Chrysler 1991 Service Manual Supplement page 80

V
5.9L (DIESEL) ENGINES 9 - 17
CYLINDER HEAD
The cylinder heads on the 1991V2 engine are a new
design and can not be interchanged with earlier mod-
els.
REMOVAL
(1) Drain the coolant. Do not waste reusable cool-
ant. If the solution is clean, drain the coolant into a
clean container for reuse.
(2) Drain the engine oil. Dispose of the used oil
properly.
(3) Disconnect the radiator and heater hoses (refer
to Group 7, Cooling System).
(4) Remove the turbocharger (Fig. 1).
(5) Remove the exhaust manifold (Fig. 4).
Fig. 4 Exhaust Minifold
(6) Remove the fuel lines and injector nozzles (refer
to Group 14, Fuel System).
(7) Remove the valve covers (Fig. 5).
Fig. 5 Valve Cover
(8) Remove the rocker levers and push rods.
(9) Remove the fuel/water separator filter (Fig. 6).
Refer to Group 14, Fuel System, for the proper pro-
cedures.
Fig. 6 Fuel/Water Separator Filter
(10) If the engine is hot, remove the cylinder head
bolts in the sequence shown in Fig. 7. The removal
sequence is not important if the engine is cold. There
are 3 sizes of head bolts. Note the position of each
bolt for future installation.
(11) Remove the cylinder head and gasket from the
cylinder block.
J9109-36
Fig. 7 Cylinder Head Bolt Removal
Sequence—Cylinder Head Hot
INSPECTION
Remove the cup plugs and inspect the coolant pas-
sages. A large build up of rust and lime will require
removal of the cylinder block for cleaning in a hot
tank.
Inspect the cylinder bores for damage or excessive
wear. Rotate the crankshaft so the piston is at Bot-
tom Dead Center (BDC) to inspect the bores.