Base
Engine Components
DODGE
Turbo Diesel
Engine
Removal,
Replacement and Testing
Page
9J-9
Engine
Rating
Dodge 5.9 Liter Diesel Engine
Engine
Model
Dodge 5.9 Liter Diesel
Rating
Hp/RPM
2500
Torque
ft-lb/RPM
319/2500
Torque
ft-lb/RPM
400/1500
Engine
Test Check
List
OK
Correct
injector for the engine
rating
used
ami only one copper
sealing
washer installed?
Seaiant
applied to the
capscrews
that
attach the
Intake
manifold
cover?
Turbocharger pre-lubricated?
Engine
filled
with
oil; oil
Iter
filled
with
oil prior to Installation
so
the engine
has
an
immediate
supply of
oil?
Fuel
filter
filled
with
fuel
and the Injection
pump
primed
using
the lever on the
lift
pump?
Engine
Run-in
1.
Make
sure
that
the
fuel
solenoid is
in
the
"OFF
position or
disconnected.
2. Crank the engine to
establish
oil
pressure
on the gauge. Do not engage the starter for more
than
30
seconds
at
a
time,
wait
two (2) minutes between engagements.
Reconnect
the
fuel
solenoid if
disconnected
ami move to the
"RUN"
position.
Note:
Bleeding of the
fuel
system
may be required to start the engine.
3. Start the engine and run at
1000-1200
RPM for 30 minutes. Observe the oil
pressure
and water temperature. If
oil
pressure
drops below 103 kPa [15
psi],
stop the engine and troubleshoot the lubrication
system,
if water
temperature
exceeds
95°C [203°F], stop the engine and allow to
cool.
Troubleshoot the cooling
system.
4.
After
completing Step 3, stop the engine and
inspect
for
leaks.
5. Restart the engine and test drive the vehicle at approximately
1
/3
throttle
in "Drive" or "High" gear. Periodically,
open the
throttle
and accelerate to governed RPM and decelerate rapidly. Repeat this procedure at least 10
The engine should be operated normally, but not at continuous high
speeds
and loads for the first 500 miles or 20
hours.
Occasional
quick acceleration
followed
by quick deceleration during this period is beneficial to engine break
in.
Change
the oil and filters
after
500 miles or 20 hours of operation. Follow oil
specifications
described in Lubrication
and Maintenance, Section 0.
times.
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