Dodge Ram Truck 1500-2500-3500. Manual — part 1426

INSTALLATION

1. If the switch is not being replaced, replace and lubricate the o-ring.

2. Install the oil pressure switch and tighten to 18 N·m (159 in. lbs.) torque.

3. Connect oil pressure switch connector.

4. Connect the battery negative cables.

5. Start engine and check for oil leaks at the switch.

PUMP - ENGINE OIL

REMOVAL

1. Disconnect the battery negative cables.

2. Remove fan/drive assembly (Refer to 7 - COOL-

ING/ENGINE/RADIATOR FAN - REMOVAL).

3. Remove the accessory drive belt (Refer to 7 -

COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).

4. Remove the fan support/hub assembly.

5. Remove crankshaft damper (Refer to 9 - ENGINE/

ENGINE

BLOCK/VIBRATION

DAMPER

-

REMOVAL) and speed indicator ring.

6. Remove power steering pump.

7. Remove accessory drive belt tensioner.

8. Remove the gear housing cover (Refer to 9 -

ENGINE/VALVE TIMING/GEAR HOUSING COVER
- REMOVAL).

9. Remove the four mounting bolts (2) and pull the oil

pump (1) from the bore in the cylinder block.

CLEANING

Clean all parts in solvent and dry with compressed air. Clean the old sealer residue from the back of the gear
housing cover and front of the gear housing.

INSPECTION

Disassemble and inspect the oil pump as follows:

1. Visually inspect the lube pump gears for chips,

cracks or excessive wear.

2. Remove the back plate (1).

3. Mark TOP on the gerotor planetary (3) using a felt

tip pen.

4. Remove the gerotor planetary (3) inspect for

excessive wear or damage. Inspect the pump
housing and gerotor drive (2) for damaged and
excessive wear.

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ENGINE - 5.9L DIESEL - SERVICE INFORMATION

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5. Install the gerotor planetary in the original position.

6. Measure the tip clearance (1). Maximum clearance

is 0.1778 mm (0.007 inch). If the oil pump is out of
limits, replace the pump.

7. Measure the clearance of the gerotor drive/gerotor

planetary (2)to port plate (1). Maximum clearance
is 0.127 mm (0.005 inch). If the oil pump is out of
limits, replace the pump.

8. Measure the clearance of the gerotor planetary to

the body bore (1). Maximum clearance is 0.381
mm (0.015 inch). If the oil pump is out of limits,
replace the pump.

9. Measure the gears backlash (3,4). The limits of a

used pump is 0.15- 0.25 mm (0.006-0.010 inch). If
the backlash is out of limits, replace the oil pump.

10. Install the back plate.

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ENGINE - 5.9L DIESEL - SERVICE INFORMATION

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INSTALLATION

1. Lubricate the pump with clean engine oil. Filling the

pump with clean engine oil during installation will
help to prime the pump at engine start up.

2. Install the pump. Verify the idler gear pin is

installed in the locating bore in the cylinder block.
Tighten the oil pump mounting bolts in two steps, in
the sequence shown in.

•

Step 1—Tighten to 8 N·m (71 in. lbs.) torque.

•

Step 2—Tighten to 24 N·m (18 ft. lbs.) torque.

3. The back plate on the pump seats against the bot-

tom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump
will not touch the cylinder block.

4. Measure the idler gear to pump drive gear back-

lash and the idler gear to crankshaft gear backlash.
The

backlash

should

be

0.15-

0.25

mm

(0.006-0.010 inch). If the backlash is out of limits,
replace the oil pump.

5. If the adjoining gear moves when you measure the

backlash, the reading will be incorrect.

6. Apply a bead of Mopar

T

Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover sealing sur-

face.

7. Install the gear housing cover (Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUSING COVER - INSTALLA-

TION).

8. Install the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION) and

speed indicator ring.

9. Install the fan support/hub assembly Refer to (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA-

TION)

10. Install power steering pump.

11. Install accessory drive belt tensioner. Torque bolt to 43 N·m (32 ft. lbs.).

12. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).

13. Install the cooling fan (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).

14. Connect battery negative cables.

15. Start engine and check for oil leaks.

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ENGINE - 5.9L DIESEL - SERVICE INFORMATION

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MANIFOLD - INTAKE

REMOVAL

1. Disconnect the battery negative cables.

2. Remove the charge air cooler outlet tube (6) from

the air inlet housing (8).

3. Remove the engine oil dipstick tube mounting bolt.

4. Remove dipstick support at fuel filter housing. Posi-

tion dipstick tube to the side.

5. Disconnect the air grid heater power cables at the

cable mounting studs.

6. Remove the engine wiring harness connections at

the air inlet housing elbow.

7. Remove the four (4) air inlet housing mounting

bolts and remove the housing from top of the
heater elements.

8. Remove the intake air grid heater (1)from the

manifold.

9. Remove the high pressure fuel lines and fuel rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES

- REMOVAL).

10. Disconnect manifold air temperature/pressure sensor connector.

11. Remove the remaining intake manifold cover-to-cylinder head bolts.

DR/DH

ENGINE - 5.9L DIESEL - SERVICE INFORMATION

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