Dodge RAM TRUCK 1500 1995 Service Manual page 991

I - 1SI S J L (DIESEL) ENGINE
(16) Connect the fuel lines to the lift pump and
fuel return. Use tags to identify the lines.
(17) Connect all electrical connections to the en­
gine. Use tags to identify their locations.
(18) Connect the transmission cooler lines.
(19) Connect the power steering hoses, if equipped.
(20) Connect the accelerator linkage, the speed
control linkage and the throttle valve linkage.
(21) Install the outlet duct. Connect the intercooler
outlet duct to the air inlet housing and the inter­
cooler.
(22) Install the inlet duct. Connect the intercooler
inlet duct to the turbocharger and the intercooler.
(23) Install the exhaust pipe to the turbocharger
outlet flange.
(24) Install the air inlet tube. Connect the air inlet
tube to the turbocharger and the air intake housing.
(25) Connect the heater hoses at the dash panel
and at the water valve.
(26) Install the generator and wire connections (re­
fer to Group 8B, Battery/Starter/Generator Service).
(27) Install the radiator (refer to Group 7, Cooling
System).
(28) Connect the lower radiator hose.
(29) Install the fan shroud.
(30) Install the fan.
(81) Connect the top radiator hose.
(82) Install the radiator overflow bottle.
(88) Install the washer bottle.
(34) If equipped, install the condenser.
(85) Install the A/C compressor with the lines at­
tached.
(36) Evacuate and charge the air conditioning sys­
tem, if equipped (refer to Group 24, Heating and Air
Conditioning for service procedures).
(87) Install the transmission oil cooler.
(88) Install the upper crossmember and top core
support.
(39) Install the serpentine belt (refer to Group 7,
Cooling System).
(40) Fill the cooling system with a mixture of 50%
water and 50% ethylene-glycol base antifreeze (refer
Group 7, Cooling System for the proper procedure).
(41) Fill the engine with the required amount of
clean engine lubricating oil (refer to Group 0, Lubri­
cation and Maintenance).
(42) Install the battery and connect the battery ca­
bles.
(43) Check the oil level after the engine has run
for 2 or 3 minutes. Oil held in the oil filter and oil
passages will cause the oil level in the pan to be
lower than normal for a short period of time.
(44) Operate the engine at idle for 5 to 10 minutes
and check for leaks and loose parts.
ROCKER LEVERS AND PUSH RODS
REMOVAL
(1) Remove the valve covers.
(2) Loosen the adjusting screw locknuts. Loosen
the adjusting screws until they stop (Fig. 1).
(3) Remove the bolts from the rocker lever pedes­
tals. Remove the pedestals and rocker lever assem­
blies (Fig. 1).
(4) Remove the push rods. The rear two push rods
must be raised through holes in cab overhang.
LOCKNUT A D J U S T I N G
J9109-31
Fig. 1 Location of Rocker Lever Components
DISASSEMBLE—ROCKER LEVERS
(1) Remove the retaining rings and thrust washers
(Fig. 1).
(2) Remove the rocker levers (Fig. 1). DO NOT dis­
assemble the rocker lever shaft and pedestal. The
pedestal and shaft must be replaced as an assembly.
(3) Remove the locknut and adjusting screw (Fig.
1).
(4) Clean all parts in a strong solution of laundry-
detergent in hot water.
(5) Use compressed air to dry the parts after rins­
ing in clean hot water. The pedestals are made from
powdered metal and may continue to show wetness
after they have been cleaned and dried.
(6) Inspect for excessive wear in the bore and the
contact surface for the valve stem.
(7) Measure the rocker lever bore diameter. The
maximum diameter is 19.05 mm (0.75 inch). Replace
if out of limits.
(8) Inspect the pedestal and shaft.
(9) Measure the shaft diameter. The minimum di­
ameter is 18.94 mm (0.746 inch). Replace if out of
limits.
ASSEMBLE—ROCKER LEVERS
(1) Install the adjusting screw and locknut.
(2) Lubricate the shaft with clean engine oil. Be
sure to assemble the intake and exhaust rocker le­
vers in the correct location.