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Installing a power belt on a 5.9 cummings desiel

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  • Dodge Master
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5.9L Diesel Engine

WARNING Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner.
Drive belts on diesel engines are equipped with a spring loaded automatic belt tensioner. This belt tensioner will be used on all belt configurations, such as with or without air conditioning.

  1. Depending on the year of the vehicle, a 3 / 8 inch or 1 / 2 inch square hole is provided in the automatic belt tensioner. Attach a 3 / 8 inch or 1 / 2 inch drive-long handle ratchet to this hole.
  2. Rotate ratchet and tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt.
  3. Remove belt from water pump pulley first.
  4. Remove belt from vehicle.

    installing a power belt on a 5.9 cummings desiel - zjlimited_354.jpg

    Fig. Accessory serpentine belt routing-2001-03 5.9L Diesel engines with A/C
    Accessory serpentine belt routing-2001-03 5.9L Diesel engines with A/C

    zjlimited_355.jpg

    Fig. Accessory serpentine belt routing-2001-03 5.9L Diesel engines without A/C
    Accessory serpentine belt routing-2001-03 5.9L Diesel engines without A/C

    zjlimited_356.jpg

    Fig. Accessory serpentine belt routing-2004-05 5.9L Diesel engines with A/C
    Accessory serpentine belt routing-2004-05 5.9L Diesel engines with A/C

    zjlimited_357.jpg

    Fig. Accessory serpentine belt routing-2004-05 5.9L Diesel engines without A/C
    Accessory serpentine belt routing-2004-05 5.9L Diesel engines without A/C


To install:

WARNING When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. The correct belt with correct length must be used. Position drive belt over all pulleys except water pump pulley.
  1. Attach a 1/2 inch ratchet to tensioner.
  2. Rotate ratchet and belt tensioner clockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove ratchet. Be sure belt is properly seated on all pulleys.


Timing Chain Cover, Chain & Sprockets
zjlimited_358.jpg

Fig. Timing chain alignment marks-3.9L, 5.2L, 5.9L and 8.0L engines

5.2L & 5.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the cooling system.
  3. Remove or disconnect the following:
    Negative battery cable Accessory drive belt Cooling fan and shroud Water pump Power steering pump Crankshaft damper Front crankshaft seal Front cover
  4. Rotate the crankshaft so that the camshaft sprocket and crankshaft sprocket timing marks are aligned.
  5. Remove the timing chain and sprockets.
To install:
  1. Install the timing chain and sprockets with the timing marks aligned. Tighten the camshaft sprocket bolt to 50 ft. lbs. (68 Nm).
  2. Install or connect the following:
    Front cover. Tighten the cover bolts to 30 ft. lbs. (41 Nm) and the oil pan bolts to 18 ft. lbs. (24 Nm). Front crankshaft seal Crankshaft damper. Tighten the bolt to 135 ft. lbs. (183 Nm). Power steering pump Water pump Cooling fan and shroud Accessory drive belt Negative battery cable
  3. Fill the cooling system.
  4. Start the engine and check for leaks.


Hope this helps.

Posted on Dec 29, 2010

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0900c15280070771.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 12: Always install a new O-ring in the diesel water pump

  1. Remove the two water pump retaining bolts and remove the pump from the engine.
  2. Remove the O-ring from the pump groove.

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