5.9L Diesel Engine: Removal & Installation Dodge Pickup R2500

Filter Removal

1. The housing cover is equipped with spring clips see scheme 28 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.

Scheme 650

Scheme 651

Scheme 652

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 650), 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 651) Verify that they are seated in the tappets.
5. Lubricate valve stem tips and install the cross-heads in their original locations.
6. Lubricate the rocker arms and pedestals and install them in their original locations (Scheme 652) Install the bolts and torque them to 36 N.m (27 ft. lbs.).
7. Verify that the valve lash settings are maintained. Refer to «EXHAUST VALVES & SEATS - STANDARD PROCEDURE»(ref-189683-S20548095712005091100000).
8. Inspect rocker housing gasket for cuts and proper installation into groove. Replace if damaged.
9. Install rocker housing and bolts. Tighten to 24 Nm (18 lb. ft.).
10. Install fuel injector. Refer to «FUEL INJECTOR»(ref-189690-S20443839482005091100000).
11. Install fuel injector tube and fuel injector tube nut. Torque to 50 N.m (37 ft. lbs.).
12. Install injector harness nuts. Tighten to 1.5 Nm (13 lb. in.).
13. Install cylinder head cover. Refer to «CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189683-S29545018412005091100000).
14. Install wire harness P-clip to cylinder head behind filter housing 24 N.m (18 ft. lbs.).
15. Connect the IAT and MAP sensor connector.
16. Install the fuel filter canister assembly and torque mounting bolts to 24 N.m (18 ft. lbs.).
17. Connect fuel lift pump, WIF sensor, and fuel heater.
18. 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
19. 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 at fuel filter housing. Hand tighten fuel rail-to-cylinder head 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 Nm ( 22 ft. lbs.). Torque fuel line nuts at fuel rail to 30 Nm (22 ft. lbs.) Torque fuel pump to fuel rail line to 30 Nm (22 ft. lbs.). Torque fuel drain banjo bolt at pressure limiting valve and front of fuel filter housing to 24 Nm (18 ft. lbs.). Torque fuel line brace bolts to 24 N.m (18 ft. lbs.). Torque rail bolts to 24 Nm (18 ft. lbs.). Connect fuel pressure sensor.
20. Install the engine lift bracket at the rear of cylinder head. Torque to 77 N.m (57 ft. lbs.).
21. Reposition number 6 fuel line shield and torque to 43 N.m (32 ft. lbs.).
22. 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.).
23. Connect fuel return line at back of cylinder head hand tight.
24. Connect fuel return line at filter housing hand tight.
25. Torque banjo connections at cylinder head and fuel filter housing to 24 Nm (18 ft. lbs.)
26. Install bracket to rear of filter housing. Torque to 24 Nm (18 ft. lbs.).
27. Using new gaskets, install the intake grid heater and air inlet housing. Torque bolts to 24 N.m (18 ft. lbs.).
28. Install wire harness P-clip and push on clip to air inlet housing.
29. Connect engine oil level indicator tube at fuel filter housing and at air inlet housing.
30. Connect the APPS connector.
31. Install the APPS assembly to the cylinder head bracket and torque bolts to 24 N.m (18 ft. lbs.).
32. Install the throttle linkage cover.
33. Install the charge air cooler-to-air inlet housing duct assembly. Torque all clamps to 11 N.m (100 in. lbs.).
34. Connect intake grid heater wires.
35. Secure engine harness to front of cylinder head with bolt at four locations.
36. Connect engine coolant temperature sensor connector.
37. Connect radiator upper hose to thermostat housing.
38. Rotate generator into position. Install upper bolt and torque upper and lower bolts.
39. Install wire harness push-on clip below bracket.
40. Install wire harness P-clip to top of bracket.
41. Install fan support and torque to 32 N.m (24 ft. lbs.).
42. Install cooling fan/drive and torque to 33 N.m (24 ft. lbs.).
43. Install accessory drive belt. Refer to «ACCESSORY DRIVE»(ref-189655).
44. Install exhaust manifold/turbocharger assembly, using new gaskets. Start all bolts/spacers by hand. Torque bolts to 43 N.m (32 ft. lbs.).
45. Install exhaust manifold heat shield. Torque to 24 N.m (18 ft. lbs.).
46. Install exhaust bolt retention straps across cylinders 5 & 6.
47. Connect turbocharger oil drain tube. Torque to 8 N.m (71 in. lbs.).
48. Perform the turbocharger pre-lube procedure. Refer to «TURBOCHARGER»(ref-189685-S35527817322005091100000) for the correct procedure.
49. Connect the turbocharger oil supply line. Torque to 24 N.m (18 ft. lbs.).
50. Install air cleaner housing and duct.
51. Connect air inlet temperature/pressure sensor.
52. Raise vehicle on hoist.
53. Install exhaust pipe to turbocharger elbow. Torque bolts to 8 N.m (72 in. lbs.).
54. Lower vehicle.
55. Fill engine coolant. Refer to «COOLING SYSTEM»(ref-189654-S22265685922005091200000).
56. Start engine and check for leaks.

REMOVAL

1. Disconnect the battery negative cables.
2. Remove cylinder head cover. Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189683-S21359583452005091100000).
3. Remove the rocker arm/pedestal fasteners see scheme 60 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 see scheme 61 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 see scheme 62 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.

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 «EXHAUST VALVES & SEATS - STANDARD PROCEDURE»(ref-189683-S20548095712005091100000) .
5. Install cylinder head cover and reusable gasket. Refer to «CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189683-S29545018412005091100000) .
6. Connect battery negative cables.

Scheme 653

Scheme 654

Scheme 655

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 656) & (Scheme 657) ).
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) - see scheme 70
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 656

Scheme 657

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 cross-hatch appearance with the lines at 15° to 25° angles see scheme 71 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 see scheme 72
8. Vertical strokes MUST be smooth continuous passes along the full length of the bore see scheme 72
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 nozzles. 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.

1. Remove the gear housing cover. Refer to «GEAR HOUSING COVER - REMOVAL»(ref-189683-S22737053112005091100000) )
2. Remove the crank gear using a heavy duty puller.
3. Split the gear and remove it from the crankshaft.

Scheme 658

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 see scheme 97 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.

Scheme 659

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 663)
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). Refer to «CLUTCH»(ref-189653).
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 660

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 «STARTER MOTOR»(ref-164936-S21331940332004081900000) 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 664)
10. Remove the rear seal retainer and gasket (Scheme 664)
11. Support the seal retainer and drive out the crankshaft seal with a hammer and suitable punch.

Scheme 661

Scheme 662

Scheme 663

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 and install to the cylinder block (Scheme 665), 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 666) 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 see scheme 108
7. Remove the seal pilot.
8. Apply a small amount of Mopar(R) 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 and torque to 43 N.m (21 ft. lbs.). Refer to «STARTER MOTOR»(ref-164936-S21331940332004081900000).
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 664

Scheme 665

Scheme 666

1. Remove camshaft. Refer to «CAMSHAFT & BEARINGS (IN BLOCK) - REMOVAL»(ref-189683-S13455535542005091100000).
2. Insert the trough (provided with tool kit) the full length of the camshaft bore see scheme 109 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 see scheme 110
4. Raise dowel rod (disengage from tappet) and allow tappet to fall into trough see scheme 111
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.

1. Disconnect the battery cables.
2. Remove the cylinder head. Refer to «CYLINDER HEAD - REMOVAL»(ref-189683-S19921821492005091100000) .
3. Remove the oil pan and suction tube. Refer to «OIL PAN - REMOVAL»(ref-189683-S01492743242005091100000) .
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.

1. Remove the accessory drive belt. Refer to «ACCESSORY DRIVE»(ref-189655) .
2. Remove the four (4) damper to crankshaft bolts and remove damper and speed indicator ring.

Scheme 667

Scheme 668

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 see scheme 134 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 see scheme 135

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»(ref-189655) .

1. Disconnect the battery negative cables.
2. Remove the viscous fan/drive assembly. Refer to «FAN DRIVE VISCOUS CLUTCH (DIESEL)»(ref-189656-S33910173782005091200000).
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 ( see scheme 136 & see scheme 137 ).
7. Remove the insulator from the vehicle.

1. With engine raised SLIGHTLY, position the insulator to the mount ( (Scheme 671) & see scheme 139 ). 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 88 N.m (65 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 (DIESEL)»(ref-189656-S33910173782005091200000).
7. Connect the battery negative cables.

Scheme 669

Scheme 670

1. Raise the vehicle on a hoist.
2. Position a transmission jack in place.
3. Remove support cushion stud nuts (Scheme 672)
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.

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 672)
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.

1. Clean the area around the oil filter head. Remove the filter from below using a cap-style filter 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 starter motor. Refer to «STARTER MOTOR»(ref-164936-S21331940332004081900000) and transmission adapter plate assembly.
6. Remove transmission and transfer case (if equipped).
7. Remove flywheel or flexplate.
8. Remove the transmission adapter plate. WARNING: HOT OIL CAN CAUSE PERSONAL INJURY.
9. Drain the engine oil. Refer to «OIL - STANDARD PROCEDURE»(ref-189683-S36520142862005091100000) .
10. Install the oil pan drain plug if sealing surface is not damaged and tighten to 50 N.m (57 ft. lbs.) torque.
11. Remove oil pan bolts, break the pan to block seal, and lower pan slightly and remove oil suction tube fasteners.
12. Remove oil pan and suction tube.

1. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar(R) Silicone Rubber Adhesive Sealant or equivalent.
2. Place suction tube in oil pan and guide them into place. 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 673) 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 671

1. Install the plunger, spring, and plug as shown in (Scheme 673) Tighten the plug to 80 N.m (60 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 672

1. Disconnect the battery negative cables.
2. Remove fan/drive assembly. Refer to «FAN DRIVE VISCOUS CLUTCH (DIESEL)»(ref-189656-S33910173782005091200000)
3. Remove the accessory drive belt. Refer to «ACCESSORY DRIVE»(ref-189655).
4. Remove the fan support/hub assembly.
5. Remove crankshaft damper. Refer to «VIBRATION DAMPER - REMOVAL»(ref-189683-S10684876732005091100000) ) and speed indicator ring.
6. Remove hydraulic pump.
7. Remove accessory drive belt tensioner.
8. Remove the gear housing cover. Refer to «GEAR HOUSING COVER - REMOVAL»(ref-189683-S22737053112005091100000).
9. Remove the four mounting bolts and pull the oil pump from the bore in the cylinder block see scheme 147

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 SYSTEMS»(ref-157342-S42197233182003081100000) .
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 8 N.m (72 in. lbs.) torque.
11. Attach the engine wire harness to the air inlet housing at two locations.
12. Prime the fuel system. Refer to the fuel priming procedure in «FUEL SYSTEMS»(ref-157342-S42197233182003081100000) .
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. Lower vehicle.
5. Disconnect the turbocharger air inlet hose.
6. Remove air cleaner assembly.
7. Disconnect the turbocharger oil supply line and the oil drain tube from the turbocharger.
8. Disconnect the charge air cooler inlet pipe from the turbocharger.
9. Remove the turbocharger and gasket from the exhaust manifold.
10. Remove the cab heater return pipe nuts from the exhaust manifold stud. Position the tube out of the way.
11. Remove heat shield.
12. Remove exhaust manifold bolt lockplates.
13. Remove the exhaust manifold-to-cylinder head bolts and spacers see scheme 157
14. Remove the exhaust manifold and gaskets see scheme 157

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 bolts to 24 Nm (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. 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.
9. 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 distribute the oil thoroughly.
10. Install and tighten the oil supply line fitting nut to 24 N.m (18 ft. lbs.) torque.
11. Position the charge air cooler inlet pipe to the turbocharger. With the clamp in position, tighten the clamp nut to 8 N.m (72 in. lbs.) torque.
12. Position the air inlet hose to the turbocharger. Tighten the clamp to 8 N.m (72 in. lbs.) torque.
13. Raise vehicle on hoist.
14. Connect the exhaust pipe to the turbocharger and tighten the bolts to 34 N.m (25 ft. lbs.) torque.
15. Lower the vehicle.
16. Connect the battery negative cables.
17. Start the engine to check for leaks.

1. Disconnect the battery negative cables.
2. Raise vehicle on hoist.
3. Partially drain engine coolant into container suitable for re-use. Refer to «COOLING SYSTEM»(ref-189654-S22265685922005091200000) .
4. Lower vehicle.
5. Remove radiator upper hose.
6. Disconnect coolant recovery bottle hose 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 lower fan shroud fasteners. Disconnect fan drive wire harness.
9. Remove the upper fan shroud-to-radiator mounting bolts.
10. Remove viscous fan/drive assembly. Refer to «FAN DRIVE VISCOUS CLUTCH (DIESEL)»(ref-189656-S33910173782005091200000) .
11. Remove the accessory drive belt. Refer to «ACCESSORY DRIVE»(ref-189655) .
12. Remove the cooling fan support/hub from the front of the engine.
13. Raise the vehicle on hoist.
14. Remove the crankshaft damper. Refer to «VIBRATION DAMPER - REMOVAL»(ref-189683-S10684876732005091100000) ) and speed indicator ring.
15. Lower the vehicle.
16. Remove the hydraulic pump.
17. Remove the accessory drive belt tensioner.
18. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces.
19. Remove the fuel injection pump. Refer to «FUEL SYSTEMS»(ref-157342-S42197233182003081100000) .
20. Disconnect the camshaft position sensor connector.
21. Disconnect and remove engine speed sensor.
22. Remove the camshaft. Refer to «CAMSHAFT & BEARINGS (IN BLOCK) - REMOVAL»(ref-189683-S13455535542005091100000) .
23. Remove the six front oil pan fasteners.
24. 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.
25. Slide a feeler gauge between the gear housing and oil pan gasket, to break the gasket seal.
26. Remove the gear housing and gasket.
27. Clean the gasket material from the cylinder block and gear housing.

1. Inspect oil pan gasket. If torn, gasket must be replaced.
2. Install a new gasket and the gear housing. Torque bolts to 24 N.m (18 ft. lbs.). Follow torque sequence.
3. If a new housing is installed, the camshaft position sensor, and engine speed sensor must be transferred to the new housing.
4. Connect the camshaft position sensor connector.
5. Install and connect engine speed sensor.
6. Install the injection pump. Refer to «FUEL SYSTEMS»(ref-157342-S42197233182003081100000) .
7. Install the camshaft. Refer to «CAMSHAFT & BEARINGS (IN BLOCK) - INSTALLATION»(ref-189683-S02667111902005091100000) ). Align the crankshaft and camshaft gear marks as shown in.
8. Install a new front crankshaft seal into the gear cover.
9. Apply a bead of Mopar(R) Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover. Be sure to surround all through holes.
10. 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.
11. Remove the seal pilot. Install front seal dust shield.
12. Raise the vehicle.
13. Trim any excess gear housing gasket to make it flush with the oil pan rail.
14. Install the crankshaft damper and speed indicator ring. Refer to «VIBRATION DAMPER - INSTALLATION»(ref-189683-S09169974232005091100000) ). Torque bolts to 40 Nm (30 ft. lbs.), plus an additional 60°.
15. Lower vehicle.
16. Install the fan support/hub assembly and tighten bolts to 32 N.m (24 ft. lbs.) torque.
17. Install the hydraulic pump.
18. Install the accessory drive belt tensioner. Torque bolt to 43 N.m (32 ft. lbs.) torque.
19. Install the accessory drive belt. Refer to «ACCESSORY DRIVE»(ref-189655) .
20. Install the upper cooling fan and shroud together. Refer to «RADIATOR FAN»(ref-189656-S26457428802005091200000) .
21. Install lower shroud and connect fan drive harness connector.
22. Install the windshield washer reservoir to the fan shroud and connect the washer pump supply hose and electrical connection.
23. Install the coolant recovery bottle to the fan shroud and connect the hose to the radiator filler neck.
24. Install the radiator upper hose and clamps.
25. Add engine oil.
26. Add coolant. Refer to «COOLING SYSTEM»(ref-189654-S22265685922005091200000) .
27. Connect the battery cables.
28. 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 «COOLING SYSTEM»(ref-189654-S22265685922005091200000) .
4. Lower vehicle.
5. Remove radiator upper hose.
6. Disconnect coolant recovery bottle hose 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 (DIESEL)»(ref-189656-S33910173782005091200000) .
9. Remove the accessory drive belt. Refer to «ACCESSORY DRIVE»(ref-189655) .
10. Remove the cooling fan support/hub from the front of the engine.
11. Raise the vehicle on hoist.
12. Remove power steering pump.
13. Remove accessory drive belt tensioner.
14. Remove the crankshaft damper and speed indicator ring. Refer to «VIBRATION DAMPER - REMOVAL»(ref-189683-S10684876732005091100000) .
15. Lower the vehicle.
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.

Scheme 673

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(R) 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 see scheme 158, 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 «VIBRATION DAMPER - INSTALLATION»(ref-189683-S09169974232005091100000).
8. Lower vehicle.
9. Install the fan support/hub assembly, 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»(ref-189655).
13. Install the cooling fan and shroud together. Refer to «RADIATOR FAN»(ref-189656-S26457428802005091200000).
14. Install the windshield washer reservoir to the fan shroud and connect the washer pump supply hose and electrical connection.
15. Install the coolant recovery bottle to the fan shroud and connect the hose to the radiator filler neck.
16. Install the radiator upper hose and clamps.
17. Add coolant. Refer to «COOLING SYSTEM»(ref-189654-S22265685922005091200000).
18. Connect the battery cables.
19. Start engine and inspect for leaks.