2001 DODGE RAM intake

(17) Remove the throttle linkage cover (Fig. 15).
(18) Remove the six (6) accelerator pedal position
sensor assembly-to-cylinder head bracket bolts (Fig.
16) and secure the entire assembly out of the way.
Disconnect the APPS connector (Fig. 17).It is notnecessary to disconnect the cables from the
throttle control assembly.
(19) Remove the intake air grid heater wires from
the grid heater.
(20) Remove engine oil level indicator tube attach-
ing bolt from the air inlet housing.
(21) Remove the charge air cooler-to-air inlet hous-
ing pipe.
(22) Remove the air inlet housing and intake grid
heater from the intake manifold cover.
(23) Remove the engine lift bracket from the rear
of the cylinder head.
Fig. 15 Throttle Linkage Cover
1 - CABLE/LEVER/LINKAGE COVER
2 - PUSH UP LOWER TAB
3 - SCREWS/CLIPS (2)
4 - TAB PUSH HERE
Fig. 16 APPS Assembly
1 - LEVER
2 - MOUNTING BOLTS (6)
3 - WIRE HARNESS CLIP
4 - CALIBRATION SCREWS (NO ADJUSTMENT)
5 - APPS ASSEMBLY
Fig. 17 APPS Connector
1 - APPS
2-TAB
3 - PUSH FOR REMOVAL
4 - APPS CONNECTOR
Fig. 18 High-Pressure Lines at Cylinder Head
BR/BEENGINE 5.9L DIESEL 9 - 247
CYLINDER HEAD (Continued)

(24)Remove the high pressure fuel lines (Fig.
18) (Fig. 19) from the engine as follows:
(a) Remove all injection line-to-intake manifold
cover support bracket bolts.
(b) Loosen the #1, 2, and 4 cylinder high pres-
sure lines at the injection pump.
(c) Loosen the #1, 2, and 4 cylinder high pres-
sure lines at the cylinder head.
(d) Remove the #1, 2, and 4 cylinder high pres-
sure line bundle from the engine.
(e) Loosen the #3, 5, and 6 cylinder high pres-
sure lines at the injection pump.
(f) Loosen the #3, 5, and 6 cylinder high pres-
sure lines at the cylinder head.
(g) Remove the #3, 5, and 6 cylinder high pres-
sure line bundle from the engine.
(25) Remove the lift pump-to-fuel filter low pres-
sure line.
(26) Remove the fuel filter-to-injection pump low
pressure line.
(27) Disconnect the water-in-fuel and fuel heater
connectors.
(28) Remove the fuel filter assembly-to-manifold
cover bolts and remove filter assembly from vehicle.
(29) Disconnect the Intake Air Temperature and
Manifold Air Pressure sensor connectors (Fig. 20).
(30) Remove the cylinder head cover (Fig. 21)
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(31) Remove the rocker levers (Fig. 22), cross
heads and push rods (Fig. 23). Mark each component
so they can be installed in their original positions.NOTE: The #5 cylinder exhaust and the #6 cylinder
intake and exhaust push rods are removed by lift-
ing them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
(32) Remove the fuel return line banjo bolt at the
rear of the cylinder head (Fig. 24). Be careful not to
drop the two (2) sealing washers.
(33) Reinstall the engine lift bracket at the rear of
cylinder head.
(34) Remove twenty six (26) cylinder head-to-block
bolts.
(35) Attach an engine lift crane to engine lift
brackets and lift cylinder head off engine and out of
vehicle.
(36) Remove the head gasket and inspect for fail-
ure.
CLEANINGÐCYLINDER HEAD
CAUTION: Do not wire brush head surface while
fuel injectors are still installed. Fuel injector dam-
age can result.
Clean the carbon from the injector nozzle seat with
a nylon or brass brush.
Scrape the gasket residue from all gasket surfaces.
Wash the cylinder head in hot soapy water solution
(88ÉC or 140ÉF).
Fig. 19 High-Pressure Lines at Fuel Injection Pump
1 - HIGH-PRESSURE LINES AT INJECTION PUMP
2 - FITTINGS
3 - FUEL INJECTION PUMP
Fig. 20 IAT and MAP Sensor Location
1 - MANIFOLD AIR PRESSURE (MAP) SENSOR
2 - REAR OF CYLINDER HEAD
3 - IAT SENSOR
4 - ELECTRICAL CONNECTOR
5 - ELECTRICAL CONNECTOR
9 - 248 ENGINE 5.9L DIESELBR/BE
CYLINDER HEAD (Continued)

(e) Install the front line bundle (cyls. #1, 2, and
4) following the same procedure used for the rear
line bundle.
(f) Torque the connections at the cylinder head
first. Torque connections to 38 N´m (28 ft. lbs.).
(g) Torque the line connections at the injection
pump to 24 N´m (18 ft. lbs.).
(h) Install the injection line support bracket to
intake cover/cylinder head bolts and torque to 24
N´m (18 ft. lbs.).
(16) Install the engine lift bracket at the rear of
cylinder head. Torque to 77 N´m (57 ft. lbs.).
(17) Install the fuel filter to injection pump low
pressure line. Inspect and replace sealing washers if
necessary. Torque banjo bolts to 24 N´m (18 ft. lbs.).
(18) Using new gaskets, install the intake grid
heater and air inlet housing. Torque bolts to 24 N´m
(18 ft. lbs.).
(19) Connect the APPS connector (Fig. 17).
(20) Install the APPS assembly. to the cylinder
head bracket and torque bolts to 12 N´m (105 in.
lbs.).
(21) Install the throttle linkage cover (Fig. 15).
(22) Install the charge air cooler-to-air inlet hous-
ing duct assembly. Torque all clamps to 11 N´m (100
in. lbs.).
(23) Connect intake grid heater wires.
(24) Fasten engine harness to front of cylinder
head with bolt.
(25) Install engine harness ground wire and torque
bolt to 24 N´m (18 ft. lbs.).
(26) Connect engine coolant temperature sensor
connector.
(27) Connect radiator upper hose to thermostat
housing.
(28) Install generator upper bracket and torque
bolts to 41 N´m (31 ft. lbs.).
(29) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(30) Install exhaust manifold/turbocharger assem-
bly. and start all bolts/spacers by hand. Torque bolts
to 43 N´m (32 ft. lbs.).
(31) Connect turbocharger oil drain tube.
(32) Perform the turbocharger pre-lube procedure.
Refer to Group 11, Exhaust System and Turbo-
charger for the correct procedure.
(33) Connect the turbocharger oil supply line.
(34) Install air cleaner housing and duct.
(35) Raise vehicle on hoist.
(36) Install exhaust pipe to turbocharger elbow
(Fig. 14). Torque bolts to 34 N´m (25 ft. lbs.).
(37) Lower vehicle.
(38) Fill engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(39) Start engine and check for leaks.
Fig. 32 Rocker Arms and Pedestal Installation
1 - ROCKER ARM
2 - PEDESTAL
Fig. 33 Cylinder Head Cover Installation
1 - BOLT (5)
2 - GASKET
3 - ªTOP FRONTº
4 - ISOLATOR (5)
9 - 252 ENGINE 5.9L DIESELBR/BE
CYLINDER HEAD (Continued)

CYLINDER HEAD COVER(S)
REMOVAL
(1) Disconnect both battery negative cables.
(2) Loosen the five (5) cylinder head cover bolts
(Fig. 34). Remove the front three bolts and leave the
rear two bolts in the cover.
(3) Lift cover off of cylinder head.
CLEANING
Using a suitable solvent, Clean and dry gasket
mating surfaces on cylinder head and cover. Wipe
gasket dry and inspect for re-use.
INSPECTION
The cylinder head cover gasket and isolators
are reusable.However, should cracks be present in
the rubber/silicone construction, the defective compo-
nents should be replaced.
INSTALLATION
(1) Install the gasket as shown in (Fig. 34). Make
sure the gasket is properly located around the cylin-
der head bolts, with the words ªtop frontº facing up
and towards front of engine.(2) Place two bolts and isolators into the rear two
mounting holes and install the cover.
(3) Install the remaining bolts and isolators. Start-
ing with the center bolt, torque in a circular pattern
to 24 N´m (18 ft. lbs.).
(4) Connect both battery negative cables.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves are made of heat resistant steel, and
have chrome plated stems to prevent scuffing. The
intake and exhaust valves are both similar in head
diameter and overall length, but they have unique
face angles which makes them non-interchangeable.
The valves are distinguished by unique dimples on
the exhaust valve head (Fig. 35).
The exhaust valve springs are made from high
strength, chrome silicon steel. The exhaust valve
springs are also exhaust brake compatible.
STANDARD PROCEDURE-VALVES,GUIDES AND
SPRINGS
REMOVAL
(1) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(2) Support cylinder head on stands, or install
head bolts upside down (through combustion surface
side) to protect injector tips from damage from work
bench.
(3) Remove the injector clamp (Fig. 36) from the
cylinder(s) to be serviced.Do not remove the bolt
shown in (Fig. 36).
Fig. 34 Cylinder Head Cover and Gasket
1 - BOLT (5)
2 - GASKET
3 - ªTOP FRONTº
4 - ISOLATOR (5)
Fig. 35 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
BR/BEENGINE 5.9L DIESEL 9 - 253

(4) Install the valve spring compressor mounting
base (special tool 8319±A) as shown in (Fig. 37).
Reinstall the injector clamp bolt finger tight.
(5) Install the compressor top plate, washer, and
nut. Using a suitable wrench, tighten the nut (clock-
wise) to compress the valve springs (Fig. 38) and
remove the locks.
(6) Rotate the compressor nut counter-clockwise to
relieve tension on the springs. Remove the spring
compressor.
(7) Remove the retainers, springs, valve seals (if
necessary), and valves (Fig. 39). Arrange or number
all components so they can be installed in their orig-
inal locations.(8)Repeat the procedure on all cylinders to be ser-
viced.
Fig. 36 Injector Clamp Removal/Installation
1 - DO NOT REMOVE
2 - INJECTOR CLAMP
Fig. 37 Spring Compressor Mounting BaseÐPart of
Tool 8319±A
1 - COMPRESSOR MOUNTING BASE
Fig. 38 Compressing Valve Springs with Tool
8319±A
1 - SPECIAL TOOL 8319-A
Fig. 39 Valve Spring, Seal, and Retainers
1 - VALVE RETAINING LOCKS
2 - VALVE
3 - SEAL
4 - SPRING
5 - RETAINER
9 - 254 ENGINE 5.9L DIESELBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

CLEANING
Clean the valve stems with crocus cloth or a
Scotch-BriteŸ pad. Remove carbon with a soft wire
brush. Clean valves, springs, retainers, and valve
retaining locks in a suitable solvent. Rinse in hot
water and blow dry with compressed air.
INSPECTION
Visually inspect the valves for abnormal wear on
the heads, stems, and tips. Replace any valve that is
worn out or bent (Fig. 40).
Measure the valve stem diameter in three places
as shown in (Fig. 41).Measure the cylinder head valve guide bore (Fig.
42). Subtract the corresponding valve stem diameter
to obtain valve stem-to-guide clearance.
Measure valve margin (rim thickness) (Fig. 43).
Fig. 40 Visually Inspect Valves for Abnormal Wear
Fig. 41 Measure Valve Stem Diameter
VALVE STEM DIAMETER
6.96 mm (0.2740 in.) MIN
7.010 mm (0.2760 in.) MAX
Fig. 42 Measure Valve Guide Bore
Fig. 43 Measure Valve Margin (Rim Thickness)
VALVE MARGIN (RIM THICKNESS)
0.72 mm (0.031 in.) MIN.
BR/BEENGINE 5.9L DIESEL 9 - 255
INTAKE/EXHAUST VALVES & SEATS (Continued)

Measure the valve spring free length and maxi-
mum inclination (Fig. 44).
Test valve spring force with tool C-647 (Fig. 45).
INSTALLATION
(1) Install new valve seals. The yellow springs are
for the intake valves and the green seals are for the
exhaust valves.(2) Install the valves in their original postion. The
exhaust valves are identified by a dimple on the
valve head (Fig. 46).
(3) Install the valve springs and retainer.
(4) Install the valve spring compressor tool 8319±A
as shown in (Fig. 37) and (Fig. 38).
(5) Compress the valve springs and install the
valve retaining locks (Fig. 39).
(6) Remove the compressor and repeat the proce-
dure on the remaining cylinders.
(7) Install the injector clamp and hold down bolts
and tighten to 10 N´m (89 in. lbs.) torque.
(8) Install the cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
STANDARD PROCEDUREÐVALVE LASH
ADJUSTMENT AND VERIFICATION
NOTE: To obtain accurate readings, valve lash mea-
surements AND adjustments should only be per-
formed when the engine coolant temperature is less
than 60É C (140É F).
The 24±valve overhead system is a ªlow-mainte-
nanceº design. Routine adjustments are no longer
necessary, however, measurement should still take
place when trouble-shooting performance problems,
or upon completion of a repair that includes removal
and installation of the valve train components.
(1) Disconnect battery negative cables.
Fig. 44 Measure Valve Spring Free Length and Max.
Inclination
VALVE SPRING FREE LENGTH
47.75 mm (1.88 in.)
MAX INCLINATION
1.5 mm (.059 in.)
Fig. 45 Testing Valve Spring with Tool C-647
1 - SPECIAL TOOL C-647
VALVE SPRING FORCE 35.33 mm @ 339.8 N (1.39 IN. @76.4
lbs.)
Fig. 46 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
9 - 256 ENGINE 5.9L DIESELBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

(2) Remove cylinder head cover (Fig. 47) (Refer to
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Remove the crankcase breather and vapor can-
ister (Fig. 48).
(4) Using the crankshaft barring tool #7471±B,
rotate the engine and align the pump gear mark with
the top dead center (TDC) mark on the gear housing
cover (Fig. 49).
(5) With the engine in this position (pump gear
mark at 12 o'clock), valve lash can be measured at
the following rocker arms:INTAKE 1±2±4 /
EXHAUST 1±3±5. Measure the valve lash by insert-
ing a feeler gauge between the rocker arm socket and
crosshead (Fig. 50). Refer to VALVE LASH LIMIT
CHART for the correct specifications. If the measure-
ment fallswithinthe limits, adjustment/resettingis
notnecessary. If measurement finds the lashout-
sideof the limits, adjustment/resettingisrequired.
VALVE LASH LIMIT CHART
INTAKE EXHAUST
0.152 mm ( 0.006 in.)
MIN.0.381 mm (0.015 in.)
MIN.
0.381 mm (0.015 in.)
MAX.0.762 mm (0.030 in.)
MAX.
note:
If measured valve lash falls within these
specifications, no adjustment/reset is necessary.
Engine operation within these ranges has no
adverse affect on performance, emissions, fuel
economy or level of engine noise.
Fig. 47 Cylinder Head Cover and Gasket
1 - BOLT (5)
2 - GASKET
3 - ªTOP FRONTº
4 - ISOLATOR (5)
Fig. 48 Crankcase Breather Vapor Canister
1 - ENGINE FRONT COVER STUD
2 - STRAP
3 - VAPOR CANISTER
4 - NUT
5 - CAP
6 - CRANKCASE BREATHER
7 - CLAMP
8 - HOSE
BR/BEENGINE 5.9L DIESEL 9 - 257
INTAKE/EXHAUST VALVES & SEATS (Continued)