5.9l Engine - Overhaul Dodge Pickup R1500

DESCRIPTION

The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal ribs for superior strength and noise reduction. The block incorporates metric straight thread o-ring fittings at lubrication oil access points. The engine (Scheme 391) is manufactured with the cylinders being a non-sleeved type cylinder. However, one approved service method is to bore out the cylinders and add cylinder sleeves to the cylinder block.

The cylinders are numbered front to rear (Scheme 392); 1 to 6. The firing order is 1-5-3-6-2-4.

Scheme 391

Scheme 392

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL

MECHANICAL TROUBLE SYMPTOM CHART

DIAGNOSIS AND TESTING - SMOKE DIAGNOSIS CHARTS

The following charts include possible causes and corrections for excess or abnormal exhaust smoke.

Small amounts of exhaust smoke (at certain times) are to be considered normal for a diesel powered engine.

SMOKE TROUBLE SYMPTOM CHART

SMOKE TROUBLE SYMPTOM CHART

SMOKE TROUBLE SYMPTOM CHART

CYLINDER COMPRESSION PRESSURE

The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.

Ensure batteries are completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnostic purposes.

1. Disconnect the fuel inlet line to the fuel transfer pump. Plug the fuel line from the fuel tank.
2. Start the engine and idle until the engine stalls (runs out of fuel).
3. Disconnect all three injector wire harness connectors at the rocker housing.
4. Remove the breather cover and cylinder head cover.
5. Remove the high pressure fuel line between the cylinder head and fuel rail for the cylinder to be tested. Use tool# 9011 to cap this fuel rail on the cylinder being tested.
6. Remove the fuel connector tube nut and fuel connector tube.
7. Remove the exhaust rocker lever.
8. Use Tool 9010 to remove the injector and copper sealing washer.
9. Install the exhaust rocker lever and torque to 36 N.m (27 ft. lbs.).
10. Cover the remaining rocker levers with clean shop towels to prevent any oil splatter under the hood.
11. Place a rag over the compression test tool fitting. Crank the engine for 2-3 seconds to purge any fuel that may have drained into the cylinder when the injector was removed.
12. Connect the compression test gauge.
13. Crank the engine for 5 seconds and record the pressure reading. Repeat this step three times and calculate the average of the three readings. NOTE: The minimum cylinder pressure is 350 psi. Cylinder pressure should be within 20% from cylinder to cylinder.
14. Combustion pressure leakage can be checked if cylinder pressure is below the specification. Perform the leakage test procedure on each cylinder according to the tester manufacturer instructions.
15. Upon completion of the test check and erase any engine related fault codes.

CYLINDER COMBUSTION PRESSURE LEAKAGE

The combustion pressure leakage test provides an accurate means for determining engine condition.

Combustion pressure leakage testing will detect

1. Exhaust and intake valve leaks (improper seating).
2. Leaks between adjacent cylinders or into water jacket.
3. Any causes for combustion/compression pressure loss

1. Start and operate the engine until it attains normal operating temperature.
2. Remove the breather cover and cylinder head cover.
3. Disconnect all three injector wire harness connectors at the rocker housing.
4. Bring the cylinder to be tested to TDC.
5. Remove the high pressure fuel line between the cylinder head and the fuel rail for the cylinder to be tested.
6. Install capping Tool 9011 onto the rail.
7. Remove the high pressure connector nut and high pressure connector with Tool 9015.
8. Remove the exhaust and intake rocker lever.
9. Use Tool 9010 to remove the injector and copper sealing washer.
10. Install compression test Tool 9007 into the injector bore.
11. Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester manufacturer's instructions.
12. Upon completion of the test check and erase any engine related fault codes.

STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS

There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in-place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket.

There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Engine RTV GEN II, Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties and can not be used in place of the other.

MOPAR® ENGINE RTV GEN II

Mopar® Engine RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® ATF RTV

Mopar® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® GASKET MAKER

Mopar® Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.

MOPAR® GASKET SEALANT

Mopar® Gasket Sealant is at slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This material is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.

FORM-IN-PLACE GASKET AND SEALER APPLICATION

Assembling parts using a form-in-place gasket requires care but it's easier than using precut gaskets.

Mopar® Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing material off the location.

Mopar® Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location.

Mopar® Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets.

STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS

Damaged or worn threads can be repaired. Essentially, this repair consists of

1. Drilling out worn or damaged threads.
2. Tapping the hole with a special Heli-Coil Tap, or equivalent.
3. Installing an insert into the tapped hole to bring the hole back to its original thread size.

STANDARD PROCEDURE-HYDROSTATIC LOCK

When an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps below.

1. Disconnect the negative cable(s) from the battery.
2. Inspect air cleaner, induction system, and intake manifold to ensure system is dry and clear of foreign material.
3. Place a shop towel around the fuel injectors to catch any fluid that may possibly be under pressure in the cylinder head. Remove the fuel injectors (Refer to «FUEL INJECTOR»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine) ).
4. With all injectors removed, rotate the crankshaft using the crankshaft barring tool (PN 7471-B).
5. Identify the fluid in the cylinders (coolant, fuel, oil, etc.).
6. Be sure all fluid has been removed from the cylinders.
7. Repair engine or components as necessary to prevent this problem from occurring again.
8. Squirt a small amount of engine oil into the cylinders to lubricate the Walls. This will prevent damage on restart.
9. Install fuel injectors (Refer to «FUEL INJECTOR»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine) ).
10. Drain engine oil. Remove and discard the oil filter (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
11. Install the drain plug. Tighten the plug to 50 N.m (37 ft. lbs.) torque.
12. Install a new oil filter (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
13. Fill engine crankcase with the specified amount and grade of oil (refer to owner's manual ).
14. Connect the negative cable(s) to the battery.
15. Start the engine and check for any leaks.

Scheme 393

1. Disconnect both battery negative cables.
2. Disconnect engine grid heater harness at grid heater relays.
3. Disconnect electrical connections from rear of alternator.
4. Recover A/C refrigerant. (Refer to «REFRIGERANT SYSTEM RECOVERY»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing__refrigerant-system-recovery) ).
5. Raise vehicle on a hoist.
6. Drain engine coolant (Refer to «DRAINING COOLING SYSTEM 5.9L DIESEL ENGINE»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-59l-diesel-engine) ).
7. Remove engine oil drain plug and drain engine oil.
8. Reinstall drain plug. Tighten to 50N.m (37 ft. lbs.) torque.
9. Lower the vehicle.
10. Remove fan/drive/shroud assembly. (Refer to «FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
11. Remove radiator upper hose.
12. Disconnect the coolant recovery bottle hose from the radiator fill neck.
13. Disconnect heater core supply and return hoses from the cylinder head fitting and coolant pipe.
14. Raise vehicle on a hoist.
15. Remove transmission and transfer case (if equipped).
16. Disconnect exhaust pipe from turbocharger extension pipe.
17. Disconnect engine harness to vehicle harness connectors.
18. Remove starter motor (Refer to «STARTERS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) ).
19. Remove flywheel/flexplate.
20. Remove transmission adapter
21. Disconnect A/C suction/discharge hose from the rear of the A/C compressor.
22. Lower vehicle.
23. Disconnect lower radiator hose from radiator outlet.
24. Automatic transmission models
25. Disconnect transmission oil cooler lines from in front of radiator using special tool #6931
26. Remove radiator. (Refer to «RADIATOR - 5.9L DIESEL»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
27. If A/C equipped, disconnect A/C condenser refrigerant lines.
28. Disconnect charge air cooler piping.
29. Remove charge air cooler mounting bolts.
30. Remove charge air cooler (and A/C condenser if equipped) from vehicle.
31. Remove damper and speed indicator ring from front of engine.
32. Remove lower fan shroud bracket from engine.
33. Remove upper fan shroud brackets from engine.
34. Disconnect engine block heater connector.
35. Disconnect A/C compressor and pressure sensor electrical connectors.
36. Remove the passenger battery ground cable from the engine block. Remove the driver side battery ground cable from the engine block.
37. Remove power steering pump from engine by removing 3 bolts.
38. Remove accelerator linkage cover.
39. Disconnect cables from on-engine APPS.
40. Disconnect the ECM power connector.
41. Disconnect the ECM ground wire from the hydroform screw.
42. Disconnect the fuel supply and return hoses. NOTE: Ensure that grounding spring remains intact with cylinder head cover.
43. Remove the cylinder head cover and grounding spring. (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
44. Disconnect the 3 injector harness connectors at the rocker housing. Disconnect the wire harnesses from the injectors.
45. Remove the rear engine lift bracket.
46. Remove cylinder #4, #5, and #6 intake and exhaust rocker arms, pedestals, and push tubes. Note the original location for re-assembly.
47. Loosen #6 fuel line shield bolts and rotate shield out of the way.
48. Remove cylinder #5 and #6 high pressure fuel lines. Remove the fuel connector tube nut and fuel connector tube. Remove cylinder #5 and #6 fuel injector.
49. Remove rocker housing.
50. Remove two cylinder head bolts according to the diagram below and install Tool # 9009. Torque bolts to 105N.m (77ft. lbs.) (Scheme 393)
51. Loosen but do not remove engine mount through bolts and nuts.
52. Disconnect hood support struts and position hood out of the way.
53. Attach a chain with two hooks to the engine lift brackets.
54. While keeping engine level, lift straight up out of the mounts.
55. Rotate nose of engine upward and pull out of chassis.

Scheme 394

1. Remove the oil fill cap.
2. Remove the breather cover bolts (Scheme 394)
3. Remove breather cover.
4. Disconnect breather tube and lube oil drain tube from breather.
5. Remove breather mounting bolts.
6. Remove breather from cylinder head cover.

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.

INSTALLATION-CRANKCASE BREATHER

1. Install a new o-ring onto the breather element.
2. Lubricate o-ring and install into cylinder head cover. Torque capscrews to 10 N.m (89 in. lbs.).
3. Connect breather tube and lube oil drain tube.
4. Install breather cover (Scheme 394) Torque to 24 N.m (18 ft. lbs.)
5. Install oil fill cap.

GENERAL DESCRIPTION

ENGINE 5.9L DIESEL GENERAL DESCRIPTION

PISTONS

PISTONS SPECIFICATIONS

PISTON PINS

PISTON PINS SPECIFICATIONS

PISTON RINGS

PISTON RINGS SPECIFICATIONS

CONNECTING RODS

CONNECTING RODS SPECIFICATIONS

CYLINDER HEAD

CYLINDER HEAD SPECIFICATIONS

OIL PRESSURE

OIL PRESSURE SPECIFICATIONS

TORQUE CHART 5.9L DIESEL ENGINE

TORQUE SPECIFICATIONS CHART 5.9L DIESEL ENGINE

Scheme 395

Scheme 396

Scheme 397

Scheme 398

Scheme 399

Scheme 400

Scheme 401

Scheme 402

Scheme 403

Scheme 404

Scheme 405

Scheme 406

Scheme 407

Scheme 408

Scheme 409

Scheme 410

The engine data plate contains specific information that is helpful to servicing and obtaining parts for the engine. The data plate can be found affixed to the breather cover on the left side of the engine. Information that can be found on the data plate includes

1. Engine Part Number
2. Date of Engine Manufacture
3. Engine Serial Number
4. Control Parts List (CPL)
5. Engine Rated Horsepower
6. Engine Firing Order
7. Engine Displacement
8. Valve Lash Reset Specification

If the engine data plate is missing or not legible, the engine serial number is used for engine identification. The engine serial number is stamped on the right side of the block, on top of the oil cooler cavity (Scheme 411)

Scheme 411

Testing Air Cleaner Element using Filter Minder™

Do not attempt to unnecessarily remove top of air cleaner housing for air cleaner element inspection on diesel engines.

The air cleaner (filter) housing is equipped with an air Filter Minder™ gauge (Scheme 412) This air flow restriction gauge will determine when air cleaner element is restricted and should be replaced.

The Filter Minder™ consists of a diaphragm and calibrated spring sealed inside of a plastic housing (Scheme 413) A yellow colored disc attached to diaphragm moves along a graduated scale on side of Filter Minder. After the engine has been shut off, a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop.

To test, turn engine off. If yellow disc (Scheme 413) has reached red colored zone on graduated scale, air cleaner element should be replaced. Refer to Removal / Installation.

Resetting Filter Minder: After air cleaner (filter) element has been replaced, press rubber button on top of Filter Minder (Scheme 413) This will allow yellow colored disc to reset. After button has been pressed, yellow disc should spring back to UP position.

If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, element appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake. Temporary high restrictions may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter Minder and retest after element has dried.

Scheme 412

Scheme 413

Filter Removal

1. The housing cover is equipped with spring clips (Scheme 412) and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal.
2. Remove air cleaner element from air cleaner housing.

INSTALLATION

1. Before installing new air cleaner element (filter), clean inside of air cleaner housing.
2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing.

The cylinder head is constructed of cast iron and is a one piece cross flow design with four valves per cylinder. The arrangement of two intake and two exhaust valves per cylinder allows for a centrally located injector. The cylinder head also includes an integral intake manifold, an integral thermostat housing, and a longitudal fuel return rifle, which exits at the rear of the head. The 24 valve design also includes integrally cast valve guides and hardened intake and exhaust valve seat inserts.

Scheme 414

Scheme 415

Scheme 416

Scheme 417

Scheme 418

1. Disconnect battery negative cables.
2. Raise vehicle on hoist.
3. Drain engine coolant.
4. Disconnect exhaust pipe from turbocharger elbow.
5. Disconnect turbocharger oil drain tube at rubber hose connection. Cap off open ports to prevent intrusion of dirt or foreign material.
6. For late model engines, remove turbocharger drain tube bolts at turbocharger.
7. Lower vehicle.
8. Disconnect air inlet temperature/pressure sensor.
9. Remove air cleaner housing and snorkel from the vehicle. Cap off turbocharger air inlet to prevent intrusion of dirt or foreign material.
10. Disconnect cab heater core supply and return hoses from the cylinder head and heater pipe.
11. Disconnect turbocharger oil supply line at the turbocharger end. Cap off open ports to prevent intrusion of dirt or foreign material.
12. Remove exhaust manifold-to-cylinder head bolts, spacers, heat shield, retention straps, and cab heater plumbing. Remove exhaust manifold and turbocharger from the vehicle as an assembly.
13. Remove cooling fan/drive/shroud assembly. (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) )
14. Remove accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
15. Remove cooling fan support from cylinder block.
16. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head.
17. Disconnect radiator upper hose from the thermostat housing.
18. Disconnect the Intake Air Temperature/Manifold Air Pressure, and Coolant Temperature sensor connectors.
19. Remove the engine harness to cylinder head attaching bolts and P-clips at front of head.
20. Remove the throttle linkage cover (Scheme 414)
21. For automatic equipped vehicles only, remove the six (6) accelerator pedal position sensor assembly-to-cylinder head bracket bolts (Scheme 415) and secure the entire assembly out of the way. Disconnect the APPS connector (Scheme 416) It is not necessary to disconnect the cables from the throttle control assembly.
22. Remove the intake air grid heater wires from the grid heater.
23. Remove engine oil level indicator tube attaching bolt at fuel filter housing bracket and inlet air connection.
24. Remove the charge air cooler-to-air inlet housing pipe.
25. Remove the engine wire harness attaching bolt and wire harness push-in fastener from air inlet housing.
26. Remove the air inlet housing and intake grid heater from the intake manifold cover.
27. Remove the two grid heater harness-to-cylinder head attaching bolts at front of cylinder head.
28. Remove the engine lift bracket from the rear of the cylinder head.
29. Remvoe the high pressure pump to fuel rail fuel line as follows: Loosen fuel line nuts at fuel pump and at fuel rail. Use a back-up wrench on the fitting at the fuel pump to keep it from loosening.
30. Remove the fuel rail to cylinder head fuel lines as follows: Loosen No. 6 high pressure fuel line shield and position out of way. Loosen the fuel line nuts at the fuel rail and at the cylinder head. Remove the fuel line bracket bolts at the intake manifold cover.
31. Remove the fuel rail as follows: Remove fuel rail pressure sensor connector. Remove banjo fitting at pressure limiting valve. Remove fuel rail bolts and fuel rail.
32. Remove the low pressure lines as follows: Remove the fuel drain banjo fitting on the front side of fuel filter housing. Remove the fuel drain banjo fitting on rear side of fuel filter housing. Remove the fuel drain line support bracket on rear side of filter housing. Disconnect fuel drain hose. Remove banjo fitting at bottom of fuel filter housing. Disconnect fuel supply hose at lift pump.
33. Disconnect fuel heater, water in fuel sensor, and fuel lift pump connectors.
34. Remove the fuel filter assembly-to-cylinder head bolts and remove filter assembly from vehicle.
35. Remove wire harness P-clip from cylinder head (located behind filter housing). NOTE: Verify that the cylinder head cover ground spring is retained in the cylinder head cover.
36. Remove the cylinder head cover(Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
37. Disconnect rocker housing injector harness connectors.
38. Remove injector harness nuts from injectors.
39. Remove the rocker levers (Scheme 417), cross heads and push rods (Scheme 418) Mark each component so they can be installed in their original positions. NOTE: The #5 cylinder exhaust and the #6 cylinder intake and exhaust push rods are removed by lifting them up and through the provided cowl panel access holes. Remove the rubber plugs to expose these relief holes.
40. Remove the fuel return line and banjo bolt at the rear of the cylinder head. Be careful not to drop the two (2) sealing washers.
41. Remove the fuel injectors (Refer to «FUEL INJECTOR»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine) ).
42. Remove rocker housing bolts and rocker housing and gasket.
43. Reinstall the engine lift bracket at the rear of cylinder head. Torque to 77 N.m (57 ft. lbs.).
44. Remove twenty six (26) cylinder head-to-block bolts.
45. Attach an engine lift crane to engine lift brackets and lift cylinder head off engine and out of vehicle.
46. Remove the head gasket and inspect for failure.

CLEANING-CYLINDER HEAD

Remove fuel injectors before cleaning (if not already removed during cylinder head removal).

Clean the carbon from the injector nozzle seat with a nylon or brass brush.

Scrape the gasket residue from all gasket surfaces.

Wash the cylinder head in hot soapy water solution (88°C or 140°F).

After rinsing, use compressed air to dry the cylinder head.

Polish the gasket surface with 400 grit paper. Use an orbital sander or sanding block to maintain a flat surface.

CLEANING-CROSSHEADS

Clean all crossheads in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn deposits. Rinse in hot water and blow dry with compressed air.

CLEANING-PUSHRODS

Clean the pushrods in a suitable solvent. Rinse in hot water and blow dry with compressed air. If necessary, use a wire brush or wheel to remove stubborn deposits.

INSPECTION - CYLINDER HEAD

Inspect the cylinder head for cracks in the combustion surface. Pressure test any cylinder head that is visibly cracked. A cylinder head that is cracked between the injector bore and valve seat can be pressure tested and reused if OK; however, if the crack extends into the valve seat insert bore, the cylinder head must be replaced.

Visually inspect the cylinder block and head combustion surfaces for localized dips or imperfections. Check the cylinder head and block combustion surfaces for overall out-of-flatness. If either the visual or manual inspection exceeds the limits, then the head or block must be surfaced.

Check the top surface for damage caused by the cylinder head gasket leaking between cylinders.

Inspect the block and head surface for nicks, erosion, etc.

Check the head distortion. Maximum overall variation end to end is 0.305 mm (0.012 inch) (Scheme 419), and maximum overall variation side to side 0.076 mm (.003 in.).

DO NOT proceed with the in-chassis overhaul if the cylinder head or block surface is damaged or not flat (within specifications).

Check block surface for distortion. Maximum variation end-to-end is 0.076 mm (.003 in.), side-to-side 0.051 mm (.002).

Scheme 419

Visually inspect the cylinder head bolts for damaged threads, corroded/pitted surfaces, or a reduced diameter due to bolt stretching.

If the bolts are not damaged, their "free length" should be measured using the cap screw stretch gauge provided with the replacement head gasket. Place the head of the bolt against the base of the slot and align the bolt with the straight edge of gauge (Scheme 420) If the end of the bolt touches the foot of the gauge, the bolt must be discarded. The maximum bolt free length is 132.1 mm (5.200 in.).

Scheme 420

INSPECTION-CROSSHEADS

Inspect the crossheads for cracks and/or excessive wear on rocker lever and valve tip mating surfaces (Scheme 421) Replace any crossheads that exhibit abnormal wear or cracks.

Scheme 421

INSPECTION-PUSHRODS

Inspect the push rod ball and socket for signs of scoring. Check for cracks where the ball and the socket are pressed into the tube (Scheme 422)

Roll the push rod on a flat work surface with the socket end hanging off the edge (Scheme 423) Replace any push rod that appears to be bent.

Scheme 422

Scheme 423

Scheme 424

Scheme 425

Scheme 426

1. Install a new gasket with the part number side up, and locate the gasket over the dowel sleeves.
2. Using an engine lifting crane, lower the cylinder head onto the engine.
3. Lightly lubricate head bolts with engine oil and install. Using the sequence shown in (Scheme 424), tighten bolts in the following steps: Torque bolts to 70 N.m (52 ft. lbs.) Back off 360 degrees in sequence Torque bolts to 105 N.m (77 ft. lbs.) Re-check all bolts to 105 N.m (77 ft. lbs.) Tighten all bolts an additional 1/4 turn (90°)
4. Install push rods into their original locations (Scheme 425) Verify that they are seated in the tappets.
5. Inspect rocker housing gasket for cuts and proper installation into groove. Replace if damaged.
6. Install rocker housing and bolts. Tighten to 24 N.m (18 lb. ft.).
7. Install fuel injector(Refer to «FUEL INJECTOR»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine) ).
8. Install injector harness nuts. Tighten to 1.25 N.m (11 lb. in.).
9. Lubricate valve stem tips and install the cross-heads in their original locations.
10. Lubricate the rocker arms and pedestals and install them in their original locations (Scheme 426) Install the bolts and torque them to 36 N.m (27 ft. lbs.).
11. Verify that the valve lash settings are maintained (Refer to «STANDARD PROCEDURE»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ). NOTE: Verify that cylinder head ground spring is properly installed and retained in the cylinder head cover, before installation.
12. Install cylinder head cover and ground spring(Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
13. Install wire harness P-clip to cylinder head behind filter housing 24 N.m (18 ft. lbs.).
14. Connect the IAT/MAP sensor connector.
15. Install the fuel filter canister assembly and torque mounting bolts to 24 N.m (18 ft. lbs.).
16. Connect fuel lift pump, WIF sensor, and fuel heater.
17. Remove the engine lift bracket at rear of cylinder head. CAUTION: Failure to follow procedure will result in fuel leaks and/or fuel system failure.
18. Install the fuel rail and high pressure fuel lines as follows: Hand tighten fuel rail bolts. Hand tighten fuel drain line to pressure limiting valve. Hand tighten banjo bolt at fuel filter housing. Hand tighten fuel rail-to-cylinder head high pressure fuel lines. Install fuel line brace bolts-to-intake manifold finger tight. Hand tighten fuel pump to fuel rail line. Torque fuel line nuts at cylinder head to 30 N.m (22 ft. lbs.). Torque fuel line nuts at fuel rail to 30 N.m (22 ft. lbs.). Using a back up wrench, torque fuel pump to fuel rail line to 37 N.m (27 ft. lbs.). At injection pump. Torque fuel pump to fuel rail line to 37 N.m (27 ft. lbs.) at fuel rail. Torque fuel drain banjo bolt at pressure limiting valve and front of fuel filter housing to 24 N.m (18 ft. lbs.). Torque fuel line brace bolts to 24 N.m (18 ft. lbs.) Torque rail bolts to 24 N.m (18 ft. lbs.). Connect fuel pressure sensor.
19. Reposition number 6 fuel line shield and torque to 43 N.m (32 ft. lbs.).
20. Install the engine lift bracket at the rear of cylinder head. Torque to 77 N.m (57 ft. lbs.).
21. Install the fuel filter to injection pump low pressure line. Inspect and replace sealing washers if necessary. Torque banjo bolts to 24 N.m (18 ft. lbs.).
22. Connect fuel return line at back of cylinder head hand tight.
23. Connect fuel return line at filter housing hand tight.
24. Torque banjo connections at cylinder head and fuel filter housing to 24 N.m (18 ft. lbs.)
25. Install bracket to rear of filter housing. Torque to 24 N.m (18 ft. lbs.).
26. Using new gaskets, install the intake grid heater and air inlet housing. Torque bolts to 24 N.m (18 ft. lbs.).
27. Install wire harness P-clip and push on clip to air inlet housing.
28. Connect engine oil level indicator tube at fuel filter housing and at air inlet housing.
29. Connect the APPS connector.
30. Install the APPS assembly to the cylinder head bracket and torque bolts to 24 N.m (18 ft. lbs.).
31. Install the throttle linkage cover.
32. Install the charge air cooler-to-air inlet housing duct assembly. Torque all clamps to 11 N.m (100 in. lbs.).
33. Connect intake grid heater wires.
34. Secure engine harness to front of cylinder head with bolt at four locations.
35. Connect engine coolant temperature sensor connector.
36. Connect radiator upper hose to thermostat housing.
37. Rotate generator into position. Install upper bolt and torque upper and lower bolts.
38. Install wire harness push-on clip below bracket.
39. Install wire harness P-clip to top of bracket.
40. Install fan support and torque to 32 N.m (24 ft. lbs.).
41. Install cooling fan/drive refer to (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
42. Install accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ). NOTE: Late model engines use a multilayer exhaust manifold gasket.
43. Install exhaust manifold/turbocharger assembly, using new gaskets. Start all bolts/spacers by hand. Torque bolts to 43 N.m (32 ft. lbs.).
44. Install exhaust manifold heat shield to exhaust manifold studs. Install retaining nuts.Torque to 24 N.m (18 ft. lbs.).
45. Install exhaust bolt retention straps across cylinders 5 & 6.
46. Using a new gasket, connect the turbocharger oil drain tube. Torque to 24 N.m (18 ft. lbs.).
47. Perform the turbocharger pre-lube procedure. Refer to «TURBOCHARGER»(/dodge/pickup-r1500/1997-2012/remont/blowers-superchargers-turbochargers/#exhaust-system-turbocharger) for the correct procedure.
48. Connect the turbocharger oil supply line. Torque to 24 N.m (18 ft. lbs.).
49. Install air cleaner housing and duct.
50. Connect air inlet temperature/pressure sensor.
51. Raise vehicle on hoist.
52. Install exhaust pipe to turbocharger elbow. Torque bolts to 11 N.m (100 in. lbs.).
53. Lower vehicle.
54. Fill engine 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) ).
55. Start engine and check for leaks.

Scheme 427

1. Disconnect both battery negative cables.
2. Remove oil fill cap.
3. Remove the breather cover.
4. Disconnect the breather hose and breather drain tube from the breather housing.
5. Remove cylinder head cover bolts (Scheme 427)
6. Remove the cylinder head cover.

Note. Verify cylinder head ground spring is still properly retained in cylinder head cover.

REMOVAL-ROCKER HOUSING

1. Remove cylinder head cover as outlined in this section.
2. Disconnect rocker housing injector harness connectors.
3. Remove injector harness nuts from injectors.
4. Remove rocker housing bolts.
5. Remove rocker housing and gasket.

CLEANING

Using a suitable solvent, Clean and dry gasket mating surfaces on cylinder head and rocker housing. Wipe gasket dry and inspect for re-use.

INSPECTION

The cylinder head cover gasket and rocker housing gasket, are reusable. However, should cracks, nicks, or tears be present in the rubber/silicone construction, the defective components should be replaced. Also replace gasket if it is no longer flexible. Inspect cylinder head cover rubber isolated capscrews for cracks, nicks, or tears. Do not reuse gasket if it has been removed from the groove in the rocker housing or cylinder head cover. Inspect cylinder head cover ground spring for proper installation and retension in cylinder head cover.

INSTALLATION - CYLINDER HEAD COVER

1. Inspect cylinder head cover gasket for cuts and proper installation in groove. Replace if damaged.
2. Position cylinder cover on top of rocker housing (Scheme 428)
3. Install bolts.
4. Starting with the center bolt, torque to 24 N.m (18 ft. lbs.).
5. Install breather hose to breather.
6. Install breather drain hose to breather.
7. Install breather cover and wire harness clip. Torque to 24 N.m (18 ft. lbs.).

Scheme 428

1. Inspect rocker housing gasket for cuts, nicks, or tears. Replace if damaged or if gasket has come out of groove.
2. Inspect rocker housing gasket for proper installation in groove. Gasket bead must be centered in groove. A gasket bead that is tilted to the side will cause an oil leak. CAUTION: When installing rocker housing onto cylinder head, do not slide housing from side to side, The gasket could fall out or be damaged.
3. Install the rocker housing. Carefully guide the rocker housing evenly down onto the cylinder head.
4. Install rocker housing bolts and tighten finger tight.
5. Torque bolts, working from center out, to 24 N.m (18ft. lbs.).
6. Install injector harness nuts to injector solenoid. Torque to 1.25 N.m (11 in. lbs.).
7. Connect rocker housing injector harness connections.

The valves are made of heat resistant steel, and have chrome plated stems to prevent scuffing. The intake and exhaust valves are both similar in head diameter and overall length, but they have unique face angles which makes them non-interchangeable. The valves are distinguished by unique dimples on the exhaust valve head (Scheme 429)

The exhaust valve springs are made from high strength, chrome silicon steel. The exhaust valve springs are also exhaust brake compatible.

Scheme 429

Scheme 430

Scheme 431

1. Remove cylinder head (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
2. Support cylinder head on stands, or install head bolts upside down (through combustion surface side) to protect injector tips from damage from work bench.
3. Install the valve spring compressor mounting base as shown in (Scheme 430)
4. Install the compressor top plate, washer, and nut. Using a suitable wrench, tighten the nut (clockwise) to compress the valve springs (Scheme 431) and remove the locks.
5. Rotate the compressor nut counter-clockwise to relieve tension on the springs. Remove the spring compressor.
6. Remove the retainers, springs, valve seals (if necessary), and valves (Scheme 432) Arrange or number all components so they can be installed in their original locations.
7. Repeat the procedure on all cylinders to be serviced.

Clean the valve stems with crocus cloth or a Scotch-Brite™ pad. Remove carbon with a soft wire brush. Clean valves, springs, retainers, and valve retaining locks in a suitable solvent. Rinse in hot water and blow dry with compressed air.

Scheme 432

Visually inspect the valves for abnormal wear on the heads, stems, and tips. Replace any valve that is worn out or bent (Scheme 433)

Scheme 433

Measure the valve stem diameter in three places as shown in (Scheme 434)

Scheme 434

Measure the cylinder head valve guide bore (Scheme 435)

VALVE GUIDE BORE SPECIFICATIONS

VALVE GUIDE BORE SPECIFICATIONS

Scheme 435

Measure valve margin (rim thickness) (Scheme 436)

Scheme 436

Measure the valve spring free length and maximum inclination (Scheme 437)

Scheme 437

Test valve spring force with tool C-647 (Scheme 438) Specification 72.0 - 80.7 lbs. when compressed to 35.33 mm (1.39 in.).

Scheme 438

Scheme 439

1. Install new valve seals. The yellow seals are for the intake valves and the green seals are for the exhaust valves.
2. Install the valves in their original postion. The exhaust valves are identified by a dimple on the valve head (Scheme 439)
3. Install the valve springs and retainer.
4. Install the valve spring compressor tool 8319-A as shown in (Scheme 430) and (Scheme 431)
5. Compress the valve springs and install the valve retaining locks (Scheme 432)
6. Remove the compressor and repeat the procedure on the remaining cylinders.
7. Install new o-ring and sealing washer on injector.
8. Lubricate o-ring and injector bore.
9. Verify sealing washer (shim) was removed with old injector.
10. Install injector Refer to (Refer to «FUEL INJECTOR»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine) ).
11. Install the cylinder head (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).

STANDARD PROCEDURE - VALVE LASH ADJUSTMENT AND VERIFICATION

Note. To obtain accurate readings, valve lash measurements AND adjustments should only be performed when the engine coolant temperature is less than 60°C (140°F).

The 24-valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when trouble-shooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors.

Scheme 440

1. Disconnect battery negative cables.
2. Remove cylinder head cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
3. Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 o'clock position. If both number one cylinder rocker levers are loose, continue to next step. If both number one clylinder rocker levers are not loose, rotate crankshaft 360 degrees.
4. With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1-2-4 / EXHAUST 1-3-5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead (Scheme 440) Refer to «VALVE LASH LIMIT CHART»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) for the correct specifications. If the measurement falls within the limits, adjustment/resetting is not necessary. If measurement finds the lash outside of the limits, adjustment/resetting is required. VALVE LASH LIMIT CHART INTAKE EXHAUST 0.152 mm (0.006 in.) MIN. 0.381 mm (0.015 in.) MIN. 0.381 mm (0.015 in.) MAX. 0.762 mm (0.030 in.) MAX. NOTE: If measured valve lash falls within these specifications, no adjustment/reset is necessary. Engine operation within these reanges has no adverse affect on performance, emissions, fuel economy or level of engine noise.
5. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: INTAKE 0.254 mm (0.010 in.) EXHAUST 0.508 mm (0.020 in.) Tighten the lock nut to 24 N.m (18 ft. lbs.) and re-check the valve lash.
6. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 o'clock position.
7. With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3-5-6 / EXHAUST 2-4-6. Use the same method as above for determining whether adjustment is necessary, and adjust those that are found to be outside of the limits.
8. Install the cylinder head cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
9. Connect the battery negative cables.

Scheme 441

Scheme 442

1. Disconnect the battery negative cables.
2. Remove the cylinder head cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
3. Disconnect rocker housing injector harness connector. Remove all injector harness solenoid nuts.
4. Remove injector(s) for cylinder(s) to be serviced. Refer to «FUEL INJECTOR»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine) for injector removal.
5. Remove the rocker housing.
6. Remove the rocker arms and crossheads from the cylinder(s) to be serviced. Mark each component so they can be installed in their original position.
7. Using the crankshaft barring tool #7471-B (Scheme 441), rotate the engine to position the damper mark in the 12 o'clock position. At this engine position, cylinders #1 and #6 can be serviced.
8. Remove the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
9. With the damper TDC mark in the 12 o'clock position, add a paint mark anywhere on the gear housing cover next to the crankshaft damper. Place another mark on the vibration damper in alignment with the mark you just made on the cover.
10. Divide the crankshaft damper into three equally sized segments as follows: Using a tape measure, measure the circumference of the crankshaft damper and divide the measurement by three (3). Measure that distance in a counter-clockwise direction from the first balancer mark and place another mark on the balancer. From the second damper mark, again measure in a counter-clockwise direction and place a mark on the damper at the same distance you measured when placing the second damper mark. The damper should now be marked in three equally spaced locations and the damper TDC mark should be in the 12 o'clock position. Remove injectors, fuel lines, and high pressure connectors for every cylinder that requires repair.
11. Compress the valve springs at cyls. #1 and #6 as follows: Install the valve spring compressor mounting base as shown in (Scheme 442) Install the top plate, washer, and nut. Using a suitable wrench tighten the nut (clock-wise) (Scheme 443) to compress the valve springs and remove the collets. Rotate the compressor nut counter-clockwise to relieve tension on springs. Remove spring compressor. Remove and replace retainers, springs, and seals as necessary. Do not rotate the engine until the springs and retainers are re-installed. Install seals, springs and retainers. Install spring compressor, compress valve springs and install the collets. Release the spring tension and remove the compressor. Verify that the collets are seated by tapping on the valve stem with a plastic hammer.
12. Using the crankshaft barring tool, rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders #2 and #5 can be serviced.
13. Repeat the valve spring compressing procedure previously performed and service the retainers, springs; and seal as necessary.
14. Using the crankshaft barring tool, rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders #3 and #4 can be serviced.
15. Repeat the spring compressing procedure previously performed and service the retainers, springs, and seals as necessary.

Scheme 443

1. Install rocker housing.
2. Install fuel injectors and high pressure fuel lines.
3. Lubricate the valve tips and install the cross-heads in their original locations.
4. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 N.m (27 ft. lbs.) torque.
5. Verify valve lash adjustment (Refer to «STANDARD PROCEDURE»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
6. Install cylinder head cover and reusable gasket (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
7. Connect battery negative cables.

The unique intake and exhaust rocker arms have their own rocker shafts and are lubricated by passages intersecting the cylinder block main oil rifle. Crossheads are used, which allow each rocker arm to operate two valves.

The solid push rods are hardened at the rocker arm and tappet contact areas for superior strength and durability.

Scheme 444

Scheme 445

Scheme 446

1. Disconnect the battery negative cables.
2. Remove cylinder head cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
3. Remove the rocker arm/pedestal fasteners (Scheme 444) and remove rocker arm and pedestal from cylinder head. Mark the arms and pedestals so they can be installed in their original position. CAUTION: When removing the rocker arms, the sockets (Scheme 445) may come loose and fall into the engine. Make sure they stay with the arm upon removal/installation.
4. Lift the push rod(s) up and out of the engine (Scheme 446) Mark them so they can be installed in their original position. NOTE: The #5 cyl. intake and exhaust and #6 cyl. intake and exhaust push rods must be raised through the provided cowl panel access holes.
5. Lift the crosshead(s) off of the valve stems. Mark them so they can be installed in their original position.

Clean all components in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn deposits. Rinse in hot water and blow dry with compressed air. Inspect oil passages in rocker arms and pedestals. Apply compressed air to lubrication orifices to purge contaminants.

Rocker Arms

1. Remove rocker shaft and inspect for cracks and excessive wear in the bore or shaft. Remove socket and inspect ball insert and socket for signs of wear. Replace retainer if necessary.

Measure the rocker arm bore and shaft (Scheme 447) (Scheme 448)

Push Rods

Inspect the push rod ball and socket for signs of scoring. Check for cracks where the ball and the socket are pressed into the tube (Scheme 449)

Scheme 447

Scheme 448

Scheme 449

Roll the push rod on a flat work surface with the socket end hanging off the edge (Scheme 450) Replace any push rod that appears to be bent.

Scheme 450

Crossheads

Inspect the crossheads for cracks and/or excessive wear on rocker lever and valve tip mating surfaces (Scheme 451)

Scheme 451

1. If previously removed, install the push rods in their original location. Verify that they are seated in the tappets.
2. Lubricate the valve tips and install the cross-heads in their original locations.
3. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 N.m (27 ft. lbs.) torque.
4. Verify valve lash adjustment (Refer to «STANDARD PROCEDURE»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
5. Install cylinder head cover and reusable gasket (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
6. Connect battery negative cables.

Scheme 452

Scheme 453

1. The combustion deck can be refaced twice. The first reface should be 0.25 mm (0.0098 inch). If additional refacing is required, an additional 0.25 mm (0.0098 inch) can be removed. Total allowed refacing is 0.50 mm (0.0197 inch) - (Scheme 452) CYLINDER BLOCK REFACING DIMENSIONS SPECIFICATIONS DIMENSION "A" 1st Reface 0.25mm (0.0098 in.) 2nd Reface 0.25mm (0.0098 in.) Dim (A) Total 0.50 mm (0.0197 in.) DIMENSION "B" Dim. "B" (STD.) 323.00 mm +/- 0.10 mm (12.7165 in. +/- 0.0039 in.) 1st Reface 322.75 mm +/- 0.10 mm (12.7067 in. +/- 0.0039 in.) 2nd Reface 322.50 mm +/- 0.10 mm (12.6968 in. +/- 0.0039 in.)
2. The upper right corner of the rear face of the block must be stamped with a X when the block is refaced to 0.25 mm (0.0098 inch). A second X must be stamped beside the first when the block is refaced to 0.50 mm (0.0197 inch) - (Scheme 453)
3. Consult the parts catalog for the proper head gaskets which must be used with refaced blocks to ensure proper piston-to-valve clearance.

Scheme 454

Scheme 455

1. New piston rings may not seat in glazed cylinder bores.
2. De-glazing gives the bore the correct surface finish required to seat the rings. The size of the bore is not changed by proper de-glazing.
3. Cover the lube and tappet holes in the top of the block with waterproof tape.
4. It crankshaft is installed, wrap connecting rod journals with clean cloth. Cover cloth with waterproof tape.
5. A correctly honed surface will have a crosshatch appearance with the lines at 15° to 25° angles (Scheme 454) For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.
6. Use a drill, a fine grit Flex-hone and a mixture of equal parts of mineral spirits and SAE 30W engine oil to de-glaze the bores.
7. The crosshatch angle is a function of drill speed and how fast the hone is moved vertically (Scheme 455)
8. Vertical strokes MUST be smooth continuous passes along the full length of the bore (Scheme 455)
9. Inspect the bore after 10 strokes.
10. Use a strong solution of hot water and laundry detergent to clean the bores. Clean the cylinder bores immediately after de-glazing.
11. Rinse the bores until the detergent is removed and blow the block dry with compressed air.
12. Check the bore cleanliness by wiping with a white, lint free, lightly oiled cloth. If grit residue is still present, repeat the cleaning process until all residue is removed. Wash the bores and the complete block assembly with solvent and dry with compressed air. Place a clean shop towel around the top main bearing saddle to deflect water and residue from piston cooling nozzels. Remove directed piston cooling nozzles if installed.
13. Be sure to remove the tape covering the lube holes, rod journals, and piston cooling nozzles after the cleaning process is complete.

STANDARD PROCEDURE-CYLINDER BORE REPAIR

Cylinder bore(s) can be repaired by one of two methods

1. Method 1:-Over boring and using oversize pistons and rings.
2. Method 2:-Boring and installing a repair sleeve to return the bore to standard dimensions.

METHOD 1-OVERSIZE BORE

Cylinder bore(s) can be repaired by one of two methods

Oversize pistons and rings are available in two sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393 inch).

Any combination of standard, 0.50 mm (0.0197 inch) or 1.00 mm (0.0393 inch) overbore may be used in the same engine.

If more than 1.00 mm (0.0393 inch) overbore is needed, a repair sleeve can be installed (refer to METHOD 2-REPAIR SLEEVE ).

Cylinder block bores may be bored twice before use of a repair sleeve is required. The first bore is 0.50 mm (0.0197 inch) oversize. The second bore is 1.00 mm (0.0393 inch) oversize.

After boring to size, use a honing stone to chamfer the edge of the bore.

CYLINDER BORE DIMENSION CHART

CYLINDER BORE DIMENSION SPECIFICATIONS CHART

A correctly honed surface will have a crosshatch appearance with the lines at 15° to 25° angles with the top of the cylinder block (Scheme 456) For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.

Scheme 456

A maximum of 1.2 micrometer (48 microinch) surface finish must be obtained.

After finish honing is complete, immediately clean the cylinder bores with a strong solution of laundry detergent and hot water.

After rinsing, blow the block dry.

Check the bore cleanliness by wiping with a white, lint-free, lightly- oiled cloth. There should be no grit residue present.

If the block is not to be used right away, coat it with a rust- preventing compound.

METHOD 2-REPAIR SLEEVE

If more than a 1.00 mm (0.03937 inch) diameter oversize bore is required, the block must be bored and a repair sleeve installed.

Bore the block cylinder bore to 104.500-104.515 mm (4.1142-4.1148 inch) - (Scheme 457)

Repair sleeves can be replaced by using a boring bar to bore out the old sleeve. DO NOT cut the cylinder bore beyond the oversize limit.

Scheme 457

REPAIR SLEEVE BLOCK REBORE DIMENSIONS CHART

REPAIR SLEEVE BLOCK REBORE DIMENSIONS SPECIFICATIONS CHART

After machining the block for the new repair sleeve, thoroughly clean the bore of all metal chips, debris and oil residue before installing the sleeve.

Cool the repair sleeve(s) to a temperature of -12°C (10°F) or below for a minimum of one hour. Be ready to install the sleeve immediately after removing it from the freezer.

Apply a coat of Loctite 620, or equivalent to the bore that is to be sleeved.

Wear protective gloves to push the cold sleeve into the bore as far as possible.

Using a sleeve driver, drive the sleeve downward until it contacts the step at the bottom of the bore (Scheme 458)

Scheme 458

A sleeve driver can be constructed as follows (Scheme 459)

Scheme 459

SLEEVE DRIVER CONSTRUCTION SPECIFICATION CHART

SLEEVE DRIVER CONSTRUCTION SPECIFICATION CHART

Set up a boring bar and machine the sleeve to 101.956 mm (4.014 inch).

After removing the boring bar, use a honing stone to chamfer the corner of the repair sleeve(s).

SLEEVE MACHINING DIMENSIONS CHART

SLEEVE MACHINING DIMENSIONS SPECIFICATIONS CHART

A correctly honed surface will have a crosshatch appearance with the lines at 15° to 25° angles with the top of the cylinder block. For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.

Finished bore inside dimension is 102.020 +/-0.020 mm (4.0165 +/-0.0008 inch).

A maximum of 1.2 micrometer (48 microinch) surface finish must be obtained.

After finish honing is complete, immediately clean the cylinder bores with a strong solution of laundry detergent and hot water.

After rinsing, blow the block dry with compressed air.

Wipe the bore with a white, lint-free, lightly oiled cloth. Make sure there is no grit residue present.

Apply a rust-preventing compound if the block will not be used immediately.

A standard diameter piston and a piston ring set must be used with a sleeved cylinder bore.

STANDARD PROCEDURE-CAM BORE REPAIR

For standard bushings, not oversized, maximum front and rear cam bushing bore diameter is 59.248 mm. (2.3326 in.). DO NOT bore the intermediate cam bore to the front cam bore oversize dimensions. Maximum front and rear camshaft bushing installed diameter is 54.147 mm. (2.1318 in.). Minimum installed diameter is 54.083 mm. (2.1293 in.). Maximum intermediate camshaft bore diameter is 54.164 mm. (2.1324 in.).

A surface finish of 2.3 micrometers (92 microinch) must be maintained. Not more than 20% of an area of any one bore may be 3.2 micrometers (126 microinch).

Camshaft bores can be repaired individually. It is not necessary to repair undamaged cam bores in order to repair individually damaged cam bores. The standard front bushing cannot be used to repair intermediate bores.

Install all cam bushings flush or below the front and rear cam bore surface. The front camshaft bushing should be installed flush with front face of block. The rear camshaft bushing should be installed flush with rear face of block. The oil hole must align to allow a 3.2 mm (0.125 inch) rod to pass through freely (Scheme 460)

Scheme 460

Measure the combustion deck face using a straight edge and a feeler gauge (Scheme 461) Cylinder block flatness: End-to-end 0.076 mm (.003 in.). Maximum variation side-to-side 0.051 mm (.002 in.).

Inspect for any localized dips or imperfections.

If the surface exceeds the limit, (Refer to STANDARD PROCEDURE ).

Scheme 461

Inspect the cylinder bores for damage or excessive wear.

Measure the cylinder bores (Scheme 462) If the cylinder bores exceed the limit, (Refer to STANDARD PROCEDURE ).

Scheme 462

BORE SPECIFICATIONS

BORE SPECIFICATIONS

Inspect the camshaft bores for scoring or excessive wear.

Measure the camshaft bores (Refer to SPECIFICATIONS ).

If a bore exceeds the limit, (Refer to STANDARD PROCEDURE ).

Inspect the tappet bores for scoring or excessive wear.

Measure tappet bore from bottom of block. Minimum tappet bore diameter 16.000 mm (0.0630 in.). Maximum tappet bore 16.055 mm. (0.632 in.).

If out of limits, replace the cylinder block.

REMOVAL-CAMSHAFT BEARINGS

Note. Measure the diameter of each bore. If the camshaft bore for the first or rear cam bushing is worn beyond the limit, install a new service bushing. Inspect the rest of the camshaft bores for damage or excessive wear.If the bores without a bushing are worn beyond the limit, the engine must be removed for machining and installation of service bushings. If badly worn, replace the cylinder block.

1. Remove the camshaft (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
2. Remove the bushing from the No.1 bore and No.7 using a universal cam bushing tool.
3. Mark the cylinder block so you can align the oil hole in the cylinder block with the oil hole in the bushing.

Scheme 463

Scheme 464

Scheme 465

1. Disconnect both battery negative cables.
2. Recover A/C refrigerant (if A/C equipped) (Refer to «REFRIGERANT SYSTEM RECOVERY»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing__refrigerant-system-recovery) ).
3. Raise vehicle on hoist.
4. Drain engine coolant into container suitable for re-use (Refer to «DRAINING COOLING SYSTEM 5.9L DIESEL ENGINE»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-59l-diesel-engine) ).
5. Lower vehicle.
6. Remove radiator upper hose.
7. Remove viscous fan/drive/shroud assembly (Refer to «FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
8. Disconnect the coolant recovery bottle hose from the radiator filler neck.
9. Disconnect lower radiator hose from radiator outlet.
10. Automatic Transmission models: Disconnect transmission oil cooler lines from front of radiator using Special Tool 6931 (unless equipped with finger-release disconnect).
11. Remove radiator mounting screws and lift radiator out of engine compartment.
12. Remove upper radiator support panel.
13. If A/C equipped, disconnect A/C condenser refrigerant lines.
14. Disconnect charge air cooler piping from the cooler inlet and outlet.
15. Remove the two charge air cooler mounting bolts.
16. Remove charge air cooler (and A/C condenser if equipped) from vehicle.
17. Remove accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
18. Remove accessory drive belt tensioner.
19. Remove the fan support/hub assembly.
20. Remove crankshaft damper and speed indicator ring (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
21. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the sealing surfaces. Remove dust seal with cover.
22. Using Special Tool 7471-B Crankshaft Barring Tool, rotate the crankshaft to align the timing marks on the crankshaft and the camshaft gears.
23. Remove the cylinder head cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
24. Remove the rocker arms, cross heads, and push rods (Scheme 463) Mark each component so they can be installed in their original positions. NOTE: The #5 cylinder intake and the #6 cylinder intake and exhaust pushrods are removed by lifting them up and through the provided cowl panel access holes. Remove the rubber plugs to expose these relief holes.
25. Raise the tappets as follows, using the wooden dowel rods (Scheme 465) provided with the Miller Tool Kit 8502. Insert the slotted end of the dowel rod into the tappet. The dowel rods for the rear two cylinders will have to be put for cowl panel clearance. Press firmly to ensure that it is seated in the tappet. Raise the dowel rod to bring the tappet to the top of its travel, and wrap a rubber band around the dowel rods (Scheme 465) to prevent the tappets from dropping into the crankcase. Repeat this procedure for the remaining cylinders.
26. Verify that the camshaft timing marks are aligned with the crankshaft mark (Scheme 464)
27. Remove the bolts from the thrust plate.
28. Remove engine mount through bolts.
29. Install engine support fixture special tool # 8534, and steel bracket/wing nut special tool # 8534A.
30. Raise engine enough to allow camshaft removal.
31. Remove the camshaft, gear and thrust plate.

Camshaft

1. Inspect the valve lobes and bearing journals for cracks, pitting, scoring, or generally excessive wear. Replace any camshaft that exceeds the allowable limits.
2. Measure the bearing journals and lobes (Scheme 466)

CAMSHAFT DIMENSIONS

CAMSHAFT DIMENSIONS SPECIFICATIONS

Scheme 466

Camshaft Bushing/Bores

Camshaft bores No. 2-6 do not use a bushing.

Scheme 467

1. Inspect the camshaft bushing and bores for signs of excessive wear.
2. Measure the camshaft bushing and bores (Scheme 467) with a telescoping bore gauge and micrometer. If out of specification, (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
3. Inspect the camshaft bushing oil holes for alignment with cylinder block (Scheme 468)

Camshaft Gear

Inspect the camshaft gear for cracks (gear and hub), and chipped/broken/fretted teeth. If replacement is necessary, camshaft and gear are replaced as an assembly. (Refer to REMOVAL ).

Scheme 468

Thrust Plate

Inspect the camshaft thrust plate for excessive wear in the camshaft contact area. Measure thrust plate thickness using the CAMSHAFT THRUST PLATE THICKNESS CHART. Replace any thrust plate that falls outside of these specifications

CAMSHAFT THRUST PLATE THICKNESS CHART

CAMSHAFT THRUST PLATE THICKNESS SPECIFICATIONS CHART

INSTALLATION - CAMSHAFT BEARINGS

1. Apply a coating of Loctite® 640 Adhesive to the backside of the new bushing. Avoid getting adhesive in the oil hole.
2. Use a universal cam bushing installation tool and install the front bushing so that it is even with the front face of the cylinder block. The oil hole must be aligned. A 3.2 mm (0.128 inch) diameter rod must be able to pass through the hole. (Scheme 469)
3. Install the rear camshaft bushing is flush with the rear face of the block. The oil hole must be aligned. A 3.2 mm (0.128 inch) diameter rod must be able to pass through the hole.
4. Measure the installed bushings at the front and rear bores. The minimum inside diameter is 54.083 mm (2.1293 inch), and the maximum inside diameter is 54.147 mm. (2.1318 in.).

Scheme 469

Scheme 470

1. Lubricate the camshaft bushing and bores with fresh engine oil or suitable equivalent.
2. Liberally coat the camshaft lobes, journals, and thrust washer with fresh engine oil or suitable equivalent. CAUTION: When installing the camshaft, DO NOT push it in farther than it will go with the thrust washer in place.
3. Install the camshaft and thrust plate. Align the timing marks as shown (Scheme 470)
4. Install the thrust plate bolts and tighten to 24 N.m (18 ft. lbs.) torque.
5. Measure camshaft back lash and end clearance. CAMSHAFT BACK LASH AND END CLEARANCE SPECIFICATION BACKLASH - 0.075-0.250 mm (0.003-0.010 inch) CLEARANCE - 0.025-0.500 mm (0.001-0.020 inch)
6. Remove the wooden dowel rods and rubber bands from the tappets.
7. Lubricate the push rods with engine oil and install in their original location. Verify that they are seated in the tappets.
8. Lubricate the valve tips with engine oil and install the crossheads in their original locations.
9. Lubricate the crossheads and push rod sockets with engine oil and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 N.m (27 ft. lbs.) torque.
10. Verify valve lash adjustment (Refer to «STANDARD PROCEDURE»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
11. Install the cylinder head cover and reusable gasket (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
12. Install gear housing cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ). Install front crankshaft dust seal.
13. Install the crankshaft damper with the speed indicator ring (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
14. Install the fan support/hub assembly Refer to (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
15. Install the power steering pump.
16. Install accessory drive belt tensioner. Torque bolt to 43 N.m (32 ft. lbs.).
17. Install the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
18. Install the charge air cooler (with a/c condenser and auxiliary transmission oil cooler, if equipped) and tighten the mounting bolts to 2 N.m (17 in. lbs.) torque.
19. Connect charge air cooler inlet and outlet pipes. Tighten clamps to 11 N.m (95 in. lbs.) torque.
20. Install the radiator upper support panel.
21. Close radiator petcock and lower the radiator into the engine compartment. Tighten the mounting bolts to 11 N.m (95 in. lbs.) torque.
22. Raise vehicle on hoist.
23. Connect radiator lower hose and install clamp.
24. Connect transmission auxiliary oil cooler lines (if equipped).
25. Lower vehicle.
26. Install the fan /drive/shroud assembly. (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) )
27. Install the coolant recovery and windshield washer fluid reservoirs to the fan shroud.
28. Connect the coolant recovery hose to the radiator filler neck.
29. Add engine 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) ).
30. Charge A/C system with refrigerant (if A/C equipped) (Refer to «REFRIGERANT SYSTEM CHARGE»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing__refrigerant-system-charge) ).
31. Connect the battery negative cables.
32. Start engine and check for engine oil and coolant leaks.

STANDARD PROCEDURE - CONNECTING ROD BEARING AND CRANKSHAFT JOURNAL CLEARANCE

1. Measure the connecting rod bore with bearings removed and the bolts tightened to 100 N.m (73 ft. lbs.) torque..
2. Measure the connecting rod bore with the bearings installed and the bolts tightened to 100 N.m (73 ft. lbs.) torque.

Measure within 20° arc from each side of the parting line. Also measure 90° from parting line.

Record the smallest and largest diameter.

Measure the diameter of the rod journal at the location shown (Scheme 471) Calculate the average diameter for each side of the journal.

Determine minimum bearing clearance by calculating the differance between the smallest connecting rod bore diameter with the bearing installed and the average diameter for each side of the crankshaft journal.

Determine the maximum bearing clearance by calculating the difference between the largest connecting rod bore diameter and the average diameter with the bearing installed for each side of the crankshaft journal.

CONNECTING ROD BEARINGS SPECIFICATION

Scheme 471

CONNECTING ROD JOURNAL DIAMETER LIMITS CHART

CONNECTING ROD JOURNAL DIAMETER LIMITS CHART

If the crankshaft is within limits, replace the bearing. If the crankshaft is out of limits, grind the crankshaft to the next smaller size and use oversize rod bearings.

The crankshaft (Scheme 472) is a forged steel, integrally balanced unit. It is supported by seven main bearings, with position number six designated as the thrust journal. The crankshaft is held in place by main caps and 12 mm capscrews. The crankshaft also has internal cross drillings to supply the connecting rods with engine oil.

Scheme 472

REMOVAL - GEAR

1. Remove the gear housing cover. (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) )
2. Split the gear and remove it from the crankshaft.

Scheme 473

1. Remove all burrs and make sure the gear surface on the end of the crankshaft is smooth.
2. If removed, install a new alignment pin. Drive the pin in using a ball- peen hammer, leaving it protruding 1.0 mm (0.039 inch) to 1.5 mm (0.059 inch) above the crankshaft (Scheme 473) WARNING: WEAR PROTECTIVE GLOVES TO PREVENT INJURY. CAUTION: DO NOT heat the gear longer than 45 minutes.
3. Heat the crankshaft gear for 45 minutes at a temperature of 149°C (300°F). Do not use torch, gear failure will occur.
4. Apply a thin coat of lubricant to the nose of the crankshaft.
5. Position the gear with the timing mark out and install it on the crankshaft using the alignment pin. Make sure the gear contacts the shoulder.

STANDARD PROCEDURE - MAIN BEARING CLEARANCE

Inspect the main bearing bores for damage or abnormal wear.

Scheme 474

Scheme 475

1. Remove bearings and measure main bearing bore diameter after torquing main bearing cap bolts to 176 N.m (130 ft. lbs.).
2. Install the crankshaft main bearings and measure main bearing bore diameter with the main bolts tightened to 176 N.m (130 ft. lbs.) torque (Scheme 474)
3. Measure the diameter of the main journal at the locations shown (Scheme 475) Calculate the average diameter for each side of the journal. MAIN BEARING BORE DIAMETER SPECIFICATION CHART ITEM MAIN BEARING BORE DIAMETER (MAXIMUM) BEARINGS INSTALLED 83.106 mm (3.2719 in.) BEARINGS REMOVED Min 87.983 mm (3.4639 in.) Max. 88.019 mm (3.4653 in.) CRANKSHAFT MAIN JOURNAL DIAMETER SPECIFICATION CHART ITEM SPECIFICATION Minimum diameter 82.962 mm (3.2662 in.) Maximum diameter 83.013 mm (3.2682 in.) Maximum out of roundness 0.050 mm (.002 in.) Maximum taper 0.013 mm (.0005 in.) Thrust distance (at No.6 position) Min. 0.065 mm (.003 in.) Max. 0.432 mm (.017 in.)
4. Calculate the main bearing journal to bearing clearance. Maximum clearance is 0.119 mm (0.00475 inch). If the crankshaft journal is within limits, replace the main bearings. If not within specifications, grind the crankshaft to next size and use oversize bearings.
5. Measure thrust distance at the No.6 position.

REMOVAL

1. Disconnect both battery negative cables.
2. Raise vehicle on hoist.
3. Partially drain engine coolant into container suitable for re-use (Refer to «DRAINING COOLING SYSTEM 5.9L DIESEL ENGINE»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-59l-diesel-engine) ).
4. Lower vehicle.
5. Remove radiator upper hose.
6. Disconnect coolant recovery bottle from radiator filler neck and lift bottle off of fan shroud.
7. Disconnect windshield washer pump supply hose and electrical connections and lift washer bottle off of fan shroud.
8. Remove viscous fan/drive assembly. (Refer to «FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
9. Remove cooling fan shroud and fan assembly from the vehicle.
10. Remove the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
11. Remove the cooling fan support/hub from the front of the engine.
12. Raise the vehicle on hoist.
13. Remove the crankshaft damper and speed indicator ring.
14. Remove power steering pump.
15. Remove accessory drive belt tensioner.
16. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces. Remove crank seal dust shield with cover.
17. Support the cover on a flat work surface with wooden blocks (Scheme 476), and using a suitable punch and hammer, drive the old seal out of the cover from the back side of the cover to the front side (Scheme 476)

Scheme 476

Scheme 477

Scheme 478

1. Clean cover and housing gasket mating surfaces. Use a suitable scraper and be careful not to damage the gear housing surface. Remove any old sealer from the oil seal bore. 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.
2. Inspect the gear housing and cover for cracks and replace if necessary. Carefully straighten any bends or imperfections in the gear cover with a ballpeen hammer on a flat surface. Inspect the crankshaft front journal for any grooves or nicks that would affect the integrity of the new seal.
3. Apply a bead of Mopar® Stud & Bearing Mount to the outside diameter of the seal. Do not lubricate the inside diameter of the new seal.
4. With the cover supported by wood blocks, install the seal into the rear of the cover using crankshaft seal installer Special Tool 8281 and driver handle C-4171 (Scheme 477) Strike the driver handle until the installation tool bottoms out on the inside of the cover. CAUTION: Do not distort or damage seal.
5. Install the plastic seal pilot (provided with seal kit) into the crankshaft seal.
6. Apply a bead of Mopar® Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover sealing surface.
7. Install the cover to the gear housing, aligning the seal pilot with the nose of the crankshaft (Scheme 478)
8. Install the cover bolts and tighten to 24 N.m (18 ft. lbs.) torque. Remove pilot tool.
9. Install dust shield over nose of crankshaft.
10. Install the crankshaft damper and speed indicator ring. Torque the bolts to 40 N.m (30 ft. lbs.). Then rotate an additional 60°. Use the engine barring tool to keep the engine from rotating during tightening operation.
11. Install the fan support/hub assembly and torque bolts to 32 N.m (24 ft. lbs.).
12. Install power steering pump.
13. Install accessory drive belt tensioner. Torque bolt to 43 N.m (32 ft.lbs.).
14. Install cooling fan (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
15. Install the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
16. Refill cooling system (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) ).
17. Connect battery negative cables.
18. Start engine and check for oil leaks.

Scheme 479

1. Disconnect the battery negative cables.
2. Remove the transmission and transfer case (if equipped).
3. Remove the clutch cover and disc (if manual transmission equipped) ).
4. Remove the flywheel or converter drive plate.
5. Drill holes 180° apart into the seal. Be careful not to contact the drill against the crankshaft.
6. Install #10 sheet metal screws in the drilled holes and remove the rear seal with a slide hammer (Scheme 479)

Scheme 480

1. Clean the crankshaft journal with a suitable solvent and dry with a clean shop towel or compressed air. Wipe the inside bore of the crankshaft seal retainer with a clean shop towel.
2. Inspect the crankshaft journal for gouges, nicks, or other imperfections. If the seal groove in the crankshaft is excessively deep, install the new seal 1/8" deeper into the retainer bore, or obtain a crankshaft wear sleeve that is available in the aftermarket.
3. Install the seal pilot and new seal, provided in the replacement kit, onto the crankshaft.
4. Remove the seal pilot.
5. Install the installation tool over crankshaft.
6. Using a ball peen hammer, strike the tool at the 12, 3, 6, and 9 o'clock positions until the alignment tool bottoms out on the retainer (Scheme 480)
7. Install the flywheel or converter drive plate. Tighten the bolts to 137 N.m (101 ft. lbs.) torque.
8. Install the clutch cover and disc (if equipped).
9. Install the transmission and transfer case (if equipped).
10. Lower vehicle.
11. Connect battery negative cables.
12. Check engine oil level and adjust, if necessary.
13. Start engine and check for oil leaks.

Scheme 481

1. Disconnect the battery negative cables.
2. Raise vehicle on hoist.
3. Remove the oil pan drain plug and drain the engine oil. Re-install plug and torque to 50 N.m (44 ft. lbs.) torque.
4. Remove transmission and transfer case (if equipped) from vehicle.
5. Remove flywheel or torque converter drive plate.
6. Disconnect starter cables from starter motor.
7. Remove starter motor (Refer to «STARTERS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) ) and transmission adapter plate assembly.
8. Remove four (4) oil pan rear bolts. Slide a feeler gauge between the seal retainer and oil pan gasket to break the seal.
9. Remove the six (6) retainer-to-block bolts (Scheme 481)
10. Remove the rear seal retainer and gasket (Scheme 481)
11. Support the seal retainer and drive out the crankshaft seal with a hammer and suitable punch.

Scheme 482

Scheme 483

Scheme 484

1. If using the old seal retainer, the crankshaft seal must be replaced.
2. Inspect oil pan gasket for nicks or cuts. If gasket is damaged, the oil pan must be removed and gasket must be replaced. Wipe oil pan gasket dry and apply light coating of RTV.
3. Using the retainer alignment/seal installation tool provided in the seal service kit, install the alignment tool into the retainer arid install to the cylinder block (Scheme 482), using a new gasket. Tighten the six (6) mounting bolts by hand.
4. The seal alignment tool is used to align rear cover properly. Starting with the center two bolts, tighten the retainer in a circular pattern to 10 N.m (89 in. lbs.). Remove the alignment tool. 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 surfaces must be completely dry when the seal is installed. Use a soap and water solution on outside diameter of seal to ease assembly.
5. Make sure the provided seal pilot is installed into the new crankshaft seal. Use the alignment/installation tool and press the seal onto the crankshaft (Scheme 483) Alternately drive the seal at the 12, 3, 6 and 9 o'clock positions.
6. Remove the alignment tool and trim the retainer gasket even with the oil pan mounting surface (Scheme 484)
7. Remove the seal pilot.
8. Apply a small amount of Mopar® Silicone Rubber Adhesive Sealant to the oil pan rail T-joints.
9. Install the four (4) oil pan rear mounting bolts and torque to 28 N.m (21 ft. lbs.).
10. Install new rectangular ring seal for cam bore.
11. Install the flywheel housing and bolts. Torque bolts to 77 N.m (57 ft. lbs.).
12. Install the flywheel or converter drive plate. Tighten bolts to 137 N.m (101 ft. lbs.).
13. Install the starter motor Refer to (Refer to «STARTERS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) ).
14. Install the transmission and transfer case (if equipped).
15. Lower vehicle.
16. Fill the crankcase with new engine oil.
17. Connect the battery negative cables.
18. Start engine and check for oil leaks.

Note. This procedure requires use of Miller Tool 8502 Tappet Replacement Kit.

Scheme 485

1. Remove camshaft (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
2. Insert the trough (provided with tool kit) the full length of the camshaft bore (Scheme 485) Make sure the cap end goes in first and the open side faces up (towards tappets).
3. Remove only one tappet at a time. Remove rubber band from one cylinder pair and attach tappet dowel not being removed to the next cylinder pair (Scheme 486)
4. Raise dowel rod (disengage from tappet) and allow tappet to fall into trough (Scheme 487)
5. Carefully remove trough ( do not rotate ) and tappet. If the tappet is not being replaced, mark it so it can be installed in its original location.
6. Re-install trough and repeat procedure on remaining tappets.

Clean tappet with a suitable solvent. Rinse in hot water and blow dry with a clean shop rag or compressed air.

Scheme 486

Scheme 487

Scheme 488

1. Visually inspect the tappet the tappet socket, stem, and face for excessive wear, cracks, or obvious damage (Scheme 488)
2. Measure the tappet stem diameter. Replace the tappet if it falls below the minimum size (Scheme 488)

Scheme 489

Scheme 490

Scheme 491

Scheme 492

1. Insert the trough the full length of the camshaft bore. Again, make sure the cap end goes in first and the open side faces up (towards tappets).
2. Lower the tappet installation tool through the push rod hole (Scheme 489) and into the trough.
3. Retrieve the tappet installation tool using the hooked rod provided with the tool kit (Scheme 490)
4. Lubricate the tappet with clean engine oil or suitable equivalent and install the tappet to the installation tool (Scheme 491)
5. Pull the tappet up and into position (Scheme 491) If difficulty is experienced getting the tappet to make the turn into the tappet bore, wiggle the trough while gently pulling up on the tappet.
6. With the tappet in place, rotate the trough one half turn so the open side is down (toward crankshaft) (Scheme 492)
7. Remove the tappet installation tool from the tappet.
8. Re-install a dowel rod and secure the rod with a rubber band.
9. Rotate the trough one half turn and repeat the procedure for the remaining tappets.
10. Install the camshaft (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).

PISTON

The piston (Scheme 493) is constructed of aluminum and is gravity cast, free floating design. The piston incorporates a centrally located high swirl combustion bowl, and utilizes a "keystone" style top compression ring (Scheme 494), and a "Tapered Face" intermediate ring (Scheme 494), for superior cylinder wall scraping. Piston cooling nozzles cool the piston and pin with engine oil supplied by the crankshaft main journals. High horsepower pistons are gallery cooled and utilize J-jet piston cooling nozzles. Pistons are directional in order to provide clearance to piston cooling nozzles.

Scheme 493

Scheme 494

The connecting rods are a split angle design. They have a pressed-in-place wrist pin bushing that is lubricated by piston cooling nozzle oil spray.

Machined connecting rods are no longer used in the diesel engine. Do not install machined connecting rods into an engine that has fractured split connecting rods.

Fractured split connecting rods are first manufactured as a single piece and then fractured into two pieces. Fractured split connecting rods can be identified by a rough and irregular surface at the connecting rod split face. To properly assemble the rod cap to the connecting rod, the bearing tangs on the connecting rod and cap must be located on the same side of the rod. The long end of the connecting rod must be assembled on the intake or camshaft side of the engine.

Each matched fractured split connecting rod and cap is an assembly and are not interchangeable. If a connecting rod or cap is damaged, the entire assembly must be replaced.

STANDARD PROCEDURE -HEAD GASKET SELECTION

1. Measure piston protrusion for all six pistons.
2. Calculate the average piston protrusion. Maximum allowable protrusion is 0.516 mm (0.020 inch).

Note. There are two different head gaskets available. One gasket is for Average piston protrusion less than 0.30 mm (0.011 inch). The other gasket is for Average piston protrusion greater than 0.30 mm (0.011 inch)

1. Disconnect the battery cables.
2. Remove the cylinder head (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
3. Remove the oil pan and suction tube (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
4. Remove bolts and the block stiffener.
5. Using Miller Tool 7471-B crankshaft barring tool, rotate the crankshaft so all of the pistons are below TDC.
6. Before removing the piston(s) from the bore(s): Remove any carbon ridge formations or deposits at the top of the bore with a dull scraper or soft wire brush. If cylinder bore wear ridges are found, use a ridge reamer to cut the ridge from the bore. DO NOT remove more metal than necessary to remove the ridge.
7. Remove the J-jet cooling nozzles, if equipped. NOTE: If cylinders have ridges, the cylinders are oversize and will more than likely need boring.
8. Using a hammer and steel stamp, stamp the cylinder number in the top of each piston. The front of the piston is identified by a stamping on the top of the piston. DO NOT stamp in the outside 5 mm (.197 in.) of the piston diameter. DO NOT stamp over the piston pin.
9. Mark the connecting rod and cap with the corresponding cylinder numbers.
10. Remove the connecting rod bolts and rod caps. Use care so the cylinder bores and connecting rods are not damaged.
11. Use a hammer handle or similar object to push the piston and connecting rod through the cylinder bore.
12. Store the piston/rod assemblies in a rack.

CLEANING-PISTON AND CONNECTING ROD

Clean the pistons and pins in a suitable solvent, rinse in hot water and blow dry with compressed air. Soaking the pistons over night will loosen most of the carbon build up. De-carbon the ring grooves with a broken piston ring and again clean the pistons in solvent. Rinse in hot water and blow dry with compressed air.

CONNECTING ROD

Clean the connecting rods in a suitable solvent, rinse in hot water and blow dry with compressed air.

INSPECTION - PISTONS

Inspect the pistons for damage and excessive wear. Check top of the piston, ring grooves, skirt and pin bore. Measure the piston skirt diameter. If the piston is out of limits, replace the piston.

PISTONS SKIRT DIAMETER SPECIFICATION

The upper groove only needs to be inspected for damage. Use a new piston ring to measure the clearance in the intermediate ring groove (Scheme 495) Minimum clearance is 0.045 mm (0.0018 inch), maximum clearance is 0.095 mm (.0037 inch). If the clearance of the intermediate ring exceeds specifications, replace the piston.

Use a new oil ring to measure the clearance in the oil groove (Scheme 495) Minimum clearance is 0.040 mm (0.0016 inch), maximum clearance is 0.085 mm (.0033 inch). If the clearance exceeds specifications, replace the piston.

Scheme 495

Measure the pin bore (Scheme 496) The maximum diameter is 40.012 mm (1.5753 inch), Minimum is 40.006 mm (1.575 inch). If the bore is over limits, replace the piston.

Scheme 496

Inspect the piston pin for nicks, gouges and excessive wear. Measure the pin diameter (Scheme 497) The minimum diameter is 39.990 mm (1.5744 inch), maximum 40.003 mm (1.5749 inch). If the diameter is out of limits, replace the pin.

Scheme 497

INSPECTION-CONNECTING ROD

Inspect the connecting rod for damage and wear. The I-Beam section of the connecting rod cannot have dents or other damage. Damage to this part can cause stress risers which will progress to breakage.

Measure the connecting rod pin bore (Scheme 498) The maximum diameter is 40.042 mm (1.5765 inch), minimum diameter is 40.019 mm (1.5756 inch). If out of limits, replace the connecting rod.

Scheme 498

Scheme 499

Scheme 500

1. Lubricate the cylinder bores with clean engine oil.
2. Generously lubricate the rings and piston skirts with clean engine oil.
3. Orientate the rings on the piston (Refer to «STANDARD PROCEDURE - PISTON RING FITTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
4. Compress the rings using a piston ring compressor tool (Scheme 499) If using a strap-type ring compressor, make sure the inside end of the strap does not hook on a ring gap and break the ring.
5. Bar the crankshaft so the rod journal for the piston to be installed is at BDC (Bottom Dead Center) - (Scheme 500)
6. Make sure the front of the piston is oriented properly according to the marking on the top of the piston and the connecting rod is oriented properly.
7. Position the piston and rod assembly into the cylinder bore with the front of the piston oriented properly according to the stamping in the top of the piston. Use care when you install the piston and connecting rod so the cylinder bore is not damaged. The long side of the connecting rod must be installed on the intake side of the engine.
8. Push the piston into the bore until the top of the piston is approximately 50 mm (2 inch) below the top of the block. Carefully pull the connecting rod onto the crankshaft journal.
9. Use clean engine oil to lubricate the threads and under the heads of the connecting rod bolts.
10. For fractured/split type connecting rods, the long end of the rod must be installed towards the intake side of the engine. The connecting rod split/face must face toward the same side as the piston notch feature on the skirt. The split face will face toward the exhaust side of the engine if properly installed.
11. Install the rod cap and bolts to the connecting rod. Tighten the connecting rod bolts evenly in 3 steps. Tighten the bolts to 30 N.m (22 ft. lbs.) torque. Tighten the bolts to 60 N.m (44 ft. lbs.) torque. Rotate 60° clockwise.
12. The crankshaft must rotate freely. Check for freedom of rotation as the caps are installed. If the crankshaft does not rotate freely, check the installation of the rod bearing and the bearing size.
13. Measure the side clearance between the connecting rod and the crankshaft. DO NOT measure the clearance between the cap and crankshaft.
14. Install J-jet piston cooling nozzles if equipped.
15. Install block stiffener. Torque to 43 N.m (32 ft. lbs.).
16. Install the suction tube and oil pan (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
17. Install the cylinder head onto the engine (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
18. Install a new filter and fill the crankcase with new engine oil. Prefill the filter with clean oil.
19. Connect the battery negative cables and start engine.

Scheme 501

Scheme 502

Scheme 503

Scheme 504

Scheme 505

1. Determine the piston diameter and obtain the appropriate ring set. The piston rings can be identified as shown in (Scheme 501)
2. 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) - (Scheme 502)
3. Use a feeler gauge to measure the piston ring gap. PISTON RING GAP SPECIFICATION CHART PISTON RING GAP CHART TOP RING 0.26 - 0.36 mm (0.010-0.014 in.) INTERMEDIATE RING 0.85-1.15 mm (0.033 - 0.045 in.) OIL CONTROL RING 0.25-0.55 mm (0.010-0.022 in.)
4. The top surface of all of the rings are identified with the word TOP or the supplier's MARK. Assemble the rings with the word TOP or the supplier's MARK up.
5. Position the oil ring expander in the oil control ring groove (bottom groove).
6. Install the oil control ring with the end gap OPPOSITE the ends on the expander (Scheme 503)
7. Install the intermediate piston ring in the second groove.
8. Install the top piston ring in the top groove (Scheme 504)
9. Position the rings as shown in (Scheme 505)

1. Remove the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
2. Remove the four (4) damper to crankshaft bolts and remove damper and speed indicator ring.

Scheme 506

Scheme 507

1. Inspect the damper hub for cracks and replace if any are found.
2. Inspect the index lines on the damper hub and the inertia member (Scheme 506) If the lines are more than 1.59 mm (1/16 in.) out of alignment, replace the damper.
3. Inspect the rubber member for deterioration or missing segments (Scheme 507)

1. Install speed indicator ring. NOTE: The speed indicator ring is located over a dowel pin.
2. Install the crankshaft damper and bolts. Tighten bolts to 40 N.m (30 ft. lbs.) torque, plus an additional 60°. NOTE: The damper must be installed so the hole is located over the dowel pin.
3. Install the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).

Scheme 508

Scheme 509

1. Disconnect the battery negative cables.
2. Remove the viscous fan/drive assembly (Refer to «FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
3. Raise vehicle on hoist.
4. Install engine support fixture tool# 8534 and steel bracket tool # 8534A
5. Loosen the thru-bolt and nut.
6. Lift the engine SLIGHTLY and remove the insulator to block bolts (Scheme 509) (Scheme 508)
7. Remove the insulator from the vehicle.

Scheme 510

Scheme 511

1. With engine raised SLIGHTLY, position the insulator to the mount (Scheme 510) (Scheme 511) Install the bolts and torque to specification.
2. Lower the engine using tool # 8534, while guiding the mount and thru-bolt into the frame mounted support cushion brackets.
3. Install the thru-bolt nut and tighten the nut to 95 N.m (70 ft. lbs.) torque.
4. Remove the engine support fixture tool #8534.
5. Lower the vehicle.
6. Install the viscous fan/drive assembly (Refer to «FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
7. Connect the battery negative cables.

1. Raise the vehicle on a hoist.
2. Position a transmission jack in place.
3. Remove support cushion stud nuts (Scheme 512)
4. Raise rear of transmission and engine SLIGHTLY.
5. Remove the bolts holding the support cushion to the transmission support bracket. Remove the support cushion.
6. If necessary, remove the bolts holding the transmission support bracket to the transmission.

Scheme 512

1. If removed, position the transmission support bracket to the transmission. Install new attaching bolts and tighten to 102 N.m (75 ft. lbs.) torque.
2. Position support cushion to transmission support bracket. Install stud nuts and tighten to 47 N.m (35 ft. lbs.) torque.
3. Using the transmission jack, lower the transmission and support cushion onto the crossmember (Scheme 512)
4. Install the support cushion bolts and tighten to 47 N.m (35 ft. lbs.) torque.
5. Remove the transmission jack.
6. Lower the vehicle.

Note. (Scheme 513) and (Scheme 514) for circuit illustrations.

Scheme 513

Scheme 514

A gear driven gerotor type oil pump is mounted behind the front gear cover in the lower right portion on the engine.

OPERATION

A gerotor style oil pump draws oil from the crank-case through the suction tube and delivers it through the block where it enters the oil cooler cover and pressure regulator valve. When oil pressure exceeds 517 kPa (75 PSI), the valve opens exposing the dump port, which routes excess oil back to the oil pump.

At the same time, oil is directed to a cast in passage in the oil cooler cover, leading to the oil cooler element. As the oil travels through the element plates, it is cooled by engine coolant traveling past the outside of the plates. It is then routed to the oil filter head and through a full flow oil filter. If a plugged filter is encountered, the filter by-pass valve opens, allowing unfiltered oil to lubricate the engine. This condition can be avoided by frequent oil and filter changes, per the maintenance schedules found in the owners manual. The by-pass valve is calibrated to open when it sees a pressure drop of more than 345 kPa (50 psi) across the oil filter.

The oil filter head then divides the oil between the engine and the turbocharger. The turbocharger receives filtered, cooled and pressurized oil through a supply line from the filter head. The oil lubricates the turbocharger and returns to the pan by way of a drain tube connecting the bottom of the turbocharger to a pressed in tube in the cylinder block.

Oil is then carried across the block to an angle drilling which intersects the main oil rifle. The main oil rifle runs the length of the block and delivers oil to the crankshaft main journals and valve train. Oil travels to the crankshaft through a series of transfer drillings (one for each main bearing) and lubricates a groove in the main bearing upper shell. From there another drilling feeds the camshaft main journals. The saddle jet piston cooling nozzles are also supplied by the main bearing upper shell. J-jet piston cooling nozzles are supplied by a separate oil rifle. Plugs are used in place of saddle jets when J-jets are used. J-jet hole locations are plugged when saddle jet cooling nozzles are used (Scheme 515) Crankshaft internal cross-drillings supply oil to the connecting rod journals.

Scheme 515

Another series of transfer drillings intersecting the main oil rifle supply the valve train components. Oil travels up the drilling, through a hole in the head gasket, and through a drilling in the cylinder head (one per cylinder), where it enters the rocker arm pedestal and is divided between the intake and exhaust rocker arm. Oil travels up and around the rocker arm mounting bolt, and lubricates the rocker shaft by cross drillings that intersect the mounting bolt hole. Grooves at both ends of the rocker shaft supply oil through the rocker arm where the oil travels to the push rod and socket balls (Scheme 513) and (Scheme 514)

DIAGNOSIS AND TESTING-ENGINE OIL PRESSURE

1. Remove the 1/8 npt plug from the top of the oil filter housing.
2. Install Oil Pressure Line and Gauge Tool C-3292 with a suitable adapter.
3. Start engine and warm to operating temperature.
4. Record engine oil pressure and compare with engine oil pressure chart. CAUTION: If engine oil pressure is zero at idle, DO NOT RUN THE ENGINE. ENGINE OIL PRESSURE (MIN) SPECIFICATION Engine Oil Pressure (MIN) At Idle 68.9 kPa (10 psi) At 2500 rpm 206.9 kPa (30 psi) If minimum engine oil pressure is below these ranges, (Refer to «DIAGNOSIS AND TESTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
5. Remove oil pressure gauge and install the 1/8 npt plug.

STANDARD PROCEDURE - ENGINE OIL LEVEL

To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable oil level is in the SAFE RANGE on the engine oil dipstick (Scheme 516)

Scheme 516

1. Position vehicle on level surface.
2. With engine OFF, allow approximately 15 minutes for oil to settle to bottom of crankcase, remove engine oil dipstick.
3. Wipe dipstick clean.
4. Replace dipstick and verify it is seated in the tube.
5. Remove dipstick, with handle held above the tip, take oil level reading.
6. Add oil only if level is below the SAFE RANGE area on the dipstick.
7. Replace dipstick

STANDARD PROCEDURE - ENGINE OIL SERVICE

Note. Change engine oil and filter at intervals specified in the owner's manual.

1. Operate the engine until the water temperature reaches 60°C (140°F). Shut the engine off.
2. Use a container that can hold at least 14 liters (15 quarts) to hold the used oil. Remove the oil drain plug and drain the used engine oil into the container.
3. Always check the condition of the used oil. This can give you an indication of engine problems that might exist. Thin, black oil indicates fuel dilution. Milky discoloration indicates coolant dilution.
4. Clean the area around the oil filter head. Remove the filter (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
5. Install new oil filter (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
6. Clean the drain plug and the sealing surface of the pan. Check the condition of the threads and sealing surface on the oil pan and drain plug.
7. Install the drain plug. Tighten the plug to 50 N.m (37 ft. lbs.) torque.
8. Use only High-Quality Multi-Viscosity lubricating oil in the Cummins Turbo Diesel engine. Choose the correct oil for the operating conditions (refer to owner's manual ).
9. Fill the engine with the correct grade of new oil (refer to owner's manual ).
10. Start the engine and operate it at idle for several minutest Check for leaks at the filter and drain plug.
11. Stop engine. Wait 15 minutes to allow the oil to drain back to the pan and check the level again.

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing of used engine oil after it has been drained from a vehicle's engine.

CLEANING AND INSPECTION

Clean the sealing surfaces.

Apply 483 kPa (70 psi) air pressure to the element to check for leaks. If the element leaks, replace the element.

1. Clean the area around the oil filter head. Remove the filter from below using a cap-stylft fitter wrench.
2. Clean the gasket surface of the filter head. The filter canister O-Ring seal can stick on the filter head. Make sure it is removed.

1. Fill the oil filter element with clean oil before installation. Use the same type oil that will be used in the engine.
2. Apply a light film of lubricating oil to the sealing surface before installing the filter. CAUTION: Mechanical over-tightening may distort the threads or damage the filter element seal.
3. Install the filter until it contacts the sealing surface of the oil filter adapter. Tighten filter an additional 1/2 turn.

1. Disconnect the battery negative cables.
2. Install engine support fixture # 8534.
3. Raise vehicle on hoist.
4. Disconnect starter cables from starter motor.
5. Remove transmission and transfer case (if equipped).
6. Remove flywheel or flexplate.
7. Remove starter motor (Refer to «STARTERS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) ) and transmission adapter plate assembly. WARNING: HOT OIL CAN CAUSE PERSONAL INJURY.
8. Drain the engine oil (Refer to «STANDARD PROCEDURE»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
9. Install the oil pan drain plug if sealing surface is not damaged and tighten to 50 N.m (37 ft. lbs.) torque.
10. Remove oil pan bolts, break the pan to block seal, and lower pan slightly and remove oil suction tube fasteners.
11. Remove oil pan and suction tube.

Remove all gasket material from the oil pan and cylinder block sealing surfaces. Extra effort may be required around T-joint areas. Clean oil pan and flush suction tube with a suitable solvent.

Inspect the oil pan, suction tube, and tube braces for cracks and damage. Replace any defective component. Inspect the oil drain plug and drain hole threads. Inspect the oil pan sealing surface for straightness. Repair any minor imperfections with a ball-peen hammer. Do not attempt to repair an oil pan by welding.

1. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar® Silicone Rubber Adhesive Sealant or equivalent.
2. Place suction tube in oil pan and guide them into place. Slide oil pan gasket into postion. Using a new tube to block gasket, install and tighten the suction tube bolts by hand. Starting with the oil pump inlet bolts, tighten the bolts to 24 N.m (18 ft. lbs.) torque. Tighten the remaining tube brace bolts to 43 N.m (32 ft. lbs.) torque.
3. Starting in the center and working outward, tighten the oil pan bolts to 28 N.m (21 ft. lbs.) torque.
4. Install the flywheel housing assembly with the starter motor attached and tighten bolts to 77 N.m (57 ft. lbs.) torque.
5. Connect starter motor cables.
6. Install the flywheel or flexplate. Torque to 137 N.m (101 ft. lbs.).
7. Install transmission and transfer case (if equipped).
8. Lower vehicle.
9. Remove the engine support fixture # 8534.
10. Install battery negative cables.
11. Fill the crankcase with new engine oil.
12. Start engine and check for leaks. Stop engine, check oil level, and adjust, if necessary.

1. Disconnect the battery negative cables.
2. Remove the threaded plug, spring and plunger (Scheme 517) Insert a finger or a seal pick to lift the plunger from the bore.

Note. If the plunger is stuck in the bore, it will be necessary to remove the filter head.

Scheme 517

1. Clean the regulator spring and plunger with a suitable solvent and blow dry with compressed air. If the plunger bore requires cleaning, it is necessary to remove the oil filter head to avoid getting debris into the engine.

Inspect the plunger and plunger bore for cracks and excessive wear. Polished surfaces are acceptable. Verify that the plunger moves freely in the bore.

Check the spring for height and load limitations (Scheme 518) Replace the spring if out of limits shown in the figure.

VALVE OPEN

1. HEIGHT: 41.25mm (1.62 inch)
2. LOAD: 126 N (28.4 lb)

FREE LENGTH: 66mm (2.6 inch)

Scheme 518

1. Install the plunger, spring, and plug as shown in (Scheme 517) Tighten the plug to 80 N.m (59 ft. lbs.) torque.
2. Connect the battery negative cables.
3. Start the engine and verify that it has oil pressure.

1. Disconnect the battery negative cables.
2. Disconnect the oil pressure switch connector.
3. Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise).

1. If the switch is not being replaced, replace and lubricate the o-ring.
2. Install the oil pressure switch and tighten to 18 N.m (159 in. lbs.) torque.
3. Connect oil pressure switch connector.
4. Connect the battery negative cables.
5. Start engine and check for oil leaks at the switch.

Scheme 519

1. Disconnect the battery negative cables.
2. Remove fan/drive assembly (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
3. Remove the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
4. Remove the fan support/hub assembly.
5. Remove crankshaft damper (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ) and speed indicator ring.
6. Remove power steering pump.
7. Remove accessory drive belt tensioner.
8. Remove the gear housing cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
9. Remove the four mounting bolts and pull the oil pump from the bore in the cylinder block (Scheme 519)

Clean all parts in solvent and dry with compressed air. Clean the old sealer residue from the back of the gear housing cover and front of the gear housing.

Disassemble and inspect the oil pump as follows

Scheme 520

Scheme 521

Scheme 522

Scheme 523

1. Visually inspect the lube pump gears for chips, cracks or excessive wear.
2. Remove the back plate (Scheme 520)
3. Mark TOP on the gerotor planetary using a felt tip pen (Scheme 520)
4. Remove the gerotor planetary (Scheme 520) Inspect for excessive wear or damage. Inspect the pump housing and gerotor drive for damaged and excessive wear.
5. Install the gerotor planetary in the original position.
6. Measure the tip clearance (Scheme 521) Maximum clearance is 0.1778 mm (0.007 inch). If the oil pump is out of limits, replace the pump.
7. Measure the clearance of the gerotor drive/gerotor planetary to port plate (Scheme 522) Maximum clearance is 0.127 mm (0.005 inch). If the oil pump is out of limits, replace the pump.
8. Measure the clearance of the gerotor planetary to the body bore (Scheme 523) Maximum clearance is 0.381 mm (0.015 inch). If the oil pump is out of limits, replace the pump.
9. Measure the gears backlash (Scheme 524) The limits of a used pump is 0.15- 0.25 mm (0.006-0.010 inch). If the backlash is out of limits, replace the oil pump.
10. Install the back plate.

Scheme 524

Scheme 525

Scheme 526

1. Lubricate the pump with clean engine oil. Filling the pump with clean engine oil during installation will help to prime the pump at engine start up.
2. Install the pump (Scheme 519) Verify the idler gear pin is installed in the locating bore in the cylinder block. Tighten the oil pump mounting bolts in two steps, in the sequence shown in (Scheme 525) Step 1-Tighten to 8 N.m (71 in. lbs.) torque. Step 2-Tighten to 24 N.m (18 ft. lbs.) torque.
3. The back plate on the pump seats against the bottom of the bore in the cylinder block. When the pump is correctly installed, the flange on the pump will not touch the cylinder block.
4. Measure the idler gear to pump drive gear backlash and the idler gear to crankshaft gear backlash (Scheme 526) The backlash should be 0.15-0.25 mm (0.006-0.010 inch). If the backlash is out of limits, replace the oil pump.
5. If the adjoining gear moves when you measure the backlash, the reading will be incorrect.
6. Apply a bead of Mopar® Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover sealing surface.
7. Install the gear housing cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
8. Install the vibration damper (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ) and speed indicator ring.
9. Install the fan support/hub assembly Refer to (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) )
10. Install power steering pump.
11. Install accessory drive belt tensioner. Torque bolt to 43 N.m (32 ft. lbs.).
12. Install the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
13. Install the cooling fan (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
14. Connect battery inegative cables.
15. Start engine and check for oil leaks.

Scheme 527

Scheme 528

1. Disconnect the battery negative cables.
2. Remove the charge air cooler outlet tube from the air inlet housing (Scheme 527)
3. Remove the engine oil dipstick tube mounting bolt (Scheme 527)
4. Remove dipstick support at fuel filter housing. Position dipstick tube to the side.
5. Disconnect the air grid heater power cables at the cable mounting studs.
6. Disconnect the ground strap at the intake cover.
7. Remove the engine wiring harness connections at the air inlet housing elbow.
8. Remove the four (4) air inlet housing mounting bolts and remove the housing from top of the heater elements.
9. Remove the intake air grid heater from the manifold (Scheme 528)
10. Remove the high pressure fuel lines and fuel rail (Refer to «FUEL LINES»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-diesel) ).
11. Remove APPS bracket from cylinder head to gain access to front intake manifold cover bolts.
12. Disconnect manifold air temperature/pressure sensor connector.
13. Remove the remaining intake manifold cover-to-cylinder head bolts.
14. Remove the intake manifold cover and gasket. Keep the gasket material and any other material out of the air intake.
15. Clean the intake manifold cover and cylinder head sealing surface.

Clean manifold in solvent and blow dry with compressed air.

Clean cylinder block gasket surfaces using a suitable solvent.

The plenum pan rail must be clean and dry (free of all foreign material).

Inspect manifold for cracks.

Inspect mating surfaces of manifold for flatness with a straightedge.

1. Using a new gasket, install the intake manifold cover.
2. Install the cover-to-cylinder head bolts that do not hold down the fuel rail. Tighten the bolts to 24 N.m (18 ft. lbs.) torque.
3. Install the high pressure rail and fuel lines (Refer to «FUEL LINES»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-diesel) ).
4. Using two (2) new gaskets, install the intake air grid heater and air inlet housing. Position the ground cable and install and tighten the bolts to 24 N.m (18 ft. lbs.) torque.
5. Connect the manifold air temperature/pressure sensor connector.
6. Install and tighten the air intake heater power supply nuts to 14 N.m (120 in. lbs.) torque.
7. Install the APPS bracket. Torque fasteners to 43 N.m (32ft lbs.) torque.
8. Install oil dipstick tube support at fuel filter housing.
9. Install the engine oil dipstick tube and mounting bolt.
10. Position the charge air cooler outlet tube onto the air inlet housing. Tighten the clamps to 11 N.m (100 in. lbs.) torque.
11. Attach the engine wire harness to the air inlet housing at two locations.
12. Prime the fuel system. Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRIMING»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-diesel__standard-procedure-fuel-system-priming) .
13. Connect the battery negative cables.

1. Disconnect the battery negative cables.
2. Raise vehicle on hoist.
3. Disconnect the exhaust pipe from the turbocharger elbow.
4. Disconnect oil drain tube from turbocharger.
5. Lower vehicle.
6. Disconnect the turbocharger air inlet hose.
7. Remove air cleaner assembly.
8. Disconnect the turbocharger oil supply line.
9. Disconnect the charge air cooler inlet pipe from the turbocharger.
10. Remove the turbocharger and gasket from the exhaust manifold.
11. Remove the cab heater return pipe nuts from the exhaust manifold stud. Position the tube out of the way.
12. Remove heat shield.
13. Remove exhaust manifold bolt lockplates.
14. Remove the exhaust manifold-to-cylinder head bolts and spacers (Scheme 529)
15. Remove the exhaust manifold and gaskets (Scheme 529)

Clean the cylinder head and exhaust manifold sealing surfaces with a suitable scraper. Use a Scotch-Brite™ pad or equivalent.

Inspect the exhaust manifold for cracks. Measure the exhaust manifold for flatness. Place a ruler over all of the exhaust ports and insert a feeler gauge between the port flange and the ruler. Maximum deviation from flat is 0.20 mm (.008 inch).

Note. Late model engines use multi layer exhaust manifold gaskets.

Scheme 529

1. Using new gaskets, install the exhaust manifold and gaskets. Install the bolts and spacers and tighten the bolts in the sequence shown in to 43 N.m (32 ft. lbs.) torque.
2. Retorque the four center bolts.
3. Install heat shield and torque nuts to 24 N.m (18 ft. lbs.).
4. Install cab heater tube.
5. Install exhaust manifold bolt retention straps.
6. Install the cab heater return hose to the manifold bolt stud. Tighten the nut to 24 N.m (18 ft. lbs.) torque.
7. Install the turbocharger and a new gasket. Apply anti-seize to the studs and then tighten the turbocharger mounting nuts to 43 N.m (32 ft. lbs.) torque.
8. Raise vehicle on hoist.
9. Install the oil drain tube and a new gasket to the turbocharger. Tighten the drain tube bolts to 24 N.m (18 ft. lbs.) torque.
10. Connect the exhaust pipe to the turbocharger and tighten the bolts to 11 N.m (100 ft. lbs.) torque.
11. Connect the wastegate command valve connector.
12. Lower the vehicle.
13. Pre-lube the turbocharger . Pour 50 to 60 cc (2 to 3 oz.) clean engine oil in the oil supply line fitting on the turbo. Rotate the turbocharger impeller by hand to distrubute the oil thoroughly.
14. Install and tighten the oil supply line fitting nut to 24 N.m (18 ft. lbs.) torque.
15. Position the charge air cooler inlet pipe to the turbocharger. With the clamp in position, tighten the clamp nut to 11 N.m (95 in. lbs.) torque.
16. Position the air inlet hose to the turbocharger. Tighten the clamp to 4 N.m (35 in. lbs.) torque.
17. Connect the battery negative cables.
18. Start the engine to check for leaks.

STANDARD PROCEDURE - TIMING VERIFICATION

1. Remove the cylinder head cover(Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
2. Remove fuel injector from cylinder number 1(Refer to «FUEL INJECTOR»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine) ).
3. Using Special Tool 7471B rotate the engine until the TDC mark on the damper is at 12 o'clock.
4. Using a 8 in.x 1/4 in. dowel rod inserted into cylinder number 1, rock the crankshaft back and forth to verify piston number 1 is at TDC.
5. With cylinder number still at TDC, inspect the keyway on the crankshaft gear for proper alignment (12 o'clock position).
6. If the keyway is not at 12 o'clock position replace the crankshaft gear assembly.
7. If the keyway is at 12 o'clock position, remove front gear cover and verify timing mark alignment between the camshaft gear and crankshaft gear, if not aligned inspect keyway on camshaft gear.
8. Inspect keyway on camshaft gear for proper alignment with the key in the camshaft, if alignment is off replace the camshaft/gear assembly.
9. If timing marks alignment is off and no damage is found at either the crankshaft or camshaft gear keyways, realign timing marks as necessary.

1. Disconnect the battery negative cables.
2. Raise vehicle on hoist.
3. Partially drain engine coolant into container suitable for re-use (Refer to «DRAINING COOLING SYSTEM 5.9L DIESEL ENGINE»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-59l-diesel-engine) ).
4. Lower vehicle.
5. Remove radiator upper hose.
6. Disconnect coolant recovery bottle hose from radiator filler neck.
7. Remove viscous fan/drive/shroud assembly (Refer to «FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
8. Remove the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
9. Remove the cooling fan support/hub from the front of the engine.
10. Raise the vehicle on hoist.
11. Remove the crankshaft damper (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ) and speed indicator ring.
12. Remove the lower fan shroud bracket.
13. Remove the upper fan shroud bracket that is mounted to the gear housing.
14. Lower the vehicle.
15. Remove the power steering pump.
16. Remove the accessory drive belt tensioner.
17. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces.
18. Remove the fuel injection pump (Refer to «FUEL INJECTION PUMP»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-diesel) ).
19. Disconnect the camshaft position sensor connector.
20. Disconnect and remove engine speed sensor.
21. Remove the camshaft (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
22. Remove the six front oil pan fasteners.
23. Remove the gear housing fasteners. NOTE: Use care when removing the gear housing, to avoid damage to the oil pan gasket, as the gasket will be reused if it is not damaged.
24. Slide a feeler gauge between the gear housing and oil pan gasket, to break the gasket seal.
25. Remove the gear housing and gasket.
26. Clean the gasket material from the cylinder block and gear housing.

Scheme 530

Scheme 531

1. Inspect oil pan gasket. If torn, gasket must be replaced.
2. Install a new gear housing gasket onto cylinder block and trim any excesss gasket material flush to oil pan rail.
3. Install the gear housing. Torque bolts to 24 N.m (18 ft. lbs.) (Scheme 530)
4. If a new housing is installed, the camshaft position sensor, and engine speed sensor must be transferred to the new housing.
5. Connect the camshaft position sensor connector.
6. Install and connect engine speed sensor.
7. Install the injection pump (Refer to «FUEL INJECTION PUMP»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-diesel) ).
8. Install the camshaft (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ). Align the crankshaft and camshaft gear marks as shown in (Scheme 531)
9. Install a new front crankshaft seal into the gear cover.
10. Apply a bead of Mopar® Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover. Be sure to surround all through holes.
11. Using the seal pilot to align the cover, install the cover to the housing and install the bolts. Tighten the bolts to 24 N.m (18 ft. lbs.) torque.
12. Remove the seal pilot. Install front seal dust shield.
13. Raise the vehicle.
14. Trim any excess gear housing gasket to make it flush with the oil pan rail.
15. Install the crankshaft damper and speed indicator ring (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ). Torque bolts to 40 N.m (30 ft. lbs.), plus an additional 60°.
16. Install the lower fan shroud bracket. Torque bolts to 24 N.m (18 ft. lbs.) torque.
17. Install the upper fan shroud brackets.
18. Lower vehicle.
19. Install the fan support/hub assembly and tighten bolts to 32 N.m (24 ft. lbs.) torque.
20. Install the power steering pump.
21. Install the accessory drive belt tensioner. Torque bolt to 43 N.m (32 ft. lbs.) torque.
22. Install the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
23. Install the upper cooling fan/drive/shroud assembly (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
24. Connect the coolant recovery bottle hose to the radiator filler neck.
25. Install the radiator upper hose and clamps.
26. Add engine oil.
27. Add 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) ).
28. Connect the battery cables.
29. Start engine and inspect for leaks.

1. Disconnect both battery negative cables.
2. Raise vehicle on hoist.
3. Partially drain engine coolant into container suitable for re-use (Refer to «DRAINING COOLING SYSTEM 5.9L DIESEL ENGINE»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-59l-diesel-engine) ).
4. Lower vehicle.
5. Remove radiator upper hose.
6. Remove viscous fan/drive/shroud assembly (Refer to «FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
7. Remove the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
8. Remove the cooling fan support/hub from the front of the engine.
9. Raise the vehicle on hoist.
10. Remove power steering pump.
11. Remove accessory drive belt tensioner.
12. Remove the crankshaft damper and speed indicator ring (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
13. Lower the vehicle.
14. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces.

Scheme 532

1. Install a new front crankshaft oil seal.
2. Obtain a seal pilot/installation tool from a crankshaft front seal service kit and install the pilot into the seal.
3. Apply a bead of Mopar® Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover. Be sure to surround all through holes.
4. Using the seal pilot to align the cover (Scheme 532), install the cover to the housing and install the bolts. Tighten the bolts to 24 N.m (18 ft. lbs.) torque.
5. Remove the seal pilot. Install front seal dust shield.
6. Raise the vehicle.
7. Install the speed indicator ring and the crankshaft damper (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) ).
8. Lower vehicle.
9. Install the fan support/hub assy, and tighten bolts to 32 N.m (24 ft. lbs.) torque.
10. Install power steering pump.
11. Install accessory drive belt tensioner. Torque bolt to 43 N.m (32 ft. lbs.) torque.
12. Install the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
13. Install the cooling fan/drive/shroud assembly (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
14. Install the radiator upper hose and clamps.
15. Add 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) ).
16. Connect the battery cables.
17. Start engine and inspect for leaks.

See also:
• DIAGNOSIS AND TESTING
• DIAGNOSIS AND TESTING - CHARGE AIR COOLER SYSTEM - LEAKS
• POWERTRAIN DIAGNOSTIC PROCEDURES (PART 1)
• POWERTRAIN DIAGNOSTIC PROCEDURES (PART 2)
• FUEL INJECTOR
• FUEL DELIVERY - DIESEL
• TURBOCHARGER
• ENGINE BLOCK HEATER - 5.9L DIESEL
• REFRIGERANT SYSTEM RECOVERY
• DRAINING COOLING SYSTEM 5.9L DIESEL ENGINE
• STARTERS
• REFILLING COOLING SYSTEM 5.9L DIESEL ENGINE
• ACCESSORY DRIVE
• REFRIGERANT SYSTEM CHARGE
• STANDARD PROCEDURE - FUEL SYSTEM PRIMING
• DIAGNOSIS AND TESTING - SMOKE DIAGNOSIS CHARTS
• REMOVAL
• METHOD 2-REPAIR SLEEVE
• STANDARD PROCEDURE