Dodge RAM TRUCK 1500 1995 Service Manual page 1004

mm
Fig. 12 Fabricated Wire Pointer
Fig. 13 Fabricated Steel Plate
Fig. 14 Fabricated Plate Location on No. 1 Cylinder
(7) Mark the vibration damper (Fig. 11).
(8) Mark the vibration damper for TDC. TDC will
be one-half the distance between the first two marks
(Fig. 11).
(9) Remove the plate and rotate the engine in the
direction of rotation until the pointer aligns with the
TDC mark.
— — 5.9L (DIESEL) ENGINE 9 -163
(10) Look for the timing pin hole in the camshaft
gear. If it is not visible, rotate the crankshaft one
complete rotation. Align the pointer with the TDC
mark.
(11) Install the timing pin housing assembly with a
new gasket.
(12) Apply a coat of Loctite 59241 liquid teflon, or
equivalent to the threads of the torx head bolts.
(13) Push the pin into the hole in the cam gear to
align the timing pin housing.
(14) Hold the pin in while tightening the torx head
bolts to 5 N-m (44 in. lbs.) torque. Be sure timing pin
is disengaged before rotating the engine.
(15) Remove the vibration damper and wire
pointer.
TAPPET
REMOVAL
(1) Remove the camshaft.
(2) Insert a trough the full length of the cam bore
(Fig. 1). Cummins Tappet Changing Tool 3822513 is
available for this job.
(3) Make sure the trough is positioned so it will
catch the tappet when the wooden dowel is removed.
(4) Identify the location of each tappet as it is re­
moved. The tappets must be installed in their origi­
nal locations.
(5) Only remove one tappet at a time. Remove the
rubber band from the two companion tappets, secur­
ing the tappet not to be removed with the rubber
band.
(6) Pull the wooden dowel from the tappet bore al­
lowing the tappet to fall into the trough (Fig. 1).
(7) Normally the tappet will fall over when it drops
into the trough. Use a flashlight to determine this. If
the tappet does not fall over, shake the trough gently
to get it to do so.
(8) Special care should be taken, when removing
the No.6 cylinder tappets. DO NOT knock or shake
the tappet over the end barrier of the trough.
(9) Carefully pull the trough and tappet from the
cam bore and remove the tappet. Repeat the process
until all tappets are removed.
INSPECTION
Inspect the tappet socket, stem and face for exces­
sive wear, cracks and other damage (Fig. 2).
The minimum tappet stem diameter is 15.925 mm
(0.627 inch) - (Fig. 2). If the tappet is out of limits,
replace the tappet.
INSTALLATION
(1) Insert the trough the full length of the cam
bore.
(2) Feed the installation tool down the tappet bore
and into the trough (Fig. 3).