Dodge dakota 2002 Service Manual page 1529

9 - 280 ENGINE 5.9L DIESEL
ENGINE 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 282
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING—ENGINE
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . 283
DIAGNOSIS AND TESTING—SMOKE
DIAGNOSIS CHARTS . . . . . . . . . . . . . . . . . 285
DIAGNOSIS AND TESTING—CYLINDER
COMPRESSION/LEAKAGE TESTS . . . . . . . 288
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS . . . . . . . . 289
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS . . . . . . . . 289
STANDARD PROCEDURE—HYDROSTATIC
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
REMOVAL
REMOVAL—ENGINE
REMOVAL—CRANKCASE BREATHER
INSTALLATION
INSTALLATION—ENGINE
INSTALLATION—CRANKCASE BREATHER
SPECIFICATIONS
5.9L DIESEL . . . . . . . . . . . . . . . . . . . . . . . . 293
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
SPECIAL TOOLS
5.9L DIESEL ENGINE
ENGINE DATA PLATE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 297
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 298
CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 298
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
CLEANING
CLEANING—CYLINDER HEAD
CLEANING—CROSSHEADS
CLEANING—PUSHRODS
INSPECTION
INSPECTION - CYLINDER HEAD . . . . . . . . . 301
INSPECTION—CROSSHEADS
INSPECTION—PUSHRODS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 302
CYLINDER HEAD COVER(S)
REMOVAL
REMOVAL—CYLINDER HEAD COVER
REMOVAL—ROCKER HOUSING
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
ENGINE 5.9L DIESEL
TABLE OF CONTENTS
page
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. 292
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INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 304
INSTALLATION
INSTALLATION—CYLINDER HEAD COVER
INSTALLATION—ROCKER HOUSING
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
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
REMOVAL - CAMSHAFT
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 318
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS
INSTALLATION - CAMSHAFT . . . . . . . . . . . . 320
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING AND CRANKSHAFT
JOURNAL CLEARANCE
CRANKSHAFT AND GEAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 322
REMOVAL—GEAR
INSTALLATION - GEAR
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . 322
. . . . . 304
. . . . . . 317
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DR
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