Page 1513 of 2627
Fig. 105 Lubrication System Circulation
1 - TO FILTER
2 - FROM FILTER
3 - TO MAIN OIL RIFLE
4 - CLOSED
5 - OPEN
6 - TO COOLER7 - FROM PUMP
8 - CLOSED
9 - OPEN
10 - OIL DRAINS BACK TO THE PUMP
11 - OIL DRAIN
12 - OIL SUPPLY
9 - 290 ENGINE 5.9L DIESELDR
LUBRICATION (Continued)
Page 1514 of 2627
Fig. 106 Lubrication System CirculationÐCont'd
DRENGINE 5.9L DIESEL 9 - 291
LUBRICATION (Continued)
Page 1515 of 2627

OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL LEVEL
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
To ensure proper lubrication of an engine, the
engine oil must be maintained at an acceptable level.
The acceptable oil level is in the SAFE RANGE on
the engine oil dipstick (Fig. 107).
(1) Position vehicle on level surface.
(2) With engine OFF, allow approximately 15 min-
utes for oil to settle to bottom of crankcase, remove
engine oil dipstick.
(3) Wipe dipstick clean.
(4) Replace dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the SAFE RANGE
area on the dipstick.
(7) Replace dipstick
STANDARD PROCEDURE - ENGINE OIL
SERVICE
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
NOTE: Change engine oil and filter at intervals
specified in the owner's manual.
(1) Operate the engine until the water tempera-
ture reaches 60ÉC (140ÉF). 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 engine problems that
might exist.
²Thin, black oil indicates fuel dilution.
²Milky discoloration indicates coolant dilution.
(4) Clean the area around the oil filter head.
Remove the filter (Refer to 9 - ENGINE/LUBRICA-
TION/OIL FILTER - REMOVAL).
(5) Install new oil filter (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION).
(6) 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.
(7) Install the drain plug. Tighten the plug to 50
N´m (37 ft. lbs.) torque.
(8) Use only High-Quality Multi-Viscosity lubricat-
ing oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(9) Fill the engine with the correct grade of new oil
(Refer to LUBRICATION & MAINTENANCE/FLUID
CAPACITIES - SPECIFICATIONS).
(10) Start the engine and operate it at idle for sev-
eral minutes. Check for leaks at the filter and drain
plug.
(11) Stop engine. Wait 15 minutes to allow the oil
to drain back to the pan and check the level again.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing of used
engine oil after it has been drained from a vehicle's
engine.
1 - ROCKER ARM
2 - ROCKER SHAFT
3 - PEDESTAL
4 - FROM MAIN OIL RIFLE
5 - TO VALVE TRAIN
6 - MAIN OIL RIFLE
7 - FROM MAIN OIL RIFLE8 - TO CAMSHAFT
9 - TO PISTON COOLING NOZZLE
10 - FROM OIL COOLER
11 - CRANKSHAFT MAIN JOURNAL
12 - ROD JOURNAL
13 - TO ROD BEARING
14 - MAIN OIL RIFLE
Fig. 107 Oil Level Indicator (Dipstick)
1 - ADD OIL MARK
2 - O-RING
3 - SAFE RANGE
9 - 292 ENGINE 5.9L DIESELDR
LUBRICATION (Continued)
Page 1546 of 2627

SPORT FASCIA REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the three screws at each trailing edge
of the fascia. (Fig. 3)
(3) Remove the five lower screws.
(4) Remove and discard the four upper push pins.
(5) Using a trim stick C-4755 or equivalent, care-
fully release the six lower clips and remove the close
out panel.
(6) Using a trim stick C-4755 or equivalent, care-
fully remove the step pad.
(7) Spread the fascia out at the wheels and remove
from the vehicle.
INSTALLATION
NOTE: The left and right inboard bumper to bracket
attachments must be secured before installing the
fascia and step pad.
ST/SLT/SLT+ FASCIA INSTALLATION
(1) Install the fascia.
(2) Position the close out panel and seat the 6
lower clips fully.
(3) Install four new upper push pin fasteners.
(4) Position the step pad onto the fascia and fully
seat the attachment clips.(5) Align the fascia to the fender with a 19 mm
(0.75 inch) gap and install the two screws at each
trailing edge of the fascia.
SPORT FASCIA INSTALLATION
(1) Position the fascia onto the bumper.
(2) Position the step pad onto the fascia and fully
seat the attachment clips.
(3) Install four new upper push pin fasteners.
(4) Install the five lower screws.
(5) Install the three screws at each trailing edge of
the fascia.
REAR BUMPER
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the license plate.
(3) Remove the bolts behind the plate.
(4) Disconnect the license plate light electrical con-
nectors.
(5) Disconnect the trailer light connector electrical
connection, if equipped.
(6) Remove the two bolts along the front upper
edge of the bumper near the frame tips.
(7) Support the bumper with a suitable lifting
device.
(8) Remove the bolts attaching the bumper support
brackets to the trailer hitch. (Fig. 4)
Fig. 3 SPORT FASCIA
1 - STEP PAD
2 - FASCIA (SPORT MODEL ONLY)
3 - SCREWS (3 PER SIDE)
4 - UPPER FASCIA SUPPORT BRACKET
5 - WHEELHOUSE SPLASH SHIELD BRACKET
6 - INBOARD BUMPER BRACKET ATTACHMENTS
7 - PUSH PIN FASTENERS (4)
8 - LOWER SCREWS (5)
Fig. 4 TRAILER HITCH
1 - HITCH
2 - LD HITCH BOLTS (4)/HD (6)
3 - BUMPER BRACKET BOLTS (4)
4 - BUMPER SUPPORT BRACKETS
DRFRAMES & BUMPERS 13 - 3
FRONT FASCIA (Continued)
Page 1565 of 2627

SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Cab mount bolts 81 60 Ð
Cargo box bolts 108 80 Ð
Front crossmember bolts - 2WD (light duty only) 61 45 Ð
Front crossmember bolts - 2WD (heavy duty only) 75 55 Ð
Front crossmember bolts - 4WD (light duty only) 102 75 Ð
Front skid plate bolts 34 25 Ð
Lower bumper support bracket bolt 54 40 Ð
Radiator crossmember bolts - lower 28 21 Ð
Radiator crossmember bolts - upper 28 21 Ð
Rear crossmember (light duty only) 102 75 Ð
Rear crossmember (heavy duty only) 115 85 Ð
Rear spring shackle bolts 163 120 Ð
Spare tire winch bolts 41 30 Ð
Trailer hitch reinforcement bracket bolt 170 125 Ð
Transfercase skid plate bolts 34 25 Ð
Transercase skid plate crossmember bolts 34 25 Ð
Transmission mount to crossmember nuts 54 40 Ð
FRONT CROSSMEMBER
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the front skid plate, if equipped. (Refer
to 13 - FRAME & BUMPERS/FRAME/FRONT SKID
PLATE - REMOVAL)
(3) Remove the bolts and remove the crossmember.
(Fig. 28) or (Fig. 29)
INSTALLATION
(1) Install the crossmember.
(2) Install the bolts;
²On light duty 2WD vehicles, tighten the bolts to
61 N´m (45 ft. lbs.).
²On light duty 4WD vehicles, tighten the bolts to
102 N´m (75 ft. lbs.).
²On heavy duty 2WD vehicles, tighten the bolts
to 75 N´m (55 ft. lbs.).
(3) Install the front skid plate, if equipped. (Refer
to 13 - FRAME & BUMPERS/FRAME/FRONT SKID
PLATE - INSTALLATION)
Fig. 28 FRONT CROSSMEMBER - 2WD
1 - CROSSMEMBER
2 - BOLTS (2 PER SIDE)
13 - 22 FRAMES & BUMPERSDR
FRAME (Continued)
Page 1566 of 2627

FRONT SKID PLATE
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the bolts. (Fig. 30)
(3) Slide skid plate back off of the crossmember
and remove.
INSTALLATION
(1) Snap the rear tabs over the front crossmember
and install the skid plate.
(2) Install the bolts and tighten to 34 N´m (25 ft.
lbs.).
FRONT TOW HOOK ASSEMBLY
REMOVAL
(1) Remove front bumper. (Refer to 13 - FRAME &
BUMPERS/BUMPERS/FRONT BUMPER -
REMOVAL)
(2) Remove the bolts and remove the tow hook
assembly. (Fig. 31) and (Fig. 32)
INSTALLATION
(1) Install the tow hook assembly and bolts hand
tight.
(2) Install the front bumper. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/FRONT BUMPER -
INSTALLATION)
(3) Tighten the tow hook bolts to 68 N´m (50 ft.
lbs.).
Fig. 29 FRONT CROSSMEMBER - 4WD
1 - BOLTS (2 PER SIDE)
2 - CROSSMEMBER
Fig. 30 FRONT SKID PLATE
1 - FRONT CROSSMEMBER
2 - FRONT SKID PLATE
3 - BOLTS (2)
Fig. 31 FRONT TOW HOOK ASSEMBLY
1 - BUMPER CENTER SUPPORT BRACKET
2 - BOLTS (6)
3 - TOW HOOK ASSEMBLY
DRFRAMES & BUMPERS 13 - 23
FRONT CROSSMEMBER (Continued)
Page 1567 of 2627

TRANSMISSION
CROSSMEMBER
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the transfercase skid plate, if
equipped. (Refer to 13 - FRAME & BUMPERS/
FRAME/TRANSFER CASE SKID PLATE -
REMOVAL)
(3) Support the transmission with a suitable lifting
device.
(4) Remove the transmission mount nuts. (Fig. 33)
or (Fig. 34)
(5) Remove the bolts and remove the crossmember.
INSTALLATION
(1) Install the crossmember and install the bolts.
²On light duty vehicles, tighten the bolts to 102
N´m (75 ft. lbs.).
²On heavy duty vehicles, tighten the bolts to 115
N´m (85 ft. lbs.).
(2) Install the transmission mount nuts and
tighten to 54 N´m (40 ft. lbs.).(3) Remove the transmission support.
(4) Install the transfercase skid plate. (Refer to 13
- FRAME & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
Fig. 32 FRONT TOW HOOK ASSEMBLY ± HEAVY
DUTY
1 - BOLTS (4 PER HOOK)
2 - HEAVY DUTY TOW HOOKS (2)
3 - BUMPER CENTER SUPPORT BRACKETS
Fig. 33 REAR CROSSMEMBER - 2WD
1 - TRANSMISSION MOUNT
2 - REAR CROSSMEMBER
3 - TRANSMISSION MOUNT NUTS (2)
4 - CROSSMEMBER BOLTS (2 PER SIDE)
Fig. 34 REAR CROSSMEMBER - 4WD
1 - TRANSMISSION MOUNT
2 - TORSION BAR
3 - CROSSMEMBER BOLTS (3 PER SIDE)
4 - REAR CROSSMEMBER
5 - TRANSMISSION MOUNT NUTS (2)
13 - 24 FRAMES & BUMPERSDR
FRONT TOW HOOK ASSEMBLY (Continued)
Page 1569 of 2627
TRANSFER CASE SKID PLATE
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Support the skid plate and remove the bolts.
(Fig. 37)
(3) Remove the skid plate.
(4) Support the skid plate crossmember and
remove the bolts.
(5) Remove the skid plate crossmember.
INSTALLATION
(1) Install the skid plate crossmember and install
the bolts.
(2) Tighten the bolts to 34 N´m (25 ft. lbs.).
(3) Install the skid plate and install the bolts.
(4) Tighten the bolts to 34 N´m (25 ft. lbs.).
Fig. 37 TRANSFER CASE SKID PLATE
1 - CROSSMEMBER BOLTS (4)
2 - SKID PLATE CROSSMEMBER
3 - SKID PLATE
4 - SKID PLATE BOLTS (4)
Fig. 36 TRAILER HITCH ± HEAVY DUTY
1 - LOCATING TAB HOLE
2 - LOCATING PIN HOLE
3 - U-NUTS (2)
4 - BUMPER SUPPORT BRACKETS5 - HITCH
6 - HITCH TO FRAME NUTS (2)
7 - BUMPER BRACKET BOLTS (4)
8 - HITCH BOLTS (6)
13 - 26 FRAMES & BUMPERSDR
TRAILER HITCH (Continued)