Dodge Ram Truck 1500-2500-3500. Manual — part 1425

mounting bolt hole. Grooves at both ends of the rocker shaft supply oil through the rocker arm where the oil travels
to the push rod and socket balls and.

DIAGNOSIS AND TESTING—ENGINE OIL PRESSURE

1. Remove the 1/8 npt plug from the top of the oil filter housing.

2. Install Oil Pressure Line and Gauge Tool C-3292 with a suitable adapter.

3. Start engine and warm to operating temperature.

4. Record engine oil pressure and compare with engine oil pressure chart.

CAUTION: If engine oil pressure is zero at idle, DO NOT RUN THE ENGINE.

Engine Oil Pressure (MIN)

At Idle

68.9 kPa (10 psi)

At 2500 rpm

206.9 kPa (30 psi)

If minimum engine oil pressure is below these ranges, (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).

5. Remove oil pressure gauge and install the 1/8 npt plug.

OIL

STANDARD PROCEDURE

STANDARD PROCEDURE - ENGINE OIL LEVEL

CAUTION: Do not overfill crankcase with engine
oil, oil foaming and oil pressure loss can result.

To ensure proper lubrication of an engine, the engine
oil must be maintained at an acceptable level. The
acceptable oil level is in the SAFE RANGE (3) on the
engine oil dipstick.

1. Position vehicle on level surface.

2. With engine OFF, allow approximately 15 minutes

for oil to settle to bottom of crankcase, remove
engine oil dipstick.

3. Wipe dipstick clean.

4. Replace dipstick and verify it is seated in the tube.

5. Remove dipstick, with handle held above the tip, take oil level reading.

6. Add oil only if level is below the SAFE RANGE area on the dipstick.

7. Replace dipstick.

STANDARD PROCEDURE - ENGINE OIL SERVICE

WARNING: HOT OIL CAN CAUSE PERSONAL INJURY.

NOTE: Change engine oil and filter at intervals specified in the owner’s manual.

1. Operate the engine until the water temperature reaches 60°C (140°F). Shut the engine off.

2. Use a container that can hold at least 14 liters (15 quarts) to hold the used oil. Remove the oil drain plug and

drain the used engine oil into the container.

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ENGINE - 5.9L DIESEL - SERVICE INFORMATION

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3. Always check the condition of the used oil. This can give you an indication of engine problems that might exist.

•

Thin, black oil indicates fuel dilution.

•

Milky discoloration indicates coolant dilution.

4. Clean the area around the oil filter head. Remove the filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER -

REMOVAL).

5. Install new oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - INSTALLATION).

6. Clean the drain plug and the sealing surface of the pan. Check the condition of the threads and sealing surface

on the oil pan and drain plug.

7. Install the drain plug. Tighten the plug to 50 N·m (37 ft. lbs.) torque.

8. Use only High-Quality Multi-Viscosity lubricating oil in the Cummins Turbo Diesel engine. Choose the correct oil

for the operating conditions (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION).

9. Fill the engine with the correct grade of new oil (Refer to LUBRICATION & MAINTENANCE/FLUID CAPACITIES

- SPECIFICATIONS).

10. Start the engine and operate it at idle for several minutes. Check for leaks at the filter and drain plug.

11. Stop engine. Wait 15 minutes to allow the oil to drain back to the pan and check the level again.

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing of used engine oil after it has been drained from a vehicle’s engine.

COOLER - ENGINE OIL & LINES

CLEANING

CLEANING AND INSPECTION

Clean the sealing surfaces.

Apply 483 kPa (70 psi) air pressure to the element to check for leaks. If the element leaks, replace the element.

FILTER - ENGINE OIL

REMOVAL

1. Clean the area around the oil filter head. Remove the filter from below using a cap-style filter wrench.

2. Clean the gasket surface of the filter head. The filter canister O-Ring seal can stick on the filter head. Make sure

it is removed.

INSTALLATION

1. Fill the oil filter element with clean oil before installation. Use the same type oil that will be used in the engine.

2. Apply a light film of lubricating oil to the sealing surface before installing the filter.

CAUTION: Mechanical over-tightening may distort the threads or damage the filter element seal.

3. Install the filter until it contacts the sealing surface of the oil filter adapter. Tighten filter an additional

1

⁄

2

turn.

PAN - ENGINE OIL

REMOVAL

1. Disconnect the battery negative cables.

2. Install engine support fixture # 8534.

3. Raise vehicle on hoist.

4. Disconnect starter cables from starter motor.

5. Remove transmission and transfer case (if equipped).

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ENGINE - 5.9L DIESEL - SERVICE INFORMATION

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6. Remove flywheel or flexplate.

7. Remove starter motor (Refer to 8 - ELECTRICAL/STARTING/STARTER MOTOR - REMOVAL) and transmission

adapter plate assembly.

WARNING: HOT OIL CAN CAUSE PERSONAL INJURY.

8. Drain the engine oil (Refer to 9 - ENGINE/LUBRICATION/OIL - STANDARD PROCEDURE).

9. Install the oil pan drain plug if sealing surface is not damaged and tighten to 50 N·m (37 ft. lbs.) torque.

10. Remove oil pan bolts, break the pan to block seal, and lower pan slightly and remove oil suction tube fasteners.

11. Remove oil pan and suction tube.

CLEANING

Remove all gasket material from the oil pan and cylinder block sealing surfaces. Extra effort may be required
around T-joint areas. Clean oil pan and flush suction tube with a suitable solvent.

INSPECTION

Inspect the oil pan, suction tube, and tube braces for cracks and damage. Replace any defective component.
Inspect the oil drain plug and drain hole threads. Inspect the oil pan sealing surface for straightness. Repair any
minor imperfections with a ball-peen hammer. Do not attempt to repair an oil pan by welding.

INSTALLATION

1. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar

T

Silicone

Rubber Adhesive Sealant or equivalent.

2. Place suction tube in oil pan and guide them into place. Slide oil pan gasket into postion.Using a new tube to

block gasket, install and tighten the suction tube bolts by hand. Starting with the oil pump inlet bolts, tighten the
bolts to 24 N·m (18 ft. lbs.) torque. Tighten the remaining tube brace bolts to 43 N·m (32 ft. lbs.) torque.

3. Starting in the center and working outward, tighten the oil pan bolts to 28 N·m (21 ft. lbs.) torque.

4. Install the flywheel housing assembly with the starter motor attached and tighten bolts to 77 N·m (57 ft. lbs.)

torque.

5. Connect starter motor cables.

NOTE: Early build engines are equipped with a standard flywheel with an NV 5600 transmission. Later
builds use a G 56 transmission, and a dual mass flywheel, which uses a crankshaft to flywheel adapter.

6. FOR EARLY BUILDS Install the flywheel or flexplate. Torque to 137 N·m (101 ft. lbs.).

7. FOR LATE BUILDS Install the flywheel to crankshaft adapter. Torque to 137 N·m (101 ft. lbs.).

8. Install transmission and transfer case (if equipped).

9. Lower vehicle.

10. Remove the engine support fixture # 8534.

11. Install battery negative cables.

12. Fill the crankcase with new engine oil.

13. Start engine and check for leaks. Stop engine, check oil level, and adjust, if necessary.

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ENGINE - 5.9L DIESEL - SERVICE INFORMATION

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VALVE - OIL PRESSURE RELIEF

REMOVAL

1. Disconnect the battery negative cables.

2. Remove the threaded plug (2), spring (4) and valve

(5). Insert a finger or a seal pick to lift the plunger
from the bore.

NOTE: If the plunger is stuck in the bore, it will be
necessary to remove the filter head.

CLEANING

1. Clean the regulator spring and plunger with a suitable solvent and blow dry with compressed air. If the plunger

bore requires cleaning, it is necessary to remove the oil filter head to avoid getting debris into the engine.

INSPECTION

Inspect the plunger and plunger bore for cracks and
excessive wear. Polished surfaces are acceptable.
Verify that the plunger moves freely in the bore.

Check the spring for height and load limitations.
Replace the spring if out of limits shown in the figure.

INSTALLATION

1. Install the plunger, spring, and plug as shown in. Tighten the plug to 80 N·m (59 ft. lbs.) torque.

2. Connect the battery negative cables.

3. Start the engine and verify that it has oil pressure.

SWITCH - OIL PRESSURE

REMOVAL

1. Disconnect the battery negative cables.

2. Disconnect the oil pressure switch connector.

3. Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise).

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ENGINE - 5.9L DIESEL - SERVICE INFORMATION

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