2003 DODGE RAM torque

(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)

Measure valve margin (rim thickness) (Fig. 28).
Measure the valve spring free length and maxi-
mum inclination (Fig. 29).
Test valve spring force with tool C-647 (Fig. 30).
Specification 72.0 Ð 80.7 lbs. when compressed to
35.33 mm (1.39 in.).
INSTALLATION
(1) Install new valve seals. The yellow seals 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. 31).
(3) Install the valve springs and retainer.
(4) Install the valve spring compressor tool 8319±A
as shown in (Fig. 22) and (Fig. 23).(5) Compress the valve springs and install the
valve retaining locks (Fig. 24).
(6) Remove the compressor and repeat the proce-
dure on the remaining cylinders.
(7) Install new o-ring and sealing washer on injec-
tor.
(8) Lubricate o-ring and injector bore.
(9) Verify sealing washer (shim) was removed with
old injector.
(10) Install injector with fuel injector connector
port facing intake manifold.
(11) Install hold-down bolt. Torque to 10 Nm (89
in. lbs.).
(12) Install fuel injector connector and connector
nut. Torque nut to 50 Nm (36.8 ft. lbs.).
(13) Install the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION).
Fig. 28 Measure Valve Margin (Rim Thickness)
VALVE MARGIN (RIM THICKNESS)
0.79 mm (0.031 in.) MIN.
Fig. 29 Measure Valve Spring Free Length and Max.
Inclination
APPROXIMATE VALVE SPRING FREE LENGTH
47.75 mm (1.88 in.)
MAX INCLINATION
1.5 mm (.059 in.)
Fig. 30 Testing Valve Spring with Tool C-647
1 - SPECIAL TOOL C-647
Fig. 31 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
DRENGINE 5.9L DIESEL 9 - 307
INTAKE/EXHAUST VALVES & SEATS (Continued)

(4) Lubricate the crossheads and push rod sockets
and install the rocker arms and pedestals in their
original locations. Tighten bolts to 36 N´m (27 ft. lbs.)
torque.
(5)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
(6) Install cylinder head cover and reusable gasket
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - INSTALLATION).
(7) Connect battery negative cables.
ROCKER ARM / ADJUSTER
ASSY
DESCRIPTION
The unique intake and exhaust rocker arms have
their own rocker shafts and are lubricated by pas-
sages intersecting the cylinder block main oil rifle.
Crossheads are used, which allow each rocker arm to
operate two valves.
The solid push rods are hardened at the rocker
arm and tappet contact areas for superior strength
and durability.
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Remove the rocker arm/pedestal fasteners (Fig.
36) and remove rocker arm and pedestal from cylin-der head. Mark the arms and pedestals so they can
be installed in their original position.
CAUTION: When removing the rocker arms, the
sockets (Fig. 37) may come loose and fall into the
engine. Make sure they stay with the arm upon
removal/installation.
(4) Lift the push rod(s) up and out of the engine
(Fig. 38). Mark them so they can be installed in their
original position.
NOTE: The #5 cyl. intake and exhaust and #6 cyl.
intake and exhaust push rods must be raised
through the provided cowl panel access holes.
(5) Lift the crosshead(s) off of the valve stems.
Mark them so they can be installed in their original
position.
CLEANING
Clean all components in a suitable solvent. If nec-
essary, use a wire brush or wheel to remove stubborn
deposits. Rinse in hot water and blow dry with com-
pressed air. Inspect oil passages in rocker arms and
pedestals. Apply compressed air to lubrication orifices
to purge contaminants.
Fig. 35 Compressing Valve Springs with Tool
8319±A
1 - SPECIAL TOOL 8319
Fig. 36 Rocker Arm and Pedestal Removal
1 - ROCKER ARM
2 - PEDESTAL
9 - 310 ENGINE 5.9L DIESELDR
INTAKE/EXHAUST VALVES & SEATS (Continued)

Crossheads
Inspect the crossheads for cracks and/or excessive
wear on rocker lever and valve tip mating surfaces
(Fig. 43).
INSTALLATION
(1) If previously removed, install the push rods in
their original location.Verify that they are seated
in the tappets.
(2) Lubricate the valve tips and install the cross-
heads in their original locations.
(3) Lubricate the crossheads and push rod sockets
and install the rocker arms and pedestals in their
original locations. Tighten bolts to 36 N´m (27 ft. lbs.)
torque.
(4)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
(5) Install cylinder head cover and reusable gasket
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - INSTALLATION).
(6) Connect battery negative cables.
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER BLOCK
REFACING
(1) The combustion deck can be refaced twice. The
first reface should be 0.25 mm (0.0098 inch). If addi-
tional refacing is required, an additional 0.25 mm
(0.0098 inch) can be removed. Total allowed refacing
is 0.50 mm (0.0197 inch) - (Fig. 44).
(2) The upper right corner of the rear face of the
block must be stamped with a X when the block is
refaced to 0.25 mm (0.0098 inch). A second X must be
stamped beside the first when the block is refaced to
0.50 mm (0.0197 inch) - (Fig. 45).
Fig. 42 Inspecting Push Rod for Flatness
Fig. 43 Inspecting Crosshead for Cracks
Fig. 44 Refacing Dimensions of the Cylinder Block
CYLINDER BLOCK REFACING DIMENSIONS
DIMENSION(A(
1st Reface 0.25mm (0.0098 in.)
2nd Reface 0.25mm (0.0098 in.)
Dim (A) Total 0.50 mm (0.0197 in.)
DIMENSION(B(
Dim.9B9(STD.)323.00 mm   0.10
mm(12.7165 in.  
0.0039 in.)
1st Reface322.75 mm   0.10
mm(12.7067 in.  
0.0039 in.)
2nd Reface322.50 mm   0.10
mm(12.6968 in.  
0.0039 in.)
9 - 312 ENGINE 5.9L DIESELDR
ROCKER ARM / ADJUSTER ASSY (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