fuel delivery - diesel

fuel delivery - diesel
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FUEL DELIVERY - DIESEL
DR
FUEL DELIVERY - DIESEL
TABLE OF CONTENTS
page
FUEL DELIVERY - DIESEL
DESCRIPTION - DIESEL FUEL SYSTEM
...
STANDARD PROCEDURE
STANDARD PROCEDURES - WATER
DRAINING AT FUEL FILTER . . . . . . . . . . . .
STANDARD PROCEDURES - CLEANING
FUEL SYSTEM PARTS . . . . . . . . . . . . . . .
STANDARD PROCEDURE - FUEL SYSTEM
PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FUEL SYSTEM PRESSURE - DIESEL . . . .
FUEL INJECTOR FIRING ORDER - DIESEL
SPECIAL TOOLS
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . .
FUEL FILTER / WATER SEPARATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
FUEL HEATER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING - FUEL HEATER .
REMOVAL
REMOVAL/INSTALLATION . . . . . . . . . . . . .
FUEL HEATER RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTION PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING - FUEL INJECTION
PUMP TIMING . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL
REMOVAL/INSTALLATION . . . . . . . . . . . . .
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page
FUEL LINES
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING - HIGHPRESSURE FUEL LINE LEAKS .
REMOVAL . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . .
FUEL PRESSURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . .
FUEL PRESSURE LIMITING VALVE
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . .
FUEL TANK
DESCRIPTION - DIESEL . . . . . . . .
REMOVAL - DIESEL . . . . . . . . . . .
INSTALLATION - DIESEL
.......
FUEL TANK MODULE
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . .
FUEL TRANSFER PUMP
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . .
CASCADE OVERFLOW VALVE
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL
REMOVAL/INSTALLATION . . . . .
WATER IN FUEL SENSOR
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . .
FUEL DRAIN CIRCUIT
OPERATION . . . . . . . . . . . . . . . . .
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DR
FUEL DELIVERY - DIESEL
DESCRIPTION - DIESEL FUEL SYSTEM
The fuel system used on the Cummins engine is an
electronically controlled, Bosch HPCR (High-Pressure
Common Rail) system. The HPCR system consists of
five main components:
• Electric Fuel Transfer (lift) Pump
• Fuel Pump/Gear Pump (attached to fuel injection pump)
• High-Pressure Fuel Injection Pump
• Fuel Injection Rail
• Fuel Injectors
Also to be considered as part of the overall fuel
system are:
• Accelerator Pedal
• Air Cleaner Housing/Element
• Fuel Drain Manifold (passage)
• Fuel Drain Valve (at filter)
• Fuel Filter/Water Separator
• Fuel Heater
• Fuel Heater Relay
• Fuel Level (gauge) Sending Unit
• Fuel Tank
• Fuel Tank Module (containing fuel gauge sending unit and separate fuel filter located at bottom of
tank module)
• Fuel Tank Filler/Vent Tube Assembly
• Fuel Tank Filler Tube Cap
• Fuel Tubes/Lines/Hoses
• High-Pressure Fuel Injector Lines
• In-Tank Fuel Filter (at bottom of fuel tank module)
• Low-Pressure Fuel Supply Lines
• Low-Pressure Fuel Return Line
• Overflow Valve
• Quick-Connect Fuel Line Fittings
• Throttle Cable
• Water Draining (maintenance)
• Water-In-Fuel (WIF) Sensor
The fuel injection pump supplies high pressure to
the fuel rail independent of engine speed. This high
pressure is then accumulated in the fuel rail. High
pressure fuel is constantly supplied to the injectors
by the fuel rail. The Engine Control Module (ECM)
controls the fueling and timing of the engine by actuating the injectors.
FUEL DELIVERY - DIESEL
14 - 57
Fuel enters the system from the electric fuel transfer (lift) pump, which is attached to the fuel filter
assembly. Fuel is forced through the fuel filter element and then enters the Fuel Pump/Gear Pump,
which is attached to the rear of the fuel injection
pump. The Fuel Pump/Gear Pump is a low-pressure
pump and produce pressures ranging from 551.5 kpa
(80 psi) to 1241 kpa (180) psi. Fuel then enters the
fuel injection pump. Low pressure fuel is then supplied to the FCA (Fuel Control Actuator).
The FCA is an electronically controlled solenoid
valve. The ECM controls the amount of fuel that
enters the high-pressure pumping chambers by opening and closing the FCA based on a demanded fuel
pressure. The FPS (Fuel Pressure Sensor) on the fuel
rail provides the actual fuel pressure. When the
actuator is opened, the maximum amount of fuel is
being supplied to the fuel injection pump. Any fuel
that does not enter the injection pump is directed to
the overflow valve. The overflow valve regulates how
much excess fuel is used for lubrication of the pump
and how much is returned to the tank through the
drain manifold.
Fuel entering the injection pump is pressurized to
between 300 - 1600 bar by three radial pumping
chambers. The pressurized fuel is then supplied to
the fuel rail.
Some fuel system components are shown in.
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 160,000 KPA (23,206
PSI). USE EXTREME CAUTION WHEN INSPECTING
FOR HIGH-PRESSURE FUEL LEAKS. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. HIGH FUEL INJECTION PRESSURE
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN.
Certain fuel system components can be found in
(Fig. 1), or (Fig. 2).
STANDARD PROCEDURE
STANDARD PROCEDURES - WATER DRAINING
AT FUEL FILTER
Refer to Fuel Filter/Water Separator removal/installation for procedures.
14 - 58
FUEL DELIVERY - DIESEL
DR
FUEL DELIVERY - DIESEL (Continued)
Fig. 1 DIESEL FUEL SYSTEM COMPONENTS
1 - ENGINE COOLANT TEMPERATURE (ECT) SENSOR
2 - THROTTLE LEVER BELLCRANK AND APPS (ACCELERATOR
PEDAL POSITION SENSOR)
3 - INTAKE MANIFOLD AIR HEATER/ELEMENTS
4 - FUEL PRESSURE SENSOR
5 - FUEL LIMITING VALVE
6 - HIGH-PRESSURE FUEL LINES
7 - FUEL HEATER
8 - HIGH-PRESSURE FUEL INJECTOR RAIL
9 - FUEL HEATER TEMPERATURE SENSOR (THERMOSTAT)
10 - FUEL FILTER/WATER SEPARATOR
11 - FUEL TRANSFER (LIFT) PUMP
12 - FUEL DRAIN MANIFOLD
13 - DRAIN VALVE
STANDARD PROCEDURES - CLEANING FUEL
SYSTEM PARTS
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system components. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
14 - FUEL SUPPLY LINE (LOW-PRESSURE, TO ENGINE)
15 - FUEL RETURN LINE CONNECTION (TO FUEL TANK)
16
17
18
19
20
21
22
23
-
FUEL DRAIN TUBE
OIL PRESSURE SENSOR
ENGINE CONTROL MODULE (ECM)
FUEL INJECTION PUMP
CRANKSHAFT POSITION (ENGINE SPEED) SENSOR
CAMSHAFT POSITION SENSOR (CMP)
FUEL CONTROL ACTUATOR (FCA)
CASCADE OVERFLOW VALVE
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
FUEL DELIVERY - DIESEL
DR
14 - 59
FUEL DELIVERY - DIESEL (Continued)
25 seconds after the starter is quickly engaged, and
then disengaged without allowing the engine to start.
The pump shuts off immediately if the key is on and
the engine stops running.
(1) Turn key to CRANK position and quickly
release key to ON position before engine starts. This
will operate fuel transfer pump for approximately 25
seconds.
(2) If the engine does not start after 25 seconds,
turn key OFF. Repeat previous step until engine
starts.
(3) Fuel system priming is now completed.
(4) Attempt to start engine. If engine will not
start, proceed to following steps. When engine does
start, it may run erratically and be noisy for a
few minutes. This is a normal condition.
CAUTION: Do not engage the starter motor for more
than 30 seconds at a time. Allow two minutes
between cranking intervals.
Fig. 2 FUEL INJECTORS
1
2
3
4
-
SOLENOID CONNECTIONS
ROCKER HOUSING
FUEL INJECTOR
PASSTHROUGH CONNECTOR
STANDARD PROCEDURE - FUEL SYSTEM
PRIMING
A certain amount of air becomes trapped in the
fuel system when fuel system components on the
supply and/or high-pressure side are serviced or
replaced. Fuel system priming is accomplished using
the electric fuel transfer (lift) pump.
Servicing or replacing fuel system components usually will not require fuel system priming.
The fuel transfer (lift) pump is self-priming: When
the key is first turned on (without cranking engine),
the pump operates for approximately 2 seconds and
then shuts off. The pump will also operate for up to
(5) Perform previous fuel priming procedure steps
using fuel transfer pump. Be sure fuel is present at
fuel tank.
(6) Crank the engine for 30 seconds at a time to
allow fuel system to prime.
WARNING: THE FUEL INJECTION PUMP SUPPLIES
EXTREMELY HIGH FUEL PRESSURE TO EACH INDIVIDUAL INJECTOR THROUGH THE HIGH-PRESSURE LINES. FUEL UNDER THIS AMOUNT OF
PRESSURE CAN PENETRATE THE SKIN AND
CAUSE PERSONAL INJURY. WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING.
DO NOT LOOSEN FUEL FITTINGS WHILE ENGINE
IS RUNNING.
WARNING: ENGINE MAY START WHILE CRANKING
STARTER MOTOR.
14 - 60
FUEL DELIVERY - DIESEL
DR
FUEL DELIVERY - DIESEL (Continued)
SPECIFICATIONS
FUEL SYSTEM PRESSURE - DIESEL
DESCRIPTION
PRESSURE
Fuel Transfer (Lift) Pump Pressure
Minimum 9.5 psi
FUEL INJECTOR FIRING ORDER - DIESEL
1–5–3–6–2–4
SPECIAL TOOLS
DIESEL FUEL SYSTEM
FUEL INJECTOR REMOVER - #9010
FUEL PRESSURE TEST ADAPTER - # 9012
PRESSURE CAP - #9011
FUEL PRESSURE TEST ADAPTER - #9014
FUEL PRESSURE TEST ADAPTER - #9013
FUEL DELIVERY - DIESEL
DR
14 - 61
FUEL DELIVERY - DIESEL (Continued)
A Water-In-Fuel (WIF) sensor is attached to side of
canister. Refer to Water-In-Fuel Sensor Description/
Operation.
The fuel heater is installed into the top of the filter/separator housing. Refer to Fuel Heater Description/Operation.
REMOVAL
FUEL INJECTOR TUBE (CONNECTOR) REMOVER #9015
SPANNER WRENCH (FUEL TANK MODULE
REMOVAL/INSTALLATION) - #6856
ENGINE ROTATING (BARRING) TOOL - #7471B
(ALSO PART OF KIT #6860)
FUEL FILTER / WATER
SEPARATOR
DESCRIPTION
The fuel filter/water separator assembly is located
on left side of engine above starter motor. The assembly also includes the fuel heater and Water-In-Fuel
(WIF) sensor, and fuel transfer pump.
OPERATION
The fuel filter/water separator protects the fuel
injection pump by removing water and contaminants
from the fuel. The construction of the filter/separator
allows fuel to pass through it, but helps prevent
moisture (water) from doing so. Moisture collects at
the bottom of the canister.
Refer to the maintenance schedules for the recommended fuel filter replacement intervals.
For draining of water from canister, refer to Fuel
Filter/Water Separator Removal/Installation section.
Refer to maintenance schedules in this manual for
recommended fuel filter replacement intervals.
Draining water from fuel filter/water separator housing:
The housing drain valve (Fig. 3) or (Fig. 4) serves
two purposes. One is to partially drain filter housing of excess water. The other is to completely drain
housing for fuel filter, drain valve, heater element, ,
water-in-fuel sensor replacement or transfer pump
replacement.
The filter housing should be partially drained
whenever water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for
approximately two seconds when ignition key is initially placed in ON position for a bulb check).
(1) A drain hose (Fig. 3) or (Fig. 4) is located at
bottom of drain valve. Place drain pan under drain.
(2) With engine not running, rotate drain valve
handle rearward to OPEN (DRAIN) position. Hold
drain valve open until all water and contaminants
have been removed and clean fuel exits.
(3) If drain valve, fuel heater element or Water-InFuel (WIF) sensor is being replaced, drain housing
completely. Dispose of mixture in drain pan according
to applicable regulations.
(4) After draining operation, push valve handle
forward to CLOSE position.
(5) Fuel Filter Replacement: The fuel filter is
located inside of the fuel filter housing.
(a) Clean all debris from around canister.
(b) Remove filter lid (Fig. 5) using a socket.
Attach socket to large hex on top of lid (Fig. 5).
Rotate counter-clockwise for removal. Remove
o-ring.
(c) Remove filter element by twisting element
sideways from filter lid.
(6) Water-In-Fuel (WIF) Sensor Replacement:
The WIF sensor is located on the side of the fuel filter housing (Fig. 3) or (Fig. 4).
(a) Disconnect electrical connector at sensor.
(b) Clean area around sensor.
(c) Remove sensor by rotating counter-clockwise.
(d) Check condition of sensor o-ring. Replace if
damaged.
(7) Fuel Heater Element Replacement: The
heater element is located in the fuel filter housing
(Fig. 3) or (Fig. 4).
(a) Remove fuel filter. See previous steps.
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FUEL DELIVERY - DIESEL
DR
FUEL FILTER / WATER SEPARATOR (Continued)
(b) Disconnect electrical connector.
(c) Remove two T-15 Torx head mounting screws
from fuel heater element.
(d) Remove fuel filter cover and filter element.
(e) Remove fuel heater.
(8) Drain Valve Replacement: The drain valve
assembly is located on the side of the fuel filter housing (Fig. 3) or (Fig. 4).
(a) Disconnect drain hose from the fuel drain
valve.
(b) Remove 4 drain valve mounting screws (T-15
Torx head).
(c) Remove drain valve from filter housing.
Fig. 4 FILTER HOUSING (LATE)
1
2
3
4
5
6
7
8
9
-
FILTER HOUSING
FUEL HEATER AND THERMOSTAT
FUEL HEATER MOUNTING SCREWS
FUEL HEATER ELEC. CONNECTOR
WIF SENSOR
WIF SENSOR ELEC. CONNECTOR
DRAIN HOSE
DRAIN VALVE MOUNTING SCREWS
DRAIN VALVE
Fig. 3 FILTER HOUSING (EARLY)
1
2
3
4
5
6
7
8
9
-
FILTER HOUSING
FUEL HEATER AND THERMOSTAT
FUEL HEATER MOUNTING SCREWS
FUEL HEATER ELEC. CONNECTOR
DRAIN VALVE
DRAIN VALVE MOUNTING SCREWS
DRAIN HOSE
WIF SENSOR
WIF SENSOR ELEC. CONNECTOR
INSTALLATION
Refer to maintenance schedules for recommended
fuel filter replacement intervals.
(1) Thoroughly clean inside of filter housing, filter
cap and all related components.
(2) Fuel Filter:
(a) The engine has a self-priming low-pressure fuel system. Refer to Standard Procedures-Fuel System Priming.
(b) Install new o-ring to canister lid and lubricate o-ring with 30W oil.
Fig. 5 FILTER COVER (LID)
1 - FILTER COVER
2 - ATTACH SOCKET HERE
FUEL DELIVERY - DIESEL
DR
14 - 63
FUEL FILTER / WATER SEPARATOR (Continued)
(c) Position new element to canister lid. Place
this assembly into canister by rotating clockwise.
(d) Tighten cap to 34 N·m (25 ft. lbs.) torque. Do
not overtighten cap.
(3) Water-In-Fuel (WIF) Sensor:
(a) Install new o-ring seal to WIF sensor.
(b) Apply a light film of clean diesel oil to o-ring
seal.
(c) Install sensor into housing.
(d) Tighten sensor to 4.5 N·m (39 in. lbs.) torque.
(e) Connect electrical connector to WIF sensor.
(4) Fuel Heater Element:
(a) Install fuel heater into fuel filter housing.
(b) Install fuel heater thermostat into fuel filter
housing.
(c) Install fuel heater mounting screws and
tighten to 1-1.5 N·m torque.
(d) Connect electrical connector to fuel heater
thermostat.
(e) Install new filter cover O-ring onto fuel filter
housing cover and lubricate with 30W oil.
(f) Tighten fuel filter housing cover (lid) to 34
N·m (25 ft. lbs.).
(5) Drain Valve:
(a) Install 2 new o-rings to valve and filter housing.
(b) Lubricate with silicon grease.
(c) Install fuel drain valve.
(d) Install 4 mounting screws and tighten to
1–1.5 N·m (8–13 in. lbs.) torque.
(e) Connect drain hose to drain valve.
(6) Start engine and check for leaks.
FUEL HEATER
DESCRIPTION
The fuel heater assembly is located on the side of
the fuel filter housing (Fig. 3) or (Fig. 4).
The heater/element assembly is equipped with a
temperature sensor (thermostat) that senses fuel
temperature. This sensor is attached to the fuel heater/element assembly.
OPERATION
The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation.
When the temperature is below 45 ±8 degrees F,
the temperature sensor allows current to flow to the
heater element warming the fuel. When the temperature is above 75 ±8 degrees F, the sensor stops current flow to the heater element.
Battery voltage to operate the fuel heater element
is supplied from the ignition switch and through the
fuel heater relay. Also refer to Fuel Heater Relay.
The fuel heater element and fuel heater relay
are not computer controlled.
The heater element operates on 12 volts, 300 watts
at 0 degrees F.
DIAGNOSIS AND TESTING - FUEL HEATER
The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation.
NOTE: The fuel heater element, fuel heater relay
and fuel heater temperature sensor are not controlled by the Engine Control Module (ECM), or the
Powertrain Control Module (PCM).
A malfunctioning fuel heater can cause a wax
build-up in the fuel filter/water separator. Wax
build-up in the filter/separator can cause engine
starting problems and prevent the engine from revving up. It can also cause blue or white fog-like
exhaust. If the heater is not operating in cold temperatures, the engine may not operate due to fuel
waxing.
The fuel heater assembly is located on the side of
fuel filter housing.
The heater assembly is equipped with a built-in
fuel temperature sensor (thermostat) that senses fuel
temperature. When fuel temperature drops below 45
degrees ± 8 degrees F, the sensor allows current to
flow to built-in heater element to warm fuel. When
fuel temperature rises above 75 degrees ± 8 degrees
F, the sensor stops current flow to heater element
(circuit is open).
Voltage to operate fuel heater element is supplied
from ignition switch, through fuel heater relay (also
refer to Fuel Heater Relay), to fuel temperature sensor and on to fuel heater element.
The heater element operates on 12 volts, 300 watts
at 0 degrees F. As temperature increases, power
requirements decrease.
A minimum of 7 volts is required to operate fuel
heater. The resistance value of heater element is less
than 1 ohm (cold) and up to 1000 ohms warm.
TESTING
(1) Disconnect electrical connector from thermostat
(Fig. 3) or (Fig. 4).
Ambient temperature must be below circuit close
temperature, If necessary, induce this ambient temperature by placing ice packs on thermostat to produce an effective ambient temperature below circuit
close temperature. For first check of thermostat you
can hear click of thermostat when circuit closes.
Measure resistance across two pins. Operating
range is 0.3 — 0.45 Ohms.
(2) If resistance is out of range, remove thermostat
and check resistance across terminal connections of
14 - 64
FUEL DELIVERY - DIESEL
DR
FUEL HEATER (Continued)
heater. The heater can be check at room temperature. Operating range is 0.3 — 0.45 Ohms.
(3) Replace heater if resistance is not within operating range.
(4) If heater is within operating range, replace
heater thermostat.
(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
REMOVAL
REMOVAL/INSTALLATION
The fuel heater/element/sensor assembly is located
inside of the fuel filter housing. Refer to Fuel Filter/
Water Separator Removal/Installation for procedures.
FUEL HEATER RELAY
DESCRIPTION
The fuel heater relay is located in Power Distribution Center (PDC) (Fig. 6). Refer to label on inside of
PDC cover for relay location.
Fig. 7 POWER DISTRIBUTION CENTER LOCATION
1
2
3
4
5
6
7
8
-
CLIP
BATTERY
TRAY
NEGATIVE CABLE
POSITIVE CABLE
CLIP
FENDER INNER SHIELD
POWER DISTRIBUTION CENTER
INSTALLATION
The fuel heater relay is located in the Power Distribution Center (PDC) (Fig. 7). Refer to label under
PDC cover for relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
Fig. 6 POWER DISTRIBUTION CENTER LOCATION
1
2
3
4
5
6
7
8
-
CLIP
BATTERY
TRAY
NEGATIVE CABLE
POSITIVE CABLE
CLIP
FENDER INNER SHIELD
POWER DISTRIBUTION CENTER
OPERATION
Battery voltage to operate the fuel heater element
is supplied from the ignition switch through the fuel
heater relay. The fuel heater element and fuel
heater relay are not computer controlled.
REMOVAL
The fuel heater relay is located in the Power Distribution Center (PDC) (Fig. 7). Refer to label under
PDC cover for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.
FUEL INJECTION PUMP
DESCRIPTION
A Robert Bosch high-pressure fuel injection pump
is used. The pump is attached to the back of the timing gear cover at the left / rear side of the engine.
OPERATION
The fuel injection pump supplies high pressure to
the fuel rail independent of engine speed. This high
pressure is then accumulated in the fuel rail. High
pressure fuel is constantly supplied to the injectors
by the fuel rail. The Engine Control Module (ECM)
controls the fueling and timing of the engine by actuating the injectors.
Fuel enters the system from the electric fuel transfer (lift) pump, which is attached to the fuel filter
assembly. Fuel is forced through the fuel filter element and then enters the Fuel Pump/Gear Pump,
which is attached to the rear of the fuel injection
FUEL DELIVERY - DIESEL
DR
14 - 65
FUEL INJECTION PUMP (Continued)
pump. The Fuel Pump/Gear Pump is a low-pressure
pump and produce pressures ranging from 551.5 kpa
(80 psi) to 1241 kpa (180) psi. Fuel then enters the
fuel injection pump. Low pressure fuel is then supplied to the FAC (Fuel Control Actuator).
The FAC is an electronically controlled solenoid
valve. The ECM controls the amount of fuel that
enters the high-pressure pumping chambers by opening and closing the FAC based on a demanded fuel
pressure. The FPS (Fuel Pressure Sensor) on the fuel
rail provides the actual fuel pressure. When the
actuator is opened, the maximum amount of fuel is
being supplied to the fuel injection pump. Any fuel
that does not enter the injection pump is directed to
the overflow valve. The overflow valve regulates how
much excess fuel is used for lubrication of the pump
and how much is returned to the tank through the
drain manifold.
Fuel entering the injection pump is pressurized to
between 300 - 1600 bar by three radial pumping
chambers. The pressurized fuel is then supplied to
the fuel rail.
DIAGNOSIS AND TESTING - FUEL INJECTION
PUMP TIMING
With the Bosch injection pump, there are no
mechanical adjustments needed or necessary to
accomplish fuel injection timing. All timing and fuel
adjustments are electrically made by the engine
mounted Engine Control Module (ECM).
ing bolts and position ECM for injection pump
removal. Do not disconnect wiring connectors
from ECM.
(4) Remove cooling fan shroud.
(5) Remove cooling fan assembly.
(6) Remove accessory drive belt.
(7) Thoroughly clean the rear of injection pump,
and attachment points for its 3 fuel lines (Fig. 10).
Also clean the opposite ends of these same 3 lines at
their attachment points.
(8) Disconnect Fuel Control Actuator (FCA) electrical connector at rear of injection pump (Fig. 11).
(9) Remove fuel line (injection pump-to-overflow
valve).
(10) Remove fuel line (injection pump-to-fuel rail).
(11) Remove fuel line (injection pump-to-fuel filter
housing).
(12) Remove fuel pump drive gear access cover
(plate) with a 1/2 inch drive ratchet. Plate is
threaded to timing gear cover (Fig. 12).
(13) Remove fuel pump drive gear mounting nut
and washer.
(14) Attach C3428B, or L4407A (or equivalent)
gear puller (Fig. 13) to pump drive gear with 2 bolts,
and separate gear from pump (a keyway is not used
on this particular injection pump). Leave drive gear
hanging loose within timing gear cover.
(15) Remove 3 injection pump mounting nuts (Fig.
14), and remove pump from engine.
REMOVAL
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system components. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Disconnect both negative battery cables at both
batteries. Cover and isolate ends of both cables.
(2) Remove intake manifold air intake tube (above
injection pump) and its rubber connector hose (Fig.
8).
(3) The Engine Control Module (ECM) is mounted
to left side of engine (Fig. 9). Remove 5 ECM mount-
Fig. 8 INTAKE TUBE AND CONNECTING HOSE
1
2
3
4
-
MANIFOLD ABOVE HEATERS
RUBBER CONNECTING HOSE
METAL INTAKE TUBE
CLAMPS (2)
14 - 66
FUEL DELIVERY - DIESEL
DR
FUEL INJECTION PUMP (Continued)
Fig. 9 ECM REMOVAL/INSTALLATION
1
2
3
4
5
-
ECM LOCATION
ELECTRICAL CONNECTORS (2)
CONNECTOR BOLTS
ECM MOUNTING BOLTS (5)
BOTTOM OF INJECTION PUMP
Fig. 11 FUEL CONTROL ACTUATOR
1 - ACTUATOR MOUNTING BOLTS
2 - FCA (FUEL CONTROL ACTUATOR)
3 - ACTUATOR ELECTRICAL CONNECTOR
Fig. 12 PUMP DRIVE GEAR ACCESS COVER
Fig. 10 OVERFLOW VALVE
1
2
3
4
-
BANJO BOLTS
PUMP MOUNTING NUTS (3)
FUEL INJECTION PUMP
CASCADE OVERFLOW VALVE
1 - FRONT TIMING GEAR COVER
2 - GEAR ACCESS PLATE (COVER)
3 - HEX DRIVE (FOR COVER REMOVAL/INSTALLATION)
FUEL DELIVERY - DIESEL
DR
14 - 67
FUEL INJECTION PUMP (Continued)
INSTALLATION
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system components. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
Fig. 13 DRIVE GEAR REMOVAL
1 - FRONT TIMING GEAR COVER
2 - GEAR PULLER TOOL
(1) Inspect pump mounting surfaces at pump and
mounting flange for nicks, cuts or damage. Inspect
o-ring surfaces for nicks, cuts or damage.
(2) Clean injection pump mounting flange at gear
housing. Also clean front of injection pump.
(3) Install new rubber o-ring into machined groove
(Fig. 14) at pump mounting area.
Fig. 14 FUEL INJECTION PUMP REMOVAL/INSTALLATION
1
2
3
4
5
-
PUMP DRIVE GEAR NUT
WASHER
PUMP DRIVE GEAR
RUBBER O-RING
FUEL INJECTION PUMP
6
7
8
9
-
PUMP MOUNTING NUTS (3)
PUMP MOUNTING STUDS (3)
O-RING MACHINED GROOVE
FRONT TIMING GEAR COVER
14 - 68
FUEL DELIVERY - DIESEL
DR
FUEL INJECTION PUMP (Continued)
(4) Apply clean engine oil to injection pump
o-ring only.
The machined tapers on both injection pump
shaft and injection pump gear must be absolutely dry, clean and free of any dirt or oil film.
This will ensure proper gear-to-shaft tightening.
(5) Clean pump gear and pump shaft at machined
tapers with an evaporative type cleaner such as
brake cleaner.
(6) Position injection pump to mounting flange on
gear cover while aligning injection pump shaft
through back of injection pump gear.
(7) After pump is positioned flat to mounting
flange, install 3 pump mounting nuts and tighten
finger tight only. Do not attempt a final tightening
at this time. Do not attempt to tighten (pull)
pump to gear cover using mounting nuts. Damage to pump or gear cover may occur. The
pump must be positioned flat to its mounting
flange before attempting to tighten 3 mounting
nuts.
(8) To prevent damage or cracking of components,
install and tighten nuts in the following sequence:
(a) Install injection pump shaft washer and nut
to pump shaft. Tighten nut finger tight only.
(b) Do preliminary (light) tightening of injection
pump shaft nut.
(c) Tighten 3 injection pump mounting nuts to 8
N·m (70.8 in. lbs.).
(d) Do a final tightening of pump shaft nut to
105 N·m (77 ft. lbs.).
(9) Install drive gear access cover (plate) using a
1/2 inch drive ratchet. Plate is threaded to timing
gear cover.
(10) Install Engine Control Module (ECM) to left
side of engine.
(11) Install fuel line (injection pump-to-overflow
valve). Tighten bolts to 24 N·m (17 ft. lbs.) torque.
(12) Install fuel line (injection pump-to-fuel rail).
Tighten to 24 N·m (17 ft. lbs.) torque.
(13) Install fuel line (injection pump-to-fuel filter
housing). Tighten to 24 N·m (17 ft. lbs.) torque.
(14) Connect Fuel Control Actuator (FCA) electrical connector to rear of injection pump.
(15) Install intake manifold air intake tube (above
injection pump). Tighten clamps.
(16) Install accessory drive belt.
(17) Install cooling fan shroud.
(18) Install cooling fan assembly.
(19) Connect both negative battery cables to both
batteries.
(20) Check system for fuel or engine oil leaks.
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is
attached to the side of the fuel tank module. The
sending unit consists of a float, an arm, and a variable resistor track (card).
OPERATION
The fuel tank module on diesel powered models
has 3 different circuits (wires). Two of these circuits
are used at the fuel gauge sending unit for fuel
gauge operation. The other wire is used for a ground.
The diesel engine does not have a fuel tank module
mounted electric fuel pump. The electric fuel pump
(fuel transfer pump) is mounted to the engine.
For Fuel Gauge Operation: A constant input
voltage source of about 12 volts (battery voltage) is
supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain
Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel tank module
electrical connector unplugged). With the connectors plugged, output voltages will vary from
about .6 volts at FULL, to about 7.0 volts at
EMPTY. The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As
fuel level increases, the float and arm move up,
which decreases voltage. As fuel level decreases, the
float and arm move down, which increases voltage.
The varied voltage signal is returned back to the
ECM through the sensor return circuit.
Both of the electrical circuits between the fuel
gauge sending unit and the ECM are hard-wired (not
multi-plexed). After the voltage signal is sent from
the resistor track, and back to the ECM, the ECM
will interpret the resistance (voltage) data and send
a message across the multi-plex bus circuits to the
instrument panel cluster. Here it is translated into
the appropriate fuel gauge level reading. Refer to
Instrument Panel for additional information.
REMOVAL
REMOVAL/INSTALLATION
For diesel removal and installation procedures,
refer to the gas section of Fuel System/Fuel Delivery.
See Fuel Level Sending Unit/Sensor Removal/Installation.
FUEL DELIVERY - DIESEL
DR
FUEL LINES
DESCRIPTION
Low-Pressure Lines
• the fuel supply line from fuel tank to fuel transfer (lift) pump.
• the fuel return line back to fuel tank.
• the fuel drain manifold line at rear of cylinder
head.
• the fuel supply line from fuel filter to fuel injection pump.
High-Pressure Lines
• the fuel line from fuel injection pump to overflow
valve.
• the fuel line from fuel injection pump to fuel
rail.
• the 6 fuel lines from fuel rail up to injector connector tubes
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 160,000 KPA (23,206
PSI). USE EXTREME CAUTION WHEN INSPECTING
FOR HIGH-PRESSURE FUEL LEAKS. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. HIGH FUEL INJECTION PRESSURE
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN.
OPERATION
High-Pressure Lines
CAUTION: The high-pressure fuel lines must be
held securely in place in their holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
repair lines that are damaged. If lines are ever
kinked or bent, they must be replaced. Use only the
recommended lines when replacement of high-pressure fuel line is necessary.
High-pressure fuel lines deliver fuel (under pressure) of up to approximately 160,000 kPa (23,206
PSI) from the injection pump to the fuel injectors.
The lines expand and contract from the high-pressure fuel pulses generated during the injection process. All high-pressure fuel lines are of the same
length and inside diameter. Correct high-pressure
fuel line usage and installation is critical to smooth
engine operation.
14 - 69
WARNING: USE EXTREME CAUTION WHEN
INSPECTING FOR HIGH-PRESSURE FUEL LEAKS.
INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
DIAGNOSIS AND TESTING - HIGH-PRESSURE
FUEL LINE LEAKS
High-pressure fuel line leaks can cause starting
problems and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES
OF UP TO 160,000 kPa (23,206 PSI), USE EXTREME
CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL LEAKS. DO NOT GET YOUR HAND OR
A FINGER NEAR A SUSPECTED LEAK. INSPECT
FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET
OF CARDBOARD. HIGH FUEL INJECTION PRESSURE CAN CAUSE PERSONAL INJURY IF CONTACT IS MADE WITH THE SKIN.
Start the engine. Move the cardboard (Fig. 15) over
the suspected high-pressure fuel line leak, and check
for fuel spray onto the cardboard. If line is leaking,
retorque line. Replace damaged, restricted or leaking
high-pressure fuel lines with the correct replacement
line.
CAUTION: The high-pressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
repair lines that are damaged. Only use the recommended lines when replacement of high-pressure
fuel line is necessary.
REMOVAL
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system components. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
14 - 70
FUEL DELIVERY - DIESEL
DR
FUEL LINES (Continued)
(7) Carefully remove each fuel line from engine.
Note position of each while removing. Do not bend
lines while removing.
Fig. 15 TYPICAL TEST FOR LEAKS USING
CARDBOARD
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - TYPICAL HIGH-PRESSURE FITTING
(1) Disconnect both negative battery cables from
both batteries. Cover and isolate ends of cables.
(2) Thoroughly clean fuel lines at both the cylinder
head and injection pump ends.
(3) If removing fuel line at either #1 or #2 cylinder,
the intake manifold air heater elements must first be
removed from top of intake manifold. Refer to Intake
Air Heater Removal / Installation for procedures.
(4) If removing fuel line at #6 cylinder, a bracket
(Fig. 16) is located above fuel line connection at cylinder head. Two bolts secure this bracket to rear of
cylinder head. The upper bolt hole is slotted. Loosen
(but do not remove) these 2 bracket bolts. Tilt
bracket down to gain access to #6 fuel line connection.
(5) Remove necessary insulated fuel line support
clamps (Fig. 17) and bracket bolts at intake manifold.
(6) Place shop towels around fuel lines at fuel rail
and injectors. If possible, do not allow fuel to drip
down side of engine.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPARATE FITTING (Fig. 18) , USE A BACK-UP WRENCH
ON FITTING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
Fig. 16 BRACKET - #6 INJECTOR
1
2
3
4
5
6
-
BRACKET
REAR OF CYLINDER HEAD
FUEL DRAIN MANIFOLD LINE (TO FUEL TANK)
BANJO BOLT
SLOTTED HOLE
BRACKET BOLTS (2)
Fig. 17 FUEL INJECTOR RAIL
1 - FUEL RAIL MOUNTING BOLTS (3)
2 - INSULATED CLAMPS
3 - FUEL INJECTOR RAIL
FUEL DELIVERY - DIESEL
DR
14 - 71
FUEL LINES (Continued)
Fig. 18 HIGH PRESSURE FUEL LINES
1
2
3
4
-
FUEL INJECTOR
HIGH-PRESSURE LINE
INJECTOR MOUNTING BOLTS
FUEL INJECTOR RAIL
INSTALLATION
All high-pressure fuel lines are of the same length
and inside diameter. Correct high-pressure fuel line
usage and installation is critical to smooth engine
operation.
(1) Position fuel line support clamp to fuel line.
Install clamp nuts/bolts and tighten finger tight.
(2) Position proper fuel line to proper injector on
engine. Tighten fittings hand tight at both ends of
line.
(3) Tighten fuel lines at high pressure injector connector to 30 N·m (22 lb. ft.).
(4) Tighten fuel lines at fuel rail to 30 N·m (22 lb.
ft.).
(5) Tighten clamp/support nuts and bolts.
(6) Install engine lifting bracket and bolt. Tighten
bolt to 77 N·m (56 lb.ft.).
5 - SEPARATE FITTING (TYPICAL)
6 - CONNECTOR TUBE RETAINER (FITTING)
7 - CONNECTOR TUBE
(7) If fuel line at either #1 or #2 cylinder has been
replaced, install intake manifold air heater elements
to top of intake manifold. Refer to Intake Air Heater
Removal / Installation for procedures.
(8) If fuel line at #6 cylinder has been replaced, tilt
metal bracket upward and tighten 2 bolts at rear of
cylinder head.
(9) Install remaining fuel line support clamps and
bracket bolts at intake manifold.
(10) Connect both negative battery cables to both
batteries.
(11) Prime fuel system. Refer to Fuel System
Priming.
(12) Check lines/fittings for leaks.
14 - 72
FUEL DELIVERY - DIESEL
FUEL PRESSURE SENSOR
DESCRIPTION
The fuel pressure sensor is mounted vertically near
the top/center of the fuel rail.
OPERATION
The fuel pressure sensor monitors actual highpressure within the fuel rail. An output signal from
this sensor (relating to fuel pressure) is sent to the
Engine Control Module (ECM).
REMOVAL
The fuel pressure sensor is mounted vertically near
the top/center of the fuel rail (Fig. 19).
(1) Disconnect electrical connector at sensor.
(2) Remove sensor from fuel rail.
(3) Inspect sensor o-ring.
DR
INSTALLATION
(1) Inspect fuel pressure sensor o-ring.
(2) Lubricate sensor o-ring with clean diesel fuel.
(3) Install sensor into fuel rail.
(4) To prevent leaks, sensor must be tightened to
prescribed torque. Tighten sensor to 101 N·m (75 ft.
lbs.) torque.
(5) Connect electrical connector to sensor.
(6) Start engine and check for fuel leaks.
FUEL PRESSURE LIMITING
VALVE
DESCRIPTION
The fuel pressure limiting valve is located on the
top of the fuel rail.
OPERATION
Fuel pressure at the fuel rail is monitered by the
fuel rail pressure sensor. If fuel pressure becomes
excessive, the pressure limiting valve opens and
vents excess pressure into the fuel drain circuit.
REMOVAL
The fuel pressure limiting valve is located on the
top of the fuel rail (Fig. 20).
Fig. 19 FUEL PRESSURE SENSOR/FUEL PRES.
LIMIT. VALVE
1
2
3
4
5
-
ELEC. CONNECTOR
BANJO BOLT
FUEL PRESSURE LIMITING VALVE
FUEL PRESSURE SENSOR
TOP OF INTAKE HEATER MANIFOLD
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system components. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Thoroughly clean area at pressure limiting
valve.
(2) Remove banjo bolt (Fig. 20) at banjo fitting.
(3) Remove pressure limiting valve from intake
manifold.
FUEL DELIVERY - DIESEL
DR
14 - 73
FUEL PRESSURE LIMITING VALVE (Continued)
(2) If vehicle is equipped with 4 doors and a 6 foot
(short) box, remove left-rear tire/wheel.
(3) Thoroughly clean area at top of fuel tank
around fuel tank module.
(4) Remove rubber cap from auxiliary fitting on
top of tank module (Fig. 21).
(5) Drain fuel tank by attaching drain hose from
an approved draining station to auxiliary fitting on
top of tank module (Fig. 21).
Fig. 20 FUEL PRESSURE SENSOR/FUEL
PRESSURE LIMITING VALVE
1
2
3
4
5
-
ELEC. CONNECTOR
BANJO BOLT
FUEL PRESSURE LIMITING VALVE
FUEL PRESSURE SENSOR
TOP OF INTAKE HEATER MANIFOLD
INSTALLATION
(1) Be sure both top of manifold and limiting valve
are clean.
(2) Assemble banjo bolt and new sealing washers
to limiting valve.
(3) Tighten banjo bolt to 24 N·M (17 ft. lbs.)
torque.
Fig. 21 FUEL TANK MODULE - DIESEL
1
2
3
4
5
6
7
- TOP OF FUEL TANK
- AUX. FITTING
- ELEC. CONNECTOR
- FUEL TANK MODULE (TOP)
- LOCKNUT
- FUEL SUPPLY LINE
- FUEL RETURN LINE
FUEL TANK
Tank Removal
DESCRIPTION - DIESEL
The fuel tank is similar to the tank used with gasoline powered models. The tank is equipped with a
separate fuel return line and a different fuel tank
module for diesel powered models. A fuel tank
mounted, electric fuel pump is not used with diesel
powered models. Refer to Fuel Tank Module for additional information.
REMOVAL - DIESEL
Fuel Tank Draining
Due to a one-way check valve installed into the
fuel fill opening fitting at the tank, the tank cannot
be drained conventionally at the fill cap.
(1) Raise vehicle.
(1) Loosen clamp and disconnect rubber fuel fill
hose at tank.
(2) Support tank with a hydraulic jack.
(3) Remove 2 fuel tank strap nuts (Fig. 22) and
remove both tank support straps.
(4) Carefully lower tank a few inches and disconnect fuel pump module electrical connector (Fig. 21)
at top of tank. To disconnect electrical connector:
Push upward on red colored tab to unlock. Push on
black colored tab while removing connector.
(5) Disconnect fuel supply and return lines at fuel
tank module (Fig. 21). Refer to Quick-Connect Fittings for procedures.
(6) Continue to lower tank for removal.
14 - 74
FUEL DELIVERY - DIESEL
DR
FUEL TANK (Continued)
(7) If fuel tank is to be replaced, remove fuel tank
module from tank. Refer to Fuel Tank Module
Removal/Installation procedures.
INSTALLATION - DIESEL
(1) If fuel tank is to be replaced, install fuel tank
module into tank. Refer to Fuel Tank Module Removal/Installation procedures.
(2) Position fuel tank to hydraulic jack.
(3) Raise tank until positioned near body.
(4) Connect fuel tank module electrical connector
at top of tank.
(5) Connect fuel supply and return lines to tank
module.
(6) Continue raising tank until positioned snug to
body.
(7) Install and position both tank support straps.
Install 2 fuel tank strap nuts and tighten. Tighten
rear strap nut first. Refer to Torque Specifications.
(8) Remove hydraulic jack.
(9) Connect rubber fill hose to fuel fill tube and
tighten clamp.
(10) Install tire / wheel (if necessary).
(11) Lower vehicle.
(12) Fill fuel tank with fuel.
(13) Start engine and check for fuel leaks near top
of module.
Fig. 22 FUEL TANK MOUNTING
1 - FUEL TANK
2 - STRAP MOUNTING STUDS
3 - VEHICLE FRAME
4 - MOUNTING STRAPS
5 - STRAP NUTS
FUEL DELIVERY - DIESEL
DR
FUEL TANK MODULE
DESCRIPTION
14 - 75
locknut and remove locknut (Fig. 24). The fuel tank
module will spring up when locknut is removed.
(4) Remove module from fuel tank.
An electric fuel pump is not used in the fuel tank
module for diesel powered engines. Fuel is supplied
by the engine mounted fuel transfer (lift) pump.
The fuel tank module is installed in the top of the
fuel tank (Fig. 23). The fuel tank module contains
the following components:
• Fuel reservoir
• A separate in-tank fuel filter
• Fuel gauge sending unit (fuel level sensor)
• Fuel supply line connection
• Fuel return line connection
• Auxiliary non-pressurized fitting
Fig. 24 LOCKNUT REMOVAL/INSTALLATION TYPICAL MODULE
1 - SPECIAL TOOL 6856
2 - LOCKNUT
INSTALLATION
CAUTION: Whenever the fuel tank module is serviced, the rubber gasket must be replaced.
Fig. 23 FUEL TANK MODULE - DIESEL
1
2
3
4
5
6
7
- TOP OF FUEL TANK
- AUX. FITTING
- ELEC. CONNECTOR
- FUEL TANK MODULE (TOP)
- LOCKNUT
- FUEL SUPPLY LINE
- FUEL RETURN LINE
(1) Thoroughly clean locknut and locknut threads
at top of tank.
(2) Using new gasket, carefully position fuel tank
module into opening in fuel tank.
(3) Position locknut over top of fuel tank module.
Install locknut finger tight.
(4) When looking down at tank from drivers side of
tank, the fuel line connectors and fuel gauge electrical connector should all be pointed to drivers side of
vehicle. Rotate and align if necessary before tightening locknut. This step must be performed to prevent the module’s float from contacting side of
fuel tank.
(5) Tighten locknut to 24 - 44 N·m (18 - 32 ft. lbs.)
torque.
(6) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
OPERATION
Refer to Fuel Gauge Sending Unit.
REMOVAL
(1) Drain and remove fuel tank. Refer to Fuel
Tank Removal/Installation.
(2) Thoroughly clean area around tank module at
top of tank.
(3) The plastic fuel tank module locknut is
threaded onto fuel tank. Install Special Tool 6856 to
FUEL TRANSFER PUMP
DESCRIPTION
The fuel transfer pump (fuel lift pump) is attached
to the rear of the fuel filter/water separator housing.
The 12–volt electric pump is operated and controlled
by the Engine Control Module (ECM).
14 - 76
FUEL DELIVERY - DIESEL
DR
FUEL TRANSFER PUMP (Continued)
OPERATION
The purpose of the fuel transfer pump is to supply
(transfer) a low-pressure fuel source: from the fuel
tank, through the fuel filter/water separator and to
the fuel injection pump. Here, the low-pressure is
raised to a high-pressure by the fuel injection pump
for operation of the high-pressure fuel injectors.
Check valves within the pump, control direction of
fuel flow and prevent fuel bleed-back during engine
shut down.
Maximum current flow to the pump is 5 amperes.
With the engine running, the pump has a 100 percent duty-cycle with a minimum pressure of 11.5 psi.
The transfer pump is self-priming: When the key is
first turned on (without cranking engine), the pump
will operate for approximately 1/2 second and then
shut off. The pump will also operate for up to 25 seconds after the starter is engaged, and then disengaged and the engine is not running. The pump
shuts off immediately if the key is on and the engine
stops running.
The fuel volume of the transfer pump will always
provide more fuel than the fuel injection pump
requires. Excess fuel is returned from the injection
pump through an overflow valve, and then back to
the fuel tank.
Fig. 25 FUEL TRANSFER (LIFT) PUMP
1
2
3
4
5
-
FILTER HOUSING
ELEC. CONNECTOR
FUEL TRANSFER (LIFT) PUMP
FUEL LINE EXTENTION
MOUNTING BOLTS (4)
REMOVAL
The fuel transfer pump (fuel lift pump) is attached
to the rear of the fuel filter/water separator housing
(Fig. 25).
(1) Drain fuel from fuel filter housing. Refer to
Fuel Filter/Water Separator - Removal. See Draining.
(2) Disconnect electrical connector (Fig. 25) from
fuel transfer pump.
(3) Disconnect fuel tank supply line from fuel
transfer pump extension line. Do this at disconnection point at inside of left inner frame rail (Fig. 26).
Refer to quick-connect fittings for procedures. The
fuel line extension is permanently attached to
the transfer pump. Do not attempt to disconnect fuel line at transfer pump.
(4) Remove 4 pump mounting bolts (hex-allen),
and remove pump from fuel filter housing.
(5) Confirm that transfer pump o-ring is also
removed from fuel filter housing.
INSTALLATION
(1) Install a new o-ring to fuel transfer pump.
(2) Lubricate o-ring and OD of transfer pump inlet
connector.
(3) Position fuel transfer pump onto fuel filter
housing. Do not use mounting bolts to draw
transfer pump to filter housing.
Fig. 26 TRANSFER PUMP FUEL LINE CONNECT
1
2
3
4
-
LEFT INNER FRAME RAIL
FUEL RETURN LINE
FUEL SUPPLY LINE
QUICK-CONNECT FITTING
FUEL DELIVERY - DIESEL
DR
14 - 77
FUEL TRANSFER PUMP (Continued)
(4) Be sure pump is positioned flat to fuel filter
housing. Install mounting bolts and evenly tighten to
7 N·m (61 in. lbs.).
(5) Connect fuel line extension at fuel supply line.
(6) Connect electrical connector to pump.
(7) Prime System: Cycle key to actuate transfer
pump or use DRB II Scan Tool to actuate transfer
pump. Check for leaks.
(8) Operate engine and check for fuel leaks.
REMOVAL
REMOVAL/INSTALLATION
The cascade overflow valve is not serviced separately.
WATER IN FUEL SENSOR
DESCRIPTION
CASCADE OVERFLOW VALVE
DESCRIPTION
The Water-In-Fuel (WIF) sensor is located on the
side of the fuel filter/water separator canister (Fig.
28), or (Fig. 29).
The cascade overflow valve is located on the top/
rear side of the fuel injection pump (Fig. 27).
Fig. 28 FILTER HOUSING (EARLY)
Fig. 27 OVERFLOW VALVE
1
2
3
4
-
BANJO BOLTS
PUMP MOUNTING NUTS (3)
FUEL INJECTION PUMP
CASCADE OVERFLOW VALVE
OPERATION
When the fuel control actuator (FCA) is opened,
the maximum amount of fuel is being delivered to
the fuel injection pump. Any fuel that does not enter
the injection pump is directed to the cascade overflow
valve. The cascade valve regulates how much excess
fuel is used for lubrication of the injection pump, and
is also used to route excess fuel through the drain
circuit and back into the fuel tank.
1
2
3
4
5
6
7
8
9
-
FILTER HOUSING
FUEL HEATER AND THERMOSTAT
FUEL HEATER MOUNTING SCREWS
FUEL HEATER ELEC. CONNECTOR
DRAIN VALVE
DRAIN VALVE MOUNTING SCREWS
DRAIN HOSE
WIF SENSOR
WIF SENSOR ELEC. CONNECTOR
14 - 78
FUEL DELIVERY - DIESEL
DR
WATER IN FUEL SENSOR (Continued)
REMOVAL
The Water-In-Fuel (WIF) sensor is located at the
side of fuel filter/water separator canister. Refer to
Fuel Filter/Water Separator Removal/Installation for
WIF sensor removal/installation procedures.
FUEL DRAIN CIRCUIT
OPERATION
Fig. 29 FILTER HOUSING (LATE)
1
2
3
4
5
6
7
8
9
-
FILTER HOUSING
FUEL HEATER AND THERMOSTAT
FUEL HEATER MOUNTING SCREWS
FUEL HEATER ELEC. CONNECTOR
WIF SENSOR
WIF SENSOR ELEC. CONNECTOR
DRAIN HOSE
DRAIN VALVE MOUNTING SCREWS
DRAIN VALVE
OPERATION
The sensor sends an input to the Engine Control
Module (ECM) when it senses water in the fuel filter/
water separator. As the water level in the filter/separator increases, the resistance across the WIF
sensor decreases. This decrease in resistance is sent
as a signal to the ECM and compared to a high
water standard value. Once the value reaches 30 to
40 kilohms, the ECM will activate the water-in-fuel
warning lamp through CCD bus circuits. This all
takes place when the ignition key is initially put in
the ON position. The ECM continues to monitor the
input at the end of the intake manifold air heater
post-heat cycle.
The Fuel Drain Circuit incorporates several
sources of fuel return. Fuel travels from the fuel tank
to the fuel transfer pump and is forced through the
fuel filter. A portion of that fuel travels through the
fuel filter and into the fuel injection pump, while the
rest of the fuel flows through a passage in the fuel
filter housing. It then goes to a fuel drain line and
returns back to the fuel tank.
The fuel that flows to the fuel pump is pressurized
and sent into a passage in the fuel pump. At this
point the fuel is channeled into two passages. One
passage sends fuel to the FCA (Fuel Control Actuator). The other passage sends fuel to the cascade
overflow valve. The overflow valve sends some fuel to
a lubrication passage. The rest of the fuel is sent to a
drain passage which connects to an external fuel
line. This fuel line is connected to the same fuel filter
housing passage that the fuel transfer pump is connected to.
Fuel that travels through the FCA is pressurized
by the fuel injection pump and sent through an
external high pressure fuel line to the fuel rail. At
the fuel rail, fuel is sent to the fuel injectors. If fuel
pressure in the fuel rail becomes excessive, the pressure limiting valve opens and sends fuel through an
external fuel line. This line is connected to the fuel
filter housing at the fuel pump drain.
At the fuel injector, fuel that is not injected is used
for lubrication of the fuel injectors. This fuel then
travels through an internal passage in the rear of the
cylinder head, an then into an external fuel line. This
line is connected to the vehicles fuel return line, and
returns excess fuel back to the fuel tank.
FUEL INJECTION - DIESEL
DR
14 - 79
FUEL INJECTION - DIESEL
TABLE OF CONTENTS
page
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION
DESCRIPTION (EARLY)
............
DESCRIPTION (LATE) . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
FUEL CONTROL ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTOR RAIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . .
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ACCELERATOR PEDAL
POSITION SENSOR
page
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . .
INLET AIR TEMPERATURE SENSOR/
PRESSURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . .
INTAKE AIR HEATER
DESCRIPTION . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . .
INTAKE AIR HEATER RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . .
INTAKE AIR TEMPERATURE SENSOR/MAP
SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . .
MAP SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . .
THROTTLE CONTROL CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . .
. . . . . 89
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A plastic cover with a movable door is used to cover
the assembly.
OPERATION
DESCRIPTION
DESCRIPTION (EARLY)
The APPS assembly is located at the top-left-front
of the engine. A plastic cover is used to cover the
assembly. The actual sensor is located behind its
mounting bracket.
DESCRIPTION (LATE)
The Accelerator Pedal Position Sensor (APPS)
assembly is located under the vehicle battery tray. A
cable connects the assembly to the accelerator pedal.
The Accelerator Pedal Position Sensor (APPS) is a
linear potentiometer. It provides the Engine Control
Module (ECM) with a DC voltage signal proportional
to the angle, or position of the accelerator pedal.
REMOVAL
Early Diesel Engines
The APPS is serviced (replaced) as one assembly
including the lever, brackets and sensor. The APPS is
calibrated to its mounting bracket. The APPS assembly is located at left-front of engine below plastic
cable/lever/linkage cover (Fig. 1).
14 - 80
FUEL INJECTION - DIESEL
DR
ACCELERATOR PEDAL POSITION SENSOR (Continued)
CAUTION: Do not attempt to remove sensor from
its mounting bracket as electronic calibration will
be destroyed (sensor-to-bracket mounting screws
are permanently attached). Two accelerator lever
set screws (Fig. 3) are used to position lever. Do
not attempt to alter positions of these set screws as
electronic calibration will be destroyed.
(1) Disconnect both negative battery cables at both
batteries.
(2) Remove cable cover (Fig. 1). Cable cover is
attached with 2 Phillips screws, 2 plastic retention
clips and 2 push tabs (Fig. 1). Remove 2 Phillips
screws and carefully pry out 2 retention clips. After
clip removal, push rearward on front tab, and
upward on lower tab for cover removal.
(3) Using finger pressure only, disconnect end of
speed control servo cable from throttle lever pin by
pulling forward on connector while holding lever
rearward (Fig. 2). DO NOT try to pull connector
off perpendicular to lever pin. Connector will
be broken.
(4) Using two small screwdrivers, pry throttle
cable connector socket from throttle lever ball (Fig.
2). Be very careful not to bend throttle lever
arm.
(5) Disconnect transmission control cable at lever
arm (if equipped). Refer to 21, Transmission.
(6) Squeeze pinch tabs on speed control cable (Fig.
2) and pull cable rearward to remove from cable
mounting bracket.
(7) Squeeze pinch tabs on throttle cable (Fig. 2)
and pull cable rearward to remove from cable mounting bracket.
(8) If equipped with an automatic transmission,
refer to 21, Transmission for transmission control
cable removal procedures.
(9) Disconnect wiring harness clip (Fig. 3) at bottom of bracket.
(10) Remove 6 mounting bolts (Fig. 3) and partially remove APPS assembly from engine. After
assembly is partially removed, disconnect electrical
connector from bottom of sensor by pushing on connector tab (Fig. 4).
(11) Remove APPS assembly from engine.
Late Diesel Engines
The APPS is serviced (replaced) as one assembly
including the sensor, plastic housing and cable. The
APPS assembly is located under the left vehicle battery tray (Fig. 5). Access to APPS is gained from over
top of left / front tire.
(1) Disconnect negative battery cable at battery.
(2) Disconnect APPS cable at accelerator pedal.
Refer to Accelerator Pedal Removal / Installation.
(3) Remove wheel house liner at left / front wheel.
Refer to Body.
Fig. 1 CABLE/LEVER/THROTTLE LINKAGE COVER
1
2
3
4
-
CABLE/LEVER/LINKAGE COVER
PUSH UP LOWER TAB
SCREWS/CLIPS (2)
TAB PUSH HERE
Fig. 2 SERVO CABLE AT THROTTLE LEVER
1 - PINCH (2) TABS
2 - CABLE MOUNTING BRACKET
3 - PINCH TABS (2)
4 - OFF
5 - THROTTLE CABLE
6 - THROTTLE LEVER
7 - THROTTLE LEVER PIN
8 - OFF
9 - CONNECTOR
10 - SPEED CONTROL CABLE
(4) Gain access to APPS electrical connector by
opening swing-down door (Fig. 6). Disconnect electrical connector.
(5) Remove 3 mounting bolts (Fig. 6).
(6) Remove APPS assembly from battery tray.
FUEL INJECTION - DIESEL
DR
14 - 81
ACCELERATOR PEDAL POSITION SENSOR (Continued)
Fig. 3 APPS ASSEMBLY
1
2
3
4
5
- LEVER
- MOUNTING BOLTS (6)
- WIRE HARNESS CLIP
- CALIBRATION SCREWS (NO ADJUSTMENT)
- APPS ASSEMBLY
1
2
3
4
- APPS
- TAB
- PUSH FOR REMOVAL
- APPS CONNECTOR
Fig. 5 APPS LOCATION (LATE)
1 - BATTERY TRAY
2 - APPS LOCATION
3 - APPS MOUNTING BOLTS
Fig. 4 APPS CONNECTOR
(7) If cable is to be separated at APPS, unsnap
cable clip from ball socket (Fig. 7). Release cable from
plastic housing by pressing on small cable release tab
(Fig. 6).
Fig. 6 APPS REMOVE / INSTALL (LATE)
1
2
3
4
5
6
- BOTTOM OF BATTERY TRAY
- ELECTRICAL CONNECTOR
- APPS
- SWING-DOWN DOOR
- CABLE (TO PEDAL)
- CABLE RELEASE TAB
14 - 82
FUEL INJECTION - DIESEL
DR
ACCELERATOR PEDAL POSITION SENSOR (Continued)
done (one time) to ensure accelerator pedal position
sensor calibration has been learned by ECM. If not
done, possible DTC’s may be set.
(12) Use DRB III scan tool to erase any DTC’s
from ECM.
Fig. 7 APPS CABLE (LATE)
1
2
3
4
5
- APPS LEVER
- BALL SOCKET
- SWING-DOWN DOOR
- CABLE CLIP
- CABLE
Late Diesel Engines
(1) Install Accelerator Pedal Position Sensor
(APPS) cable to accelerator pedal. Refer to Accelerator Pedal Removal / Installation.
(2) Connect electrical connector to APPS.
(3) If necessary, connect cable to APPS lever ball
socket (snaps on).
(4) Snap APPS cable cover closed.
(5) Position APPS assembly to bottom of battery
tray and install 3 bolts. Refer to Torque Specifications.
(6) Install wheelhouse liner. Refer to Body.
(7) Perform the following procedure:
(a) Connect negative battery cables to both batteries.
(b) Turn key switch ON, but do not crank
engine.
(c) Leave key switch ON for a minimum of 10
seconds. This will allow ECM to learn electrical
parameters.
(8) If necessary, use DRB IIIt Scan Tool to erase
any Diagnostic Trouble Codes (DTC’s) from PCM.
INSTALLATION
Early Diesel Engines
The APPS is serviced (replaced) as one assembly
including the lever, brackets and sensor. The APPS is
calibrated to its mounting bracket.
(1) Snap electrical connector into bottom of sensor.
(2) Position APPS assembly to engine and install 6
bolts. Tighten bolts to 24 N·m (18 ft. lbs.) torque.
(3) Connect wiring harness clip at bottom of
bracket.
(4) If equipped with an automatic transmission,
refer to Group 21, Transmission for transmission control cable installation procedures.
(5) Install speed control cable into mounting
bracket. Be sure pinch tabs have secured cable.
(6) Install throttle cable into mounting bracket. Be
sure pinch tabs have secured cable.
(7) Connect throttle cable at lever (snaps on).
(8) Connect speed control cable to lever by pushing
cable connector rearward onto lever pin while holding lever forward.
(9) Install cable cover.
(10) Connect both negative battery cables to both
batteries.
(11) ECM Calibration: Turn key to ON position.
Without starting engine, slowly press throttle pedal
to floor and then slowly release. This step must be
CAMSHAFT POSITION
SENSOR
DESCRIPTION
The Camshaft Position Sensor (CMP) on the 5.9L
diesel engine is located below the fuel injection
pump. It is bolted to the back of the timing gear
cover.
OPERATION
The diesel Camshaft Position Sensor (CMP) contains a hall effect device. A rotating target wheel
(tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches
located on the tonewheel. As the tonewheel rotates,
the notches pass the tip of the CMP.
When the leading edge of the tonewheel notch
passes the tip of the CMP, the following occurs: The
interruption of magnetic field causes the voltage to
switch high resulting in a signal of approximately 5
volts.
When the trailing edge of the tonewheel notch
passes the tip of the CMP, the following occurs: The
change of the magnetic field causes the signal voltage
to switch low to 0 volts.
FUEL INJECTION - DIESEL
DR
14 - 83
CAMSHAFT POSITION SENSOR (Continued)
The CMP (Fig. 8) provides a signal to the Engine
Control Module (ECM) at all times when the engine
is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for
engine speed. The Crankshaft Position Sensor (CKP)
is the primary engine speed indicator for the engine
after the engine is running.
Fig. 9 5.9L DIESEL CMP
1
2
3
4
5
6
7
Fig. 8 5.9L DIESEL CMP
1
2
3
4
5
6
7
-
CMP
FUEL INJECTION PUMP (BOTTOM)
ELECTRONIC CONTROL MODULE (ECM)
ECM ELEC. CONNECTOR
CMP ELEC. CONNECTOR
CMP MOUNTING BOLT
BACK OF TIMING GEAR COVER
-
CMP
FUEL INJECTION PUMP (BOTTOM)
ELECTRONIC CONTROL MODULE (ECM)
ECM ELEC. CONNECTOR
CMP ELEC. CONNECTOR
CMP MOUNTING BOLT
BACK OF TIMING GEAR COVER
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to back of timing
chain cover. If sensor is not flush, damage to sensor mounting tang may result.
(4) Install mounting bolt and tighten. Refer to
Torque Specifications.
(5) Connect electrical connector to sensor.
REMOVAL
The Camshaft Position Sensor (CMP) on the 5.9L
diesel engine is located below the fuel injection
pump. It is bolted to the back of the timing gear
cover (Fig. 9).
(1) Disconnect electrical connector at CMP sensor
(Fig. 9).
(2) Remove sensor mounting bolt.
(3) Carefully twist sensor from timing gear cover.
(4) Check condition of sensor o-ring.
INSTALLATION
(1) Clean out machined hole in back of timing gear
cover.
(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into timing gear cover with a
slight rocking action. Do not twist sensor into position as damage to o-ring may result.
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the
engine next to the engine harmonic balancer.
OPERATION
The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the
engine is running (Fig. 10). The CKP contains a hall
effect device. A rotating, notched target wheel (tonewheel) for the CMP is located on the engine harmonic balancer (Fig. 11). This hall effect device
detects notches located on the tonewheel. As the
14 - 84
FUEL INJECTION - DIESEL
DR
CRANKSHAFT POSITION SENSOR (Continued)
tonewheel rotates, the notches pass the tip of the
CKP.
When the leading edge of the tonewheel notch passes
the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high
resulting in a signal of approximately 5 volts.
When the trailing edge of the tonewheel notch
passes the tip of the CKP, the following occurs: The
change of the magnetic field causes the signal voltage
to switch low to 0 volts.
The Camshaft Position Sensor (CMP) also provides
a signal to the Engine Control Module (ECM) at all
times when the engine is running. The ECM uses
this CMP information primarily on engine start-up.
Once the engine is running, the ECM uses the CMP
as a backup sensor for engine speed.
Fig. 11 CKP NOTCHED TONEWHEEL
1 - ENGINE HARMONIC BALANCER
2 - NOTCHED TONEWHEEL
3 - FRONT OF CRANKSHAFT
Fig. 10 5.9L DIESEL CKP
1
2
3
4
5
6
-
ENGINE HARMONIC BALANCER
FRONT OF TIMING GEAR COVER
CKP MOUNTING BOLT
ELEC. CONNECTOR
CKP SENSOR
NOTCHES
REMOVAL
(1)
(2)
(Fig.
(3)
(4)
Raise and support vehicle
Disconnect electrical connector at CKP sensor
12).
Remove 1 sensor mounting bolt.
Remove CKP sensor.
INSTALLATION
(1) Position and install CKP sensor to engine.
(2) Install 1 sensor mounting bolt. Refer to Torque
Specifications.
Fig. 12 5.9L DIESEL CKP
1
2
3
4
5
6
-
ENGINE HARMONIC BALANCER
FRONT OF TIMING GEAR COVER
CKP MOUNTING BOLT
ELEC. CONNECTOR
CKP SENSOR
NOTCHES
(3) Install electrical connector to CKP sensor (Fig.
12).
FUEL INJECTION - DIESEL
DR
FUEL CONTROL ACTUATOR
DESCRIPTION
The Fuel Control Actuator (FCA) is located at the
rear of the high-pressure, fuel injection pump.
OPERATION
The Fuel Control Actuator (FCA) is an electronically controlled solenoid valve. The ECM controls the
amount of fuel that enters the high-pressure pumping
chambers by opening and closing the FCA based on a
demanded fuel pressure. When the FCA is opened,
the maximum amount of fuel is being supplied to the
fuel injection pump. Any fuel that does not enter the
injection pump is directed to the overflow valve. The
overflow valve regulates how much excess fuel is used
for lubrication of the pump and how much is returned
to the fuel tank through the drain manifold.
An audible click from the FCA is normal when
operating the key to either the ON or OFF positions.
REMOVAL
The Fuel Control Actuator (FCA) is located at the
rear of the high-pressure, fuel injection pump (Fig. 13).
(1) Clean FCA mounting area at rear of fuel injection pump with an evaporative-type cleaner.
(2) Disconnect electrical connector at FCA.
(3) Remove 2 FCA mounting bolts.
(4) Remove FCA from injection pump.
(5) After removal, inspect FCA for corrosion or
damage. Shake the FCA and listen for a rattle. If
FCA does not rattle, replace it.
INSTALLATION
(1) Install new o-rings to the Fuel Control Actuator (FCA).
(2) Lubricate o-rings with clean, light grease.
(3) Using new mounting bolts, install FCA into
injection pump. Tighten the micro-encapsulated bolts
in two stages. First to 3 N·m (27 in. lbs.), and then to
7 N·m (62 in. lbs.) torque. Do not pause more than
two minutes between tightening stages as bolts may
lose their ability to retain torque.
(4) Ensure FCA is mounted flush to injection
pump.
(5) Connect electrical connector to FCA.
(6) Start engine and observe for leaks.
FUEL INJECTOR
DESCRIPTION
Six individual, solenoid actuated high-pressure fuel
injectors are used (Fig. 14). The injectors are vertically
mounted into a bored hole in the top of the cylinder
head. This bored hole is located between the intake/
exhaust valves. High-pressure connectors (Fig. 15),
mounted into the side of the cylinder head, connect
each fuel injector to each high-pressure fuel line.
Fig. 14 FUEL INJECTOR - DIESEL
Fig. 13 FUEL CONTROL ACTUATOR
1 - ACTUATOR MOUNTING BOLTS
2 - FCA (FUEL CONTROL ACTUATOR)
3 - ACTUATOR ELECTRICAL CONNECTOR
14 - 85
1 - SOLENOID ELECTRICAL CONNECTOR STUDS
2 - MOUNTING BOLTS
3 - MOUNTING PLATES
4- COPPER SEALING WASHER
5 - INJECTOR TIP
6 - INJECTOR O-RING
7 - INJECTOR ELECTRICAL SOLENOID
14 - 86
FUEL INJECTION - DIESEL
DR
FUEL INJECTOR (Continued)
Fig. 15 HIGH-PRESSURE CONNECTOR
1 - HIGH-PRESSURE CONNECTOR (TO FUEL INJECTOR)
2 - O-RING
3 - CONNECTOR RETAINER
OPERATION
High-pressure fuel is supplied from the injection
pump, through a high-pressure fuel line, through a
fuel pressure limiting valve, into a fuel rail, through
high-pressure lines, through steel connectors and
into the solenoid actuated fuel injector. The ECM
actuates the solenoid causing the needle valve to rise
and fuel flows through the spray holes in the nozzle
tip into the combustion chamber.
Each fuel injector is connected to the fuel rail by a
high-pressure fuel line with a steel connector. This
steel connector is positioned into the cylinder head
and sealed with an o-ring. The connectors are sealed
to the high-pressure fuel lines with fittings. The ferrule on the end of the high-pressure fuel line pushes
against the steel connector when the fuel line fitting
is torqued into the cylinder head. This torquing force
provides a sealing pressure between both the fuel
line-to-connector and the fuel connector-to-fuel injector. The fitting torque is very critical. If the fitting is under torqued, the mating surfaces will not
seal and a high-pressure fuel leak will result. If the
fitting is over torqued, the connector and injector will
deform and also cause a high-pressure fuel leak. This
leak will be inside the cylinder head and will not be
4 - FUEL RAIL
5 - HIGH-PRESSURE FUEL LINES
6 - LOCATING PINS
visible. The result will be a possible fuel injector
miss-fire and low power.
The fuel injectors use hole type nozzles. High-pressure flows into the side of the injector, the ECM activates the solenoid causing the injector needle to lift
and fuel to be injected. The clearances in the nozzle
bore are extremely small and any sort of dirt or contaminants will cause the injector to stick. Because of
this, it is very important to do a thorough cleaning of
any lines before opening up any fuel system component. Always cover or cap any open fuel connections
before a fuel system repair is performed.
Each fuel injector connector tube contains an edge
filter that breaks up small contaminants that enter
the injector. The edge filter uses the injectors pulsating high-pressure to break up most particles so they
are small enough to pass through the injector. The
edge filters are not a substitute for proper
cleaning and covering of all fuel system components during repair.
The bottom of each fuel injector is sealed to the
cylinder head with a 1.5mm thick copper shim (gasket). The correct thickness shim must always be reinstalled after removing an injector.
Fuel pressure in the injector circuit decreases after
injection. The injector needle valve is immediately
DR
FUEL INJECTION - DIESEL
14 - 87
FUEL INJECTOR (Continued)
closed and fuel flow into the combustion chamber is
stopped. Exhaust gases are prevented from entering
the injector nozzle by the needle valve.
REMOVAL
CAUTION: Refer to Cleaning Fuel System Parts.
Six individual, solenoid actuated high-pressure fuel
injectors are used (Fig. 14). The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the
intake/exhaust valves. High-pressure connectors (Fig.
15), mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line.
(1) Disconnect both negative battery cables from
both batteries. Cover and isolate ends of cables.
(2) Remove breather assembly.
(3) Remove valve cover. Refer to Engines for procedures.
(4) Remove necessary high pressure fuel line connecting necessary fuel injector rail to high pressure
connector. Refer to Fuel Line Removal for procedures.
(5) A connector retainer (nut) (Fig. 15) is used on
each connector tube. Remove this nut(s) by unthreading from cylinder head.
(6) Using special high-pressure connector removal
tool #9015 (Fig. 16), or (Fig. 17) remove necessary
high-pressure connector(s) from cylinder head. Tool
#9015 threads onto connector tube. Use tool to pry
connector tube(s) from cylinder head.
(7) Remove necessary exhaust rocker arm assembly(s).
(8) Disconnect injector solenoid wire nuts at top of
injectors (Fig. 18).
(9) Remove 2 fuel injector hold-down clamp bolts
at each injector being removed.
(10) USING TOOL #9010:
(a) Special Tool #9010 (Fig. 19) is equipped with
2 clamshell clamps, a sliding retainer sleeve to
retain the clamshell clamps, a 2–piece mounting
stud, and a pivoting handle. Do not attempt to
remove the fuel injector with any other
device. Damage to injector will occur.
(b) The rocker housing (Fig. 18) is bolted to the
top of cylinder head. The mounting stud from tool
#9010 was meant to temporarily replace a rocker
housing mounting bolt. Remove the necessary
rocker housing mounting bolt. These mounting
bolts are located at the center of each of the 3
rocker housing support bridges.
(c) Install and tighten 2–piece mounting stud to
rocker housing. If removing the #6 fuel injector,
separate the 2–piece mounting stud. Install lower
half of mounting stud to center of rocker housing
bridge. Install upper half of mounting stud to lower
half.
(d) Position tool handle to mounting stud and
install handle nut. Leave handle nut loose to allow
a pivoting action.
(e) Position lower part of clamshell halves to
sides of fuel injector (wider shoulder to bottom).
The upper part of clamshell halves should also be
positioned into machined shoulder on the handles
pivoting head.
(f) Slide the retainer sleeve over pivoting handle
head to lock clamshell halves together.
(g) Be sure handle pivot nut is loose.
(h) Depress handle downward to remove fuel
injector straight up from cylinder head bore.
(11) Remove and discard injector sealing washer.
This should be located on tip of injector (Fig. 20) or
(Fig. 21).
Fig. 16 CONNECTOR TUBE REMOVAL
1 - CONNECTOR TUBE
2 - TOOL #9015
3 - CYLINDER HEAD (LEFT SIDE)
INSTALLATION
(1) Inspect fuel injector.
(a) Look for burrs on injector inlet.
(b) Check nozzle holes for hole erosion or plugging.
(c) Inspect end of nozzle for burrs or rough
machine marks.
(d) Look for cracks at nozzle end.
(e) Check nozzle color for signs of overheating.
Overheating will cause nozzle to turn a dark yellow/
tan or blue (depending on overheating temperature).
(f) If any of these conditions occur, replace injector.
(2) Thoroughly clean fuel injector cylinder head
bore with special Cummins wire brush tool or equivalent (Fig. 22). Blow out bore hole with compressed air.
14 - 88
FUEL INJECTION - DIESEL
DR
FUEL INJECTOR (Continued)
Fig. 19 FUEL INJECTOR REMOVER - #9010
Fig. 17 TOOL #9015 AND CONNECTOR TUBE
1
2
3
4
-
CONNECTOR TUBE
LOCATING PINS
RUBBER O-RING
TOOL #9015
Fig. 20 FUEL INJECTOR SEALING WASHER (SHIM)
LOCATION
1 - FUEL INJECTOR
2 - COPPER SEALING WASHER (SHIM)
Fig. 18 FUEL INJECTORS
1
2
3
4
-
SOLENOID CONNECTIONS
ROCKER HOUSING
FUEL INJECTOR
PASSTHROUGH CONNECTOR
(3) The bottom of fuel injector is sealed to cylinder
head bore with a copper sealing washer (shim) of a
certain thickness (Fig. 20). A new shim with correct
thickness must always be re-installed after removing
injector. Measure thickness of injector shim (Fig. 21).
Shim Thickness: 1.5 mm (.060”)
(4) Install new shim (washer) to bottom of injector.
Apply light coating of clean engine oil to washer. This
will keep washer in place during installation.
(5) Install new o-ring to fuel injector. Apply small
amount of clean engine oil to o-ring.
(6) Note fuel inlet port on high pressure connector.
This must be positioned towards intake manifold.
Position injector into cylinder head bore being
extremely careful not to allow injector tip to touch
sides of bore. Press fuel injector into cylinder head
with finger pressure only.
(7) Install fuel injector hold down clamp and hold
down bolts. Alternately tighten clamp bolts to 10 N·m
(89 in. lbs.) torque.
(8) Connect injector solenoid wires and nuts to top
of injectors (Fig. 18). Tighten connector nuts to 1.5
FUEL INJECTION - DIESEL
DR
14 - 89
FUEL INJECTOR (Continued)
FUEL INJECTOR RAIL
DESCRIPTION
The fuel injector rail is bolted to the top of the
intake manifold.
OPERATION
The fuel rail is used as a distribution device to
supply high-pressure fuel to the high-pressure fuel
lines.
REMOVAL
Fig. 21 MEASURING INJECTOR SEALING WASHER
(SHIM)
1 - SHIM
N·m (14 in. lbs.). Be very careful not to overtighten these nuts as damage to fuel injector
will occur.
(9) Install exhaust rocker arm assembly.
(10) Set exhaust valve lash. Refer to Engine.
(11) Install high pressure connector and its
retainer nut. Tighten nut to 50 N·m (37 ft. lbs.)
torque.
(12) Install high pressure fuel line. Refer to Fuel
Line Installation.
(13) Install valve cover. Refer to Engine.
(14) Install breather assembly.
(15) Connect negative battery cables to both batteries.
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system components. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Disconnect both negative battery cables at both
batteries. Isolate ends of both cables.
(2) Disconnect electrical connector at fuel pressure
sensor.
(3) Remove banjo bolt at fuel limiting valve and
remove fuel limiting valve.
(4) Disconnect necessary wiring harness retention
clips from intake manifold.
(5) Lift 2 rubber covers to gain access to positive
(+), intake heater cable nuts. Remove 2 nuts and
remove 2 cables from studs.
(6) Carefully remove 4 high-pressure fuel lines
from top of injector rail engine. Note position of each
line while removing. Do not bend lines while
removing.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPARATE FITTING, USE A BACK-UP WRENCH ON FITTING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
Fig. 22 CLEANING CYLINDER HEAD INJECTOR
BORE - TYPICAL BORE
1 - TYPICAL INJECTOR BORE
2 - WIRE BRUSH
(7) Carefully remove 2 high-pressure fuel lines at
each end of injector rail. Note position of each line
while removing. Do not bend lines while removing.
14 - 90
FUEL INJECTION - DIESEL
DR
FUEL INJECTOR RAIL (Continued)
(8) Remove 3 injector rail mounting bolts (Fig. 23).
(9) Remove rail from top of intake manifold.
OPERATION
The Inlet Air Temperature/Pressure Sensor is a
combination dual-function sensor. The sensor element
extends into the intake air stream at the top of the
air filter housing. Ambient air temperature as well as
barometric pressure is monitored by this sensor. The
Engine Control Module (ECM) monitors signals from
this sensor.
REMOVAL
The Inlet Air Temperature/Pressure Sensor is
located on the air cleaner cover (Fig. 24).
(1) Disconnect electrical connector at sensor (Fig.
25).
(2) Remove two Torx-type mounting screws.
(3) Remove sensor from air cleaner cover.
(4) Check condition of sensor o-ring (Fig. 26).
Fig. 23 FUEL INJECTOR RAIL
1 - FUEL RAIL MOUNTING BOLTS (3)
2 - INSULATED CLAMPS
3 - FUEL INJECTOR RAIL
INSTALLATION
(1) Clean any dirt/debris from top of intake manifold and bottom of fuel rail.
(2) Position fuel rail to top of manifold and install
3 mounting bolts. Tighten 3 bolts to 24 N·m (18 ft.
lbs.) torque.
(3) Install all high-pressure lines to rail. Refer to
Fuel Lines for procedures.
(4) Reposition wiring harness to intake manifold
and install new tie wraps.
(5) Position fuel limiting valve and install banjo
bolt. Tighten bolt to 30 N·m (22 ft. lbs.) torque.
(6) Connect electrical connector to fuel pressure
sensor.
(7) Position 2 positive (+) cables to intake heater
studs. Install 2 nuts.
(8) Connect battery cables to both batteries.
(9) Start engine and check for leaks.
INLET AIR TEMPERATURE
SENSOR/PRESSURE SENSOR
DESCRIPTION
The combination, dual function Inlet Air Temperature/Pressure Sensor is located on the air cleaner (filter) cover.
Fig. 24 IAT/PRESSURE SENSOR LOCATION - 5.9L
DIESEL
1
2
3
4
5
-
CLIPS
FILTER COVER
FILTER MINDER™
INLET AIR TEMPERATURE/ PRESSURE SENSOR
FILTER HOUSING
INSTALLATION
(1) Check condition of sensor o-ring.
(2) Position sensor into top of air cleaner cover
with a slight twisting action.
(3) Install 2 mounting screws.
(4) Install electrical connector.
FUEL INJECTION - DIESEL
DR
14 - 91
INLET AIR TEMPERATURE SENSOR/PRESSURE SENSOR (Continued)
INTAKE AIR HEATER
DESCRIPTION
The intake manifold air heater element assembly
is located in the top of the intake manifold.
OPERATION
Fig. 25 INLET/PRESSURE SENSOR REMOVAL/
INSTALLATION
1
2
3
4
-
INLET/PRESSURE SENSOR
ELEC. CONNECTOR
SENSOR MOUNTING SCREWS (2)
TOP OF AIR FILTER COVER
The air heater elements are used to heat incoming
air to the intake manifold. This is done to help
engine starting and improve driveability with cool or
cold outside temperatures.
Electrical supply for the 2 air heater elements is
controlled by the Engine Control Module (ECM)
through the 2 air heater relays. Refer to Intake Manifold Air Heater Relays for more information.
Two heavy-duty cables connect the 2 air heater elements to the 2 air heater relays. Each of these cables
will supply approximately 95 amps at 12 volts to an
individual heating element within the heater block
assembly.
Refer to the Powertrain Diagnostic Procedures
manual for an electrical operation and complete
description of the intake heaters, including pre-heat
and post-heat cycles.
REMOVAL
If servicing either of the heater elements, the
entire block/element assembly must be replaced.
(1) Disconnect both negative battery cables at both
batteries. Cover and isolate ends of both cables.
(2) Remove both the intake manifold air intake
tube (above injection pump), and its rubber connector
hose (Fig. 27).
(3) Lift 2 rubber covers (Fig. 28) to gain access to 2
positive (+) cable nuts. Remove these 2 nuts (Fig. 29)
and remove 2 cables from studs.
(4) Disconnect ground strap (Fig. 28) at heater element stud.
(5) Remove wiring harness clips.
(6) Remove engine oil dipstick tube bracket from
air inlet connection and fuel filter housing.
(7) Remove 4 housing mounting bolts (Fig. 28) and
remove heater element assembly.
INSTALLATION
Fig. 26 SENSOR O-RING
1 - IAT/PRESSURE SENSOR
2 - O-RING
If servicing either of the heater elements, the
entire block/element assembly must be replaced.
(1) Using 2 new gaskets, position element assembly and air housing to intake manifold.
(2) Position ground cable to air housing.
(3) Install 4 housing bolts and tighten to 24 N·m
(18 ft. lbs.) torque.
(4) Connect 2 positive (+) heater cables at cable
mounting studs. Do not allow either of the cable
eyelets to contact any other metal source other
than the cable nuts/studs.
14 - 92
FUEL INJECTION - DIESEL
DR
INTAKE AIR HEATER (Continued)
Fig. 27 INTAKE TUBE AND CONNECTING HOSE
1
2
3
4
-
MANIFOLD ABOVE HEATERS
RUBBER CONNECTING HOSE
METAL INTAKE TUBE
CLAMPS (2)
Fig. 29 AIR HEATER ELEMENTS
1
2
3
4
5
6
7
- MOUNTING BOLTS (4)
- AIR HEATER MANIFOLD
- INTAKE MANIFOLD
- HEATER ELEMENTS
- LOWER GASKET
- NUTS (2) POSITIVE CABLES
- UPER GASKET
(5) Install engine oil dipstick tube and mounting
bolt.
(6) Connect rubber connector hose and intake tube
to air intake housing.
(7) Connect both negative battery cables at both
batteries.
INTAKE AIR HEATER RELAY
DESCRIPTION
Fig. 28 AIR HEATER MANIFOLD
1
2
3
4
5
6
-
GROUND CABLE
MOUNTING BOLTS (4)
RUBBER COVERS
OIL DIPSTICK TUBE
DIPSTICK MOUNTING BOLT
NUT (GROUND CABLE)
The 2 intake manifold air heater relays are located
in the engine compartment. They are attached to a
common bracket. This bracket is attached to the
right battery tray (Fig. 30).
OPERATION
The Engine Control Module (ECM) operates the 2
heating elements through the 2 intake manifold air
heater relays.
FUEL INJECTION - DIESEL
DR
14 - 93
INTAKE AIR HEATER RELAY (Continued)
(3) Lift four rubber shields from all 4 cables.
(4) Remove four nuts at cable connectors. Note
position of wiring before removing.
(5) Remove relay mounting bracket bolts and
remove relay assembly.
INSTALLATION
(1) Install relay assembly to battery tray. Tighten
mounting bolts to 4.5 N·m (40 in. lbs.) torque.
(2) Connect eight electrical connectors to relays.
(3) Connect battery cables to both batteries.
INTAKE AIR TEMPERATURE
SENSOR/MAP SENSOR
DESCRIPTION
The combination, dual function Intake Manifold
Air Temperature Sensor/MAP Sensor is installed into
the top of the intake manifold.
Fig. 30 INTAKE MANIFOLD AIR HEATER RELAYS
OPERATION
Refer to Powertrain Diagnostic Procedures for an
electrical operation and complete description of the
intake heaters, including pre-heat and post-heat
cycles.
The combination, dual function Intake Manifold
Air Temperature Sensor/MAP Sensor is installed into
the top of the intake manifold with the sensor element extending into the air stream.
The IAT portion of the sensor provides an input
voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the
ECM indicating turbocharger boost pressure.
REMOVAL
REMOVAL
1
2
3
4
-
BATTERY
CABLES TO INTAKE HEATERS
RELAY TRIGGER WIRES
INTAKE AIR HEATER RELAYS (2)
The 2 intake manifold air heater relays are located
in the engine compartment. They are attached to a
common bracket. This bracket is attached to the
right battery tray (Fig. 30).
The mounting bracket and both relays are replaced
as an assembly.
(1) Disconnect both negative battery cables at both
batteries.
(2) Disconnect four relay trigger wires at both
relays. Note position of wiring before removing.
The combination, dual function Intake Manifold
Air Temperature Sensor/MAP (IAT/MAP) sensor is
installed into the top of the intake manifold (Fig. 31).
(1) Clean area around sensor.
(2) Disconnect electrical connector from IAT/MAP
sensor.
(3) Remove two T-15 Torx headed screws.
(4) Remove sensor from intake manifold.
(5) Check condition of sensor o-ring (Fig. 32).
14 - 94
FUEL INJECTION - DIESEL
DR
INTAKE AIR TEMPERATURE SENSOR/MAP SENSOR (Continued)
INSTALLATION
(1)
(2)
(3)
(4)
(5)
Check condition of sensor o-ring.
Clean sensor mounting area at intake manifold
Position sensor into intake manifold.
Install and tighten 2 screws.
Connect electrical connector to sensor.
MAP SENSOR
DESCRIPTION
A combination, dual function Intake Manifold Air
Temperature Sensor/MAP Sensor is used. Refer to
Intake Air Temperature Sensor/MAP Sensor for information.
THROTTLE CONTROL CABLE
REMOVAL
Fig. 31 INTAKE/MAP SENSOR
1
2
3
4
-
TOP OF INTAKE MANIFOLD
IAT/MAP SENSOR
ELEC. CONNECTOR
MOUNTING BOLTS (2)
Fig. 32 SENSOR O-RING
1 - IAT/MAP SENSOR
2 - O-RING
Early Diesel Engine
(1) Disconnect both negative battery cables at both
batteries.
(2) From inside vehicle, hold up accelerator pedal.
Remove plastic cable retainer and throttle cable core
wire from upper end of pedal arm (Fig. 33). The plastic cable retainer snaps into pedal arm.
(3) From inside vehicle, remove cable clip (Fig. 33).
(4) Remove cable core wire at pedal arm.
(5) Remove cable housing from dash panel and
pull cable into engine compartment.
(6) Remove cable cover (Fig. 34). Cable cover is
attached with 2 Phillips screws, 2 plastic retention
clips and 2 push tabs (Fig. 34). Remove 2 Phillips
screws and carefully pry out 2 retention clips. After
clip removal, push rearward on front tab, and
upward on lower tab for cover removal.
(7) Using 2 screwdrivers, pry cable connector
socket from throttle lever ball (Fig. 35). Be very
careful not to bend throttle lever arm.
FUEL INJECTION - DIESEL
DR
14 - 95
THROTTLE CONTROL CABLE (Continued)
Fig. 35 SERVO CABLE AT THROTTLE LEVER
Fig. 33 ACCELERATOR PEDAL MOUNTING
1
2
3
4
5
- ACCELERATOR CABLE
- PLASTIC RETAINER (CLIP)
- THROTTLE PEDAL ARM
- PEDAL / BRACKET ASSEMBLY
- CABLE CLIP
1 - PINCH (2) TABS
2 - CABLE MOUNTING BRACKET
3 - PINCH TABS (2)
4 - OFF
5 - THROTTLE CABLE
6 - THROTTLE LEVER
7 - THROTTLE LEVER PIN
8 - OFF
9 - CONNECTOR
10 - SPEED CONTROL CABLE
Late Diesel Engine
The Throttle Control Cable on the late diesel
engine connects the accelerator pedal to the Accelerator Pedal Position Sensor (APPS). A separate
mechanical cable is not routed to the throttle body.
CAUTION: Be careful not to damage or kink cable
core wire (within cable sheathing) while servicing
accelerator pedal, cables or APPS.
Fig. 34 CABLE/LEVER/THROTTLE LINKAGE COVER
1
2
3
4
-
CABLE/LEVER/LINKAGE COVER
PUSH UP LOWER TAB
SCREWS/CLIPS (2)
TAB PUSH HERE
(1) Disconnect both negative battery cables at both
batteries.
(2) From inside vehicle, hold up accelerator pedal.
Remove plastic cable retainer and throttle cable core
wire from upper end of pedal arm (Fig. 36). The plastic cable retainer snaps into pedal arm.
(3) Remove cable core wire at pedal arm.
(4) Remove APPS. Refer to (Diesel) Accelerator
Pedal Position Sensor (APPS) Removal / Installation.
(5) From inside vehicle, remove cable clip (Fig. 36).
(6) Remove cable housing from dash panel and
pull cable into engine compartment.
(7) Remove cable housing at APPS bracket by
pressing on release tab with a small screwdriver. To
prevent cable housing breakage, press on tab
only enough to release cable from APPS
bracket.
14 - 96
FUEL INJECTION - DIESEL
DR
THROTTLE CONTROL CABLE (Continued)
(3) Install remaining cable housing end into and
through dash panel opening (snaps into position).
The two plastic pinch tabs should lock cable to dash
panel.
(4) From inside vehicle, hold up accelerator pedal.
Install throttle cable core wire and plastic cable
retainer into and through upper end of pedal arm
(the plastic retainer is snapped into pedal arm).
When installing plastic retainer to accelerator pedal
arm, note index tab on pedal arm (Fig. 33). Align
index slot on plastic cable retainer to this index tab.
(5) Connect negative battery cables to both batteries.
(6) Before starting engine, operate accelerator
pedal to check for any binding.
(7) Install cable/lever cover.
Fig. 36 ACCELERATOR PEDAL MOUNTING
1
2
3
4
5
- ACCELERATOR CABLE
- PLASTIC RETAINER (CLIP)
- THROTTLE PEDAL ARM
- PEDAL / BRACKET ASSEMBLY
- CABLE CLIP
INSTALLATION
Early Diesel Engine
(1) Install cable through mounting hole on cable
mounting bracket (Fig. 35). Cable snaps into bracket.
Be sure 2 pinch tabs are secure.
(2) Using large pliers, connect cable end socket to
throttle lever ball (snaps on).
Late Diesel Engine
(1) Attach cable to Accelerator Pedal Position Sensor (APPS). Refer to APPS (Diesel) Removal / Installation.
(2) Push cable housing into rubber grommet and
through opening in dash panel.
(3) From inside vehicle, install clip holding cable
to dashpanel (Fig. 36).
(4) From inside vehicle, slide throttle cable core
wire into opening in top of pedal arm.
(5) Push cable retainer (clip) into pedal arm opening until it snaps in place.
(6) Before starting engine, operate accelerator
pedal to check for any binding.
(7) If necessary, use DRB IIIt Scan Tool to erase
any APPS Diagnostic Trouble Codes (DTC’s) from
PCM.
9 - 280
ENGINE 5.9L DIESEL
DR
ENGINE 5.9L DIESEL
TABLE OF CONTENTS
page
ENGINE 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING—ENGINE
DIAGNOSIS - MECHANICAL . . . . . . . . . .
DIAGNOSIS AND TESTING—SMOKE
DIAGNOSIS CHARTS . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING—CYLINDER
COMPRESSION/LEAKAGE TESTS . . . . .
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-INPLACE GASKETS AND SEALERS . . . . . .
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS . . . . . .
STANDARD PROCEDURE—HYDROSTATIC
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL
REMOVAL—ENGINE . . . . . . . . . . . . . . . .
REMOVAL—CRANKCASE BREATHER
..
INSTALLATION
INSTALLATION—ENGINE . . . . . . . . . . . .
INSTALLATION—CRANKCASE BREATHER
SPECIFICATIONS
5.9L DIESEL . . . . . . . . . . . . . . . . . . . . . .
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS
5.9L DIESEL ENGINE
...............
ENGINE DATA PLATE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING
CLEANING—CYLINDER HEAD . . . . . . . .
CLEANING—CROSSHEADS . . . . . . . . . .
CLEANING—PUSHRODS . . . . . . . . . . . .
INSPECTION
INSPECTION - CYLINDER HEAD . . . . . . .
INSPECTION—CROSSHEADS
........
INSPECTION—PUSHRODS . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVER(S)
REMOVAL
REMOVAL—CYLINDER HEAD COVER . .
REMOVAL—ROCKER HOUSING . . . . . . .
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . .
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page
INSPECTION
. . . . . . . . . . . . . . . . . . . . . . . . . 304
INSTALLATION
INSTALLATION—CYLINDER HEAD COVER . 304
INSTALLATION—ROCKER 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 PROCEDURE—CYLINDER
BORE REPAIR . . . . . . . . . . . . . . . . . . . . . . . 313
STANDARD PROCEDURE—CAM BORE
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
INSPECTION
. . . . . . . . . . . . . . . . . . . . . . . . . 316
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVAL—CAMSHAFT 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
REMOVAL—GEAR . . . . . . . . . . . . . . . . . . . . . 322
INSTALLATION - GEAR . . . . . . . . . . . . . . . . . . 322
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . 322
ENGINE 5.9L DIESEL
DR
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
SOLID LIFTERS/TAPPETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION
......................
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . .
STANDARD PROCEDURE - HEAD GASKET
SELECTION . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING—PISTON AND CONNECTING
ROD
...........................
INSPECTION
INSPECTION—PISTONS . . . . . . . . . . . .
INSPECTION—CONNECTING ROD . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . .
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION
......................
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING—ENGINE OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . .
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . .
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STANDARD PROCEDURE - ENGINE OIL
SERVICE . . . . . . . . . . . . . . . . . . . . . . .
OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION . . . . . . .
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . .
OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION
.....................
INSTALLATION . . . . . . . . . . . . . . . . . . . .
OIL PRESSURE RELIEF VALVE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION
.....................
INSTALLATION . . . . . . . . . . . . . . . . . . . .
OIL PRESSURE SENSOR/SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . .
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION
.....................
INSTALLATION . . . . . . . . . . . . . . . . . . . .
INTAKE MANIFOLD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION
.....................
INSTALLATION . . . . . . . . . . . . . . . . . . . .
EXHAUST MANIFOLD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION
.....................
INSTALLATION . . . . . . . . . . . . . . . . . . . .
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION . . . . . . . . . . . . . . . . . . .
GEAR HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . .
GEAR HOUSING COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . .
9 - 281
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9 - 282
ENGINE 5.9L DIESEL
DR
ENGINE 5.9L DIESEL
DESCRIPTION
The cylinder block is constructed of cast iron. The
casting is a skirted design which incorporates longitudal 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. 2 Cylinder Numbering
Fig. 1 CumminsT 24-Valve Turbo-Diesel Engine
ENGINE 5.9L DIESEL
DR
9 - 283
ENGINE 5.9L DIESEL (Continued)
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - MECHANICAL
CONDITION
LUBRICATING OIL
PRESSURE LOW
POSSIBLE CAUSES
1. Low oil level.
CORRECTION
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.
LUBRICATING OIL
PRESSURE TOO HIGH
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 cooler
6. 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 nozzles
12.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.
1. 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 binding
4. Check and replace valve.
9 - 284
ENGINE 5.9L DIESEL
DR
ENGINE 5.9L DIESEL (Continued)
CONDITION
LUBRICATING OIL LOSS
POSSIBLE CAUSES
CORRECTION
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.
COMPRESSION KNOCKS
EXCESSIVE VIBRATION
EXCESSIVE ENGINE
NOISES
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.
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.
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
damper
3. 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.
1. 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).
ENGINE 5.9L DIESEL
DR
9 - 285
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 TESTING—SMOKE
DIAGNOSIS CHARTS
The following charts include possible causes and
corrections for excess or abnormal exhaust 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 MinderT at 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. Perform 9Cylinder Cutout
Test9 using 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.
9 - 286
ENGINE 5.9L DIESEL
DR
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. Perform 9Cylinder cutout
Test9 using 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.
ENGINE 5.9L DIESEL
DR
9 - 287
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 MinderT at 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.
9 - 288
ENGINE 5.9L DIESEL
DR
ENGINE 5.9L DIESEL (Continued)
EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE
CORRECTION
Excessive piston ring end gap.
Remove pistons and measure piston ring end gap
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS
- STANDARD PROCEDURE).
Excessive cylinder bore wear and taper.
Remove pistons and measure cylinder bore wear and
taper (Refer to 9 - ENGINE/ENGINE BLOCK STANDARD PROCEDURE).
Cylinder damage.
Remove pistons and inspect cylinder bore for cracks or
porosity. Repair with cylinder liner if necessary. (Refer
to 9 - ENGINE/ENGINE BLOCK - STANDARD
PROCEDURE).
Piston damage.
Remove pistons and inspect for cracks, holes. Measure
piston for out-of-round and taper (Refer to 9 ENGINE/ENGINE BLOCK/PISTON & CONNECTING
ROD - INSPECTION).
Turbocharger failure.
(Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
DIAGNOSIS AND TESTING—CYLINDER
COMPRESSION/LEAKAGE TESTS
CYLINDER COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunctions.
Ensure batteries are completely charged and the
engine starter motor is in good operating condition.
Otherwise, the indicated compression pressures may
not be valid for diagnostic purposes.
(1) Disconnect the fuel inlet line to the fuel transfer pump. Plug the fuel line from the fuel tank.
(2) Start the engine and idle until the engine stalls
(runs out of fuel).
(3) Disconnect all three injector wire harness connectors at the rocker housing.
(4) Remove the breather cover and cylinder head
cover.
(5) Remove the high pressure fuel line between the
cylinder head and fuel rail for the cylinder to be
tested.
(6) Remove the exhaust rocker lever.
(7) Use Tool 9010 to remove the injector and copper sealing washer.
(8) Install the exhaust rocker lever and torque to
43 N·m (32 ft. lbs.).
(9) Cover the remaining rocker levers with clean
shop towels to prevent any oil splatter under the
hood.
(10) Place a rag over the compression test tool fitting. Crank the engine for 2–3 seconds to purge any
fuel that may have drained into the cylinder when
the injector was removed.
(11) Connect the compression test gauge.
(12) Crank the engine for 5 seconds and record the
pressure reading. Repeat this step three times and
calculate the average of the three readings.
(13) Combustion pressure leakage can be checked
if cylinder pressure is below the specification. Perform the leakage test procedure on each cylinder
according to the tester manufacturer instructions.
(14) Upon completion of the test check an erase
any engine related fault codes.
CYLINDER COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
• Exhaust and intake valve leaks (improper seating).
• Leaks between adjacent cylinders or into water
jacket.
• Any causes for combustion/compression pressure
loss
(1) Start and operate the engine until it attains
normal operating temperature.
(2) Remove the breather cover and cylinder head
cover.
(3) Disconnect all three injector wire harness connectors at the rocker housing.
(4) Bring the cylinder to be tested to TDC.
(5) Remove the high pressure fuel line between the
cylinder head and the fuel rail for the cylinder to be
tested.
(6) Install capping Tool 9011 onto the rail.
(7) Remove the high pressure connector nut and
high pressure connector with Tool 9015.
(8) Remove the exhaust and intake rocker lever.
DR
ENGINE 5.9L DIESEL
9 - 289
ENGINE 5.9L DIESEL (Continued)
STANDARD PROCEDURE
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARt GASKET SEALANT
Mopart Gasket Sealant is a slow drying, permanently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This material is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will prevent corrosion. Mopart Gasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results. Do not use form-inplace gasket material unless specified. Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, Mopart ATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARt ENGINE RTV GEN II
Mopart Engine RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARt ATF RTV
Mopart ATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARt GASKET MAKER
Mopart Gasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
Assembling parts using a form-in-place gasket
requires care but it’s easier than using precut gaskets.
Mopart Gasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smearing material off the location.
Mopart Engine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
Mopart Gasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
(9) Use Tool 9010 to remove the injector and copper sealing washer.
(10) Install compression test Tool 9007 into the
injector bore.
(11) Connect the leakage tester and perform the
leakage test procedure on each cylinder according to
the tester manufacturer’s instructions.
(12) Upon completion of the test check and erase
any engine related fault codes.
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essentially, this repair consists of:
• Drilling out worn or damaged threads.
• Tapping the hole with a special Heli-Coil Tap, or
equivalent.
9 - 290
ENGINE 5.9L DIESEL
DR
ENGINE 5.9L DIESEL (Continued)
• Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDURE—HYDROSTATIC
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 battery.
(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 crankshaft 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 SYSTEM/FUEL
INJECTION/FUEL
INJECTOR
INSTALLATION).
(10) Drain engine oil. Remove and discard the oil
filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - 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 - SPECIFICATIONS).
(14) Connect the negative cable(s) to the battery.
(15) Start the engine and check for any leaks.
REMOVAL
REMOVAL—ENGINE
(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 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD 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/RADIATOR 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 - ELECTRICAL/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/ENGINE/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 sensor electrical connectors.
ENGINE 5.9L DIESEL
DR
9 - 291
ENGINE 5.9L DIESEL (Continued)
(35) Remove the passenger battery ground cable
from the engine block. Remove the driver side battery ground cable from the engine block.
(36) Remove power steering pump from engine by
removing 3 bolts.
(37) Remove accelerator linkage cover.
(38) Disconnect cables from APPS if early model build
(39) If late model build,
(40) Disconnect the ECM power connector.
(41) Disconnect the ECM ground wire from the
hydroform screw.
(42) Disconnect the fuel supply and return hoses.
(43) Remove the cylinder head cover. (Refer to 9 ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(44) Disconnect the 3 injector harness connectors
at the rocker housing. Disconnect the wire harnesses
from the injectors.
(45) Remove the rear engine lift bracket.
(46) Remove cylinder #4, #5, and #6 intake and
exhaust rocker arms, pedestals, and push tubes. Note
the original location for re-assembly.
(47) Loosen #6 fuel line shield bolts and rotate
shield out of the way.
(48) Remove cylinder #5 and #6 high pressure fuel
lines. Remove the fuel connector tube nut and fuel connector tube. 46. Remove cylinder #5 and #6 fuel injector.
(49) Remove rocker housing.
(50) Remove two cylinder head bolts in location 4
and 12 according to the diagram below and install
Tool # 9009 (Fig. 3).
(51) Loosen but do not remove engine mount
through bolts and nuts.
(52) Disconnect hood support struts and position
hood out of the way.
(53) Attach a chain with two hooks to the engine
lift brackets.
(54) While keeping engine level, lift straight up
out of the mounts.
(55) Rotate nose of engine upward and pull out of
chassis.
REMOVAL—CRANKCASE BREATHER
(1) Remove the oil fill cap.
(2) Remove the breather cover bolts (Fig. 4).
(3) Remove breather cover.
(4) Disconnect breather tube and lube oil drain
tube from breather.
(5) Remove breather mounting bolts.
(6) Remove breather from cylinder head cover.
Fig. 4 Crankcase Breather Vapor Canister
1 - BREATHER COVER BOLT
2 - BREATHER COVER
3 - BREATHER TUBE
4 - ROCKER COVER
5 - BREATHER TUBE MOUNTING BRACKET
6 - LUBE OIL DRAIN TUBE
7 - O-RING
8 - BREATHER
9- BREATHER MOUNTING BOLT
INSTALLATION
Fig. 3 ENGINE LIFT BRACKET
1 - Head bolt
2 - Engine Lift Bracket
3 - Head Bolt
INSTALLATION—ENGINE
(1) Remove cylinder head bolts in locations 4 and
12 according to the diagram below. Install special
Tool 9009.
9 - 292
ENGINE 5.9L DIESEL
DR
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 ftlbs). 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. Follow 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 sensor 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 alternator.
(52) Start the engine and inspect for engine oil,
coolant, and fuel leaks.
INSTALLATION—CRANKCASE 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.
ENGINE 5.9L DIESEL
DR
9 - 293
ENGINE 5.9L DIESEL (Continued)
SPECIFICATIONS
DESCRIPTION
Piston Pins
5.9L DIESEL
DESCRIPTION
SPECIFICATION
Engine Type
In-Line 6 Cyl. Turbo
Diesel
Bore and Stroke
Pin Diameter (Min.)
39.990 mm (1.5744
inch)
(Max)
40.003 mm (1.5749 in.)
Bore Diameter (Min)
40.006 mm (1.5750
inch.
(Max)
40.012 mm (1.5753 in.)
102.0 X 120.0 mm
(4.02 X 4.72 in.)
Displacement
SPECIFICATION
5.9L (359 cu. in.)
Piston Ring End Gap
Top Ring
Compression Ratio
0.26 – 0.36 mm
(0.010 – 0.014 in.)
305/250/235 H.P. Version
17.2:1
Horsepower (A/T and 5
Speed M/T)
235 @ 2700 rpm
(CARB)
Intermediate
250 @2900 rpm (49
State)
Oil Control
Horsepower (6 Speed M/T
Only)
305 @ 2900 rpm
Connecting Rods
Torque Rating (A/T and 5
Speed M/T)
460 ft. lbs. @ 1400 rpm
Pin Bore Diameter (Max.
w/busing installed)
40.019 mm – 40.042
mm (1.5764 – 1.5765
in.)
Torque Rating (6 Speed
M/T Only)
555 ft. lbs. @ 1400 rpm
Side Clearance
0.100 – 0.330 mm
Firing Order
1-5-3-6-2-4
Lubrication System
Pressure Feed-Full Flow
With Bypass Valve
0.85 – 1.15 mm
(0.33 – 0.045 in.)
0.25 – 0.55 mm
(0.010 – 0.021 in.)
(0.004 – 0.013 in.)
CYLINDER HEAD
Cylinder Block
Cast Iron
Overall Flatness End to
End (Max.)
Crankshaft
Induction Hardened
Forged Steel
Overall Flatness Side to
Side (Max.)
0.076 mm (0.003 in.)
Cylinder Head
Cast Iron With Valve
Seat Inserts
Intake Valve Seat Angle
30°
Exhaust Valve Seat Angle
45°
Combustion Chambers
High Swirl Bowl
Valve Stem Diameter
Camshaft
Chilled Ductile Iron
(Min)
6.96 mm (0.2740 in.)
Pistons
Cast Aluminum
(Max)
7.01 mm (0.2760 in.)
Connecting Rods
Cross Rolled Micro Alloy
Valve Rim Thickness
(Min.)
0.79 mm (0.031 in.)
PISTONS AND CONNECTING RODS
Piston
Skirt Diameter
0.305 mm (0.012 in.)
OIL PRESSURE
101.864 – 101.887 mm
At Idle
69 kPa (10 psi)
(4.010 – 4.011 in.)
At 2,500 rpm
207 kPa (30 psi)
Regulating Valve Opening
Pressure
517 kPa (75 psi)
Oil Filter Bypass Pressure
Setting
344.75 kPa (50 psi)
Ring Groove Clearance
Intermediate (Min.)
0.045 mm (.0018 inch)
(Max)
0.095 mm (0.0037 inch)
Oil Control (Min)
0.040 mm (.0016 inch)
(Max)
0.085 mm (0.0033 inch)
9 - 294
ENGINE 5.9L DIESEL
DR
ENGINE 5.9L DIESEL (Continued)
TORQUE
SPECIAL TOOLS
TORQUE CHART 5.9L DIESEL ENGINE
5.9L DIESEL ENGINE
N·m
In.
Lbs.
Ft.
Lbs.
Step 1
30
—
22
Step 2
60
—
44
Step 3
Rotate 60 degrees
DESCRIPTION
Connecting Rod—Bolts
Crankshaft Main Cap—Bolts
Step 1
50
37
Step 2
80
59
Step 3
Rotate 90°
Cylinder Head—Bolts
Universal Driver Handle - C4171
Step 1
70
—
52
Step 2
Back off 360 degrees
Step 3
105
—
77
Step 4 Verify
105
—
77
Step 5
Rotate All Bolts 1/4
Turn
Cylinder Head Cover Bolts
24
—
18
Breather Cover Bolts
24
—
18
HPC Nut
50
Fuel Delivery Lines—Banjo
24
—
18
Fuel Drain Line—Banjo
24
—
18
Fuel line—rail to cylinder
head
30
—
22
Fuel line—pump to fuel rail
30
—
22
Injector fuel line brace
24
—
18
Fuel rail holddown bolt
24
Oil Pan—Bolts
28
—
21
Oil Pan—Drain Plug
50
—
37
Oil Pressure Regulator—Plug
80
—
60
Oil Pressure Switch
18
—
13
Step1
8
—
6
Step2
24
—
18
Oil Suction Tube (Flange)—
Bolts
24
—
18
Oil Suction Tube (Brace)—
Bolt
43
—
32
Rocker Arm/Pedestal—Bolts
36
—
27
Crankshaft Barring Tool - 7471 - B
37
Crankshaft Front Oil Seal Installer - 8281
18
Valve Spring Compressor - 8319A
Oil Pump—Bolts
Test Plug - 8442
ENGINE 5.9L DIESEL
DR
ENGINE 5.9L DIESEL (Continued)
Adapter - 8462
Compression Test Adapter - 9007
Engine Support Fixture - 8534
Engine Lift Bracket - 9009
TAPPET INSTALLATION TOOL - 8502
Fuel Injector Remover - 9010
STEEL BRACKET - 8534-A
2
9 - 295
9 - 296
ENGINE 5.9L DIESEL
DR
ENGINE 5.9L DIESEL (Continued)
FUEL BLOCKOFF PLUG - 9011
Fuel Injector Tube (Connector) Remover - 9015
FUEL TEST FITTING - 9013
TURBO TEST ADAPTER - 9022
ENGINE 5.9L DIESEL
DR
ENGINE DATA PLATE
DESCRIPTION
The engine data plate contains specific information
that is helpful to servicing and obtaining parts for the
engine. The data plate can be found in two places. Some
models have a data plate is located on the left side of
the engine, affixed to the APPS bracket. Some models
will have the data plate affixed to the breather cover on
the left side of the engine. Information that can be
found on the data plate includes:
• Date of Engine Manufacture
• Engine Serial Number
• Control Parts List (CPL)
• Engine Rated Horsepower
• Engine Firing Order
• Engine Displacement
• Valve Lash Reset Specifications
If the engine data plate is missing or not legible,
the engine serial number is used for engine identification. The engine serial number is stamped on the
right side of the block, on top of the oil cooler cavity
(Fig. 5).
9 - 297
has experienced. A drop in air pressure due to an air
cleaner element restriction moves diaphragm and
yellow disc will indicate size of air drop.
CAUTION: Certain engine degreasers or cleaners
may discolor or damage plastic housing of Filter
Minder. Cover and tape Filter Minder if any engine
degreasers or cleaners are to be used.
To test, turn engine off. If yellow disc (Fig. 7) has
reached red colored zone on graduated scale, air cleaner
element should be replaced. Refer to Removal / Installation.
Resetting Filter Minder: After air cleaner (filter)
element has been replaced, press rubber button on
top of Filter Minder (Fig. 7). This will allow yellow
colored disc to reset. After button has been pressed,
yellow disc should spring back to UP position.
If Filter Minder gauge has reached red colored
zone, and after an examination of air cleaner (filter)
element, element appears to be clean, high reading
may be due to a temporary condition such as snow
build-up at air intake. Temporary high restrictions
may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this
occurs, allow element to dry out during normal
engine operation. Reset rubber button on top of Filter
Minder and retest after element has dried.
Fig. 5 Engine Serial Number Location
AIR CLEANER ELEMENT
REMOVAL
Testing Air Cleaner Element using Filter Minder™
Do not attempt to unnecessarily remove top
of air cleaner housing for air cleaner element
inspection on diesel engines.
The air cleaner (filter) housing is equipped with an
air Filter Minder™ gauge (Fig. 6). This air flow
restriction gauge will determine when air cleaner element is restricted and should be replaced.
The Filter Minder™ consists of a diaphragm and
calibrated spring sealed inside of a plastic housing
(Fig. 7). A yellow colored disc attached to diaphragm
moves along a graduated scale on side of Filter
Minder. After engine has been shut off, a ratcheting
device located within Filter Minder will hold yellow
disc at highest restriction that air cleaner element
Fig. 6 5.9L DIESEL AIR CLEANER - FILTER
MINDER™
1
2
3
4
5
-
CLIPS
FILTER COVER
FILTER MINDER™
INLET AIR TEMPERATURE/ PRESSURE SENSOR
FILTER HOUSING
9 - 298
ENGINE 5.9L DIESEL
DR
AIR CLEANER ELEMENT (Continued)
REMOVAL
Fig. 7 FILTER MINDER™ - 5.9L DIESEL
1
2
3
4
5
-
PRESS BUTTON TO RESET
YELLOW DISC
RED ZONE
TO AIR FILTER HOUSING
FILTER MINDER
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 (filter), 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 cylinder. 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 hardened intake and exhaust valve seat inserts.
(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 sensor.
(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 rubber 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 turbocharger 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 cylinder head.
(16) Disconnect radiator upper hose from the thermostat housing.
(17) Disconnect the Intake Air Temperature, Manifold 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 attaching bolt at fuel filter housing bracket and inlet air
connection..
(23) Remove the charge air cooler-to-air inlet housing pipe.
ENGINE 5.9L DIESEL
DR
9 - 299
CYLINDER HEAD (Continued)
Fig. 8 Throttle Linkage Cover
1
2
3
4
-
CABLE/LEVER/LINKAGE COVER
PUSH UP LOWER TAB
SCREWS/CLIPS (2)
TAB PUSH HERE
Fig. 9 APPS Assembly
1
2
3
4
5
- LEVER
- MOUNTING BOLTS (6)
- WIRE HARNESS CLIP
- CALIBRATION SCREWS (NO ADJUSTMENT)
- APPS ASSEMBLY
(24) Remove the engine wire harness attaching
bolt and wire harness push-in fastener from air inlet
housing.
(25) Remove the air inlet housing and intake grid
heater from the intake manifold cover.
(26) Remove the two grid heater harness-to-cylinder head attaching bolts at front of cylinder head.
Fig. 10 APPS Connector
1
2
3
4
- APPS
- TAB
- PUSH FOR REMOVAL
- APPS CONNECTOR
(27) Remove the engine lift bracket from the rear
of the cylinder head.
(28) Remove the high pressure pump to fuel
rail fuel line as follows:
(a) Loosen fuel line nuts at fuel pump and at
fuel rail.
(b) Use a back-up wrench on the fitting at the
fuel pump to keep it from loosening.
(29) Remove the fuel rail to cylinder head fuel
lines as follows:
(a) Loosen No. 6 high pressure fuel line shield
and position out of way.
(b) Loosen the fuel line nuts at the fuel rail and
at the cylinder head.
(c) Remove the fuel line bracket bolts at the
intake manifold cover.
(30) Remove the fuel rail as follows:
(a) Remove fuel rail pressure sensor connector.
(b) Remove banjo fitting at pressure limiting
valve.
(c) Remove fuel rail bolts and fuel rail.
(31) Remove the low pressure lines as follows:
(a) Remove the fuel drain banjo fitting on the
front side of fuel filter housing.
(b) Remove the fuel drain banjo fitting on rear
side of fuel filter housing.
(c) Remove the fuel drain line support bracket
on rear side of filter housing.
(d) Remove fuel drain hose.
9 - 300
ENGINE 5.9L DIESEL
DR
CYLINDER HEAD (Continued)
(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 lifting them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
Fig. 12 Push Rod Removal
(41) Remove rocker housing bolts and rocker housing 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 failure.
CLEANING
CLEANING—CYLINDER HEAD
CAUTION: Do not wire brush head surface while
fuel injectors are still installed. Fuel injector damage can result.
Fig. 11 Rocker Arm and Pedestal Removal
1 - ROCKER ARM
2 - PEDESTAL
(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).
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
(88°C or 140°F).
After rinsing, use compressed air to dry the cylinder head.
Polish the gasket surface with 400 grit paper. Use
an orbital sander or sanding block to maintain a flat
surface.
CLEANING—CROSSHEADS
Clean all crossheads in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn
deposits. Rinse in hot water and blow dry with compressed air.
DR
ENGINE 5.9L DIESEL
9 - 301
CYLINDER HEAD (Continued)
CLEANING—PUSHRODS
Clean the pushrods in a suitable solvent. Rinse in
hot water and blow dry with compressed air. If necessary, use a wire brush or wheel to remove stubborn
deposits.
INSPECTION
INSPECTION - CYLINDER HEAD
Inspect the cylinder head for cracks in the combustion surface. Pressure test any cylinder head that is
visibly cracked. A cylinder head that is cracked
between the injector bore and valve seat can be pressure tested and reused if OK; however, if the crack
extends into the valve seat insert bore, the cylinder
head must be replaced.
Visually inspect the cylinder block and head combustion surfaces for localized dips or imperfections.
Check the cylinder head and block combustion surfaces for overall out-of-flatness. If either the visual or
manual inspection exceeds the limits, then the head
or block must be surfaced.
Check the top surface for damage caused by the
cylinder head gasket leaking between cylinders.
Inspect the block and head surface for nicks, erosion, etc.
Check the head distortion. Maximum overall variation end to end is 0.305 mm (0.012 inch) (Fig. 13),
and maximum overall variation side to side 0.076
mm ( .003 in.).
DO NOT proceed with the in-chassis overhaul if
the cylinder head or block surface is damaged or not
flat (within specifications).
Check block surface for distortion. Maximum variation end-to-end is 0.076 mm ( .003 in.), side-to-side
0.051 mm (.002).
Visually inspect the cylinder head bolts for damaged threads, corroded/pitted surfaces, or a reduced
diameter due to bolt stretching.
If the bolts are not damaged, their “free length”
should be measured using the cap screw stretch
gauge provided with the replacement head gasket.
Place the head of the bolt against the base of the slot
and align the bolt with the straight edge of gauge
(Fig. 14). If the end of the bolt touches the foot of the
gauge, the bolt must be discarded. The maximum
bolt free length is 132.1 mm (5.200 in.).
Fig. 14 Head Bolt Stretch Gauge
INSPECTION—CROSSHEADS
Inspect the crossheads for cracks and/or excessive
wear on rocker lever and valve tip mating surfaces
(Fig. 15). Replace any crossheads that exhibit abnormal wear or cracks.
Fig. 15 Inspecting Crosshead for Cracks
Fig. 13 Cylinder Head Combustion Deck Face
1 - STRAIGHT EDGE
2 - FEELER GAUGE
9 - 302
ENGINE 5.9L DIESEL
DR
CYLINDER HEAD (Continued)
INSPECTION—PUSHRODS
Inspect the push rod ball and socket for signs of
scoring. Check for cracks where the ball and the
socket are pressed into the tube (Fig. 16).
Roll the push rod on a flat work surface with the
socket end hanging off the edge (Fig. 17). Replace
any push rod that appears to be bent.
Fig. 16 Inspecting Push Rod for Cracks
(b)
(c)
(d)
(e)
Back off 360 degrees in sequence
Torque bolts to 105 N·m (77 ft. lbs.)
Re-check all bolts to 105 N·m (77 ft. lbs.)
Tighten all bolts an additional 1⁄4 turn (90°)
Fig. 18 Cylinder Head Bolt Torque Sequence
(4) Install push rods into their original locations
(Fig. 19). Verify that they are seated in the tappets.
Fig. 17 Inspecting Push Rod for Flatness
INSTALLATION
WARNING: THE OUTSIDE EDGE OF THE HEAD
GASKET IS VERY SHARP. WHEN HANDLING THE
NEW HEAD GASKET, USE CARE NOT TO INJURE
YOURSELF.
(1) Install a new gasket with the part number side
up, and locate the gasket over the dowel sleeves.
(2) Using an engine lifting crane, lower the cylinder head onto the engine.
(3) Lightly lubricate head bolts with engine oil and
install. Using the sequence shown in (Fig. 18),
tighten bolts in the following steps:
(a) Torque bolts to 70 N·m (52 ft. lbs.)
Fig. 19 Push Rod Installation
(5) Lubricate valve stem tips and install the crossheads in their original locations.
(6) Lubricate the rocker arms and pedestals and
install them in their original locations (Fig. 20).
Install the bolts and torque them to 36 N·m (27 ft.
lbs.).
(7) Verify that the valve lash settings are maintained (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
(8) Inspect rocker housing gasket for cuts and
proper installation into groove. Replace if damaged.
ENGINE 5.9L DIESEL
DR
9 - 303
CYLINDER HEAD (Continued)
Fig. 20 Rocker Arm and Pedestal Removal
1 - ROCKER ARM
2 - PEDESTAL
(9) Install rocker housing and bolts. Tighten to 24
Nm (18 lb. ft.).
(10) Install fuel injector(Refer to 14 - FUEL SYSTEM/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 cylinder 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 limiting valve. Hand tighten at fuel filter housing.
(c) Hand tighten fuel rail-to-cylinder head lines.
(d) Install fuel line brace bolts-to-intake manifold 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 limiting 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 housing 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.
9 - 304
ENGINE 5.9L DIESEL
DR
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 assembly, 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
cylinders 5 & 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 Turbocharger 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
REMOVAL—CYLINDER 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.
REMOVAL—ROCKER HOUSING
(1) Remove cylinder head cover as outlined in this
section.
(2) Disconnect rocker housing injector harness connectors.
(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 housing gasket, are reusable. However, should cracks,
nicks, or tears be present in the rubber/silicone construction, the defective components should be
replaced. Also replace gasket if it is no longer flexible. Inspect o-rings on cylinder head cover bolts.
INSTALLATION
INSTALLATION—CYLINDER 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 housing.
(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.).
INSTALLATION—ROCKER 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 installation 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 Tool XXXX guide pins (or equivalent)
into the cylinder head at rocker housing bolt locations #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 solenoid. Torque to 1.5 Nm (13 in. lbs.).
(9) Connect rocker housing injector harness connections.
ENGINE 5.9L DIESEL
DR
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves are made of heat resistant steel, and
have chrome plated stems to prevent scuffing. The
intake and exhaust valves are both similar in head
diameter and overall length, but they have unique
face angles which makes them non-interchangeable.
The valves are distinguished by unique dimples on
the exhaust valve head (Fig. 21).
The exhaust valve springs are made from high
strength, chrome silicon steel. The exhaust valve
springs are also exhaust brake compatible.
9 - 305
(6) Remove the retainers, springs, valve seals (if
necessary), and valves (Fig. 24). Arrange or number
all components so they can be installed in their original locations.
(7) Repeat the procedure on all cylinders to be serviced.
Fig. 22 Spring Compressor Mounting Base—Part of
Tool 8319–A
1 - COMPRESSOR MOUNTING BASE
Fig. 21 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVES, GUIDES
AND SPRINGS
REMOVAL
(1) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(2) Support cylinder head on stands, or install
head bolts upside down (through combustion surface
side) to protect injector tips from damage from work
bench.
(3) Install the valve spring compressor mounting
base as shown in (Fig. 22).
(4) Install the compressor top plate, washer, and
nut. Using a suitable wrench, tighten the nut (clockwise) to compress the valve springs (Fig. 23) and
remove the locks.
(5) Rotate the compressor nut counter-clockwise to
relieve tension on the springs. Remove the spring
compressor.
Fig. 23 Compressing Valve Springs with Tool
8319–A
1 - SPECIAL TOOL 8319
CLEANING
Clean the valve stems with crocus cloth or a
Scotch-Brite™ pad. Remove carbon with a soft wire
brush. Clean valves, springs, retainers, and valve
retaining locks in a suitable solvent. Rinse in hot
water and blow dry with compressed air.
9 - 306
ENGINE 5.9L DIESEL
DR
INTAKE/EXHAUST VALVES & SEATS (Continued)
Measure the valve stem diameter in three places
as shown in (Fig. 26).
Fig. 26 Measure Valve Stem Diameter
VALVE STEM DIAMETER
6.96 mm (0.2740 in.) MIN
7.010 mm (0.2760 in.) MAX
Measure the cylinder head valve guide bore (Fig. 27).
Fig. 24 Valve Spring, Seal, and Retainers
1
2
3
4
5
-
VALVE RETAINING LOCKS
VALVE
SEAL
SPRING
RETAINER
INSPECTION
Visually inspect the valves for abnormal wear on
the heads, stems, and tips. Replace any valve that is
worn out or bent (Fig. 25).
VALVE GUIDE BORE SPECIFICATIONS
VALVE GUIDE BORE SPECIFICATIONS
Valve guide bore
diameter
Min.
7.027 mm (0.2767 in.)
Max.
7.077 mm (0.2786 in.)
Min.
0.584 mm ( 0.023 in.)
Max.
1.092 mm ( 0.043 in.)
Min.
0.965 mm ( 0.028 in.)
Max.
1.473 mm (0.058 in.)
Installed valve guide
depth
Intake
Exhaust
Fig. 25 Visually Inspect Valves for Abnormal Wear
Fig. 27 Measure Valve Guide Bore
ENGINE 5.9L DIESEL
DR
9 - 307
INTAKE/EXHAUST VALVES & SEATS (Continued)
Measure valve margin (rim thickness) (Fig. 28).
Fig. 28 Measure Valve Margin (Rim Thickness)
VALVE MARGIN (RIM THICKNESS)
0.79 mm (0.031 in.) MIN.
Measure the valve spring free length and maximum inclination (Fig. 29).
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.)
Test valve spring force with tool C-647 (Fig. 30).
Specification 72.0 — 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).
Fig. 30 Testing Valve Spring with Tool C-647
1 - SPECIAL TOOL C-647
Fig. 31 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
(5) Compress the valve springs and install the
valve retaining locks (Fig. 24).
(6) Remove the compressor and repeat the procedure on the remaining cylinders.
(7) Install new o-ring and sealing washer on injector.
(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).
9 - 308
ENGINE 5.9L DIESEL
DR
INTAKE/EXHAUST VALVES & SEATS (Continued)
STANDARD PROCEDURE - VALVE LASH
ADJUSTMENT AND VERIFICATION
NOTE: To obtain accurate readings, valve lash measurements AND adjustments should only be performed when the engine coolant temperature is less
than 60° C (140° F).
The 24–valve overhead system is a “low-maintenance” 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 falls within the limits, adjustment/resetting is not necessary. If measurement
finds the lash outside of the limits, adjustment/resetting is required.
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.
Fig. 32 Measuring Valve Lash - Typical
1 - INTAKE
2 - FEELER GAUGE
3 - EXHAUST
(5) If adjustment/resetting is required, loosen the
lock nut on rocker arms and turn the adjusting screw
until the desired lash is obtained:
• INTAKE 0.254 mm (0.010 in.)
• EXHAUST 0.508 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
crankshaft one revolution (360°) 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 necessary, 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 connector. 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
ENGINE 5.9L DIESEL
DR
9 - 309
INTAKE/EXHAUST VALVES & SEATS (Continued)
mark in the 12 o’clock position. At this engine position, cylinders #1 and #6 can be serviced.
(8) Remove the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).
(9) With the damper TDC mark in the 12 o’clock
position, add a paint mark anywhere on the gear
housing cover next to the crankshaft damper. Place
another mark on the vibration damper in alignment
with the mark you just made on the cover.
(10) Divide the crankshaft damper into three
equally sized segments as follows:
(a) Using a tape measure, measure the circumference of the crankshaft damper and divide the
measurement by three (3).
(b) Measure that distance in a counter-clockwise
direction from the first balancer mark and place
another mark on the balancer.
(c) From the second damper mark, again measure in a counter-clockwise direction and place a
mark on the damper at the same distance you
measured when placing the second damper mark.
The damper should now be marked in three
equally spaced locations and the damper TDC
mark should be in the 12 o’clock position.
(d) Remove injectors, fuel lines, and high pressure connectors for every cylinder that requires
repair.
35) to compress the valve springs and remove the
collets.
(e) Rotate the compressor nut counter-clockwise
to relieve tension on springs. Remove spring compressor.
(f) Remove and replace retainers, springs, and
seals as necessary.
(g) Do not rotate the engine until the
springs and retainers are re-installed.
(h) Install seals, springs and retainers. Install
spring compressor, compress valve springs and
install the collets.
(i) Release the spring tension and remove the
compressor. Verify that the collets are seated by
tapping on the valve stem with a plastic hammer.
(12) Using the crankshaft barring tool, rotate the
engine until the next crankshaft damper paint mark
aligns with the mark you placed on the cover. In this
position, cylinders #2 and #5 can be serviced.
(13) Repeat the valve spring compressing procedure previously performed and service the retainers,
springs, and seals as necessary.
(14) Using the crankshaft barring tool, rotate the
engine until the next crankshaft damper paint mark
aligns with the mark you placed on the cover. In this
position, cylinders #3 and #4 can be serviced.
(15) Repeat the spring compressing procedure previously performed and service the retainers, springs,
and seals as necessary.
Fig. 33 Rotating Engine with Barring Tool - Typical
1 - REAR FLANGE
2 - BARRING TOOL
(11) Compress the valve springs at cyls. #1 and #6
as follows:
(a) Remove bolts and injector hold-down clamp.
(b) Using miller special tool #9010, remove injector.
(c) Install the valve spring compressor mounting
base as shown in (Fig. 34).
(d) Install the top plate, washer, and nut. Using
a suitable wrench tighten the nut (clock-wise) (Fig.
Fig. 34 Spring Compressor Mounting Base—Part of
Tool 8319–A
1 - COMPRESSOR MOUNTING BASE
INSTALLATION
(1) Install rocker housing.
(2) Install fuel injectors and high pressure fuel
lines.
(3) Lubricate the valve tips and install the crossheads in their original locations.
9 - 310
ENGINE 5.9L DIESEL
DR
INTAKE/EXHAUST VALVES & SEATS (Continued)
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.
Fig. 35 Compressing Valve Springs with Tool
8319–A
1 - SPECIAL TOOL 8319
(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/CYLINDER 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 passages 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-
Fig. 36 Rocker Arm and Pedestal Removal
1 - ROCKER ARM
2 - PEDESTAL
CLEANING
Clean all components in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn
deposits. Rinse in hot water and blow dry with compressed air. Inspect oil passages in rocker arms and
pedestals. Apply compressed air to lubrication orifices
to purge contaminants.
ENGINE 5.9L DIESEL
DR
9 - 311
ROCKER ARM / ADJUSTER ASSY (Continued)
Fig. 37 Rocker Arm Assembly Identification
1
2
3
4
5
- NUT
- ADJUSTING SCREW
- ROCKER SHAFT
- RETAINER
- SOCKET
Fig. 39 Measuring Rocker Arm Bore
ROCKER ARM BORE (MAX.)
22.027 mm (.867 in.)
Fig. 40 Measuring Rocker Arm Shaft
ROCKER ARM SHAFT (MIN.)
21.965 mm (.865 in.)
Fig. 38 Push Rod Removal/Installation
INSPECTION
Rocker Arms
(1) Remove rocker shaft and inspect for cracks and
excessive wear in the bore or shaft. Remove socket
and inspect ball insert and socket for signs of wear.
Replace retainer if necessary.
Measure the rocker arm bore and shaft (Fig. 39)
(Fig. 40).
Push Rods
Inspect the push rod ball and socket for signs of
scoring. Check for cracks where the ball and the
socket are pressed into the tube (Fig. 41).
Roll the push rod on a flat work surface with the
socket end hanging off the edge (Fig. 42). Replace
any push rod that appears to be bent.
Fig. 41 Inspecting Push Rod for Cracks
9 - 312
ENGINE 5.9L DIESEL
DR
ROCKER ARM / ADJUSTER ASSY (Continued)
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 additional 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).
Fig. 42 Inspecting Push Rod for Flatness
Crossheads
Inspect the crossheads for cracks and/or excessive
wear on rocker lever and valve tip mating surfaces
(Fig. 43).
Fig. 44 Refacing Dimensions of the Cylinder Block
CYLINDER BLOCK REFACING DIMENSIONS
DIMENSION (A(
Fig. 43 Inspecting Crosshead for Cracks
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 crossheads 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/CYLINDER HEAD COVER(S) - INSTALLATION).
(6) Connect battery negative cables.
1st Reface
2nd Reface
Dim (A) Total
0.25mm
0.25mm
0.50 mm
(0.0098 in.)
(0.0098 in.)
(0.0197 in.)
DIMENSION (B(
Dim. 9B9 (STD.)
1st Reface
2nd Reface
323.00 mm ± 0.10
mm
322.75 mm ± 0.10
mm
322.50 mm ± 0.10
mm
(12.7165 in. ±
0.0039 in.)
(12.7067 in. ±
0.0039 in.)
(12.6968 in. ±
0.0039 in.)
(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).
ENGINE 5.9L DIESEL
DR
9 - 313
ENGINE BLOCK (Continued)
Fig. 45 Stamp Block after Reface
(3) Consult the parts catalog for the proper head
gaskets which must be used with refaced blocks to
ensure proper piston-to-valve clearance.
STANDARD PROCEDURE - CYLINDER BORE DE-GLAZE
(1) New piston rings may not seat in glazed cylinder bores.
(2) De-glazing gives the bore the correct surface
finish required to seat the rings. The size of the bore
is not changed by proper de-glazing.
(3) Cover the lube and tappet holes in the top of
the block with waterproof tape.
(4) It crankshaft is installed, wrap connecting rod
journals with clean cloth. Cover cloth with waterproof tape.
(5) A correctly honed surface will have a crosshatch appearance with the lines at 15° to 25° angles
(Fig. 46). For the rough hone, use 80 grit honing
stones. To finish hone, use 280 grit honing stones.
Fig. 47 De-Glazing Drill Speed and Vertical Speed
(9) Inspect the bore after 10 strokes.
(10) Use a strong solution of hot water and laundry detergent to clean the bores. Clean the cylinder
bores immediately after de-glazing.
(11) Rinse the bores until the detergent is removed
and blow the block dry with compressed air.
(12) Check the bore cleanliness by wiping with a
white, lint free, lightly oiled cloth. If grit residue is
still present, repeat the cleaning process until all residue is removed. Wash the bores and the complete
block assembly with solvent and dry with compressed
air. Place a clean shop towel around the top main
bearing saddle to deflect water and residue from piston cooling nozzels. Remove directed piston cooling
nozzles if installed.
(13) Be sure to remove the tape covering the lube
holes, rod journals, and piston cooling nozzles after
the cleaning process is complete.
STANDARD PROCEDURE—CYLINDER BORE
REPAIR
Cylinder bore(s) can be repaired by one of two
methods:
• Method 1:—Over boring and using oversize pistons and rings.
• Method 2:—Boring and installing a repair sleeve
to return the bore to standard dimensions.
METHOD 1—OVERSIZE BORE
Fig. 46 Cylinder Bore Crosshatch Pattern
(6) Use a drill, a fine grit Flex-hone and a mixture
of equal parts of mineral spirits and SAE 30W engine
oil to de-glaze the bores.
(7) The crosshatch angle is a function of drill
speed and how fast the hone is moved vertically (Fig.
47).
(8) Vertical strokes MUST be smooth continuous
passes along the full length of the bore (Fig. 47).
Cylinder bore(s) can be repaired by one of two
methods:
Oversize pistons and rings are available in two
sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393
inch).
Any combination of standard, 0.50 mm (0.0197
inch) or 1.00 mm (0.0393 inch) overbore may be used
in the same engine.
9 - 314
ENGINE 5.9L DIESEL
DR
ENGINE BLOCK (Continued)
If more than 1.00 mm (0.0393 inch) overbore is
needed, a repair sleeve can be installed (refer to
Method 2—Repair Sleeve).
Cylinder block bores may be bored twice before use
of a repair sleeve is required. The first bore is 0.50
mm (0.0197 inch) oversize. The second bore is 1.00
mm (0.0393 inch) oversize.
After boring to size, use a honing stone to chamfer
the edge of the bore.
CYLINDER BORE DIMENSION CHART
DESCRIPTION
MEASUREMENT
BORING DIAMETER
DIMENSION
1st. REBORE - 102.469
mm (4.0342 in.)
If the block is not to be used right away, coat it
with a rust- preventing compound.
METHOD 2—REPAIR SLEEVE
If more than a 1.00 mm (0.03937 inch) diameter
oversize bore is required, the block must be bored
and a repair sleeve installed.
Bore the block cylinder bore to 104.500-104.515
mm (4.1142-4.1148 inch) - (Fig. 49).
Repair sleeves can be replaced by using a boring
bar to bore out the old sleeve. DO NOT cut the cylinder bore beyond the oversize limit.
2nd. REBORE - 102.969
mm (4.0539 in.)
HONING DIAMETER
DIMENSIONS
STANDARD - 102.020 ±
0.020 mm (4.0165 ±
0.0008 in.)
1st. REBORE - 102.520
± 0.020 mm (4.0362 ±
0.0008 in.)
2nd. REBORE - 103.020
± 0.020 mm 4.0559 ±
0.0008 in.)
CHAMFER
DIMENSIONS
Approx. 1.25 mm (0.049
in.) by 15°
A correctly honed surface will have a crosshatch
appearance with the lines at 15° to 25° angles with
the top of the cylinder block (Fig. 48). For the rough
hone, use 80 grit honing stones. To finish hone, use
280 grit honing stones.
Fig. 48 Crosshatch Pattern of Repaired Sleeve(s)
A maximum of 1.2 micrometer (48 microinch) surface finish must be obtained.
After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry
detergent and hot water.
After rinsing, blow the block dry.
Check the bore cleanliness by wiping with a white,
lint-free, lightly- oiled cloth. There should be no grit
residue present.
Fig. 49 Block Bore for Repair Sleeve Dimensions
1 - BORE DIAMETER
2 - STEP DIMENSION
REPAIR SLEEVE BLOCK REBORE
DIMENSIONS CHART
BORE DIAMETER
STEP DIMENSION
104.500 + 0.015 mm
(4.1142 + 0.0006 in.)
6.35 mm (0.25 in.)
After machining the block for the new repair
sleeve, thoroughly clean the bore of all metal chips,
debris and oil residue before installing the sleeve.
Cool the repair sleeve(s) to a temperature of -12°C
(10°F) or below for a minimum of one hour. Be ready
to install the sleeve immediately after removing it
from the freezer.
Apply a coat of Loctite 620, or equivalent to the
bore that is to be sleeved.
Wear protective gloves to push the cold sleeve into
the bore as far as possible.
ENGINE 5.9L DIESEL
DR
9 - 315
ENGINE BLOCK (Continued)
Using a sleeve driver, drive the sleeve downward
until it contacts the step at the bottom of the bore
(Fig. 50).
Set up a boring bar and machine the sleeve to
101.956 mm (4.014 inch).
After removing the boring bar, use a honing stone
to chamfer the corner of the repair sleeve(s).
SLEEVE MACHINING DIMENSIONS CHART
ITEM
MEASUREMENT
SLEEVE PROTRUSION
MIN. - FLUSH WITH
BLOCK
MAX. - 0.050 mm
(0.0019 in.)
Fig. 50 Sleeve Installation
1 - SLEEVE DRIVER
2 - SLEEVE
3 - CONTACT
A sleeve driver can be constructed as follows (Fig.
51).
Fig. 51 Sleeve Driver Construction
1 - DRIVE
2 - HANDLE
SLEEVE DRIVER CONSTRUCTION
SPECIFICATION CHART
ITEM
MEASUREMENT
A
127 mm (5 in.)
B
38 mm (1.5 in.)
C
6.35 mm (0.25 in.)
D
25.4 mm (1 in.)
E
101 mm (3.976 in.)
F
107.343 mm (4.226 in.)
SLEEVE DIAMETER
101.956 mm (4.014 in.)
SLEEVE CHAMFER
APPROX. 1.25 mm
(0.049 in.) by 15°
A correctly honed surface will have a crosshatch
appearance with the lines at 15° to 25° angles with
the top of the cylinder block. For the rough hone, use
80 grit honing stones. To finish hone, use 280 grit
honing stones.
Finished bore inside dimension is 102.020 ±0.020
mm (4.0165 ±0.0008 inch).
A maximum of 1.2 micrometer (48 microinch) surface finish must be obtained.
After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry
detergent and hot water.
After rinsing, blow the block dry with compressed
air.
Wipe the bore with a white, lint-free, lightly oiled
cloth. Make sure there is no grit residue present.
Apply a rust-preventing compound if the block will
not be used immediately.
A standard diameter piston and a piston ring set
must be used with a sleeved cylinder bore.
STANDARD PROCEDURE—CAM BORE REPAIR
For standard bushings, not oversized, maximum
front and rear cam bushing bore diameter is 59.248
mm. (2.3326 in.). DO NOT bore the intermediate cam
bore to the front cam bore oversize dimensions. Maximum front and rear camshaft bushing installed
diameter is 54.147 mm. (2.1318 in.). Minimum
installed diameter is 54.083 mm. (2.1293 in.). Maximum intermediate camshaft bore diameter is 54.164
mm. (2.1324 in.).
A surface finish of 2.3 micrometers (92 microinch)
must be maintained. Not more than 20% of an area
of any one bore may be 3.2 micrometers (126 microinch).
Camshaft bores can be repaired individually. It is
not necessary to repair undamaged cam bores in
order to repair individually damaged cam bores. The
9 - 316
ENGINE 5.9L DIESEL
DR
ENGINE BLOCK (Continued)
standard front bushing cannot be used to repair
intermediate bores.
Install all cam bushings flush or below the front
and rear cam bore surface. The front camshaft bushing should be installed flush with front face of block.
The rear camshaft bushing should be installed flush
with rear face of block. The oil hole must align to
allow a 3.2 mm (0.125 inch) rod to pass through
freely (Fig. 52).
Inspect the cylinder bores for damage or excessive
wear.
Measure the cylinder bores (Fig. 54). If the cylinder bores exceed the limit, (Refer to 9 - ENGINE/ENGINE BLOCK - STANDARD PROCEDURE).
Fig. 54 Cylinder Bore Diameter
Fig. 52 Oil Hole Alignment
BORE SPECIFICATIONS
1 - CAMSHAFT BUSHING
INSPECTION
Measure the combustion deck face using a straight
edge and a feeler gauge (Fig. 53). Cylinder block flatness: End-to-end 0.076 mm ( .003 in.). Maximum
variation side-to-side 0.051 mm (.002 in.).
Inspect for any localized dips or imperfections.
If the surface exceeds the limit, (Refer to 9 ENGINE/ENGINE BLOCK - STANDARD PROCEDURE).
Fig. 53 Combustion Deck Face Measurement
1 - STRAIGHT EDGE
2 - FEELER GAUGE
BORE DIAMETER
Min.
102.000 mm (4.0157 in.)
Max.
102.116 mm (4.0203 in.)
OUT OF ROUNDNESS
Max.
0.038 mm (0.0015 in.)
Max.
0.076 mm (.003 in.)
TAPER
Inspect the camshaft bores for scoring or excessive
wear.
Measure the camshaft bores (Refer to 9 - ENGINE
- SPECIFICATIONS).
If a bore exceeds the limit, (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - STANDARD PROCEDURE).
Inspect the tappet bores for scoring or excessive
wear.
Measure tappet bore from bottom of block. Minimum tappet bore diameter 16.000 mm (0.0630 in.).
Maximum tappet bore 16.055 mm. (0.632 in.).
If out of limits, replace the cylinder block.
DR
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVAL
REMOVAL—CAMSHAFT 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 bushing. Inspect the rest of the camshaft bores for damage or excessive wear.If the bores without a
bushing are worn beyond the limit, the engine must
be removed for machining and installation of service 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/PLUMBING - STANDARD PROCEDURE).
(3) Raise vehicle on hoist.
(4) Drain engine coolant into container suitable for
re-use (Refer to 7 - COOLING - STANDARD PROCEDURE).
(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: Disconnect transmission oil cooler lines from front of radiator 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.
ENGINE 5.9L DIESEL
9 - 317
(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 indicator ring (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION 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 Barring 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.
Fig. 55 Push Rod Removal/Installation
(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.
9 - 318
ENGINE 5.9L DIESEL
DR
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
(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 tappets from dropping into the crankcase.
(c) Repeat this procedure for the remaining cylinders.
(26) Verify that the camshaft timing marks are
aligned with the crankshaft mark (Fig. 56).
(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 limits.
(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)
Fig. 56 Timing Mark Alignment
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
Fig. 57 Use Wooden Dowel Rods to Secure Tappets
in Place - Typical
(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.
Min.
45.632 mm.
(1.797 in.)
Max.
46.312 mm.
(1.823 in.)
ENGINE 5.9L DIESEL
DR
9 - 319
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
Fig. 60 Inspecting Oil Hole Alignment
1 - CAMSHAFT BUSHING
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
Camshaft Bushing/Bores
Camshaft bores No. 2–6 do not use 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).
Fig. 61 Inspect Camshaft Gear Hub for Cracks Typical
Fig. 59 Measuring Camshaft Bushing and Bores
Fig. 62 Inspect Camshaft Gear for Cracks and
Fretting - Typical
9 - 320
ENGINE 5.9L DIESEL
DR
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:
(3) Install the camshaft and thrust plate. Align the
timing marks as shown (Fig. 64).
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 Loctitet 640 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.).
Fig. 63 Oil Hole Alignment
1 - CAMSHAFT BUSHING
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 equivalent.
CAUTION: When installing the camshaft, DO NOT
push it in farther than it will go with the thrust
washer in place.
Fig. 64 Timing Mark Alignment
(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 — 0.075—0.250 mm
(0.003—0.013 inch)
CLEARANCE — 0.025—0.500 mm
(0.001—0.020 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 pedestals 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 - INSTALLATION). Install front crankshaft dust seal.
(13) Install the crankshaft damper with the speed
indicator ring (Refer to 9 - ENGINE/ENGINE
BLOCK/VIBRATION DAMPER - INSTALLATION).
ENGINE 5.9L DIESEL
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9 - 321
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 condenser 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 mounting 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 radiator 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 CONDITIONING/PLUMBING - STANDARD PROCEDURE).
(32) Connect the battery negative cables.
(33) Start engine and check for engine oil and coolant leaks.
Record the smallest and largest diameter.
Measure the diameter of the rod journal at the
location shown (Fig. 65). Calculate the average diameter 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 calculating the difference between the largest connecting rod
bore diameter and the average diameter with the bearing installed for each side of the crankshaft journal.
CONNECTING ROD BEARINGS
Fig. 65 Connecting Rod Journal Diameter Limits
STANDARD PROCEDURE - CONNECTING ROD
BEARING AND CRANKSHAFT JOURNAL
CLEARANCE
(1) Measure the connecting rod bore with bearings
removed and the bolts tightened to 100 N·m (73 ft.
lbs.) torque..
(2) Measure the connecting rod bore with the bearings installed and the bolts tightened to 100 N·m
(73 ft. lbs.) torque.
Measure within 20° arc from each side of the parting line. Also measure 90° from parting line.
DESCRIPTION
MEASUREMENT
CONNECTING ROD
BORE, BEARINGS
REMOVED
MIN. 72.99 mm (2.874
in.)
MAX. 73.01 mm (2.875
in.)
CONNECTING ROD
BORE, BEARINGS
INSTALLED
MIN. 69.05 mm (2.719
in.)
MAX. 69.10 mm (2.720
in.)
CONNECTING ROD JOURNAL DIAMETER
LIMITS CHART
DESCRIPTION
CRANKSHAFT ROD JOURNAL
DIAMETER
BEARING CLEARANCE
MEASUREMENT
Min. 68.96 mm (2.715 in.)
Max. 69.01 mm (2.717 in.)
Min. 0.04 mm (.002 in.)
Max. 0.12 mm (0.005 in.)
If the crankshaft is within limits, replace the bearing. If the crankshaft is out of limits, grind the
crankshaft to the next smaller size and use oversize
rod bearings.
9 - 322
ENGINE 5.9L DIESEL
CRANKSHAFT AND GEAR
DR
truding 1.0 mm (0.039 inch) to 1.5 mm (0.059 inch)
above the crankshaft (Fig. 67).
DESCRIPTION
The crankshaft (Fig. 66) is a forged steel, integrally
balanced unit. It is supported by seven main bearings, 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 connecting rods with engine oil.
Fig. 67 Installing Alignment Pin
1 - ALIGNMENT PIN
WARNING: WEAR PROTECTIVE GLOVES TO PREVENT INJURY.
CAUTION: DO NOT heat the gear longer than 45
minutes.
(3) Heat the crankshaft gear for 45 minutes at a
temperature of 149°C (300°F). 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.
Fig. 66 Crankshaft
REMOVAL—GEAR
(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 crankshaft.
INSTALLATION - GEAR
(1) Remove all burrs and make sure the gear surface 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-
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 measure main bearing bore diameter with the main bolts
tightened to 176 N·m (130 ft. lbs.) torque (Fig. 68).
ENGINE 5.9L DIESEL
DR
9 - 323
CRANKSHAFT MAIN BEARINGS (Continued)
(3) Measure the diameter of the main journal at
the locations shown (Fig. 69). Calculate the average
diameter for each side of the journal.
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
roundness
0.050 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.)
Fig. 68 Crankshaft Main Bearing Bore Diameter
1 - MAIN BEARING CAPS
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.)
Fig. 69 Crankshaft Main Journal Diameter
(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 specifications, grind the crankshaft to next size and use oversize 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 - STANDARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle from radiator 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.
9 - 324
ENGINE 5.9L DIESEL
DR
CRANKSHAFT OIL SEAL - FRONT (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).
(5) Install the plastic seal pilot (provided with seal
kit) into the crankshaft seal.
Fig. 71 Installing Seal Into Cover With Tool 8281
1 - SEAL INSTALLER 8281
2 - DRIVER HANDLE C4171
3 - SEAL
Fig. 70 Removing Seal from Cover
1 - PUNCH
INSTALLATION
(1) Clean cover and housing gasket mating surfaces. 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 ballpeen hammer on a flat surface. Inspect the crankshaft front journal for any grooves or nicks that
would affect the integrity of the new seal.
(3) Apply a bead of Mopart Stud & 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 crankshaft seal installer Special Tool 8281 and driver handle 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.
Fig. 72 Installing Front Cover with Seal Pilot
1 - SEAL PILOT
(6) Apply a bead of Mopart Silicone Rubber Adhesive 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 indicator ring. Torque the bolts to 40 N·m (30 ft. lbs.).
Then rotate an additional 60°. Use the engine bar-
ENGINE 5.9L DIESEL
DR
9 - 325
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/ENGINE/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 180° 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 surfaces 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 compressed 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
1/8” deeper into the retainer bore, or obtain a crankshaft wear sleeve that is available in the aftermarket.
(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 alignment tool bottoms out on the retainer (Fig. 74).
Fig. 74 Seal Installation Using Alignment Tool and
Hammer
1
2
3
4
Fig. 73 Crankshaft Rear Seal Removal
1
2
3
4
-
NO. 10 SCREW
REAR SEAL
CRANKSHAFT
SLIDE HAMMER
-
SEAL PILOT TOOL
INSTALLATION TOOL
SEAL
RETAINER
(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 - INSTALLATION).
(9) Install the transmission and transfer case (if
equipped).
(10) Lower vehicle.
9 - 326
ENGINE 5.9L DIESEL
DR
CRANKSHAFT OIL SEAL - REAR (Continued)
(11) Connect battery negative cables.
(12) Check engine oil level and adjust, if necessary.
(13) Start engine and check for oil leaks.
CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove the oil pan drain plug and drain the
engine oil. Re-install plug and torque to 50 N·m (44
ft. lbs.) torque.
(4) Remove transmission and transfer case (if
equipped) from vehicle.
(5) Remove flywheel or torque converter drive
plate.
(6) Disconnect starter cables from starter motor.
(7) Remove starter motor (Refer to 8 - ELECTRICAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
(8) Remove four (4) oil pan rear bolts. Slide a
feeler guage between the seal retainer and oil pan
gasket to break the seal.
(9) Remove the six (6) retainer-to-block bolts (Fig.
75).
(10) Remove the rear seal retainer and gasket
(Fig. 75).
(11) Support the seal retainer and drive out the
crankshaft seal with a hammer and suitable punch.
(2) Inspect oil pan gasket for nickes or cuts. If gasket is damaged, the oil pan must be removed and
gasket must be replaced. Wipe oil pan gasket dry and
apply light coating of RTV.
(3) Using the retainer alignment/seal installation
tool provided in the seal service kit, install the alignment tool into the retainer and install to the cylinder
block (Fig. 76), using a new gasket. Tighten the six
(6) mounting bolts by hand.
Fig. 76 Aligning Seal Retainer with Alignment/
Installation Tool
1 - ALIGNMENT / INSTALLATION TOOL
2 - SEAL RETAINER
(4) The seal alignment tool is used to align rear
cover properly. Starting with the center two bolts,
tighten the retainer in a circular pattern to 10 N·m
(89 in. lbs.). Remove the alignment tool.
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 surfaces must be completely dry when the seal is
installed. Use a soap and water solution on outside
diameter of seal to ease assembly.
Fig. 75 Crankshaft Rear Seal Retainer and Gasket
1 - RETAINER
2 - GASKET
3 - BOLT
INSTALLATION
(1) If using the old seal retainer, the crankshaft
seal must be replaced.
(5) Make sure the provided seal pilot is installed
into the new crankshaft seal. Use the alignment/installation tool and press the seal onto the crankshaft
(Fig. 77). Alternately drive the seal at the 12, 3, 6
and 9 o’clock positions.
(6) Remove the alignment tool and trim the
retainer gasket even with the oil pan mounting surface (Fig. 78).
(7) Remove the seal pilot.
(8) Apply a small amount of Mopart Silicone Rubber Adhesive Sealant to the oil pan rail T-joints.
(9) Install the four (4) oil pan rear mounting bolts
and torque to 28 N·m (21 ft. lbs.).
(10) Install new rectangular ring seal for cam bore.
ENGINE 5.9L DIESEL
DR
9 - 327
CRANKSHAFT REAR OIL SEAL RETAINER (Continued)
SOLID LIFTERS/TAPPETS
REMOVAL
NOTE: This procedure requires use of Miller Tool
8502 Tappet Replacement Kit.
Fig. 77 Installing Seal Using Alignment Tool and
Hammer
1
2
3
4
-
(1) Remove camshaft (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(2) Insert the trough (provided with tool kit) the
full length of the camshaft bore (Fig. 79). Make sure
the cap end goes in first and the open side faces up
(towards tappets).
(3) Remove only one tappet at a time. Remove
rubber band from one cylinder pair and attach tappet
dowel not being removed to the next cylinder pair
(Fig. 80).
SEAL PILOT TOOL
INSTALLATION TOOL
SEAL
RETAINER
Fig. 79 Inserting the Trough - Typical
Fig. 78 Trimming Excess Gasket Material
1 - TROUGH
1 - GASKET
(11) Install the flywheel housing and bolts. Torque
bolts to 77 N·m (57 ft. lbs.).
(12) Install the flywheel or converter drive plate.
Tighten bolts to 137 N·m (101 ft. lbs.).
(13) Install the starter motor and torque to 43 N·m
(21 ft. lbs.)(Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(14) Install the transmission and transfer case (if
equipped).
(15) Lower vehicle.
(16) Fill the crankcase with new engine oil.
(17) Connect the battery negative cables.
(18) Start engine and check for oil leaks.
Fig. 80 Secure Dowel/Tappet to Adjacent Cylinder typical
9 - 328
ENGINE 5.9L DIESEL
DR
SOLID LIFTERS/TAPPETS (Continued)
(4) Raise dowel rod (disengage from tappet) and
allow tappet to fall into trough (Fig. 81).
(5) Carefully remove trough (do not rotate) and
tappet. If the tappet is not being replaced, mark it so
it can be installed in its original location.
(6) Re-install trough and repeat procedure on
remaining tappets.
INSTALLATION
(1) Insert the trough the full length of the camshaft bore. Again, make sure the cap end goes in first
and the open side faces up (towards tappets).
(2) Lower the tappet installation tool through the
push rod hole (Fig. 83) and into the trough.
(3) Retrieve the tappet installation tool using the
hooked rod provided with the tool kit (Fig. 84).
Fig. 81 Lift Dowel Rod to Disengage from Tappet typical
CLEANING
Clean tappet with a suitable solvent. Rinse in hot
water and blow dry with a clean shop rag or compressed air.
Fig. 83 Insert Installation Tool through Push Rod
Hole - Typical
INSPECTION
(1) Visually inspect the tappet the tappet socket,
stem, and face for excessive wear, cracks, or obvious
damage (Fig. 82).
(2) Measure the tappet stem diameter. Replace the
tappet if it falls below the minimum size (Fig. 82).
Fig. 84 Retrieve Tappet Installation Tool through
Cam Bore - Typical
Fig. 82 Tappet Inspection
TAPPET STEM DIAMETER
15.936 mm (0.627 in.) MIN.
15.977 mm (0.629 in.) MAX.
ENGINE 5.9L DIESEL
DR
9 - 329
SOLID LIFTERS/TAPPETS (Continued)
(4) Lubricate the tappet with clean engine oil or
suitable equivalent and install the tappet to the
installation tool (Fig. 85).
(5) Pull the tappet up and into position (Fig. 85). If
difficulty is experienced getting the tappet to make
the turn into the tappet bore, wiggle the trough
while gently pulling up on the tappet.
(6) With the tappet in place, rotate the trough one
half turn so the open side is down (toward crankshaft) (Fig. 86).
(7) Remove the tappet installation tool from the
tappet.
(8) Re-install a dowel rod and secure the rod with
a rubber band.
(9) Rotate the trough one half turn and repeat the
procedure for the remaining tappets.
(10) Install the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - INSTALLATION).
PISTON & CONNECTING ROD
DESCRIPTION
PISTONS
The piston (Fig. 87) is constructed of aluminum
and is gravity cast, free floating design. The piston
incorporates a centrally located high swirl combustion bowl, and utilizes a “keystone” style top compression ring (Fig. 88), and a “Tapered Face”
intermediate ring (Fig. 88), for superior cylinder wall
scraping. Piston cooling nozzles cool the piston and
pin with engine oil supplied by the crankshaft main
journals. High horsepower pistons are gallery cooled
and utilize J-jet piston cooling nozzles.
Fig. 85 Insert Tool and Pull Tappet Into Place Typical
Fig. 87 Piston - Typical
Fig. 88 Piston Ring Identification
Fig. 86 Rotate Trough One Half Turn (180°) - Typical
9 - 330
ENGINE 5.9L DIESEL
DR
PISTON & CONNECTING ROD (Continued)
CONNECTING RODS
The connecting rods are a split angle design (Fig.
89). They have a pressed-in-place wrist pin bushing
that is lubricated by piston cooling nozzle oil spray.
There are two different types of connecting rods:
machined and fractured split. The main different
between the two styles is the surface finish on the
connecting rod split face.
Machined connecting rods can be identified by a
machined surface at the connecting rod and cap split
face. Machined connecting rods have numbers
stamped on the rod cap and connecting rod near the
parting line. The number stamped on the connecting
rod must match the number stamped on the rod cap
and be installed on the camshaft or intake side of the
engine.
Fractured split connecting rods are first manufactured as a single piece and then fractured into two
pieces. Fractured split connecting rods can be identified by a rough and irregular surface at the connecting rod split face. To properly assemble the rod cap to
the connecting rod, the bearing tangs on the connecting rod and cap must be located on the same side of
the rod. The long end of the connecting rod must be
assembled on the intake or camshaft side of the
engine.
Measuring methods and specifications are common
between fractured split and machined connecting
rods.
Both fractures split and machined connecting rods
and caps are machined as an assembly and are not
interchangeable. If a connecting rod or cap is damaged, the entire assembly must be replaced.
Machined and fractured split connecting rods cannot
be used in the same engine.
STANDARD PROCEDURE - HEAD GASKET
SELECTION
(1) Measure piston protrusion for all six pistons.
(2) Calculate the average piston protrusion. Maximum allowable protrusion is 0.516 mm (0.020 inch).
NOTE: There are two different head gaskets available. One gasket is for Average piston protrusion
less than 0.30 mm (0.011 inch). The other gasket is
for Average piston protrusion greater than 0.30 mm
(0.011 inch)
REMOVAL
(1) Disconnect the battery cables.
(2) Remove the cylinder head (Refer to 9 ENGINE/CYLINDER HEAD - REMOVAL).
(3) Remove the oil pan and suction tube (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(4) Remove bolts and the block stiffener.
Fig. 89 Connecting Rod
(5) Using Miller Tool 7471-B crankshaft barring
tool, rotate the crankshaft so all of the pistons are
below TDC.
(6) Before removing the piston(s) from the bore(s):
(a) Remove any carbon ridge formations or
deposits at the top of the bore with a dull scraper
or soft wire brush.
(b) If cylinder bore wear ridges are found, use a
ridge reamer to cut the ridge from the bore. DO
NOT remove more metal than necessary to remove
the ridge.
(7) Remove the J-jet cooling nozzels, if equipped.
NOTE: If cylinders have ridges, the cylinders are
oversize and will more than likely need boring.
(8) Using a hammer and steel stamp, stamp the
cylinder number in the top of each piston. The front
of the piston is identified by a stamping on the top of
the piston. DO NOT stamp in the outside 5 mm (.197
in.) of the piston diameter. DO NOT stamp over the
piston pin.
(9) Mark the connecting rod and cap with the corresponding cylinder numbers.
(10) Remove the connecting rod bolts and rod caps.
Use care so the cylinder bores and connecting rods
are not damaged.
ENGINE 5.9L DIESEL
DR
9 - 331
PISTON & CONNECTING ROD (Continued)
(11) Use a hammer handle or similar object to
push the piston and connecting rod through the cylinder bore.
(12) Store the piston/rod assemblies in a rack.
CLEANING—PISTON AND CONNECTING ROD
CAUTION: DO NOT use bead blast to clean the pistons. DO NOT clean the pistons and rods in an acid
tank.
PISTON
The upper groove only needs to be inspected for
damage. Use a new piston ring to measure the clearance in the intermediate ring groove (Fig. 91). Minimum clearance is 0.045 mm (0.0018 inch), maximum
clearance is 0.095 mm (.0037 inch). If the clearance
of the intermediate ring exceeds specifications,
replace the piston.
Use a new oil ring to measure the clearance in the
oil groove (Fig. 91). Minimum clearance is 0.040 mm
(0.0016 inch), maximum clearance is 0.085 mm
(.0033 inch). If the clearance exceeds specifications,
replace the piston.
Clean the pistons and pins in a suitable solvent,
rinse in hot water and blow dry with compressed air.
Soaking the pistons over night will loosen most of the
carbon build up. De-carbon the ring grooves with a
broken piston ring and again clean the pistons in solvent. Rinse in hot water and blow dry with compressed air.
CONNECTING ROD
Clean the connecting rods in a suitable solvent,
rinse in hot water and blow dry with compressed air.
INSPECTION
Fig. 91 Intermediate and Oil Ring Clearances
INSPECTION—PISTONS
Inspect the pistons for damage and excessive wear.
Check top of the piston, ring grooves, skirt and pin
bore. Measure the piston skirt diameter (Fig. 90). If
the piston is out of limits, replace the piston.
1 - FEELER GAUGE
2 - RING
3 - PISTON
Measure the pin bore (Fig. 92). The maximum
diameter is 40.012 mm (1.5753 inch), Minimum is
40.006 mm (1.575 inch). If the bore is over limits,
replace the piston.
Fig. 90 Piston Skirt Diameter
PISTON SKIRT DIAMETER (MIN.)
101.887 mm (4.011 in. )
Fig. 92 Piston Pin Bore
1 - PISTON
2 - PIN BORE
9 - 332
ENGINE 5.9L DIESEL
DR
PISTON & CONNECTING ROD (Continued)
Inspect the piston pin for nicks, gouges and excessive wear. Measure the pin diameter (Fig. 93). The
minimum diameter is 39.990 mm (1.5744 inch), maximum 40.003 mm (1.5749 inch). If the diameter is out
of limits, replace the pin.
(3) Compress the rings using a piston ring compressor tool (Fig. 95). If using a strap-type ring compressor, make sure the inside end of the strap does
not hook on a ring gap and break the ring.
Fig. 95 Piston Ring Compressor Tool
1 - PISTON RING COMPRESSOR TOOL
Fig. 93 Piston Pin Diameter
1 - PISTON PIN
(4) Bar the crankshaft so the rod journal for the
piston to be installed is at BDC (Bottom Dead Center) - (Fig. 96).
INSPECTION—CONNECTING ROD
Inspect the connecting rod for damage and wear.
The I-Beam section of the connecting rod cannot have
dents or other damage. Damage to this part can
cause stress risers which will progress to breakage.
Measure the connecting rod pin bore (Fig. 94). The
maximum diameter is 40.042 mm (1.5765 inch), minimum diameter is 40.019 mm (1.5756 inch). If out of
limits, replace the connecting rod.
Fig. 96 Piston/Rod Assembly at BDC
Fig. 94 Connecting Rod Pin Bore
1 - CONNECTING ROD
INSTALLATION
(1) Lubricate the cylinder bores with clean engine
oil.
(2) Generously lubricate the rings and piston
skirts with clean engine oil.
(5) Make sure the front of the piston is oriented
properly according to the marking on the top of the
piston and the numbers on the rod and cap are oriented as illustrated.
(6) Position the piston and rod assembly into the
cylinder bore with the front of the piston oriented
properly according to the stamping in the top of the
piston. In this position the numbers on the connecting rod should be facing the intake or camshaft side
of the engine, and the rod bolt hex heads toward the
oil cooler. Use care when you install the piston and
connecting rod so the cylinder bore is not damaged. If
a fractured split connecting rod is being installed, the
long side of the connecting rod must be installed on
the intake side of the engine.
(7) Push the piston into the bore until the top of
the piston is approximately 50 mm (2 inch) below the
top of the block. Carefully pull the connecting rod
onto the crankshaft journal.
ENGINE 5.9L DIESEL
DR
9 - 333
PISTON & CONNECTING ROD (Continued)
(8) Use clean engine oil to lubricate the threads
and under the heads of the connecting rod bolts.
(9) For machined connecting rods, the number
stamped on the rod cap at the parting line must
match and be installed towards the intake or camshaft side of the engine (Fig. 97). For fractured/
split type connecting rods, the long end of the rod
must be installed towards the intake side of the
engine.
(a) The connecting rod split/face must face
toward the same side as the piston notch feature
on the skirt. The split face will face toward the oil
cooler side of the engine if properly installed.
Fig. 98 Side Clearance between Connecting
Rod/Crankshaft
1 - FEELER GAUGE
·Minimum 0.33 mm (.013 inch)
·MAX. 0.10mm (.004 inch)
(16) Install the cylinder head onto the engine
(Refer to 9 - ENGINE/CYLINDER HEAD - INSTALLATION).
(17) Install a new filter and fill the crankcase with
new engine oil.
(18) Connect the battery negative cables and start
engine.
Fig. 97 Correct Rod Cap Installation
(10) Install the rod cap and bolts to the connecting
rod. Tighten the connecting rod bolts evenly in 3
steps.
• Tighten the bolts to 30 N·m (22 ft. lbs.) torque.
• Tighten the bolts to 60 N·m (44 ft. lbs.) torque.
• Rotate 60° clockwise.
(11) The crankshaft must rotate freely. Check for
freedom of rotation as the caps are installed. If the
crankshaft does not rotate freely, check the installation of the rod bearing and the bearing size.
(12) Measure the side clearance between the connecting rod and the crankshaft (Fig. 98). DO NOT
measure the clearance between the cap and crankshaft.
(13) Install J-jet piston cooling nozzles if equipped.
(14) Install block stiffener. Torque to 43 N·m (32 ft.
lbs.).
(15) Install the suction tube and oil pan (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - INSTALLATION).
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Determine the piston diameter and obtain the
appropriate ring set. The piston rings can be identified as shown in (Fig. 99).
Fig. 99 Piston Ring Identification
9 - 334
ENGINE 5.9L DIESEL
DR
PISTON RINGS (Continued)
(2) Position each ring in the cylinder and use a
piston to square it with the bore at a depth of 89.0
mm (3.5 inch) - (Fig. 100).
Fig. 101 Oil Control Ring/Expander Location in
Groove
Fig. 100 Position of Ring in Cylinder Bore
1 - OIL CONTROL RING
2 - EXPANDER
3 - PISTON
1 - PISTON
2 - CYLINDER BORE
3 - DEPTH
(3) Use a feeler gauge to measure the piston ring
gap.
PISTON RING GAP CHART
TOP RING
0.26 - 0.36 mm
(0.010 - 0.014
in.)
INTERMEDIATE
RING
0.85-1.15 mm
(0.033 - 0.045
in.)
OIL CONTROL
RING
0.25-0.55 mm
(0.010 - 0.022
in.)
Fig. 102 Piston Ring Installation Tool
1 - PISTON RING INSTALLATION TOOL
(4) The top surface of all of the rings are identified
with the word TOP or the supplier’s MARK. Assemble the rings with the word TOP or the supplier’s
MARK up.
(5) Position the oil ring expander in the oil control
ring groove (bottom groove).
(6) Install the oil control ring with the end gap
OPPOSITE the ends on the expander (Fig. 101).
(7) Install the intermediate piston ring in the second groove.
(8) Install the top piston ring in the top groove
(Fig. 102).
(9) Position the rings as shown in (Fig. 103).
Fig. 103 Piston Ring Orientation
1 - TOP RING
2 - INTERMEDIATE RING
3 - OIL CONTROL RING
ENGINE 5.9L DIESEL
DR
VIBRATION DAMPER
9 - 335
INSTALLATION
(1) Install speed indicator ring.
REMOVAL
(1) Remove the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).
(2) Remove the four (4) damper to crankshaft bolts
and remove damper and speed indicator ring.
INSPECTION
(1) Inspect the damper hub for cracks and replace
if any are found.
(2) Inspect the index lines on the damper hub and
the inertia member (Fig. 104). If the lines are more
than 1.59 mm (1/16 in.) out of alignment, replace the
damper.
(3) Inspect the rubber member for deterioration or
missing segments (Fig. 105).
NOTE: The speed indicator ring is located over a
dowel pin.
(2) Install the crankshaft damper and bolts.
Tighten bolts to 40 N·m (30 ft. lbs.) torque, plus an
additional 60°.
NOTE: The damper must be installed so the hole is
located over the dowel pin.
(3) Install the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).
FRONT MOUNT
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the viscous fan/drive assembly (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN REMOVAL).
(3) Raise vehicle on hoist.
(4) Install engine support fixture tool# 8534 and
steel bracket tool # 8534A
(5) Loosen the thru-bolt and nut.
(6) Lift the engine SLIGHTLY and remove the
insulator to block bolts (Fig. 107) (Fig. 106).
(7) Remove the insulator from the vehicle.
INSTALLATION
Fig. 104 Inspect Index Lines for Alignment
1 - INDEX LINES
2 - HUB
3 - INERTIA MEMBER
Fig. 105 Inspect Damper Rubber Member
(1) With engine raised SLIGHTLY, position the
insualtor to the mount (Fig. 108) (Fig. 109). Install
the bolts and torque to specification.
(2)
(3) Lower the engine using tool # 8534, while guiding the mount and thru-bolt into the frame mounted
support cushion brackets.
(4) Install the thru-bolt nut and tighten the nut to
88 N·m (65 ft. lbs.) torque.
(5) Remove the engine support fixture tool #8534.
(6) Lower the vehicle.
(7) Install the viscous fan/drive assembly (Refer to
7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
(8) Connect the battery negative cables.
9 - 336
ENGINE 5.9L DIESEL
DR
FRONT MOUNT (Continued)
Fig. 106 RH Insulator
1 - Mount
2 - Insulator
3 - Bolt
Fig. 108 LH Insulator
1 - Bolt
2 - Insulator
3 - Mount
Fig. 107 LH Insulator
1 - Bolt
2 - Insulator
3 - Mount
Fig. 109 RH Insulator
1 - Mount
2 - Insulator
3 - Bolt
ENGINE 5.9L DIESEL
DR
REAR MOUNT
LUBRICATION
REMOVAL
DESCRIPTION
(1) Raise the vehicle on a hoist.
(2) Position a transmission jack in place.
(3) Remove support cushion stud nuts (Fig. 110).
(4) Raise rear of transmission and engine
SLIGHTLY.
(5) Remove the bolts holding the support cushion
to the transmission support bracket. Remove the support cushion.
(6) If necessary, remove the bolts holding the
transmission support bracket to the transmission.
INSTALLATION
(1) If removed, position the transmission support
bracket to the transmission. Install new attaching
bolts and tighten to 102 N·m (75 ft. lbs.) torque.
(2) Position support cushion to transmission support bracket. Install stud nuts and tighten to 47 N·m
(35 ft. lbs.) torque.
(3) Using the transmission jack, lower the transmission and support cushion onto the crossmember
(Fig. 110).
(4) Install the support cushion bolts and tighten to
47 N·m (35 ft. lbs.) torque.
(5) Remove the transmission jack.
(6) Lower the vehicle.
9 - 337
NOTE: Refer to (Fig. 111) and (Fig. 112) for circuit
illustrations.
A gear driven gerotor type oil pump is mounted
behind the front gear cover in the lower right portion
on the engine.
OPERATION
A gerotor style oil pump draws oil from the crankcase through the suction tube and delivers it through
the block where it enters the oil cooler cover and
pressure regulator valve. When oil pressure exceeds
517 kPa (75 PSI), the valve opens exposing the dump
port, which routes excess oil back to the oil pump.
At the same time, oil is directed to a cast in passage in the oil cooler cover, leading to the oil cooler
element. As the oil travels through the element
plates, it is cooled by engine coolant traveling past
the outside of the plates. It is then routed to the oil
filter head and through a full flow oil filter. If a
plugged filter is encountered, the filter by-pass valve
opens, allowing unfiltered oil to lubricate the engine.
This condition can be avoided by frequent oil and filter changes, per the maintenance schedules found in
Fig. 110 Engine Rear Support Cushion Assembly
9 - 338
ENGINE 5.9L DIESEL
DR
LUBRICATION (Continued)
the owners manual. The by-pass valve is calibrated
to open when it sees a pressure drop of more than
345 kPa (50 psi) across the oil filter.
The oil filter head then divides the oil between the
engine and the turbocharger. The turbocharger
receives filtered, cooled and pressurized oil through a
supply line from the filter head. The oil lubricates
the turbocharger and returns to the pan by way of a
drain tube connecting the bottom of the turbocharger
to a pressed in tube in the cylinder block.
Oil is then carried across the block to an angle
drilling which intersects the main oil rifle. The main
oil rifle runs the length of the block and delivers oil
to the crankshaft main journals and valve train. Oil
travels to the crankshaft through a series of transfer
drillings (one for each main bearing) and lubricates a
groove in the main bearing upper shell. From there
another drilling feeds the camshaft main journals.
The saddle jet piston cooling nozzles are also supplied by the main bearing upper shell. J-jet piston
cooling nozzles are supplied by a separate oil rifle.
Plugs are used in place of saddle jets when J-jets are
used. J-jet hole locations are plugged when saddle jet
cooling nozzles are used. Crankshaft internal crossdrillings supply oil to the connecting rod journals.
Another series of transfer drillings intersecting the
main oil rifle supply the valve train components. Oil
travels up the drilling, through a hole in the head
gasket, and through a drilling in the cylinder head
(one per cylinder), where it enters the rocker arm
pedestal and is divided between the intake and
exhaust rocker arm. Oil travels up and around the
rocker arm mounting bolt, and lubricates the rocker
shaft by cross drillings that intersect the mounting
bolt hole. Grooves at both ends of the rocker shaft
supply oil through the rocker arm where the oil travels to the push rod and socket balls (Fig. 111) and
(Fig. 112).
DIAGNOSIS AND TESTING—ENGINE OIL
PRESSURE
(1) Remove the 1/8 npt plug from the top of the oil
filter housing.
(2) Install Oil Pressure Line and Gauge Tool
C-3292 with a suitable adapter.
(3) Start engine and warm to operating temperature.
(4) Record engine oil pressure and compare with
engine oil pressure chart.
CAUTION: If engine oil pressure is zero at idle, DO
NOT RUN THE ENGINE.
Engine Oil Pressure (MIN)
At Idle
68.9 kPa (10 psi)
At 2500 rpm
206.9 kPa (30 psi)
If minimum engine oil pressure is below these
ranges, (Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
(5) Remove oil pressure gauge and install the 1/8
npt plug.
ENGINE 5.9L DIESEL
DR
LUBRICATION (Continued)
Fig. 111 Lubrication System Circulation
1
2
3
4
5
6
-
TO FILTER
FROM FILTER
TO MAIN OIL RIFLE
CLOSED
OPEN
TO COOLER
7 - FROM PUMP
8 - CLOSED
9 - OPEN
10 - OIL DRAINS BACK TO THE PUMP
11 - OIL DRAIN
12 - OIL SUPPLY
9 - 339
9 - 340
ENGINE 5.9L DIESEL
LUBRICATION (Continued)
Fig. 112 Lubrication System Circulation—Cont’d
DR
ENGINE 5.9L DIESEL
DR
9 - 341
OIL (Continued)
1
2
3
4
5
6
7
-
ROCKER ARM
ROCKER SHAFT
PEDESTAL
FROM MAIN OIL RIFLE
TO VALVE TRAIN
MAIN OIL RIFLE
FROM MAIN OIL RIFLE
8 - TO CAMSHAFT
9 - TO PISTON COOLING NOZZLE
10 - FROM OIL COOLER
11 - CRANKSHAFT MAIN JOURNAL
12 - ROD JOURNAL
13 - TO ROD BEARING
14 - MAIN OIL RIFLE
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE
STANDARD PROCEDURE
WARNING:
INJURY.
STANDARD PROCEDURE - ENGINE OIL LEVEL
HOT
OIL CAN
CAUSE
PERSONAL
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
NOTE: Change engine oil and filter at intervals
specified in the owner’s manual.
To ensure proper lubrication of an engine, the
engine oil must be maintained at an acceptable level.
The acceptable oil level is in the SAFE RANGE on
the engine oil dipstick (Fig. 113).
Unless the engine has exhibited loss of oil pressure, run the engine for about five minutes before
checking oil level. Checking engine oil level of a cold
engine is not accurate.
(1) Operate the engine until the water temperature reaches 60°C (140°F). Shut the engine off.
(2) Use a container that can hold at least 14 liters
(15 quarts) to hold the used oil. Remove the oil drain
plug and drain the used engine oil into the container.
(3) Always check the condition of the used oil. This
can give you an indication of engine problems that
might exist.
• Thin, black oil indicates fuel dilution.
• Milky discoloration indicates coolant dilution.
(4) Clean the area around the oil filter head.
Remove the filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - REMOVAL).
(5) Install new oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - INSTALLATION).
(6) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and sealing surface on the oil pan and drain plug.
(7) Install the drain plug. Tighten the plug to 50
N·m (37 ft. lbs.) torque.
(8) Use only High-Quality Multi-Viscosity lubricating oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES DESCRIPTION).
(9) Fill the engine with the correct grade of new oil
(Refer to LUBRICATION & MAINTENANCE/FLUID
CAPACITIES - SPECIFICATIONS).
(10) Start the engine and operate it at idle for several minutes. Check for leaks at the filter and drain
plug.
(11) Stop engine. Wait several minutes to allow the
oil to drain back to the pan and check the level
again.
Fig. 113 Oil Level Indicator (Dipstick)
1 - ADD OIL MARK
2 - O-RING
3 - SAFE RANGE
(1) Position vehicle on level surface.
(2) With engine OFF, allow approximately ten minutes for oil to settle to bottom of crankcase, remove
engine oil dipstick.
(3) Wipe dipstick clean.
(4) Replace dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the SAFE RANGE
area on the dipstick.
(7) Replace dipstick
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing of used
engine oil after it has been drained from a vehicle’s
engine.
9 - 342
ENGINE 5.9L DIESEL
DR
OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION
Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. If the element leaks, replace the
element.
(10) Install the oil pan drain plug if sealing surface is not damaged and tighten to 50 N·m (57 ft.
lbs.) torque.
(11) Remove oil pan bolts, break the pan to block
seal, and lower pan slightly and remove oil suction
tube fasteners.
(12) Remove oil pan and suction tube.
CLEANING
OIL FILTER
Remove all gasket material from the oil pan and
cylinder block sealing surfaces. Extra effort may be
required around T-joint areas. Clean oil pan and
flush suction tube with a suitable solvent.
REMOVAL
INSPECTION
(1) Clean the area around the oil filter head.
Remove the filter from below using a cap-style filter
wrench.
(2) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter
head. Make sure it is removed.
Inspect the oil pan, suction tube, and tube braces
for cracks and damage. Replace any defective component. Inspect the oil drain plug and drain hole
threads. Inspect the oil pan sealing surface for
straightness. Repair any minor imperfections with a
ball-peen hammer. Do not attempt to repair an oil
pan by welding.
INSTALLATION
(1) Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine.
(2) Apply a light film of lubricating oil to the sealing surface before installing the filter.
CAUTION: Mechanical over-tightening may distort
the threads or damage the filter element seal.
(3) Install the filter until it contacts the sealing
surface of the oil filter adapter. Tighten filter an
additional 1⁄2 turn.
OIL PAN
REMOVAL
(1) Disconnect the battery negative cables.
(2) Install engine support fixture # 8534.
(3) Raise vehicle on hoist.
(4) Disconnect starter cables from starter motor.
(5) Remove starter motor (Refer to 8 - ELECTRICAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
(6) Remove transmission and transfer case (if
equipped).
(7) Remove flywheel or flexplate.
(8) Remove the transmission adapter plate.
WARNING:
INJURY.
HOT
OIL CAN
CAUSE
PERSONAL
(9) Drain the engine oil (Refer to 9 - ENGINE/LUBRICATION/OIL - STANDARD PROCEDURE).
INSTALLATION
(1) Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use
Mopart Silicone Rubber Adhesive Sealant or equivalent.
(2) Place suction tube in oil pan and guide them
into place. Using a new tube to block gasket, install
and tighten the suction tube bolts by hand. Starting
with the oil pump inlet bolts, tighten the bolts to 24
N·m (18 ft. lbs.) torque. Tighten the remaining tube
brace bolts to 43 N·m (32 ft. lbs.) torque.
(3) Starting in the center and working outward,
tighten the oil pan bolts to 28 N·m (21 ft. lbs.)
torque.
(4) Install the flywheel housing assembly with the
starter motor attached and tighten bolts to 77 N·m
(57 ft. lbs.) torque.
(5) Connect starter motor cables.
(6) Install the flywheel or flexplate. Torque to 137
N·m (101 ft. lbs.).
(7) Install transmission and transfer case (if
equipped).
(8) Lower vehicle.
(9) Remove the engine support fixture # 8534.
(10) Install battery negative cables.
(11) Fill the crankcase with new engine oil.
(12) Start engine and check for leaks. Stop engine,
check oil level, and adjust, if necessary.
ENGINE 5.9L DIESEL
DR
9 - 343
OIL PRESSURE RELIEF VALVE
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the threaded plug, spring and plunger
(Fig. 114). Insert a finger or a seal pick to lift the
plunger from the bore.
NOTE: If the plunger is stuck in the bore, it will be
necessary to remove the filter head.
Fig. 115 Oil Pressure Regulator Spring Check
OIL PRESSURE SENSOR/
SWITCH
REMOVAL
(1) Disconnect the battery negative cables.
(2) Disconnect the oil pressure switch connector.
(3) Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise).
Fig. 114 Oil Pressure Regulator
1
2
3
4
5
-
OIL FILTER
PLUG
GASKET
SPRING
VALVE
CLEANING
(1) Clean the regulator spring and plunger with a
suitable solvent and blow dry with compressed air. If
the plunger bore requires cleaning, it is necessary to
remove the oil filter head to avoid getting debris into
the engine.
INSPECTION
Inspect the plunger and plunger bore for cracks
and excessive wear. Polished surfaces are acceptable.
Verify that the plunger moves freely in the bore.
Check the spring for height and load limitations
(Fig. 115). Replace the spring if out of limits shown
in the figure.
INSTALLATION
(1) Install the plunger, spring, and plug as shown
in (Fig. 114). Tighten the plug to 80 N·m (60 ft. lbs.)
torque.
(2) Connect the battery negative cables.
(3) Start the engine and verify that it has oil pressure.
INSTALLATION
(1) If the switch is not being replaced, replace and
lubricate the o-ring.
(2) Install the oil pressure switch and tighten to
18 N·m (159 in. lbs.) torque.
(3) Connect oil pressure switch connector.
(4) Connect the battery negative cables.
(5) Start engine and check for oil leaks at the
switch.
OIL PUMP
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove fan/drive assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(3) Remove the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).
(4) Remove the fan support/hub assembly.
(5) Remove crankshaft damper (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL) and speed indicator ring.
(6) Remove hydraulic pump.
(7) Remove accessory drive belt tensioner.
(8) Remove the gear housing cover (Refer to 9 ENGINE/VALVE TIMING/GEAR HOUSING COVER
- REMOVAL).
9 - 344
ENGINE 5.9L DIESEL
DR
OIL PUMP (Continued)
(9) Remove the four mounting bolts and pull the
oil pump from the bore in the cylinder block (Fig.
116).
Fig. 117 Gerotor Planetary and Gerotor
1 - OIL PUMP BACK PLATE
2 - GEROTOR
3 - GEROTOR PLANETARY
Fig. 116 Oil Pump Removal/Installation
1 - OIL PUMP
2 - BOLT (4)
CLEANING
Clean all parts in solvent and dry with compressed
air. Clean the old sealer residue from the back of the
gear housing cover and front of the gear housing.
INSPECTION
Disassemble and inspect the oil pump as follows:
(1) Visually inspect the lube pump gears for chips,
cracks or excessive wear.
(2) Remove the back plate (Fig. 117).
(3) Mark TOP on the gerotor planetary using a felt
tip pen (Fig. 117).
(4) Remove the gerotor planetary (Fig. 117).
Inspect for excessive wear or damage. Inspect the
pump housing and gerotor drive for damaged and
excessive wear.
(5) Install the gerotor planetary in the original
position.
(6) Measure the tip clearance (Fig. 118). Maximum
clearance is 0.1778 mm (0.007 inch). If the oil pump
is out of limits, replace the pump.
(7) Measure the clearance of the gerotor drive/
gerotor planetary to port plate (Fig. 119). Maximum
clearance is 0.127 mm (0.005 inch). If the oil pump is
out of limits, replace the pump.
(8) Measure the clearance of the gerotor planetary
to the body bore (Fig. 120). Maximum clearance is
0.381 mm (0.015 inch). If the oil pump is out of limits, replace the pump.
(9) Measure the gears backlash (Fig. 121). The
limits of a used pump is 0.15- 0.25 mm (0.006-0.010
Fig. 118 Measuring Tip Clearance
1 - FEELER GAUGE
Fig. 119 Measuring Gerotor to Port Plate Clearance
1 - PORT PLATE
2 - GEROTOR
inch). If the backlash is out of limits, replace the oil
pump.
(10) Install the back plate.
INSTALLATION
(1) Lubricate the pump with clean engine oil. Filling the pump with clean engine oil during installation will help to prime the pump at engine start up.
ENGINE 5.9L DIESEL
DR
9 - 345
OIL PUMP (Continued)
(3) The back plate on the pump seats against the
bottom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump
will not touch the cylinder block.
(4) Measure the idler gear to pump drive gear
backlash and the idler gear to crankshaft gear backlash (Fig. 123). The backlash should be 0.15- 0.25
mm (0.006-0.010 inch). If the backlash is out of limits, replace the oil pump.
(5) If the adjoining gear moves when you measure
the backlash, the reading will be incorrect.
Fig. 120 Measuring Gerotor Planetary to Body Bore
Clearance
1 - BODY BORE
2 - GEROTOR PLANETARY
Fig. 123 Idler Gear to Pump Drive Gear and
Crankshaft Gear Backlash
Fig. 121 Measure Gear Backlash
1
2
3
4
-
OIL PUMP DRIVE GEAR
IDLER GEAR
BACKLASH
BACKLASH
(2) Install the pump (Fig. 116). Verify the idler
gear pin is installed in the locating bore in the cylinder block. Tighten the oil pump mounting bolts in
two steps, in the sequence shown in (Fig. 122).
• Step 1—Tighten to 8 N·m (71 in. lbs.) torque.
• Step 2—Tighten to 24 N·m (18 ft. lbs.) torque.
(6) Apply a bead of Mopart Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover
sealing surface.
(7) Install the gear housing cover (Refer to 9 ENGINE/VALVE TIMING/GEAR HOUSING COVER
- INSTALLATION).
(8) Install the vibration damper (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER INSTALLATION) and speed indicator ring.
(9) Install the fan support/hub assembly and
torque bolts to 32 N·m (24 ft. lbs.).
(10) Install hydraulic pump.
(11) Install accessory drive belt tensioner. Torque
bolt to 43 N·m (32 ft. lbs.).
(12) Install the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).
(13) Install the cooling fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
(14) Connect battery negative cables.
(15) Start engine and check for oil leaks.
INTAKE MANIFOLD
REMOVAL
Fig. 122 Oil Pump Mounting Bolt Torque Sequence
(1) Disconnect the battery negative cables.
(2) Remove the charge air cooler outlet tube from
the air inlet housing (Fig. 124).
(3) Remove the engine oil dipstick tube mounting
bolt (Fig. 124).
9 - 346
ENGINE 5.9L DIESEL
DR
INTAKE MANIFOLD (Continued)
(4) Remove dipstick support at fuel filter housing.
Position dipstick tube to the side.
(5) Disconnect the air grid heater power cables at
the cable mounting studs.
(6) Disconnect the ground strap at the intake
cover.
(7) Remove the engine wiring harness connections
at the air inlet housing elbow.
(8) Remove the four (4) air inlet housing mounting
bolts and remove the housing from top of the heater
elements.
(9) Remove the intake air grid heater from the
manifold (Fig. 125).
Fig. 125 Intake Air Grid Heater
1 - INTAKE AIR GRID HEATER
2 - GASKET
(15) Clean the intake manifold cover and cylinder
head sealing surface.
CLEANING
Fig. 124 Charge Air Cooler Air Tube
1
2
3
4
5
6
7
8
9
- FRONT WIRING CLIP
- GROUND CABLE
- TUBE BOLT
- ENGINE OIL DIPSTICK TUBE
- CLAMPS
- AIR TUBE (INT. MAN.-TO-INTERCOOLER)
- RUBBER HOSE
- AIR INTAKE HOUSING
- CABLE BRACKET HOUSING
(10) Remove the high pressure fuel lines and fuel
rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL LINES - REMOVAL).
(11) Remove APPS bracket from cylinder head to
gain access to front intake manifold cover bolts.
(12) Disconnect manifold air temperature/pressure
sensor connector.
(13) Remove the remaining intake manifold coverto-cylinder head bolts.
(14) Remove the intake manifold cover and gasket.
Keep the gasket material and any other material out
of the air intake.
Clean manifold in solvent and blow dry with compressed air.
Clean cylinder block gasket surfaces using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) Using a new gasket, install the intake manifold
cover.
(2) Install the cover-to-cylinder head bolts that do
not hold down the fuel rail. Tighten the bolts to 24
N·m (18 ft. lbs.) torque.
(3) Install the high pressure rail and fuel lines
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL LINES - INSTALLATION).
(4) Using two (2) new gaskets, install the intake
air grid heater and air inlet housing. Position the
ground cable and install and tighten the bolts to 24
N·m (18 ft. lbs.) torque.
ENGINE 5.9L DIESEL
DR
9 - 347
INTAKE MANIFOLD (Continued)
(5) Connect the manifold air temperature/pressure
sensor connector.
(6) Install and tighten the air intake heater power
supply nuts to 14 N·m (120 in. lbs.) torque.
(7) Install the APPS bracket. Torque fasteners to
43 N·m (32ft lbs.) torque.
(8) Install oil dipstick tube support at fuel filter
housing.
(9) Install the engine oil dipstick tube and mounting bolt.
(10) Position the charge air cooler outlet tube onto
the air inlet housing. Tighten the clamps to 8 N·m
(72 in. lbs.) torque.
(11) Attach the engine wire harness to the air inlet
housing at two locations.
(12) Prime the fuel system. Refer to the fuel priming procedure in Group 14, Fuel System.
(13) Connect the battery negative cables.
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Disconnect the exhaust pipe from the turbocharger elbow.
(4) Lower vehicle.
(5) Disconnect the turbocharger air inlet hose.
(6) Remove air cleaner assembly.
(7) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger.
(8) Disconnect the charge air cooler inlet pipe from
the turbocharger.
(9) Remove the turbocharger and gasket from the
exhaust manifold.
(10) Remove the cab heater return pipe nuts from
the exhaust manifold stud. Position the tube out of
the way.
(11) Remove heat shield.
(12) Remove exhaust manifold bolt lockplates.
(13) Remove the exhaust manifold-to-cylinder head
bolts and spacers (Fig. 126).
(14) Remove the exhaust manifold and gaskets
(Fig. 126).
CLEANING
Clean the cylinder head and exhaust manifold sealing surfaces with a suitable scraper. Use a ScotchBrite™ pad or equivalent.
INSPECTION
Inspect the exhaust manifold for cracks. Measure
the exhaust manifold for flatness. Place a ruler over
all of the exhaust ports and insert a feeler gauge
Fig. 126 Exhaust Manifold and Gaskets
1
2
3
4
5
6
-
RETAINING STRAP
BOLT (7)
SPACER
MANIFOLD, EXHAUST
GASKET
BOLT (5)
between the port flange and the ruler. Maximum
deviation from flat is 0.20 mm (.008 inch).
INSTALLATION
(1) Using new gaskets, install the exhaust manifold and gaskets. Install the bolts and spacers and
tighten the bolts in the sequence shown in to 43 N·m
(32 ft. lbs.) torque.
(2) Retorque the four center bolts.
(3) Install heat shield and torque bolts to 24 Nm
(18 ft. lbs.).
(4) Install cab heater tube.
(5) Install exhaust manifold bolt retention straps.
(6) Install the cab heater return hose to the manifold bolt stud. Tighten the nut to 24 N·m (18 ft. lbs.)
torque.
(7) Install the turbocharger and a new gasket.
Apply anti-seize to the studs and then tighten the
turbocharger mounting nuts to 43 N·m (32 ft. lbs.)
torque.
9 - 348
ENGINE 5.9L DIESEL
DR
EXHAUST MANIFOLD (Continued)
(8) Install the oil drain tube and a new gasket to
the turbocharger. Tighten the drain tube bolts to 24
N·m (18 ft. lbs.) torque.
(9) Pre-lube the turbocharger. Pour 50 to 60 cc
(2 to 3 oz.) clean engine oil in the oil supply line fitting on the turbo. Rotate the turbocharger impeller
by hand to distrubute the oil thoroughly.
(10) Install and tighten the oil supply line fitting
nut to 24 N·m (18 ft. lbs.) torque.
(11) Position the charge air cooler inlet pipe to the
turbocharger. With the clamp in position, tighten the
clamp nut to 8 N·m (72 in. lbs.) torque.
(12) Position the air inlet hose to the turbocharger.
Tighten the clamp to 8 N·m (72 in. lbs.) torque.
(13) Raise vehicle on hoist.
(14) Connect the exhaust pipe to the turbocharger
and tighten the bolts to 34 N·m (25 ft. lbs.) torque.
(15) Lower the vehicle.
(16) Connect the battery negative cables.
(17) Start the engine to check for leaks.
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION
(1) Remove the cylinder head cover(Refer to 9 ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(2) Remove fuel injector from cylinder number
1(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(3) Using Special Tool 7471B rotate the engine
until the TDC mark on the damper is at 12 o’clock.
(4) Using a 8 in.x 1/4 in. dowel rod inserted into
cylinder number 1, rock the crankshaft back and
forth to verify piston number 1 is at TDC.
(5) With cylinder number still at TDC, inspect the
keyway on the crankshaft gear for proper alignment
(12 o’clock position).
(6) If the keyway is not at 12 o’clock position
replace the crankshaft gear assembly.
(7) If the keyway is at 12 o’clock position, remove
front gear cover and verify timing mark alignment
between the camshaft gear and crankshaft gear, if
not aligned inspect keyway on camshaft gear.
(8) Inspect keyway on camshaft gear for proper
alignment with the key in the camshaft, if alignment
is off replace the camshaft/gear assembly.
(9) If timing marks alignment is off and no damage is found at either the crankshaft or camshaft
gear keyways, realign timing marks as necessary.
GEAR HOUSING
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STANDARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle hose from
radiator 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 lower fan shroud fasteners. Disconnect
fan drive wire harness.
(9) Remove the upper fan shroud-to-radiator
mounting bolts.
(10) Remove viscous fan/drive assembly (Refer to 7
- COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(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 (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL) and speed indicator ring.
(15) Lower the vehicle.
(16) Remove the hydraulic pump.
(17) Remove the accessory drive belt tensioner.
(18) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the gasket surfaces.
(19) Remove the fuel injection pump (Refer to 14 FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP - REMOVAL).
(20) Disconnect the camshaft position sensor connector.
(21) Disconnect and remove engine speed sensor.
(22) Remove the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(23) Remove the six front oil pan fasteners.
(24) Remove the gear housing fasteners.
NOTE: Use care when removing the gear housing,
to avoid damage to the oil pan gasket, as the gasket will be reused if it is not damaged.
(25) Slide a feeler gauge between the gear housing
and oil pan gasket, to break the gasket seal.
(26) Remove the gear housing and gasket.
ENGINE 5.9L DIESEL
DR
9 - 349
GEAR HOUSING (Continued)
(27) Clean the gasket material from the cylinder
block and gear housing.
INSTALLATION
(1) Inspect oil pan gasket. If torn, gasket must be
replaced.
(2) Install a new gasket and the gear housing.
Torque bolts to 24 N·m (18 ft. lbs.). Follow torque
sequence.
(3) If a new housing is installed, the camshaft
position sensor, and engine speed sensor must be
transferred to the new housing.
(4) Connect the camshaft position sensor connector.
(5) Install and connect engine speed sensor.
(6) Install the injection pump (Refer to 14 - FUEL
SYSTEM/FUEL
DELIVERY/FUEL
INJECTION
PUMP - INSTALLATION).
(7) Install the camshaft (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - INSTALLATION). Align the crankshaft
and camshaft gear marks as shown in.
(8) Install a new front crankshaft seal into the
gear cover.
(9) Apply a bead of Mopart Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover.
Be sure to surround all through holes.
(10) Using the seal pilot to align the cover, install
the cover to the housing and install the bolts.
Tighten the bolts to 24 N·m (18 ft. lbs.) torque.
(11) Remove the seal pilot. Install front seal dust
shield.
(12) Raise the vehicle.
(13) Trim any excess gear housing gasket to make
it flush with the oil pan rail.
(14) Install the crankshaft damper and speed indicator ring (Refer to 9 - ENGINE/ENGINE BLOCK/
VIBRATION DAMPER - INSTALLATION). Torque
bolts to 40 Nm (30 ft. lbs.), plus an additional 60°.
(15) Lower vehicle.
(16) Install the fan support/hub assembly and
tighten bolts to 32 N·m (24 ft. lbs.) torque.
(17) Install the hydraulic pump.
(18) Install the accessory drive belt tensioner.
Torque bolt to 43 N·m (32 ft. lbs.) torque.
(19) Install the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).
(20) Install the upper cooling fan and shroud
together (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
(21) Install lower shroud and connect fan drive
harness connector.
(22) Install the windshield washer reservoir to the
fan shroud and connect the washer pump supply
hose and electrical connection.
(23) Install the coolant recovery bottle to the fan
shroud and connect the hose to the radiator filler
neck.
(24) Install the radiator upper hose and clamps.
(25) Add engine oil.
(26) Add coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).
(27) Connect the battery cables.
(28) Start engine and inspect for leaks.
GEAR HOUSING COVER
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 - STANDARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle hose from
radiator 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 viscous fan/drive assembly (Refer to 7 COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(9) Remove the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).
(10) Remove the cooling fan support/hub from the
front of the engine.
(11) Raise the vehicle on hoist.
(12) Remove power steering pump.
(13) Remove accessory drive belt tensioner.
(14) Remove the crankshaft damper and speed
indicator ring (Refer to 9 - ENGINE/ENGINE
BLOCK/VIBRATION DAMPER - REMOVAL).
(15) Lower the vehicle.
(16) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the gasket surfaces.
9 - 350
ENGINE 5.9L DIESEL
DR
GEAR HOUSING COVER (Continued)
INSTALLATION
(1) Install a new front crankshaft oil seal.
(2) Obtain a seal pilot/installation tool from a
crankshaft front seal service kit and install the pilot
into the seal.
(3) Apply a bead of Mopart Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover.
Be sure to surround all through holes.
(4) Using the seal pilot to align the cover (Fig.
127), install the cover to the housing and install the
bolts. Tighten the bolts to 24 N·m (18 ft. lbs.) torque.
Fig. 127 Installing Cover with Seal Pilot
1 - SEAL PILOT
(5) Remove the seal pilot. Install front seal dust
shield.
(6) Raise the vehicle.
(7) Install the speed indicator ring and the crankshaft damper (Refer to 9 - ENGINE/ENGINE
BLOCK/VIBRATION DAMPER - INSTALLATION).
(8) Lower vehicle.
(9) Install the fan support/hub assy, and tighten
bolts to 32 N·m (24 ft. lbs.) torque.
(10) Install power steering pump.
(11) Install accessory drive belt tensioner. Torque
bolt to 43 N·m (32 ft. lbs.) torque.
(12) Install the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).
(13) Install the cooling fan and shroud together
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN INSTALLATION).
(14) Install the windshield washer reservoir to the
fan shroud and connect the washer pump supply
hose and electrical connection.
(15) Install the coolant recovery bottle to the fan
shroud and connect the hose to the radiator filler
neck.
(16) Install the radiator upper hose and clamps.
(17) Add coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).
(18) Connect the battery cables.
(19) Start engine and inspect for leaks.
MANUAL TRANSMISSION - NV5600
DR
21 - 87
MANUAL TRANSMISSION - NV5600
TABLE OF CONTENTS
page
page
MANUAL TRANSMISSION - NV5600
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 87
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 89
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 90
CLEANING - TRANSMISSION . . . . . . . . . . . . . 104
INSPECTION
. . . . . . . . . . . . . . . . . . . . . . . . . 104
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 120
SPECIFICATIONS - NV5600 . . . . . . . . . . . . . . 122
SPECIAL TOOLS . . . . . . . .
ADAPTER HOUSING SEAL
REMOVAL . . . . . . . . . . . . .
INSTALLATION . . . . . . . . .
EXTENSION HOUSING SEAL
REMOVAL . . . . . . . . . . . . .
INSTALLATION . . . . . . . . .
SHIFT COVER
REMOVAL . . . . . . . . . . . . .
INSTALLATION . . . . . . . . .
MANUAL TRANSMISSION NV5600
To drain the trans remove the bottom PTO cover
bolt. Fill the trans through the plug to the rear of the
PTO cover (Fig. 1). Dry fill is approximately 4.5 liters
(9.5 pints) or to the bottom edge of the fill plug hole.
The gear ratios are:
GEAR RATIOS
DESCRIPTION
The NV5600 is a six speed constant mesh manual
transmission (Fig. 1). All gear ranges including
reverse are synchronized. First and second gears utilize dual cone synchronizers in order to aid shifting.
Sixth gear is an overdrive range. The transmission
uses cast iron for the gear case and extension/
adapter housing and aluminum for the clutch housing.
. . . . . . . . . . . . . . . 122
. . . . . . . . . . . . . . . 127
. . . . . . . . . . . . . . . 127
. . . . . . . . . . . . . . . 127
. . . . . . . . . . . . . . . 127
. . . . . . . . . . . . . . . 128
. . . . . . . . . . . . . . . 128
GEAR
RATIO
FIRST
5.63:1
SECOND
3.38:1
THIRD
2.04:1
FOURTH
1.39:1
FIFTH
1.00:1
SIXTH
0.73:1
REVERSE
5.63:1
21 - 88
MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)
Fig. 1 NV5600 MANUAL TRANSMISSION
DR
MANUAL TRANSMISSION - NV5600
DR
21 - 89
MANUAL TRANSMISSION - NV5600 (Continued)
IDENTIFICATION
The transmission has two identification tags
attached to the driver side upper clutch housing (Fig.
2). One tag provides the transmission part number.
The second tag provides sequencing and build date
information. The information on the tags are essential to correct parts ordering.
before checking. These recommendations will ensure
an accurate check and avoid an underfill or overfill
condition. Always check the lubricant level after any
addition of fluid to avoid an incorrect lubricant level
condition.
Leaks can occur at the mating surfaces of the gear
case, adaptor or extension housing, or from the front/
rear seals. A suspected leak could also be the result
of an overfill condition. Leaks at the rear of the
extension or adapter housing will be from the housing oil seals. Leaks at component mating surfaces
will probably be the result of inadequate sealer, gaps
in the sealer, incorrect bolt tightening or use of a
non-recommended sealer. A leak at the front of the
transmission will be from either the front bearing
retainer or retainer seal. Lubricant may be seen dripping from the clutch housing after extended operation. If the leak is severe, it may also contaminate
the clutch disc causing the disc to slip, grab and or
chatter.
HARD SHIFTING
Fig. 2 IDENTIFICATION TAG LOCATION
1 - IDENTIFICATION TAGS
OPERATION
The driver selects a particular gear by moving the
shift lever to the desired gear position. As the shift
lever moves the selected shift rail, the shift fork
attached to that rail begins to move. The fork is positioned in a groove in the outer circumference of the
synchronizer sleeve. As the shift fork moves the synchronizer sleeve, the synchronizer begins to speed-up
or slow down the selected gear (depending on
whether we are up-shifting or down-shifting). The
synchronizer does this by having the synchronizer
hub splined to the mainshaft or the countershaft in
some cases, and moving the blocker ring into contact
with the gear’s friction cone. As the blocker ring and
friction cone come together, the gear speed is brought
up or down to the speed of the synchronizer. As the
two speeds match, the splines on the inside of the
synchronizer sleeve become aligned with the teeth on
the blocker ring and friction cone and eventually will
slide over the teeth, locking the gear to the mainshaft or countershaft through the synchronizer.
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill or an incorrect lubricant level check. A correct lubricant level
check can only be made when the vehicle is level.
Also allow the lubricant to settle for a minute or so
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants. The consequence of using non-recommended lubricants is
noise, excessive wear, internal bind and hard shifting. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indications of component damage are usually hard shifting and noise.
Component damage, incorrect clutch adjustment or
damaged clutch pressure plate or disc are additional
probable causes of increased shift effort. Incorrect
adjustment or a worn/damaged pressure plate or disc
can cause incorrect release. If clutch problem is
advanced, gear clash during shifts can result. Worn
or damaged synchro rings can cause gear clash when
shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise during normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds. Severe highly audible transmission noise is
generally the initial indicator of a lubricant problem.
Insufficient, improper or contaminated lubricant
will promote rapid wear of gears, synchros, shift
rails, forks and bearings. The overheating caused by
a lubricant problem, can also lead to gear breakage.
REMOVAL
(1) Shift transmission into Neutral.
21 - 90
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(2) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(3) Remove the bolts holding the shift tower to the
isolator plate and transmission gear case.
(4) Remove the shift tower and isolator plate from
the transmission gear case.
(5) Raise and support vehicle.
(6) Remove skid plate, if equipped.
(7) Mark propeller shaft/shafts and axle yokes for
installation reference.
(8) Remove propeller shaft.
(9) Disconnect and remove exhaust system as necessary.
(10) Disconnect wires at backup light switch.
(11) Support engine with adjustable safety stand
and wood block.
(12) If transmission is to be disassembled for
repair, remove drain bolt at bottom of PTO cover and
drain lubricant from transmission (Fig. 3).
FOUR WHEEL DRIVE
(1) Disconnect transfer case shift linkage at transfer case range lever.
(2) Support and secure transfer case with safety
chains to a transmission jack.
(3) Remove transfer case mounting nuts.
(4) Move transfer case rearward until input gear
clears transmission mainshaft.
(5) Lower transfer case assembly and move it from
under vehicle.
(6) Support and secure transmission with safety
chains to a transmission jack.
(7) Remove bolts/nuts attaching transmission
mount to rear crossmember.
(8) Remove rear crossmember bolts and pry out
crossmember.
(9) Remove transmission clutch housing bolts at
the engine block.
(10) Move transmission rearward until input shaft
clears clutch disc.
(11) Lower transmission and remove it from under
vehicle.
DISASSEMBLY
NOTE: Use Fixture 8241 for moving and handling
the transmission. The fixture supports the transmission at the center of gravity in order to ease mounting the transmission into the build fixture.
(1) Mount the transmission into Fixture 8230 (Fig. 4).
Fig. 3 NV5600 DRAIN BOLT
1 - PTO COVER
2 - DRAIN BOLT
(13) Remove clutch slave cylinder splash shield, if
equipped.
(14) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
(15) Remove wire harness from clips on transmission.
TWO WHEEL DRIVE
(1) Remove bolts/nuts mounting transmission to
the rear mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember bolts and pry out
crossmember.
(4) Remove transmission clutch housing bolts at
the engine block.
(5) Slide transmission and jack rearward until
input shaft clears clutch disc and pressure plate.
(6) Lower transmission jack and remove transmission from under vehicle.
Fig. 4 TRANSMISSION FIXTURE
1 - FIXTURE
2 - TRANSMISSION
MANUAL TRANSMISSION - NV5600
DR
21 - 91
MANUAL TRANSMISSION - NV5600 (Continued)
(2) Rotate the transmission to the horizontal position, if necessary.
(3) Remove the shift tower (Fig. 5) and isolator
plate (Fig. 6).
(4) Remove primary shift rail detent plug (Fig. 7).
Fig. 7 PRIMARY SHIFT RAIL DETENT PLUG
1 - DETENT PLUG
(5) Remove primary shift rail detent spring (Fig.
8).
Fig. 5 REMOVE SHIFT TOWER
1 - SHIFT TOWER
2 - TRANSMISSION
Fig. 8 PRIMARY SHIFT RAIL DETENT SPRING
1 - DETENT SPRING
Fig. 6 SHIFT TOWER ISOLATOR PLATE
1 - ISOLATOR PLATE
2 - TRANSMISSION
21 - 92
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(6) Remove primary shift rail detent plunger (Fig.
9).
Fig. 11 SHIFT RAIL BLOCKER BOLT
1 - BLOCKER BOLT
Fig. 9 PRIMARY SHIFT RAIL DETENT PLUNGER
1 - DETENT PLUNGER
(7) Remove clutch housing bolts (10) (Fig. 10) from
inside the housing.
(2) Remove extension/adapter housing from the
transmission gear case with Puller 8244 (Fig. 12).
NOTE: It may be necessary to straighten the housing during removal due to the tendency for the
reverse idler shaft to bind into one side of the
housing.
Fig. 10 CLUTCH HOUSING BOLTS
1 - BOLTS (10)
(8) Remove shift rail blocker bolt (Fig. 11) from the
side of the transmission gear case.
EXTENSION/ADAPTER HOUSING
(1) Remove bolts holding the extension/adapter
housing onto the transmission gear case.
Fig. 12 TRANSMISSION CASE PULLER
1 - PULLER
2 - EXTENSION/ADAPTER HOUSING
MANUAL TRANSMISSION - NV5600
DR
21 - 93
MANUAL TRANSMISSION - NV5600 (Continued)
(3) Remove crossover detent plug, spring and
plunger from the extension/adapter housing (Fig. 13).
NOTE: Tag all countershaft pre-load shims from
between the bearing race and the housing (Fig. 16).
(8) Remove crossover cam bushing from the extension/adapter housing with Remover 8240.
Fig. 13 CROSSOVER CAM DETENT PLUG
1 - DETENT PLUG
2 - EXTENSION HOUSING
Fig. 15 COUNTERSHAFT REAR BEARING RACE
(4) Remove bolt and washer holding the crossover
cam to the extension/adapter housing (Fig. 14).
(5) Remove crossover cam from the extension/
adapter housing.
1 - REMOVER
Fig. 16 COUNTERSHAFT REAR BEARING RACE
AND SHIM
Fig. 14 CROSSOVER CAM BOLT
1 - CROSSOVER CAM
2 - BOLT
3 - EXTENSION HOUSING
(6) Remove back-up lamp switch from the extension/adapter housing.
(7) Remove countershaft rear bearing race from
the extension/adapter housing with Remover L-4518
(Fig. 15).
1 - PRE-LOAD SHIM
2 - BEARING RACE
(9) On 4X2 vehicles, remove extension housing
seal with a pry tool or a slide hammer and screw.
(10) On 4X4 vehicles, remove adapter housing seal
with a pry tool or a slide hammer and screw.
21 - 94
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
REVERSE GEAR
(1) Remove crossover cam rollers and pin (Fig. 17).
(4) Remove reverse idler gear rear bearing, bearing spacer, front bearing and front thrust washer
from the idler gear shaft.
(5) Remove reverse countershaft rear bearing from
the countershaft reverse gear assembly with Puller
C-293-PA and Adapters C-293-52 (Fig. 19).
Fig. 17 CROSSOVER CAM ROLLERS AND PIN
1 - CROSSOVER CAM PIN
2 - CROSSOVER CAM ROLLERS
(2) Remove reverse idler thrust washer from the
reverse idler.
(3) Remove reverse idler and reverse countershaft
gears together (Fig. 18).
Fig. 19 COUNTERSHAFT REAR BEARING PULLER
1 - PULLER
2 - ADAPTERS
(6) Seperate countershaft reverse gear and sleeve.
(7) Remove output shaft nut with Wrench 8226 on
the shaft nut and Socket 6993 or 6984 to hold the
shaft (Fig. 20). Discard output shaft nut from the
output shaft.
NOTE: If necessary strike the flat side area of
Wrench 8226 with a hammer to break the nut loose.
Fig. 18 REVERSE IDLER AND COUNTERSHAFT
GEARS
1 - REVERSE IDLER GEAR
2 - COUNTERSHAFT REVERSE GEAR
Fig. 20 LOOSEN OUTPUT SHAFT NUT
1 - WRENCH
2 - SOCKET
MANUAL TRANSMISSION - NV5600
DR
21 - 95
MANUAL TRANSMISSION - NV5600 (Continued)
(8) Remove output shaft ball bearing assembly and
reverse thrust washer from the output shaft (Fig.
21).
(10) Remove reverse gear bearing sleeve from the
output shaft (Fig. 23).
NOTE: If necessary heat the sleeve slightly with a
heat gun. Do not use a torch to heat the sleeve or
damage to the output shaft may occur.
Fig. 21 OUTPUT SHAFT BEARING AND THRUST
WASHER
1 - OUTPUT SHAFT BALL BEARING
2 - THRUST WASHER
(9) Remove reverse gear, reverse gear synchronizer
cone, reverse gear outer blocker ring and reverse
gear bearing (Fig. 22).
Fig. 23 REVERSE BEARING SLEEVE
1 - REVERSE GEAR BEARING SLEEVE
(11) Remove roll-pin securing the reverse shift fork
to the reverse shift rail with a 6 mm (7/32 in.) punch
and hammer.
Fig. 22 REVERSE GEAR COMPONENTS
1
2
3
4
-
REVERSE GEAR
REVERSE BEARING
BLOCKER RING
FRICTION CONE
21 - 96
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(12) Remove reverse shift fork and synchronizer as
an assembly from the reverse shift rail and the output shaft (Fig. 24).
Fig. 25 TRANSMISSION CASE LIFT FIXTURE
1 - FIXTURE
2 - TRANSMISSION CASE
Fig. 24 REVERSE SHIFT FORK AND SYNCHRO
1 - REVERSE SYNCHRO
2 - REVERSE SHIFT FORK
TRANSMISSION GEAR CASE
(1) Remove remaining bolts holding the transmission gear case to the clutch housing.
(2) Remove the shift socket roll pin with a 6 mm
(7/32 in.) punch and hammer.
(3) Turn shift socket so it won’t catch the case
when lifting it up.
(4) Install Fixture 8232 to the transmission gear
case.
(5) Attach an engine crane or equivalent to Fixture
8232 and remove the transmission gear case from the
clutch housing (Fig. 25).
(6) Remove rear output shaft and countershaft
bearing races from the transmission gear case with a
brass drift and hammer.
GEARTRAIN
(1) Remove bolts holding the 5-6 crossover bracket
to the clutch housing (Fig. 26).
Fig. 26 5-6 CROSSOVER BRACKET BOLTS
1 - 5-6 CROSSOVER BRACKET
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(2) Attach Fixture 8232 to the output shaft and
countershaft (Fig. 27).
Fig. 28 Remove Holding Tool
Fig. 27 FIXTURE/OUTPUT SHAFT
1 - HOLDING TOOL
2 - 5-6 SYNCHRO
1 - OUTPUT SHAFT
2 - FIXTURE
(3) Attach an engine crane or equivalent to Fixture
8232 and raise the geartrain approximately 1/4 in.
from the clutch housing.
(4) Remove 5-6 crossover bracket from the clutch
housing.
(5) Lower the geartrain back into the clutch housing.
(6) Install Holding Tool 8242 (Fig. 28) onto the 5-6
synchro and tighten the screw to hold the 5-6 synchro together during the removal operation.
NOTE: Note the order of the shift fork arms at the
primary shift rail, while in the Neutral position.
(7) Raise geartrain and shift rails until all the
shift rails clear the clutch housing.
(8) Remove shift rails from the rest of the
geartrain (Fig. 29).
(9) Raise the geartrain until the input shaft is
clear of the clutch housing.
Fig. 29 SHIFT RAILS
1 - 5-6 SHIFT RAIL
21 - 97
21 - 98
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(10) Remove geartrain from the clutch housing and
install the geartrain into Support Stand 8246 (Fig.
30).
Fig. 31 FRONT COUNTERSHAFT BEARING
1 - PULLER
2 - JAWS
Fig. 30 GEARTRAIN FIXTURE
1 - FIXTURE
2 - SUPPORT STAND
(11) Remove Fixture 8232 from the output shaft
and the countershaft.
(12) Separate the countershaft from the output
shaft.
(13) Separate the output shaft from the input
shaft. Hold the 5-6 synchro together while removing
the output shaft to prevent the synchro sleeve from
being dislodged from the synchro hub.
COUNTERSHAFT BEARINGS
(1) Remove snap-ring holding the front countershaft bearing onto the countershaft.
(2) Remove front countershaft bearing with Collar
6444-8, Jaws 6451, Puller Rods 6444-4 and Puller
6444 (Fig. 31).
(3) Remove rear countershaft bearing with Collar
6444-8, Jaws 6447, Puller Rods 6444-4, Puller 6444
and suitable press button (Fig. 32).
Fig. 32 REAR COUNTERSHAFT BEARING
1 - PULLER
2 - JAWS
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
OUTPUT SHAFT BEARINGS
(1) Remove snap-ring holding the pocket bearing
onto the output shaft.
(2) Remove pocket bearing from the output shaft
with Sleeve 6444-8, Jaws 8234, Puller Rods 6444-4
and the remainder of Puller 6444 (Fig. 33).
(3) Remove snap-ring holding the rear output shaft
bearing onto the output shaft.
(4) Use Collar 6444-8, Jaws 8271 and Puller Rods
6444-3 for 4X2 vehicles or Puller Rods 6444-4 for 4X4
vehicles with the remainder of Puller 6444 to remove
the rear output shaft bearing from the output shaft.
(5) Remove rear output shaft thrust washer from
the output shaft.
Fig. 34 FIFTH GEAR BLOCKER RING
1 - FIFTH GEAR BLOCKER RING
2 - INPUT SHAFT
Fig. 33 OUTPUT SHAFT POCKET BEARING
1 - PULLER
2 - JAWS
INPUT SHAFT
(1) Remove fifth gear blocker ring from the input
shaft (Fig. 34).
(2) Remove fifth gear friction cone from the input
shaft (Fig. 35).
Fig. 35 FIFTH GEAR FRICTION CONE
1 - FRICTION CONE
2 - INPUT SHAFT
21 - 99
21 - 100
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(3) Remove output shaft pocket bearing race from
the input shaft with Puller L-4518 (Fig. 36).
Fig. 37 INPUT SHAFT BEARING
Fig. 36 OUTPUT SHAFT POCKET BEARING RACE
1 - PULLER
2 - JAWS
1 - PULLER
2 - INPUT SHAFT
(4) Remove input shaft bearing and oil guide from
the input shaft with Collar 6444-8, Jaws 8243, Puller
Rods 6444-6 and the remainder of Puller 6444 (Fig.
37).
OUTPUT SHAFT
NOTE: Some gear and synchro components can be
installed backwards. Mark the gears, clutch gears,
synchro hubs, and sleeves for installation reference
during disassembly. Use paint or a scribe for marking purposes. Then stack the geartrain parts in
order of removal.
(1) Remove first gear from the output shaft.
(2) Remove first gear bearing from the output
shaft (Fig. 38).
(3) Remove first gear blocker rings (2) and cones
from the 1-2 synchro assembly (Fig. 39).
(4) Install the remainder of the output shaft into
Fixture 8227 with press blocks under second gear.
(5) Install shaft and Fixture assembly into a shop
press (Fig. 40).
(6) Press second gear, 1-2 synchro assembly and
first gear bearing sleeve from the output shaft.
(7) Remove second gear bearing from the output
shaft.
Fig. 38 FIRST GEAR BEARING
1 - OUTPUT SHAFT
2 - FIRST GEAR BEARING
(8) Reverse output shaft in the Fixture 8227 with
press blocks positioned under the 5-6 synchro assembly.
(9) Press the 5-6 synchro assembly from the output shaft.
MANUAL TRANSMISSION - NV5600
DR
21 - 101
MANUAL TRANSMISSION - NV5600 (Continued)
(10) Remove sixth gear and the sixth gear bearing
from the output shaft (Fig. 41).
Fig. 39 FIRST GEAR BLOCKER RINGS AND
FRICTION CONE
1 - OUTPUT SHAFT
2 - FIRST GEAR BLOCKER RINGS
3 - FIRST GEAR FRICTION CONE
Fig. 41 SIXTH GEAR COMPONENTS
1
2
3
4
5
Fig. 40 SECOND GEAR, 1-2 SYNCHRO & FIRST
GEAR BEARING SLEEVE
1
2
3
4
5
-
OUTPUT SHAFT
FIRST GEAR BEARING SLEEVE
SECOND GEAR
FIXTURE
1-2 SYNCHRO
-
SIXTH GEAR FRICTION CONE
SIXTH GEAR
OUTPUT SHAFT
SIXTH GEAR BLOCKER RING
5-6 SYNCHRO
21 - 102
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
COUNTERSHAFT
(1) Install the countershaft into Fixture 8227 with
press blocks located under the fifth countershaft
gear.
(2) Place the assembly into a shop press.
(3) Use Guide 8235 on end of countershaft and
press the countershaft fifth gear from the countershaft (Fig. 42).
Fig. 43 SIXTH COUNTERSHAFT GEAR
1 - GUIDE
2 - SIXTH COUNTER SHAFT GEAR
3 - FIXTURE
Fig. 42 FIFTH COUNTERSHAFT GEAR
1 - GUIDE
2 - FIFTH COUNTER SHAFT GEAR
3 - FIXTURE
(4) Place countershaft in Fixture 8227 with press
blocks placed under the sixth countershaft gear.
(5) Use Guide 8235 on end of countershaft and
press the countershaft sixth gear from the countershaft (Fig. 43).
(6) Remove countershaft from the press and Fixture 8227.
(7) Remove fourth countershaft gear, friction cone,
blocker ring and bearing from the countershaft (Fig.
44).
(8) Install countershaft into Fixture 8227 with
press blocks located under the third countershaft
gear.
Fig. 44 FOURTH COUNTERSHAFT GEAR
COMPONENTS
1
2
3
4
5
-
FOURTH GEAR BLOCKER RING
FOURTH GEAR BEARING
COUNTERSHAFT
FOURTH GEAR FRICTION CONE
FOURTH COUNTERSHAFT GEAR
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(9) Place assembly into a shop press and press
third countershaft gear, 3-4 synchro and fourth countershaft gear bearing sleeve from the countershaft
(Fig. 45).
Fig. 46 THIRD GEAR BEARING
1 - COUNTERSHAFT
2 - 2-3 THRUST WASHER
3 - THIRD COUNTERSHAFT GEAR BEARING
Fig. 45 THIRD COUNTERSHAFT GEAR
COMPONENTS
1
2
3
4
5
-
THIRD COUNTERSHAFT GEAR
FIXTURE
3-4 SYNCHRO
BEARING SLEEVE
COUNTERSHAFT
(10) Remove countershaft from the press and Fixture 8227.
(11) Remove third countershaft gear bearing from
the countershaft (Fig. 46).
(12) The 2-3 thrust washer should not normally
need to be removed from the countershaft. If necessary slide 2-3 thrust washer off countershaft.
CLUTCH HOUSING
(1) Remove input shaft retainer bolts from the
clutch housing and remove retainer (Fig. 47).
Fig. 47 INPUT SHAFT RETAINER
1 - INPUT SHAFT RETAINER
2 - CLUTCH HOUSING
21 - 103
21 - 104
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(2) Remove countershaft oil guide from the countershaft front bearing bore in the clutch housing (Fig.
48).
Fig. 49 FRONT COUNTERSHAFT BEARING RACE
1 - CLUTCH HOUSING
2 - HANDLE
3 - REMOVER
Fig. 48 COUNTERSHAFT OIL GUIDE
1 - CLUTCH HOUSING
2 - COUNTERSHAFT OIL GUIDE
(3) Remove countershaft front bearing race, endplay shims and spacer from the clutch housing with
Remover 6061-1 and Handle C-4171 (Fig. 49).
(4) Remove input shaft bearing race with Remover/
Installer 8237 and Handle C-4171.
(5) Remove input shaft oil guide and retainer seal
(Fig. 50).
CLEANING - TRANSMISSION
Clean the gears, bearings shafts, extension/adapter
housing and gear case with solvent. Dry all parts
except the bearings with compressed air. Allow the
bearings to either air dry or wipe them dry with
clean shop towels.
INSPECTION
NOTE: Minor corrosion, nicks, or pitting can be
smoothed with 400 grit emery and polished out with
crocus cloth.
Inspect the reverse idler gear, bearings, shaft and
thrust washers. Replace the bearings if the rollers
are worn, chipped, cracked, flat-spotted or brinnelled.
Replace the gear if the teeth are chipped, cracked or
worn thin.
Inspect the front bearing retainer and bearing cup.
Replace the bearing cup if scored, cracked, brinnelled
Fig. 50 OIL GUIDE AND SEAL
1 - INPUT SHAFT OIL GUIDE
2 - INPUT SHAFT OIL SEAL
or rough. Check the release bearing slide surface of
the retainer carefully. Replace the retainer if worn or
damaged in any way.
Inspect mainshaft bearing surfaces, splines, snap
ring grooves and threads. Replace the shaft if any
surfaces exhibit considerable wear or damage.
MANUAL TRANSMISSION - NV5600
DR
21 - 105
MANUAL TRANSMISSION - NV5600 (Continued)
Inspect the countershaft and bearings. Replace the
shaft if any surfaces exhibit considerable wear or damage.
Inspect shift forks for wear and distortion. Check
fit of the sleeve in the fork to be sure the two parts
fit and work smoothly. Replace the fork if the roll pin
holes are worn oversize or damaged. Do not attempt
to salvage a worn fork. Replace shift fork roll pins if
necessary or if doubt exists about their condition.
The all bearings for wear, roughness, flat spots, pitting or other damage. Replace the bearings if necessary.
Inspect the blocker rings and fiction cones. replace
either part if worn or damaged in any way. Replace if
the friction material is burned, flaking off or worn.
Inspect synchro components wear or damage.
Replace parts if worn, cracked or distorted.
Inspect all of the thrust washers and locating pins.
Replace the pins if bent or worn. Replace the washers if worn or the locating pin notches are distorted.
Inspect the case and housing/adapter sealing and
mating surfaces are free of burrs and nicks. Inspcet the
alignment dowels in the case top surface and in the
housing/adapter are tight and in good condition. Replace
the gear case or housing/adapter if cracked or broken.
ASSEMBLY
(3) Install second gear synchro friction cone over
the blocker ring and onto second gear (Fig. 52).
Fig. 52 FRICTION CONE
1 - GEAR
2 - FRICTION CONE
(4) Install second gear synchro outer blocker ring
over the second gear synchro friction cone. Align one
of the lugs on the outer ring with a lug on the inner
ring (Fig. 53).
NOTE: Gaskets are not used in the transmission.
Use Mopar Gasket Maker or equivalent on all gear
case and extension housing sealing surfaces.
OUTPUT SHAFT
(1) Place second gear on bench with the synchro
clutch ring up.
(2) Install second gear synchro inner blocker ring
onto second gear (Fig. 51).
Fig. 53 OUTER BLOCKER RING
1 - OUTER BLOCKER RING
2 - LUG
3 - GEAR
Fig. 51 INNER BLOCKER RING
1 - INNER BLOCKER RING
2 - GEAR
21 - 106
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(5) Install 1-2 synchro assembly onto the second
gear assembly (Fig. 54).
Fig. 54 3-4 SYNCHRO ASSEMBLY
1 - SYNCHRO
2 - GEAR
(6) Reverse assembly on the bench.
(7) Lubricate and install second gear bearing into
second gear (Fig. 55).
Fig. 56 OUTPUT SHAFT INTO 1-2 SYNCHRO
1 - OUTPUT SHAFT
2 - 1-2 SYNCHRO
3 - SECOND GEAR
(13) Install first gear synchro friction cone over the
blocker ring and onto first gear (Fig. 52).
(14) Install first gear synchro outer blocker ring
over the first gear synchro friction cone. Align one of
the lugs on the outer ring with a lug on the inner
ring (Fig. 53).
(15) Reverse the output shaft in the press.
(16) Install first gear bearing sleeve onto the output shaft.
Fig. 55 SECOND GEAR AND BEARING
1 - BEARING
2 - GEAR
(8) Place 1-2 synchro, second gear and second gear
bearing assembly on shop press with second gear facing upward.
(9) Install output shaft into the second gear 1-2
synchro assembly with the front of the output shaft
facing upward (Fig. 56).
(10) Press the output shaft into position.
(11) Place first gear on bench with the synchro
clutch ring up.
(12) Install first gear synchro inner blocker ring
onto first gear (Fig. 51).
MANUAL TRANSMISSION - NV5600
DR
21 - 107
MANUAL TRANSMISSION - NV5600 (Continued)
(17) Install first gear bearing sleeve the remainder
of the way onto the output shaft using Installer 8228
and a shop press (Fig. 57).
Fig. 58 FIRST GEAR AND BLOCKER ASSEMBLY
1 - OUTPUT SHAFT
2 - FIRST GEAR ASSEMBLY
Fig. 57 FIRST GEAR BEARING SLEEVE
1 - INSTALLER
2 - FIRST GEAR BEARING SLEEVE
(18) Install first gear and blocker assembly onto
the output shaft (Fig. 58).
(19) Install first gear bearing over the output shaft
and into first gear.
(20) Install output shaft thrust washer onto the
output shaft (Fig. 59).
Fig. 59 OUTPUT SHAFT THRUST WASHER
1 - OUTPUT SHAFT
2 - OUTPUT SHAFT THRUST WASHER
21 - 108
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(21) Install rear output shaft bearing onto the output shaft with Installer 8228 and a shop press (Fig.
60).
(22) Install a new snap-ring to hold the rear output bearing onto the output shaft. Install the thickest snap-ring which will fit into the groove.
Fig. 61 SIXTH GEAR
1 - SIXTH GEAR
2 - SIXTH GEAR BEARING
Fig. 60 REAR OUTPUT SHAFT BEARING
1 - INSTALLER
2 - REAR OUTPUT SHAFT BEARING
(23) Reverse output shaft in the Fixture 8227 and
support the shaft with press blocks under first gear.
(24) Install sixth gear bearing onto the output
shaft.
(25) Install sixth gear onto the output shaft and
over the sixth gear bearing (Fig. 61).
(26) Install the sixth gear friction cone onto sixth
gear.
(27) Install sixth gear blocker ring over the sixth
gear friction cone (Fig. 62).
Fig. 62 SIXTH GEAR BLOCKER RING
1 - SIXTH GEAR BLOCKER RING
2 - SIXTH GEAR FRICTION CONE
MANUAL TRANSMISSION - NV5600
DR
21 - 109
MANUAL TRANSMISSION - NV5600 (Continued)
(28) Install Guide 8235 onto the end of the output
shaft (Fig. 63).
Fig. 64 5-6 SYNCHRO
Fig. 63 OUTPUT SHAFT GUIDE
1 - INSTALLER
2 - 5-6 SYNCHRO
1 - GUIDE
2 - OUTPUT SHAFT
(29) Install 5-6 synchro over Guide 8235 and onto
the output shaft.
(30) Press 5-6 synchro (Fig. 64) onto the output
shaft with Installer 8156 and a shop press.
(31) Install output shaft pocket bearing onto the
output shaft.
(32) Press pocket bearing the remainder of the
way onto the output shaft using Guide 8235 and a
shop press (Fig. 65).
(33) Install a new snap-ring to hold the output
shaft pocket bearing onto the output shaft.
Fig. 65 OUTPUT SHAFT POCKET BEARING
1 - GUIDE
2 - POCKET BEARING
21 - 110
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
COUNTERSHAFT
(1) Place third countershaft gear on the bench
with the synchro clutch ring up.
(2) Install third countershaft gear friction cone
onto third gear (Fig. 66).
Fig. 68 3-4 SYNCHRO ASSEMBLY
1 - SYNCHRO
2 - GEAR
Fig. 66 FRICTION CONE AND THIRD GEAR
1 - FRICTION CONE
2 - GEAR
3 - CLUTCH RING
(9) Install countershaft through the third gear/3-4
synchro assembly.
(10) Press countershaft into the 3-4 synchro
assembly (Fig. 69).
(3) Install third countershaft gear blocker ring
onto the friction cone (Fig. 67).
Fig. 67 BLOCKER RING ONTO FRICTION CONE
1 - BLOCKER RING
2 - GEAR
3 - FRICTION CONE
(4) Install 3-4 synchro assembly onto the blocker
ring/gear assembly (Fig. 68).
(5) Reverse the assembly on the bench.
(6) Install third countershaft gear bearing into the
third countershaft gear.
(7) Install 2-3 thrust washer onto the countershaft.
(8) Place third gear/3-4 synchro assembly in a shop
press.
Fig. 69 COUNTERSHAFT INTO 3-4 SYNCHRO
1 - COUNTERSHAFT
2 - 2-3 THRUST WASHER
3 - THIRD COUNTERSHAFT GEAR
DR
MANUAL TRANSMISSION - NV5600
21 - 111
MANUAL TRANSMISSION - NV5600 (Continued)
(11) Install fourth countershaft gear bearing sleeve
onto the output shaft.
(12) Press fourth countershaft bearing sleeve onto
the countershaft with Installer 8228 and a shop
press.
(13) Place fourth countershaft gear on the bench
with the synchro clutch ring up.
(14) Install fourth countershaft gear friction cone
onto fourth countershaft gear (Fig. 66).
(15) Install fourth countershaft gear blocker ring
onto the friction cone (Fig. 67).
(16) Install fourth countershaft gear bearing into
the fourth countershaft gear.
(17) Place sixth countershaft gear in the shop
press.
(18) Position fourth countershaft gear assembly
onto the sixth countershaft gear (Fig. 70).
Fig. 70 FOURTH COUNTERSHAFT ONTO SIXTH
COUNTERSHAFT GEAR
1 - FOURTH BEARING
2 - FOURTH COUNTERSHAFT GEAR
3 - SIXTH COUNTERSHAFT GEAR
(19) Install countershaft into the fourth/sixth countershaft gear assembly in the shop press.
(20) Press countershaft into sixth gear (Fig. 71).
CAUTION: Gear and shaft must be aligned while
pressing or the gear will bind on the shaft.
Fig. 71 COUNTERSHAFT INTO SIXTH GEAR
1 - COUNTERSHAFT
2 - SIXTH COUNTERSHAFT GEAR
3 - 3-4 SYNCHRO
(21) Place fifth countershaft gear into the shop
press.
21 - 112
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(22) Install countershaft into the fifth countershaft
gear and press countershaft into fifth gear (Fig. 72).
CAUTION: Gear and shaft must be aligned while
pressing or the gear will bind on the shaft.
(23) Place front countershaft bearing onto the
countershaft.
(24) Install front countershaft bearing onto the
countershaft with Installer 8236 and Handle C-4171.
(25) Install a new snap-ring to hold the front
countershaft bearing onto the countershaft.
(26) Place rear countershaft bearing onto the countershaft.
INPUT SHAFT
(1) Place the input shaft bearing onto the input
shaft.
(2) Install input shaft bearing with Installer
MD998805 (Fig. 73).
Fig. 72 COUNTERSHAFT TO FIFTH
COUNTERSHAFT GEAR
1 - COUNTERSHAFT
2 - FIFTH COUNTERSHAFT GEAR
Fig. 73 INPUT SHAFT BEARING
1 - INSTALLER
2 - INPUT SHAFT BEARING
MANUAL TRANSMISSION - NV5600
DR
21 - 113
MANUAL TRANSMISSION - NV5600 (Continued)
(3) Position the input shaft bearing oil guide on
the input shaft (Fig. 74).
Fig. 75 OUTPUT SHAFT POCKET BEARING RACE
1 - HANDLE
2 - INPUT SHAFT
3 - INSTALLER
Fig. 74 INPUT SHAFT OIL GUIDE
1 - INPUT SHAFT
2 - INPUT SHAFT OIL GUIDE
(4) Install input shaft bearing oil guide with
Installer MD998805.
(5) Place the output shaft pocket bearing race in
the input shaft.
(6) Install output shaft pocket bearing race into
the input shaft with Installer C-4628 and Handle
C-4171 (Fig. 75).
CLUTCH HOUSING
(1) Install input shaft bearing race so that the
bearing race protrudes 0.3 in. above the front surface
of the clutch housing. Install bearing race with
Remover/Installer 8237 and Handle C-4171.
(2) Install countershaft front bearing race into the
clutch housing so that the bearing race protrudes 0.4
in. above the front surface of the clutch housing.
Install bearing race with Remover 6061-1 and Handle C-4171.
(3) Install countershaft oil guide and spacer into
the countershaft front bearing bore in the clutch
housing (Fig. 76).
(4) Clean all old sealer from the input shaft
retainer and the clutch housing but DO NOT apply
Fig. 76 OIL GUIDE AND SPACER
1 - 0.3 IN. BEYOND FLUSH
2 - 0.4 IN. BEYOND FLUSH
new sealer at this time. New sealer will be applied
after all the preload measurements are made and
end-play shims are installed.
21 - 114
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
NOTE: Do not replace the input shaft seal at this
time. A new seal will be installed after all the preload measurements are made and endplay shims
are installed.
(5) Install countershaft into the Support Stand
8246 and verify that all gears are meshed with their
mates on the output shaft (Fig. 78).
(5) Install input shaft retainer onto the clutch
housing and install bolts to hold the input shaft
retainer.
GEARTRAIN
(1) Install
(2) Install
shaft.
(3) Install
gear friction
(4) Install
77).
input shaft into Support Stand 8246.
fifth gear friction cone onto the input
fifth gear blocker ring onto the fifth
cone.
output shaft into the input shaft (Fig.
Fig. 78 COUNTERSHAFT WITH OUTPUT SHAFT
1 - COUNTERSHAFT
2 - OUTPUT SHAFT
3 - SUPPORT STAND
Fig. 77 OUTPUT SHAFT AND INPUT SHAFT
1 - OUTPUT SHAFT
2 - INPUT SHAFT
3 - SUPPORT STAND
MANUAL TRANSMISSION - NV5600
DR
21 - 115
MANUAL TRANSMISSION - NV5600 (Continued)
(6) Install Fixture 8232 to the output shaft and
countershaft.
(7) Install Holding Tool 8242 onto the 5-6 synchro
and tighten the screw to hold the 5-6 synchro
together during the remainder of the installation procedure.
(8) Attach a engine crane or equivalent to Fixture
8232 and move the geartrain from the Support Stand
8246 to the clutch housing (Fig. 79).
Fig. 80 SHIFT RAILS INSTALLED
1 - SHIFT RAILS
(11) With the geartrain approximately 1/4 in. from
the clutch housing, remove Holding Tool 8242 from
the 5-6 synchro (Fig. 81).
Fig. 79 GEARTRAIN FIXTURE
1 - FIXTURE
2 - SUPPORT STAND
(9) Install shift forks and rails onto the geartrain
(Fig. 80).
NOTE: The closest shift arm to the geartrain is for
Reverse. The next is 5-6, then 3-4 and then 1-2
when moving out from the geartrain.
(10) Install geartrain and shift rails into the clutch
housing. Lower the geartrain and rails into the housing slowly while guiding input shaft through input
shaft seal. Avoid any binds on the shift rails, forks
and synchros as the rails enter their bushings.
CAUTION: Do not damage input shaft seal with the
input shaft splines.
Fig. 81 HOLDING TOOL
1 - HOLDING TOOL
2 - 5-6 SYNCHRO
(12) Install 5-6 crossover bracket and arm to the
shift rails and the clutch housing.
21 - 116
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(13) Lower geartrain the remainder of the way
into the clutch housing.
(14) Install the 5-6 crossover bracket bolts and
tighten to 28 N·m (20 ft. lbs.) (Fig. 82).
Fig. 82 5-6 CROSSOVER BRACKET BOLTS
1 - 5-6 CROSSOVER BRACKET
(15) Remove engine crane and Fixture 8232 from
the output shaft and the countershaft.
Fig. 83 LIFT FIXTURE
1 - FIXTURE
2 - TRANSMISSION CASE
TRANSMISSION GEAR CASE
(1) Install rear output shaft bearing race into the
transmission gear case with Installer C-4308 and
Handle C-4171.
(2) Install rear countershaft bearing race into the
transmission gear case with Installer 8153 and Handle C-4171.
(3) Install Fixture 8232 to the transmission gear
case.
NOTE: Shift socket must be loose on the shift shaft
and is rotated a minimum of 90° from its normal
position. This will ensure enough clearance to
install the transmission gear case.
(4) Apply sealant to the clutch housing.
(5) Attach an engine crane or equivalent to Fixture
8232 and install the transmission gear case onto the
clutch housing (Fig. 83).
(6) Install clutch housing bolts and tighten to 48
N·m (35 ft.lbs.).
(7) Install shift socket roll pin with a suitable 6
mm (7/32 in.) punch and hammer.
MAINSHAFT AND COUNTERSHAFT ENDPLAY
(1) With transmission in vertical position, use
Socket 6993 to rotate the shafts and seat the bearings.
(2) Measure mainshaft endplay with Dial Indicator
Set C-3339 and Extension Rod 8161 installed onto
the rear of the transmission gear case (Fig. 84).
Fig. 84 MEASURE MAINSHAFT ENDPLAY
1 - DIAL INDICATOR
2 - EXTENSION ROD
3 - MAIN SHAFT
DR
MANUAL TRANSMISSION - NV5600
21 - 117
MANUAL TRANSMISSION - NV5600 (Continued)
(3) Measure countershaft end-play with Dial Indicator Set C-3339 and Extension Rod 8161 installed
onto the rear of the transmission gear case (Fig. 85).
Fig. 86 REVERSE SHIFT FORK AND SYNCHRO
1 - REVERSE SYNCHRO
2 - REVERSE SHIFT FORK
Fig. 85 MEASURE COUNTERSHAFT END-PLAY
1 - EXTENSION ROD
2 - DIAL INDICATOR
3 - COUNTERSHAFT
(4) Rotate transmission into a horizontal position
and remove the input shaft retainer.
(5) Install shims necessary to achieve an end-play
of 0-0.10 mm (0-0.004 in.) for the mainshaft and
countershaft.
(2) Install roll-pin securing the reverse shift fork
to the reverse shift rail with 6 mm (7/32 in.) punch
and a hammer.
(3) Install reverse gear bearing sleeve onto the
output shaft with Installer 6446 if necessary (Fig.
87).
NOTE: Countershaft shims go between the bearing
race and spacer. Mainshaft shims go into the input
shaft retainer.
(6) Install a new input shaft seal into the input
shaft retainer with Installer C-4965.
(7) Install input shaft oil guide with C-3972-A and
Handle C-4171.
(8) Apply sealer to the input shaft retainer and
install retainer onto the clutch housing. Install bolts
and tighten to 28 N·m (20 ft.lbs.).
REVERSE GEAR
(1) Install reverse shift fork and synchronizer as
an assembly onto the reverse shift rail and output
shaft (Fig. 86).
NOTE: Raised square shoulder and snap-ring on
the synchro face the case.
Fig. 87 REVERSE BEARING SLEEVE
1 - REVERSE GEAR BEARING SLEEVE
21 - 118
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(4) Install reverse gear, reverse gear synchronizer
cone, reverse gear outer blocker ring and reverse
gear bearing (Fig. 88).
Fig. 89 OUTPUT SHAFT BEARING AND THRUST
WASHER
1 - OUTPUT SHAFT BALL BEARING
2 - THRUST WASHER
(11) Install reverse idler gear rear bearing, bearing
spacer, front bearing, and front thrust washer onto
the idler gear shaft.
(12) Install idler and reverse countershaft gears
together (Fig. 90).
Fig. 88 REVERSE GEAR COMPONENTS
1
2
3
4
-
REVERSE GEAR
REVERSE BEARING
BLOCKER RING
FRICTION CONE
(5) Install output shaft ball bearing assembly and
reverse thrust washer onto the output shaft (Fig. 89).
NOTE: Raised shoulder on thrust washer faces
away from the reverse gear.
(6) Install a new output shaft nut onto the output
shaft.
(7) With Wrench 8226 on the output shaft nut and
Socket 6993 or 6984 holding the output shaft, tighten
the nut to 339 N·m (250 ft.lbs.).
(8) Stake nut into the slot in the output shaft with
a 9 mm (5/16 in.) punch.
(9) Press countershaft reverse gear into the sleeve
with a shop press.
(10) Install reverse countershaft rear bearing onto
the countershaft reverse gear assembly with Installer
C-4652 and Handle C-4171.
Fig. 90 REVERSE IDLER AND COUNTERSHAFT
GEARS
1 - REVERSE IDLER GEAR
2 - COUNTERSHAFT REVERSE GEAR
DR
MANUAL TRANSMISSION - NV5600
21 - 119
MANUAL TRANSMISSION - NV5600 (Continued)
(13) Install reverse idler thrust washer from the
reverse idler.
(14) Install crossover cam rollers and pin (Fig. 91).
Fig. 91 CROSSOVER CAM ROLLERS AND PIN
1 - CROSSOVER CAM PIN
2 - CROSSOVER CAM ROLLERS
EXTENSION/ADAPTER HOUSING
(1) Install extension housing bushing with
Installer 8156 and Handle C-4171, if necessary. The
oil feed hole must be at the 12 o’clock position when
installed.
(2) On 4X2 vehicles, install extension housing seal
with Installer 8154 and Handle C-4171, with the
weep hole at the bottom.
Fig. 92 Measure Height of Reverse Countershaft
1 - MEASURE DISTANCE FROM RACE TO GAUGE BAR
NOTE: Drain hole located in the dust boot portion
of the seal must face downward ( toward the
ground) when installed.
(3) On 4X4 vehicles, install adapter housing seal
with Installer C-3860-A and Handle C-4171.
(4) Install the crossover cam bushing into the
extension/adapter housing with Installer 8239 and
Handle C-4171.
(5) Clean the rear of the transmission case of all
sealer.
(6) Install reverse countershaft gear bearing race
onto the reverse countershaft gear bearing.
(7) Measure the distance from the back of the
bearing race to Gauge Bar 6311 (Fig. 92).
(8) Measure thickness of the gauge bar and record
the total of the two measurements.
(9) Clean all the sealer from the extension/adapter
housing.
(10) Place Gauge Bar 6311 across the housing face.
Measure the distance from the top of the bar to the
bottom of the reverse countershaft bearing race bore
(Fig. 93).
(11) Subtract thickness of the gauge bar from the
measurement and record the result.
Fig. 93 MEASURE DEPTH OF REVERSE
COUNTERSHAFT GEAR BEARING RACE BORE
1 - GAUGE BAR TO BEARING RACE BORE MEASUREMENT
(12) The difference between the two measurements is
the end-play for the reverse countershaft gear assembly.
(13) Install shims to achieve 0.15-0.25 mm (0.0060.010 in.) end-play for the reverse countershaft gear
assembly into the reverse countershaft bearing race
bore.
21 - 120
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
(14) Use Installer to install the reverse countershaft bearing race into the extension/adapter housing.
(15) Install back-up lamp switch into the extension/adapter housing and tighten to 28 N·m (20
ft.lbs.).
(16) Install crossover cam into the extension/
adapter housing.
(17) Install bolt to hold the crossover cam to the
extension/adapter housing (Fig. 94).
(20) Install extension/adapter housing onto the
transmission case.
(21) Install bolts to hold the extension/adapter
housing onto the transmission gear case. Tighten
bolts to 48 N·m (35 ft.lbs.).
(22) Install shift rail blocker bolt and tighten bolt
to 55 N·m (41 ft.lbs.).
(23) Install primary shift rail detent plunger,
spring and plug into the transmission case. Tighten
detent plug to 47.5 N·m (35 ft.lbs.).
(24) Install shift tower onto the transmission case
and tighten bolts to 9 N·m (7 ft.lbs.).
INSTALLATION
NOTE: If installing a new transmission, use all components supplied with the transmission. If a new
shift tower is supplied with the new transmission,
do not re-use the original shift tower.
Fig. 94 CROSSOVER CAM BOLT
1 - CROSSOVER CAM
2 - BOLT
3 - EXTENSION HOUSING
(18) Install crossover detent plunger, spring and
plug into the extension/adapter housing. Tighten the
plug to 47.5 N·m (35 ft.lbs.) (Fig. 95).
Fig. 95 CROSSOVER CAM DETENT PLUG
1 - DETENT PLUG
2 - EXTENSION HOUSING
(19) Apply sealer to the surface of the transmission case.
(1) Apply a light coat of Mopar high temperature
bearing grease or equivalent to contact surfaces of
following components:
• input shaft splines.
• release bearing slide surface of front retainer.
• release bearing bore.
• release fork.
• release fork ball stud.
• propeller shaft slip yoke.
(2) Apply sealer to threads of bottom PTO cover
bolt and install bolt in case.
(3) Mount transmission on jack and position transmission under vehicle.
(4) Raise transmission until input shaft is centered
in clutch disc hub.
(5) Move transmission forward and start input
shaft in clutch disc and pilot bushing/bearing.
(6) Work transmission forward until seated against
engine block. Do not allow transmission to remain
unsupported after input shaft has entered clutch
disc.
(7) Install and tighten transmission-to-engine
block bolts.
(8) Install clutch slave cylinder.
(9) Connect backup light switch wires.
(10) Position transmission harness wires in clips
on transmission.
(11) Install transmission mount on transmission or
rear crossmember.
(12) Install rear crossmember.
(13) Remove transmission jack and engine support
fixture.
(14) Fill transmission with required lubricant (Fig.
96). Check lubricant level in transfer case if
equipped.
MANUAL TRANSMISSION - NV5600
DR
21 - 121
MANUAL TRANSMISSION - NV5600 (Continued)
FOUR WHEEL DRIVE
Fig. 96 FILL PLUG
1 - FILL PLUG
TWO WHEEL DRIVE
(1) Install propeller shaft with referece marks
aligned.
(2) Install exhaust system components.
(3) Remove support and lower vehicle.
(4) Shift transmission into third gear.
(5) Clean the mating surfaces of shift tower and
isolator plate with suitable wax and grease remover.
(6) Apply Mopar Gasket Maker or equivalent to
sealing surface of the transmission case. Do not over
apply sealant.
(7) Install isolator plate onto the transmission case
metal side down.
(8) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and top
of isolator plate.
(9) Verify shift tower, isolator plate and the shift
socket are properly aligned.
(10) Install bolts to hold the shift tower to the isolator plate and the transmission case. Tighten bolts
to 10.2–11.25 N·m (7.5–8.3 ft. lbs.).
(11) Install shift boot and bezel.
(1) Install and secure transfer case on the transmission jack.
(2) Raise and align transfer case input gear with
transmission mainshaft.
(3) Move transfer case forward and seat it on
adapter.
(4) Install and tighten transfer case mounting nuts
to 41-47 N·m (30-35 ft. lbs.) if case has 3/8 studs. If
case has 5/16 studs tighten to 30-41 N·m (22-30 ft.
lbs.).
(5) Connect transfer case shift lever to range lever
on transfer case.
(6) Install propeller shafts with reference marks
aligned.
(7) Install transfer case skid plate, if equipped,
and crossmember. Tighten attaching bolts/nuts to 41
N·m (30 ft. lbs.).
(8) Install exhaust system components.
(9) Remove support and lower vehicle.
(10) Shift transmission into third gear.
(11) Clean the mating surfaces of shift tower, isolator plate and transmission case with suitable wax
and grease remover.
(12) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the transmission case. Do not
over apply sealant.
(13) Install isolator plate onto the transmission
case, metal side down.
(14) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and top
of isolator plate.
(15) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
(16) Install the bolts to hold the shift tower to the
isolator plate and the transmission case. Tighten the
shift tower bolts to 10.2-11.25 N·m (7.5-8.3 ft. lbs.).
(17) Install shift lever boot and bezel.
21 - 122
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
SPECIFICATIONS - NV5600
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Plug, Crossover Cam and Detent
48
35
-
Bolt, Input Retainer
28
20
-
Bolt, 5-6 Crossover Bracket
28
20
-
Bolt, Clutch Housing
48
35
-
Bolt, Extension/Adapter Housing
48
35
-
Bolt, Shift Tower
9
7
80
Switch, Back-up Lamp
28
20
-
Bolt, Shift Blocker
55
41
-
Bolt, PTO Cover
40
30
-
Pivot, Clutch Release Lever
22
16
-
Plug, Fill
30
22
-
Nut, Output Shaft
339
250
-
SPECIAL TOOLS
REMOVER 8155
HANDLE C-4171
INSTALLER 8156
INSTALLER C-3972-A
INSTALLER 8154
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
JAWS 6451
WRENCH 8226
SOCKET 6984
INSTALLER 6061
SOCKET 6984
INSTALLER 6448
PULLER 6444
INSTALLER C-4308
ROD EXTENSION 8161
JAWS 6447
21 - 123
21 - 124
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
REMOVER 8233
FIXTURE 8227
REMOVER 8234
INSTALLER 8228
GUIDE 8235
FIXTURE 8230
INSTALLER 8236
FIXTURE 8232
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
INSTALLER/REMOVER 8237
FIXTURE 8241
HOLDING 8242
INSTALLER/REMOVE 8238
REMOVER 8243
INSTALLER 8239
REMOVER 8240
PULLER 8244
21 - 125
21 - 126
MANUAL TRANSMISSION - NV5600
DR
MANUAL TRANSMISSION - NV5600 (Continued)
DIAL INDICATOR C-3339
REMOVER 8245
INSTALLER C-4965
REMOVER L-4418
SUPPORT STAND 8246
PULLER C-293-PA
REMOVER 8262
ADAPTERS C-293-52
INSTALLER MD998805
REMOVER 8271
DR
MANUAL TRANSMISSION - NV5600
21 - 127
ADAPTER HOUSING SEAL
INSTALLATION
REMOVAL
(1) Install extension housing bushing
Installer 8156 and Handle C-4171 (Fig. 98).
with
(1) Raise and support vehicle.
(2) Mark propeller shaft and yokes for installation
reference and remove shaft.
(3) Remove the transfer case.
(4) Remove the adapter housing seal with a pry
tool or slide hammer with a screw.
INSTALLATION
(1) Install adapter housing seal with Installer and
Handle C-4171.
(2) Install transfer case.
(3) Install propeller shaft with reference marks
aligned.
(4) Check fluid level.
(5) Remove support and lower vehicle.
Fig. 98 Install Extension Housing Bushing
EXTENSION HOUSING SEAL
REMOVAL
(1) Mark propeller shaft and pinion yoke for
installation reference and remove the propeller shaft.
(2) Remove extension housing seal with a pry tool
or a slide hammer and screw.
(3) Remove extension housing bushing with
Remover 8155 (Fig. 97).
1 - HANDLE
2 - INSTALLER
3 - BUSHING
(2) Install extension housing seal with Installer
8154 and Handle C-4171 (Fig. 99).
Fig. 99 EXTENSION HOUSING SEAL INSTALLER
1 - INSTALLER
2 - HANDLE
Fig. 97 EXTENSION HOUSING BUSHING REMOVAL
1 - REMOVER
(3) Install propeller shaft with reference marks
aligned.
(4) Check and fill transmission.
21 - 128
MANUAL TRANSMISSION - NV5600
DR
SHIFT COVER
REMOVAL
(1) Shift transmission into Neutral.
(2) Unscrew and remove the shift lever extension
from the shift
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(4) Remove the bolts holding the shift tower to the
isolator plate and transmission gear case.
(5) Remove the shift tower (Fig. 100) and isolator
plate (Fig. 101) from the transmission.
Fig. 101 SHIFT TOWER ISOLATOR PLATE
1 - ISOLATOR PLATE
2 - TRANSMISSION
INSTALLATION
Fig. 100 SHIFT TOWER
1 - SHIFT TOWER
2 - TRANSMISSION
(1) Shift transmission into third gear.
(2) Clean the mating surfaces of shift tower, isolator plate and transmission gear case with suitable
wax and grease remover.
(3) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the transmission. Do not over
apply sealant.
(4) Install isolator plate onto the transmission,
metal side down.
(5) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and isolator plate.
(6) Verify shift tower, isolator plate and shift tower
bushings are properly aligned.
(7) Install shift tower bolts and tighten the shift
tower bolts to 8-10 N·m (7-9 ft. lbs.).
(8) Install shift lever extension, shift boot and
bezel.
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