1993 DODGE TRUCK height

•

3.9L
ENGINE
9 - 25
VALVES
/
VALVE
SPRINGS

The valves are arranged in-line and inclined 18°.
The rocker pivot support and the valve guides are cast integral with the heads. This procedure requires the removal of the cylinder
head.

REMOVAL
(1) Remove the cylinder head.
(2) Compress valve springs using Valve Spring
Compressor Tool MD-998772A.
(3) Remove valve retaining locks, valve spring re­
tainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original location.

VALVE
CLEANING
Clean valves thoroughly. Discard burned, warped
and cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
VALVE
INSPECTION
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve. Measure valve stem guide clearance as follows:
(a) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 10). The special sleeve places the valve at the correct height for
checking with a dial indicator.

Fig.
10 Positioning Valve with Tool C-3973
(b) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 11).
(c) Move valve to and from the indicator. The to­
tal dial indicator reading should not exceed 0.432
mm (0.017 inch). Ream the guides for valves with
oversize stems if dial indicator reading is excessive
or if the stems are scuffed or scored.
Service valves with oversize stems are available
(Fig. 12).
Slowly turn reamer by hand and clean guide thor­
oughly before installing new valve. Ream the valve
guides from standard to 0.381 mm (0,015 inch).
Fig.
11 Measuring Valve Guide Wear

Reamer
O/S

Valve
Guide
Size

0.076
mm
8.026
-
8.052
mm

(0.003 in.) (0.316 -0.317 in.)

0.381
mm 8.331 -8.357 mm
(0.015 in.)
(0.328-0.329
in.)
J9309-30

Fig.
12
Reamer
Sizes

Use a 2 step procedure so the valve guides are
reamed true in relation to the valve seat:

•
Step 1-Ream to 0.0763 mm (0.003 inch).

•
Step 2-Ream to 0.381 mm (0.015 inch).

REFACING
VALVES
/
VALVE
SEATS
The intake and exhaust valves have a 43-1/4° to
43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle
(Fig. 13).

VAL¥ES
Inspect the remaining margin after the valves are
refaced (Fig. 14). Valves with less than 1.190 mm (0.047 inch) margin should be discarded.

VALVE
SEATS

CAUTION:
DO NOT
un-shroud
valves
during
valve

seat
refacing (Fig. 15).
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat­ ing stones. A true and complete surface must be ob­
tained.
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 inch) total indicator reading.

A
-
SEAT
WIDTH
-
INTAKE
1.016
-
1.524
mm
(0.040
-
0.060
in.)

EXHAUST
1.524
-
2.032
mm
(0.060
-
0.080
in.)

B
-
FACE
ANGLE
(INTAKE
& EXHAUST)
4374°
-
433A°

C
-
SEAT
ANGLE
(INTAKE
& EXHAUST)
4474°
-
44%°
D
-
CONTACT SURFACE

J9309-95
Fig.
13
Valve
Face and
Seat
Angles
i
INTAKE
VALVE
\
MARGIN
/ "

>FACE'
•STEM"
VALVE SPRING
RETAINER LOCK GROOVE EXHAUST
VALVE
J9209-127

Fig.
14 Intake and
Exhaust
Valves
(3) Inspect
the
valve seat with Prussian blue
to de­

termine where
the
valve contacts
the
seat.
To do

this,
coat valve seat LIGHTLY with Prussian blue
then
set
valve
in
place. Rotate
the
valve with light
pressure.
If the
blue
is
transferred
to the
center
of

valve face, contact
is
satisfactory.
If
the blue
is
trans­
ferred
to the top
edge
of
valve face, lower valve seat
with
a 15°
stone.
If
the blue
is
transferred
to
bottom edge
of
valve face raise valve seat with
a 60°
stone.

(4)
When seat
is
properly positioned
the
width
of

intake seats should
be 1.016-1.524 mm (0.040-0.060

inch).
The
width
of the
exhaust seats should
be 1.524-2.032 mm (0.060-0.080
inch).
Fig.
15 Refacing
Valve
Seats

VALVE
SPRING
INSPECTION
Whenever valves have been removed
for
inspection,
reconditioning
or
replacement, valve springs should
be tested.
As an
example
the
compression length
of

the spring
to be
tested
is 1-5/16
inch. Turn table
of

Valve Spring Tester Tool
C-647
until surface
is in
line with
the 1-5/16
inch mark
on the
threaded stud.
Be sure
the
zero mark
is to the
front (Fig.
16).
Place spring over stud
on the
table
and
lift compressing
le­

ver
to set
tone device. Pull
on
torque wrench until
ping
is
heard. Take reading
on
torque wrench
at
this instant. Multiply this reading
by 2.
This will give
the spring load
at
test length. Fractional measure­ ments
are
indicated
on the
table
for
finer adjust­ments. Refer
to
specifications
to
obtain specified
height
and
allowable tensions. Discard
the
springs
that
do not
meet specifications.
SPECIAL

TOOL
C-647

9209-37
Fig.
16 Testing
Valve
Spring
for
Compressed

Length
with
Tool
C-647

INSTALLATION
(1)
Coat valve stems with lubrication
oil and
insert
them
in
cylinder head.

•
3.9L
ENGINE
9 - 27 (2) If valves or seats are reground, check valve
stem height. If valve is too long, replace cylinder
head.
(3) Install new seals on all valve guides. Install
valve springs and valve retainers.
(4) Compress valve springs with Valve Spring
Compressor Tool MD-998772A, install locks and re­
lease tool. If valves and/or seats are ground, measure
the installed height of springs. Make sure the mea­ surement is taken from bottom of spring seat in cyl­
inder head to the bottom surface of spring retainer. If
spacers are installed, measure from the top of spacer.
If height is greater than 42.86 mm (1-11/16 inches), install a 1.587 mm (1/16 inch) spacer in head coun-
terbore. This should bring spring height back to nor­
mal 41.27 to 42.86 mm (1-5/8 to
1-11/16
inch).

VALVE STEM SEAL
/
SPRING REPLACEMENT
This procedure is done with the cylinder head in­
stalled. (1) Set engine basic timing to TDC and remove air
cleaner. (2) Remove cylinder head covers and spark plugs.
(3) Remove coil wire from distributor and secure to
good ground to prevent engine from starting. (4) Using suitable socket and flex handle at crank­
shaft retaining bolt, turn engine so the No.l piston is
at Top Dead Center on the compression stroke. (5) Remove rocker arms.
(6) With air hose attached to an adapter installed
in No.l spark plug hole, apply 620-689 kPa (90-100
psi) air pressure. (7) Using Valve Spring Compressor Tool
MD-998772A, compress valve spring and remove re­
tainer valve locks and valve spring. (8) Install seals on the exhaust valve stem and po­
sition down against valve guides. (9) The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the valve stem as a guide. DO NOT force seal against
top of guide. When installing the valve retainer
locks,
compress the spring only enough to install the
locks.
(10) Follow the same procedure on the remaining 5
cylinders using the firing sequence
1-6-5-4-3-2.
Make sure piston in cylinder is at TDC on the valve spring
that is being removed. (11) Remove adapter from the No.l spark plug

hole.
(12) Install rocker arms.
(13) Install covers and coil wire to distributor.
(14) Install air cleaner.
(15) Road test vehicle.

HYDRAULIC
TAPPETS
Before disassembling any part of the engine to cor­
rect tappet noise, check the oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at the pressure sending unit. The pressure should be be­
tween 207-552 kPa (30-80 psi) at 3,000 RPM.
Check the oil level after the engine reaches normal
operating temperature. Allow 5 minutes to stabilize
oil level, check dipstick.
The oil level in the pan should never be above the
FULL mark or below the ADD OIL mark on dipstick.
Either of these 2 conditions could be responsible for
noisy tappets.

OIL
LEWEL

HIGH
If oil level is above the FULL mark, it is possible
for the connecting rods to dip into the oil. With the engine running, this condition could create foam in
the oil pan. Foam in oil pan would be fed to the hy­ draulic tappets by the oil pump causing them to lose
length and allow valves to seat noisily.

LOW
Low oil level may allow oil pump to take in air.
When air is fed to the tappets, they lose length
which allows valves to seat noisily. Any leaks on in­
take side of oil pump through which air can be drawn will create the same tappet action. Check the
lubrication system from the intake strainer to the
pump cover, including the relief valve retainer cap.
When tappet noise is due to aeration, it may be in­
termittent or constant, and usually more than 1 tap­
pet will be noisy. When oil level and leaks have been corrected, operate the engine at fast idle. Run engine
for a sufficient time to allow all of the air inside the
tappets to be bled out.

TAPPET
NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate en­
gine at idle with cylinder head covers removed. (2) Feel each valve spring or rocker arm to detect
noisy tappet. The noisy tappet will cause the affected
spring and/or rocker arm to vibrate or feel rough in
operation.
Worn valve guides or cocked springs are some­
times mistaken for noisy tappets. If such is the
case, noise may be dampened by applying side
thrust on the valve spring. If noise is not appre­ ciably reduced, it can be assumed the noise is in
the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear.
(3) Valve tappet noise ranges from light noise to a
heavy click. A light noise is usually caused by exces­ sive leak down around the unit plunger or by the
plunger partially sticking in the tappet body cylin­ der. The tappet should be replaced. A heavy click is
caused by a tappet check valve not seating or by for­
eign particles becoming wedged between the plunger
and the tappet body. This will cause the plunger to
stick in the down position. This heavy click will be

ENGINE SPECIFICATIONS
(CONT.)

Valve
Springs
Free
Length (Approx.)
49.962
mm

(1.967
in)

Spring
Tension @ 41.66 mm = 378 N (Valve Closed) (@ 1.64 in = 85 lbs)

Spring
Tension @ 30.89 mm = 890 N (Valve Open) (@ 1.212 in = 200 lbs)
Number of
Coils
6.8
Installed Height. 41.66 mm
(Spring
Seat to Retainer) (1.64 in)
Wire Diameter 4.50 mm (0.177 in) Valve Timing

Exhaust
Valve

Closes
(ATC) 16°

Opens
(BBC) 52°
Duration
248°

Intake
Valve
Closes
(ABC) 50°

Opens
(BTC) . . 10°
Duration
240°
Valve Overlap 26°

J9309-33

OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
CONDITION

IDENTIFICATION

LOCATION
OF IDENTIFICATION

CRANKSHAFT
JOURNALS
(UNDERSIZE)

0.0254
mm
(0.001
in.)
RorM

M-2-3 etc. (indicating no. 2 and 3 main bearing
journal)

and/or R-l-4 etc. (indicating no. 1 and 4 connecting rod

journal)
Steel stamped (near notch) on no. 6 crankshaft
counterweight.

HYDRAULIC
TAPPETS

(OVERSIZE)

0.2032
mm
(0.008
in.)
Diamond-shaped
stamp

Top
pad -
front
of engine and
flat
ground on outside surface of each O/S
tappet
bore.

VALVE
STEMS
(OVERSIZE)

0.127 mm
(0.005
in.)
X

Milled pad adjacent to two tapped holes
(3/8 in.) on each end of cylinder head.

J9309-81

•
5.2L
ENGINE
I - 55
Fig. 10 Positioning Valve with Tool C-3973 sleeve places the valve at the correct height for
checking with a dial indicator.
(b) Attach Dial Indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being measured (Fig. 11).
Fig. 11 Measuring Valve Guide Wear
(c) Move valve to and from the indicator. The to­
tal dial indicator reading should not exceed
0.432

mm
(0.017
inch). Ream the guides for valves with
oversize stems if dial indicator reading is excessive
or if the stems are scuffed or scored. Service valves with oversize stems are available
(Fig. 12).

Reamer
O/S
Valve
Guide
Size

0.076
mm
8.026
-
8.052
mm

(0.003
in.)
(0.316-0.317in.)

0.381
mm
8.331
-
8.357
mm

(0.015
In.)
(0.328-0.329
In.)

J9309-30

Fig. 12 Reamer Sizes
Slowly turn reamer
by
hand
and
clean guide thor­
oughly before installing
new
valve. Ream
the valve

guides from standard
to 0,381 mm
(0.015 Inch).
Use
a 2
step procedure
so the
valve guides
are

reamed true
in
relation
to the
valve seat:

• Step
1-Ream
to 0.0763 mm (0.003 inch),
• Step 2—Ream, to 0.381 mm (0.015 inch).

REFACING
VAL
WES
/
WAL
WE
SEATS
The intake and exhaust valves have a 43-1/4° to
43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle
(Fig.
13).
CONTACT

A
-
SEAT
WIDTH
-
INTAKE
1.016-1.524
mm
(0.040
-
0.060
in.)
EXHAUST
1.524 -
2.032
mm
(0.060
-
0.080
in.)

B
-
FACE ANGLE (INTAKE
&
EXHAUST)
437.°
-433//

C
-
SEAT ANGLE (INTAKE
&
EXHAUST)
447/ - 447/
D
-
CONTACT SURFACE
J9309-95

Fig. 13 Valve Face and Seat Angles

VALVES
Inspect the remaining margin after the valves are
refaced (Fig. 14). Valves with less than 1.190 mm (0.047 inch) margin should be discarded.

VALVE
SEATS

CAUTION:
DO NOT
un-shroud valves
during
valve

seat
refacing (Fig.
15).
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat­ ing stones. A true and complete surface must be ob­
tained.
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 inch) total indicator reading. (3) Inspect the valve seat with Prussian blue to de­
termine where the valve contacts the seat. To do
this,
coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of

9
- 56 5.2L
ENGINE

•

VALVE
SPRING
RETAINER LOCK GROOVE
EXHAUST

VALVE

J9209-127 the spring load at test length. Fractional measure­
ments are indicated on the table for finer adjust­
ments. Refer to specifications to obtain specified
height and allowable tensions. Discard the springs
that do not meet specifications.
SPECIAL

TOOL
C-647

Fig.
14 Intake and
Exhaust
Valves

Fig.
15 Refacing
Valve
Seats
valve face, contact is satisfactory. If the blue is trans­
ferred to the top edge of valve face, lower valve seat
with a 15° stone. If the blue is transferred to bottom edge of valve face raise valve seat with a 60° stone.
(4) When seat is properly positioned the width of
intake seats should be
1.016-1.524
mm (0.040-0.060

inch).
The width of the exhaust seats should be
1.524-2.032
mm (0.060-0.080 inch).
WALVE SPRING INSPECTION Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested. As an example the compression length of
the spring to be tested is
1-5/16
inch. Turn table of Valve Spring Tester Tool C-647 until surface is in line with the
1-5/16
inch mark on the threaded stud.
Be sure the zero mark is to the front (Fig. 16). Place spring over stud on the table and lift compressing le­
ver to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by 2. This will give ^
9209-37

Fig.
16 Testing
Valve
Spring
for
Compressed
Length
with
Tool
C-647

INSTALLATION
(1) Coat valve stems with lubrication oil and insert
them in cylinder head.
(2) If valves or seats are reground, check valve
stem height. If valve is too long, replace cylinder
head.
(3) Install new seals on all valve guides. Install
valve springs and valve retainers.
(4) Compress valve springs with Valve Spring
Compressor Tool MD-998772A, install locks and re­
lease tool. If valves and/or seats are ground, measure
the installed height of springs. Make sure the mea­ surement is taken from bottom of spring seat in cyl­
inder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer.
If height is greater than 42.86 mm (1-11/16 inches),
install a 1.587 mm (1/16 inch) spacer in head coun-
terbore. This should bring spring height back to nor­ mal 41.27 to 42.86 mm (1-5/8 to
1-11/16
inch).

VALVE STEM SHIELD
/
SPRING REPLACEMENT
# This procedure is done with the cylinder head in­
stalled. (1) Set engine basic timing to Top Dead Center
(TDC) and remove air cleaner. (2) Remove cylinder head covers and spark plugs.
(3) Remove coil wire from distributor and secure to
good ground to prevent engine from starting. (4) Using suitable socket and flex handle at crank­
shaft retaining bolt, turn engine so the No.l piston is
at TDC on the compression stroke. (5) Remove rocker arms.

ENGINE SPECIFICATIONS (CONT,)

Valve Springs Free
Length
(Approx.)
49.962
mm
(1.967
in)

Spring Tension
.
@ 41.66 mm
= 378 N
(Valve
Closed)
(@ 1.64 in . 85 lbs)

Spring Tension
.
@ 30.89 mm
=
890
N (Valve Open) (@
1.212
in =
200
lbs)

Number
of
Coils
............... 6.8
Installed Height
41.66
mm (Spring Seat to Retainer)
(1.64
in)
Wire Diameter .
4.50
mm
(0.177
in)
Valve Timing

Exhaust Valve
Closes
(ATC)
16°

Opens
(BBC)
52° Duration
248°

Intake Valve
Closes
(ABC)
50°

Opens
(BTC)
. 10° Duration .
240°

Valve Overlap ... 26°

J9309-33

OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
CONDITION

IDENTIFICATION

LOCATION
OF
IDENTIFICATION

CRANKSHAFT JOURNALS (UNDERSIZE)

0.0254 mm (0.001
in.) RorM

M-2-3
etc. (indicating no. 2 and 3 main bearing journal)
and/or
R-l-4 etc.
(indicating no.
1
and 4 connecting rod journal) Milled flat on no. 8 crankshaft counterweight.

HYDRAULIC TAPPETS (OVERSIZE)

0.2032
mm
(0.008
in.) •
Diamond-shaped stamp top pad - front of
engine and flat ground on outside surface of
each O/S tappet bore.

VALVE
STEMS
(OVERSIZE)
0.127 mm (0.005
in.) X
Milled pad adjacent to two tapped holes

(3/8
in.) on each end of cylinder head.

J9309-82

•
5.9L
ENGINE
9 - 85 sleeve places the valve at the correct height for
checking with a dial indicator.

Fig.
11
Measuring
Valve
Guide
Wear
(c) Move valve to and from the indicator. The to­
tal dial indicator reading should not exceed 0.432
mm (0.017 inch). Ream the guides for valves with
oversize stems if dial indicator reading is excessive
or if the stems are scuffed or scored. Service valves with oversize stems are available
(Fig. 12).

Reamer O/S Valve Guide Size
0.076
mm
8.026
-
8.052
mm

(0.003
in.)
(0.316-0.317
in.)

0.381
mm
8.331
-
8.357
mm

(0.015
in.)
(0.328-0.329
in.)

J9309-30
Fig.
12
Reamer
Sizes
Slowly turn reamer by hand and clean guide thor­
oughly before installing new valve. Ream the valve
guides from standard to 0.381 mm (0.015 inch).
Use a 2 step procedure so the valve guides are
reamed true in relation to the valve seat:
• Step
1-Ream
to 0.0763 mm (0.003 inch).
• Step 2-Ream to 0.381 mm (0.015 inch).
REFACING VALVES / VALVE SEATS The intake and exhaust valves have a 43-1/4° to
43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle (Fig. 13).

CONTACT

A
-
SEAT
WIDTH
-
INTAKE
1.016-1.524
mm
(0.040
-
0.060
in.)
EXHAUST
1.524 -
2.032
mm
(0.060
-
0.080
in.)

B
-
FACE ANGLE (INTAKE
&
EXHAUST)
4374°-433/4°

C
-
SEAT ANGLE (INTAKE
&
EXHAUST)
447/ - 443A°
D
-
CONTACT SURFACE

J9309-95

Fig.
13
Valve
Face and
Seat
Angles

VALVES
Inspect the remaining margin after the valves are
refaced (Fig. 14). Valves with less than 1.190 mm (0.047 inch) margin should be discarded.

VALVE
SEATS
CAUTION:
DO NOT
un-shroud valves during valve
seat refacing
(Fig. 15).
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat­ ing stones. A true and complete surface must be ob­
tained.
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 inch) total indicator reading.
(3)
Inspect the valve seat with Prussian blue to de­
termine where the valve contacts the seat. To do

this,
coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of