DODGE TRUCK 1993 Service Repair Manual

9
- 136 5.9L
(DIESEL)
ENGINE

• MIN.
68.962 mm (2.715
inch)
MAX. 69.013 mm (2.717 inch)
Out-of-Round - Max.
0.050
mm (0.002 inch)
Taper - Max. 0.013 mm (0.0005 inch)
Bearing Clearance - Max.

0.089
mm (0.0035 inch)
J9109-91

Fig.
7
Connecting
Rod
Journal
Diameter Limits
Install the retaining ring into the pin groove on the
FRONT side of the piston.
Fig.
8 Proper Markings on the
Piston
and

Connecting
Rod (2) Lubricate the pin and bore with engine oil.
(3) Install the piston pin in the opposite side of the
installed retaining pin. Pistons do not require heat­
ing to install the pin, however, the piston does need
to be at room temperature or above.
(4) Determine the piston diameter and obtain the
appropriate ring set. The piston rings can be identi­
fied as shown in Fig. 9. TOP RING INTERMEDIATE
RING
OIL CONTROL RING TOP J9109-69

Fig.
9
Piston
Ring
Identification

(5) Position each ring in the cylinder and use a
piston to square it with the bore at a depth of 89.0 mm (3.5 inch) - (Fig. 10). (6) Use a feeler gauge to measure the piston ring
gap (Fig. 11).
Fig.
10 Position of
Ring
in Cylinder
Bore

MINIMUM MAXIMUM
TOP
0.400
mm
(0.0160 inch)
0.700
mm
(0.0275 inch)
INTERMEDIATE
0.250
mm
(0.0100 inch)
0.550
mm
(0.0215 inch)
OIL CONTROL
0.250
mm
(0.0100 inch)
0.550
mm
(0.0215 inch)
J9109-71
Fig.
11
Piston
Ring
Gap

•

5.9L (DIESEL) ENGINE
9 - 137 (7) The top surface of all of the rings are identified
with the word TOP or the supplier's MARK. Assem­
ble the rings with the word TOP or the supplier's MARK up.
(8) Position the oil ring expander in the oil control
ring groove (bottom groove). (9) Install the oil control ring with the end gap
OPPOSITE the ends on the expander (Fig. 12). OIL CONTROL
RING
PISTON EXPANDER
J9109-72

Fig.
12 Oil Control
Ring/Expander
Location in
Groove
(10) Install the intermediate piston ring in the sec­
ond groove (Fig. 13).
(11) Install the top piston ring in the top groove
(Fig. 13). PISTON RING
INSTALLATION
TOOL J9109-74

Fig.
13
Piston
Ring
Installation
Tool (12) Position the rings as shown in Fig. 14.
(13) Install the original bearings as removed or in­
stall new bearings. If new bearings are used, be sure
to obtain the proper bearing clearance (Fig. 15). (14) DO NOT lubricate the side of the bearing that
is against the connecting rod or cap. Apply a coat of
Lubriplate 105, or equivalent to the new upper and
lower connecting rod bearings.

INSTALLATION
(1) Lubricate the cylinder bore with clean engine

oil.
(2) Generously lubricate the rings and piston
skirts with clean engine oil. (3) Compress the rings using a piston ring com- TOP
RING
INTERMEDIATE
RING
OIL CONTROL
RING

J9109-73

Fig.
14
Piston
Ring
Positioning
STANDARD
J9109-82
OVERSIZE
0.250 mm (.0098 in.
0.500 mm (.0197 in.
0.750 mm (.0295 in. 1.000 mm (.0394 in.

Fig.
15
Connecting
Rod Bearing
Size
Location pressor tool (Fig. 16). If using a strap-type ring com­
pressor, make sure the inside end of the strap does
not hook on a ring gap and break the ring.
PISTON
RING
COMPRESSOR TOOL J9109-83

Fig.
16
Piston
Ring
Compressor
Tool (4) Bar the crankshaft so the rod journal for the
piston to be installed is at BDC (Bottom Dead Cen­
ter) - (Fig. 17).
(5) Be sure the FRONT marking on the piston and
the numbers on tlie rod and cap are oriented as illus­
trated.
(6) Position the piston and rod assembly into the
cylinder bore with the word FRONT on the piston to­
wards the front of the cylinder block. Use care when
you install the piston and connecting rod so the cyl­ inder bore is not damaged.
(7) Push the piston into the bore until the top of
the piston is approximately 50 mm (2 inch) below the

9
- 138 5.9L
(DIESEL)
ENGINE

J9109-84

Fig.
17
Piston/Rod
Assembly
at BDC
top
of the
block. Carefully pull
the
connecting
rod

onto
the
crankshaft journal.
(8)
Use
clean engine
oil to
lubricate
the
threads
and under
the
heads
of the
connecting
rod
bolts. (9)
The 4
digit number stamped
on the rod cap at

the parting line must match
and be
installed towards
the
oil
cooler side
of the
engine
(Fig. 18).
O
o

-—-—.—
f
'
-
ro o

O —

—"k

J9109-85
Fig.
18
Correct
Rod
Cap
Installation

(10) Install
the rod cap and
bolts
to the
connecting
rod. Tighten
the
connecting
rod and
bolt evenly
in 3
steps.

• Tighten
the
bolts
to 35 Nun (26 ft. lbs.)
torque. • Tighten
the
bolts
to 70 N*m (51 ft. lbs.)
torque.
• Tighten
the
bolts
to 100 Nun (73 ft. lbs.)
torque. (11)
The
crankshaft must rotate freely. Check
for

freedom
of
rotation
as the
caps
are
installed.
If the
crankshaft does
not
rotate freely, check
the
installa­
tion
of the rod
bearing
and the
bearing size.
(12) Measure
the
side clearance between
the
con­
necting
rod and the
crankshaft
(Fig. 19). DO NOT

measure
the
clearance between
the cap and
crank­ shaft.
(13) Install
the
suction tube
and oil pan.
(14) Install
the
cylinder head onto
the
block.
(15) Install
the
engine assembly into
the
vehicle.
SIDE
CLEARANCE
LIMITS

MIN.
MAX. 0.100
mm

0.300
mm

(0.004 inch)
(0.012 inch)
Fig.
19
Side
Clearance between
Connecting
Rod/

Crankshaft

CRANKSHAFT

REMOVAL (1) Remove
the
rear crankshaft seal housing.
(2) Remove
the
gear housing.
(3) Rotate
the
engine
to a
horizontal position
and

remove
the
main bearing bolts. (4)
The
main bearing caps should
be
numbered.
If

they
are not, be
sure
to
mark them, beginning with
number
one at the
front
and
ending with number seven
at the
rear
(Fig. 1).

MAIN BEARING

CAP

J9109-87

Fig.
1
Numbering
Main Bearing
Caps

CAUTION:
DO NOT pry on the
main
caps
to free

them from
the
cylinder
block.

(5)
Use two of the
main bearing
cap
bolts
to
"wig­

gle"
the
main
cap
loose, being careful
not to
damage
the bolt threads
(Fig. 2).
Remove
the
caps.

WARNING:
USE
A
HOIST
TO
AVOID
INJURY.

(6) Lift
the
crankshaft
and
gear from
the
cylinder
block
(Fig. 3).

•

5.9L
(DIESEL) ENGINE 9 - 139

Fig.
2 Main Beating Cap
Removal
CAUTION:
Crankshaft must be
lifted
straight
off the

bearings
to
prevent
damage
to the
thrust
bearings.

Fig.
3 Lifting Crankshaft out of Cylinder
Block

(7)
Remove the main bearings from the block and
the main caps. (8) Remove the piston cooling nozzles by using a
3/16 inch pin punch to push them out (Fig. 4).

Fig.
4
Piston
Cooling
Nozzles

CLEANING
AND
INSPECTION
Clean the crankshaft oil galley holes with a nylon
brush. Rinse in clean solvent and dry with compressed air. Inspect the front and rear seal contact areas of the
crankshaft for scratches or grooving. The service seal kit will position the seal slightly
deeper into the seal bore so it will contact the crank­
shaft at a different location. If this has already been
done and the crankshaft has two worn areas, install
a wear sleeve to provide a new contact surface for
the seal.
Inspect the rod and main journal for deep scores,
signs of overheating and other abnormal marks.

CRANKSHAFT
REWORK
Crankshaft main and rod journals may be ground
in increments of 0.25 mm (0.0098 inch) up to a total
of 1.00 mm (0.0394 inch). The only exception is the main journal thrust
width surface. This journal must be ground in incre­ ments of 0.50 mm (0.0197 inch) up to a total of 1.00
mm (0.0394 inch). The thrust surface is located on
the No.6 main bearing. When the thrust surface re­ quires grinding, the main journal must be ground to
the same undersize dimension.

MAIN
JOURNAL
All main journals are to be ground in the opposite
direction of engine rotation (clockwise as viewed
from the front of crankshaft). Polish the journals in
the same direction as engine rotation.
The main bearing grinding specifications are
shown in Fig. 5.

STANDARD
MAIN
JOURNAL
DIAMETER
83.000 +0.013 mm
(3.2677 ±0.0005 inch)

WORN
MAIN
JOURNAL
DIAMETER
LIMIT
82.962 (3.2662
inch)

UNDERSIZES
REGRIND
TO
0.25 mm
(0.0098
inch)
82.750 ±0.013 mm
(3.2579 ±0.0005
inch)

0.50 mm
(0.0197
inch)
82.500 +0.013 mm
(3.2480 +0.0005
inch)

0.75 mm
(0.0295
inch)
82.250 +0.013 mm
(3.2381 ±0.0005
inch)

1.00 mm
(0.0394 inch) 82.000 +0.013 mm
(3.2283 ±0.0005 inch)

OUT-OF
ROUND
&
TAPER
(MAX.)
0.005 mm (0.0002 inch)

ALL
MAIN
JOURNALS
ARE
TO
BE
PARALLEL

TO
THE
FRONT
AND
REAR
MAINS
WITHIN:
0.030
mm
(0.001 inch)
J9109-125

Fig.
5 Crankshaft Main
Journal
Dimensions

Thrust journals can be ground in the same incre­
ments and using the same specifications as all other main journals. The main journal radius may be ground using either the preferred or the alternative

9
- 140 5.9L
(DIESEL)
ENGINE

• procedure providing
the
thrust surface width
is not

being ground.
The
preferred procedure must
be
used
when
the
main bearing thrust width surface
is
ground. When
the
thrust surface width requires
grinding,
the
main journal must
be
ground
to the

same undersize dimension
(Fig. 6).
THRUST JOURNAL WIDTH
37.500 ±0.025
mm

(1.4764 ±0.001 inch)
UNDERSIZES REGRIND WIDTH
TO

0.50 mm 38.000 ±0.025
mm

(0.0197 inch) (1.4961 ±0.001 inch

1.00
mm 38.500 ±0.025
mm

(0.0394 inch) (1.5158 ±0.001 inch)
J9109-127
Fig.
6
Crankshaft Thrust
Journal
Width
Dimensions

The thrust surface
is to be
ground
on
center within
0.10
mm
(0.004 inch).
It
also must
be
perpendicular
to
the
front
and
rear mains within 0.0015
mm
(0.00006 inch)
per
radial inch
on the
thrust area
(Fig.
7). The
surface finish requirement
is 0.04 mi­

crometer
(16.0
microinch).
JOURNAL

J9109-128

Fig.
7
Crankshaft Thrust Surface PREFERRED PROCEDURE:
Smoothly blend
a 4.20
±0.020
mm
(0.1654 ±0.0008
inch) radius
to the
ground diameters
(Fig. 8).

CAUTION:
DO NOT use the
Alternative Procedure
when
the
thrust
surface
width
is
ground.

ALTERNATIVE PROCEDURE: Smoothly blend
a 1.25
±0.020
mm
(0.0492 ±0.0008
inch) radius
to the
ground diameters
(Fig. 9).

ROD
JOURNAL
All
rod
journals
are to be
ground
in the
opposite
di­

rection
of
engine rotation (clockwise
as
viewed from
ORIGINAL
RADIUS

JOURNAL
SURFACE
®
SURFACE
FINISH

®
0.8
micrometer
(32.0
microinch)
for
a
minimum
of 45°
into
the fillet
beyond journal surface

1.6
micrometer
(64.0
microinch)
for remainder
of fillet

©
0.4
micrometer
(16.0
microinch)

J9109-129
Fig.
8
Grind
Crankshaft Main Journal—Preferred

Method

the front
of
crankshaft). Polish
the
journals
in the
same direction
as
engine rotation. The
rod
bearing grinding specifications
are
shown
in
Fig. 10.
PREFERRED PROCEDURE:
Smoothly blend
a 4.00
±0.020 (0.1575 ±0.0008
inch) radius
to the
ground diameters
and
side faces (Fig.
11).

ALTERNATIVE PROCEDURE: Smoothly blend
a 1.25
±0.020
mm
(0.0492 ±0.0008
inch) radius
to the
ground journals
(Fig. 12).

CRANKSHAFT
FRONT
SEAL

REMOVAL
(1) Remove
the
drive belt.
(2) Remove
the
vibration damper.
(3) Drill
two 1/Sth
inch holes into
the
seal face,
180° apart. (4)
Use a
slide hammer tool with
a #10
metal
screw. Pull alternating from side-to-side until
the
seal
is
free.

INSTALLATION
(1)
The
sealing surface
on the
crankshaft must
be

free from
all oil
residue
to
prevent seal leaks.

5-9L
(DIESEL) ENGINE
9 - 141

ORIGINAL RADIUS
NEW UNDERCUT RADIUS JOURNAL SURFACE ORIGINAL RADIUS
NEW UNDERCUT RADIUSs
SURFACE FINISH
®
0.8 micrometer (32.0 microinch) for a minimum of
45°
into the

fillet
beyond journal surface
(D 1.6 micrometer (64.0 microinch) for remainder of
fillet

©
0.4 micrometer (16.0 microinch)

WIDTH
OF
REGRIND/UNDERCUT RADIUS
®
34.5
±0.025
mm
(1.358
±0.001
in)
JOURNAL SURFACE

J9109-130

Fig. 9 Grind Crankshaft Main Journal—Alternative Method
STANDARD ROD JOURNAL DIAMETER 69.000 +0.013 mm
(2.7165 ±0.0005 inch)
WORN ROD JOURNAL DIAMETER LIMIT 68.962 (2.7150 inch)
UNDERSIZES REGRIND TO
0.25 mm
(0.0098 inch) 68.750 +0.013 mm
(2.7067 ±0.0005 inch)
0.50 mm
(0.0197 inch) 68.500 +0.013 mm
(2.6969 ±0.0005 inch)
0.75 mm
(0.0295 inch) 68.250 +0.013 mm
(2.6870 ±0.0005 inch)
1.00 mm
(0.0394 inch) 68.000 +0.013 mm
(2.6772 ±0.0005 inch)
OUT-OF ROUND & TAPER (MAX.) 0.005 mm (0.0002 inch)
ALL MAIN JOURNALS
ARE
TO
BE
PARALLEL
TO THE FRONT AND REAR MAINS WITHIN: 0.030 mm (0.001 inch)
J9109-126
Fig. 10 Crankshaft Rod Journal Dimensions
(2) If the gear cover was replaced, use the align­
ment tool from the seal kit to make sure the cover is aligned with the crankshaft.
SURFACE FINISH
©
0.8 micrometer (32.0 microinch)
for a minimum of 45° into the
fillet
beyond journal surface 1.6 micrometer (64.0 microinch)
for remainder of
fillet
0.4 micrometer (16.0 microinch)
CD

©

J9109-131

Fig. 11 Crankshaft Rod Journal Grind—Preferred Method
(3) Apply a bead of Loctite 277 to the outside di­
ameter of the seal.
(4) Install the pilot from the seal kit onto the
crankshaft.
(5) Install the seal onto the pilot and start it into
the gear housing cover seal bore. (6) Remove the pilot.
(7) Use the alignment/installation tool and a plas­
tic hammer to install the seal to the correct depth.
(8) Install the vibration damper, but DO NOT
tighten the damper bolt until the belt is installed.
(9) Install the drive belt.
(10) Tighten the vibration damper bolts to 125
Nun (92 ft. lbs.) torque. Use the engine barring tool
to keep the engine from rotating during torquing op­ eration.
CRANKSHAFT REAR SEAL HOUSING AND
SEAL

REMOVAL

(1) Remove the rear seal housing and gasket (Fig.

13).
(2) Support the seal area of the rear seal housing
and press/drive out the seal using a hammer and a
pin pinch.
(3) Clean the rear seal housing.

9
- 142 5.9L
(DIESEL)
ENGINE

•

ORIGINAL
RADIUS

SURFACE
FINISH

®
0.3
micrometer
(32.0
microinch)
for a
minimum
of
45° into the
^ fillet
beyond
journal
surface

v§/
1.6
micrometer
(64.0
microinch)

^ for
remainder
of
fillet

v£)
0.4
micrometer
(16.0
microinch)
WIDTH OF REGRIND/UNDERCUT RADIUS

©
34.79
±
0.025
mm
(1.369
±0.001 in)
J9109-132

Fig.
12
Grind
Crankshaft Rod Journal—Alternative
Method

Fig.
13 Crankshaft Rear
Seal
Housing/Gasket

INSTALLATION
(1) Clean and dry the rear crankshaft sealing sur­

face.
The seal lip and the sealing surface on the
crankshaft must be free from all oil residue to pre­ vent seal leaks.
(2) Assemble the rear seal housing and gasket to
the cylinder block with the bolts.
(3) Align the seal housing to the crankshaft with
the alignment tool provided in the seal kit (Fig. 14). Make sure the seal housing is level with both sides
of the block oil pan rail. Tighten the bolts to 9 N*m
(7 ft. lbs.) torque.
(4) Remove the alignment tool and trim the gasket
even with the oil pan mounting surface (Fig. 14).
Fig.
14 Crankshaft Rear
Seal
Housing
Alignment

Tool
(5) The rubber O.D. rear crankshaft seals are lu­
bricated with soapy water. Seals without rubber O.D. use Loctite 277, or equivalent.
(6) Install the seal pilot (provided with the replace­
ment kit) onto the crankshaft. Push the seal onto the
crankshaft (Fig. 15).
(7) Remove the seal pilot.

Fig.
15 Crankshaft Rear
Seal
Pilot
(8) Use alignment and installation tool packaged
in the seal kit (Fig. 16). Alternately, drive the seal at
the 12, 3, 6 and 9 o'clock positions to prevent bend­ ing the seal carrier during installation.

•

5.9L
(DIESEL)
ENGINE
9 - 143

ALIGNMENT
AND
INSTALLATION TOOL
J9109-102

Fig.
16 Crankshaft Rear
Seal
Alignment/Installation
Tool

CRANKSHAFT REAR SEAL
REMOVAL
(1) Remove
the
transmission (refer
to
Group
21,

Transmission
for the
proper procedure). (2) Remove
the
clutch cover.
(3) Remove
the
clutch plate. (4) Remove
the
flywheel.
(5) Drill holes
180°
apart into
the
seal.
Be
careful
not
to get the
drill against
the
crankshaft. (6) Install
#10
sheet metal screws
in the
drilled
holes
and
remove
the
rear seal with
a
slide hammer (Fig.
17).

NO.
10

SCREW
\W

CRANKSHAFT
J9109-60

Fig.
17 Crankshaft Rear
Seal
Removal

INSTALLATION
CAUTION:
The
seal
lip
and
the
sealing surface
on

the crankshaft must
be
free
from
all oil
residue
to

prevent
seal leaks.

The crankshaft
and
seal must
be dry
when
the
seal
is installed. (1) Install
the
seal pilot, provided
in the
replace­
ment
kit, on the
crankshaft. Push
the
seal
on the pi­

lot
and
crankshaft.
(2) Remove
the
seal pilot. (3) Seal
O.D.
lubricant/sealant:
• Rubber
O.D,
rear crankshaft seals
are
lubricated
with soapy water.
• Seals without rubber
O.D. use
Loctite
277 or

equivalent sealant.
(4)
Use the
alignment tool
to
install
the
seal
to the

correct depth
in the
housing.
Use a
hammer
to
drive
the seal into
the
housing until
the
alignment tool stops against
the
housing
(Fig. 18).

(5)
Hit the
tool
at the 12, 3, 6 and 9
o'clock posi­
tions
to
drive
the
seal evenly
and
prevent bending
the seal housing. ALIGNMENT
TOOL-
J9109-6T

Fig.
18
Seal
Installation
using
Alignment
Tool
FLYWHEEL
RING GEAR
REMOVAL
(1) Remove
the
transmission.
(2) Remove
the
clutch cover.
(3) Remove
the
clutch plate.
(4) Remove
the
flywheel.

WARNING: WEAR
EYE
PROTECTION WHEN
YOU
DRIVE
THE
GEAR FROM
THE
FLYWHEEL.
DO NOT

USE
A
STEEL DRIFT
PIN.

(5)
Use a
drift
pin to
drive
the
ring gear from
the

flywheel
(Fig. 19).
Strike
the
gear
at
several points around
the
wheel until
it is off.

(6) Heat
the new
ring
for 20
minutes
in an
oven
preheated
to
127°C (250°F).

WARNING: WEAR PROTECTIVE GLOVES WHEN
YOU INSTALL
THE
HEATED GEAR.
(7) Install
the
gear.
The
gear must
be
installed
so

the bevel
on the
teeth
is
towards
the
crankshaft side of
the
flywheel
(Fig. 19).

9 - 146 5.9L (DIESEL) ENGINE
•

DIAL

INDICATOR

CYLINDER BLOCK
GASKET

J9109-97
Fig.
26 Position of Dial Indicator CRANKSHAFT
END

CLEARANCE
CRANKSHAFT
GEAR
MIN.
MAX.
0.130
mm
0.300 mm (0M5 inch)
(0.012 inch)

J9109-98

Fig.
27 Crankshaft End Clearance
OIL PAN / SUCTION TU1E
REMOVAL (1) Remove the engine from the vehicle and mount
on an engine stand.

WARNING:
HOT OIL CAN
CAUSE PERSONAL
IN­

JURY.

(2) Drain the used engine oil. Dispose of the used
oil properly. (3) Remove the oil pan and gasket (Fig. 1). Be sure
to connect the support bracket.
(4) If required, remove the suction tube and gasket
(Fig. 1).
INSTALLATION (1) Clean the sealing surface.
(2) Install the suction tube and gasket. Tighten the
bolts to 24 Nin (18 ft. lbs.) torque.
(3) Fill the joint between the pan rail/gear housing
and pan rail/rear cover with sealant. Use Three Bond 1207-C, or equivalent.
SUCTION

TUBE

J9109-19

Fig.
1 Oil Pan,
Suction
Tube and
Gasket
(4) Install the pan and gasket (Fig. 1). Tighten the
bolts to 24 N-m (18 ft. lbs.) torque.
(5) Install the drain plug with
a
new sealing
washer and tighten to 80 Nnn (60 ft. lbs.) torque.
(6) Install the engine assembly into the vehicle.
(7) Fill the engine with clean lubrication oil (refer
to Group 0, Lubrication and Maintenance). Run the engine and check for leaks.
(8) Stop the engine and let it set for five minutes.
Check the oil level, and add oil if needed.
OIL
PUMP
The non-intercooled turbocharged engine oil pumps
can not be used on intercooled engines.
REMOVAL (1) Remove the radiator (refer to Group 7, Cooling
System for the proper procedure). (2) Loosen the crankshaft vibration damper and re­
move the drive belt.
(3) Remove the fan clutch assembly. (4) Remove the fan hub.
(5) Remove the oil fill tube.
(6) Remove the crankshaft vibration damper.
(7) Remove the gear housing cover.
(8) Remove the four mounting bolts and pull the
pump from the bore in the cylinder block (Fig. 2).
CLEAN AND INSPECT Visually inspect the lube pump gears for chips,
cracks or excessive wear.
Remove the back plate (Fig. 3).
Mark TOP on the gerotor planetary using a felt tip
pen (Fig. 3). Remove the gerotor planetary (Fig. 3).

•

5.9L (DIESEL) ENGINE
9 - 147
©

Fig.
2 Oil
Pump
Removal
J9109-20

OIL PUMP
BACK PLATE
GEROTOR
GEROTOR
PLANETARY.

J9109-156

Fig.
3 Gerotor Planetary and Gerotor Inspect for excessive wear or damage.
Clean all parts in solvent and dry with compressed
air.
Inspect the pump housing and gerotor drive for
damaged and excessive wear.
Install the gerotor planetary in the original posi­
tion. The chamfer must be on the O.D. and down. Measure the tip clearance (Fig. 4). Maximum clear­
ance is 0.1778 mm (0.007 inch). If the oil pump is out
of limits, replace the pump.
FEELER
GAUGE

J9109-21
Measure the clearance of the gerotor drive/gerotor
planetary to port plate (Fig. 5). Maximum clearance is 0.127 mm (0.005 inch). If the oil pump is out of

limits,
replace the pump. PORT
PLATE
GEROTOR

J9109-22
Fig.
5 Gerotor to Port
Plate
Clearance
Measure the clearance of the gerotor planetary to
the body bore (Fig. 6). Maximum clearance is 0.381 mm (0.015 inch). If the oil pump is out of limits, re­
place the pump.
BODY

BORE
GEROTOR
PLANETARY

J9109-23
Fig.
6 Gerotor Planetary to
Body
Bore
Clearance
Measure the gears backlash (Fig. 7). The limits of
a used pump is 0.080-0.380 mm (0.003-0.015 inch). If
the backlash is out of limits, replace the oil pump. Install the back plate.
OIL PUMP DRIVE
GEAR IDLER GEAR
BACKLASH BACKLASH
J9109-24
Fig.
4 Tip Clearance
Fig.
7 Measure Gear
Backlash

INSTALLATION

(1) Lubricate the pump with clean engine oil. Fill­
ing the pump with clean engine oil during installa­
tion will help to prime the pump at engine start up.