Dodge Ram Truck 1500-2500-3500. Manual — part 1428

8. Install the camshaft (Refer to 9 - ENGINE/ENGINE

BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
INSTALLATION). Align the crankshaft and camshaft
gear marks as shown.

9. Install a new front crankshaft seal into the gear cover.

10. Apply a bead of Mopar

T

Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover. Be sure to

surround all through holes.

11. Using the seal pilot to align the cover, install the cover to the housing and install the bolts. Tighten the bolts to

24 N·m (18 ft. lbs.) torque.

12. Remove the seal pilot. Install front seal dust shield.

13. Raise the vehicle.

14. Trim any excess gear housing gasket to make it flush with the oil pan rail.

15. Install the crankshaft damper and speed indicator ring (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION

DAMPER - INSTALLATION). Torque bolts to 40 Nm (30 ft. lbs.), plus an additional 60°.

16. Install the lower fan shroud bracket. Torque bolts to 24 N·m (18 ft. lbs.) torque.

17. Install the upper fan shroud brackets.

18. Lower vehicle.

19. Install the fan support/hub assembly and tighten bolts to 32 N·m (24 ft. lbs.) torque.

20. Install the power steering pump.

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

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

23. Install the upper cooling fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTAL-

LATION).

24. Connect the coolant recovery bottle hose to the radiator filler neck.

25. Install the radiator upper hose and clamps.

26. Add engine oil.

27. Add coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).

28. Connect the battery cables.

29. Start engine and inspect for leaks.

9 - 2634

ENGINE - 5.9L DIESEL - SERVICE INFORMATION

DR/DH

COVER - TIMING

REMOVAL

1. Disconnect both battery negative cables.

2. Raise vehicle on hoist.

3. Partially drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCEDURE).

4. Lower vehicle.

5. Remove radiator upper hose.

6. Remove viscous fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).

7. Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).

8. Remove the cooling fan support/hub from the front of the engine.

9. Raise the vehicle on hoist.

10. Remove power steering pump.

11. Remove accessory drive belt tensioner.

12. Remove the crankshaft damper and speed indicator ring (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION

DAMPER - REMOVAL).

13. Lower the vehicle.

14. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar

the gasket surfaces.

INSTALLATION

1. Install a new front crankshaft oil seal.

2. Obtain a seal pilot (1) installation tool from a crank-

shaft front seal service kit and install the pilot into
the seal.

3. Apply a bead of Mopar

T

Silicone Rubber Adhesive

Sealant or equivalent to the gear housing cover. Be
sure to surround all through holes.

4. Using the seal pilot to (1) align the cover , install

the cover to the housing and install the bolts.
Tighten the bolts to 24 N·m (18 ft. lbs.) torque.

5. Remove the seal pilot. Install front seal dust shield.

6. Raise the vehicle.

7. Install the speed indicator ring and the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION

DAMPER - INSTALLATION).

8. Lower vehicle.

9. Install the fan support/hub assy, and tighten bolts to 32 N·m (24 ft. lbs.) torque.

10. Install power steering pump.

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

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

13. Install the cooling fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA-

TION).

14. Install the radiator upper hose and clamps.

15. Add coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).

16. Connect the battery cables.

17. Start engine and inspect for leaks.

DR/DH

ENGINE - 5.9L DIESEL - SERVICE INFORMATION

9 - 2635

EXHAUST SYSTEM

TABLE OF CONTENTS

page

page

EXHAUST SYSTEM

DESCRIPTION

GAS ENGINES

. . . . . . . . . . . . . . . . . . . . . . . . 2

5.9L DIESEL

. . . . . . . . . . . . . . . . . . . . . . . . . . 3

DIAGNOSIS AND TESTING

GAS ENGINE

. . . . . . . . . . . . . . . . . . . . . . . . . 4

DIESEL ENGINE

. . . . . . . . . . . . . . . . . . . . . . . 4

SPECIFICATIONS

TORQUE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . 6

CONVERTER-CATALYTIC

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . . 7

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

REMOVAL

3.7L/4.7L ENGINE

. . . . . . . . . . . . . . . . . . . . . . 7

5.7L ENGINE

. . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.9L DIESEL ENGINE

. . . . . . . . . . . . . . . . . . . 8

8.3L ENGINE

. . . . . . . . . . . . . . . . . . . . . . . . . . 9

INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 9

INSTALLATION

3.7L/4.7L ENGINE

. . . . . . . . . . . . . . . . . . . . . . 9

5.7L ENGINE

. . . . . . . . . . . . . . . . . . . . . . . . . 10

5.9L ENGINE DIESEL

. . . . . . . . . . . . . . . . . . 10

8.3L ENGINE

. . . . . . . . . . . . . . . . . . . . . . . . . 11

PIPE EXHAUST

REMOVAL

3.7L/4.7L/5.7L ENGINE

. . . . . . . . . . . . . . . . . . 11

5.9L DIESEL

. . . . . . . . . . . . . . . . . . . . . . . . . 12

8.3L ENGINE

. . . . . . . . . . . . . . . . . . . . . . . . . 12

INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . 12

INSTALLATION

3.7L/4.7L/5.7L ENGINE

. . . . . . . . . . . . . . . . . 13

5.9L DIESEL

. . . . . . . . . . . . . . . . . . . . . . . . . 13

8.3L ENGINE

. . . . . . . . . . . . . . . . . . . . . . . . . 14

HEAT SHIELDS

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 14

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 16

MUFFLER

REMOVAL

3.7L/4.7L/5.7L ENGINE

. . . . . . . . . . . . . . . . . 17

8.3L ENGINE

. . . . . . . . . . . . . . . . . . . . . . . . . 18

5.9L DIESEL ENGINE

. . . . . . . . . . . . . . . . . . 18

INSTALLATION

3.7L/4.7L/5.7L ENGINE

. . . . . . . . . . . . . . . . . 19

8.3L ENGINE

. . . . . . . . . . . . . . . . . . . . . . . . . 19

5.9L DIESEL ENGINE

. . . . . . . . . . . . . . . . . . 20

TAILPIPE

REMOVAL

3.7L/4.7L/5.7L ENGINE

. . . . . . . . . . . . . . . . . 20

5.9L DIESEL

. . . . . . . . . . . . . . . . . . . . . . . . . 21

8.3L ENGINE

. . . . . . . . . . . . . . . . . . . . . . . . . 21

INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . 21

INSTALLATION

3.7L/4.7L/5.7L ENGINE

. . . . . . . . . . . . . . . . . 22

5.9L DIESEL

. . . . . . . . . . . . . . . . . . . . . . . . . 22

8.3L ENGINE

. . . . . . . . . . . . . . . . . . . . . . . . . 23

TURBOCHARGER SYSTEM

DIAGNOSIS AND TESTING

TURBOCHARGER BOOST PRESSURE

. . . . . 23

TURBOCHARGER

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 24

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 25

REMOVAL

TURBOCHARGER

. . . . . . . . . . . . . . . . . . . . . 27

TURBOCHARGER OIL DRAIN TUBE

. . . . . . . 28

CLEANING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . 28

INSTALLATION

TURBOCHARGER

. . . . . . . . . . . . . . . . . . . . . 30

TURBOCHARGER OIL DRAIN TUBE

. . . . . . . 31

WASTEGATE - ELECTRONIC ACTUATOR

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 32

CHARGE AIR COOLER AND PLUMBING

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 32

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 33

DIAGNOSIS AND TESTING

CHARGE AIR COOLER SYSTEM - LEAKS

. . . 33

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

CLEANING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . 34

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 35

DR/DH

EXHAUST SYSTEM

11 - 1