Downloaded from www.Manualslib.com manuals search engine 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. 70).
(3) Immerse the piston head and rings in clean
engine 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. Be sure connecting rod, con-
necting rod cap and cylinder bore number are the
same. 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. 71).
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) Remove the vibration damper.
(4) Remove the timing chain cover.
(5) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time.
(6) Lift the crankshaft out of the block.
Fig. 70 Proper Ring Installation
1 ± OIL RING SPACER GAP
2 ± SECOND COMPRESSION RING GAP OIL RING RAIL GAP
(TOP)
3 ± OIL RING RAIL GAP (BOTTOM)
4 ± TOP COMPRESSION RING GAP
Fig. 71 Location of Crankshaft Identification
1 ± 1/4º LETTERS
2 ± (ROD)
3 ± (MAIN)
CRANKSHAFT IDENTIFICATION MARK
LOCATION CHART
UNDERSIZE JOURNAL IDENTIFICATION
STAMP
0.025 mm (0.001 in.)
(ROD)R1-R2-R3 or R4
0.025 mm (0.001 in.)
(MAIN)M1-M2-M3-M4 or M5
9 - 176 5.9L ENGINEDN
REMOVAL AND INSTALLATION (Continued)
Downloaded from www.Manualslib.com manuals search engine CYLINDER BLOCK
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
²The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
²The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
²The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coor-
dinated with the fitting of pistons and rings so spec-
ified clearances may be maintained.
Refer to Standard Service Procedures in the begin-
ning of this Group for the proper honing of cylinder
bores.
INTAKE MANIFOLD
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
EXHAUST MANIFOLD
CLEANING
Clean mating surfaces on cylinder head and mani-
fold, wash with solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks, Inspect mating sur-
faces of manifold for flatness with a straight edge.
Seal surfaces must be flat within 0.1 mm (0.004 inch)
overall.
SPECIFICATIONS
5.9L ENGINE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Engine Type 90É V-8 OHV
Bore and Stroke 101.6 x 90.9 mm
(4.00 x 3.58 in.)
Displacement 5.9L (360 c.i.)
Compression Ratio 9.1:1
Firing Order 1±8±4±3±6±5±7±2
Lubrication Pressure Feed ±
Full Flow Filtration
Cooling System Liquid Cooled ±
Forced Circulation
Cylinder Block Cast Iron
Cylinder Head Cast Iron
Crankshaft Nodular Iron
Camshaft Nodular Cast Iron
Combustion Chambers Wedge -
High Swirl Valve
Shrouding
Pistons Aluminum Alloy w/strut
Connecting Rods Forged Steel
Cylinder Compression 689.5 kPa
Pressure (Min.) (100 psi)
DESCRIPTION SPECIFICATION
CAMSHAFT
Bearing Diameter
No. 1 50.800 ± 50.825 mm
(2.000 ± 2.001 in.)
No. 2 50.394 ± 50.419 mm
(1.984 ± 1.985 in.)
No. 3 50.013 ± 50.038 mm
(1.969 ± 1.970 in.)
No. 4 49.606 ± 49.632 mm
(1.953 ± 1.954 in.)
No. 5 39.688 ± 39.713 mm
(1.5625 ± 1.5635 in.)
DN5.9L ENGINE 9 - 185
CLEANING AND INSPECTION (Continued)
Downloaded from www.Manualslib.com manuals search engine DESCRIPTION SPECIFICATION
PISTONS
Clearance at Top of Skirt 0.013 ± 0.038 mm
(0.0005 ± 0.0015 in.)
Land Clearance (Diam.) 0.508 ± 0.660 mm
(0.020 ± 0.026 in.)
Piston Length 81.03 mm (3.19 in.)
Piston Ring Groove
DepthÐ
#1&2 4.761 ± 4.912 mm
(0.187 ± 0.193 in.)
Piston Ring Groove
DepthÐ
#3 3.996 ± 4.177 mm
(0.157 ± 0.164 in.)
Weight 582 ± 586 grams
(20.53 ± 20.67 oz.)
PISTON PINS
Clearance in Piston 0.006 ± 0.019 mm
(0.00023 ± 0.00074 in.)
Diameter 25.007 ± 25.015 mm
(0.9845 ± 0.9848 in.)
End Play NONE
Length 67.8 ± 68.3 mm
(2.67 ± 2.69 in.)
PISTON RINGS
Ring Gap
Compression Ring (Top) 0.30 ± 0.55 mm
(0.012 ± 0.022 in.)
Compression Ring (2nd) 0.55 ± 0.80 mm
(0.022 ± 0.031 in.)
Oil Control (Steel Rails) 0.381 ± 1.397 mm
(0.015 ± 0.055 in.)
Ring Side Clearance
Compression Rings 0.040 ± 0.085 mm
(0.0016 ± 0.0033 in.)
Oil Ring (Steel Rails) 0.05 ± 0.21 mm
(0.002 ± 0.008 in.)
Ring Width
Compression rings 1.530 ± 1.555 mm
(0.060 ± 0.061 in.)DESCRIPTION SPECIFICATION
Oil Ring (Steel Rails) ±
Max.0.447 ±0.473 mm
(0.018 ± 0.019 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) 33É
Opens (BBDC) 56É
Duration 269É
Intake Valve
Closes (ATDC) 62É
Opens (BBDC) 7É
Duration 249É
Valve Overlap 41É
OVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
ITEM U/S
(O/S)IDENTI-
FICATIONIDENTI-
FICATION
LOCATION
Crank-
shaft
Journals0.0254
mm
(0.001
in.) U/SR or M M-2-3
ect.
(indicating
No. 2 and 3
main bearing
journal)
and/or R-1-4
ect.
(indicating
No. 1 and 4
connecting
rod journal)Milled flat on
No. 8
crankshaft
counterweight.
Hydraulic
Tappets0.2032
mm
(0.008
in.)
(O/S)lDiamond-
shaped stamp
top pad - front
of engine and
flat ground on
outside
surface of
each O/S
tappet bore.
Valve
Stems0.127
mm
(0.005
in.)
(O/S)X Milled pad
adjacent to
two tapped
holes (3/8 in.)
on each end
of cylinder
head.
9 - 188 5.9L ENGINEDN
SPECIFICATIONS (Continued)
