2003 DODGE RAM radiator

(1) Remove oil pressure sending unit from back of
block.
(2) Insert a 3.175 mm (1/8 in.) finish wire, or
equivalent, into passage.
(3) Plug should be 190.0 to 195.2 mm (7-1/2 to
7-11/16 in.) from machined surface of block (Fig. 19).
If plug is too high, use a suitable flat dowel to posi-
tion properly.
(4) If plug is too low, remove oil pan and No. 4
main bearing cap. Use suitable flat dowel to position
properly. Coat outside diameter of plug with Mopart
Stud and Bearing Mount Adhesive. Plug should be
54.0 to 57.7 mm (2-1/8 to 2-5/16 in.) from bottom of
the block.CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVALÐCAMSHAFT
NOTE: The camshaft has an integral oil pump and
distributor drive gear (Fig. 20).
(1) Remove the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL).
(2) Remove the A/C Condenser (if equipped)
(3) Remove the engine cover.
(4) Remove intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(5) Remove cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(6) Remove timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL) and timing chain (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(7) Remove rocker arms.
(8) Remove push rods and tappets. Identify each
part so it can be installed in its original location.
(9) Remove distributor and lift out the oil pump
and distributor drive shaft.
(10) Remove camshaft thrust plate, note location of
oil tab (Fig. 21).
(11) Install a long bolt into front of camshaft to aid
in removal of the camshaft. Remove camshaft, being
careful not to damage cam bearings with the cam
lobes.
INSTALLATIONÐCAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2
inches) of its final position in cylinder block.
(2) Install Camshaft Holder Tool C-3509 with
tongue back of distributor drive gear (Fig. 22).
Fig. 19 Oil Line Plug
1 - RIGHT OIL GALLERY
2 - CYLINDER BLOCK
3 - OIL FROM FILTER TO SYSTEM
4 - OIL TO FILTER
5 - FROM OIL PUMP
6 - CRANKSHAFT
7 - PLUG
Fig. 20 Camshaft and Sprocket Assembly
1 - THRUST PLATE
2 - OIL PUMP AND DISTRIBUTOR DRIVE GEAR INTEGRAL WITH
CAMSHAFT
3 - CAMSHAFT SPROCKET
9 - 250 ENGINE - 5.9LDR
ENGINE BLOCK (Continued)

(3) Hold tool in position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block.Tool should remain
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower right hole in
thrust plate.Tighten bolts to 24 N´m (210 in. lbs.)
torque. Top edge of tab should be flat against thrust
plate in order to catch oil for chain lubrication.(5) Install timing chain and gears (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(6) Measure camshaft end play (Refer to 9 -
ENGINE - SPECIFICATIONS). If not within limits
install a new thrust plate.
(7) Each tappet reused must be installed in the
same position from which it was removed.When
camshaft is replaced, all of the tappets must be
replaced.
(8) Install distributor and distributor drive shaft.
(9) Install push rods and tappets.
(10) Install rocker arms.
(11) Install timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(12) Install cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(13) Install intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSTALLA-
TION).
(14) Install the engine cover.
(15) Install the A/C Condenser (if equipped)
(16) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
(17) Start engine check for leaks.
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING ROD
BEARING FITTING
Fit all rods on a bank until completed. DO NOT
alternate from one bank to another, because connect-
ing rods and pistons are not interchangeable from
one bank to another.
The bearing caps are not interchangeable and
should be marked at removal to ensure correct
assembly.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing shell,
be certain that the V-groove in the shell is in line
with the V-groove in the cap. This provides lubrica-
tion of the cylinder wall in the opposite bank.
The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and
caps.
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 in.).
Bearings are available in 0.025 mm (0.001 in.), 0.051
mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 mm
(0.010 in.) and 0.305 mm (0.012 in.) undersize.
Install the bearings in pairs. DO NOT use a new
bearing half with an old bearing half. DO NOT
file the rods or bearing caps.
Fig. 21 Timing Chain Oil
1 - THRUST PLATE FRONT SIDE
2 - CHAIN OIL TAB
3 - THRUST PLATE REAR SIDE
Fig. 22 Camshaft Holding Tool C-3509 (Installed
Position)
1 - SPECIAL TOOL C-3509
2 - DRIVE GEAR
3 - DISTRIBUTOR LOCK BOLT
DRENGINE - 5.9L 9 - 251
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

(5) Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and
nuts to 34 N´m (25 ft. lbs.) torque.
(6) Lower the vehicle.
(7) Connect the negative cable to the battery.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(3) Remove power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(4) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(5) Loosen oil pan bolts and remove the front bolt
at each side.
(6) Remove the cover bolts.
(7) Remove chain case cover and gasket using
extreme caution to avoid damaging oil pan gasket.
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
(2) The water pump mounting surface must be
cleaned.
(3) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of MopartSilicone Rubber Adhe-
sive Sealant, or equivalent, at the joint between tim-
ing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.NOTE: Special Tool 6635 must be used to align the
front cover and seal with the crankshaft.
(4) Position the special tool 6635 onto the crank-
shaft (Fig. 75).
(5) Tighten chain case cover bolts to 41 N´m (30
ft.lbs.) torque. Tighten oil pan bolts to 24 N´m (215
in. lbs.) torque.
(6) Remove special tool 6635.
(7)
Inspect the seal flange on the vibration damper.
(8) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(9) Install water pump and housing assembly
using new gaskets (Refer to 7 - COOLING/ENGINE/
WATER PUMP - INSTALLATION).
(10) Install power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(11) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(12) Install the cooling system fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(13) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(14) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(15) Connect the negative cable to the battery.
(16) Start engine check for leaks.
Fig. 74 Engine Exhaust Manifold Installation - 5.9L
Engines
1 - EXHAUST MANIFOLD (LEFT)
2 - BOLTS & WASHERS
3 - NUTS & WASHERS
4 - EXHAUST MANIFOLD (RIGHT)
5 - BOLTS & WASHERS
Fig. 75 Position Special Tool 6635 onto Crankshaft
1 - SPECIAL TOOL 6635
2 - OIL SEAL
3 - TIMING CHAIN COVER
9 - 278 ENGINE - 5.9LDR
EXHAUST MANIFOLD (Continued)

²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Disconnect the negative cable(s) from the bat-
tery.
(2) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(3) Place a shop towel around the fuel injectors to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the fuel injectors (Refer
to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL
INJECTOR - REMOVAL).
(4) With all injectors removed, rotate the crank-
shaft using the crankshaft barring tool (PN 7471±B).
(5) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(6) Be sure all fluid has been removed from the
cylinders.
(7) Repair engine or components as necessary to
prevent this problem from occurring again.
(8) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(9) Install fuel injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
(10) Drain engine oil. Remove and discard the oil
filter (Refer to 9 - ENGINE/LUBRICATION/OIL FIL-
TER - REMOVAL).
(11) Install the drain plug. Tighten the plug to 50
N´m (37 ft. lbs.) torque.
(12) Install a new oil filter (Refer to 9 - ENGINE/
LUBRICATION/OIL FILTER - INSTALLATION).
(13) Fill engine crankcase with the specified
amount and grade of oil (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES - SPECIFICA-
TIONS).
(14) Connect the negative cable(s) to the battery.
(15) Start the engine and check for any leaks.
REMOVAL
REMOVALÐENGINE
(1) Disconnect both battery negative cables.
(2) Disconnect engine grid heater harness at grid
heater relays.(3) Disconnect electrical connections from rear of
alternator.
(4) Recover A/C refrigerant. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
(5) Raise vehicle on a hoist.
(6) Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(7) Remove engine oil drain plug and drain engine
oil.
(8) Remove fan/drive assembly. Refer to Section 7
± Fan/Drive Removal
(9) Remove radiator upper hose.
(10) Remove upper fan shroud mounting bolts.
(11) Disconnect the coolant recovery bottle hose
from the radiator fill neck and remove bottle.
(12) Using a 36mm wrench, remove viscous fan/
drive assembly. (Refer to 7 - COOLING/ENGINE/RA-
DIATOR FAN - REMOVAL).
(13) Remove cooling fan and shroud together.
(14) Disconnect heater core supply and return
hoses from the cylinder head fitting and coolant pipe.
(15) Raise vehicle on a hoist.
(16) Remove transmission and transfer case (if
equipped).
(17) Disconnect exhaust pipe from turbocharger
extension pipe.
(18) Disconnect engine harness to vehicle harness
connectors.
(19) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(20) Remove flywheel/flexplate.
(21) Remove transmission adapter
(22) Disconnect A/C suction/discharge hose from
the rear of the A/C compressor.
(23) Lower vehicle.
(24) Disconnect lower radiator hose from radiator
outlet.
(25) Automatic transmission models:
(26) Disconnect transmission oil cooler lines from
in front of radiator using special tool #6931
(27) Remove radiator. (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(28) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(29) Disconnect charge air cooler piping.
(30) Remove charge air cooler mounting bolts.
(31) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(32) Remove damper and speed indicator ring from
front of engine.
(33) Disconnect engine block heater connector.
(34) Disconnect A/C compressor and pressure sen-
sor electrical connectors.
9 - 290 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

(2) Lower engine into the engine compartment and
install the engine the engine mount through bolts
and nuts.
(3) Tighten the mount through bolts and nuts to
88 N-m (65 ft-lbs) torque.
(4) Remove the engine lifting device (Tool 9009).
(5) Check cylinder head capscrew length and
install into cylinder head.
(6) Torque alternately to 70 N-m (52 ft-lbs). Torque
alternately to 105 N-m (77 ft-lbs). Rotate 90 degrees.
(7) Install rocker housing. Torque to 24 N-m (18 ft-
lbs). Refer to Section 9 Rocker Housing Installation
(8) Replace injector o-ring and sealing washer on
injectors #5 and #6. Install injectors and alternately
tighten hold-down capscrews to 10 N-m (89 in-lbs).
(9) Install fuel connector tube and fuel connector
tube nut. Torque to 50 N-m (37 ft-lb). 10.
(10) Install #5 and #6 high pressure fuel lines. Fol-
low correct torque sequence per section 14. Torque
fuel line fittings to 30 N-m (22 ft-lb). Torque brace
capscrew to 24 N-m (18 ft-lb).
(11) Install rear engine lift bracket. Torque to 77
N-m (57 ft-lb).
(12) Install push tubes, rocker arms, and pedestals
for cylinders #4, #5, and #6. Torque the mounting
bolts to 36 N-m (27 ft-lbs).
(13) Reset valve lash on cylinders #4, #5, and #6.
Torque adjusting nuts to 24 N-m (18 ft-lbs).
(14) Install cylinder head cover. Torque to 24 N-m
(18 ft-lbs).(Refer to 9 - ENGINE/CYLINDER HEAD -
INSTALLATION).
(15) Connect breather tube and lube oil drain tube
to breather housing. Install breather housing. Torque
capscrews to 24 N-m (18 ft-lbs)
(16) Connect fuel supply and return hoses.
(17) Connect ECM ground to hydroform screw.
Connect ECM power connector.
(18) Install the APPS cable(s) to the APPS. Install
the throttle linkage cover.
(19) Install the power steering pump.
(20) Install the damper and speed indicator ring.
Torque to 40 N-m (30 ft-lb) plus 60 degrees.
(21) Connect the engine block heater connection.
(22) Connect the A/C compressor and pressure sen-
sor connectors
(23) Install the charge air cooler and a/c condenser
(if equipped). Install and tighten the charge air
cooler mounting bolts to 2 N-m (17 in-lbs).
(24) Connect the charge air cooler piping. Torque
all clamps to 8 N-m (72 in-lbs).
(25) Connect the a/c refrigerant lines to the a/c
condenser (if equipped).
(26) Install the radiator upper support panel.
(27) Install radiator.
(28) Connect the transmission quick-connect oil
cooler lines.(29) Raise vehicle.
(30) Connect a/c compressor suction/discharge hose
(if equipped).
(31) Install the radiator lower hose and clamps.
(32) Install the battery negative cables to the
engine block on the driver and passenger side.
(33) Install the transmission adapter with a new
camshaft rectangular ring seal. Torque to 77 N-m (57
ft-lb).
(34) Install the flywheel/flexplate. Torque to 137
N-m (101 ft-lb).
(35) Install the starter motor. Torque to 43 N-m
(32 ft-lb). (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(36) Connect engine to vehicle harness connectors.
(37) Install transmission and transfer case (if
equipped).
(38) Connect the exhaust pipe to the turbocharger
elbow.
(39) Connect the transmission auxiliary oil cooler
lines (if equipped).
(40) Lower the vehicle.
(41)
Connect the heater core supply and return hoses.
(42) Install the cooling fan and upper fan shroud
at the same time. (Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - INSTALLATION).
(43) Install the coolant recovery bottle.
(44) Install the windshield washer bottle.
(45) Install the upper radiator hose and clamps.
(46) Raise vehicle.
(47) Connect electronically controlled fan drive
wire harness. Install lower radiator fan shroud.
(48) Change oil filter and install new engine oil.
(49) Fill the cooling system with coolant. (Refer to
7 - COOLING - STANDARD PROCEDURE).
(50) Connect grid heater harness at grid heater
relays.
(51) Connect electrical connections to rear of alter-
nator.
(52) Start the engine and inspect for engine oil,
coolant, and fuel leaks.
INSTALLATIONÐCRANKCASE BREATHER
(1) Install a new o-ring onto the breather element.
(2) Lubricate o-ring and install into cylinder head
cover. Torque capscrews to 10 N´m (89 in. lbs.).
(3) Connect breather tube and lube oil drain tube.
(4) Install breather cover (Fig. 4). Torque to 24
N´m (18 ft. lbs.)
(5) Install oil fill cap.
9 - 292 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

Filter Removal
(1) The housing cover is equipped with spring clips
(Fig. 6) and is hinged with plastic tabs. Unlatch clips
from top of air cleaner housing and tilt housing cover
up for cover removal.
(2) Remove air cleaner element from air cleaner
housing.
INSTALLATION
(1) Before installing new air cleaner element (fil-
ter), clean inside of air cleaner housing.
(2) Position air cleaner cover to tabs on front of air
cleaner housing. Latch spring clips to seal cover to
housing.
CYLINDER HEAD
DESCRIPTION
The cylinder head is constructed of cast iron and is
a one piece cross flow design with four valves per cyl-
inder. The arrangement of two intake and two
exhaust valves per cylinder allows for a centrally
located injector. The cylinder head also includes an
integral intake manifold, an integral thermostat
housing, and a longitudal fuel return rifle, which
exits at the rear of the head. The 24 valve design
also includes integrally cast valve guides and hard-
ened intake and exhaust valve seat inserts.
REMOVAL
(1) Disconnect battery negative cables.
(2) Raise vehicle on hoist.
(3) Drain engine coolant.
(4) Disconnect exhaust pipe from turbocharger
elbow.
(5) Lower vehicle.
(6) Disconnect air inlet temperature/pressure sen-
sor.
(7) Remove air cleaner housing and snorkel from
the vehicle. Cap off turbocharger air inlet to prevent
intrusion of dirt or foreign material.
(8) Disconnect cab heater core supply and return
hoses from the cylinder head and heater pipe.
(9) Disconnect turbocharger oil drain tube at rub-
ber hose connection. Cap off open ports to prevent
intrusion of dirt or foreign material.
(10) Disconnect turbocharger oil supply line at the
turbocharger end. Cap off open ports to prevent
intrusion of dirt or foreign material.
(11) Remove exhaust manifold-to-cylinder head
bolts, spacers, heat shield, retention straps, and cab
heater plumbing. Remove exhaust manifold and tur-
bocharger from the vehicle as an assembly.
(12) Remove cooling fan assembly.
(13) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(14) Remove cooling fan support from cylinder
block.
(15) Remove upper generator bolt, loosen lower
generator bolt, and rotate generator away from cylin-
der head.
(16) Disconnect radiator upper hose from the ther-
mostat housing.
(17) Disconnect the Intake Air Temperature, Man-
ifold Air Pressure, and Coolant Temperature sensor
connector.
(18) Remove the engine harness to cylinder head
attaching bolts and P-clips at front of head.
(19) Remove the throttle linkage cover (Fig. 8).
(20) Remove the six (6) accelerator pedal position
sensor assembly-to-cylinder head bracket bolts (Fig.
9) and secure the entire assembly out of the way.
Disconnect the APPS connector (Fig. 10).It is not
necessary to disconnect the cables from the
throttle control assembly.
(21) Remove the intake air grid heater wires from
the grid heater.
(22) Remove engine oil level indicator tube attach-
ing bolt at fuel filter housing bracket and inlet air
connection..
(23) Remove the charge air cooler-to-air inlet hous-
ing pipe.
Fig. 7 FILTER MINDERŸ - 5.9L DIESEL
1 - PRESS BUTTON TO RESET
2 - YELLOW DISC
3 - RED ZONE
4 - TO AIR FILTER HOUSING
5 - FILTER MINDER
9 - 298 ENGINE 5.9L DIESELDR
AIR CLEANER ELEMENT (Continued)

(9) Install rocker housing and bolts. Tighten to 24
Nm (18 lb. ft.).
(10) Install fuel injector(Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
(11) Install fuel injector tube and fuel injector tube
nut. Torqu to 50 N´m (37 ft. lbs.).
(12) Install injector harness nuts. Tighten to 1.5
Nm (13 lb. in.).
(13) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(14) Install wire harness P-clip to cylinder head
behind filter housing 24 N´m (18 ft. lbs.).
(15) Connect the IAT and MAP sensor connector.
(16) Install the fuel filter canister assembly and
torque mounting bolts to 24 N´m (18 ft. lbs.).
(17) Connect fuel lift pump, WIF sensor, and fuel
heater.
(18) Remove the engine lift bracket at rear of cyl-
inder head.
CAUTION: Failure to follow procedure will result in
fuel leaks and/or fuel system failure.
(19)Install the fuel rail and high pressure
fuel lines as follows:
(a) Hand tighten fuel rail bolts.
(b) Hand tighten fuel drain line to pressure lim-
iting valve. Hand tighten at fuel filter housing.
(c) Hand tighten fuel rail-to-cylinder head lines.(d) Install fuel line brace bolts-to-intake mani-
fold finger tight.
(e) Hand tighten fuel pump to fuel rail line.
(f) Torque fuel line nuts at cylinder head to 30
Nm ( 22 ft. lbs.).
(g) Torque fuel line nuts at fuel rail to 30 Nm
(22 ft. lbs.)
(h) Torque fuel pump to fuel rail line to 30 Nm
(22 ft. lbs.).
(i) Torque fuel drain banjo bolt at pressure lim-
iting valve and front of fuel filter housing to 24 Nm
(18 ft. lbs.).
(j) Torque fuel line brace bolts to 24 N´m (18 ft.
lbs.).
(k) Torque rail bolts to 24 Nm (18 ft. lbs.).
(l) Connect fuel pressure sensor.
(20) Install the engine lift bracket at the rear of
cylinder head. Torque to 77 N´m (57 ft. lbs.).
(21) Reposition number 6 fuel line shield and
torque to 43 N´m (32 ft. lbs.).
(22) 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.).
(23) Connect fuel return line at back of cylinder
head hand tight.
(24) Connect fuel return line at filter housing hand
tight.
(25) Torque banjo connections at cylinder head and
fuel filter housing to 24 Nm (18 ft. lbs.)
(26) Install bracket to rear of filter housing.
Torque to 24 Nm (18 ft. lbs.).
(27) Using new gaskets, install the intake grid
heater and air inlet housing. Torque bolts to 24 N´m
(18 ft. lbs.).
(28) Install wire harness P-clip and push on clip to
air inlet housing.
(29) Connect engine oil level indicator tube at fuel
filter housing and at air inlet housing.
(30) Connect the APPS connector.
(31) Install the APPS assembly to the cylinder
head bracket and torque bolts to 24 N´m (18 ft. lbs.).
(32) Install the throttle linkage cover.
(33) Install the charge air cooler-to-air inlet hous-
ing duct assembly. Torque all clamps to 11 N´m (100
in. lbs.).
(34) Connect intake grid heater wires.
(35) Secure engine harness to front of cylinder
head with bolt at four locations.
(36) Connect engine coolant temperature sensor
connector.
(37) Connect radiator upper hose to thermostat
housing.
(38) Rotate generator into position. Install upper
bolt and torque upper and lower bolts.
(39) Install wire harness push-on clip below
bracket.
Fig. 20 Rocker Arm and Pedestal Removal
1 - ROCKER ARM
2 - PEDESTAL
DRENGINE 5.9L DIESEL 9 - 303
CYLINDER HEAD (Continued)

CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS
NOTE: Measure the diameter of each bore. If the
camshaft bore for the first or rear cam bushing is
worn beyond the limit, install a new service bush-
ing. Inspect the rest of the camshaft bores for dam-
age or excessive wear.If the bores without a
bushing are worn beyond the limit, the engine must
be removed for machining and installation of ser-
vice bushings. If badly worn, replace the cylinder
block.
(1) Remove the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(2) Remove the bushing from the No.1 bore and
No.7 using a universal cam bushing tool.
(3) Mark the cylinder block so you can align the oil
hole in the cylinder block with the oil hole in the
bushing.
REMOVAL - CAMSHAFT
(1) Disconnect both battery negative cables.
(2) Recover A/C refrigerant (if A/C equipped) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE).
(3) Raise vehicle on hoist.
(4) Drain engine coolant into container suitable for
re-use (Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(5) Lower vehicle.
(6) Remove radiator upper hose.
(7) Remove viscous fan/drive assembly and fan
shroud (Refer to 7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL).
(8) Disconnect the coolant recovery bottle hose
from the radiator filler neck.
(9) Disconnect lower radiator hose from radiator
outlet.
(10)Automatic Transmission models:Discon-
nect transmission oil cooler lines from front of radia-
tor using Special Tool 6931 (unless equipped with
finger-release disconnect).
(11) Remove radiator mounting screws and lift
radiator out of engine compartment.
(12) Remove upper radiator support panel.
(13) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(14) Disconnect charge air cooler piping from the
cooler inlet and outlet.(15) Remove the two charge air cooler mounting
bolts.
(16) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(17) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(18) Remove accessory drive belt tensioner.
(19) Remove the fan support/hub assembly.
(20) Remove crankshaft damper and speed indica-
tor ring (Refer to 9 - ENGINE/ENGINE BLOCK/VI-
BRATION DAMPER - REMOVAL).
(21) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the sealing surfaces. Remove dust
seal with cover.
(22) Using Special Tool 7471±B Crankshaft Bar-
ring Tool, rotate the crankshaft to align the timing
marks on the crankshaft and the camshaft gears.
(23) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(24) Remove the rocker arms, cross heads, and
push rods (Fig. 55). Mark each component so they
can be installed in their original positions.
NOTE: The #5 cylinder intake and the #6 cylinder
intake and exhaust pushrods are removed by lifting
them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
(25) Raise the tappets as follows, using the wooden
dowel rods (Fig. 57)provided with the Miller Tool Kit
8502.
(a) Insert the slotted end of the dowel rod into
the tappet.The dowel rods for the rear two
cylinders will have to be cut for cowl panel
clearance.Press firmly to ensure that it is seated
in the tappet.
Fig. 55 Push Rod Removal/Installation
DRENGINE 5.9L DIESEL 9 - 317