INSTALLATION - ENGINE Dodge Pickup R1500

INSTALLATION - ENGINE

1. Remove cylinder head bolts according to the diagram below. Install special Tool 9009. Torque bolts to 105N.m (77ft. lbs.)
2. Lower engine into the engine compartment and install the engine mount through bolts and nuts.
3. Tighten the mount through bolts and nuts to 88 N.m (65 ft-lbs) torque.
4. Remove the engine lifting device (Tool 9009).
5. Check cylinder head capscrew length and install into cylinder head.
6. Torque in 4 steps to: Step 1-Tighten to 70 N.m (52 ft. lbs.) torque. Step 2-Back off 360°. Step 3-Tighten to 105 N.m (77 ft. lbs.) torque. Step 4-Rotate 90°.
7. Install rocker housing. Torque to 24 N.m (18 ft-lbs). Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
8. Replace injector o-ring and sealing washer on injectors #5 and #6. Install injectors and torque using the following steps: Step 1-Install injector hold-down capscrews and torque to 5 N.m (44 in. lbs.) torque. Step 2-Loosen injector hold-down capscrews. Step 3-Install HPC connector tube and nut. Torque nut to 15 N.m (11 ft. lbs.) torque. Step 4-Torque injector hold-down capscrews to 10 N.m (89 in. lbs.) torque. Step 5-Torque HPC connector tube nut to 50 N.m (37 ft. lbs.) torque.
9. Install #5 and #6 high pressure fuel lines. Follow correct torque sequence per section 14. Torque fuel line fittings to 30 N.m (22 ft-lb). Torque brace capscrew to 24 N.m (18 ft-lb).
10. Install rear engine lift bracket. Torque to 77 N.m (57 ft-lb).
11. Install push tubes, rocker arms, and pedestals for cylinders #4, #5, and #6. Torque the mounting bolts to 36 N.m (27 ft-lbs).
12. Reset valve lash on cylinders #4, #5, and #6. Torque adjusting nuts to 24 N.m (18 ft-lbs). NOTE: Verify proper installation of cylinder head cover ground spring into cylinder head cover.
13. Install cylinder head cover. Torque to 24 N.m (18 ft-lbs). (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
14. Connect breather tube and lube oil drain tube to breather housing cover. Install breather cover. Torque capscrews to 24 N.m (18 ft-lbs)
15. Connect fuel supply and return hoses.
16. Connect ECM ground to hydroform screw. Connect ECM power connector.
17. Install the APPS cable(s) to the APPS. Install the throttle linkage cover.
18. Install the power steering pump.
19. Install the damper and speed indicator ring. Torque to 40 N.m (30 ft-lb) plus 60 degrees.
20. Install lower fan shroud bracket. Torque to 24 N.m (18 ft-lb).
21. Install upper fan shroud brackets, but do not tighten fasteners at this time.
22. Connect the engine block heater connection.
23. Connect the A/C compressor and pressure sensor connectors
24. Install the charge air cooler and a/c condenser (if equipped). Install and tighten the charge air cooler mounting bolts to 2 N.m (17 in-lbs).
25. Connect the charge air cooler piping. Torque all clamps to 8 N.m (72 in-lbs).
26. Connect the a/c refrigerant lines to the a/c condenser (if equipped).
27. Install the radiator upper support panel.
28. Install radiator.
29. Connect the transmission quick-connect oil cooler lines.
30. Raise vehicle.
31. Connect a/c compressor suction/discharge hose (if equipped).
32. Install the radiator lower hose and clamps.
33. Install the battery negative cables to the engine block on the driver and passenger side.
34. Install the transmission adapter with a new camshaft rectangular ring seal. Torque to 77 N.m (57 ft-lb).
35. Install the flywheel/flexplate. Torque to 137 N.m (101 ft-lb).
36. Install the starter motor. Torque to 43 N.m (32 ft-lb). (Refer to «STARTERS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) ).
37. Connect engine to vehicle harness connectors.
38. Install transmission and transfer case (if equipped).
39. Connect the exhaust pipe to the turbocharger elbow.
40. Connect the transmission auxiliary oil cooler lines (if equipped).
41. Lower the vehicle.
42. Connect the heater core supply and return hoses.
43. Install the cooling fan/drive/shroud assembly. (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
44. Install the coolant recovery bottle.
45. Install the windshield washer bottle.
46. Install the upper radiator hose and clamps.
47. Raise vehicle.
48. Change oil filter and install new engine oil.
49. Fill the cooling system with coolant. (Refer to «REFILLING COOLING SYSTEM 5.9L DIESEL ENGINE»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-59l-diesel-engine) ).
50. Connect grid heater harness at grid heater relays.
51. Connect electrical connections to rear of alternator.
52. Start the engine and inspect for engine oil, coolant, and fuel leaks.