Dodge Ram Truck 1500-2500-3500. Manual — part 1404
STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain the original center line.
Damaged or worn threads can be repaired. Essentially, this repair consists of:
•
Drilling out worn or damaged threads.
•
Tapping the hole with a special Heli-Coil Tap, or equivalent.
•
Installing an insert into the tapped hole to bring the hole back to its original thread size.
STANDARD PROCEDURE—HYDROSTATIC LOCK
CAUTION: DO NOT use the starter motor to rotate the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps below.
1. Disconnect the negative cable(s) from the battery.
2. Inspect air cleaner, induction system, and intake manifold to ensure system is dry and clear of foreign material.
3. Place a shop towel around the fuel injectors to catch any fluid that may possibly be under pressure in the cyl-
inder head. Remove the fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR -
REMOVAL).
4. With all injectors removed, rotate the crankshaft using the crankshaft barring tool (PN 7471–B).
5. Identify the fluid in the cylinders (coolant, fuel, oil, etc.).
6. Be sure all fluid has been removed from the cylinders.
7. Repair engine or components as necessary to prevent this problem from occurring again.
8. Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
9. Install fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).
10. Drain engine oil. Remove and discard the oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER -
REMOVAL).
11. Install the drain plug. Tighten the plug to 50 N·m (37 ft. lbs.) torque.
12. Install a new oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - INSTALLATION).
13. Fill engine crankcase with the specified amount and grade of oil (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - SPECIFICATIONS).
14. Connect the negative cable(s) to the battery.
15. Start the engine and check for any leaks.
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ENGINE - 5.9L DIESEL - SERVICE INFORMATION
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REMOVAL
REMOVAL - ENGINE
1. Disconnect both battery negative cables.
2. Disconnect engine grid heater harness at grid
heater relays.
3. Disconnect electrical connections from rear of alter-
nator.
4. Recover A/C refrigerant. (Refer to 24 - HEATING &
AIR
CONDITIONING/PLUMBING
-
STANDARD
PROCEDURE).
5. Raise vehicle on a hoist.
6. Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
7. Remove engine oil drain plug and drain engine oil.
8. Reinstall drain plug. Tighten to 50N·m (37 ft. lbs.)
torque.
9. Lower the vehicle.
10. Remove fan (3) and fan drive (2). Refer to (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
11. Remove fan shroud mounting bracket (3) and
shroud. Refer to (Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - REMOVAL).
12. Remove radiator upper hose.
13. Disconnect the coolant recovery bottle hose from
the radiator fill neck.
14. Disconnect heater core supply and return hoses
from the cylinder head fitting and coolant pipe.
15. Raise vehicle on a hoist.
16. Remove
transmission
and
transfer
case
(if
equipped).
17. Disconnect exhaust pipe from turbocharger exten-
sion pipe.
18. Disconnect engine harness to vehicle harness
connectors.
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ENGINE - 5.9L DIESEL - SERVICE INFORMATION
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19. Remove starter motor (2) (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
20. Remove flywheel/flexplate.
21. Remove transmission adapter.
22. Disconnect A/C suction/discharge hose from the rear of the A/C compressor.
23. Lower vehicle.
24. Disconnect lower radiator hose from radiator outlet.
25. Automatic transmission models:
26. Disconnect transmission oil cooler lines from in front of radiator using special tool #6931
27. Remove radiator. (Refer to 7 - COOLING/ENGINE/RADIATOR - REMOVAL).
28. If A/C equipped, disconnect A/C condenser refrigerant lines.
29. Disconnect charge air cooler piping.
30. Remove charge air cooler mounting bolts (1).
31. Remove charge air cooler (2) from vehicle.
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ENGINE - 5.9L DIESEL - SERVICE INFORMATION
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32. Remove the A/C condenser (1).
33. Remove damper and speed indicator ring from
front of engine.
34. Remove
lower
fan
shroud
bracket
(3)
from
engine.
35. Remove upper fan shroud brackets from engine.
36. Disconnect engine block heater connector.
37. Disconnect A/C compressor and pressure sensor
electrical connectors.
38. Remove the passenger battery ground cable from
the engine block. Remove the driver side battery
ground cable from the engine block.
39. Remove power steering pump from engine by
removing 3 bolts.
40. Disconnect the ECM power connector.
41. Disconnect the ECM ground wire from the hydro-
form screw.
42. Disconnect the fuel supply and return hoses.
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ENGINE - 5.9L DIESEL - SERVICE INFORMATION
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