2003 DODGE RAM engine system

(e) Remove banjo fitting at bottom of fuel filter
housing.
(f) Disconnect fuel supply hose at lift pump.
(32) Disconnect fuel heater, water in fuel sensor,
and fuel lift pump connectors.
(33) Remove the fuel filter assembly-to-cylinder
head bolts and remove filter assembly from vehicle.
(34) Remove wire harness P-clip from cylinder
head (located behind filter housing).
(35) Remove the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(36) Disconnect rocker housing injector harness
connectors.
(37) Remove injector harness nuts from injectors.
(38) Remove the rocker levers (Fig. 11), cross
heads and push rods (Fig. 12). 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.
(39) Remove the fuel return line and banjo bolt at
the rear of the cylinder head. Be careful not to drop
the two (2) sealing washers.
(40) Remove the fuel injectors (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
REMOVAL).(41) Remove rocker housing bolts and rocker hous-
ing and gasket.
(42) Reinstall the engine lift bracket at the rear of
cylinder head. Torque to 77 N´m (57 ft. lbs.).
(43) Remove twenty six (26) cylinder head-to-block
bolts.
(44) Attach an engine lift crane to engine lift
brackets and lift cylinder head off engine and out of
vehicle.
(45) Remove the head gasket and inspect for fail-
ure.
CLEANING
CLEANINGÐCYLINDER HEAD
CAUTION: Do not wire brush head surface while
fuel injectors are still installed. Fuel injector dam-
age can result.
Remove fuel injector before cleaning (if not already
removed during cylinder head removal).
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).
After rinsing, use compressed air to dry the cylin-
der head.
Polish the gasket surface with 400 grit paper. Use
an orbital sander or sanding block to maintain a flat
surface.
CLEANINGÐCROSSHEADS
Clean all crossheads in a suitable solvent. If neces-
sary, use a wire brush or wheel to remove stubborn
deposits. Rinse in hot water and blow dry with com-
pressed air.
Fig. 11 Rocker Arm and Pedestal Removal
1 - ROCKER ARM
2 - PEDESTAL
Fig. 12 Push Rod Removal
9 - 300 ENGINE 5.9L DIESELDR
CYLINDER HEAD (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)

(40) Install wire harness P-clip to top of bracket.
(41) Install fan support and torque to 32 N´m (24
ft. lbs.).
(42) Install cooling fan/drive and torque to 33 N´m
(24 ft. lbs.).
(43) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(44) Install exhaust manifold/turbocharger assem-
bly, using new gaskets. Start all bolts/spacers by
hand. Torque bolts to 43 N´m (32 ft. lbs.).
(45) Install exhaust manifold heat shield. Torque
to 24 N´m (18 ft. lbs.).
(46) Install exhaust bolt retention straps across
cylinders5&6.
(47) Connect turbocharger oil drain tube. Torque to
8 N´m (71 in. lbs.).
(48) Perform the turbocharger pre-lube procedure.
Refer to Group 11, Exhaust System and Turbo-
charger for the correct procedure.
(49) Connect the turbocharger oil supply line.
Torque to 24 N´m (18 ft. lbs.).
(50) Install air cleaner housing and duct.
(51) Connect air inlet temperature/pressure sensor.
(52) Raise vehicle on hoist.
(53) Install exhaust pipe to turbocharger elbow.
Torque bolts to 8 N´m (72 in. lbs.).
(54) Lower vehicle.
(55) Fill engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(56) Start engine and check for leaks.
CYLINDER HEAD COVER(S)
REMOVAL
REMOVALÐCYLINDER HEAD COVER
(1) Disconnect both battery negative cables.
(2) Remove oil fill cap.
(3) Remove the breather cover.
(4) Disconnect the breather hose and breather
drain tube from the breather housing.
(5) Remove cylinder head cover bolts.
(6) Remove the cylinder head cover.
REMOVALÐROCKER HOUSING
(1) Remove cylinder head cover as outlined in this
section.
(2) Disconnect rocker housing injector harness con-
nectors.
(3) Remove injector harness nuts from injectors.
(4) Remove rocker housing bolts.
(5) Remove rocker housing and gasket.
CLEANING
Using a suitable solvent, Clean and dry gasket
mating surfaces on cylinder head and rocker housing.
Wipe gasket dry and inspect for re-use.
INSPECTION
The cylinder head cover gasket, rocker hous-
ing gasket, are reusable.However, should cracks,
nicks, or tears be present in the rubber/silicone con-
struction, the defective components should be
replaced. Also replace gasket if it is no longer flexi-
ble. Inspect o-rings on cylinder head cover bolts.
INSTALLATION
INSTALLATIONÐCYLINDER HEAD COVER
(1) Inspect cylinder head cover gasket for cuts and
proper installation in groove. Replace if damaged.
(2) Position cylinder cover on top of rocker hous-
ing.
(3) Install bolts.
(4) Starting with the center bolt, torque to 24 N´m
(18 ft. lbs.).
(5) Install breather hose to breather.
(6) Install breather drain hose to breather.
(7) Install breather cover and wire harness clip.
Torque to 24 N´m (18 ft. lbs.).
INSTALLATIONÐROCKER HOUSING
(1) Inspect rocker housing gasket for cuts, nicks,
or tears. Replace if damaged or if gasket has come
out of groove.
(2) Inspect rocker housing gasket for proper instal-
lation in groove. Gasket bead must be centered in
groove. A gasket bead that is tilted to the side will
cause an oil leak.
(3) Install ToolXXXXguide pins (or equivalent)
into the cylinder head at rocker housing bolt loca-
tions #1 and #5.
(4) Install the rocker hoiusing over the guide pins.
Carefully gyide the rocker housing evenly down onto
the cylinder head.
(5) With guide pins in place, install remaining
rocker housing bolts and tighten finger tight.
(6) Remove guide pins and install remaining
rocker housing bolts finger tight.
(7) Install rocker housing and bolts. Torque bolts,
working from center out, to 24 Nm (18ft. lbs.).
(8) Install injector harness nuts to injector sole-
noid. Torque to 1.5 Nm (13 in. lbs.).
(9) Connect rocker housing injector harness con-
nections.
9 - 304 ENGINE 5.9L DIESELDR
CYLINDER HEAD (Continued)

STANDARD PROCEDURE - VALVE 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 or
injectors.
(1) Disconnect battery negative cables.
(2) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Using the crankshaft barring tool #7471±B,
rotate crankshaft to align damper TDC mark to
12:00 o'clock position.
(a) If both number one cylinder rocker levers are
loose, continue to next step.
(b) If both number one clylinder rocker levers
are not loose, rotate crankshaft 360 degrees.
(4) With the engine in this position, valve lash can
be measured at the following rocker arms:INTAKE
1±2±4 / EXHAUST 1±3±5. Measure the valve lash by
inserting a feeler gauge between the rocker arm
socket and crosshead (Fig. 32). Refer to VALVE
LASH LIMIT CHART for the correct specifications. If
the measurement fallswithinthe limits, adjust-
ment/resettingis notnecessary. If measurement
finds the lashoutsideof the limits, adjustment/re-
settingisrequired.
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.(5) If adjustment/resetting is required, loosen the
lock nut on rocker arms and turn the adjusting screw
until the desired lash is obtained:
²INTAKE0.254 mm (0.010 in.)
²EXHAUST0.508 mm (0.020 in.) Tighten the
lock nut to 24 Nm (18 ft. lbs.) and re-check the valve
lash.
(6) Using the crankshaft barring tool, rotate the
crankshaftone revolution (360É) to align the
damper TDC mark to the 12 o'clock position.
(7) With the engine in this position, valve lash can
be measured at the remaining rocker arms:INTAKE
3±5±6 / EXHAUST 2±4±6. Use the same method as
above for determining whether adjustment is neces-
sary, and adjust those that are found to be outside of
the limits.
(8) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(9) Connect the battery negative cables.
REMOVAL - VALVE SPRINGS AND SEALS
(1) Disconnect the battery negative cables.
(2) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Disconnect rocker housing injector harness con-
nector. Remove all injector harness solenoid nuts.
(4) Remove injector(s) for cylinder(s) to be serviced.
Refer to Group 14 for injector removal.
(5) Remove the rocker housing.
(6) Remove the rocker arms and crossheads from
the cylinder(s) to be serviced. Mark each component
so they can be installed in their original position.
(7) Using the crankshaft barring tool #7471±B
(Fig. 33), rotate the engine to position the damper
Fig. 32 Measuring Valve Lash - Typical
1 - INTAKE
2 - FEELER GAUGE
3 - EXHAUST
9 - 308 ENGINE 5.9L DIESELDR
INTAKE/EXHAUST VALVES & SEATS (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)

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)

Fig. 111 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
DRENGINE 5.9L DIESEL 9 - 339
LUBRICATION (Continued)

Fig. 112 Lubrication System CirculationÐCont'd
9 - 340 ENGINE 5.9L DIESELDR
LUBRICATION (Continued)