Dodge ram truck 3500 1996 Service Manual page 1153

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5.9L (DIESEL) ENGINE 9 - 1 6 3
5.9L (DIESEL) ENGINE
INDEX
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GENERAL INFORMATION
OIL FILTER 163
PISTON GRADING 163
DESCRIPTION AND OPERATION
ENGINE DESCRIPTION 164
LUBRICATION SYSTEM 164
OIL P R E S S U R E REGULATOR VALVE 166
TIMING PIN 166
SERVICE PROCEDURES
CAM BORE REPAIR 173
CONNECTING ROD BEARING AND
CRANKSHAFT JOURNAL CLEARANCE 174
CRANKSHAFT REWORK 175
CYLINDER BLOCK CUP PLUG
REPLACEMENT 174
CYLINDER BLOCK REFACING . 170
CYLINDER BORE REPAIR 171
CYLINDER B O R E S — D E - G L A Z E 170
MAIN BEARING CLEARANCE 178
OIL FILTER 166
PISTON GRADING P R O C E D U R E 174
VALVE S E R V I C E 167
REMOVAL AND INSTALLATION
CAMSHAFT 189
CRANKSHAFT FRONT S E A L 195
CRANKSHAFT GEAR 197
CRANKSHAFT REAR S E A L HOUSING 196
CRANKSHAFT REAR S E A L 195
CRANKSHAFT 193
CYLINDER HEAD 182
ENGINE ASSEMBLY 180
ENGINE FRONT MOUNTS 178
G E N E R A L I N F O R M A T I O N
PISTON GRADING
When rebuilding an engine with the original cylin­
der block, crankshaft and pistons, make sure the pis­
tons are installed in the original cylinder.
If replacing the piston(s), make sure the replace­
ment piston(s) are the same grade as the original pis­
ton.
If a new cylinder block or crankshaft is used, the
piston grading procedure MUST be performed to
determine the proper piston grade for each cylinder.
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ENGINE REAR MOUNT 179
FLYWHEEL RING GEAR 197
GEAR HOUSING COVER 184
GEAR HOUSING 185
OIL FILTER BYPASS VALVE 198
OIL PAN AND SUCTION TUBE 191
OIL P R E S S U R E REGULATOR VALVE AND
SPRING 199
OIL PUMP 198
PISTON AND CONNECTING ROD ASSEMBLY . 192
ROCKER L E V E R S AND PUSH RODS 182
TAPPET 190
TIMING PIN HOUSING ASSEMBLY 186
TIMING PIN 186
VALVES AND VALVE SPRINGS 184
DISASSEMBLY AND ASSEMBLY
PISTON AND CONNECTING ROD ASSEMBLY . 200
ROCKER L E V E R S . 199
CLEANING AND INSPECTION
CAMSHAFT 205
CRANKSHAFT 208
CYLINDER BLOCK 206
CYLINDER HEAD 202
OIL C O O L E R ELEMENT AND GASKET 202
OIL PUMP 205
PISTON AND CONNECTING ROD ASSEMBLY . 207
TAPPET 204
VALVES AND VALVE SPRINGS 203
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT 209
SPECIFICATIONS
5.9L (DIESEL) ENGINE 210
OIL FILTER
When replacing the oil filter, use replacement filter
specified in your Operator's Manual.
CAUTION: The internal filtering medium of some
filters has been known to disintegrate. Debris from
failed filters may plug the piston oil cooling noz­
zles, resulting in scuffed pistons and eventual
engine failure.