2003 DODGE RAM engine

ENGINE 5.9L DIESEL
TABLE OF CONTENTS
page page
ENGINE 5.9L DIESEL
DESCRIPTION........................282
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - MECHANICAL............283
DIAGNOSIS AND TESTINGÐSMOKE
DIAGNOSIS CHARTS.................285
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION/LEAKAGE TESTS.......288
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS........289
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS........289
STANDARD PROCEDUREÐHYDROSTATIC
LOCK..............................290
REMOVAL
REMOVALÐENGINE..................290
REMOVALÐCRANKCASE BREATHER....291
INSTALLATION
INSTALLATIONÐENGINE..............291
INSTALLATIONÐCRANKCASE BREATHER . 292
SPECIFICATIONS
5.9L DIESEL........................293
TORQUE...........................294
SPECIAL TOOLS
5.9L DIESEL ENGINE.................294
ENGINE DATA PLATE
DESCRIPTION........................297
AIR CLEANER ELEMENT
REMOVAL............................297
INSTALLATION........................298
CYLINDER HEAD
DESCRIPTION........................298
REMOVAL............................298
CLEANING
CLEANINGÐCYLINDER HEAD..........300
CLEANINGÐCROSSHEADS............300
CLEANINGÐPUSHRODS..............301
INSPECTION
INSPECTION - CYLINDER HEAD.........301
INSPECTIONÐCROSSHEADS..........301
INSPECTIONÐPUSHRODS.............302
INSTALLATION........................302
CYLINDER HEAD COVER(S)
REMOVAL
REMOVALÐCYLINDER HEAD COVER....304
REMOVALÐROCKER HOUSING.........304
CLEANING...........................304INSPECTION.........................304
INSTALLATION
INSTALLATIONÐCYLINDER HEAD COVER . 304
INSTALLATIONÐROCKER HOUSING.....304
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................305
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVES,
GUIDES AND SPRINGS................305
STANDARD PROCEDURE - VALVE LASH
ADJUSTMENT AND VERIFICATION.......308
REMOVAL - VALVE SPRINGS AND SEALS . . . 308
INSTALLATION........................309
ROCKER ARM / ADJUSTER ASSY
DESCRIPTION........................310
REMOVAL............................310
CLEANING...........................310
INSPECTION..........................311
INSTALLATION........................312
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
BLOCK REFACING...................312
STANDARD PROCEDURE - CYLINDER
BORE - DE-GLAZE...................313
STANDARD PROCEDUREÐCYLINDER
BORE REPAIR.......................313
STANDARD PROCEDUREÐCAM BORE
REPAIR ............................315
INSPECTION.........................316
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS......317
REMOVAL - CAMSHAFT...............317
INSPECTION.........................318
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS . . 320
INSTALLATION - CAMSHAFT............320
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING AND CRANKSHAFT
JOURNAL CLEARANCE................321
CRANKSHAFT AND GEAR
DESCRIPTION........................322
REMOVALÐGEAR.....................322
INSTALLATION - GEAR..................322
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
CLEARANCE........................322
9 - 280 ENGINE 5.9L DIESELDR

CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................323
INSTALLATION........................324
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................325
INSTALLATION........................325
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................326
INSTALLATION........................326
SOLID LIFTERS/TAPPETS
REMOVAL............................327
CLEANING...........................328
INSPECTION.........................328
INSTALLATION........................328
PISTON & CONNECTING ROD
DESCRIPTION........................329
STANDARD PROCEDURE - HEAD GASKET
SELECTION.........................330
REMOVAL............................330
CLEANINGÐPISTON AND CONNECTING
ROD ..............................331
INSPECTION
INSPECTIONÐPISTONS...............331
INSPECTIONÐCONNECTING ROD.......332
INSTALLATION........................332
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................333
VIBRATION DAMPER
REMOVAL............................335
INSPECTION.........................335
INSTALLATION........................335
FRONT MOUNT
REMOVAL............................335
INSTALLATION........................335
REAR MOUNT
REMOVAL............................337
INSTALLATION........................337
LUBRICATION
DESCRIPTION........................337
OPERATION..........................337
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE.........................338
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
LEVEL.............................341STANDARD PROCEDURE - ENGINE OIL
SERVICE...........................341
OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION...........342
OIL FILTER
REMOVAL............................342
INSTALLATION........................342
OIL PAN
REMOVAL............................342
CLEANING...........................342
INSPECTION.........................342
INSTALLATION........................342
OIL PRESSURE RELIEF VALVE
REMOVAL............................343
CLEANING...........................343
INSPECTION.........................343
INSTALLATION........................343
OIL PRESSURE SENSOR/SWITCH
REMOVAL............................343
INSTALLATION........................343
OIL PUMP
REMOVAL............................343
CLEANING...........................344
INSPECTION.........................344
INSTALLATION........................344
INTAKE MANIFOLD
REMOVAL............................345
CLEANING...........................346
INSPECTION.........................346
INSTALLATION........................346
EXHAUST MANIFOLD
REMOVAL............................347
CLEANING...........................347
INSPECTION.........................347
INSTALLATION........................347
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION.......................348
GEAR HOUSING
REMOVAL............................348
INSTALLATION........................349
GEAR HOUSING COVER
REMOVAL............................349
INSTALLATION........................350
DRENGINE 5.9L DIESEL 9 - 281

ENGINE 5.9L DIESEL
DESCRIPTION
The cylinder block is constructed of cast iron. The
casting is a skirted design which incorporates longi-
tudal ribs for superior strength and noise reduction.
The block incorporates metric straight thread o-ring
fittings at lubrication oil access points. The engine
(Fig. 1) is manufactured with the cylinders being a
non-sleeved type cylinder. However, one approved
service method is to bore out the cylinders and add
cylinder sleeves to the cylinder block.
The cylinders are numbered front to rear (Fig. 2); 1
to 6. The firing order is 1±5±3±6±2±4.
Fig. 1 CumminsT24-Valve Turbo-Diesel Engine
Fig. 2 Cylinder Numbering
9 - 282 ENGINE 5.9L DIESELDR

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL
PRESSURE LOW1. Low oil level. 1. (a) Check and fill with clean engine oil.
(b) Check for a severe external oil leak that
could reduce the pressure.
2. Oil viscosity thin, diluted or wrong
specification.2. (a) Verify the correct engine oil is being
used. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
2. (b) Look for reduced viscosity from fuel
dilution.
3. Improperly operating pressure
switch/gauge.3. Verify the pressure switch is functioning
correctly. If not, replace switch/gauge.
4. Relief valve stuck open. 4. Check/replace valve.
6. If cooler was replaced, shipping
plugs may have been left in cooler6. Check/remove shipping plugs.
7. Worn oil pump. 7. Check and replace oil pump.
8. Suction tube loose or seal leaking. 8. Check and replace seal.
9. Loose main bearing cap. 9. Check and install new bearing. Tighten
cap to proper torque.
10. Worn bearings or wrong bearings
installed.10. Inspect and replace connecting rod or
main bearings. Check and replace directed
piston cooling nozzles.
11. Directed piston cooling nozzles
under piston, bad fit into main
carrier.11. Check directed piston cooling nozzles
position.
12. Loose oil rifle plug with saddle-jet
style nozzles12.Tighten oil rifle plug.
13. Loose directed piston cooling
nozzle.13. Tighten directed piston cooling nozzle.
14. Both J-jet and saddle jet style
cooling nozzle installed.14. Install correct style jet.
LUBRICATING OIL
PRESSURE TOO HIGH1. Pressure switch/gauge not
operating properly.1. Verify pressure switch is functioning
correctly. If not, replace switch/gauge.
2. Engine running too cold. 2. Refer to Coolant Temperature Below
Normal (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
3. Oil viscosity too thick. 3. Make sure the correct oil is being used.
(Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
4. Oil pressure relief valve stuck
closed or binding4. Check and replace valve.
DRENGINE 5.9L DIESEL 9 - 283
ENGINE 5.9L DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as
required.
2. Crankcase being overfilled. 2. Verify that the correct dipstick is being
used.
3. Incorrect oil specification or
viscosity.3. (a) Make sure the correct oil is being
used (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(b) Look for reduced viscosity from dilution
with fuel.
(c) Review/reduce oil change intervals.
4. Oil cooler leak 4. Check and replace the oil cooler.
5. High blow-by forcing oil out the
breather.5. Check the breather tube area for signs of
oil loss. Perform the required repairs.
6. Turbocharger leaking oil to the air
intake.6. Inspect the air ducts for evidence of oil
transfer. Repair as required.
COMPRESSION KNOCKS 1. Air in the fuel system. 1. Identify location of air leak and repair. Do
not bleed high pressure fuel system.
2. Poor quality fuel or water/gasoline
contaminated fuel.2. Verify by operating from a temporary
tank with good fuel. Clean and flush the
fuel tank. Replace fuel/water separator filter.
3. Engine overloaded. 3. Verify the engine load rating is not being
exceeded.
4. Improperly operating injectors. 5. Check and replace misfiring/inoperative
injectors.
EXCESSIVE VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts.
2. Damaged fan or improperly
operating accessories.2. Check and replace the vibrating
components.
3. Improperly operating vibration
damper3. Inspect/replace vibration damper.
4. Improperly operating electronically
controlled viscous fan drive.4. Inspect/replace fan drive.
5. Worn or damaged generator
bearing.5. Check/replace generator.
6. Flywheel housing misaligned. 6. Check/correct flywheel alignment.
7. Loose or broken power
component.7. Inspect the crankshaft and rods for
damage that causes an unbalance
condition. Repair/replace as required.
8. Worn or unbalanced driveline
components.8. Check/repair driveline components.
EXCESSIVE ENGINE
NOISES1. Drive belt squeal, insufficient
tension or abnormally high loading.1. Check the automatic tensioner and
inspect the drive belt. Make sure water
pump, tensioner pulley, fan hub, generator
and power steering pump turn freely.
2. Intake air or exhaust leaks. 2. Refer to Excessive Exhaust Smoke
(Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
9 - 284 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
3. Excessive valve lash. 3. Adjust valves. Make sure the push rods
are not bent and rocker arms, adjusting
screws, crossheads, are not severely worn.
Replace bent or severely worn components.
4. Turbocharger noise. 4. Check turbocharger impeller and turbine
wheel for housing contact. Repair/replace
as required.
5. Gear train noise. 5. Visually inspect and measure gear
backlash. Replace gears as required.
6. Power function knock. 6. Check/replace rod and main bearings.
DIAGNOSIS AND TESTINGÐSMOKE
DIAGNOSIS CHARTS
The following charts include possible causes and
corrections forexcess or abnormalexhaust smoke.Small amounts of exhaust smoke (at certain times)
are to be considered normal for a diesel powered
engine.
EXCESSIVE BLACK SMOKE
POSSIBLE CAUSE CORRECTION
Air filter dirty or plugged. Check Filter MinderTat air filter (Refer to 9 - ENGINE/
AIR INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
Air intake system restricted. Check entire air intake system including all hoses and
tubes for restrictions, collapsed parts or damage.
Repair/replace as necessary.
Air Leak in Intake System. Check entire air intake system including all hoses and
tubes for cracks, loose clamps and/or holes in rubber
ducts. Also check intake manifold for loose mounting
hardware.
Diagnostic Trouble Codes (DTC's) active or multiple,
intermittent DTC's.Refer to Powertrain Diagnostic Procedures Information.
Engine Control Module (ECM) not calibrated or ECM
has incorrect calibration.Refer to Powertrain Diagnostic Procedures Information.
Exhaust system restriction is above specifications. Check exhaust pipes for damage/restrictions. Repair as
necessary.
Fuel grade is not correct or fuel quality is poor. Temporarily change fuel brands and note condition.
Change brand if necessary.
Fuel injection pump malfunctioning. A DTC may have been set. If so, refer to Powertrain
Diagnostic Procedures Information.
Fuel injector malfunctioning. A DTC may have been set. Perform9Cylinder Cutout
Test9using DRB scan tool to isolate individual
cylinders. Also refer to Powertrain Diagnostic
Procedures Information and, to (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
DIAGNOSIS AND TESTING).
Fuel return system restricted. Check fuel return lines for restriction (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Intake manifold restricted. Remove restriction.
DRENGINE 5.9L DIESEL 9 - 285
ENGINE 5.9L DIESEL (Continued)

EXCESSIVE BLACK SMOKE
POSSIBLE CAUSE CORRECTION
Manifold Air Pressure (Boost) Sensor or sensor circuit
malfunctioning.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Raw fuel in intake manifold. Fuel injectors leaking on engine shutdown. Do Fuel
Injector Test (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - DIAGNOSIS AND
TESTING).
Turbocharger air intake restriction. Remove restriction.
Turbocharger damaged. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
Turbocharger has excess build up on compressor
wheel and/or diffuser vanes.(Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - CLEANING).
Turbocharger wheel clearance out of specification. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Air in fuel supply: Possible leak in fuel supply side
(between transfer pump and fuel tank module).(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL
TRANSFER PUMP - DIAGNOSIS AND TESTING).
Coolant leaking into combustion chamber. Do pressure test of cooling system (Refer to 7 -
COOLING - DIAGNOSIS AND TESTING).
Diagnostic Trouble Codes (DTC's) active or multiple,
intermittent DTC's.Refer to Powertrain Diagnostic Procedures Information.
In very cold ambient temperatures, engine block heater
is malfunctioning (if equipped).(Refer to 7 - COOLING/ENGINE/ENGINE BLOCK
HEATER - REMOVAL).
Engine coolant temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check
thermostat operation (Refer to 7 - COOLING/ENGINE/
ENGINE COOLANT THERMOSTAT - DIAGNOSIS AND
TESTING).
Engine Control Module (ECM) not calibrated or has
incorrect calibration.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel filter plugged. Refer to Powertrain Diagnostic Manual for fuel system
testing.
Fuel grade not correct or fuel quality is poor. Temporarily change fuel brands and note condition.
Change brand if necessary.
Fuel heater element or fuel heater temperature sensor
malfunctioning. This will cause wax type build-up in fuel
filter.Refer to Fuel Heater Testing (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL HEATER -
DIAGNOSIS AND TESTING).
Fuel injector malfunctioning. A DTC should have been set. Perform9Cylinder cutout
Test9using DRB scan tool to isolate individual
cylinders. Also refer to Powertrain Diagnostic
Procedures Information and, (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
DIAGNOSIS AND TESTING).
Fuel injector hold-downs loose. Torque to specifications.
9 - 286 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Fuel injector protrusion not correct. Check washer (shim) at bottom of fuel injector for
correct thickness. (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - INSTALLATION)
Fuel injection pump malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel supply side restriction to transfer pump. Refer to Powertrain Diagnostic Manual for fuel system
testing.
Fuel transfer (lift) pump malfunctioning. A DTC may have been set. Refer to Powertrain
Diagnostic Procedures Information.
Intake/Exhaust valve adjustments not correct (too tight). (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/
EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
Intake manifold air temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Intake manifold heater circuit not functioning correctly in
cold weather.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check heater
elements for correct operation.
Intake manifold heater elements not functioning
correctly in cold weather.A DTC should have been set if heater elements are
malfunctioning. Refer to Powertrain Diagnostic
Procedures Information.
Internal engine damage (scuffed cylinder). Analyze engine oil and inspect oil filter to locate area of
probable damage.
Restriction in fuel supply side of fuel system. Refer to Powertrain Diagnostic Manual for fuel system
testing.
EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Dirty air cleaner or restricted turbocharger intake duct. Check Filter MinderTat air filter housing. (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
ELEMENT - REMOVAL).
Air leak in boost system between turbocharger
compressor outlet and intake manifold.Service air charge system..
Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - REMOVAL).
Restricted turbocharger drain tube. Remove turbocharger drain tube and remove
obstruction.
Crankcase ventilation system plugged. Inspect crankcase ventilation system for function
Valve seals are worn, brittle, or improperly installed. Replace valve stem oil seals (Refer to 9 - ENGINE/
CYLINDER HEAD/INTAKE/EXHAUST VALVES &
SEATS - REMOVAL).
Valve stems and/or guides are worn. Remove valves and inspect valves and guides. (Refer
to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
Broken or Improperly installed piston rings. Tear down engine and inspect piston rings.
DRENGINE 5.9L DIESEL 9 - 287
ENGINE 5.9L DIESEL (Continued)