Dodge RAM TRUCK 1500 1995 Service Manual page 1002

Bl?
5 J L (DIESEL)
ENGINE
9
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onto the crankshaft. Install the seal onto the pilot
and start into the gear housing cover. Remove the pi­
lot.
(9) Use the alignment/installation tool and a plas­
tic hammer to install the seal to the correct depth. To
prevent damage to the seal carrier, hit the align­
ment/installation tool alternately at the 12, 8, 6 and
9 o'clock positions.
(10) Install the oil fill tube and mounting bolts.
Tighten the bolts to 43 N-m (32 ft. lbs.) torque.
(11) Install the vibration damper. DO NOT tighten
the bolts to the correct torque valve at this time.
(12) Install the belt tensioner. Tighten the mount­
ing bolts to 43 N-m (32 ft. lbs.) torque.
(13) Raise the belt tensioner to install the belt.
(14) Tighten the vibration damper bolts to 125 N-m
(92 ft. lbs.) torque. Use an engine barring tool to
keep the engine from rotating during tightening op­
eration.
TIMING PIN
The timing pin is used for three different proce­
dures:
© Valve adjustment
• Top Dead Center (TDC) location
• Fuel injector pump timing procedure
Refer to Fuel Injector Pump in the Diesel Engine—
Component Removal/Installation section of Group 14,
Fuel System.
TIMING PIN REPLACEMENT
The timing pin can be replaced without removing
the assembly from the gear housing.
(1) Remove the timing pin by prying the retaining
ring out with a small screwdriver. Replace the retain­
ing ring if it is damaged during removal.
(2) If timing pin assembly is removed from gear
housing, it must be precisely reset to obtain exact
TDC.
(3) Install a new O-Ring, lubricate the pin and po­
sition in the housing (Fig. 7). Install the new retain­
ing ring to 1.5 mm (0.059 inch).
TIMING PIN HOUSING ASSEMBLY AND
GASKET
REMOVAL
(1) Locate TDC for cylinder No.l.
(2) Remove the timing pin housing assembly and
gasket.
(3) Clean any gasket material from the gear hous­
ing and from the timing pin housing assembly.
INSTALLATION—CYLINDER HEAD ON
The location of the timing pin assembly on the gear
housing is critical for correct engine adjustment. Fol­
low this procedure to install the assembly so that it
corresponds to TDC for cylinder No.l.
Fig, 7 Engine Timing Pin Location
(1) Look through the hole in the gear housing and
rotate the engine until the hole in the cam gear can
be seen.
(2) Remove the injector nozzles from all of the cyl­
inders. This step is important to vent the cylinders so
the crankshaft can be rotated smoothly to locate TDC
for cylinder No.l.
(3) Temporarily install the vibration damper.
(4) Fabricate and install a wire pointer (Fig. 8).
This can be done by forming a piece of wire that can
be tighten under one of the gear housing capscrews.
The wire should extend from the gear cover to a
place on the crankshaft vibration damper that is eas­
ily seen.
Fig. 8 Fabricated Wire Pointer
(5) Rotate the crankshaft one-quarter rotation in
the direction of engine rotation.
(6) Tighten the adjusting screw for the No.l intake
valve to zero lash plus 5 turns.
CAUTION: Use extreme care when rotating the
crankshaft. Use of too much force could damage
the valve or push rod (Fig. 9).