Manual sections
Repair manual

5.9l Engine - Overhaul Dodge Pickup R1500

Step-by-step instructions on "5.9l Engine - Overhaul" for Dodge Pickup R1500 (1997–2012). Pick an article — removal, installation, adjustment and diagnostics with illustrations.

DESCRIPTION

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL

DIAGNOSIS AND TESTING - SMOKE DIAGNOSIS CHARTS

CYLINDER COMPRESSION PRESSURE

CYLINDER COMBUSTION PRESSURE LEAKAGE

STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS

MOPAR® ENGINE RTV GEN II

MOPAR® ATF RTV

MOPAR® GASKET MAKER

MOPAR® GASKET SEALANT

FORM-IN-PLACE GASKET AND SEALER APPLICATION

STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS

STANDARD PROCEDURE-HYDROSTATIC LOCK

INSTALLATION - ENGINE

INSTALLATION-CRANKCASE BREATHER

GENERAL DESCRIPTION

PISTONS

PISTON PINS

PISTON RINGS

CONNECTING RODS

CYLINDER HEAD

OIL PRESSURE

TORQUE CHART 5.9L DIESEL ENGINE

Testing Air Cleaner Element using Filter Minder™

Filter Removal

INSTALLATION

CLEANING-CYLINDER HEAD

CLEANING-CROSSHEADS

CLEANING-PUSHRODS

INSPECTION - CYLINDER HEAD

INSPECTION-CROSSHEADS

INSPECTION-PUSHRODS

REMOVAL-ROCKER HOUSING

CLEANING

INSPECTION

INSTALLATION - CYLINDER HEAD COVER

VALVE GUIDE BORE SPECIFICATIONS

STANDARD PROCEDURE - VALVE LASH ADJUSTMENT AND VERIFICATION

Rocker Arms

Push Rods

Crossheads

STANDARD PROCEDURE-CYLINDER BORE REPAIR

METHOD 1-OVERSIZE BORE

CYLINDER BORE DIMENSION CHART

METHOD 2-REPAIR SLEEVE

REPAIR SLEEVE BLOCK REBORE DIMENSIONS CHART

SLEEVE DRIVER CONSTRUCTION SPECIFICATION CHART

SLEEVE MACHINING DIMENSIONS CHART

STANDARD PROCEDURE-CAM BORE REPAIR

BORE SPECIFICATIONS

REMOVAL-CAMSHAFT BEARINGS

Camshaft

CAMSHAFT DIMENSIONS

Camshaft Bushing/Bores

Camshaft Gear

Thrust Plate

CAMSHAFT THRUST PLATE THICKNESS CHART

INSTALLATION - CAMSHAFT BEARINGS

STANDARD PROCEDURE - CONNECTING ROD BEARING AND CRANKSHAFT JOURNAL CLEARANCE

CONNECTING ROD JOURNAL DIAMETER LIMITS CHART

REMOVAL - GEAR

STANDARD PROCEDURE - MAIN BEARING CLEARANCE

REMOVAL

PISTON

STANDARD PROCEDURE -HEAD GASKET SELECTION

CLEANING-PISTON AND CONNECTING ROD

CONNECTING ROD

INSPECTION - PISTONS

INSPECTION-CONNECTING ROD

OPERATION

DIAGNOSIS AND TESTING-ENGINE OIL PRESSURE

STANDARD PROCEDURE - ENGINE OIL LEVEL

STANDARD PROCEDURE - ENGINE OIL SERVICE

USED ENGINE OIL DISPOSAL

CLEANING AND INSPECTION

STANDARD PROCEDURE - TIMING VERIFICATION