5.9L Diesel Engine: Adjustments Dodge Pickup R2500

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 630

Scheme 631

1. Disconnect battery negative cables.
2. Remove cylinder head cover. Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189683-S21359583452005091100000).
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 cylinder 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 630) Refer to VALVE LASH LIMIT CHART (Scheme 631) 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.
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 Nm (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 «CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189683-S29545018412005091100000).
9. Connect the battery negative cables.

Scheme 632

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 position. The exhaust valves are identified by a dimple on the valve head (Scheme 632)
3. Install the valve springs and retainer.
4. Install the valve spring compressor tool 8319-A as shown in see scheme 44 and see scheme 45
5. Compress the valve springs and install the valve retaining locks see scheme 46
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 with fuel injector connector port facing intake manifold.
11. Install hold-down bolt. Torque to 10 Nm (89 in. lbs.).
12. Install fuel injector connector and connector nut. Torque nut to 50 Nm (36.8 ft. lbs.).
13. Install the cylinder head. Refer to «CYLINDER HEAD - INSTALLATION»(ref-189683-S08770119162005091100000).