2003 DODGE RAM Diesel

(b) Raise the dowel rod to bring the tappet to
the top of its travel, and wrap a rubber band
around the dowel rods (Fig. 57) to prevent the tap-
pets from dropping into the crankcase.
(c) Repeat this procedure for the remaining cyl-
inders.
(26) Verify that the camshaft timing marks are
aligned with the crankshaft mark (Fig. 56).
(27) Remove the bolts from the thrust plate.
(28) Remove engine mount through bolts.
(29) Install engine support fixture special tool #
8534,and steel bracket/wing nut special tool #
8534A.(30) Raise engine enough to allow camshaft
removal.
(31) Remove the camshaft, gear and thrust plate.
INSPECTION
Camshaft
(1) Inspect the valve lobes and bearing journals for
cracks, pitting, scoring, or generally excessive wear.
Replace any camshaft that exceeds the allowable lim-
its.
(2) Measure the bearing journals and lobes (Fig.
58).
CAUTION: If Camshaft lobes are worn, requiring
camshaft replacement, it is necessary to replace the
tappets also. (Refer to 9 - ENGINE/ENGINE BLOCK/
SOLID LIFTERS - REMOVAL).
CAMSHAFT DIMENSIONS
CAMSHAFT DIMENSIONS
Journal diameter (No.1 and No.7)
Min. 54.028 mm.
(2.127 in.)
Max. 54.048 mm.
(2.128 in.)
Journal diameter (No.2 through
No.6)
Min. 53.962 mm.
(2.1245 in.)
Max. 54.013 mm.
(2.1265 in.)
Diameter of peak of lobe
Intake
Min. 47.175 mm
(1.857 in.)
Max 47.855 mm.
Exhaust
Min. 45.632 mm.
(1.797 in.)
Max. 46.312 mm.
(1.823 in.)
Fig. 56 Timing Mark Alignment
Fig. 57 Use Wooden Dowel Rods to Secure Tappets
in Place - Typical
9 - 318 ENGINE 5.9L DIESELDR
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

Camshaft Bushing/Bores
Camshaft bores No. 2±6do notuse a bushing.
(1) Inspect the camshaft bushing and bores for
signs of excessive wear.
(2) Measure the camshaft bushing and bores (Fig.
59) with a telescoping bore gauge and micrometer. If
out of specification, (Refer to 9 - ENGINE/ENGINE
BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
(3) Inspect the camshaft bushing oil holes for
alignment with cylinder block (Fig. 60).
Camshaft Gear
Inspect the camshaft gear for cracks (gear and
hub) (Fig. 61), and chipped/broken/fretted teeth (Fig.
62). If replacement is necessary, camshaft and gear
are replaced as an assembly. (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
Fig. 58 Measuring
1 - VALVE LOBE
2 - CAMSHAFT JOURNAL
Fig. 59 Measuring Camshaft Bushing and Bores
Fig. 60 Inspecting Oil Hole Alignment
1 - CAMSHAFT BUSHING
Fig. 61 Inspect Camshaft Gear Hub for Cracks -
Typical
Fig. 62 Inspect Camshaft Gear for Cracks and
Fretting - Typical
DRENGINE 5.9L DIESEL 9 - 319
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

Thrust Plate
Inspect the camshaft thrust plate for excessive
wear in the camshaft contact area. Measure thrust
plate thickness using the CAMSHAFT THRUST
PLATE THICKNESS CHART. Replace any thrust
plate that falls outside of these specifications:
CAMSHAFT THRUST PLATE THICKNESS CHART
MIN. 9.34 mm (0.368 in.)
MAX. 9.60 mm (0.378 in.)
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS
(1) Apply a coating of Loctitet640 Adhesive to the
backside of the new bushing. Avoid getting adhesive
in the oil hole.
(2) Use a universal cam bushing installation tool
and install the front bushing so that it is even with
the front face of the cylinder block. The oil hole must
be aligned. A 3.2 mm (0.128 inch) diameter rod must
be able to pass through the hole. (Fig. 63).
(3) Install the rear camshaft bushing is flush with
the rear face of the block. The oil hole must be
aligned. A 3.2 mm (0.128 inch) diameter rod must be
able to pass through the hole.
(4) Measure the installed bushings at the front
and rear bores. The minimum inside diameter is
54.083 mm (2.1293 inch), and the maximum inside
diameter is is 54.147 mm. (2.1318 in.).
INSTALLATION - CAMSHAFT
(1) Lubricate the camshaft bushing and bores with
fresh engine oil or suitable equivalent.
(2) Liberally coat the camshaft lobes, journals, and
thrust washer with fresh engine oil or suitable equiv-
alent.
CAUTION: When installing the camshaft, DO NOT
push it in farther than it will go with the thrust
washer in place.(3) Install the camshaft and thrust plate. Align the
timing marks as shown (Fig. 64).
(4) Install the thrust plate bolts and tighten to 24
N´m (18 ft. lbs.) torque.
(5) Measure camshaft back lash and end clearance.
BACKLASH Ð 0.075Ð0.250 mm
(0.003Ð0.013 inch)
CLEARANCE Ð 0.025Ð0.500 mm
(0.001Ð0.020 inch)
(6) Remove the wooden dowel rods and rubber
bands from the tappets.
(7) Lubricate the push rods with engine oil and
install in their original location.Verify that they
are seated in the tappets.
(8) Lubricate the valve tips with engine oil and
install the crossheads in their original locations.
(9) Lubricate the crossheads and push rod sockets
with engine oil and install the rocker arms and ped-
estals in their original locations. Tighten bolts to 36
N´m (27 ft. lbs.) torque.
(10)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
(11) Install the cylinder head cover and reusable
gasket (Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(12)
Install gear housing cover (Refer to 9 - ENGINE/
VALVE TIMING/GEAR HOUSING COVER - INSTAL-
LATION). Install front crankshaft dust seal.
(13) Install the crankshaft damper with the speed
indicator ring (Refer to 9 - ENGINE/ENGINE
BLOCK/VIBRATION DAMPER - INSTALLATION).
Fig. 63 Oil Hole Alignment
1 - CAMSHAFT BUSHING
Fig. 64 Timing Mark Alignment
9 - 320 ENGINE 5.9L DIESELDR
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

(14) Install the fan support/hub assembly and
tighten bolts to 33 N´m (24 ft. lbs.) torque.
(15) Install the power steering pump.
(16) Install accessory drive belt tensioner. Torque
bolt to 43 Nm (43 ft. lbs.).
(17) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(18) Install the charge air cooler (with a/c con-
denser and auxiliary transmission oil cooler, if
equipped) and tighten the mounting bolts to 2 N´m
(17 in. lbs.) torque.
(19) Connect charge air cooler inlet and outlet
pipes. Tighten clamps to 11 N´m (95 in. lbs.) torque.
(20) Install the radiator upper support panel.
(21) Close radiator petcock and lower the radiator
into the engine compartment. Tighten the mounting
bolts to 11 N´m (95 in. lbs.) torque.
(22) Raise vehicle on hoist.
(23)
Connect radiator lower hose and install clamp.
(24) Connect transmission auxiliary oil cooler lines
(if equipped).
(25) Lower vehicle.
(26) Install the fan shroud and tighten the mount-
ing screws to 6 N´m (50 in. lbs.) torque.
(27) Install the electronically controlled viscous
fan/drive assembly. Connect harness connector.(Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(28) Install the coolant recovery and windshield
washer fluid reservoirs to the fan shroud.
(29) Connect the coolant recovery hose to the radi-
ator filler neck.
(30) Add engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(31) Charge A/C system with refrigerant (if A/C
equipped) (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(32) Connect the battery negative cables.
(33) Start engine and check for engine oil and cool-
ant leaks.
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING ROD
BEARING AND CRANKSHAFT JOURNAL
CLEARANCE
(1) Measure the connecting rod bore with bearings
removedand the bolts tightened to 100 N´m (73 ft.
lbs.) torque..
(2) Measure the connecting rod bore with the bear-
ingsinstalledand the bolts tightened to 100 N´m
(73 ft. lbs.) torque.
Measure within 20É arc from each side of the part-
ing line. Also measure 90É from parting line.Record the smallest and largest diameter.
Measure the diameter of the rod journal at the
location shown (Fig. 65). Calculate the average diam-
eter for each side of the journal.
Determine minimum bearing clearance by calculating
the differance between the smallest connecting rod bore
diameter with the bearing installed and the average
diameter for each side of the crankshaft journal.
Determine the maximum bearing clearance by calcu-
lating the difference between the largest connecting rod
bore diameter and the average diameter with the bear-
ing installed for each side of the crankshaft journal.
DESCRIPTION MEASUREMENT
CONNECTING ROD
BORE, BEARINGS
REMOVEDMIN. 72.99 mm (2.874
in.)
MAX. 73.01 mm (2.875
in.)
CONNECTING ROD
BORE, BEARINGS
INSTALLEDMIN. 69.05 mm (2.719
in.)
MAX. 69.10 mm (2.720
in.)
If the crankshaft is within limits, replace the bear-
ing. If the crankshaft is out of limits, grind the
crankshaft to the next smaller size and use oversize
rod bearings.
Fig. 65 Connecting Rod Journal Diameter Limits
CONNECTING ROD JOURNAL DIAMETER
LIMITS CHART
DESCRIPTION MEASUREMENT
CRANKSHAFT ROD JOURNAL
DIAMETERMin. 68.96 mm (2.715 in.)
Max. 69.01 mm (2.717 in.)
BEARING CLEARANCE Min. 0.04 mm (.002 in.)
Max. 0.12 mm (0.005 in.)
DRENGINE 5.9L DIESEL 9 - 321
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

CRANKSHAFT AND GEAR
DESCRIPTION
The crankshaft (Fig. 66) is a forged steel, integrally
balanced unit. It is supported by seven main bear-
ings, with position number six designated as the
thrust journal. The crankshaft is held in place by
main caps and 12 mm capscrews. The crankshaft
also has internal cross drillings to supply the con-
necting rods with engine oil.
REMOVALÐGEAR
(1) Remove the gear housing cover. (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- REMOVAL)
(2) Remove the crank gear using a heavy duty
puller.
(3) Split the gear and remove it from the crank-
shaft.
INSTALLATION - GEAR
(1) Remove all burrs and make sure the gear sur-
face on the end of the crankshaft is smooth.
(2) If removed, install a new alignment pin. Drive
the pin in using a ball- peen hammer, leaving it pro-truding 1.0 mm (0.039 inch) to 1.5 mm (0.059 inch)
above the crankshaft (Fig. 67).
WARNING: WEAR PROTECTIVE GLOVES TO PRE-
VENT INJURY.
CAUTION: DO NOT heat the gear longer than 45
minutes.
(3) Heat the crankshaft gear for 45 minutes at a
temperature of 149ÉC (300ÉF).Do not use torch,
gear failure will occur.
(4) Apply a thin coat of lubricant to the nose of the
crankshaft.
(5) Position the gear with the timing mark out and
install it on the crankshaft using the alignment pin.
Make sure the gear contacts the shoulder.
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - MAIN BEARING
CLEARANCE
Inspect the main bearing bores for damage or
abnormal wear.
(1) Remove bearings and measure main bearing
bore diameter after torquing main bearing cap bolts
to 176 Nm (130 ft. lbs.).
(2) Install the crankshaft main bearings and mea-
sure main bearing bore diameter with the main bolts
tightened to 176 N´m (130 ft. lbs.) torque (Fig. 68).
Fig. 66 Crankshaft
Fig. 67 Installing Alignment Pin
1 - ALIGNMENT PIN
9 - 322 ENGINE 5.9L DIESELDR

(3) Measure the diameter of the main journal at
the locations shown (Fig. 69). Calculate the average
diameter for each side of the journal.
MAIN BEARING BORE DIAMETER CHART
ITEM MAIN BEARING BORE
DIAMETER (MAXIMUM)
BEARINGS INSTALLED 83.106 mm (3.2719 in.)
BEARINGS REMOVED Min 87.983 mm (3.4639
in.)
Max. 88.019 mm (3.4653
in.)
CRANKSHAFT MAIN JOURNAL DIAMETER
CHART
ITEM SPECIFICATION
Minimum diameter 82.962 mm (3.2662 in.)
Maximum diameter 83.013 mm (3.2682 in.)
Maximum out of
roundness0.050 mm (.002 in.)
Maximum taper 0.013 mm (.0005 in.)
Thrust distance (at No.6
position)Min. 0.065 mm (.003 in.)
Max. 0.432 mm (.017 in.)
(4) Calculate the main bearing journal to bearing
clearance. Maximum clearance is 0.119 mm (0.00475
inch). If the crankshaft journal is within limits,
replace the main bearings. If not within specifica-
tions, grind the crankshaft to next size and use over-
size bearings.
(5) Measure thrust distance at the No.6 position.
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect both battery negative cables.
(2) Raise vehicle on hoist.
(3) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle from radia-
tor filler neck and lift bottle off of fan shroud.
(7) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(8) Remove the fan shroud-to-radiator mounting
bolts.
(9) Remove viscous fan/drive assembly. (Refer to 7
- COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(10) Remove cooling fan shroud and fan assembly
from the vehicle.
(11) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove the cooling fan support/hub from the
front of the engine.
(13) Raise the vehicle on hoist.
(14) Remove the crankshaft damper and speed
indicator ring.
(15) Remove hydraulic pump.
(16) Remove accessory drive belt tensioner.
Fig. 68 Crankshaft Main Bearing Bore Diameter
1 - MAIN BEARING CAPS
Fig. 69 Crankshaft Main Journal Diameter
DRENGINE 5.9L DIESEL 9 - 323
CRANKSHAFT MAIN BEARINGS (Continued)

(17) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the gasket surfaces. Remove crank
seal dust shield with cover.
(18) Support the cover on a flat work surface with
wooden blocks (Fig. 70), and using a suitable punch
and hammer, drive the old seal out of the cover from
the back side of the cover to the front side (Fig. 70).
INSTALLATION
(1) Clean cover and housing gasket mating sur-
faces. Use a suitable scraper and be careful not to
damage the gear housing surface. Remove any old
sealer from the oil seal bore. Thoroughly clean the
front seal area of the crankshaft. The seal lip and the
sealing surface on the crankshaft must be free from
all oil residue to prevent seal leaks.
(2) Inspect the gear housing and cover for cracks
and replace if necessary. Carefully straighten any
bends or imperfections in the gear cover with a ball-
peen hammer on a flat surface. Inspect the crank-
shaft front journal for any grooves or nicks that
would affect the integrity of the new seal.
(3) Apply a bead of MopartStud & Bearing Mount
to the outside diameter of the seal. Do not lubricate
the inside diameter of the new seal.
(4) With the cover supported by wood blocks,
install the seal into the rear of the cover using crank-
shaft seal installer Special Tool 8281 and driver han-
dle C-4171 (Fig. 71). Strike the driver handle until
the installation tool bottoms out on the inside of the
cover.
CAUTION: Do not distort or damage seal.(5) Install the plastic seal pilot (provided with seal
kit) into the crankshaft seal.
(6) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover
sealing surface.
(7) Install the cover to the gear housing, aligning
the seal pilot with the nose of the crankshaft (Fig.
72).
(8) Install the cover bolts and tighten to 24 N´m
(18 ft. lbs.) torque. Remove pilot tool.
(9) Install dust shield over nose of crankshaft.
(10) Install the crankshaft damper and speed indi-
cator ring. Torque the bolts to 40 N´m (30 ft. lbs.).
Then rotate an additional 60É. Use the engine bar-
Fig. 70 Removing Seal from Cover
1 - PUNCH
Fig. 71 Installing Seal Into Cover With Tool 8281
1 - SEAL INSTALLER 8281
2 - DRIVER HANDLE C4171
3 - SEAL
Fig. 72 Installing Front Cover with Seal Pilot
1 - SEAL PILOT
9 - 324 ENGINE 5.9L DIESELDR
CRANKSHAFT OIL SEAL - FRONT (Continued)

ring tool to keep the engine from rotating during
tightening operation.
(11) Install the fan support/hub assembly and
torque bolts to 32 N´m (24 ft. lbs.).
(12) Install hydraulic pump.
(13) Install accessory drive belt tensioner. Torque
bolt to 43 Nm (32 ft.lbs.).
(14) Install cooling fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(15) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(16) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(17) Connect battery negative cables.
(18) Start engine and check for oil leaks.
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the transmission and transfer case (if
equipped).
(3) Remove the clutch cover and disc (if manual
transmission equipped) (Refer to 6 - CLUTCH/
CLUTCH DISC - REMOVAL).
(4) Remove the flywheel or converter drive plate.
(5) Drill holes 180É apart into the seal. Be careful
not to contact 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. 73).
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 sur-
faces must be completely dry when the seal is
installed. Use a soap and water solution on outside
diameter of seal to ease assembly.
(1) Clean the crankshaft journal with a suitable
solvent and dry with a clean shop towel or com-
pressed air. Wipe the inside bore of the crankshaft
seal retainer with a clean shop towel.
(2) Inspect the crankshaft journal for gouges,
nicks, or other imperfections. If the seal groove in the
crankshaft is excessively deep, install the new seal
1/8º deeper into the retainer bore, or obtain a crank-
shaft wear sleeve that is available in the aftermar-
ket.
(3) Install the seal pilot and new seal, provided in
the replacement kit, onto the crankshaft.
(4) Remove the seal pilot.
(5) Install the installation tool over crankshaft.
(6) Using a ball peen hammer, strike the tool at
the 12, 3, 6, and 9 o'clock positions until the align-
ment tool bottoms out on the retainer (Fig. 74).
(7) Install the flywheel or converter drive plate.
Tighten the bolts to 137 N´m (101 ft. lbs.) torque.
(8) Install the clutch cover and disc (if equipped)
(Refer to 6 - CLUTCH/CLUTCH DISC - INSTALLA-
TION).
(9) Install the transmission and transfer case (if
equipped).
(10) Lower vehicle.
Fig. 73 Crankshaft Rear Seal Removal
1 - NO. 10 SCREW
2 - REAR SEAL
3 - CRANKSHAFT
4 - SLIDE HAMMER
Fig. 74 Seal Installation Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
DRENGINE 5.9L DIESEL 9 - 325
CRANKSHAFT OIL SEAL - FRONT (Continued)