Dodge ram truck 3500 1996 Service Manual page 1070

9 - 80 5,21 ENGINE
R E M O V A L AND INSTALLATION ( C o n t i n u e d )
This will reduce internal leakage and help maintain
higher oil pressure at idle.
Fig, 48 Location of Cup Piugs in Oii Galleries
REMOVAL
(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).
CYLINDER
^ BLOCK ^ /
DRIFT 9209-41
Fig. 49 Core Hole Plug Removal
INSTALLATION
Thoroughly clean inside of cup plug hole in 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.
(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 U B 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).
SPWNG CAP J9109-220
Fig. 50 Hydraulic Tappet Assembly