1993 DODGE TRUCK Service Repair Manual

9
- 108 §.9L
(DIESEL) ENGINE

•

J9109-12
Fig.
3
Engine
Front
Mount
INSTALLATION
(1) Install the engine mounting brackets to the
block, if removed (Fig. 3). Tighten the bolts to 60 N-m (44 ft. lbs.) torque. (2) With the engine raised slightly, install the in­
sulators using the locating pin. Tighten the nuts to 109 N-m (80 ft. lbs.) torque.
(3) Install the bracket onto the insulator and
tighten the nut to 109 Nnn (80 ft. lbs.) torque.
(4) Lower engine with lifting fixture while guiding
insulator studs into attaching holes in crossmember and brackets.
(5) Tighten attaching nuts and bolts to specified
torques (Fig. 3).
(6) Lower the vehicle.
(7) Remove lifting fixture.

ENGINE REAR SUPPORT

REMOVAL-2WD
(1) Raise the vehicle on a hoist.
(2) Position a transmission jack under the trans­
mission.
(3) Remove the through-bolt from the transmission
support bracket/insulator (Fig. 4). (4) Raise the transmission SLIGHTLY.
(5) Remove the insulator nuts (Fig. 4).
(6) Remove the transmission blocker bracket nuts
and remove the bracket (Fig. 4). (7) Remove the insulator/crossmember bracket
nuts and remove the bracket (Fig. 4).
INSULATOR

TRANSMISSION
BLOCKER
BRACKET
TRANSMISSION

SUPPORT
BRACKET

INSULATOR/

CROSSMEMBER
BRACKET

CROSSMEMBER
J9109-149

Fig.
4 Rear
Engine
Support—2WD INSTALLA
TION-2WD

(1) Install the insulator/crossmember bracket to
the crossmember. Tighten the nuts to 41 N-m (30 ft. lbs.) torque.
(2) Install the transmission blocker bracket to the
crossmember and the insulator/crossmember bracket (Fig. 4). Tighten the nuts to 41 N-m (30 ft. lbs.)
torque. (3) Install the insulator to the crossmember and
the insulator/crossmember bracket (Fig. 4). Tighten
the nuts to 41 N-m (30 ft. lbs.) torque. (4) Lower the transmission until the insulator is
lined up with the transmission support bracket. (5) Install the through-bolt and tighten the nut to
68 N-m (50 ft. lbs.) torque. (6) Remove the transmission jack.
(7) Lower the vehicle.
REMOVAL-4WD (1) Raise the vehicle on a hoist.
(2) Remove the skid plate (if equipped) from the
rear crossmember and transmission crossmember
(Fig. 5).

SKID
PLATE ^MATTACHING BOLTSl

.MIMING

PU873

Fig.
5
Skid
Plate

(3) Position a transmission jack under the trans­
mission. (4) Remove the nuts from the transfer case to plate
bolts and from the transfer case to strut bolts (Fig.

6).

•
5.9L
(DIESEL) ENGINE
9 - 109 (5) Raise the rear of the transmission and engine
SLIGHTLY.

(6)
Remove the mounting bolts and nuts. Remove
the washers, sleeves and insulators (Fig. 6). (7) The plate and strut will be removed as a unit.
Remove the bolts, washers and nuts (Fig. 6).

J9109-150

Fig.
6 Rear
Engine
Mount—4WD

INSTALL A
TION—4
WD
(1) Assemble the plate and the strut (Fig. 6).
Tighten the nuts to 240 N-m (150 ft. lbs.) torque.
(2) Install the plate and strut assembly to the rail
with the insulators, sleeves, washers and mounting
bolts (Fig. 6). Tighten the nuts to 240 N-m (150 ft. lbs.) torque.
(3) Lower the rear of the engine and transmission
until the transfer case aligns with the holes in the
plate and the strut.
(4) Install the nuts to the transfer case to plate
bolts and to the transfer case to strut bolts (Fig. 6). Tighten the nuts to 240 N-m (150 ft. lbs.) torque.
(5) Remove the transmission jack.
(6) Install the skid plate.
(7) Lower the vehicle.

ENGINE
ASSEMBLY

REMOVAL
(1) Disconnect the electrical connection into the
hood. Scribe the hood hinge bolt locations and re­
move the hood (Fig. 7).
(2) Disconnect the battery cables and remove the
battery.
(3) Drain the coolant from the cooling system (re­
fer to Group 7, Cooling System for the proper proce-
Fig.
7
Scribe
Hood
Hinge

dures).
DO NOT waste reusable coolant. If the
solution is clean, drain the coolant into a clean con­
tainer for reuse.
(4) Disconnect the radiator hoses. Remove the fan
shroud, fan/fan clutch assembly and radiator (refer to
Group 7, Cooling Systems for the proper procedures). (5) Disconnect the heater hoses at the dash panel
and at the water valve (Fig. 8).

Fig.
8 Heater
Hoses

(6) Disconnect the air inlet tube from the turbo­
charger (Fig. 9) and the air intake housing. Remove
the tube.
(7) Remove the exhaust pipe from the turbocharger
outlet flange (Fig. 9).
(8) Disconnect the intercooler inlet duct from the
turbocharger and the intercooler (Fig. 10). Remove
the inlet duct.
(9) Disconnect the intercooler outlet duct from the
air inlet housing and the intercooler (Fig. 10). Re­
move the outlet duct.

9
- 119 5.9L
(DIESEL) ENGINE
Fig.
10 intercooler
Ducts
(10) Remove the drive belt. Disconnect the genera­
tor ground wire. Remove the generator and set aside (Fig. 11).
(11) Remove the A/0 compressor and set aside. The
A/C compressor is located below the generator. (12) Disconnect the accelerator linkage, the speed
control linkage and the throttle valve linkage (Fig.
12).

(13) Raise and support the vehicle on a hoist.

(14)
Drain the engine lubricating oil. Dispose of
the oil according to all applicable regulations. (15) Disconnect the exhaust pipe steady rest clamp
and remove. (16) Disconnect the starter connections (Fig. 13).
(17) Disconnect the transmission cooler lines.
(18) AUTOMATIC TRANSMISSION: (a) Remove torque converter bolt access cover. •
Fig, 11 Generator Removal
Fig. 12 Accelerator/Speed
Control/Throttle
Valve

Linkage
(b) Mark
torque
converter and
drive
plate for
as­

sembly
alignment.
Note
that bolt
holes
in crank­
shaft flange, drive plate and torque converter all

have
one offset hole.
(c) Rotate crankshaft in clockwise direction until
converter
bolts
are accessible. Then remove
bolts

one
at a
time.
Rotate crankshaft with socket wrench on damper pulley bolt.
(d) Support the transmission.

(e)
Remove bell housing bolts and inspection
plate. (19) MANUAL TRANSMISSION:
Refer to Group 21, Transmissions for the G360
Manual Transmission Removal procedure. (20) Lower the vehicle.
(21) Disconnect the power steering lines.

- 5.9L
(DIESEL)
ENGINE
9 - 111
J9109-1 13

Fig.
13
Starter
Connections
(22) Disconnect the vacuum pump lines.

(23)
Disconnect all electrical connections from the
engine. Put tags on the connections to identify their
locations.
(24) Disconnect the fuel lines to the lift pump and
fuel return. Use tags to identify the lines (Fig. 14).

Fig.
14
Lift
Pump
and
Fuel
Lines

(25) Put a cover or tape over all engine openings.
(26) Make sure that the lifting brackets are
mounted with the eye up. If not, remove the bracket
and install in the proper position. Tighten the lifting
bracket bolts to 77 N«m (57 ft. lbs.) torque. (27) Use the lifting brackets to apply tension to
the engine. Remove the engine mount through-bolts from the cylinder block mounting bracket.

CAUTION:
When
removing the
engine,
take care not
to
damage
the wiper motor and voltage regulator
mounted
on the
dash
panel (Fig. 15).
(28) Lift the engine out of the vehicle (Fig. 16).
(29) Install the engine on a suitable stand.
(30) Remove all accessories and brackets not previ­
ously removed for use with the replacement engine.
Fig.
15 Wiper Motor/Voltage Regulator

ENGINE

/
HOIST

Ml
J9109-H

Fig.
16 Lifting
Engine
from Vehicle
INSTALLATION

(1) If removed, install and tighten the rear engine
lifting bracket to 77 N-m (57 ft. lbs.) torque. DO
NOT exceed this torque valve.
(2) Check the data plate to verify that the replace­
ment engine is the same model and rating as the en­ gine that was removed.

(3)
Install all accessories and brackets that had
been removed from the previous engine. (4) Use the lifting brackets to lift the engine off of
the stand.

9
- 112 5.9L
(DIESEL)
ENGINE

• (5) Position the engine in the chassis and install
the through bolt. Tighten the through bolt nut to 41
N-m (30 ft. lbs.) torque. (6) Make sure the lifting brackets are mounted
with the eye down. (7) Remove the covers or tape covering the engine
openings. (8) Connect the fuel lines to the lift pump and fuel
return.
(9) Connect all electrical connections.
(10) Connect the power steering lines.
(11) Raise and support the vehicle on a hoist.
(12) AUTOMATIC TRANSMISSION:

CAUTION:
If new
flex
plate is installed, remove

flashing
from the engine
back
plate at the 5 and 7
o'clock
positions.

(a) Rotate converter until alignment mark on the
converter is aligned with mark on drive plate.
Off­

set holes in plate are next to 1/8 inch hole in inner
circle of drive plate.
(b) Install bell housing bolts. Tighten the bolts to
41 N-m (30 ft. lbs.) torque. (c) With the torque converter plate aligned to the
torque converter, install and tighten the bolts to 31 N-m (270 in. lbs.) torque. (d) Install the converter housing access plate.
(e) Remove the transmission support.
(13) MANUAL TRANSMISSION:
Refer to Group 21, Transmissions for the G360
Manual Transmission Installation procedure. (14) Connect the ground cable and tighten the nut
to 22 N-m (16 ft. lbs.) torque. Connect the solenoid cable and tighten the nut to 5 N-m (44 in. lbs.)
torque.
(15) Connect the transmission cooler lines.
(16) Install the exhaust pipe to the exhaust sys­
tem.
(17) Lower the vehicle.
(18) Install the A/C compressor and tighten the
bolts to 47 N-m (35 ft. lbs.) torque. If removed, con­ nect the clutch electrical wire.
(19) Install the generator. Tighten the upper
mounting bolts to 24 N-m (18 ft. lbs.) torque. Now
tighten the lower mounting bolts to 43 N-m (32 ft. lbs.) torque. Connect all wires.
(20) Install the radiator, fan/fan clutch assembly
and fan shroud (refer to Group 7, Cooling Systems
for the proper procedures). Connect the radiator

hoses.

(21) Position the intercooler inlet duct to the tur­
bocharger and the intercooler. With the clamps in po­ sition, tighten the clamp nut to 8 N-m (72 in. lbs.)
torque. (22) Position the intercooler outlet duct to the air
inlet housing and the intercooler. With the clamps in
position, tighten the clamp nut to 8 N-m (72 in. lbs.)
torque.
(23) Connect the air intake tube to the turbo­
charger inlet flange and the air cleaner housing.
Tighten the clamps to 8 N-m (72 in. lbs.) torque. (24) Install the exhaust pipe to the turbocharger.
Tighten the steady rest clamp to 8 N-m (72 in. lbs.) torque.
(25) Make sure the air intake and exhaust pipe
connections are tight and free of leaks.
(26) Fill the engine with the required amount of
clean engine lubricating oil (refer to Group 0, Lubri­ cation and Maintenance).
(27) Fill the cooling system with a mixture of 50%
water and 50% ethylene-glycol base antifreeze (refer Group 7, Cooling System for the proper procedure).
(28) Install the battery and connect the battery ca­

bles.

(29) Check the oil level after the engine has run
for 2 or 3 minutes. Oil held in the oil filter and oil passages will cause the oil level in the pan to be lower.
(30) Operate the engine at idle for 5 to 10 minutes
and check for leaks and loose parts.

ROCKER LEVERS
/
POSH
RODS

REMOVAL (1) Remove the valve covers (Fig. 1). (2) Loosen the adjusting screw locknuts. Loosen
the adjusting screws until they stop (Fig. 2).

•
5.9L
(DIESEL)
ENGINE
9 - 113
(3)
Remove the bolts from the rocker lever pedes­

tals.
Remove the pedestals and rocker lever assem­
blies (Fig. 2).

(4)
Remove the push rods.

LOCKNUT
ADJUSTING

J9109-31

Fig.
2 Location of
Rocker
Lever
Components

DISASSEMBLE—ROCKER
LEVERS
(1) Remove the retaining rings and thrust washers
(Fig. 2).

(2)
Remove the rocker levers (Fig. 2). DO NOT dis­
assemble the rocker lever shaft and pedestal. The
pedestal and shaft must be replaced as an assembly.

(3)
Remove the locknut and adjusting screw (Fig.

2).
(4)
Clean all parts in a strong solution of laundry
detergent in hot water.

(5)
Use compressed air to dry the parts after rins­
ing in clean hot water. The pedestals are made from
powdered metal and may continue to show wetness after they have been cleaned and dried.

(6)
Inspect for excessive wear in the bore and the
contact surface for the valve stem.

(7)
Measure the rocker lever bore diameter. The
maximum diameter is 19.05 mm (0.75 inch). Replace if out of limits.
(8) Inspect the pedestal and shaft.
(9) Measure the shaft diameter. The minimum di­
ameter is 18.94 mm
(0.746
inch). Replace if out of

limits.

ASSEMBLE-ROCKER
LEVERS
(1) Install the adjusting screw and locknut.

(2)
Lubricate the shaft with clean engine oil. Be
sure to assemble the intake and exhaust rocker le­
vers in the correct location.

(3)
Position the levers on the rocker shaft. Install
the thrust washers.

(4)
Clean the push rods in the hot soapy water.

(5)
Inspect the push rod ball and socket for signs of
scoring or cracks where the ball and the socket are
pressed into the tube.
(6)
Check the push rods for roundness and
straightness.

(7)
Install the push rods into the sockets of the
valve tappets. Lubricate the push rod sockets with clean engine oil.
(8) Make sure the rocker lever adjusting screws
are completely backed out.

INSTALLATION
(1) Make sure the dowel rings in the pedestals are
installed into the dowel bores in the cylinder head. (2) If the push rod is holding pedestal off head, bar
the engine until the pedestal will set on the head surface without interference.

(3)
Use clean engine oil to lubricate the cylinder
head bolt threads and under the bolt heads.
(4)
Install the long bolts (12 mm) into the rocker
lever pedestals. Tighten the bolts as follows:
• Step
1—Tighten
the bolts, in sequence (Fig. 3), to
90 N»m (66 ft. lbs.) torque. Check the torque. If lower
than 90 N»m (66 ft. lbs.), tighten to this torque.
• Step 2—Tighten the bolts, in sequence (Fig. 3), to 120 N-m (89 ft. lbs.) torque. Check the torque. If
lower than 120 N-m (89 ft. lbs.), tighten to this
torque.
• Step 3—Tighten the bolts, in sequence (Fig. 3), an additional 90°.
C=J FRONT

J9109-32

Fig.
3
Rocker
Lever
(Head Boits) Tightening
Sequence

(5)
Tighten the 8 mm bolts to 24 Nnn (18 ft. lbs.)
torque.
(6)
Install the valve cover. Tighten the valve cover
bolt to 24 Nnn (18 ft. lbs.) torque.

CYLINDER
HEAD
These cylinder heads can only be used on engines
with an intercooler. DO NOT interchange with ear­ lier models.

REMOVAL
(1) Drain the coolant. DO NOT waste reusable
coolant. If the solution is clean, drain the coolant into a clean container for reuse.

(2)
Drain the engine oil. Dispose of the used oil
properly.

9
- 114 5.9L
(DIESEL) ENGINE
—

Fig.
4
Exhaust
Manifold
(6) Remove the fuel lines and injector nozzles (re­
fer to Group 14, Fuel System).
(7) Remove the valve covers (Fig. 5).

Fig.
5
Valve
Cover

(8) Remove the rocker levers and push rods.
(9) Remove the fuel/water separator filter (Fig. 6).
Refer to Group 14, Fuel System, for the proper pro­
cedures.
(10) If the engine is hot, remove the cylinder head
bolts in the sequence shown in Fig. 7..The removal sequence is not important if the engine is cold. There
are 3 sizes of head bolts. Note the position of each
bolt for future installation.
(11) Remove the cylinder head and gasket from the
cylinder block.
•

Fig. 6 Fuel/Water Separator Filter J9109-36
Fig. 7 Cylinder Head Bolt Removal Sequence—Cylinder Head Hot

INSPECTION
Remove the cup plugs and inspect the coolant pas­

sages.
A large build up of rust and lime will require
removal of the cylinder block for cleaning in a hot
tank.
Inspect the cylinder bores for damage or excessive
wear. Rotate the crankshaft so the piston is at Bot­
tom Dead Center (BDC) to inspect the bores. Measure the cylinder bores (Fig. 8). DO NOT pro­
ceed with in-chassis repair if the bores are damaged
or worn beyond the limits (refer to Cylinder Bore Re­
pair - Cylinder Block).
Check the top surface for damage caused by the
cylinder head gasket leaking between cylinders.
Inspect the block and head surface for nicks, ero­
sion, etc. Check the head distortion (Fig. 9). The distortion of
the combustion deck face is not to exceed 0.010 mm (0.0004 inch) in any 50.8 mm (2.00 inch) diameter.
Overall variation end to end or side to side 0.30 mm (0.012 inch).
(3) Disconnect the radiator and heater hoses (refer
to Group 7, Cooling System). (4) Remove the turbocharger.
(5) Remove the exhaust manifold (Fig. 4).

* ^ ^ ^ — 5.IL
(DIESEL) ENGINE
9 - 115
MIN. 102.0 mm (4.0157 inch) MAX. 102.1 16 mm (4.0203 inch)
Out-of-Round 0.038 mm (0.0015 inch)
Taper 0.76 mm (0.003 inch) Oversize pistons and rings are
available for bored cylinder blocks.
J9109-75

Fig.
8 Cylinder
Bore
Diameter
DO NOT proceed with the in-chassis overhaul if
the cylinder head or block surface is damaged or not
flat (within specifications).

Fig.
9 Cylinder Head
Combustion
Deck
Face
Measurement

REFACING
HEAD
SURFACE
The cylinder head combustion deck may be refaced
in whatever increments necessary to clean up the
surface and maintain the surface finish and flatness
tolerances. The combined total of stock removed must
not exceed 1.00 mm (0.03937 inch). The amount of stock removed each time must be steel stamped above combustion deck edge, on the lower right hand
corner of the rear face (Fig. 10). Check valve protru­ sion after head surface refacing.
Surface finish requirements are
1.5-3.2
microme­
ters (60-126 microinch).

CLEANING
Clean the carbon from the injector nozzle seat with
a nylon or brass brush. Scrape the gasket residue from all gasket surfaces.
REFERENCE
STOCK
TOTAL
(MAX.)
1.00 mm
(0.03937
inch)

REFERENCE
HEIGHT
(MIN.)
94.00
±0.25
mm

(3.7008
±0.0010
inch)

SURFACE
FINISH
1.5 to 3.2 micrometers
(60 to 128 microinches)
J9109-134

Fig.
10 Cylinder Head
Stock
Removal

Wash the cylinder head in hot soapy water solution
(88°C or 140°F). After rinsing, use compressed air to dry the cylin­
der head.
Polish the gasket surface with 400 grid paper. Use
an orbital sander or sanding block to maintain a flat
surface.

INSTALLATION
(1) The cylinder block and head must be clean and
dry. (2) Position the gasket onto the dowels (Fig. 11).
Make sure the gasket is correctly aligned with the
holes in the cylinder block.
(3)
Carefully put the cylinder head onto the gasket
and cylinder block. Make sure the cylinder head is
installed onto the dowels in the cylinder block (Fig.
11).
(4) Install the push rods and rocker levers.
(5) Use clean engine oil to lubricate the cylinder
head bolt threads and under the bolt heads. (6) The cylinder head bolts are 3 different sizes. In­
stall the bolts in the proper hole. Tighten the bolts as
follows: • Step
1—Tighten
all bolts, in sequence (Fig. 12), to
90 N#m (66 ft. lbs.) torque. Check the torque. If lower
than 90 N*m (66 ft. lbs.), tighten to this torque. • Step 2—Tighten all long 12 mm bolts (Nos. 4, 5,
12,
13, 20 and 21), in sequence (Fig. 12), to 120 N*m
(89 ft. lbs.) torque. Check the torque. If lower than 120 N«m (89 ft. lbs.), tighten to this torque.
• Step 3 —Tighten all bolts, in sequence (Fig. 12), an additional 90°.