Dodge ram truck 3500 1996 Service Manual page 1059

B R
1.2L E N G I N E I - I I
R E M O V A L A N D
INSTALLATION
( C o n t i n u e d )
(15) Connect the accelerator linkage and i f so
equipped, the speed control and transmission kick-
down cables.
(16) Install the fuel lines.
(17) 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.
(18) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(19) Place the cylinder head cover gaskets i n posi­
tion and install cylinder head covers. Tighten the
bolts to 11 N-m (95 in. lbs.) torque.
(20) Install closed crankcase ventilation system.
(21) Connect the evaporation control system.
(22) Install the air cleaner.
(23) Install the heat shields. Tighten the bolts to
41 N-m (30 ft. lbs.) torque.
(24) Fill cooling system (refer to Group 7, Cooling
System for proper procedure).
(25) Connect the negative cable to the battery.
¥AL¥ES AND ¥AL¥E SPIiNIS
REMOVAL
(1) Remove the cylinder head.
(2) Compress valve springs using Valve Spring
Compressor Tool MD- 998772A.
(3) - Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation i n
original location.
INSTALLATION
(1) Clean valves thoroughly. Discard burned,
warped and cracked valves.
(2) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(3) Measure valve stems for wear. I f wear exceeds
0.051 mm (0.002 Inch), replace the valve.
(4) Coat valve stems with lubrication oil and insert
them in cylinder head.
(5) I f valves or seats are reground, check valve
stem height. I f valve is too long, replace cylinder
head.
(6) Install new seals on all valve guides. Install
valve springs and valve retainers.
(7) 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. Make sure the
measurement 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 inch)
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 inch).
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
tion.
(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 i n cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to
next oversize. Replace with oversize tappet.
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets and push rods in their original
positions. Ensure that the oil feed hole In the side of
the tappet body faces up (away from the crankshaft).
(3) Install aligning yokes with ARROW toward
camshaft.
(4) Install yoke retainer. Tighten the bolts to 23
N-m (200 in. lbs.) torque. Install intake manifold.
(5) Install push rods in original positions.
(6) Install rocker arm.
(7) Install cylinder head cover.
(8) Start and operate engine. Warm up to normal
operating temperature.
CAUTION; To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
¥IBRATI0N
D A M P E R .
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove fan shroud retainer bolts and set
shroud back over engine.
(3) Remove the cooling system' fan.
(4) Remove the serpentine belt (refer to Group 7,
Cooling System).
(5) Remove the vibration damper pulley.