Dodge ram truck 3500 1996 Service Manual page 1024

9 - 34 3 J L ENGINE B R
R E M O V A L AND I N S T A L L A T I O N (Continued)
Fig. 20 Cylinder Head Bolt -Tightening Sequence
CAUTION: When tightening the rocker arm bolts,
be sure the piston in that cylinder is NOT at TDC.
Contact between the waives and piston could occur.
(4) Install push rods and rocker arm assemblies in
their original positions. Tighten the bolts to 28 N-m
(21 ft. lbs.) torque.
(5) Install the intake manifold and throttle body
assembly. Refer to Group 11, Exhaust System and
Intake Manifold.
(6) Install exhaust manifolds. Tighten , the bolts
and nuts to 34 N-m (25 ft. lbs.) torque.
(7) Adjust spark plugs to specifications. Refer to
Group 8D, Ignition System. Install the plugs and
tighten to 41 N-m (30 ft. lbs.) torque.
(8) Install coil wires.
(9) Connect heat Indicator sending unit wire.
(10) Connect the heater hoses and bypass hose.
(11) Install distributor cap and wires.
(12) Hook up the return spring.
(13) Connect the accelerator linkage and, i f so
equipped, the speed control and transmission kick-
down cables.
(14) Install the fuel lines.
(15) Install the generator and drive belt. Tighten
generator mounting bolt to 41 N-m (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 N-m
(200 in. lbs.) torque. Refer to Group 7, Cooling Sys­
tem for adjusting the belt tension.
(16) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(17) Place the cylinder head cover gaskets in posi­
tion and install cylinder head covers. Tighten the
bolts to 11 N-m (95 in. lbs.) torque.
(18) Install closed crankcase ventilation system.
(19) Connect the evaporation control system.
(20) Install the air cleaner.
(21) Install the heat shields. Tighten the bolts to
41 N-m (30 ft. lbs.) torque.
(22) Fill cooling system. Refer to Group 7, Cooling
System for proper procedure.
(23) Connect the negative cable to the battery.
VALVES AND VALVE SPRINGS—CYLINDER HEAD
RE10VED
REMOVAL
(1) Compress valve springs using Valve Spring
Compressor Tool MD-998772-A.
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals, and valve springs.
(3) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original locations.
INSTALLATION
(1) Coat valve stems with lubrication oil and insert
them in cylinder head.
(2) I f valves or seats are reground, check valve
stem height. I f valve is too long, replace cylinder
head.
(3) Install new seals on all valve guides. Install
valve springs and valve retainers.
(4) Compress valve springs with Valve Spring
Compressor Tool MD-998772A, install locks and
release tool. I f valves and/or seats are ground, mea­
sure the installed height of springs. Be sure the mea­
surement is taken from bottom of spring seat in
cylinder head to the bottom surface of spring
retainer. I f spacers are installed, measure from the
top of spacer. I f height is greater than 42.86 mm
(1-11/16 inches), install a 1.587 mm (1/16 in.) spacer
in head counterbore. This should bring spring height
back to normal 41.27 to 42.86 mm (1-5/8 to 1-11/16
in.).
HYDRAULIC TAPPETS
REMOVAL
(1) Remove the air cleaner.
(2) Remove cylinder head cover.
(3) Remove rocker assembly and push rods. Iden­
tify push rods to ensure installation in original loca­
tions.
(4) Remove intake manifold.
(5) Remove yoke retainer and aligning yokes.
(6) Slide Hydraulic Tappet Remover/Installer Tool
C-4129-A through opening in cylinder head and seat
tool firmly in the head of tappet.
(7) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed, identify tappets to
ensure installation in original location.
(8) I f the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to
next oversize. Replace with oversize tappet.