5.9l 6-cyl. 12v Diesel Engine [code D] Dodge Pickup R3500

ENGINE IDENTIFICATION

Note. For repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES article in GENERAL INFORMATION.

Engine may be identified by eighth character of Vehicle Identification Number (VIN). VIN is stamped on a metal tab located near lower left corner of windshield.

ENGINE IDENTIFICATION CODES

VALVE CLEARANCE ADJUSTMENT

Note. Valve clearance must be adjusted with engine temperature less than 140°F (60°C).

Scheme 1

1. Engine may be rotated by removing dust cover from transmission adapter plate and installing Engine Barring Tool (7471B) in transmission adapter plate. (Scheme 1) Note location of timing pin located below fuel injection pump. (Scheme 1) CAUTION: Use care when engaging timing pin to avoid breaking tip of timing pin. Ensure timing pin is disengaged before rotating engine.
2. Push timing pin toward front of engine. Slowly rotate engine clockwise (viewed from front of engine), while holding tension on timing pin. Rotate engine until timing pin engages machined hole on camshaft gear and cylinder No. 1 is at TDC.
3. Remove EGR tube and gaskets (if equipped). EGR tube fits between EGR valve (on air inlet housing on top of intake manifold cover) and exhaust manifold. Remove nameplate located above valve covers. Remove valve covers. Ensure cylinder No. 1 push rods are loose and valves are closed. If cylinder No. 1 push rods are not loose or valves are not closed, disengage timing pin. Rotate engine 360 degrees. Engage timing pin.
4. With cylinder No. 1 at TDC, use feeler gauge to check valve clearance on proper valves. See STEP 1 in «VALVE ADJUSTING SEQUENCE»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table. If valve clearance is not within specification, adjust using rocker lever adjusting screw. See «VALVE CLEARANCE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table. Tighten rocker lever adjusting screw nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
5. Once valve clearances are checked and adjusted on proper valves, place reference marks on vibration damper and front gear cover. Disengage timing pin. Rotate crankshaft clockwise 360 degrees, and realign reference marks.
6. Check valve clearance on proper valves. See STEP 2 in «VALVE ADJUSTING SEQUENCE»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table. Adjust clearance if not within specification. See «VALVE CLEARANCE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table. Tighten rocker lever adjusting screw nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
7. Using NEW gaskets, install valve covers. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Install nameplate.
8. On models with EGR tube, install EGR tube using NEW gaskets, with all bolts and nuts loosely installed. Alternately tighten EGR tube-to-EGR valve bolts to specification. Ensure EGR tube is installed squarely on EGR valve. Tighten EGR tube-to-exhaust manifold nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).

VALVE ADJUSTING SEQUENCE

VALVE CLEARANCE SPECIFICATIONS (1)

Scheme 2

Scheme 3

1. Disconnect negative battery cables. Remove EGR tube and gaskets (if equipped). EGR tube fits between EGR valve (on air inlet housing on top of intake manifold cover) and exhaust manifold. Ensure area around fuel injection pump and high-pressure fuel lines is clean.
2. Remove No. 1 valve cover. Engine may be rotated by removing dust cover from transmission adapter plate and installing Engine Barring Tool (7471B) in transmission adapter plate. (Scheme 1)
3. Note location of timing pin. (Scheme 1) Push timing pin toward front of engine. Slowly rotate engine clockwise (viewed from front of engine) while holding tension on timing pin. Rotate engine until timing pin engages machined hole on camshaft gear. (Scheme 1) This positions cylinder No. 1 at TDC on compression stroke. CAUTION: Use care when engaging timing pin to avoid breaking tip of timing pin. Ensure timing pin is disengaged before rotating engine.
4. Ensure cylinder No. 1 push rods are loose and valves are closed. If cylinder No. 1 push rods are not loose or valves are not closed, disengage timing pin and rotate crankshaft 360 degrees.
5. Place reference mark on vibration damper and front timing gear cover to indicate TDC position. Disengage timing pin. Mark high-pressure fuel line location for installation reference. Remove high-pressure fuel line for fuel injector No. 1 at fuel injection pump.
6. It may be necessary to also disconnect high-pressure fuel line from fuel injector No.1 for fuel line removal. DO NOT bend high-pressure fuel line during removal.
7. Using Socket (6840), loosen but DO NOT remove delivery valve holder on fuel injection pump for fuel injector No.1. (Scheme 2) Remove socket from fuel delivery valve holder. CAUTION: When removing delivery valve holder, DO NOT allow spring, fill piece and any shims to fall from delivery valve holder. Delivery valve holder may rotate with resistance, as an "O" ring is located on outside of delivery valve holder.
8. Ensure area around delivery valve holder is clean. Unscrew delivery valve holder from fuel injection pump. Slightly tip delivery valve holder outward while holding shim(s), fill piece and spring in delivery valve holder. (Scheme 2) DO NOT allow components to fall from delivery valve holder.
9. Using magnet, remove delivery valve assembly from fuel injection pump. (Scheme 2)
10. Install Adapter (6842) in fuel injection pump finger tight. Using Allen wrench, loosen set screw on adapter. Install Dial Indicator (6859) and Indicator Tip (6843) into the adapter. (Scheme 3)
11. Position dial indicator to read 7-9 mm on small inner dial on dial indicator. Tighten set screw. NOTE: Small inner dial on dial indicator is marked in 1 mm increments. Large outer dial on dial indicator is marked in.01 mm increments. One revolution of large outer dial is equal to 1 mm. CAUTION: Ensure timing pin is disengaged from camshaft gear before rotating engine or timing pin will be damaged.
12. Ensure timing pin is disengaged from machined hole on camshaft gear. Using engine barring tool, rotate engine counterclockwise (viewed from front of engine) 1/4 turn or until dial indicator reading stops decreasing.
13. Zero dial indicator and note reading on small inner dial. Rotate engine clockwise (viewed from front of engine) to TDC. Ensure timing pin easily engages machined hole on camshaft gear to verify TDC. Disengage timing pin from camshaft gear. Note plunger lift reading on dial indicator.
14. Note Cummins Parts List (CPL) number and TIMING TDC specification stamped on engine data plate located on fuel injection pump side of gear housing. Using TIMING TDC specification, note if plunger lift is within specification. See «PLUNGER LIFT SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table. PLUNGER LIFT SPECIFICATIONS Timing TDC Specification Plunger Lift Reading (mm) Calif. Models (CPL 2174 & 2308) 14.0 4.29-4.62 Except Calif. Models (CPL 2175) 13.5 4.89-5.25
15. If plunger lift is within specification, no adjustment of fuel injection pump timing is required. Proceed to «FINAL REASSEMBLY»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__final-reassembly). If plunger lift is not within specification, fuel injection pump timing must be adjusted. Proceed to ADJUSTING FUEL INJECTION PUMP TIMING.

Scheme 4

1. Remove oil fill tube and adapter elbow from front timing gear cover by rotating assembly counterclockwise (viewed from front of engine). Loosen fuel injection pump drive gear nut while holding engine from rotating using engine barring tool.
2. Install pencil-type magnet in end of shaft on fuel injection pump. Perform STEP 1 in illustration. (Scheme 4) Magnet is used to prevent fuel injection pump drive gear nut and washer from falling into timing gear cover during removal. NOTE: If pencil-type magnet is not available, place shop towel below fuel injection pump drive gear nut and front timing gear cover to prevent nut from falling into engine.
3. Remove fuel injection pump drive gear nut and washer from shaft. DO NOT allow nut or washer to fall in front timing cover.
4. Install one thrust washer, one bearing and then another thrust washer from Thrust Washer & Bearing Kit (6862) on shaft. Ensure thrust washers and bearing are installed in correct order. Thrust washer and bearing are used to prevent fuel injection pump drive gear from rotating on shaft when tightening fuel injection pump drive gear nut.
5. Install fuel injection pump drive gear nut on shaft, allowing clearance between thrust washers and bearing. DO NOT tighten nut at this time. Rotate engine clockwise (viewed from front of engine) until correct plunger lift is obtained on dial indicator.
6. Once correct plunger lift is obtained on dial indicator, use Puller (L-4407A) to pull fuel injection pump drive gear from tapered area on shaft of fuel injection pump. Perform STEP 2 in illustration. (Scheme 4) Ensure plunger lift reading on dial indicator is still correct after pulling fuel injection pump drive gear from shaft.
7. Rotate engine 20-30 degrees counterclockwise (viewed from front of engine), and then rotate back clockwise to TDC. This removes backlash from gear train. CAUTION: Ensure tapered area on fuel injection pump drive gear and shaft on fuel injection pump are clean. Tapered area must be clean to ensure proper seating of fuel injection pump drive gear on shaft.
8. Loosen, but DO NOT remove, bolts used for installing puller. Ensure no oil or dirt exists on tapered area of fuel injection pump drive gear and shaft.
9. Using puller, rotate fuel injection pump drive gear counterclockwise while pushing fuel injection pump drive gear on shaft of fuel injection pump. This removes backlash between fuel injection pump drive gear and camshaft gear.
10. Hand tighten fuel injection pump drive gear nut. Remove puller from fuel injection pump drive gear. Tighten fuel injection pump drive gear nut to 11 ft. lbs. (15 N.m) to seat fuel injection pump drive gear on shaft.
11. Install pencil-type magnet in end of shaft on fuel injection pump. Remove fuel injection pump drive gear nut, thrust washers and bearing. Install washer and fuel injection pump drive gear nut. Remove magnet.
12. While holding engine from rotating using engine barring tool, tighten fuel injection pump drive gear nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Repeat steps 12) through 14) under CHECKING FUEL INJECTION PUMP TIMING to verify proper plunger lift is obtained. Readjust if necessary. If plunger lift is correct, proceed to FINAL REASSEMBLY.

Final Reassembly

1. Install oil fill tube and adapter elbow on front timing gear cover. Remove dial indicator, indicator tip and adapter from fuel injection pump.
2. Install delivery valve assembly in fuel injection pump. Ensure delivery valve assembly is installed in correct direction. (Scheme 2)
3. Lubricate threads on delivery valve holder with SAE 90W gear oil. DO NOT lubricate metal delivery valve washer or seating area on delivery valve holder.
4. Ensure fill piece, shim(s) and spring are properly installed in delivery valve holder in fuel injection pump. DO NOT allow fill piece, shim(s) or spring to fall from delivery valve holder during installation.
5. Install delivery valve holder in 2 steps. Tighten delivery valve holder to 29 ft. lbs. (39 N.m). Using one motion, tighten delivery valve holder to 85 ft. lbs. (115 N.m). Install high-pressure fuel line on delivery valve holder. Tighten high-pressure fuel line nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
6. On models with EGR tube, install EGR tube using NEW gaskets with all bolts and nuts loosely installed. Alternately tighten EGR tube-to-EGR valve bolts to specification. Ensure EGR tube is installed squarely on EGR valve. Tighten EGR tube-to-exhaust manifold nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). CAUTION: When installing EGR tube, ensure EGR tube-to-EGR valve bolts are alternately tightened to specification so EGR tube is installed squarely on EGR valve. WARNING: Use care when bleeding high-pressure fuel line, as fuel is under extreme pressure and could penetrate skin, causing personal injury. Wear safety goggles and protective clothing when bleeding high-pressure fuel lines.
7. Reconnect negative battery cables. Loosen high-pressure fuel line nut at fuel injector (if not previously done) so fuel line can be bled. Crank engine until steady flow of fuel is observed at fuel injector. Tighten high-pressure fuel line nut to specification. Start engine and check for fuel leaks.

THROTTLE POSITION (TP) SENSOR

Note. TP sensor is used only on A/T models and models with EGR system.

Scheme 5

Scheme 6

Scheme 7

Scheme 8

1. Warm engine to normal operating temperature. Ensure throttle lever stop contacts low idle speed adjusting screw with accelerator pedal in idle position. (Scheme 5)
2. Using optical tachometer, check idle speed with A/C on and with transmission in Drive (A/T models) or Neutral (M/T models). Ensure engine idle speed is within specification. See «ENGINE IDLE SPEED SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table.
3. If idle speed is correct, proceed to step 5). If engine idle speed is not within specification, loosen lock nut on low idle speed adjusting screw. (Scheme 5) Turn low idle speed adjusting screw to obtain correct engine idle speed. ENGINE IDLE SPEED SPECIFICATIONS (1) Application Engine Idle Speed A/T (2) (3) 750-800 RPM M/T (2) (4) 780 RPM (1) Idle speed is stamped on engine data plate. If engine data plate specification varies from specification listed, use engine data plate specification. (2) Check with engine at normal operating temperature. (3) Check with A/C on and transmission in Drive. (4) Check with A/C on and transmission in Neutral.
4. Tighten lock nut. Recheck idle speed. Once correct engine idle speed is obtained, check for proper linkage rod adjustment. Ensure ignition is off.
5. Fully depress accelerator pedal to full throttle and visually ensure throttle lever break-over exists. If throttle lever break-over exists, linkage rod should stop moving and throttle lever should continue to move toward rear of vehicle. (Scheme 6) If throttle lever break-over does not exist, linkage rod adjustment is required.
6. Remove intercooler outlet duct from air inlet housing for access to linkage rod at fuel injection pump. Disconnect throttle cable, cruise control cable and throttle valve cable (A/T models) at fuel injection pump.
7. Loosen, but DO NOT remove, bolts "A", "B" and "C" at throttle lever. Perform STEP 1 in illustration. (Scheme 7)
8. Pivot throttle lever on fuel injection pump lever so distance between location "D" at rear of throttle lever and location "E" at rear of throttle cable bracket is 10.25" (260.0 mm). Perform STEP 2 in illustration. (Scheme 7) Ensure fuel injection pump lever remains in closed throttle position when measuring the distance. Once proper distance is obtained, tighten bolts "A", "B" and "C" to 89 INCH lbs. (10 N.m)
9. To verify correct throttle break-over distance, measure distance from rear of throttle cable mounting stud at location "F" to rear of cable mounting bracket at location "G". (Scheme 8) Measure this distance with throttle at closed throttle position and at full throttle position. Ensure fuel injection pump lever remains in closed throttle position or full throttle position when measuring distance. Record both measurements.
10. This difference between both measurements obtained in step 9) should be 1.26-1.42" (32.0-36.0 mm). If difference between both measurements is within specification, go to step 14). If the difference between both measurements is not within specification, go to next step.
11. If distance between both measurements is less than specified, remove nut and ball stud from throttle lever. (Scheme 9) Move ball stud upward/rearward one notched hole on fuel injection pump lever. (Scheme 9) Each notched hole will change the measurement about.047" (1.2 mm). Go to step 13).
12. If the distance between both measurements is more than specified, remove nut and ball stud from throttle lever. (Scheme 9) Move ball stud downward/forward one notched hole on fuel injection pump lever. (Scheme 9) Each notched hole will change measurement about.047" (1.2 mm).
13. Reinstall nut on ball stud. Tighten nut to 89 INCH lbs. (10 N.m). Recheck both measurements. Readjust if necessary. After correct measurement is obtained, repeat step 5) to ensure correct throttle lever break-over.
14. Reinstall throttle cable, cruise control cable and throttle valve cable (A/T models) at fuel injection pump. Reinstall intercooler outlet duct on air inlet housing.

Scheme 9

Scheme 10

Scheme 11

Scheme 12

1. Before performing Throttle Position (TP) sensor adjustment, fully depress accelerator pedal to full throttle and visually ensure throttle lever break-over exists. If throttle lever break-over exists, linkage rod should stop moving and throttle lever should continue to move toward rear of vehicle. (Scheme 6)
2. If throttle lever break-over exists, go to next step. If throttle lever break-over does not exist, linkage rod adjustment is required. See «CHECKING IDLE SPEED & LINKAGE»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Once throttle lever break-over exists, go to next step.
3. Verify TP sensor linkage distance from center of ball to rear face of cable mounting bracket is 5.0" (127 mm) before proceeding with TP sensor adjustment. (Scheme 10)
4. Ensure low idle speed is within specification. See «CHECKING IDLE SPEED & LINKAGE»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Turn engine off.
5. Connect scan tool to Data Link Connector (DLC). DLC is located below driver's side of instrument panel. (Scheme 11) Access SENSOR display on scan tool.
6. Turn ignition on. DO NOT start engine. With throttle at idle position, note TP voltage on scan tool. TP voltage should be.8-1.2 volts at idle position. Open throttle to full throttle position. TP voltage should be 3-4.1 volts.
7. If TP voltage is correct, turn ignition off. Remove scan tool. If TP voltage is incorrect, linkage rod must be adjusted.
8. Remove intercooler outlet duct from air inlet housing for access to linkage rod at fuel injection pump. Loosen nut "A" (right-hand thread) and nut "B" (left-hand thread) on linkage rod while holding adjusting nut on linkage rod. (Scheme 12)
9. Rotate adjusting nut to change length of linkage rod to obtain TP voltage of.8-1.2 volts with linkage rod at idle position. Open throttle to full throttle and note TP voltage. TP voltage should be 3-4.1 volts. NOTE: DO NOT lengthen or shorten linkage rod more than.04" (1.0 mm) from base adjustment of 5" (127 mm) from center of ball to rear face of cable mounting bracket. (Scheme 10) Replace TP sensor if proper voltage cannot be obtained with linkage rod length of 4.96-5.04" (126-128 mm).
10. Once correct voltage is obtained, tighten nuts "A" and "B" on linkage rod. Ensure linkage rod slightly rotates without binding at ball at each end of linkage rod. If binding exists, loosen either nut "A" or "B" until binding is eliminated. Retighten nut.
11. Operate throttle and check for any binding. Ensure throttle lever stop contacts low idle speed adjusting screw with throttle in idle position. (Scheme 5) Ensure idle speed is still correct. See CHECKING IDLE SPEED & LINKAGE. Reinstall intercooler outlet duct. Turn ignition off. Remove scan tool.

FUEL LINE BLEEDING

Note. Fuel line bleeding is necessary if fuel injection pump is replaced, fuel filter/water separator is not filled with diesel fuel before installing, or vehicle ran out of fuel. Bleed high-pressure fuel lines if connections are loosened or replaced. If engine has not been operated for an extended time, bleed fuel lines before next initial start-up.

1. To bleed low-pressure fuel lines and fuel filter/water separator, loosen fuel bleed bolt. Fuel bleed bolt is located in center of fuel supply line banjo bolt on top of fuel filter/water separator. (Scheme 13)
2. Operate rubber primer button on fuel transfer pump until steady fuel stream flows from fuel bleed bolt. Tighten fuel bleed bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). CAUTION: Ensure parking brake is applied and transmission is in Neutral before bleeding fuel injection pump or high-pressure fuel lines. DO NOT operate starter for more than 30 seconds when bleeding fuel injection pump or high-pressure fuel lines. Allow 2-minute intervals between starter operations.
3. To bleed air from fuel injection pump, ensure parking brake is applied and transmission is in Neutral, as engine may start when operating starter to bleed air from fuel injection pump. Operate starter for 30 seconds to bleed any trapped air in fuel injection pump.
4. To bleed high-pressure fuel lines, ensure parking brake is applied and transmission is in Neutral, as engine may start when operating starter to bleed high-pressure fuel lines. Loosen high-pressure fuel line nut at fuel injector.
5. Operate starter until steady fuel flow exists at high-pressure fuel line. Tighten high-pressure fuel line nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Start engine. Repeat procedure on each injector until engine operates smoothly.

Scheme 13

TROUBLE SHOOTING

To trouble shoot mechanical engine components, see appropriate table in TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL INFORMATION.

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

COOLING SYSTEM BLEEDING

Scheme 14

Removal

1. Remove batteries. Drain cooling system and engine oil. Remove upper crossmember and top core support. Remove front bumper.
2. On A/T models, ensure area around disconnect fitting on oil cooler lines on transmission oil cooler are clean. Disconnect oil cooler lines from transmission oil cooler by disengaging retainer on quick disconnect fitting on oil cooler line and pulling oil cooler line from transmission oil cooler.
3. Remove transmission oil cooler-to-intercooler bolts/nuts. Remove transmission oil cooler. On all models, note direction of serpentine belt routing for installation reference. Serpentine belt must be routed in proper direction to prevent water pump from rotating in wrong direction and causing engine overheating. Remove serpentine belt.
4. On A/C-equipped models, discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect and plug hoses and openings at condenser. Remove condenser. Remove A/C compressor with hoses attached, and secure aside.
5. On all models, remove windshield washer fluid bottle and radiator overflow bottle. Remove radiator and fan shroud. Remove generator with wires attached, and secure aside.
6. Disconnect necessary control cables, electrical connections and heater coolant hoses. Disconnect air inlet tube from turbocharger and air filter housing. Remove air inlet tube.
7. Disconnect exhaust pipe from turbocharger. Remove intercooler inlet duct from turbocharger and intercooler. Remove intercooler outlet duct from intercooler and air inlet housing.
8. Disconnect hoses at power steering pump (if equipped), vacuum pump lines and fuel lines. Raise and support vehicle. Manufacturer recommends removing oil pan during engine removal. Remove oil pan. See «OIL PAN»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) .
9. Manufacturer recommends removing transmission from vehicle for engine removal. Remove transmission. For A/T, see appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. For M/T, see appropriate article in CLUTCHES. Remove engine mount bolts. Using hoist, remove engine assembly.

Installation

1. To install, reverse removal procedure. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) . Adjust fluid levels. CAUTION: If installing front engine mounts on cylinder block, install NEW bolts. Always use NEW bolts when installing transmission support bracket for rear mount on transmission case. Transmission support bracket is located between transmission case and the rear mount.
2. On A/T models, before installing oil cooler lines on transmission and transmission oil cooler, ensure all fittings are clean. Install oil cooler line into quick disconnect fitting. Push oil cooler line inward until a click is heard. Pull on oil cooler line to ensure oil cooler line is locked in place. Fill transmission with Mopar ATF Plus Type 7176 fluid. CAUTION: When refilling cooling system, ensure engine is NOT running. If engine is running when filling cooling system water pressure will hold the one-way check valve closed, not allowing air to bleed from cooling system. See procedures in «COOLING SYSTEM BLEEDING»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__cooling-system-bleeding) for additional information on one-way check valve.
3. On all models, ensure serpentine belt is properly routed. See DRIVE BELT ROUTING in appropriate article in ENGINE COOLING for proper serpentine belt routing. Fill cooling system with engine not running. Evacuate and charge A/C system (if equipped).

INTAKE MANIFOLD COVER & INTAKE MANIFOLD AIR HEATER

Note. Intake manifold air heater is incorporated into intake manifold cover.

1. Disconnect negative battery cables. Disconnect intercooler outlet duct from air inlet housing. (Scheme 16)
2. Remove EGR tube and gaskets (if equipped). EGR tube fits between EGR valve on air inlet housing on top of intake manifold cover and exhaust manifold. Remove air inlet housing.
3. Mark high-pressure fuel line location for installation reference. Remove high-pressure fuel lines. DO NOT bend high-pressure fuel lines during removal.
4. Disconnect electrical connectors for intake manifold air heater. Disconnect electrical connectors from necessary sensors or switches mounted on intake manifold cover. Remove bolts, intake manifold cover and gasket.

1. To install, reverse removal procedure. Use NEW gaskets. Apply thread sealant on threads of intake manifold cover bolts before installing. Tighten all bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) .
2. On models with EGR tube, install EGR tube using NEW gaskets with all bolts and nuts loosely installed. Alternately tighten EGR tube-to-EGR valve bolts to specification. Ensure EGR tube is installed squarely on EGR valve. Tighten EGR tube-to-exhaust manifold nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) . CAUTION: When installing EGR tube, ensure EGR tube-to-EGR valve bolts are alternately tightened to specification so EGR tube is installed squarely on EGR valve.
3. On all models, install and bleed high-pressure fuel lines. See «FUEL LINE BLEEDING»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__fuel-line-bleeding) .

1. Disconnect negative battery cables. Disconnect air inlet tube and exhaust pipe from turbocharger. Remove and plug turbocharger oil lines.
2. Disconnect line from wastegate actuator on turbocharger. Remove intercooler inlet duct from turbocharger and intercooler. (Scheme 16) Remove nuts, turbocharger and gasket.
3. Remove coolant line bracket-to-exhaust manifold bolts. Remove EGR tube and gaskets (if equipped). EGR tube fits between EGR valve on air inlet housing on top of intake manifold cover and exhaust manifold. On all models, remove bolts, exhaust manifold and gasket.

1. To install, reverse removal procedure. Use NEW gaskets. Tighten exhaust manifold bolts to specification in sequence. (Scheme 15) See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
2. Apply anti-seize compound on turbocharger mounting studs before installing turbocharger retaining nuts. Install oil drain tube on turbocharger. Before installing oil supply line, pour about 3 ounces of clean engine oil in oil inlet while spinning turbocharger.
3. On models with EGR tube, install EGR tube using NEW gaskets with all bolts and nuts loosely installed. Alternately tighten EGR tube-to-EGR valve bolts to specification. Ensure EGR tube is installed squarely on EGR valve. Tighten EGR tube-to-exhaust manifold nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). CAUTION: When installing EGR tube, ensure EGR tube-to-EGR valve bolts are alternately tightened to specification so EGR tube is installed squarely on EGR valve.
4. On all models, to install remaining components, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).

Scheme 15

1. Remove grille. Remove front support bracket located above center of intercooler. On A/C-equipped models, discharge A/C system using approved refrigerant recovery/recycling equipment.
2. Disconnect and plug hoses and openings at condenser. Remove condenser. On all models, remove intercooler inlet and outlet ducts. (Scheme 16) Remove intercooler bolts. Pivot intercooler forward and upward to remove.

To install, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Evacuate and charge A/C system (if equipped).

Scheme 16

1. Disconnect negative battery cables. Drain cooling system and engine oil. Disconnect necessary coolant hoses and electrical connections. Remove exhaust manifold and turbocharger. See procedures under «EXHAUST MANIFOLD & TURBOCHARGER»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
2. Manufacturer recommends removing fuel injectors before removing cylinder head. See «FUEL INJECTOR»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__fuel-injector).
3. Rotate handle on drain valve forward to DRAIN position and partially drain fuel filter/water separator. Drain valve is located near top of fuel filter/water separator. (Scheme 13)
4. Remove drain hose from drain valve. Disconnect electrical connector from Water-In-Fuel (WIF) sensor on side of fuel filter/water separator. Support canister for fuel filter/water separator and remove canister nut from top of filter mounting head. (Scheme 13) Remove "O" ring from top of shaft inside the canister. Remove filter mounting head from cylinder head.
5. On all models, remove rocker lever assembly and push rods. See «ROCKER LEVER ASSEMBLY & PUSH RODS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). CAUTION: Note location and length of cylinder head bolts for reassembly reference. Different length bolts are used and must be installed in correct location.
6. Remove cylinder head bolts in sequence. (Scheme 17) Remove cylinder head and cylinder head gasket.

Scheme 17

Inspection

1. Inspect cylinder head for warpage at deck surface. Resurface cylinder head if warpage exceeds specification. See «CYLINDER HEAD»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS. Replace cylinder head if total metal removed exceeds.039" (1.00 mm). NOTE: An "X" mark indicates cylinder block deck surface was resurfaced.0098" (.250 mm), while "XX" mark indicates cylinder block deck surface was resurfaced to total of.0196" (.500 mm). (Scheme 18) CAUTION: If replacing cylinder head, ensure replacement cylinder head is correct application for models with intercooler. Cylinder head for earlier models without intercooler is not interchangeable on models with intercooler.
2. Inspect cylinder block deck warpage. Warpage should not exceed specification. See «CYLINDER BLOCK»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS.

Scheme 18

1. Check upper right corner of cylinder block for resurfacing mark. (Scheme 18) If no mark exists, cylinder block deck surface has not been resurfaced. Cylinder block deck surface can only be resurfaced twice: once at.0098" (.250 mm) and then again at an additional.0098" (.250 mm) for total limit of.0196" (.500 mm).
2. An "X" mark indicates cylinder block deck surface was resurfaced.0098" (.250 mm), while "XX" mark indicates cylinder block deck surface was resurfaced to total of.0196" (.500 mm).
3. Different thickness cylinder head gasket must be installed depending on amount cylinder block deck surface was resurfaced. Install thickest cylinder head gasket if cylinder block deck surface was resurfaced to maximum. Consult parts department for proper cylinder head gasket application to provide proper valve-to-piston clearance.
4. Ensure sealing surfaces, cylinder head bolts and holes in cylinder block are clean and dry. Install dowels in cylinder block (if removed). Install NEW cylinder head gasket. Ensure all holes are aligned.
5. Install cylinder head. Ensure cylinder head properly seats on dowels in cylinder block. Lubricate bottom side of bolt head and threads on cylinder head bolts with engine oil.
6. Install all bolts except those for rocker lever assembly. DO NOT tighten bolts at this time. Install rocker lever assembly before tightening cylinder head bolts.
7. Install push rods in original position. Lubricate push rod sockets and valve stems with clean engine oil. Ensure rocker lever adjusting screw is completely loosened. Install rocker lever assemblies in original position. Ensure pedestals on rocker lever assemblies align with dowels in cylinder head. NOTE: If pedestal on rocker lever assembly is lifted upward from cylinder head, rotate engine until pedestal contacts cylinder head. Ensure adjusting screw is completely loosened.
8. Lubricate remaining bolts with engine oil. Install and tighten cylinder head bolts to specification using proper sequence. (Scheme 17) See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Tighten remaining rocker lever assembly bolts to specification.
9. Adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__valve-clearance-adjustment) under ADJUSTMENTS. Using NEW gaskets, install rocker lever covers. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
10. Install fuel injectors using proper procedure. See «FUEL INJECTOR»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__fuel-injector). Install filter housing on cylinder head.
11. Install exhaust manifold and turbocharger using proper procedure. See «EXHAUST MANIFOLD & TURBOCHARGER»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
12. Ensure inside of fuel filter/water separator canister is clean. Install NEW "O" ring on shaft inside canister. Install NEW fuel filter/water separator and NEW seal ring in canister. Coat seal ring with engine oil. CAUTION: When installing canister on filter mounting head, ensure tab areas on outside of canister align with tabs on filter mounting head to prevent damage to canister and filter mounting head.
13. Fill canister for fuel filter/water separator with diesel fuel. Install canister with fuel filter/water separator on filter mounting head. Ensure canister fully engages with filter mounting head and tab areas on outside of canister align with tabs on filter mounting head (to prevent damage to canister and filter mounting head). Install and tighten canister nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). CAUTION: When refilling cooling system, ensure engine is not running. If engine is running when filling cooling system, the water pressure will hold one-way check valve closed, not allowing air to bleed from cooling system. See «COOLING SYSTEM BLEEDING»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__cooling-system-bleeding) for additional information on one-way check valve.
14. To install remaining components, reverse removal procedure. Bleed fuel lines. See «FUEL LINE BLEEDING»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__fuel-line-bleeding). Fill crankcase and cooling system. Ensure cooling system is filled with engine not running.

FRONT TIMING GEAR COVER & CRANKSHAFT FRONT SEAL

Note. Remove front timing gear cover for servicing of crankshaft front seal. Seal is installed from rear of front timing cover.

1. Disconnect both negative battery cables. Remove fan and shroud. Remove serpentine belt. Remove fan hub. Remove belt tensioner.
2. Remove oil fill tube and adapter. Remove vibration damper. Remove bolts and timing gear cover.
3. Support cover on a flat surface with wooden blocks. Using a suitable punch, remove crankshaft front seal.

1. Ensure timing gear cover and front of crankshaft are clean. Apply Loctite 277 to outside diameter of seal. Install seal using Crankshaft Seal Installer (8281).
2. Install plastic seal pilot (included with seal kit) into crankshaft seal. Apply a bead of silicone sealer to cover sealing surface.
3. Install timing gear cover. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) . Remove plastic seal pilot.
4. To install remaining components, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) .

1. Remove EGR tube and gaskets (if equipped). EGR tube fits between EGR valve on air inlet housing on top of intake manifold cover and exhaust manifold. Remove valve covers.
2. Loosen rocker lever adjusting screw lock nuts. Loosen rocker lever adjusting screws until they stop. Remove bolts and rocker lever assemblies.
3. Remove push rods. Remove 2 rear push rods through access holes in cowl panel. Mark component location for installation reference.

1. Install push rods in original position. Lubricate push rod sockets and valve stems with clean engine oil. Ensure rocker lever adjusting screw is completely loosened. Install rocker lever assemblies in original position. Ensure pedestals on rocker lever assembly align with dowels in cylinder head. NOTE: If pedestal on rocker lever assembly is lifted upward from cylinder head, rotate engine until pedestal contacts cylinder head. Ensure adjusting screw is completely loosened.
2. Lubricate bottom side of bolt head and threads on rocker lever assembly bolts with engine oil. Install all bolts in rocker lever assemblies.
3. Tighten rocker lever assembly 12-mm bolts to specification in sequence. (Scheme 19) See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
4. Tighten 8-mm bolts to specification. See TORQUE SPECIFICATIONS. Adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__valve-clearance-adjustment) under ADJUSTMENTS. Using NEW gaskets, install valve covers. Install and tighten bolts to specification.
5. On models with EGR tube, install EGR tube using NEW gaskets with all bolts and nuts loosely installed. Alternately tighten EGR tube-to-EGR valve bolts to specification. Ensure EGR tube is installed squarely on EGR valve. Tighten EGR tube-to-exhaust manifold nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).

Scheme 19

1. Disconnect negative battery cables. Drain cooling system. Remove fan shroud and radiator. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove A/C condenser.
2. Remove intercooler. See «INTERCOOLER»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Remove transmission oil cooler (A/T models).
3. On all models, remove upper radiator support. Remove rocker lever assembly and push rods. See «ROCKER LEVER ASSEMBLY & PUSH RODS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Remove front timing gear cover. See «FRONT TIMING GEAR COVER & CRANKSHAFT FRONT SEAL»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__front-timing-gear-cover-crankshaft).
4. Remove fuel transfer pump. See «FUEL TRANSFER PUMP»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Install dowel through push rod hole. Using plastic hammer, lightly tap dowel into each tappet. (Scheme 20) Raise tappets upward, away from camshaft. Install rubber band around both intake and exhaust tappet dowels to retain tappets from camshaft. CAUTION: Before removing camshaft, place reference mark on camshaft gear and fuel injection pump drive gear for reassembly reference to ensure proper fuel injection pump timing. Place reference mark on both gears once timing marks on camshaft gear and crankshaft gear are aligned. (Scheme 16) If reference mark is not installed at time of camshaft removal, check fuel injection pump timing once camshaft is installed.
5. Rotate crankshaft and align timing marks on camshaft gear and crankshaft gear. (Scheme 21) Place reference mark on camshaft gear and fuel injection pump drive gear for reassembly reference to ensure proper fuel injection pump timing.
6. Remove camshaft thrust plate bolts, camshaft and thrust plate. Inspect camshaft gear for damage and replace if necessary. See «CAMSHAFT GEAR»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Inspect tappet-to-camshaft contact areas for wear. Replace tappets if necessary. See «TAPPETS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__tappets).

Scheme 20

Scheme 21

Inspect camshaft bearings. See CAMSHAFT BEARINGS . Measure camshaft journals and camshaft lobe height. Replace camshaft if damaged or not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS.

1. Coat camshaft bearings, camshaft journals and thrust plate with Lubriplate 105. Install camshaft so timing marks on camshaft gear and crankshaft gear are aligned. (Scheme 21) CAUTION: DO NOT push camshaft inward beyond area for thrust plate. Excessive inward movement of camshaft will dislodge plug in rear of cylinder block, causing oil leak. CAUTION: Ensure reference mark placed on fuel injection pump drive gear and camshaft gear are aligned. If reference mark is not aligned or was not made during removal procedure, check fuel injection pump timing. See «FUEL INJECTION PUMP TIMING»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) under ADJUSTMENTS.
2. Install and tighten camshaft thrust plate bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Using dial indicator, check gear backlash between camshaft gear, crankshaft gear and fuel injection pump drive gear. Check camshaft end play.
3. Gear backlash and camshaft end play should be within specification. See «CAMSHAFT»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS.
4. To install remaining components, reverse removal procedure. Ensure fuel transfer pump bolts are tightened evenly to specification to prevent damage to fuel transfer pump. Adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__valve-clearance-adjustment) under ADJUSTMENTS.
5. On A/T models, before installing oil cooler lines on transmission oil cooler, ensure all fittings are clean. Install oil cooler line into quick disconnect fitting. Push oil cooler line inward until a click is heard. Pull on oil cooler line to ensure oil cooler line is locked in place. Fill transmission with Mopar ATF Plus Type 7176 fluid.

CAMSHAFT BEARINGS

Note. Camshaft bearing is used only on front camshaft journal and is replaceable. All other camshaft journal bores in cylinder block should have same I.D. as front camshaft bearing. If remaining bores exceed specification, camshaft bores must be machined to accommodate service bearings. Camshaft bearing bore for front camshaft journal may be bored for oversize camshaft bearing.

1. Inspect camshaft bearing for scratches or damage. Measure bore I.D. of camshaft bearing and journal bores in cylinder block.
2. If bore I.D. exceeds specification, replace camshaft bearing or machine journal bores for service bearing. See «CAMSHAFT»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS.
3. If journal bore in cylinder block (except front camshaft journal) exceeds specification, journal bore may be bored to 2.253" (57.23 mm) for service bearing.

1. Using camshaft bearing remover/installer, drive camshaft bearing from cylinder block. Ensure front camshaft bearing bore in cylinder block I.D. is within specification. See «CAMSHAFT»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS. Front camshaft bearing bore in cylinder block may be bored to 2.273" (57.73 mm) for oversize camshaft bearing.
2. Mark camshaft bearing and cylinder block for oil hole alignment. Apply Loctite 609 on outside of camshaft bearing. DO NOT allow Loctite to enter oil passage on camshaft bearing.
3. Using camshaft bearing remover/installer, install camshaft bearing until camshaft bearing is even with front of cylinder block. Using .128" (3.25 mm) diameter rod, check alignment between oil hole and cylinder block. After installation of camshaft bearing, ensure I.D. of camshaft bearing is within specification. See «CAMSHAFT SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS.

1. Remove camshaft. See «CAMSHAFT»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) . Using press and support blocks, press camshaft from camshaft gear.
2. To install, ensure camshaft gear keyway and key are free of burrs. Heat camshaft gear at 350°F (177°C) for 45 minutes. DO NOT heat camshaft gear for longer than 45 minutes at specified temperature or camshaft gear will be distorted.
3. Coat camshaft surface with Lubriplate 105. Press heated camshaft gear onto camshaft with timing marks facing away from camshaft. Ensure camshaft gear is seated against shoulder on camshaft.

CRANKSHAFT GEAR

Note. Manufacturer lists procedure with crankshaft removed.

1. Using gear puller, remove crankshaft gear from crankshaft. To install, place NEW alignment pin (if removed) in crankshaft with pointed end of pin toward crankshaft. Ensure alignment pin protrudes .063-.094" (1.60-2.38 mm) above surface of crankshaft.
2. Ensure alignment pin and pin slot in crankshaft gear are free of burrs, and end of crankshaft is smooth. Heat crankshaft gear at 250°F (121°C) for 45 minutes. DO NOT heat crankshaft gear for longer than 45 minutes at specified temperature.
3. Install heated crankshaft gear on crankshaft with timing mark facing outward. Ensure alignment pin and slot in crankshaft gear align. Ensure crankshaft gear is seated against shoulder on crankshaft.

1. Remove camshaft. See «CAMSHAFT»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Install plastic trough from Tappet Changing Set (3822513) the full length of camshaft bore area of cylinder block. (Scheme 22) Ensure plastic trough is positioned under tappet to retain tappet when dowel is removed. CAUTION: DO NOT remove more than one tappet at a time. Ensure tappet in plastic trough falls over before removing. Use care when removing tappets from No. 6 cylinder to prevent shaking tappets over top of plastic trough.
2. Remove rubber band and dowel (installed during camshaft removal) from tappet. Allow tappet to fall into plastic trough. Ensure tappet in plastic trough falls over. Remove plastic trough and tappet. Mark tappet location for installation reference.

Scheme 22

Inspect tappets for wear in camshaft contact area. Measure tappet stem O.D. at top and bottom of stem. Replace tappet if O.D. is not within specification. Ensure cylinder block tappet bore is within specification. See TAPPETS table under ENGINE SPECIFICATIONS.

1. Install plastic trough in camshaft area of cylinder block. Position tappet installer through push rod hole of cylinder head and guide out front of plastic trough. (Scheme 22) Lubricate tappet with Lubriplate 105. NOTE: Tappet should be installed on tappet installer several times before installing in cylinder block to aid in removal of tappet installer from tappet once installed in cylinder block.
2. Install tappet on tappet installer. Pull tappet up plastic trough and align with original installation location. If necessary, pull plastic trough toward front of cylinder block to allow tappet to drop down and align with cylinder block bore.
3. Once tappet is installed in cylinder block bore, rotate plastic trough so rounded side of trough is against bottom of tappet. This will hold tappet in place. Install dowel and rubber band to retain tappet. Install camshaft and remaining components.

GEAR HOUSING

Note. Manufacturer lists procedure with engine removed.

1. Remove engine. See «ENGINE»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Remove camshaft. See «CAMSHAFT»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Remove fuel injection pump. See «FUEL INJECTION PUMP»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__fuel-injection-pump).
2. Disconnect necessary hoses and remove vacuum pump and power steering pump assembly. Remove bolts, gear housing and gasket. (Scheme 23)

To install, reverse removal procedure. Use NEW gaskets. Use sealant on gasket that fits between gear housing and vacuum pump. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

Scheme 23

1. To remove timing pin, position cylinder No. 1 at TDC on compression stroke. Engine may be rotated by removing dust cover from transmission adapter plate and installing Engine Barring Tool (7471B) in transmission adapter plate. (Scheme 1) CAUTION: Use care when engaging timing pin to avoid breaking tip of timing pin. Ensure timing pin is disengaged before rotating engine.
2. Note location of timing pin. (Scheme 1) Push timing pin toward front of engine. Slowly rotate engine clockwise (viewed from front of engine) while holding tension on timing pin. Rotate engine until timing pin engages machined hole on camshaft gear and cylinder No. 1 is at TDC.
3. If removing only timing pin, remove retaining ring and timing pin. If removing timing pin assembly, ensure cylinder No. 1 is at TDC on compression stroke and timing pin engages in camshaft gear. Remove timing pin assembly and gasket.

Note. Different installation procedure is used for installing timing pin assembly depending on whether or not cylinder head is installed.

Scheme 24

1. If only timing pin was removed, install NEW "O" ring on timing pin. Lubricate "O" ring and timing pin with engine oil.
2. Install timing pin in housing of timing pin assembly. Install NEW retaining ring. Ensure retaining ring is fully seated. When retaining ring is fully seated the distance from end of housing on timing pin assembly to the retaining ring should be.059" (1.50 mm).
3. If timing pin assembly was removed, timing pin must be accurately located. Look through hole of gear housing. Rotate engine until timing pin hole in camshaft gear can be seen.
4. Manufacturer recommends removing fuel injectors on all cylinders to provide smooth engine rotation. See «FUEL INJECTOR»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__fuel-injector).
5. Temporarily install vibration damper (if removed). Fabricate and install pointer to align with vibration damper. Rotate crankshaft 1/4 turn clockwise in normal direction of rotation. (Scheme 24)
6. Valve cover for cylinder No. 1 must be removed. Remove EGR tube and gaskets (if equipped) for access to valve cover for cylinder No. 1. EGR tube fits between EGR valve (on air inlet housing on top of intake manifold cover) and the exhaust manifold.
7. Remove valve cover and gasket from cylinder No. 1. Loosen lock nut and tighten intake valve rocker lever adjusting screw on cylinder No. 1 to zero lash plus an additional 5 turns. Tighten lock nut. CAUTION: Use care when rotating engine. Use of excessive force could result in damage to intake valve or piston.
8. Slowly rotate crankshaft counterclockwise in opposite direction of rotation until piston slightly contacts intake valve. Place reference mark on vibration damper at fabricated pointer.
9. Slowly rotate crankshaft clockwise in normal direction of rotation until piston contacts intake valve with same amount of force. Place reference mark on vibration damper at fabricated pointer.
10. Measure distance between reference marks. Place reference mark on vibration damper at a point halfway between reference marks. This is TDC mark. Completely loosen intake valve rocker lever adjusting screw on cylinder No. 1. Intake valve rocker lever adjusting screw on cylinder No. 1 must be loosened before rotating engine or push rod or intake valve may be damaged. CAUTION: Ensure intake valve rocker lever adjusting screw on cylinder No. 1 is completely loosened before rotating engine or push rod, or intake valve may be damaged.
11. Rotate crankshaft clockwise in normal direction of rotation until pointer is aligned with TDC mark. Rotate crankshaft clockwise one full revolution until pointer is aligned with TDC mark.
12. Look through back side of gear housing and note timing pin hole in camshaft gear. If timing pin hole is not visible, rotate crankshaft clockwise one full revolution.
13. Using NEW gasket, install timing pin assembly. Hold timing pin in pin hole on camshaft gear. Align housing on timing pin assembly with bolt holes. Coat threads of bolts for timing pin assembly with thread sealant. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Remove fabricated pointer. CAUTION: Ensure timing pin is disengaged before rotating engine.
14. Disengage timing pin from camshaft gear. Adjust valve clearance on cylinder No. 1. See «VALVE CLEARANCE ADJUSTMENT»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__valve-clearance-adjustment) under ADJUSTMENTS. Install fuel injectors using proper procedure. See «FUEL INJECTOR»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__fuel-injector).
15. Using NEW gasket, install rocker lever cover. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
16. On models with EGR tube, if EGR tube was removed, install EGR tube using NEW gaskets, with all bolts and nuts loosely installed. Alternately tighten EGR tube-to-EGR valve bolts to specification. Ensure EGR tube is installed squarely on EGR valve. Tighten EGR tube-to-exhaust manifold nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). CAUTION: When installing EGR tube, ensure EGR tube-to-EGR valve bolts are alternately tightened to specification so EGR tube is installed squarely on EGR valve.
17. On all models, to install remaining components, reverse removal procedure. Install and bleed high-pressure fuel lines. See «FUEL LINE BLEEDING»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__fuel-line-bleeding).

Installation (With Cylinder Head Removed)

1. If only timing pin was removed, install NEW "O" ring on timing pin. Lubricate "O" ring and timing pin with engine oil.
2. Install timing pin in housing of timing pin assembly. Install NEW retaining ring. Ensure retaining ring is fully seated. When retaining ring is fully seated the distance from end of housing on timing pin assembly to retaining ring should be.059" (1.50 mm).
3. If timing pin assembly was removed, timing pin must be accurately located. Temporarily install vibration damper (if removed). Fabricate and install pointer to align with vibration damper. (Scheme 24) If front timing gear cover is removed, install flat washer between gear housing and fabricated pointer to prevent damage to gear housing.
4. Fabricate cylinder block plate. (Scheme 25) Using bolts, install cylinder block plate over cylinder No. 1. Rotate crankshaft clockwise (viewed from front of engine) in normal direction of rotation until piston contacts cylinder block plate. Place reference mark on vibration damper at fabricated pointer.
5. Slowly rotate crankshaft counterclockwise in opposite direction of rotation until piston contacts cylinder block plate. Place reference mark on vibration damper at fabricated pointer.
6. Measure distance between reference marks. Place reference mark on vibration damper at a point halfway between reference marks. This is TDC mark.
7. Remove cylinder block plate. Rotate crankshaft clockwise until fabricated pointer aligns with TDC mark. Look through back side of gear housing and note timing pin hole in camshaft gear. If timing pin hole is not visible, rotate crankshaft one revolution.
8. Using NEW gasket, install timing pin assembly. Hold timing pin in pin hole on camshaft gear. Align housing on timing pin assembly with bolt holes. Coat threads of bolts for timing pin assembly with thread sealant. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Remove fabricated pointer. Disengage timing pin from camshaft gear.

Scheme 25

1. Remove transmission. For A/T, see appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. For M/T, see appropriate article in CLUTCHES. Remove clutch pressure plate and disc (if equipped), and flywheel or flexplate. Drill 2 holes in face of oil seal, 180 degrees apart. Install sheet metal screws in holes. Using slide hammer, remove oil seal. CAUTION: Crankshaft and crankshaft rear oil seal lip must be free of oil during installation to prevent oil seal leakage.
2. To install, ensure all sealing surfaces are clean and dry. Install oil seal pilot provided with oil seal on rear of crankshaft. Install oil seal on oil seal pilot. Push oil seal from oil seal pilot onto crankshaft. Remove oil seal pilot.
3. Install oil seal using oil seal aligner/installer provided with oil seal. Drive oil seal aligner/installer in 4 equally spaced areas until oil seal aligner/installer bottoms. Remove oil seal aligner/installer.
4. To install remaining components, reverse removal procedure. Tighten flywheel/flexplate bolts in a crisscross pattern to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) .

CRANKSHAFT REAR OIL SEAL HOUSING

Note. Manufacturer lists procedure with transmission, flywheel/flexplate and oil pan removed.

Remove bolts, crankshaft rear oil seal housing and gasket from rear of cylinder block. Support crankshaft rear oil seal housing. Drive rear oil seal from crankshaft rear oil seal housing.

Note. Crankshaft and crankshaft rear oil seal lip must be free of oil during installation to prevent oil seal leakage. Ensure crankshaft rear oil seal housing is even with bottom of cylinder block surface to prevent oil leakage.

1. Ensure all sealing surfaces are clean and dry. Using NEW gasket, install crankshaft rear oil seal housing on cylinder block. DO NOT tighten bolts at this time.
2. Install oil seal aligner/installer (provided with oil seal) on rear of crankshaft. Ensure crankshaft rear oil seal housing is even with bottom of cylinder block surface. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) .
3. Trim crankshaft rear oil seal housing gasket even with cylinder block surface. Remove oil seal aligner/installer. Install oil seal pilot (provided with oil seal) on rear of crankshaft. Install oil seal on oil seal pilot. Push oil seal from oil seal pilot onto crankshaft. Remove oil seal pilot.
4. Install oil seal using oil seal aligner/installer provided with oil seal. Drive on oil seal aligner/installer in 4 equally spaced areas until oil seal aligner/installer bottoms. Remove oil seal aligner/installer.

1. Remove transmission. See appropriate article in CLUTCHES. Remove clutch pressure plate and disc, and flywheel. Note direction of flywheel ring gear installation. Using Brass drift and hammer, drive flywheel ring gear from flywheel. CAUTION: Install flywheel ring gear must be installed with chamfered edge on teeth toward crankshaft side of flywheel.
2. To install, heat flywheel ring gear at 250°F (121°C) for 20 minutes. Install flywheel ring gear on flywheel with chamfered edge on teeth toward crankshaft side of flywheel.

FUEL INJECTOR

1. Disconnect negative battery cables. Manufacturer recommends removing high-pressure fuel lines for access to fuel injectors.
2. Remove EGR tube and gaskets (if equipped) for access to high-pressure fuel lines and fuel injectors (if necessary). EGR tube fits between EGR valve (on air inlet housing on top of intake manifold cover) and the exhaust manifold. Remove nameplate located above valve covers.
3. Mark high-pressure fuel line location for installation reference. Remove necessary clamps for high-pressure fuel lines. Ensure area around high-pressure fuel line nut at fuel injector and fuel injection pump is clean.
4. Disconnect high-pressure fuel lines at fuel injector and fuel injection pump. Remove high-pressure fuel lines. DO NOT bend high-pressure fuel lines.
5. Remove fuel injector drain line-to-fuel injector banjo bolt and seal washer from each fuel injector. Plug all fuel openings. Remove fuel injector drain line assembly retaining clamp at rear of cylinder head.
6. Remove fuel injector drain line bolt with seal washers at filter housing or filter mounting head. (Scheme 13) Remove fuel injector drain line. Ensure area around fuel injector is clean. NOTE: Some fuel injectors may contain a rubber seal ring or an "O" ring in groove on top of fuel injector retaining nut. CAUTION: If area around fuel injector retaining nut and fuel injector is rusty, fuel injector may rotate when removing fuel injector retaining nut. Fuel injector and cylinder head may be damaged if fuel injector rotates during removal of fuel injector retaining nut. Apply penetrating oil on fuel injector and retaining nut if rust exists before attempting fuel injector retaining nut removal.
7. Hold body of fuel injector with wrench while removing fuel injector retaining nut from cylinder head. If fuel injector retaining nut can be removed, go to step 9). If fuel injector retaining nut cannot be removed, remove rubber seal ring or "O" ring (if equipped) from groove on top of fuel injector retaining nut.
8. Spray area around fuel injector retaining nut and fuel injector with penetrating oil. Hold body of fuel injector with wrench while removing fuel injector retaining nut from cylinder head. Go to next step.
9. Remove rubber seal ring or "O" ring (if equipped) from groove on top of fuel injector retaining nut (if not previously removed). Using hammer and brass drift, lightly tap body of fuel injector to loosen fuel injector in cylinder head.
10. Pull fuel injector from cylinder head. It may be necessary to use Fuel Injector Puller (3823276) to pull fuel injector from cylinder head. If fuel injector is difficult to pull from cylinder head, spray carburetor cleaner around outside of fuel injector while trying to pull fuel injector from cylinder head. This will aid in dissolving carbon deposits at fuel injector and cylinder head. Remove copper sealing washer (located below fuel injector) from cylinder head if it was not removed with fuel injector.

1. Clean fuel injector bore on cylinder head with wire brush. Apply light coat of engine oil on NEW copper sealing washer. Install copper sealing washer on spray tip of fuel injector. Engine oil is used to aid holding sealing washer in place. Coat injector retaining nut and top of fuel injector body with anti-seize compound. CAUTION: Align ball on side of fuel injector with notch on cylinder head before tightening fuel injector retaining nut.
2. Install fuel injector in original position. Align ball on side of fuel injector with notch on cylinder head. Install and tighten fuel injector retaining nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) .
3. Once fuel injector retaining nut is tightened, install NEW rubber seal ring or "O" ring (if equipped) into groove on top of fuel injector. Rubber seal ring or "O" ring is used to prevent water from entering bore on cylinder head.
4. To install remaining components, reverse removal procedure. Use NEW seal washers. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) . Bleed high-pressure fuel lines. See «FUEL LINE BLEEDING»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__fuel-line-bleeding) .

FUEL INJECTION PUMP

Note. New or rebuilt fuel injection pumps should have a NEW overflow valve installed on fuel injection pump. (Scheme 26) Overflow valve is used to secure fuel return line on fuel injection pump. DO NOT install used overflow valve on a new or rebuilt fuel injection pump. If used fuel injection pump is being sent out for testing or calibration, ensure original overflow valve is installed in used fuel injection pump.

Scheme 26

1. Disconnect negative battery cables. Disconnect necessary electrical connections at fuel injection pump. Disconnect intercooler outlet duct from air inlet housing. (Scheme 16)
2. Remove EGR tube and gaskets (if equipped). EGR tube fits between EGR valve (on air inlet housing on top of intake manifold cover) and exhaust manifold. Remove nameplate located above valve covers.
3. Remove clamp, and position oil dipstick tube aside. Disconnect electrical connectors for intake manifold air heater. Intake manifold air heater is incorporated into intake manifold cover. Remove bolts, intake manifold cover and gasket. (Scheme 16)
4. Remove throttle lever bracket (with control cables) from side of fuel injection pump. Disconnect lines from Air Flow Control (AFC), located on top of fuel injection pump. (Scheme 27)
5. Remove fuel injection pump fuel supply line and gaskets. Fuel supply line fits between fuel injection pump and filter housing or filter mounting head for fuel filter/water separator.
6. Remove overflow valve and fuel return line with gaskets from fuel injection pump. (Scheme 26) Overflow valve holds fuel return line on fuel injection pump. Overflow valve and fuel return line are on back side of fuel injection pump, near front of fuel injection pump. DO NOT remove retainer from center of overflow valve if overflow valve is equipped with retainer. (Scheme 26)
7. Remove high-pressure fuel lines from fuel injection pump. Disconnect oil supply line from side of fuel injection pump. Remove oil fill tube and adapter elbow from front timing gear cover by rotating assembly counterclockwise (viewed from front of engine).
8. Engine may be rotated by removing dust cover from transmission adapter plate and installing Engine Barring Tool (7471B) in transmission adapter plate. (Scheme 1)
9. Disconnect air inlet tube from turbocharger. Note location of timing pin. (Scheme 1) Push timing pin toward front of engine. Slowly rotate engine clockwise (viewed from front of engine) while holding tension on timing pin. Rotate engine until timing pin engages machined hole on camshaft gear. This positions cylinder No. 1 at TDC on compression stroke. CAUTION: To prevent damage to timing pin, ensure timing pin is disengaged from camshaft gear before attempting to loosen fuel injection pump drive gear nut. DO NOT allow engine to rotate when loosening fuel injection pump drive gear nut.
10. Disengage timing pin. While keeping engine from rotating with engine barring tool, loosen fuel injection pump drive gear nut. Install pencil-type magnet in end of shaft on fuel injection pump. Perform STEP 1. (Scheme 4) Magnet is used to prevent fuel injection pump drive gear nut and washer from falling into front timing gear cover during removal. NOTE: If pencil-type magnet is not available, place shop towel below fuel injection pump drive gear nut and front timing gear cover to prevent nut from falling into engine.
11. Remove fuel injection pump drive gear nut and washer from the shaft. DO NOT allow nut or washer to fall in front timing gear cover.
12. Using Puller (L-4407A), pull fuel injection pump drive gear from tapered area on shaft of fuel injection pump. DO NOT pull gear too far forward or front timing gear cover may be damaged.
13. Remove fuel injection pump-to-lower mounting bracket bolts. These are the vertical bolts located at rear of fuel injection pump. Remove fuel injection pump-to-gear housing nuts. Remove fuel injection pump. DO NOT scratch or damage shaft on fuel injection pump during removal.

Note. Properly position original fuel injection pump shaft by engaging pump timing pin to provide proper fuel injection pump timing before installing. NEW or rebuilt fuel injection pumps should be shipped with pump shaft properly positioned and pump timing pin engaged to provide proper fuel injection pump timing.

1. If installing original fuel injection pump, pump shaft must be properly positioned by engaging pump timing pin to provide proper fuel injection pump timing. NEW or rebuilt fuel injection pumps should be shipped with pump shaft properly positioned and pump timing pin engaged. NOTE: If necessary to check shaft positioning for fuel injection pump timing on fuel injection pump, proceed to next step.
2. For positioning pump shaft on original fuel injection pump or checking NEW or rebuilt pump shaft positioning, remove access plug and pump timing pin from side of fuel injection pump. (Scheme 27)
3. Rotate fuel injection pump shaft until pump timing tooth is centered in access plug opening on fuel injection pump. Install pump timing pin so slot in pump timing pin engages with pump timing tooth. (Scheme 27) Temporarily install access plug. NOTE: It may be necessary to slightly rotate fuel injection pump shaft when engaging pump timing pin. DO NOT force slot on pump timing pin onto pump timing tooth.
4. If installing original fuel injection pump, check condition of "O" ring on front of fuel injection pump. Replace "O" ring (if necessary).
5. For installation of replacement or original fuel injection pump, ensure shaft area of fuel injection pump drive gear and shaft on fuel injection pump are clean. Apply clean engine oil to fuel injection pump mounting area in gear housing and "O" ring on front of fuel injection pump. CAUTION: DO NOT use fuel injection pump-to-gear housing nuts to pull fuel injection pump into gear housing or fuel injection pump or gear housing may be damaged.
6. Install fuel injection pump on mounting studs on rear of gear housing. Ensure fuel injection pump is flat against gear housing. Install fuel injection pump-to-gear housing nuts finger tight. DO NOT tighten nuts at this time. CAUTION: Ensure fuel injection pump-to-gear housing nuts are tightened to specification before tightening fuel injection pump-to-lower mounting bracket bolts. Nuts and bolts must be tightened in proper sequence to prevent damage to fuel injection pump or gear housing.
7. Install fuel injection pump-to-lower mounting bracket bolts finger tight. Tighten fuel injection pump-to-gear housing nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Tighten fuel injection pump-to-lower mounting bracket bolts.
8. Install pencil-type magnet in end of shaft on fuel injection pump. Install washer and fuel injection pump drive gear nut. Remove magnet.
9. Tighten fuel injection pump drive gear nut to preliminary torque of 11 ft. lbs. (15 N.m). DO NOT overtighten nut, as pump timing pin may be damaged. This is not the final tightening torque.
10. Disengage timing pin from camshaft gear. Remove access plug and pump timing pin from side of fuel injection pump. (Scheme 27) Tighten fuel injection pump drive gear nut to final torque of 122 ft. lbs. (165 N.m) while preventing engine from rotating.
11. Fuel injection pump timing must now be checked. Ensure timing pin is disengaged from camshaft gear. Rotate engine clockwise (viewed from front of engine) until timing pin engages machined hole on camshaft gear.
12. Ensure pump timing tooth is centered in access plug opening on fuel injection pump. Install pump timing pin so slot in pump timing pin engages with pump timing tooth. (Scheme 27)
13. If pump timing pin engages with pump timing tooth, proceed to step 16). If pump timing pin will not engage, remove fuel injection pump drive gear nut and washer.
14. Using puller, pull fuel injection pump drive gear from tapered area on shaft of fuel injection pump. Rotate fuel injection pump shaft until pump timing tooth is centered in access plug opening on fuel injection pump. Ensure pump timing pin engages with pump timing tooth.
15. Install washer and fuel injection pump drive gear nut. Tighten fuel injection pump drive gear nut to specification while keeping engine from rotating. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Proceed to next step.
16. Remove pump timing pin. Reverse pump timing pin and install in fuel injection pump so slot area is facing outward and pump timing pin is disengaged. (Scheme 27)
17. Install sealing washer and access plug. Tighten access plug to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
18. To install remaining components, reverse removal procedure. Use NEW gaskets. Tighten bolts/nuts to specification. NOTE: When installing fuel return line, a new or rebuilt fuel injection pump should have a NEW overflow valve installed on fuel injection pump. (Scheme 20) DO NOT install used overflow valve on a new or rebuilt fuel injection pump.
19. On models with EGR tube, install EGR tube using NEW gaskets with all bolts and nuts loosely installed. Alternately tighten EGR tube-to-EGR valve bolts to specification. Ensure EGR tube is installed squarely on EGR valve. Tighten EGR tube-to-exhaust manifold nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). CAUTION: New or rebuilt fuel injection pumps must be pre-lubricated before operating to prevent premature governor wear.
20. If installing new or rebuilt fuel injection pump, remove oil fill plug from top of fuel injection pump. (Scheme 27) Add 25 ounces (.74 liters) of clean engine oil to fuel injection pump. Install and tighten oil fill plug to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
21. On all fuel injection pumps, install and bleed fuel lines. See «FUEL LINE BLEEDING»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__fuel-line-bleeding). Check adjustment of Throttle Position (TP) sensor if equipped. See «THROTTLE POSITION (TP) SENSOR»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__throttle-position-tp-sensor) under ADJUSTMENTS. Adjust engine oil level (if necessary).

Scheme 27

1. Disconnect negative battery cables. Remove starter. Ensure area around fuel transfer pump and lines are clean. Fuel transfer pump is located on driver's side of engine.
2. Place drain pan below fuel transfer pump. Disconnect fuel line at fuel transfer pump and fuel heater. (Scheme 13) Remove rubber fuel hose located between fuel heater and fuel transfer pump. CAUTION: Camshaft must be properly positioned before removing or installing fuel transfer pump so lobe on camshaft is pointing away from plunger on fuel transfer pump. If lobe on camshaft is against plunger on fuel transfer pump, removal or installation of fuel transfer pump will be difficult and fuel transfer pump may be damaged.
3. To place cylinder No. 1 at TDC on compression stroke, remove dust plug from transmission adapter plate and install Engine Barring Tool (7471B) in transmission adapter plate. (Scheme 1) Engine barring tool is used to rotate engine. CAUTION: Use care when engaging timing pin to avoid breaking tip of timing pin. Ensure timing pin is disengaged before rotating engine.
4. Note location of timing pin. (Scheme 1) Timing pin is located on back of gear housing, just above vacuum pump and below fuel injection pump. Push timing pin toward front of engine.
5. Using engine barring tool, slowly rotate engine clockwise (viewed from front of engine) while holding tension on timing pin. Rotate engine until timing pin engages machined hole on camshaft gear. This positions cylinder No. 1 at TDC on compression stroke. CAUTION: To prevent damage to timing pin, ensure timing pin is disengaged from camshaft gear before rotating engine.
6. Once cylinder No. 1 is at TDC on compression stroke, disengage timing pin from camshaft gear. Continue to rotate engine clockwise (viewed from front of engine) an additional 180-270 degrees. This positions lobe on camshaft away from plunger on fuel transfer pump. CAUTION: When removing fuel transfer pump, DO NOT allow plunger in fuel transfer pump to catch on cylinder block and fall into the engine.
7. Remove bolts and fuel transfer pump with fuel heater and gasket. DO NOT allow plunger in fuel transfer pump to catch on cylinder block and fall into engine.

1. To install, reverse removal procedure. Ensure gasket sealing surfaces are clean. Using NEW gasket, install fuel transfer pump and fuel heater on cylinder block. Install bolts in fuel transfer pump. Tighten bolts evenly to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) . CAUTION: Tighten bolts evenly when installing fuel transfer pump to prevent damage to fuel transfer pump, as plunger is being compressed when bolts are tightened.
2. Tighten fuel lines to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) . Install starter and negative battery cables. Bleed low-pressure fuel lines. See «FUEL LINE BLEEDING»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__fuel-line-bleeding) under ADJUSTMENTS.

ENGINE SPEED SENSOR

Note. Engine speed sensor may also be referred to as crankshaft position sensor.

1. Engine speed sensor is located on front of timing gear cover, just above vibration damper. (Scheme 28) Disconnect electrical wiring harness connector for engine speed sensor.
2. Note routing of electrical wiring harness for engine speed sensor. Remove electrical wiring harness retaining clips. Note location of spacers between engine speed sensor and timing gear cover. Remove bolts, engine speed sensor and spacers.

1. Install spacers and engine speed sensor with bolts finger tight. DO NOT tighten bolts, as engine speed sensor air gap between tip of engine speed sensor and vibration damper must be adjusted. CAUTION: DO NOT align engine speed sensor with notches on vibration damper when adjusting engine speed sensor air gap, or sensor will be damaged when engine is started. (Scheme 28)
2. Engine speed sensor air gap should be.049-.051" (1.25-1.30 mm). Install proper thickness brass (non-magnetic) feeler gauge between tip of engine speed sensor and vibration damper.
3. Gently push engine speed sensor downward against brass feeler gauge. Tighten engine speed sensor bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). Remove feeler gauge and recheck air gap. Reinstall electrical wiring harness.

Scheme 28

Note. TP sensor is used only on A/T models and models with EGR system.

Disconnect electrical connector from bottom of TP sensor. TP sensor is located on throttle lever bracket. (Scheme 10) Remove bolts and TP sensor.

1. Install TP sensor on throttle lever bracket with electrical connector on TP sensor facing downward. The TP sensor is spring loaded and must be rotated counterclockwise until bolt holes are aligned when installing on throttle lever bracket.
2. Rotate TP sensor counterclockwise until bolt holes are aligned. Install and tighten bolts. Reinstall electrical connector. Operate throttle and check for binding in throttle linkage. Check TP sensor adjustment. See «THROTTLE POSITION (TP) SENSOR»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__throttle-position-tp-sensor) under ADJUSTMENTS.

1. Disconnect negative battery cables. Drain cooling system. Remove bolt retaining wiring harness near top of water pump. Position wiring harness aside.
2. Note serpentine belt routing for installation reference. Serpentine belt must be routed in proper direction to prevent water pump from rotating in the wrong direction and causing engine overheating.
3. Remove serpentine belt. Remove bolts, water pump and "O" ring.

1. To install, reverse removal procedure. Use NEW "O" ring. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) . CAUTION: When refilling cooling system, ensure engine is not running. If engine is running when filling cooling system water pressure will hold one-way check valve closed, not allowing air to bleed from cooling system. See procedures in «COOLING SYSTEM BLEEDING»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__cooling-system-bleeding) for additional information on the one-way check valve.
2. Ensure serpentine belt is properly routed. Fill cooling system with engine not running. Start engine after installation is complete. Check for water leaks.

THERMOSTAT

1. Disconnect negative battery cables. Drain cooling system. Note serpentine belt routing for installation reference. Serpentine belt must be routed in proper direction to prevent water pump from rotating in wrong direction and causing engine overheating.
2. Remove serpentine belt. Disconnect upper radiator hose and coolant hoses from thermostat housing. Remove generator upper mounting bracket.
3. Loosen, but DO NOT remove, lower pivot bolt on generator. Pivot generator for access to thermostat housing. Remove bolts, thermostat housing, outer seal, thermostat, inner seal and lifting bracket. (Scheme 29)

1. To install, reverse removal procedure. Use NEW seals. Ensure inner seal and thermostat are installed in proper direction. (Scheme 29) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d). CAUTION: When refilling cooling system, ensure engine is not running. If engine is running when filling cooling system the water pressure will hold the one-way check valve closed, not allowing air to bleed from cooling system. See procedures in «COOLING SYSTEM BLEEDING»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__cooling-system-bleeding) for additional information on one-way check valve.
2. Ensure serpentine belt is properly routed. See DRIVE BELT ROUTING article in ENGINE COOLING section for proper serpentine belt routing. Fill cooling system with engine not running.

Scheme 29

1. Drain engine oil. Disconnect negative battery cables. Remove transmission. For A/T, see appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. For M/T, see appropriate article in CLUTCHES. Remove starter and flywheel/flexplate.
2. Remove oil pan bolts. Slightly lower oil pan. Remove oil suction tube if necessary for oil pan removal. Remove oil pan and gasket.
3. To install, reverse removal procedure. Use NEW gaskets. Apply sealant at crankshaft rear seal housing and gear housing-to-cylinder block junction areas before installing gasket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) . Fill with engine oil.

Cylinder Head

Inspect cylinder head warpage at deck surface. Resurface cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Replace cylinder head if total material removed exceeds .039" (1.00 mm). Ensure cylinder head height is within specification.

Note. An "X" mark indicates cylinder block deck surface was resurfaced .0098" (.250 mm), while "XX" mark indicates cylinder block deck surface was resurfaced to total of .0196" (.500 mm).

Valve Springs

Check valve spring free length, out-of-square and pressure. Replace valve spring if not within specification. See VALVES & VALVE SPRINGS table Under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals

Intake and exhaust valve stem oil seals are the same. Ensure valve stem oil seals are seated on cylinder head.

Note. Valve guides may be either thick wall or thin wall. Note wall thickness before servicing valve guides.

Valve Guides

1. Cylinder head valve guide bore must be reamed if valve guide I.D. exceeds specification. See «CYLINDER HEAD»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table Under ENGINE SPECIFICATIONS. Ream cylinder head to proper dimension. See «VALVE GUIDE INSTALLATION SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table.
2. Service valve guides must be centered with valve seats within.01378" (.3500 mm), and squared with deck surface to.004" (.10 mm) within a 1.9685" (49.999 mm) radius. If thin wall valve guide is used, go to next step. If thick wall valve guide is used, go to step 5).
3. On thin wall valve guides, lubricate valve guide with engine oil. Install valve guide until bottom of valve guide is even with cylinder head boss. (Scheme 30)
4. Valve guide may require trimming so top of valve guide is even with cylinder head boss. Ream valve guide to specification. See «VALVE GUIDE INSTALLATION SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table.
5. On thick wall valve guides, lubricate valve guide with engine oil Install valve guide until valve guide protrusion above cylinder head is within specification. Ream valve guide to specification. (Scheme 30) See «VALVE GUIDE INSTALLATION SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table.

VALVE GUIDE INSTALLATION SPECIFICATIONS

Scheme 30

Scheme 31

Scheme 32

1. On cylinder heads containing integral valve seats, valve seats may be ground only once. Replace integral valve seats that have been ground with service valve seats.
2. Reground integral valve seats should be identified by a single "X" stamped on side of cylinder head. (Scheme 31) Cylinder head should be stamped "XX" if service valve seats have been installed. (Scheme 31) CAUTION: On integral valve seats, install service valve seats if material removed from cylinder head is.010" (.25 mm) or more.
3. To determine if cylinder head has been resurfaced before determining valve grind depth, inspect lower right rear corner of cylinder head (just above deck surface), for marking indicating amount of material removed. Marking should be on exhaust manifold side of cylinder head.
4. If no marking exists, measure cylinder head height from deck surface to rocker cover surface. If cylinder head height is 3.730" (94.75 mm) or greater, valve seats can be reground if not previously done.
5. On integral valve seats only, check valve grind depth. Install resurfaced valve in original location of cylinder head. Using dial indicator, measure distance from cylinder head surface to face of valve. (Scheme 32) Record this depth measurement as "A".
6. Grind valve seats at proper angle to remove scores and scratches. See «CYLINDER HEAD»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS. Install valve in proper location after grinding valve seat.
7. Measure valve depth again and record it as measurement "B". To determine valve grind depth, subtract measurement "A" from "B". Service valve seats should be installed if valve grind depth exceeds.010" (.25 mm).
8. Mark cylinder head after grinding valve seats. (Scheme 31) On integral valve seats and service valve seats, install valves in original location. Measure valve depth again. Replace valve if valve depth is not.039-.060" (.99-1.52 mm).
9. Lap each valve and measure valve seat width. Valve seat must be ground if valve seat width is not within specification. See «CYLINDER HEAD»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS. Valve Seat Replacement
10. Ensure valve guide I.D. is within specification. See «CYLINDER HEAD»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS. Defective valve guides must be replaced before replacing valve seats. Valve seat must be machined to specification for service valve seat installation. (Scheme 33)
11. Press service valve seats into cylinder head. Stake valve seats in position. Grind valve seats at proper angle. See «CYLINDER HEAD»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS. Install valve in proper location.
12. Using dial indicator, measure distance from cylinder head surface to face of valve to determine valve depth. Replace valve if valve depth is not.039-.060" (.99-1.52 mm).
13. Lap each valve. Measure valve seat width. Valve seat must be ground if valve seat width is not within specification. See «CYLINDER HEAD»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS.

Scheme 33

Valves

Ensure valve stem diameter and margin are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. When installing valves, NEW valve spring keepers must be used. DO NOT reuse valve spring keepers.

Valve Seat Correction Angles

Use 15-degree stone to grind upper area of valve seat and 60-degree stone to grind lower area of valve seat.

Rocker Levers

1. To disassemble, remove rings from ends of rocker lever assembly. Remove thrust washers. Mark component location for reassembly reference.
2. Remove rocker levers. DO NOT remove rocker lever shaft from pedestal. Rocker lever shaft and pedestal are serviced as an assembly. Remove adjusting screw and lock nut from rocker lever.
3. Inspect components for damage or wear. Ensure adjusting screw rotates freely in rocker lever. Measure rocker lever bore I.D. and rocker lever shaft O.D. Replace components if not within specification. See «ROCKER LEVER SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table.
4. To reassemble, coat components with engine oil and reverse disassembly procedure. Ensure components are installed in original location. (Scheme 34)

ROCKER LEVER SPECIFICATIONS

Scheme 34

Tappets

Inspect tappets for wear in camshaft contact area. Measure tappet stem O.D. at top and bottom of stem. Replace tappet if O.D. is not within specification. Ensure cylinder block tappet bore is within specification. See TAPPETS table under ENGINE SPECIFICATIONS.

CYLINDER BLOCK ASSEMBLY

Piston & Rod Assembly

1. Measure piston pin bore on the piston. Replace piston if bore exceeds specification. See «PISTONS, PINS & RINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS.
2. Measure piston pin outside diameter. Replace piston pin if outside diameter is not within specification. See «PISTONS, PINS & RINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS.
3. Install NEW No. 2 compression ring in middle ring groove of piston. Using feeler gauge, measure side clearance between compression ring and groove of piston. Replace piston if clearance exceeds.006" (.15 mm).
4. Install NEW No. 3 oil ring in lower ring groove of piston. Using feeler gauge, measure clearance between oil ring and groove of piston. Replace piston if clearance exceeds.005" (.13 mm).
5. If replacement piston is used, it must be the same piston grade as original piston. For information on piston grades, see PISTON GRADING.
6. Piston must be installed on connecting rod with arrow and connecting rod number properly located. (Scheme 35) Piston and connecting rod assembly must be installed in original cylinder, with arrow on top of piston toward front of engine.

Scheme 35

Fitting Pistons

Measure piston diameter at .50" (12.7 mm) from bottom of piston skirt at 90-degree angle to piston pin. Replace piston if diameter is not within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. If replacing piston, ensure piston is the same piston grade as original piston. For information on piston grades, see PISTON GRADING.

Piston Grading

1. Piston grading procedure must be performed on each cylinder if cylinder block, connecting rod, or crankshaft is replaced, or cylinder block is resurfaced. Piston grading procedure can be performed using any one of the original piston and connecting rod assemblies. Piston grading procedure must be performed on each cylinder using same piston and connecting rod assembly.
2. Remove piston rings from any original piston. Install piston and connecting rod assembly in cylinder No. 1 on cylinder block. Ensure arrow on top of piston is toward front of engine.
3. Install rod bearings in connecting rod and connecting rod cap. Lubricate rod bearings with engine oil. Install connecting rod cap on connecting rod. Ensure 4-digit number on connecting rod cap and connecting rod match. Install with numbers toward oil cooler side of engine. (Scheme 35)
4. Lubricate connecting rod bolt threads and head of bolts with engine oil. Install and tighten connecting rod bolts to 26 ft. lbs. (35 N.m).
5. Install dial indicator on deck surface of cylinder block with tip of dial indicator resting on deck surface. Ensure no burrs exist between dial indicator and deck surface. Burrs may be removed with fine grit stone (if necessary).
6. Zero dial indicator. Move dial indicator directly over the piston so tip of dial indicator will contact the outer area on top of piston. Ensure no side-to-side movement exists on dial indicator.
7. Rotate crankshaft until piston is at TDC. Rotate crankshaft clockwise and counterclockwise to obtain the highest dial indicator reading. This is the piston protrusion. Record piston protrusion for later use.
8. Remove dial indicator. Remove piston and connecting rod assembly. Repeat procedure on each cylinder using the same piston and connecting rod assembly. Record piston protrusion on each cylinder for later use.
9. Piston grades are determined by distance from top of piston pin opening to top of piston (dimension "A"). (Scheme 36) Piston grade is indicated by 4-digits stamped on top of piston. (Scheme 36) See «PISTON GRADE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table for dimension "A", piston grade number and piston grade letter. PISTON GRADE SPECIFICATIONS Dimension A In. (mm) Piston Grade Number Piston Grade Letter A/T 2.029-2.031 (51.54-51.59) 2571 A 2.033-2.035 (51.64-51.69) 2572 B 2.037-2.039 (51.74-51.80) 2573 C M/T 2.029-2.031 (51.54-51.59) 6631 A 2.033-2.035 (51.64-51.69) 6632 B 2.037-2.039 (51.74-51.80) 6633 C
10. Note piston grade number stamped on top of piston used for checking piston grading. This piston may be referred to as the measuring piston. If piston grade number cannot be read, it may be necessary to measure dimension "A" to determine piston grade. (Scheme 36) See «PISTON GRADE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table.
11. Using piston grade number and piston protrusion for each cylinder, determine replacement piston grade. See «PISTON GRADE APPLICATION»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table. For example: if measuring piston used for checking piston grading was 2571 and piston protrusion was.024" (.61 mm), use a replacement piston with a grade number of 2571 or letter "A".

Note. Piston grade number can be cross-referenced by parts department to determine the replacement piston.

PISTON GRADE APPLICATION

Scheme 36

Piston Rings

1. Ensure piston ring end gap and side clearance are within specification. See «PISTONS, PINS & RINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS.
2. Install piston rings with identification mark toward top of piston and piston rings properly positioned. (Scheme 37) Ensure expander in oil ring is installed with ends of expander opposite ends of oil ring.

Scheme 37

Rod Bearings

1. Before installing rod bearings, lubricate connecting rod bolt threads and head of bolts with engine oil. Install rod bearings. Install connecting rod and piston in cylinder block so arrow on top of piston is toward front of engine. (Scheme 35) CAUTION: Ensure 4-digit number on connecting rod cap and connecting rod match. Install with numbers toward oil cooler side of engine. (Scheme 35)
2. Install and tighten connecting rod bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
3. Ensure connecting rod bearing oil clearance and side play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) and «CONNECTING RODS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) tables under ENGINE SPECIFICATIONS.

Crankshaft & Main Bearings

1. Ensure main bearing caps are numbered for location before removing. Ensure main bearing and connecting rod journal diameters are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS. CAUTION: If replacement crankshaft or connecting rods are used, proper piston grade must be installed. For information on piston grades, see PISTON GRADING. CAUTION: Before installing upper main bearings in cylinder block, ensure piston cooling nozzle is installed in bore of cylinder block, next to upper main bearing oil supply passage. No. 1 main bearing does not contain a piston cooling nozzle.
2. Install all main bearings. Ensure dowel rings are installed in main bearing caps before installing. Ensure number on main bearing cap faces oil cooler side of engine. Ensure No. 1 main bearing cap is at front of crankshaft, and No. 7 is at flywheel/flexplate end of engine.
3. Lubricate main bearing cap bolt threads and underside of bolt head with engine oil. Install and tighten main bearing cap bolts to specification using 3 steps. (Scheme 38) See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
4. Ensure main bearing oil clearance and crankshaft end play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS.

Scheme 38

Cylinder Block Tappet Bores

Ensure tappet bore diameter does not exceed specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS.

Cylinder Block Deck Surface

1. Using feeler gauge and straightedge, inspect deck surface for warpage. Cylinder block must be resurfaced if warpage exceeds specification. See «CYLINDER BLOCK»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS. CAUTION: If replacement cylinder block is used or cylinder block is resurfaced, proper piston grade must be installed. For information on piston grades, see PISTON GRADING.
2. Check upper right corner of cylinder block for resurfacing mark. (Scheme 18) If no mark exists, cylinder block deck surface has not been resurfaced. Cylinder block deck surface can only be resurfaced twice: once at.0098" (.250 mm), and then again at an additional.0098" (.250 mm) for total limit of.0197" (.500 mm).
3. An "X" mark indicates cylinder block deck surface was resurfaced once at.0098" (.250 mm), while "XX" mark indicates cylinder block deck surface was resurfaced to total of.0197" (.500 mm). Mark cylinder block if deck surface is resurfaced.

Cylinder Block Bore

1. Measure cylinder bore diameter at 1" (25 mm) and 4.5" (114 mm) below top of cylinder block. Bore cylinder block if diameter, out-of-round or taper exceeds specification. See «CYLINDER BLOCK»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table under ENGINE SPECIFICATIONS.
2. Cylinder block can be bored twice for oversized pistons and rings. Oversized pistons and rings are available in .0197" (.500 mm) and .0393" (.998 mm) sizes.
3. If more than .0393" (.998 mm) oversize bore is required, cylinder block can be bored to 4.1142-4.1148" (104.500-104.515 mm) for a repair sleeve which restores bore to standard dimensions.

Cylinder Block Camshaft Bearings

1. Camshaft bearing is used only on front camshaft journal and is replaceable. All other camshaft journal bores in cylinder block should have same I.D. as front camshaft bearing.
2. If remaining bores exceed specification, machine camshaft bores to accommodate service bearings. Inspect camshaft bearings. See «CAMSHAFT BEARINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__camshaft-bearings) .

TURBOCHARGER ASSEMBLY

Note. Turbocharger assembly should only be serviced by authorized facility.

ENGINE LUBRICATION SYSTEM

Gerotor type oil pump provides pressurized lubrication through a cross passage to main passage, and then to overhead, camshaft and crankshaft. Oil passes around cylinder head bolts, into passages of rocker lever pedestals and out to rocker levers. Piston cooling nozzles are located in cylinder block main bearing saddles, except for No. 1 main bearing. (Scheme 39)

No piston cooling nozzle is used on No. 1 main bearing saddle. Oil for cylinder No. 1 piston is received from No. 2 main bearing saddle, and oil for No. 2 piston is supplied from No. 3 bearing saddle, etc. Oil cooler housing contains oil pressure regulator valve and oil filter by-pass valve. When oil pressure from oil pump exceeds 65 psi (4.6 kg/cm 2 ), oil pressure regulator valve opens, allowing oil to return to the oil pan. Oil filter by-pass valve will open if oil filter becomes restricted, allowing oil to flow to engine components. Oil filter by-pass valve is located on rear side of oil cooler housing.

Scheme 39

Crankcase Capacity

Oil capacity is approximately 11 qts. (10.4L) with oil filter.

Oil Pressure

Minimum oil pressure is 10 psi (.7 kg/cm 2 ) at idle, and 30 psi (2.1 kg/cm 2 ) at 2500 RPM.

PISTON COOLING NOZZLES

Note. No. 1 main bearing does not contain a piston cooling nozzle.

1. Remove crankshaft and upper main bearings. Using 3/16" pin punch, remove piston cooling nozzle from cylinder block. CAUTION: Use only hand force to install piston cooling nozzles. DO NOT use hammer, or piston cooling nozzle will be damaged.
2. Inspect piston cooling nozzles for damaged spray tip or cracks. To install, use pin punch and install piston cooling nozzle until it is even with, or slightly below, main bearing saddle surface.

Removal & Disassembly

1. Remove front timing gear cover. See «FRONT TIMING GEAR COVER & CRANKSHAFT FRONT SEAL»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__front-timing-gear-cover-crankshaft). Remove oil pump bolts and oil pump. (Scheme 39)
2. Remove rear sealing plate from rear of oil pump. Mark top of gerotors for reassembly reference. Remove outer gerotor from oil pump housing.

1. Inspect components for damage or excessive wear. Install outer gerotor in oil pump housing in original direction of installation with chamfered side of outer gerotor facing downward, toward oil pump housing.
2. Using feeler gauge, measure gerotor tip clearance between tip on inner gerotor and tip on outer gerotor. Replace oil pump if gerotor tip clearance exceeds specification. See «OIL PUMP SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table.
3. Place straightedge on oil pump housing, above inner and outer gerotors. Using feeler gauge, measure gerotor-to-sealing plate clearance between gerotors and straightedge. Replace oil pump if gerotor tip clearance exceeds specification. See «OIL PUMP SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table.
4. Using feeler gauge, measure outer gerotor-to oil pump housing clearance. Replace oil pump if gerotor tip clearance exceeds specification. See «OIL PUMP SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table.
5. Measure backlash between gears on oil pump. Replace oil pump if gerotor tip clearance exceeds specification. See «OIL PUMP SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) table.

OIL PUMP SPECIFICATIONS

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure outer gerotor is installed in original location with chamfered side of gerotor facing downward, toward oil pump housing. CAUTION: Ensure outer gerotor is installed with chamfered side toward oil pump housing, away from rear sealing plate surface.
2. Lubricate oil pump with engine oil. Install oil pump on cylinder block. CAUTION: Ensure idler gear locating pin is aligned with cylinder block during installation. When oil pump is correctly installed, flange on oil pump will not contact cylinder block, as rear sealing plate contacts bottom of bore in cylinder block.
3. Install and tighten oil pump bolts to specification in sequence. (Scheme 40) See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d).
4. Using dial indicator, check gear backlash on both gears. Ensure adjoining gear does not rotate while measuring gear backlash. Gear backlash must be within specification. (Scheme 40) If gear backlash exceeds specification, replace oil pump. Install remaining components.

Scheme 40

Drain cooling system. Remove oil filter. Disconnect turbocharger oil supply line. Remove bolts, oil cooler housing, gaskets and oil cooler element. (Scheme 39)

Testing

1. Plug outlet fitting of oil cooler element. Install air hose fitting in inlet fitting. Install pressure regulator and air hose. Apply 70 psi (4.9 kg/cm 2 ) air pressure to oil cooler element. Submerge oil cooler element in container of water.
2. Check for air bubbles, indicating leak exists. Turn off air pressure and remove test equipment. Replace oil cooler element if leaks exist.

1. To install, reverse removal procedure. Use NEW gaskets. Install and tighten oil cooler housing bolts and turbocharger oil supply line to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d) . CAUTION: DO NOT refill cooling system with engine running. If engine is running when filling cooling system, water pressure will hold one-way check valve closed, not allowing air to bleed from cooling system. See «COOLING SYSTEM BLEEDING»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#59l-6-cyl-12v-diesel-engine-code-d__cooling-system-bleeding) in REMOVAL & INSTALLATION for additional information on one-way check valve.
2. Fill oil filter with oil before installing. Fill cooling system with engine not running.

Remove oil pressure regulator valve plug, sealing washer, spring and oil pressure regulator valve from oil cooler housing. (Scheme 39)

1. Inspect oil pressure regulator valve for scoring or wear. Ensure valve moves freely in bore of oil cooler housing.
2. Check free length of spring for oil pressure regulator valve. Replace spring if free length is not 2.60" (66.0 mm).
3. Using spring tension tester, check tension on spring for oil pressure regulator valve. Replace spring if tension is not 28.4 lbs. at 1.62" (12.9 kg at 41.1 mm).

To install, reverse removal procedure. Use NEW sealing washer. Tighten oil pressure regulator valve plug to specification. See TORQUE SPECIFICATIONS .

Remove oil cooler housing. See OIL COOLER . Remove oil filter by-pass valve from rear of oil cooler housing. To install, drive NEW oil filter by-pass valve into oil cooler housing until valve bottoms in bore on oil cooler housing. Install oil cooler housing.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS SPECIFICATION

CONNECTING RODS

PISTONS, PISTON PINS & PISTON RINGS SPECIFICATION

PISTONS, PINS & RINGS

CYLINDER BLOCK SPECIFICATION

CYLINDER BLOCK

ENGINE VALVES & VALVE SPRINGS SPECIFICATION

VALVES & VALVE SPRINGS

CYLINDER HEAD SPECIFICATION

CYLINDER HEAD

CAMSHAFT SPECIFICATION

CAMSHAFT

TAPPETS SPECIFICATION

TAPPETS

See also:
• ENGINE OVERHAUL PROCEDURES
• COMPUTER RELEARN PROCEDURES - CHRYSLER CORP.
• TROUBLE SHOOTING - BASIC PROCEDURES
• VALVE ADJUSTING SEQUENCE
• FINAL REASSEMBLY
• COOLING SYSTEM BLEEDING
• FUEL LINE BLEEDING
• FUEL INJECTOR
• CYLINDER BLOCK ASSEMBLY
• VALVE CLEARANCE ADJUSTMENT
• FRONT TIMING GEAR COVER & CRANKSHAFT FRONT SEAL
• TAPPETS
• CAMSHAFT BEARINGS
• FUEL INJECTION PUMP
• THROTTLE POSITION (TP) SENSOR
• CYLINDER BLOCK