1993 DODGE TRUCK Service Repair Manual

9
- 92 5.9L
ENGINE

•

Fig.
11 Camshaft
Bearings
Removal
and
Installation
with Tool
C-3132-A
shoe lock and by reversing removal procedure, care­
fully drive bearing shell into place. (3) Install remaining bearings in the same man­
ner. Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the main bearing. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft. Be sure this plug does not leak.
INSTALLATION (1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2 inches) of its final position in cylinder block.
Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1
pint of Mopar Crankcase Conditioner, or equiv­ alent. The oil mixture should be left in engine
for a minimum of 805 km (500 miles). Drain at
the next normal oil change.

(2)
Install Camshaft Gear Installer Tool C-3509
with tongue back of distributor drive gear (Fig. 12).

Fig.
12 Camshaft
Holding
Tool C-3509 (Installed
Position)

(3) Hold tool in position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block. Tool should remain
installed until the camshaft and crankshaft sprockets and timing chain have been installed. (4) Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower right hole in thrust
plate. Tighten bolts to 24 N-m (210 in. lbs.) torque.
Top edge of tab should be flat against thrust plate in
order to catch oil for chain lubrication.
(5) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores. (6) Place timing chain around both sprockets.
(7) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam­ shaft sprocket. (8) Lift sprockets and chain (keep sprockets tight
against the chain in position as described). (9) Slide both sprockets evenly over their respec­
tive shafts and use a straightedge to check alignment of timing marks (Fig. 13).

Fig.
13
Alignment
of Timing Marks
(10) Install the camshaft bolt/cup washer. Tighten
bolt to 68 N-m (50 ft. lbs.) torque.
(11) Measure camshaft end play. Refer to Specifi­
cations for proper clearance. If not within limits, in­ stall a new thrust plate.
(12) Each tappet reused must be installed in the
same position from which it was removed. When
camshaft is replaced, all of the tappets must be
replaced.

DISTRIBUTOR

REMOVAL Refer to Group 8D, Ignition Systems for the proper
procedure.
REMOVAL-DRIVE SHAFT BUSHING (1) Insert Distributor Drive Shaft Bushing Puller
Tool C-3052 into old bushing and thread down until a tight fit is obtained (Fig. 14).
(2) Hold puller screw and tighten puller nut until
bushing is removed.
INSTALLATION-DRIVE SHAFT BUSHING (1) Slide new bushing over burnishing end of Dis­
tributor Drive Shaft Bushing Driver/Burnisher Tool
C-3053.
Insert the tool and bushing into the bore.

•

5.9L
ENGINE
9 - 93

Fig.
14
Removing
Distributor Driveshaft
Bushing
(2) Drive bushing and tool into position, using a
hammer (Fig. 15).
Fig.
15 Distributor Driveshaft
Bushing
Installation

(3) As the burnisher is pulled through the bushing,
the bushing is expanded tight in the block and bur­ nished to correct size (Fig. 16). DO NOT ream this
bushing.

Fig.
16
Burnishing
Distributor Driveshaft
Bushing
DISTRIBUTOR
TIMING
Before installing the distributor and oil pump drive
shaft, time engine as follows: (1) Rotate crankshaft until No.l cylinder is at top
dead center on the firing stroke. (2) When in this position, the timing mark on vi­
bration damper should be under "0" on the timing in­ dicator.
(3) Coat shaft and drive gear with engine oil. In­
stall the shaft so that after the gear spirals into
place, it will index with the oil pump shaft. The slot
Fig.
17 Position of Installed Distributor Drive Gear
on top of drive gear should be aligned towards left
front intake manifold attaching bolt hole (Fig. 17).

INSTALLATION
Refer to Group 8D, Ignition Systems for the proper
procedure.

OIL
PAN

REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil. (5) Remove exhaust pipe.
(6) Remove left engine to transmission strut.
(7) Remove oil pan and one-piece gasket.

CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove. DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the en­

gine.
Clean oil pan in solvent and wipe dry with a clean
cloth. Clean oil screen and pipe thoroughly in clean sol­
vent. Inspect condition of screen.

INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor­
tion. Straighten flange, if necessary.

INSTALLATION
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier in­stallation and removal with a screwdriver (Fig. 1).
(2) Install the dowels in the cylinder block (Fig. 2). (3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the corner of the cap and the cylinder block.

-17
" x
5/16" BOLT
DOWEL
E
SLOT J9209-106
Fig. 1 Fabrication of Alignment Dowels

DOWEL
^^^^
DOWEL

J9309-79
F/g.
2 Position of Dowels in Cylinder
Block

(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24
N*m (215 in. lbs.) torque.
(7) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 Nmi (215 in. lbs.) torque.
(8) Install the drain plug. Tighten drain plug to 34
N-m (25 ft. lbs.) torque. (9) Install the engine to transmission strut.
(10) Install exhaust pipe.
(11) Lower vehicle.
(11) Install dipstick.
(12) Connect the negative cable to the battery.
(13) Fill crankcase with oil to proper level.
OIL
PU1P
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from rear main bearing

cap.
DISASSEMBLE
(1) Remove the relief valve as follows: (a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole into the relief valve retainer cap and in­
sert a self-threading sheet metal screw.
(b) Clamp screw into a vise and while supporting
oil pump, remove cap by tapping pump body using a soft hammer. Discard retainer cap and remove spring and relief valve (Fig. 3).
OIL PUMP ASSEMBLY

SPRING
COTTER
PIN

RELIEF VALVE

'
RETAINER CAP RH174
Fig.
3 Oil
Pressure
Relief
Valve
(2) Remove oil pump cover (Fig. 4).
(3) Discard oil seal ring.
(4) Remove pump rotors and shaft (Fig. 4).
(5) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.

INNER ROTOR AND SHAFT DISTRIBUTOR DRIVESHAFT

BODY
(REFERENCE) COTTER
PIN

LARGE
CHAMFERED

EDGE
SPRING
RETAINER

CAP
RY10B

Fig.
4 Oil
Pump

INSPECTION
Mating surface of the oil pump cover should be
smooth. Replace pump assembly If cover is scratched
or grooved.

•
5.9L
ENGINE
9 - 95 Lay a straightedge across the pump cover surface
(Fig. 5). If a 0.038 mm (0.0015 inch) feeler gauge can
be inserted between cover and straightedge, pump assembly should be replaced.
Fig.
5
Checking
Oil
Pump
Cover
Flatness
Measure thickness and diameter of OUTER rotor.
If outer rotor thickness measures 20.9 mm (0.825
inch) or less or if the diameter is 62.7 mm (2.469 inches) or less, replace outer rotor (Fig. 6).
Fig.
6
Measuring
Outer Rotor
Thickness

If inner rotor measures 20.9 mm (0.825 inch) or

less,
replace inner rotor and shaft assembly (Fig. 7).
Fig.
7
Measuring
Inner
Rotor
Thickness
Slide outer rotor into pump body. Press rotor to the
side with your fingers and measure clearance be­
tween rotor and pump body (Fig. 8). If clearance is 0.356 mm (0.014 inch) or more, replace oil pump as­
sembly.
Fig.
8
Measuring
Outer Rotor Clearance in
Housing

Install inner rotor and shaft into pump body. If
clearance between inner and outer rotors is 0.203
mm (0.008 inch) or more, replace shaft and both ro­
tors (Fig. 9).
OUTER

ROTOR

INNER

ROTOR

RH179
Fig.
9
Measuring
Clearance Between
Rotors

Place a straightedge across the face of the pump,
between bolt holes. If a feeler gauge of 0.102 mm (0.004 inch) or more can be inserted between rotors
and the straightedge, replace pump assembly (Fig.

10).
Inspect oil pressure relief valve plunger for scoring
and free operation in its bore. Small marks may be
removed with 400-grit wet or dry sandpaper.
The relief valve spring has a free length of approx­
imately 49.5 mm (1.95 inches). The spring should
test between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 inches). Replace spring that fails
to meet these specifications (Fig. 11).
If oil pressure was low and pump is within specifi­
cations, inspect for worn engine bearings or other
reasons for oil pressure loss.

9
- 96 5.9L
ENGINE

•

Fig.
11 Proper installation of Retainer Cap
ASSEMBLE

(1)
Install pump rotors and shaft, using new parts
as required.

(2)
Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N-m (95 in. lbs.) torque.

(3)
Install the relief valve and spring. Insert the
cotter pin.
(4)
Tap on a new retainer cap.

(5)
Prime oil pump before installation by filling ro­
tor cavity with engine oil.

INSTALLATION
(1) Install oil pump. During installation slowly ro­
tate pump body to ensure driveshaft-to-pump rotor shaft engagement.

(2)
Hold the oil pump base flush against mating
surface on No.4 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41 N-m (30 ft. lbs.) torque.
(3)
Install the oil pan.

PISTON
/
CONNECTING ROD ASSEMBLY
The pistons are elliptically turned so that the di­
ameter at the pin boss Is less than its diameter
across the thrust face. This allows for expansion un­
der normal operating conditions. Under operating temperatures, expansion forces the pin bosses away
from each other, causing the piston to assume a more
nearly round shape.
All pistons are machined to the same weight, re­
gardless of size, to maintain piston balance.
The piston pin rotates in the piston only and is re­
tained by the press interference fit of the piston pin in the connecting rod.

REMOVAL
(1) Remove the engine from the vehicle.
(2) Remove the cylinder head.
(3) Remove the oil pan.

(4)
Remove top ridge of cylinder bores with are li­
able ridge reamer before removing pistons from cyl­
inder block. Be sure to keep tops of pistons covered
during this operation.

(5)
Be sure the connecting rod and connecting rod
cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts. (6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston and connecting rod assemblies from the engine, ro­
tate crankshaft so that the connecting rod is centered in cylinder bore and at BDC. Be careful not to nick crankshaft journals. (7) After removal, install bearing cap on the mat­
ing rod.
INSPECTION Check the crankshaft connecting rod journal for ex­
cessive wear, taper and scoring. Check the cylinder block bore for out-of-round,
taper, scoring and scuffing. Check the pistons for taper and elliptical shape be­
fore they are fitted into the cylinder bore (Fig. 12).
FITTING PISTONS Piston and cylinder wall must be clean and dry.
Specified clearance between the piston and the cylin­
der wall is 0.013-0.038 mm
(0.0005-0.0015
inch).
Piston diameter should be measured at the top of
skirt, 90° to piston pin axis. Cylinder bores should be
measured halfway down the cylinder bore and trans­
verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21°C (70°F).
FITTING RINGS (1) Measurement of end gaps:
(a) Measure piston ring gap 2 inches from bot­
tom of cylinder bore. An inverted piston can be used to push the rings down to ensure positioning
rings squarely in the cylinder bore before measur­ ing.
(b) Insert feeler stock in the gap. The compres­
sion ring gap should be between
0.254-0.508
mm

•

5.9L
ENGINE
9 - 97

DIAMETER
(D)
SHOULD
BE

0.0000-0.0152
mm

(0.0000-0.0006
in.
LARGER
THAN
(C)
98.704-98.831
mm

(3.886-3.891
in.]
FEELER
GAUGE

H-c -#-D

ELLIPTICAL
SHAPE
OF
THE
PISTON

SKIRT
SHOULD
BE
0.254-0.304
mm

(0.010-0.012
in.)
LESS AT
DIAMETER
(A)
THAN
ACROSS
THE
THRUST
FACES
AT
DIAMETER
(B).

J9309-9

Fig.
12
Piston
Measurements (0.010-0.020 inch). The second compression ring
gap should be between 0.508-0.762 mm (0.020-
0.030 inch). The oil ring gap should be 0.254-1.270
mm (0.010-0.050 inch).
(c) Rings with insufficient end gap may be prop­
erly filled to the correct dimension. Rings with ex­
cess gaps should not be used.
(2) Install rings and confirm ring side clearance: (a) Install oil rings being careful not to nick or
scratch the piston.
(b) Install the compression rings using Installa­
tion Tool C-4184. The top compression may be in­ stalled with either side up. The second compression
ring must be installed with the identification mark
face up (toward top of piston) and the chamfer should face down. An identification mark on the
ring is a drill point, a stamped letter "O", an oval depression or the word TOP.
(c) Measure side clearance between piston ring
and ring land (Fig. 13). Clearance should be 0.038-
0.076 mm (0.0015-0.0030 inch) for the compression

rings.
The steel rail oil ring should be free in groove, but should not exceed 0.203 mm (0.0080
inch) side clearance. (d) Pistons with insufficient or excessive side
clearance should be replaced. (3) Arrange ring gaps 90° apart as shown in Fig.

14.

CONNECTING ROD BEARINGS Fit all rods on a bank until completed. DO NOT al­
ternate from one bank to another, because connect­ ing rods and pistons are not interchangeable from
one bank to another.
GROOVE

J9209-136

Fig.
13
Measuring
Piston
Ring
Side
Clearance
OIL
RING

SPACER
GAP
TOP
COMPRESSION
RING
GAP
SECOND
COMPRESSION

RING
GAP

OIL
RING
RAIL
GAP (TOP) OIL
RING
RAIL

GAP
(BOTTOM)
J9309-80

Fig.
14 Proper
Ring
Installation

The bearing caps are not interchangeable and
should be marked at removal to ensure correct as­ sembly.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing
shell, make certain that the V-groove in the shell is
in line with the V-groove in the cap. This provides
lubrication of the cylinder wall in the opposite bank.
The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and
caps.

Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 inch). Bearings are available in 0.025 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under­
size.
Install the bearings in pairs. DO NOT use a
new bearing half with an old bearing
half.
DO
NOT file the rods or bearing caps.
INSTALLATION (1) Be sure that compression ring gaps are stag­
gered so that neither is in line with oil ring rail gap.

(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 14).
(3) Immerse the piston head and rings in clean en­
gine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench (part of Tool C-385). Be
sure position
of
rings does

not change
during this operation.

(4) Install connecting rod bolt protectors on rod

bolts,
the long protector should be installed on the numbered side of the connecting rod. (5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal. (7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer of the connecting rod bore must be Installed toward
crankshaft journal fillet.
(8) Install rod caps. Install nuts on cleaned and
oiled rod bolts and tighten nuts to 61 N*m (45 ft. lbs.)
torque. (9) Install the oil pan.
(10) Install the cylinder head.
(11) Install the engine Into the vehicle.

CRANKSHAFT
A crankshaft which has undersize journals will be
stamped with 1/4 inch letters on the milled flat on
the No.3 crankshaft counterweight (Fig. 15). FOR EXAMPLE: R2 stamped on the No.3 crank­
shaft counterweight indicates that the No.2 rod jour­
nal is 0.025 mm (0.001 in) undersize. M4 indicates
that the No.4 main journal is 0.025 mm (0.001 in) undersize. R3 M2 indicates that the No.3 rod journal
and the No.2 main journal are 0.025 mm (0.001 In)
undersize. When a crankshaft is replaced, all main and con­
necting rod bearings should be replaced with new
bearings. Therefore, selective fitting of the bearings is not required when a crankshaft and bearings are
replaced.

REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap.
(3) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time. (4) Lift the crankshaft out of the block.
(5) Remove and discard the crankshaft rear oil

seals.
(6) Remove and discard the front crankshaft oil
seal. Undersize Journal
Identification
Stamp

0.025
mm
(0.001
inch) (Rod)

0.025
mm
(0.001
inch) (Main)
R1-R2-R3
or R4

M1-AA2-M3-AA4
or AA5
V/
LETTERS—/R-l-2>
(ROD)
VM-WHMAIN)

J9309-52

Fig.
15 Location of Crankshaft
identification

INSPECTION
OF
JOURNALS
The crankshaft connecting rod and main journals
should be checked for excessive wear, taper and scor­
ing. The maximum taper or out-of-round on any
crankshaft journal is 0.025 mm (0.001 inch).
Journal grinding should not exceed 0.305 mm
(0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.3 main bearing. DO
NOT nick crank pin or bearing fillets. After grind­ ing, remove rough edges from crankshaft oil holes
and clean out all oil passages.

CAUTION:
After any journal
grind,
it is important

that
the
final
paper or cloth
polish
be in the
same
direction as the engine rotates.

INSTALLATION
(1) Lightly oil the new upper seal lips with engine

oil.
(2) Install the new upper rear bearing oil seal with
the yellow paint facing towards the rear of the en­
gine.

(3) Position the crankshaft into the cylinder block.
(4) Lightly oil the new lower seal lips with engine

oil.
(5) Install the new lower rear bearing oil seal into
the bearing cap with the yellow paint facing towards the rear of the engine. (6) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap (Fig. 16). Do not over apply sealant or allow the seal­
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica­
tion.
(7) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more
than 2 times for proper engagement.
(8) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately

•

5.9L ENGINE
9 - 99

BEARING
CAP
J9309-72

Fig.
16 Sealant Application to Bearing Cap tighten to 115 N-m (85 ft. lbs.) torque.
(9) Install oil pump.
(10) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­
ply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove. (11) Install new front crankshaft oil seal. (12) Immediately install the oil pan.

MOPAR SILICONE SEALANT

RUBBER
ADHESIVE APPLIED
Fig.
17
Apply
Sealant to Bearing Cap to
Block
Joint

CRANKSHAFT
MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly. Upper and lower bearing halves are NOT inter­
changeable. Lower main bearing halves of No.2 and
4 are interchangeable. Upper and lower No.3 bearing halves are flanged
to carry the crankshaft thrust loads. They are NOT interchangeable with any other bearing halves in the
engine (Fig. 18). Bearing shells are available in stan­
dard and the following undersizes: 0.25 mm (0.001

inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch). Never install an undersize bearing that will reduce
clearance below specifications.

Fig.
18 Main Bearing
Identification

REMOVAL (1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap. (3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 19).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.

Fig.
19 Upper Main Bearing
Removal
and
Installation
with
Tool C-3059

INSTALLATION
Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight­ ened. All bearing capbolts removed during service
procedures are to be cleaned and oiled before instal­ lation.