW
DIAMETER
LIMITS

8.019-8.029
mm
(0.3157-0.3165
inch)
WORN
LIMIT

8.090
mm
(0.3185
inch)

J9109-135

Fig.
5
Valve
Guide
Bore

INSTALLATION
THIN WALL-SERVICE GUIDES Machine the cylinder head valve guide bores to
11.125 ±0.013 mm (0.4380 ±0.0005 inch) in diame­
ter (Fig. 6).
Service valve guides must be centered with valve
seats within 0.35 mm (0.01378 inch) diameter. They
must also be square with the combustion face within 0.10 mm (0.004 inch) at 50.0 mm (1.9685 inch) ra­

dius.

Lubricate the valve guides with oil and press the
guides flush to the bottom of the bosses. Trim off the top of the valve guides flush to top of
guide bosses, if necessary. Machine the valve guide bores to
8.029
±0.010 mm
(0.3161 ±0.0004 inch) - (Fig. 6). The valve guide bore must be centered with the
valve seat within 0.35 mm (0.0138 inch) diameter. It also must be square with the combustion face within
0.010 mm (0.0004 inch) at 50.0 mm (2.0 inch) radius. THICK WALL-SERVICE GUIDES
Machine the cylinder head valve guide bores to
14.000 ±0.013 mm (0.5512 ±0.0005 inch) diameter
(Fig. 7). Valve guides must be centered with valve seats
within 0.35 mm (0.01378 inch) diameter. Valve guides must also be square with the combustion face
within 0.10 mm (0.004 inch) at 50.0 mm (2.0 inch) radius. Lubricate the valve guides with oil and press in
the guides to 12.25 ±0.50 mm (0.4823 ±0.020 inch) protrusion above the cylinder head. Ream the bores to
8.029
±0.010 mm (0.3161
±0.0004 inch) - (Fig. 7).

i - 118 5.9L
(DIESEL) ENGINE

VALVE GUIDE
BORES

EXHAUST CYLINDER
HEAD
INTAKE
CYLINDER HEAD VALVE GUIDE
BORES

CYLINDER HEAD VALVE GUIDE
BORES
11.125
±0.013 mm (0.438 ± 0.0005 in)

VALVE GUIDE
BORES

8.029
±0.010
mm
(0.3161 ±0.0004 in)

J9109-136

Fig.
6
Service
Valve
Guides—Thin
Wall

VALVE GUIDE
BORES
CYLINDER HEAD
EXHAUST INTAKE
CYLINDER HEAD VALVE GUIDE
BORES
CYLINDER HEAD VALVE GUIDE
BORES

14.000 ±0.013
mm
(0.5512 ± 0.0005 in)
VALVE GUIDE
BORES

8.029
±0.010
mm
(0.3161 ±0.0004 in)
J9109-137

Fig.
7
Service
Valve
Guides—Thick
Wall

VALVE
SPRINGS
Measure
the
valve spring length.
The
approximate
free length
is
55.63
mm
(2.190 inch) with
the
maxi­ mum inclination
of 1.0 mm
(0.039 inch).
Measure
the
valve spring force. 289.32
N (65 lbs.)

is
the
minimum acceptable load required
to
compress
the spring
to a
height
of
49.25
mm (1.94
inch). If
the
valve spring does
not
meet
the
limits above,
replace
the
spring.
VALVE
SEATS
INSPECTION
Cylinder head with integral valve seats
can be

ground only once. Previously ground integral seats
must
be
replaced with service seats. One
X
stamped into
the
head casting identify seats
that have been ground previously
(Fig. 8).

Two
X's
stamped
on the
head indicate service seats
have been installed
(Fig. 8).
Service seats
can be
ground.
SERVICE SEATS

INSTALLED
n
o

REGROUND INTEGRAL
VALVE SEAT

J9109-138

Fig.
8
Reworked
Cylinder Head
Seats—Stamped
Identification
On
the
integral seat head,
if
0.254
mm
(0.010 inch)
or more
has
been removed from
the
head combustion surface, service seats must
be
installed. To determine
if the
head
has
been previously
re­

surfaced, before calculating valve depth, process
as

follows:
(1) Check
the
rear lower right corner
of the
head
for
a
stamping that would indicate previous resurfac­ ing
(e.g.
.003).
(2)
To
verify
the
information,
or if no
amount
is in­

dicated, measure
the
head height
(Fig. 9).
(3)
If the
head height
is
94.75
mm
(3.730 inch)
or

greater,
the
valve seats
may be
ground,
if
they have
not been ground previously.
CYLINDER
HEAD

HEIGHT

J9109-139

Fig.
9
Cylinder Head Height

•

5.9L (DIESEL) ENGINE
9 - 119
INTEGRAL VALWE SEAT GRINDING

After resurfacing the valves and determining that
all valves meet specifications, install the valves in
their designated locations and measure valve depth (Fig. 10). The valve depth is the distance from the
valve face to the head deck. Record the depth of each valve.

CYLINDER
HEAD DECK GRIND
TO 15°

VALVE
DEPTH
J9109-140

Fig.
10
Valve
Depth
Grind the valve seats to remove scores, scratches
and burns. The seat angle should be—Intake 30° and
Exhaust 45°. Install the valves in their respective bores and
measure the depth again (Fig. 10). Record the depth
of each valve.
The grinding depth is the difference between the
measurement before grinding and the measurement after grinding. The grinding depth maximum limit (integral seats only) is 0.254 mm (0.010 inch). Ser­
vice valve seats are available for over limit integral
valve seats.
Identify ground valve seats by stamping the cylin­
der head.
Install the valves in their designated locations and
measure the depth of each. The valve depth limit (In­
tegral and Inserted Seats) is 0.99 mm to 1.52 mm (0.039 inch to 0.060 inch). Replace the valve if the
depth is over this limit.
Apply a light coat of valve lapping compound to
each valve and lap each valve to its mating seat.
Remove the valves and clean lapping compound
from the valves and seats.
Measure the valve seat width indicated by the lap­
ping surface. The valve seat width limit is
1.50-2.00

mm (0.060-0.080 inch).
If required, grind the areas with a 60° stone and a
15° stone to center the seat on the valve face. Main­
tain the valve seat width limits (Fig. 11).

SERVICE
VALVE
SEAT
INSTALLATION
Inspect the valve guide bores as described in the
valve guide section of this manual. If it is necessary
to install valve guides, install the guides before in­ stalling the service seats.
J9109-141
Fig.
11
Grind
Valve
Seat

Replacement valve seat inserts must be installed if
the valve seats have been ground previously. The il­ lustrated marks indicate valve seats have been
ground previously.
Machine the cylinder head to install the service
valve seats (Figs. 12 and 13).

COMBUSTION FACE VALVE
SEAT
DEPTH VALVE SEAT DEPTH

10.40 ±0.10 mm
(0.4094
±0.004
inch)

VALVE SEAT
WIDTH

47.0
±0.013
mm
(1.8504
±
0.0005
in)

MAXIMUM
RADIUS

0.40 mm
(0.0157
inch) MAX.

SURFACE FINISH

3.2 micrometers
(128.0
microinch)

J9109-142

Fig.
12
Machining
for
Service
Valve
Seats—Intake
Valve

Press service seats into the machined pockets.
Stake the valve seats into the pockets.

9
- 120 5.9L
(DIESEL)
ENGINE

•

COMBUSTION
FACE

VALVE
SEAT

DEPTH

'///
A
I
V

1

VALVE
SEAT
DEPTH

10.20 ±0.10 mm
(0.4015
±0.004
inch)
VALVE
SEAT
WIDTH

43.65
±0.013
mm
(1.7185
±0.0005
in)

MAXIMUM
RADIUS

0.40 mm
(0.0157
inch) MAX.

SURFACE
FINISH

3.2 micrometers
(128.0
microinch)

J9109-143

Fig.
13
Machining
for
Service
Valve
Seats—Exhaust
Valve

SERVICE VALVE SEAT GRINDING
Install the valves in their designated location and
measure the valve depth. The valve depth is the dis­
tance from the valve face to the head deck. Record the depth of each valve (Fig. 14). The depth
is 0.99-1.52 mm (0.039-0.060 inch).
Grind the valve seats to remove scores, scratches
and burns. The valve seat angle is 30° (Intake) and
45° (Exhaust). Install the valves in their respective bores and
measure the depth again (Fig. 14). The valve depth
limit is 0.99-1.52 mm (0.039-0.060 inch). Replace the
valve if the depth is over the limit.
Apply a light coat of valve lapping compound to
each valve and lap each valve to its companion seat.
Remove the valves and clean the lapping compound
from the valve and seats.
Measure the valve seat width indicated by the
lapped surface (Fig. 15). The width limits are
1.5-2.0

mm (0.060-0.080 inch). If required, grind lower area
with 60° stone and upper area with 15° stone (Fig.
15).
Be sure to center the seat on the valve face.
Maintain the valve seat within limits.
MIN.
-
0.990
mm
(0.039
inch)

MAX.
- 1.520 mm
(0.060
inch)

J9109-44
Fig.
14
Valve
Depth
with
Seat
Insert

MINIMUM

1.5 mm

(0.060
inch)
MAXIMUM
2.0
mm

(0.080
inch)
J9109-45

Fig.
15
Valve
Seat
Width

SERVICE VALVE SEAT REPLACEMENT
To replace service seat inserts, machine the insert
in the same manner as if machining out the internal
seat. Hold the same tolerances and follow the same
installation procedures.

INSTALLATION
(1) Clean all cylinder head components before as­
sembling.
(2) Install the valve stem seals (Fig. 16). The in­
take and exhaust valve seals are the same.
(3) Lubricate the stems with SAE 90W oil before
installing the valves. Install the valves in the same
positions as removed.
(4) Compress the valve spring after installing the
spring and retainer (Fig. 17).
(5) Install new valve collets and release the spring
tension (Fig. 17).

WARNING: WEAR PROTECTIVE EQUIPMENT
AND
DO
NOT
STAND
IN
LINE
WITH
THE VALVE STEM

WHEN TAPPING THE VALVES.

•

Fig.
17
Valve,
Valve
Spring
and Collet
Installation
(6) Tap the ends of the valve stems with a mallet
to verify the collets are seated. (7) Install the cylinder head.
(8) Check the valve clearance adjustment.

VALVE CLEARANCE ADJUSTMENT
Use the timing pin to locate Top Dead Center
(TDC) for cylinder No.l (Fig. 18). The timing pin is
located at the back of the gear housing and below the
injection pump. Be sure to disengage the timing pin
after locating top dead center. Adjust the valves when the engine is cold, below
60°C (140°F).

STEP
1 Adjust the clearance for the valves shown in Fig.

19.
The valve lash adjustment is 0.254 mm (0.010
inch) for the intake valve. The valve lash adjustment
is 0.508 mm (0.020 inch) for the exhaust valve. Tighten the valve adjusting nuts to 24 N*m (18 ft.
lbs.) torque.
Be sure timing pin is disengaged before rotating
the crankshaft. Mark the pulley and rotate the crankshaft 360°.
5JL (DIESEL) ENGINE
9 - 121

Fig.
18 Locating TDC
using
Timing Pin
I = INTAKE E = EXHAUST

E
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J9109-34 FRONT
mz£>
Fig.
19
Adjust
Valve
Clearance—Step 1

STEP
2 Adjust the clearance for the valves shown in Fig.

20.
The valve lash adjustment is 0.254 mm (0.010
inch) for the intake valve. The valve lash adjustment
is 0.508 mm (0.020 inch) for the exhaust valve.
Tighten the bolts to 24 N*m (18 ft. lbs.) torque.
I = INTAKE E = EXHAUST

El
IE IE
©©©©©©
J9109-35 FRONT

Fig.
20
Adjust
Valve
Clearance—Step 2

9
- 122 5.9L
(DIESEL) ENGINE

•
GEAR
HOUSING
/
COVER

GEAR
HOUSING
REMOVAL
(1) Remove the engine assembly from the vehicle.
(2) Remove the front end components and the gear
housing cover (refer to Gear Housing Cover Removal
for the proper procedures). (3) Remove the following:
• Camshaft
• Gear driven accessories
• Fuel injection pump (refer to Group 14, Fuel Sys­
tem)
• Fan hub assembly (refer to Group 7, Cooling Sys­
tem)
(4) Remove the gear housing and gasket (Fig. 1).
(5) Clean the gasket material from the cylinder
block.

Fig.
1 Gear
Housing/Gasket

INSTALLATION
(1) Install a new gasket and the gear housing.
Tighten the bolts to 24 N*m (18 ft. lbs.) torque. (2) Install the camshaft. Make sure the alignment
marks on the camshaft and crankshaft gears are aligned (Fig. 2),
(3) If a new housing is installed, the timing pin as­
sembly must be accurately located. (4) Install the following:
• Fan hub assembly (refer to Group 7, Cooling Sys­
tem)
• Fuel injection pump (refer to Group 14, Fuel Sys­
tem) • Gear driven accessories (5) Install the gear housing cover (refer to Gear
Housing Cover Installation for the proper proce­
dures).

(6) Install the front end components.
(7) Install the engine assembly into the vehicle. J9109-104

Fig.
2 Camshaft/Crankshaft Gear
Alignment

GEAR
HOUSING COVER REMOVAL

(1) Remove fan drive assembly.
(2) Remove the fan belt (Fig. 3).
(3) Remove belt tensioner (Fig. 3).
Fig.
3 Drive Belt
Installation

(4) Remove oil fill tube and adaptor (Fig. 4).
(5) Remove vibration damper.

-158
Fig.
4 Oil Fill Tube

•
5.9L
(DIESEL)
ENGINE
9 - 123 (6) Remove the bolts that hold the gear cover to
the gear housing. (7) Gently pry the cover away from the housing,
taking care not to mar the gasket surfaces (Fig. 5). (8) Clean the old gasket residue from the back of
the gear cover and front of the gear housing.

Fig.
5 Gear
Housing
and
Cover

INSTALLATION
(1) Lubricate the front gear train with clean en­
gine oil.
(2) Thoroughly clean the front seal area of the
crankshaft. The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks.
(3) Install the gear housing cover and a new gas­
ket.
(4) Install the bolts but DO NOT tighten them at
this time.
(5) Use the alignment/installation tool from the
seal kit to align the cover to the crankshaft (Fig. 6). (6) Tighten the gear housing cover bolts to 24 N*m
(18 ft. lbs.) torque.
Fig.
6 Alignment/Installation Tool
(7) Remove the alignment/installation tool. Always
use a seal pilot when you install a seal.
(8) Apply a bead of Loctite 277 to the outside di­
ameter of the seal. Install the pilot from the seal kit onto the crankshaft. Install the seal onto the pilot
and start into the gear housing cover. Remove the pi­
lot. (9) Use the alignment/installation tool and a plas­
tic hammer to install the seal to the correct depth.
To prevent damage to the seal carrier, hit the align­ ment/installation tool alternately at the 12, 3, 6 and 9 o'clock positions.
(10) Install the oil fill tube and mounting bolts.
Tighten the bolts to 43 N*m (32 ft. lbs.) torque. (11) Install the vibration damper. DO NOT tighten
the bolts to the correct torque valve at this time.
(12) Install the belt tensioner. Tighten the mount­
ing bolts to 43 Nnn (32 ft. lbs.) torque. (13) Raise the belt tensioner to install the belt.
(14) Tighten the vibration damper bolts to 125
N*m (92 ft. lbs.) torque. Use an engine barring tool to keep the engine from rotating during tightening op­
eration.

TIMING
PIN TIMING PIN REPLACEMENT The timing pin can be replaced without removing
the assembly from the gear housing. (1) Remove the timing pin by prying the retaining
ring out with a small screwdriver. Replace the re­
taining ring if it is damaged during removal.
(2) If timing pin assembly is removed from gear
housing, it must be precisely reset to obtain exact

TDC.

(3) Install a new O-Ring, lubricate the pin and po­
sition in the housing (Fig. 7). Install the new retain­
ing ring to 1.5 mm (0.059 inch).
Fig.
7
Engine
Timing Pin Location
TIMING PIN HOUSING ASSEMBLY/ GASKET
REMOVAL

(1) Locate TDC for cylinder No.l.
(2) Remove the timing pin housing assembly and
gasket.
(3) Clean any gasket material from the gear hous-

9
- 124 5.9L
(DIESEL)
ENGINE

Fig.
8 Fabricated Wire Pointer (5) Rotate the crankshaft one-quarter rotation in
the opposite direction of engine rotation (counter­ clockwise).
(6) Tighten the No.l cylinder exhaust valve adjust­
ing screw two complete turns. Tighten the locknut.
CAUTION; Use extreme
care
that
the
piston
does
not
push
against
the
exhaust
valve with so
much

force that it
bends
the
push
rod (Fig. 9).
(7) Rotate the crankshaft slowly in the direction of
engine rotation until the piston touches the exhaust
valve (Fig. 9). (8) Mark the vibration damper corresponding to
the wire pointer (Fig. 9).
(9) Rotate the crankshaft in the opposite direction
until the piston touches the valve (Fig. 10). Make sure that the piston touches the valve with approxi­
mately the same amount of force as in the previous step (Fig. 10).
(10) Mark the vibration damper again (Fig. 10). (11) Measure the distance and mark the pulley at
one-half that distance between the two marks. This •

Fig.
9 Locate and Mark
Vibration
Damper—First
Mark

Fig.
10 Mark
Vibration
Damper—Second
Mark
Fig.
11 Location of Top
Dead
Center (TDC) mark is the TDC mark (Fig. 11).
(12) Completely loosen the No.l cylinder exhaust
valve adjusting screw. (13) Rotate the crankshaft with Cummins Barring
Tool 3377371 approximately 180° in the direction of engine rotation until the pointer is aligned with the
TDC mark. Look through the back side of the gear housing for the timing pin hole in the camshaft gear.
ing and from the timing pin housing assembly.

INSTALLATION
(CYLINDER
HEAD
ON) The location of the timing pin assembly on the
gear housing is critical for correct engine adjustment.
Follow this procedure to install the assembly so that it corresponds to TDC for cylinder No.l. (1) Look through the hole in the gear housing and
rotate the engine until the hole in the cam gear can
be seen. (2) Adjust the No.l cylinder exhaust rocker lever
to have zero (0) valve clearance.
(3) Remove the injector nozzles from all of the cyl­
inders. This step is important to vent the cylinders so
the crankshaft can be rotated smoothly to locate TDC
for cylinder No.l.
(4) Temporarily install the vibration damper. Fab­
ricate and install a wire pointer (Fig. 8).

•

5JL
(DIESEL) ENGINE
9 - 125 (14) Reset the valves on No.l cylinder and install
valve cover.
(15) Install timing pin housing assembly and a
new gasket.
(16) Apply a coat of Loctite 59241 Liquid Teflon, or
equivalent to the threads of the Torx head bolts. (17) Hold the timing pin in the hole to align the
housing and install the Torx head bolts. Tighten the
Torx bolts to 5 N»m (44 in. lbs.) torque.
(18) Install the injectors and bleed the fuel system
(refer to Group 14, Fuel System).

INSTALLATION
(CYLINDER
HEAD
OFF) The timing pin assembly is precisely located on the
gear housing to correspond to TDC for Cylinder No.l.
The timing pin assembly must be relocated if the gear housing is interchanged.
(1) Temporarily install the vibration damper and a
fabricated wire pointer (Fig. 12). Put a flat washer
between the pointer and gear housing to prevent damage to the gear housing.
(2) Fabricate a steel plate (Fig. 13).

Fig.
12 Fabricated
Wire
Pointer
Fig.
13 Fabricated
Steel
Plate
(3) Use two flywheel housing bolts to assemble the
plate over No.l cylinder (Fig. 14).

Fig.
14 Fabricated
Plate
Location on No.1 Cylinder (4) Rotate the crankshaft in the direction of rota­
tion until the piston contacts the plate.
(5) Mark the vibration damper (Fig. 11).
(6) Rotate the engine in the opposite direction un­
til the piston contacts the plate. (7) Mark the vibration damper (Fig. 11).
(8) Mark the vibration damper for TDC. TDC will
be one-half the distance between the first two marks (Fig. 11).
(9) Remove the plate and rotate the engine in the
direction of rotation until the pointer aligns with the
TDC mark. (10) Look for the timing pin hole in the camshaft
gear. If it is not visible, rotate the crankshaft one
complete rotation. Align the pointer with the TDC
mark.
(11) Install the timing pin housing assembly with
a new gasket. (12) Apply a coat of Loctite 59241 liquid teflon, or
equivalent to the threads of the torx head bolts.
(13) Push the pin into the hole in the cam gear to
align the timing pin housing.
(14) Hold the pin in while tightening the torx head
bolts to 5 Nnn (44 in. lbs.) torque. Be sure timing pin is disengaged before rotating the engine.
(15) Remove the vibration damper and wire
pointer.

TAPPET
REMOVAL (1) Remove the camshaft. (2) Insert a trough the full length of the cam bore
(Fig. 1). Cummins Tappet Changing Tool 3822513 is
available for this job.
(3) Make sure the trough is positioned so it will
catch the tappet when the wooden dowel is removed. (4) Identify the location of each tappet as it is re­
moved. The tappets must be installed in their origi­
nal locations.