Dodge RAM TRUCK 1500 1995 Service Manual page 1003

I - 162 5.9L (DIESEL) ENGINE B R
(7) Rotate the crankshaft slowly in the opposite di­
rection of normal engine rotation until the piston
touches the intake valve (Fig. 9).
(8) Mark the vibration damper at the wire pointer
(Fig. 9).
-Fig. 9 Locate and Mark Vibration Damper—First
Mark
(9) Rotate the crankshaft in the direction of nor­
mal engine rotation until the piston touches the in­
take valve (Fig. 10). Make sure that the piston
touches the intake valve with approximately
the same amount of force as in the previous
step (Fig. 1 0 ) .
(10) Mark the vibration damper at the wire pointer
(Fig. 10).
Fig. 10 Mark Vibration Damper—Second Mark
(11) Measure the distance and mark the vibration
damper at one-half that distance between the two
marks. This mark is the TDC mark (Fig. 11).
(12) Completely loosen the intake valve adjusting
screw. If not done, damage to the intake valve or
push rod could occur when the crankshaft is rotated.
Fig. 11 Location of Top Dead Center (TDC)
(13) Rotate the crankshaft in the direction of nor­
mal engine rotation until the pointer is aligned with
the TDC mark. Rotate crankshaft one additional
turn.
(14) The timing pin hole in the cam gear should be
visible or felt through the back side of the gear hous­
ing. If not, the crankshaft must be rotated one revo­
lution in the direction of engine rotation.
(15) Apply a coat of Loctite™ 59241 (Liquid Te­
flon), or equivalent to the threads of the Torx head
bolts. Install the timing pin assembly and new
O-ring.
(16) Hold the timing pin in the hole to align the
housing and install the Torx head bolts. Tighten the
Torx bolts to 5 N-m (44 in. lbs.) torque.
(17) Install the remaining rocker lever pedestal as­
semblies. Tighten the rocker lever pedestal mounting
capscrews.
(18) Adjust the valves.
(19) Install the injectors and bleed the fuel system
(refer to Group 14, Fuel System).
(20) Install the fuel pump (refer to Group 14, Fuel
System).
(21) Install the gear cover.
(22) Remove the pointer. Install the crankshaft vi­
bration damper.
INSTALLATION—CYLINDER HEAD iFF
The timing pin assembly is precisely located on the
gear housing to correspond to TDC for Cylinder No.l.
The timing pin assembly must be relocated if the
gear housing is interchanged.
(1) Temporarily install the vibration damper and a
fabricated wire pointer (Fig. 12). Put a fiat washer
between the pointer and gear housing to prevent
damage to the gear housing.
(2) Fabricate a steel plate (Fig. 13).
(3) Use two flywheel housing bolts to assemble the
plate over No.l cylinder (Fig. 14).
(4) Rotate the crankshaft in the direction of rota­
tion until the piston contacts the plate.
(5) Mark the vibration damper (Fig. 11).
(6) Rotate the engine in the opposite direction un­
til the piston contacts the plate.