1993 DODGE TRUCK Service Repair Manual

9
- 124 5.9L
(DIESEL)
ENGINE

Fig.
8 Fabricated Wire Pointer (5) Rotate the crankshaft one-quarter rotation in
the opposite direction of engine rotation (counter­ clockwise).
(6) Tighten the No.l cylinder exhaust valve adjust­
ing screw two complete turns. Tighten the locknut.
CAUTION; Use extreme
care
that
the
piston
does
not
push
against
the
exhaust
valve with so
much

force that it
bends
the
push
rod (Fig. 9).
(7) Rotate the crankshaft slowly in the direction of
engine rotation until the piston touches the exhaust
valve (Fig. 9). (8) Mark the vibration damper corresponding to
the wire pointer (Fig. 9).
(9) Rotate the crankshaft in the opposite direction
until the piston touches the valve (Fig. 10). Make sure that the piston touches the valve with approxi­
mately the same amount of force as in the previous step (Fig. 10).
(10) Mark the vibration damper again (Fig. 10). (11) Measure the distance and mark the pulley at
one-half that distance between the two marks. This •

Fig.
9 Locate and Mark
Vibration
Damper—First
Mark

Fig.
10 Mark
Vibration
Damper—Second
Mark
Fig.
11 Location of Top
Dead
Center (TDC) mark is the TDC mark (Fig. 11).
(12) Completely loosen the No.l cylinder exhaust
valve adjusting screw. (13) Rotate the crankshaft with Cummins Barring
Tool 3377371 approximately 180° in the direction of engine rotation until the pointer is aligned with the
TDC mark. Look through the back side of the gear housing for the timing pin hole in the camshaft gear.
ing and from the timing pin housing assembly.

INSTALLATION
(CYLINDER
HEAD
ON) The location of the timing pin assembly on the
gear housing is critical for correct engine adjustment.
Follow this procedure to install the assembly so that it corresponds to TDC for cylinder No.l. (1) Look through the hole in the gear housing and
rotate the engine until the hole in the cam gear can
be seen. (2) Adjust the No.l cylinder exhaust rocker lever
to have zero (0) valve clearance.
(3) Remove the injector nozzles from all of the cyl­
inders. This step is important to vent the cylinders so
the crankshaft can be rotated smoothly to locate TDC
for cylinder No.l.
(4) Temporarily install the vibration damper. Fab­
ricate and install a wire pointer (Fig. 8).

•

5JL
(DIESEL) ENGINE
9 - 125 (14) Reset the valves on No.l cylinder and install
valve cover.
(15) Install timing pin housing assembly and a
new gasket.
(16) Apply a coat of Loctite 59241 Liquid Teflon, or
equivalent to the threads of the Torx head bolts. (17) Hold the timing pin in the hole to align the
housing and install the Torx head bolts. Tighten the
Torx bolts to 5 N»m (44 in. lbs.) torque.
(18) Install the injectors and bleed the fuel system
(refer to Group 14, Fuel System).

INSTALLATION
(CYLINDER
HEAD
OFF) The timing pin assembly is precisely located on the
gear housing to correspond to TDC for Cylinder No.l.
The timing pin assembly must be relocated if the gear housing is interchanged.
(1) Temporarily install the vibration damper and a
fabricated wire pointer (Fig. 12). Put a flat washer
between the pointer and gear housing to prevent damage to the gear housing.
(2) Fabricate a steel plate (Fig. 13).

Fig.
12 Fabricated
Wire
Pointer
Fig.
13 Fabricated
Steel
Plate
(3) Use two flywheel housing bolts to assemble the
plate over No.l cylinder (Fig. 14).

Fig.
14 Fabricated
Plate
Location on No.1 Cylinder (4) Rotate the crankshaft in the direction of rota­
tion until the piston contacts the plate.
(5) Mark the vibration damper (Fig. 11).
(6) Rotate the engine in the opposite direction un­
til the piston contacts the plate. (7) Mark the vibration damper (Fig. 11).
(8) Mark the vibration damper for TDC. TDC will
be one-half the distance between the first two marks (Fig. 11).
(9) Remove the plate and rotate the engine in the
direction of rotation until the pointer aligns with the
TDC mark. (10) Look for the timing pin hole in the camshaft
gear. If it is not visible, rotate the crankshaft one
complete rotation. Align the pointer with the TDC
mark.
(11) Install the timing pin housing assembly with
a new gasket. (12) Apply a coat of Loctite 59241 liquid teflon, or
equivalent to the threads of the torx head bolts.
(13) Push the pin into the hole in the cam gear to
align the timing pin housing.
(14) Hold the pin in while tightening the torx head
bolts to 5 Nnn (44 in. lbs.) torque. Be sure timing pin is disengaged before rotating the engine.
(15) Remove the vibration damper and wire
pointer.

TAPPET
REMOVAL (1) Remove the camshaft. (2) Insert a trough the full length of the cam bore
(Fig. 1). Cummins Tappet Changing Tool 3822513 is
available for this job.
(3) Make sure the trough is positioned so it will
catch the tappet when the wooden dowel is removed. (4) Identify the location of each tappet as it is re­
moved. The tappets must be installed in their origi­
nal locations.

9
- 126 5.9L
(DIESEL) ENGINE

•
(5)
Only remove one tappet at a time. Remove the
rubber band from the two companion tappets, secur­ ing the tappet not to be removed with the rubber
band.
(6) Pull the wooden dowel from the tappet bore al­
lowing the tappet to fall into the trough (Fig. 1).
(7) Normally the tappet will fall over when it
drops into the trough. Use a flashlight to determine

this.
If the tappet does not fall over, shake the
trough gently to get it to do so.
(8) Special care should be taken, when removing
the No.6 cylinder tappets. DO NOT knock or shake
the tappet over the end barrier of the trough.
(9) Carefully pull the trough and tappet from the
cam bore and remove the tappet. Repeat the process
until all tappets are removed.

Fig.
1
Tappet
Removal
using
a Trough

INSPECTION
Inspect the tappet socket, stem and face for exces­
sive wear, cracks and other damage (Fig. 2).
The minimum tappet stem diameter is 15.925 mm
(0.627 inch) - (Fig. 2). If the tappet is out of limits,
replace the tappet.

NORMAL
WEAR

STEM DIAMETER-
ABNORMAL

WEAR

J9109-152

Fig.
2
Tappet
Inspection
INSTALLATION

(1) Insert the trough the full length of the cam

bore.
(2) Feed the installation tool down the tappet bore
and into the trough (Fig. 3).

J9109-153
Fig.
3
Tappet
Installation
Tool
(3) Feed the installation tool cord through the cam

bores.
Carefully pull the trough and installation tool out the front. The barrier at the rear of the trough
will assure the tool will be pulled out with it.
(4) Lubricate the tappets with Lubriplate 105, or
equivalent. (5) Insert the installation tool into the tappet (Fig.

4).
To aid in removing the installation tool after the
tappets is installed, work the tool in and out of the
tappet several times before installing the tappets. (6) Place the tappet and tool in the trough and
slide the trough back into the cam bore (Fig. 4).
J9109-155'

Fig.
4 Insert
Installation
Tool
into
Tappet
(7) Pull the tool/tappet through the cam bore and
up into the tappet bore (Fig. 5).
(8) Difficulty could be experienced in getting the
tappet to make the bend from the trough up to the tappet bore (due to the webbing of the block). If this
occurs, pull the trough out enough to allow the tap-

•
5.9L
(DIESEL) ENGINE
9 - 127

Fig.
5 Pull
Tappet/Tool
into
Position pet to drop down and align
itself.
Now pull the tap­
pet up into the bore carefully. (9) After the tappet has been pulled up into posi­
tion, slide the trough back into the cam bore and ro­ tate it 1/2 turn. This will position the round side of
the trough up, which will hold the tappet in place.
(10) Remove the installation tool from the tappet. (11) Install a wooden dowel into the top of the tap­
pet and secure it with a rubber band.
(12) Repeat this process until all tappets have been
installed. (13) Install the camshaft.

CAMSHAFT
REMOVAL (1) Remove the following parts:
• Valve covers
• Rocker lever assemblies
• Push rods • Drive belt
• Fan hub assembly • Vibration damper
• Gear housing cover
• Lift pump (2) Insert the dowels through the push tube holes
and into the top of each tappet. When properly in­
stalled, the dowels can be used to pull the tappets up (Fig. 6).
(3) Pull the tappets up and wrap a rubber band
around the top of the dowel rods (Fig. 6). This will
prevent the tappets from dropping down.
(4) Rotate the crankshaft to align the crankshaft
to camshaft timing marks (Fig. 7).
(5) Remove the bolts from the thrust plate (Fig. 8)
(6) Remove the camshaft, gear and thrust plate.

INSPECTION
Inspect the lift pump lobe, valve lobes and bearing
journals for wear, cracking, pitting and other dam­
age.
DOWEL
TOOL
Fig.
6
Holding
Tappets in Place
(Cummins
Tool 3822513)
J9109-51

Fig.
7
Align
Crankshaft to Camshaft
Fig.
8 Thrust
Plate
Bolt
Location
Clean the camshaft and gear with solvent and a
lint free cloth.
Inspect the gear teeth for wear and damage. Look
for cracks at the root of the teeth. Measure the bearing journals, lift pump lobe and
valve lobes (Fig. 9).

9
- 128 5.9L
(DIESEL)
ENGINE

•

CAMSHAFT

JOURNAL
CAMSHAFT
JOURNAL
DIAMETER
(MIN.

53.962 mm (2.1245
inch)

VALVE
LOBE
HEIGHT
(MIN..)
INTAKE
- 47.040 mm (1.852
inch)

EXHAUST
- 46.770 mm (1.841
inch)

LIFT
PUMP
LOBE
DIAMETER
(MIN.)

35.500 mm (1.398
inch)

J9109-53

Fig.
9 Bearing Journal/Valve
Lobe
Measurements

CAMSHAFT
BUSHING-REPLACEMENT
(1) Measure the diameter of each bore. (The limit
for the bushing in the No.l bore is the same as for
the other bores without bushings). The limit of the inside diameter is 54.133 mm (2.1312 inch). If the
camshaft bore for the first cam bushing is worn be­
yond the limit, install a new service bushing. Inspect the rest of the camshaft bores for damage or exces­ sive wear.
(2) If the bores without a bushing are worn beyond
the limit, the engine must be removed for machining and installation of service bushings. If badly worn,
replace the cylinder block.
(3) Remove the bushing from the No.l bore, using
a universal cam bushing tool.
(4) Mark the cylinder block so you can align the
oil hole in the cylinder block with the oil hole in the
bushing.
(5) Use a universal cam bushing installation tool
and install the bushing so that it is even with the
front face of the cylinder block. The oil hole must .be aligned. A 3.2 mm (0.128 inch) diameter rod must be able to pass through the hole (Fig. 10). (6) Measure the installed bushing. The limit of the
inside diameter is 54.133 mm (2.1312 inch).

CAMSHAFT
GEAR-REPLACEMENT
(1) Press the camshaft out of the gear. J9109-54

Fig.
10 Oil Hole
Alignment

(2) Remove all burrs and smooth any rough sur­
faces caused by removing the gear. (3) Install the camshaft key.
(4) Lubricate the camshaft surface with Lubriplate

105,
or equivalent.
(5) Heat the gear in an oven at 121°C (250°F) for
45 minutes.

WARNING:
WEAR
PROTECTIVE
GLOVES
TO
HAN­
DLE
THE HOT
GEAR.

(6) Install the gear with the timing marks visible.
Be sure the gear is seated against the camshaft shoulder.
(7) If the camshaft is not to be used immediately,
lubricate the lobes and journals to prevent rust.

INSTALLATION
(1) Apply a coat of Lubriplate 105 to the camshaft

bores.
(2) Lubricate the camshaft lobes, journals and
thrust washer with Lubriplate 105, or equivalent.

CAUTION:
When
installing
the
camshaft,
DO NOT

push
it in
farther
than
it
will
go
with
the
thrust

washer
in
place.
Pushing
it too far
can
dislodge
the
plug
in the
rear
of the
camshaft
bore
and
cause
an

oil
leak.

(3) Install the camshaft/thrust washer. Align the
timing marks as illustrated (Fig. 11). (4) Install the thrust washer bolts and tighten to
24 N-m (18 ft. lbs.) torque.
(5) Verify the camshaft has the correct amount of
backlash and end clearance (Fig. 12).
(6) Install the following parts:
• Lift pump • Gear housing cover
• Vibration damper
• Fan hub assembly
• Drive belt
• Push rods
• Rocker lever assemblies
• Valve covers (7) Install the engine in the vehicle.

•
BACKLASH - 0.080-0.330 mm (0.003-0.013 inch)
CLEARANCE - 0.152-0.254 mm (0.006-0.010 inch)
Fig.
12 Camshaft
Backlash
and End Clearance
(8) Operate the engine at idle for five to ten min­
utes and check for leaks and loose parts.

CYLINDER BLOCK

REMOVAL (1) Remove the engine assembly from the vehicle.
(2) Remove the cylinder head from the block.
(3) Remove the camshaft.
(4) Remove the piston/connecting rod assemblies.

INSPECTION
Measure the combustion deck face using a straight
edge and a feeler gauge (Fig. 1). The distortion of the
combustion deck face is not to exceed 0.010 mm (0.0004 inch) in any 50.00 mm (2.0 inch) diameter.
Overall variation end to end or side to side is 0.075
mm (0.003 inch).
If the surface exceeds the limit, refer to Cylinder
Block Refacing. 5.9L
(DIESEL) ENGINE
9 - 129

Fig.
1
Combustion
Deck
Face Measurement Inspect the cylinder bores for damage or excessive
wear.
Measure the cylinder bores (Fig. 2). If the cylinder
bores exceeds the limit, refer to Cylinder Bore Re­
pair. 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 0.0 76 mm (0.003 inch) Oversize pistons and rings are
available for bored cylinder blocks.

J9209-167

Fig.
2 Cylinder
Bore
Diameter
Inspect the camshaft bores for scoring or excessive
wear.
Measure the camshaft bores (Fig. 3). Limit for the
No.l bore applies to the ID of the bushing.
If a bore exceeds the limit, refer to Camshaft Bore
Repair.
Inspect the tappet bores for scoring or excessive
wear (Fig. 4). If out of limits, replace the cylinder block.

CYLINDER BORES—DE-GLAZE
(1) New piston rings may not seat in glazed cylin­
der bores.
(2) De-glazing gives the bore the correct surface
finish required to seat the rings. The size of the bore
is not changed by proper de-glazing.

9
- 130 5.9L
(DIESEL) ENGINE

• CAMSHAFT BORE DIAMETER
MAX.
54.133
mm
(2.1312
inch)
J9109-78

Fig.
3 Camshaft
Bores

BORE DIAMETER
MAX. 16.055 mm (0.632 inch)
J9109-79

Fig.
4
Tappet
Bore
Diameter
(3) Cover the lube holes in the top of the block
with waterproof tape.
(4) A correctly honed surface will have a cross-
hatch appearance with the lines at 15° to 25° angles (Fig. 5). For the rough hone, use 80 grit honing
stones. To finish hone, use 280 grit honing stones.
(5) Use a drill, a fine grit Flexi-hone and a mix­
ture of equal parts of mineral spirits and SAE 30W engine oil to de-glaze the bores.
(6) The Crosshatch angle is a function of drill speed
and how fast the hone is moved vertically (Fig. 6).
TOP
OF
BLOCK
Fig.
5 Cylinder
Bore
Crosshatch
Pattern
(7) Vertical strokes MUST be smooth continuous
passes along the full length of the bore (Fig. 6).
1
STROKE
(f+|)/PER
SECOND

Fig.
6 De-Glazing Drill
Speed
and
Vertical
Speed
(8) Inspect the bore after 10 strokes.
(9) Use a strong solution of hot water and laundry
detergent to clean the bores. Clean the cylinder bores
immediately after de-glazing.
(10) Rinse the bores until the detergent is removed
and blow the block dry with compressed air. (11) Check the bore cleanliness by wiping with a
white, lint free, lightly oiled cloth. If grit residue is still present, repeat the cleaning process until all res­
idue is removed. Wash the bores and the complete
block assembly with solvent and dry with compressed air.
(12) Be sure to remove the tape covering the lube
holes after the cleaning process is complete.

CYLINDER BLOCK REFACING
(1) The combustion deck can be refaced twice. The
first reface should be 0.15 mm (0.0059 inch). If addi­
tional refacing is required, an additional 0.35 mm (0.0138 inch) can be removed. Total allowed refacing
is 0.50 mm (0.0197 inch) - (Fig. 7).
(2) The upper right corner of the rear face of the
block must be stamped with a X when the block is refaced to 0.15 mm (0.0059 inch). A second X must

•
5.9L (DIESEL) ENGINE
9 - 131

1st REFACE
0.15 mm

(0.0058
inch)

2nd REFACE
0.35 mm
(0.0138

inch)

®
Total
0.50
mm
(0.0197

inch)

®
Standard
323.00
mm ±0.10 mn i

(12.7165
inch
±0.0039
inch)

1st
RE
FACE
322.85 mm ±0.10 mm

(12.7106
inch
±0.0039
inch)
2nd
REFACE
322.50
mm ±0.10 mn i

(12.6968
inch
±0.0039
inch)
J9109-118
Fig.
7 Refacing
Dimensions
of the Cylinder
Block

1st REFACE
X

2nd REFACE
XX
J9109-116

Fig.
8
Stamp
Block
after
Reface
be stamped beside the first when the block is refaced
to 0.50 mm (0.0197 inch) - (Fig. 8). (3) Consult the parts catalog for the proper head
gaskets which must be used with refaced blocks to
ensure proper piston-to-valve clearance (Fig. 9).
CYLINDER BORE REPAIR Cylinder bore(s) can be repaired by one of two
methods:

•
Method
1:—Over
boring and using oversize pistons and rings.
GASKET
FOR

0.15 mm

(0.0058
inch)
REFACE
GASKET FOR
0.50
mm

(0.0197
inch)
REFACE
Fig.
9 Proper Head
Gasket
•
Method 2:—Boring and installing a repair sleeve
to leturn the bore to standard dimensions.

METHOD 1-0WERS1ZE
BORE
Oversize pistons and rings are available in two
sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393

inch).

Any combination of standard, 0.50 mm (0.0197
inch) or 1.00 mm (0.0393 inch) overbore may be used
in the same engine.
If more than 1.00 mm (0.0393 inch) overbore is
needed, a repair sleeve can be installed (refer to
Method 2—Repair Sleeve).
Cylinder block bores may be bored twice before use
of a repair sleeve is required (Fig. 10). The first bore
is 0.50 mm (0.0197 inch) oversize. The second bore is 1.00 mm (0.0393 inch) oversize.
After boring to size, use a honing stone to chamfer
the edge of the bore (Fig. 10). A correctly honed surface will have a Crosshatch
appearance with the lines at 15° to 25° angles with
the top of the cylinder block (Fig. 11). For the rough
hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones. A maximum of 1.2 micrometer (48 microinch) sur­
face finish must be obtained. After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry detergent and hot water. After rinsing, blow the block dry. Check the bore cleanliness by wiping with a white,
lint-free, lightly-oiled cloth. There should be no grit
residue present. If the block is not to be used right away, coat it
with a rust-preventing compound.

METHOD 2—REPAIR
SLEEWE
If more than a 1.00 mm (0.03937 inch) diameter
oversize bore is required, the block must be bored and a repair sleeve installed.