Chrysler 1991 Service Manual Supplement page 78

5.9L (DIESEL) ENGINES 9 - 15
INSTALLATION
(1) If removed, install and tighten the rear engine
lifting bracket to 77 N-m (57 ft. lbs.) torque. Do not
exceed this torque valve.
(2) Check the data plate to verify that the replace-
ment engine is the same model and rating as the en-
gine that was removed.
(3) Install all accessories and brackets that had
been removed from the previous engine.
(4) Use the lifting brackets to lift the engine off of
the stand.
(5) Position the' engine in the chassis and install
the through bolt. Tighten the through bolt nut to 41
N-m (30 ft. lbs.) torque.
(6) Remove the covers or tape covering the engine
openings.
- (7) Connect the fuel lines to the lift pump and fuel
return.
(8) Connect all electrical connections.
(9) Connect the power steering lines.
(10) Raise and support the vehicle on a hoist.
(11) MANUAL TRANSMISSION-See Group 21,
Transmissions for the G360 Manual Transmission In-
stallation procedure.
(12) AUTOMATIC TRANSMISSION
CAUTION; If new flei plate is installed, remove
flashing from the engine back plate at the 5 and 7
o'clock positions.
(a) Rotate converter until alignment mark on the
converter is aligned with mark on drive plate. Off-
set holes in plate are next to 1/8 inch hole in inner
circle of drive plate (Fig. 8).
(b) Install bell housing bolts. Tighten the bolts to
41 N-m (30 ft. lbs.) torque.
(c) With the torque converter plate aligned to the
torque converter, install and tighten the bolts to 31
N-m (270 in. lbs.) torque.
(d) Install the converter housing access plate.
(e) Remove the transmission support.
(13) Connect the ground cable and tighten the nut
to 22 N # m (16 ft. lbs.) torque. Connect the solenoid
cable and tighten the nut to 5 N-m (44 in. lbs.)
torque.
(14) Connect the transmission cooler lines.
(15) Install the exhaust pipe to the exhaust system.
(16) Lower the vehicle.
(17) Install the A/C compressor and tighten the
bolts to 47 N # m (35 ft. lbs.) torque. If removed, con-
nect the clutch electrical wire.
(18) Install the alternator. Tighten the upper
mounting bolts to 24 N-m (18 ft. lbs.) torque. Now
tighten the lower mounting bolts to 43 N-m (32 ft.
lbs.) torque. Connect all wires.
(19) Install the radiator, fan/fan clutch assembly
and fan shroud (refer to Group 7, Cooling Systems
for the proper procedures). Connect the radiator
hoses.
(20) Position the intercooler inlet duct to the turbo-
charger and the intercooler (Fig. 4). With the clamps
in position, tighten the clamp nut to 8 N-m (72 in.
lbs.) torque.
(21) Position the intercooler outlet duct to the air
inlet housing and the intercooler (Fig. 4). With the
clamps in position, tighten the clamp nut to 8 N-m
(72 in. lbs.) torque.
(22) Connect the air intake tube to the turbo-
charger inlet flange and the air cleaner housing.
Tighten the clamps to 8 N-m (72 in. lbs.) torque.
(23) Install the exhaust pipe to the turbocharger.
Tighten the steady rest clamp to 8 N-m (72 in. lbs.)
torque.
(24) Make sure the air intake and exhaust pipe
connections are tight and free of leaks.
(25) Fill the engine with the required amount of
clean engine lubricating oil (see Group 0, Lubrication
and Maintenance).
(26) Fill the cooling system with a mixture of 50%
water and 50% ethylene-glycol base antifreeze (refer
Group 7, Cooling System for the proper procedure).
(27) Install the battery and connect the battery ca-
bles.
(28) Check the oil level after the engine has run for
2 or 3 minutes. Oil held in the oil filter and oil pas-
sages will cause the oil level in the pan to be lower.
(29) Operate the engine at idle for 5 to 10 minutes
and check for leaks and loose parts.
ROCKER
LEVERS/PUSH
RODS
REMOVAL
(1) Remove the valve covers (Fig. 1).
(2) Loosen the adjusting screw locknuts. Loosen the
adjusting screws until they stop (Fig. 2).
(3) Remove the bolts from the rocker lever pedes-
tals. Remove the pedestals and rocker lever assem-
blies (Fig. 2).
(4) Remove the push rods.
DISASSEMBLE-ROCKER LEVERS
(1) Remove the retaining rings and thrust washers
(Fig. 2).
(2) Remove the rocker levers (Fig. 2). Do not disas-
semble the rocker lever shaft and pedestal. The ped-
estal and shaft must be replaced as an assembly.
(3) Remove the locknut and adjusting screw (Fig.
2).
(4) Clean all parts in a strong solution of laundry
detergent in hot water.
(5) Use compressed air to dry the parts after rins-
ing in clean hot water. The pedestals are made from