Dodge Ram Truck 1500-2500-3500. Manual — part 1415
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 and
remove rocker arm (1) and pedestal (2) from cylin-
der head. Mark the arms and pedestals so they
can be installed in their original position.
CAUTION: When removing the rocker arms, the
sockets 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. Mark
them so they can be installed in their original posi-
tion.
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.
CLEANING
Clean all components in a suitable solvent. If neces-
sary, use a wire brush or wheel to remove stubborn
deposits. Rinse in hot water and blow dry with com-
pressed air. Inspect oil passages in rocker arms and
pedestals. Apply compressed air to lubrication orifices
to purge contaminants.
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ENGINE - 5.9L DIESEL - SERVICE INFORMATION
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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.
Push Rods
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ENGINE - 5.9L DIESEL - SERVICE INFORMATION
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Inspect the push rod ball and socket for signs of scor-
ing. Check for cracks where the ball and the socket
are pressed into the tube.
Roll the push rod on a flat work surface with the
socket end hanging off the edge. Replace any push
rod that appears to be bent.
Crossheads
Inspect the crossheads for cracks and/or excessive
wear on rocker lever and valve tip mating surfaces.
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 loca-
tions. 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. FOR EARLY BUILDS Install cylinder head cover and reusable gasket (Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
6. FOR LATE BUILDS Install cylinder head cover.
7. Connect battery negative cables.
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ENGINE - 5.9L DIESEL - SERVICE INFORMATION
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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).
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).
3. Consult the parts catalog for the proper head gas-
kets 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 jour-
nals with clean cloth. Cover cloth with waterproof
tape.
DR/DH
ENGINE - 5.9L DIESEL - SERVICE INFORMATION
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