1993 DODGE TRUCK Service Repair Manual

9
- 140 5.9L
(DIESEL)
ENGINE

• procedure providing
the
thrust surface width
is not

being ground.
The
preferred procedure must
be
used
when
the
main bearing thrust width surface
is
ground. When
the
thrust surface width requires
grinding,
the
main journal must
be
ground
to the

same undersize dimension
(Fig. 6).
THRUST JOURNAL WIDTH
37.500 ±0.025
mm

(1.4764 ±0.001 inch)
UNDERSIZES REGRIND WIDTH
TO

0.50 mm 38.000 ±0.025
mm

(0.0197 inch) (1.4961 ±0.001 inch

1.00
mm 38.500 ±0.025
mm

(0.0394 inch) (1.5158 ±0.001 inch)
J9109-127
Fig.
6
Crankshaft Thrust
Journal
Width
Dimensions

The thrust surface
is to be
ground
on
center within
0.10
mm
(0.004 inch).
It
also must
be
perpendicular
to
the
front
and
rear mains within 0.0015
mm
(0.00006 inch)
per
radial inch
on the
thrust area
(Fig.
7). The
surface finish requirement
is 0.04 mi­

crometer
(16.0
microinch).
JOURNAL

J9109-128

Fig.
7
Crankshaft Thrust Surface PREFERRED PROCEDURE:
Smoothly blend
a 4.20
±0.020
mm
(0.1654 ±0.0008
inch) radius
to the
ground diameters
(Fig. 8).

CAUTION:
DO NOT use the
Alternative Procedure
when
the
thrust
surface
width
is
ground.

ALTERNATIVE PROCEDURE: Smoothly blend
a 1.25
±0.020
mm
(0.0492 ±0.0008
inch) radius
to the
ground diameters
(Fig. 9).

ROD
JOURNAL
All
rod
journals
are to be
ground
in the
opposite
di­

rection
of
engine rotation (clockwise
as
viewed from
ORIGINAL
RADIUS

JOURNAL
SURFACE
®
SURFACE
FINISH

®
0.8
micrometer
(32.0
microinch)
for
a
minimum
of 45°
into
the fillet
beyond journal surface

1.6
micrometer
(64.0
microinch)
for remainder
of fillet

©
0.4
micrometer
(16.0
microinch)

J9109-129
Fig.
8
Grind
Crankshaft Main Journal—Preferred

Method

the front
of
crankshaft). Polish
the
journals
in the
same direction
as
engine rotation. The
rod
bearing grinding specifications
are
shown
in
Fig. 10.
PREFERRED PROCEDURE:
Smoothly blend
a 4.00
±0.020 (0.1575 ±0.0008
inch) radius
to the
ground diameters
and
side faces (Fig.
11).

ALTERNATIVE PROCEDURE: Smoothly blend
a 1.25
±0.020
mm
(0.0492 ±0.0008
inch) radius
to the
ground journals
(Fig. 12).

CRANKSHAFT
FRONT
SEAL

REMOVAL
(1) Remove
the
drive belt.
(2) Remove
the
vibration damper.
(3) Drill
two 1/Sth
inch holes into
the
seal face,
180° apart. (4)
Use a
slide hammer tool with
a #10
metal
screw. Pull alternating from side-to-side until
the
seal
is
free.

INSTALLATION
(1)
The
sealing surface
on the
crankshaft must
be

free from
all oil
residue
to
prevent seal leaks.

5-9L
(DIESEL) ENGINE
9 - 141

ORIGINAL RADIUS
NEW UNDERCUT RADIUS JOURNAL SURFACE ORIGINAL RADIUS
NEW UNDERCUT RADIUSs
SURFACE FINISH
®
0.8 micrometer (32.0 microinch) for a minimum of
45°
into the

fillet
beyond journal surface
(D 1.6 micrometer (64.0 microinch) for remainder of
fillet

©
0.4 micrometer (16.0 microinch)

WIDTH
OF
REGRIND/UNDERCUT RADIUS
®
34.5
±0.025
mm
(1.358
±0.001
in)
JOURNAL SURFACE

J9109-130

Fig. 9 Grind Crankshaft Main Journal—Alternative Method
STANDARD ROD JOURNAL DIAMETER 69.000 +0.013 mm
(2.7165 ±0.0005 inch)
WORN ROD JOURNAL DIAMETER LIMIT 68.962 (2.7150 inch)
UNDERSIZES REGRIND TO
0.25 mm
(0.0098 inch) 68.750 +0.013 mm
(2.7067 ±0.0005 inch)
0.50 mm
(0.0197 inch) 68.500 +0.013 mm
(2.6969 ±0.0005 inch)
0.75 mm
(0.0295 inch) 68.250 +0.013 mm
(2.6870 ±0.0005 inch)
1.00 mm
(0.0394 inch) 68.000 +0.013 mm
(2.6772 ±0.0005 inch)
OUT-OF ROUND & TAPER (MAX.) 0.005 mm (0.0002 inch)
ALL MAIN JOURNALS
ARE
TO
BE
PARALLEL
TO THE FRONT AND REAR MAINS WITHIN: 0.030 mm (0.001 inch)
J9109-126
Fig. 10 Crankshaft Rod Journal Dimensions
(2) If the gear cover was replaced, use the align­
ment tool from the seal kit to make sure the cover is aligned with the crankshaft.
SURFACE FINISH
©
0.8 micrometer (32.0 microinch)
for a minimum of 45° into the
fillet
beyond journal surface 1.6 micrometer (64.0 microinch)
for remainder of
fillet
0.4 micrometer (16.0 microinch)
CD

©

J9109-131

Fig. 11 Crankshaft Rod Journal Grind—Preferred Method
(3) Apply a bead of Loctite 277 to the outside di­
ameter of the seal.
(4) Install the pilot from the seal kit onto the
crankshaft.
(5) Install the seal onto the pilot and start it into
the gear housing cover seal bore. (6) Remove the pilot.
(7) Use the alignment/installation tool and a plas­
tic hammer to install the seal to the correct depth.
(8) Install the vibration damper, but DO NOT
tighten the damper bolt until the belt is installed.
(9) Install the drive belt.
(10) Tighten the vibration damper bolts to 125
Nun (92 ft. lbs.) torque. Use the engine barring tool
to keep the engine from rotating during torquing op­ eration.
CRANKSHAFT REAR SEAL HOUSING AND
SEAL

REMOVAL

(1) Remove the rear seal housing and gasket (Fig.

13).
(2) Support the seal area of the rear seal housing
and press/drive out the seal using a hammer and a
pin pinch.
(3) Clean the rear seal housing.

9
- 142 5.9L
(DIESEL)
ENGINE

•

ORIGINAL
RADIUS

SURFACE
FINISH

®
0.3
micrometer
(32.0
microinch)
for a
minimum
of
45° into the
^ fillet
beyond
journal
surface

v§/
1.6
micrometer
(64.0
microinch)

^ for
remainder
of
fillet

v£)
0.4
micrometer
(16.0
microinch)
WIDTH OF REGRIND/UNDERCUT RADIUS

©
34.79
±
0.025
mm
(1.369
±0.001 in)
J9109-132

Fig.
12
Grind
Crankshaft Rod Journal—Alternative
Method

Fig.
13 Crankshaft Rear
Seal
Housing/Gasket

INSTALLATION
(1) Clean and dry the rear crankshaft sealing sur­

face.
The seal lip and the sealing surface on the
crankshaft must be free from all oil residue to pre­ vent seal leaks.
(2) Assemble the rear seal housing and gasket to
the cylinder block with the bolts.
(3) Align the seal housing to the crankshaft with
the alignment tool provided in the seal kit (Fig. 14). Make sure the seal housing is level with both sides
of the block oil pan rail. Tighten the bolts to 9 N*m
(7 ft. lbs.) torque.
(4) Remove the alignment tool and trim the gasket
even with the oil pan mounting surface (Fig. 14).
Fig.
14 Crankshaft Rear
Seal
Housing
Alignment

Tool
(5) The rubber O.D. rear crankshaft seals are lu­
bricated with soapy water. Seals without rubber O.D. use Loctite 277, or equivalent.
(6) Install the seal pilot (provided with the replace­
ment kit) onto the crankshaft. Push the seal onto the
crankshaft (Fig. 15).
(7) Remove the seal pilot.

Fig.
15 Crankshaft Rear
Seal
Pilot
(8) Use alignment and installation tool packaged
in the seal kit (Fig. 16). Alternately, drive the seal at
the 12, 3, 6 and 9 o'clock positions to prevent bend­ ing the seal carrier during installation.

•

5.9L
(DIESEL)
ENGINE
9 - 143

ALIGNMENT
AND
INSTALLATION TOOL
J9109-102

Fig.
16 Crankshaft Rear
Seal
Alignment/Installation
Tool

CRANKSHAFT REAR SEAL
REMOVAL
(1) Remove
the
transmission (refer
to
Group
21,

Transmission
for the
proper procedure). (2) Remove
the
clutch cover.
(3) Remove
the
clutch plate. (4) Remove
the
flywheel.
(5) Drill holes
180°
apart into
the
seal.
Be
careful
not
to get the
drill against
the
crankshaft. (6) Install
#10
sheet metal screws
in the
drilled
holes
and
remove
the
rear seal with
a
slide hammer (Fig.
17).

NO.
10

SCREW
\W

CRANKSHAFT
J9109-60

Fig.
17 Crankshaft Rear
Seal
Removal

INSTALLATION
CAUTION:
The
seal
lip
and
the
sealing surface
on

the crankshaft must
be
free
from
all oil
residue
to

prevent
seal leaks.

The crankshaft
and
seal must
be dry
when
the
seal
is installed. (1) Install
the
seal pilot, provided
in the
replace­
ment
kit, on the
crankshaft. Push
the
seal
on the pi­

lot
and
crankshaft.
(2) Remove
the
seal pilot. (3) Seal
O.D.
lubricant/sealant:
• Rubber
O.D,
rear crankshaft seals
are
lubricated
with soapy water.
• Seals without rubber
O.D. use
Loctite
277 or

equivalent sealant.
(4)
Use the
alignment tool
to
install
the
seal
to the

correct depth
in the
housing.
Use a
hammer
to
drive
the seal into
the
housing until
the
alignment tool stops against
the
housing
(Fig. 18).

(5)
Hit the
tool
at the 12, 3, 6 and 9
o'clock posi­
tions
to
drive
the
seal evenly
and
prevent bending
the seal housing. ALIGNMENT
TOOL-
J9109-6T

Fig.
18
Seal
Installation
using
Alignment
Tool
FLYWHEEL
RING GEAR
REMOVAL
(1) Remove
the
transmission.
(2) Remove
the
clutch cover.
(3) Remove
the
clutch plate.
(4) Remove
the
flywheel.

WARNING: WEAR
EYE
PROTECTION WHEN
YOU
DRIVE
THE
GEAR FROM
THE
FLYWHEEL.
DO NOT

USE
A
STEEL DRIFT
PIN.

(5)
Use a
drift
pin to
drive
the
ring gear from
the

flywheel
(Fig. 19).
Strike
the
gear
at
several points around
the
wheel until
it is off.

(6) Heat
the new
ring
for 20
minutes
in an
oven
preheated
to
127°C (250°F).

WARNING: WEAR PROTECTIVE GLOVES WHEN
YOU INSTALL
THE
HEATED GEAR.
(7) Install
the
gear.
The
gear must
be
installed
so

the bevel
on the
teeth
is
towards
the
crankshaft side of
the
flywheel
(Fig. 19).

9 - 146 5.9L (DIESEL) ENGINE
•

DIAL

INDICATOR

CYLINDER BLOCK
GASKET

J9109-97
Fig.
26 Position of Dial Indicator CRANKSHAFT
END

CLEARANCE
CRANKSHAFT
GEAR
MIN.
MAX.
0.130
mm
0.300 mm (0M5 inch)
(0.012 inch)

J9109-98

Fig.
27 Crankshaft End Clearance
OIL PAN / SUCTION TU1E
REMOVAL (1) Remove the engine from the vehicle and mount
on an engine stand.

WARNING:
HOT OIL CAN
CAUSE PERSONAL
IN­

JURY.

(2) Drain the used engine oil. Dispose of the used
oil properly. (3) Remove the oil pan and gasket (Fig. 1). Be sure
to connect the support bracket.
(4) If required, remove the suction tube and gasket
(Fig. 1).
INSTALLATION (1) Clean the sealing surface.
(2) Install the suction tube and gasket. Tighten the
bolts to 24 Nin (18 ft. lbs.) torque.
(3) Fill the joint between the pan rail/gear housing
and pan rail/rear cover with sealant. Use Three Bond 1207-C, or equivalent.
SUCTION

TUBE

J9109-19

Fig.
1 Oil Pan,
Suction
Tube and
Gasket
(4) Install the pan and gasket (Fig. 1). Tighten the
bolts to 24 N-m (18 ft. lbs.) torque.
(5) Install the drain plug with
a
new sealing
washer and tighten to 80 Nnn (60 ft. lbs.) torque.
(6) Install the engine assembly into the vehicle.
(7) Fill the engine with clean lubrication oil (refer
to Group 0, Lubrication and Maintenance). Run the engine and check for leaks.
(8) Stop the engine and let it set for five minutes.
Check the oil level, and add oil if needed.
OIL
PUMP
The non-intercooled turbocharged engine oil pumps
can not be used on intercooled engines.
REMOVAL (1) Remove the radiator (refer to Group 7, Cooling
System for the proper procedure). (2) Loosen the crankshaft vibration damper and re­
move the drive belt.
(3) Remove the fan clutch assembly. (4) Remove the fan hub.
(5) Remove the oil fill tube.
(6) Remove the crankshaft vibration damper.
(7) Remove the gear housing cover.
(8) Remove the four mounting bolts and pull the
pump from the bore in the cylinder block (Fig. 2).
CLEAN AND INSPECT Visually inspect the lube pump gears for chips,
cracks or excessive wear.
Remove the back plate (Fig. 3).
Mark TOP on the gerotor planetary using a felt tip
pen (Fig. 3). Remove the gerotor planetary (Fig. 3).

•

5.9L (DIESEL) ENGINE
9 - 147
©

Fig.
2 Oil
Pump
Removal
J9109-20

OIL PUMP
BACK PLATE
GEROTOR
GEROTOR
PLANETARY.

J9109-156

Fig.
3 Gerotor Planetary and Gerotor Inspect for excessive wear or damage.
Clean all parts in solvent and dry with compressed
air.
Inspect the pump housing and gerotor drive for
damaged and excessive wear.
Install the gerotor planetary in the original posi­
tion. The chamfer must be on the O.D. and down. Measure the tip clearance (Fig. 4). Maximum clear­
ance is 0.1778 mm (0.007 inch). If the oil pump is out
of limits, replace the pump.
FEELER
GAUGE

J9109-21
Measure the clearance of the gerotor drive/gerotor
planetary to port plate (Fig. 5). Maximum clearance is 0.127 mm (0.005 inch). If the oil pump is out of

limits,
replace the pump. PORT
PLATE
GEROTOR

J9109-22
Fig.
5 Gerotor to Port
Plate
Clearance
Measure the clearance of the gerotor planetary to
the body bore (Fig. 6). Maximum clearance is 0.381 mm (0.015 inch). If the oil pump is out of limits, re­
place the pump.
BODY

BORE
GEROTOR
PLANETARY

J9109-23
Fig.
6 Gerotor Planetary to
Body
Bore
Clearance
Measure the gears backlash (Fig. 7). The limits of
a used pump is 0.080-0.380 mm (0.003-0.015 inch). If
the backlash is out of limits, replace the oil pump. Install the back plate.
OIL PUMP DRIVE
GEAR IDLER GEAR
BACKLASH BACKLASH
J9109-24
Fig.
4 Tip Clearance
Fig.
7 Measure Gear
Backlash

INSTALLATION

(1) Lubricate the pump with clean engine oil. Fill­
ing the pump with clean engine oil during installa­
tion will help to prime the pump at engine start up.

9
- 148 5.9L
(DIESEL) ENGINE

• Make sure the idler gear pin is installed in the lo­
cating bore in the cylinder block. (2) Install the pump. Tighten the oil pump mount­
ing bolts in two steps and in the sequence shown (Fig. 2).
• Step
1—Tighten
to 5 N«m (44 in. lbs.) torque.
• Step 2-Tighten to 24 N*m (18 ft. lbs.) torque. (3) The back plate on the pump seats against the
bottom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump will not touch the cylinder block.
(4) Measure the idler gear to pump drive gear
backlash and the idler gear to crankshaft gear back­ lash (Fig. 8). The backlash should be 0.080-0.330 mm (0.003-0.013 inch). If the backlash is out of limits, re­
place the oil pump drive gear and the idler gear.
(5) If the adjoining gear moves when you measure
the backlash, the reading will be incorrect.

Fig.
8
idler
Gear to
Pump
Drive Gear and Crankshaft Gear
Backlash

OIL FILTER
When replacing the oil filter, Chrysler Corporation
recommends use of the replacement filter specified in
your Operator's Manual.

CAUTION:
The
internal filtering medium
of
some
fil­

ters
has
been known
to
disintegrate. Debris from
failed filters
may
plug
the
piston
oil
cooling noz­

zles,
resulting
in
scuffed pistons
and
eventual
en­

gine
failure.
REMOVAL

WARNING:
HOT OIL CAN
CAUSE PERSONAL
IN­

JURY.

(1) Operate the engine until the water tempera­
ture reaches 60°C (140°F). Shut the engine off.
(2) Use a container that can hold at least 14 liters
(15 quarts) to hold the used oil. Remove the oil drain
plug and drain the used engine oil into the container.
(3) Always check the condition of the used oil. This
can give you an indication of some engine problems
that might exist. • Thin, black oil indicates fuel dilution.
• Milky discoloration indicates coolant dilution.
(4) Clean the area around the lubricating oil filter
head. Remove the filter using a 90-95 mm filter
wrench.
(5) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter
head. Make sure it is removed.
INSTALLATION (1) Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine.
(2) Apply a light film of lubricating oil to the seal­
ing surface before installing the filter.

CAUTION:
Mechanical over-tightening
may
distort
the threads
or
damage
the filter
element seal.

(3) Install the filter as specified by the filter man­
ufacturer. (4) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and seal­ ing surface on the oil pan and drain plug.
(5) Install the drain plug using a new sealing washer.
Tighten the plug to 80 N-m (60 ft. lbs.) torque.
(6) Use only High-Quality Multi-Viscosity lubricat­
ing oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions outlined in Group 0, Lubrication and Maintenance.
(7) Fill the enginfe with the correct grade of new

oil.
The engine capacity is i0.4 liters (11 quarts) in
the crankcase and 0.95 liters (1 quart) in the lubri­ cating oil filter. (8) Start the engine and operate it at idle for several
minutes. Check for leaks at the filter and drain plug.
(9) Stop the engine. Wait approximately 5 minutes
to let the oil in the upper parts of the engine to drain
back to the oil pan. Check the oil level again. Add oil as necessary to bring the level to the "H" (High)
mark on the dipstick.

OIL FILTER
BYPASS
VALWE
REMOVAL
(1) Remove the oil cooler cover (Fig. 9). (2) Remove the valve from the cooler cover (Fig. 9).
INSTALLATION (1) Drive the new valve in until it bottoms against
the step in the bypass valve bore (Fig. 10).
(2) Install the oil cooler cover.

OIL PRESSURE REGULATOR VALVE
/
SPRING
When oil pressure from the oil pump exceeds 448
kPa (65 psi), the regulator valve opens to allow oil to
drain back into the pan.

5.9L
(DIESEL) ENGINE
9 - 149

FILTER
BYPASS-
VALVE
OIL COOLER COVER
Fig. 9
Removing
Filter
Bypass
Valve
n

J9109-16
FILTER

BYPASS
VALVE OIL COOLER
COVER
J9109-15

Fig. 10 Installing New
Filter
Bypass
Valve

REMOVAL
(1) Remove the threaded plug, gasket, spring and
valve (Fig. 11). (2) Check the spring for height and load limita­
tions (Fig. 12). Replace the spring if out of limits.

OIL
FILTER PLUG GASKET
SPRING

J9109-14

Fig. 11 Oil
Pressure
Regulator
VALVE OPEN

•
HEIGHT:
39.98mm
(1.574
inch)
•
LOAD:
91 N (20.5 lb)

ASSEMBLED

•
HEIGHT:
44.98mm (1.77 inch) •
LOAD:
60 N (13.5 lb)
J9109-13

Fig. 12 Oil
Pressure
Regulator
Spring
Check
INSTALLATION
(1) Clean and inspect the plunger, bore and seat
before assembly. The plunger must move freely in
the valve bore.
(2) Install the valve, spring, gasket and plug.
Tighten the plug to 80 N*m (60 ft. lbs.) torque.

OIL COOLER ELEMENT
/
GASKET
The non-intercooled turbocharged engine filter
head/coolers can not be used on intercooled engines.

REMOVAL
(1) Drain the cooling system (refer to Group 7,
Cooling System for the proper procedures).
(2) Remove the oil filter.
(3) Clean around the oil cooler cover. (4) Disconnect the turbocharger supply line (Fig.

13).
J9109-17

Fig. 13 Turbocharger
Supply
Line
(5) Remove the oil cooler cover, gaskets and cooler
element.

CLEANING
AND
INSPECTION
Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. If the element leaks, replace the element.