Dodge ram truck 3500 1996 Service Manual page 1035

s i t
3.9L ENGINE 9 - 45
HESiCWAL AND INSTALLATION (Continued)
(7) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten the cap bolts
to 115 N-m (85 ft. lbs.) torque.
(8) Install oil pump.
(9) Apply Mopar Silicone Rubber Adhesive Sealant,
or equivalent, at bearing cap-to-block joint to provide
cap to block and oil pan sealing. Apply enough seal­
ant so that a small amount is squeezed out. With­
draw nozzle and wipe excess sealant off the oil pan
seal groove.
(10) Immediately install the oil pan.
ENGINE CORE OIL AND CAMSHAFT PLUGS
Engine core plugs have been pressed into the oil
galleries behind the camshaft thrust plate (Fig. 48).
This will reduce internal leakage and help maintain
higher oil pressure at idle.
Fig. 48 Location of Cup Plugs in Oil Galleries
MEMOWAL
(1) Using a blunt tool such as a drift or a screw­
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 49).
(2) With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig.
49).
INSTALLATION
Thoroughly clean inside of cup plug hole i n cylin­
der block or head. Be sure to remove old sealer.
Be certain the new plug is cleaned of all oil or
grease.
(1) Coat edges of plug and core hole with Mopar
Gasket Maker, or equivalent.
CAUTION: DO NOT drive cup plug Into the casting,
as restricted coolant flow can result and cause seri­
ous engine problems.
CYLINDER
• - B L O C K ' /
Fig. 49 Core Hole Plug Removal
(2) Using proper plug drive, drive cup plug into
hole. The sharp edge of the plug should be at least
0.50 mm (0.020 in.) inside the lead-in chamfer.
(3) I t is not necessary to wait for curing of the
sealant. The cooling system can be filled and the
vehicle placed in service immediately.
D I S A S S E M B L Y A N D A S S E M B L Y
HYDRAULIC TAPPETS
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable
to work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. DO NOT dis­
assemble a tappet on a dirty work bench.
DISASSEMBLE
(1) Pry out plunger retainer spring clip (Fig. 50).
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, check valve, check valve spring, check valve
retainer, and plunger spring (Fig. 50). Check valve
could be flat or ball.
ASSEMBLE
(1) Clean all tappet parts in a solvent that will
remove all varnish and carbon.
(2) Replace tappets that are unfit for further ser­
vice with new assemblies.
(3) I f plunger shows signs of scoring or wear,
install a new tappet assembly. I f valve is pitted, or
valve seat on end of plunger is prevented from seat­
ing, install a new tappet assembly.
(4) Assemble tappets (Fig. 50).