5.9L Diesel Engine: Overview Dodge Pickup R2500

DESCRIPTION

The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudinal ribs for superior strength and noise reduction. The block incorporates metric straight thread o-ring fittings at lubrication oil access points. The engine (Scheme 608) 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 609); 1 to 6. The firing order is 1-5-3-6-2-4.

Scheme 608

Scheme 609

Scheme 610

Scheme 611

Scheme 612

The engine data plate contains specific information that is helpful to servicing and obtaining parts for the engine. The data plate can be found in two places. Some models have a data plate located on the left side of the engine, affixed to the APPS bracket. Some models will have the data plate affixed to the breather cover on the left side of the engine. Information that can be found on the data plate includes

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

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 613)

Scheme 613

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 longitudinal 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 614

Scheme 615

Scheme 616

Scheme 617

Scheme 618

1. Disconnect battery negative cables.
2. Raise vehicle on hoist.
3. Drain engine coolant.
4. Disconnect exhaust pipe from turbocharger elbow.
5. Lower vehicle.
6. Disconnect air inlet temperature/pressure sensor.
7. Remove air cleaner housing and snorkel from the vehicle. Cap off turbocharger air inlet to prevent intrusion of dirt or foreign material.
8. Disconnect cab heater core supply and return hoses from the cylinder head and heater pipe.
9. Disconnect turbocharger oil drain tube at rubber hose connection. Cap off open ports to prevent intrusion of dirt or foreign material.
10. Disconnect turbocharger oil supply line at the turbocharger end. Cap off open ports to prevent intrusion of dirt or foreign material.
11. 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.
12. Remove cooling fan assembly.
13. Remove accessory drive belt. Refer to «ACCESSORY DRIVE»(ref-189655).
14. Remove cooling fan support from cylinder block.
15. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head.
16. Disconnect radiator upper hose from the thermostat housing.
17. Disconnect the Intake Air Temperature, Manifold Air Pressure, and Coolant Temperature sensor connector.
18. Remove the engine harness to cylinder head attaching bolts and P-clips at front of head.
19. Remove the throttle linkage cover (Scheme 614)
20. Remove the six (6) accelerator pedal position sensor assembly-to-cylinder head bracket bolts (Scheme 615) and secure the entire assembly out of the way. Disconnect the APPS connector (Scheme 616) It is not necessary to disconnect the cables from the throttle control assembly.
21. Remove the intake air grid heater wires from the grid heater.
22. Remove engine oil level indicator tube attaching bolt at fuel filter housing bracket and inlet air connection..
23. Remove the charge air cooler-to-air inlet housing pipe.
24. Remove the engine wire harness attaching bolt and wire harness push-in fastener from air inlet housing.
25. Remove the air inlet housing and intake grid heater from the intake manifold cover.
26. Remove the two grid heater harness-to-cylinder head attaching bolts at front of cylinder head.
27. Remove the engine lift bracket from the rear of the cylinder head.
28. Remove 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.
29. 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.
30. 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.
31. 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. Remove fuel drain hose. Remove banjo fitting at bottom of fuel filter housing. Disconnect fuel supply hose at lift pump.
32. Disconnect fuel heater, water in fuel sensor, and fuel lift pump connectors.
33. Remove the fuel filter assembly-to-cylinder head bolts and remove filter assembly from vehicle.
34. Remove wire harness P-clip from cylinder head (located behind filter housing).
35. Remove the cylinder head cover. Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189683-S21359583452005091100000).
36. Disconnect rocker housing injector harness connectors.
37. Remove injector harness nuts from injectors.
38. Remove the rocker levers (Scheme 617), cross heads and push rods (Scheme 618) 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.
39. 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.
40. Remove the fuel injectors. Refer to «FUEL INJECTOR»(ref-189690-S20443839482005091100000).
41. Remove rocker housing bolts and rocker housing and gasket.
42. Reinstall the engine lift bracket at the rear of cylinder head. Torque to 77 N.m (57 ft. lbs.).
43. Remove twenty six (26) cylinder head-to-block bolts.
44. Attach an engine lift crane to engine lift brackets and lift cylinder head off engine and out of vehicle.
45. Remove the head gasket and inspect for failure.

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 619)

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

Scheme 619

Scheme 620

Scheme 621

Scheme 622

1. Remove cylinder head. Refer to «CYLINDER HEAD - REMOVAL»(ref-189683-S19921821492005091100000).
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 620)
4. Install the compressor top plate, washer, and nut. Using a suitable wrench, tighten the nut (clockwise) to compress the valve springs (Scheme 621) 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 622) Arrange or number all components so they can be installed in their original locations.
7. Repeat the procedure on all cylinders to be serviced.

Scheme 623

Scheme 624

Scheme 625

1. Disconnect the battery negative cables.
2. Remove the cylinder head cover. Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189683-S21359583452005091100000).
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»(ref-189690-S20443839482005091100000) 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 623), 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»(ref-189655).
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: Remove bolts and injector hold-down clamp. Using miller special tool #9010, remove injector. Install the valve spring compressor mounting base as shown in (Scheme 624) Install the top plate, washer, and nut. Using a suitable wrench tighten the nut (clock-wise) (Scheme 625) 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 seals 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.

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.

The crankshaft see scheme 96 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 626

Note. Refer to see scheme 141 and see scheme 142 for circuit illustrations.

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. Crankshaft internal cross-drillings supply oil to the connecting rod journals.

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 see scheme 141 and see scheme 142

Scheme 627

Scheme 628

Scheme 629

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 see scheme 143 CAUTION: If engine oil pressure is zero at idle, DO NOT RUN THE ENGINE If minimum engine oil pressure is below these ranges, refer to «DIAGNOSIS AND TESTING»(ref-189683-S16494666942005091100000).
5. Remove oil pressure gauge and install the 1/8 npt plug.