Dodge RAM TRUCK 1500 1995 Service Manual page 992

B R 5 J L (DIESEL) ENGINE I -151
(3) Position the levers on the rocker shaft. Install
the thrust washers.
(4) Clean the push rods in the hot soapy water.
(5) Inspect the push rod ball and socket for signs
of scoring or cracks where the ball and the socket are
pressed into the tube,
(6) Check the push rods for roundness and
straightness.
(7) Install the push rods into the sockets of the
valve tappets. Lubricate the push rod sockets with
clean engine oil.
(8) Make sure the rocker lever adjusting screws
are completely backed out.
INSTALLATION
(1) Make sure the dowel rings in the pedestals are
installed into the dowel bores in the cylinder head.
(2) If the push rod is holding pedestal off head, bar
the engine until the pedestal will set on the head
surface without interference.
(3) Use clean engine oil to lubricate the cylinder
head bolt threads and under the bolt heads.
(4) Install the long bolts (12 mm) into the rocker
lever pedestals. Tighten the bolts as follows:
• Step 1—Tighten the bolts, in sequence (Fig. 2), to
90 N-m (66 ft. lbs.) torque. Check the torque. If lower
than 90 N-m (66 ft. lbs.), tighten to this torque.
• Step 2—Tighten the bolts, in sequence (Fig. 2), to
120 N-m (89 ft. lbs.) torque. Check the torque. If
lower than 120 N-m (89 ft. lbs.), tighten to this
torque.
• Step 3—Tighten the bolts, in sequence (Fig. 2), an
additional 90°.
C=i
FRONT
J9109-32
Fig. 2 Rocker Lever (Head Bolts) Tightening
Sequence
(5) Tighten the 8 mm bolts to 24 N-m (18 ft. lbs.)
torque.
(6) Install the valve cover. Tighten the valve cover
bolt to 24 N-m (18 ft. lbs.) torque.
CYLINDER
HEAD
These cylinder heads can only be used on engines
with an intercooler. DO NOT interchange with ear­
lier models.
REMOVAL
(1) Drain the coolant. DO NOT waste reusable
coolant. If the solution is clean, drain the coolant into
a clean container for reuse.
(2) Drain the engine oil. Dispose of the used oil
properly.
(3) Disconnect the radiator and heater hoses (refer
to Group 7, Cooling System).
(4) Remove the turbocharger.
(5) Remove the exhaust manifold (Fig. 3).
Fig. 3 Exhaust Manifold
(6) Remove the fuel lines and injector nozzles (re­
fer to Group 14, Fuel System).
(7) Remove the valve covers.
(8) Remove the rocker levers and push rods.
(9) Remove the fuel filter/water separator (Fig. 4).
Refer to Group 14, Fuel System, for the proper pro­
cedures. Remove the remote fuel filter/water separa­
tor head.
(10) If the engine is hot, remove the cylinder head
bolts in the sequence shown in Fig. 5. The removal
sequence is not important if the engine is cold. There
are 3 sizes of head bolts. Note the position of each
bolt for future installation.
(11) Remove the cylinder head and gasket from the
cylinder block.
INSPECTION
Remove the cup plugs and inspect the coolant pas­
sages. A large build up of rust and lime will require
removal of the cylinder block for cleaning in a hot
tank.
Inspect the cylinder bores for damage or excessive
wear. Rotate the crankshaft so the piston is at Bot­
tom Dead Center (BDC) to inspect the bores.
Measure the cylinder bores (Fig. 6). DO NOT pro­
ceed with in-chassis repair if the bores are damaged
or worn beyond the limits (refer to Cylinder Bore Re­
pair - Cylinder Block).
Check the top surface for damage caused by the
cylinder head gasket leaking between cylinders.