Dodge Ram Truck 1500-2500-3500. Manual — part 1407
49. Install the cooling fan (3) and fan drive (2). (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
50. Install the fan shroud mounting bracket (3) and
shroud. (Refer to 7 - COOLING/ENGINE/RADIA-
TOR FAN - INSTALLATION).
51. Install the windshield washer bottle.
52. Install the upper radiator hose and clamps.
53. Raise vehicle.
54. Change oil filter and install new engine oil.
55. Fill the cooling system with coolant. (Refer to 7 -
COOLING - STANDARD PROCEDURE).
56. Connect grid heater harness at grid heater relays.
57. Connect electrical connections to rear of alterna-
tor.
58. Start the engine and inspect for engine oil, cool-
ant, and fuel leaks.
INSTALLATION - CRANKCASE BREATHER - EARLY BUILD
1. Install a new o-ring onto the breather element.
2. Lubricate o-ring and install into cylinder head cover. Torque capscrews to 10 N·m (89 in. lbs.).
3. Connect breather tube and lube oil drain tube.
4. Install breather cover. Torque to 24 N·m (18 ft. lbs.)
5. Install oil fill cap.
9 - 2550
ENGINE - 5.9L DIESEL - SERVICE INFORMATION
DR/DH
SPECIFICATIONS
SPECIFICATIONS - 5.9L DIESEL
GENERAL DESCRIPTION
DESCRIPTION
SPECIFICATION
Engine Type
In-Line 6 Cyl. Turbo Diesel
Displacement
5.9 Liters
359 ( Cubic Inches)
Bore
102.0 mm (4.02 in.)
Stroke
120.0 mm (4.72 in.)
Compression Ratio
17.2:1
325 H.P
Cylinder Pressure (Minimum)
350 psi.
Horsepower High Output 48 RE A/T and NV 5600 or G
56 M/T
325 HP @ 2900 RPM
Torque Rating High Output ( 48RE A/T and NV 5600 or
G 56 M/T)
600 LB-FT @ 1400 RPM
Lubrication System
Pressure Feed-Full Flow With Bypass Valve
Firing Order
1-5-3-6-2-4
Cylinder Block
Cast Iron
Crankshaft
Induction Hardened Forged Steel
Cylinder Head
Cast Iron With Valve Seat Inserts
Combustion Chambers
High Swirl Bowl
Camshaft
Chilled Ductile Iron
Pistons
Cast Aluminum
Connnecting Rods
Cross Rolled Micro Alloy
PISTONS
DESCRIPTION
SPECIFICATION
Metric
Standard
Skirt Diameter
101.775 - 101.793 mm
4.007 - 4.008 in.
Ring Groove Clearance
Intermediate (Min)
0.045 mm
.0018 in
(Max)
0.095 mm
0.0037 in.
Oil Control ( Min)
0.040 mm
.0016 in.
(Max)
0.085 mm
.0033 in.
DR/DH
ENGINE - 5.9L DIESEL - SERVICE INFORMATION
9 - 2551
PISTON PINS
DESCRIPTION
SPECIFICATION
Metric
Standard
Pin Diameter ( Min)
39.990 mm
1.5744 in.
(Max)
40.003 mm
1.5749 in.
Bore Diameter (Min)
40.006 mm
1.5750 in.
(Max)
40.012
1.5753 in.
PISTON RINGS
DESCRIPTION
SPECIFICATION
Metric
Standard
Ring Gap
Top Ring
0.26 - 0.36mm
0.010 - 0.014 in.
Intermediate
0.85 - 1.15 mm
0.033 - 0.045in.
Oil Control
0.25 - 0.55 mm
0.010 - 0.21 in.
CONNECTING RODS
DESCRIPTION
SPECIFICATION
Metric
Standard
Pin Bore Diameter (Min. w/ bushing
installed)
40.019 mm
1.5764 in.
Pin Bore Diameter (Max. w/ bushing
installed)
40.042 mm
1.5765 in.
Side Clearance (Min)
0.100 mm
0.004 in.
Side Clearance (Max)
0.330 mm
0.013 in.
CYLINDER HEAD
DESCRIPTION
SPECIFICATION
Overall Flatness End To End (max)
0.305 mm (0.012 in.)
Overall Flatness Side To Side (Max)
0.076 mm (0.003 in.)
Intake Valve Seat Angle
30°
Exhaust Valve Seat Angle
45°
Valve Stem Diameter
(Min)
6.96 mm (0.2740 in.)
(Max)
7.01 mm (0.2760 in.)
Valve Rim Thickness (Min.)
0.79 mm (0.031 in.)
OIL PRESSURE
SPECIFICATION
SPECIFICATION
At Idle
69 kPa (10 psi)
@ 2500 rpm
207 kPa (30 psi)
Regulating Valve Opening Pressure
517 kPa (75 psi)
Oil Filter Bypass Pressure Setting
344.75 kPa (50 psi)
9 - 2552
ENGINE - 5.9L DIESEL - SERVICE INFORMATION
DR/DH
TORQUE
TORQUE CHART 5.9L DIESEL ENGINE
DESCRIPTION
N·m
In. Lbs.
Ft. Lbs.
Connecting Rod—Bolts
Step 1
30
—
22
Step 2
60
—
44
Step 3
Rotate 60 degrees
Crankshaft Main Cap—Bolts
Step 1
50
37
Step 2
80
59
Step 3
Rotate 90°
Cylinder Head—Bolts
Step 1
70
—
52
Step 2
Back off 360 degrees
Step 3
105
—
77
Step 4 Verify
105
—
77
Step 5
Rotate All Bolts 1/4 Turn
Cylinder Head Cover Bolts
24
—
18
Breather Cover Bolts
24
—
18
HPC Nut
50
—
37
Flexplate to Engine
137
—
101
Flywheel to Engine ( NV 5600 )
137
—
101
Flywheel/Crankshaft Adapter
137
—
101
G 56 Dual Mass Flywheel
Fuel Delivery Lines—Banjo
24
—
18
Fuel Drain Line—Banjo
24
—
18
Fuel line—rail to cylinder head
30
—
22
Fuel line—pump to fuel rail
37
—
27
Injector fuel line brace
24
—
18
#6 Fuel Line Brace Nut at Lift Bracket Stud
24
—
18
Fuel rail holddown bolt
24
—
18
Oil Pan—Bolts
28
—
21
Oil Pan—Drain Plug
50
—
37
Oil Pressure Regulator—Plug
80
—
59
Oil Pressure Switch
18
—
13
Oil Pump—Bolts
Step1
8
—
6
Step2
24
—
18
Oil Suction Tube (Flange)—Bolts
24
—
18
Oil Suction Tube (Brace)—Bolt
43
—
32
Rocker Arm/Pedestal—Bolts
36
—
27
DR/DH
ENGINE - 5.9L DIESEL - SERVICE INFORMATION
9 - 2553
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