Dodge ram truck 3500 1996 Service Manual page 1104

9 - 114 5.9L ENGINE
BR
R E M O V A L A N D INSTALLATION gConfinueci)
UPPER SEAL REPLACEMENT—CRANKSHAFT
INSTALLED
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap.
(3) Remove the rear main bearing cap. Remove
and discard the old lower oil seal.
(4) Carefully remove and discard the old upper oil
seal.
(5) Clean the cylinder block mating surfaces before
oil seal installation.
(6) Lightly oil the new upper seal lips with engine
oil. To allow ease of installation of the seal, loosen at
least the 2 main bearing caps forward of the rear
bearing cap.
(7) Rotate the new upper seal into the cylinder
block being careful not to shave or cut the outer sur­
face of the seal. To assure proper installation, use the
installation tool provided with the kit. Install the
new seal with the white paint facing towards the
rear of the engine.
(8) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(9) Apply 5 mm (0.20 in) drop of Loctite 518, or equiva­
lent, on each side of the rear main bearing cap (Fig. 44).
DO NOT over apply sealant or allow the sealant to contact
the rubber seal. Assemble bearing cap to cylinder block
immediately after sealant application. Be sure the white
paint faces toward the rear of the engine.
(10) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
(11) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten ALL cap bolts
to 115 N-m (85 ft. lbs.) torque.
(12) Install oil pump.
(13) Apply Mopar® Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 45)
(Fig. 8). Apply enough sealant until a small amount
is squeezed out. Withdraw nozzle and wipe excess
sealant off the oil pan seal groove.
(14) Immediately install the oil pan.
LOWER SEAL REPLACEMENT
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap.
(3) Remove the rear main bearing cap and discard
the old lower seal.
(4) Clean the rear main cap mating surfaces
including the oil pan seal grooves.
(5) Carefully install a new upper seal (refer to
Upper Seal Replacement - Crankshaft Installed pro­
cedure above).
(6) Lightly oil the new lower seal lips with engine
oil.
(7) Install a new lower seal in bearing cap with
white paint facing the rear of engine.
(8) Apply 5 mm (0.20 in) drop of Loctite 518, or equiva­
lent, on each side of the rear main bearing cap (Fig. 44).
DO NOT over apply sealant or allow the sealant to contact
the rubber seal. Assemble bearing cap to cylinder block
immediately after sealant application.
(9) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. DO NOT remove excess
material after assembly DO NOT strike rear cap
more than 2 times for proper engagement.
(10) 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.
(11) Install oil pump.
(12) Apply Mopar® Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 45).
Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal­
ant off the oil pan seal groove.
(13) Immediately install the oil pan.
ENGINE CORE PLUGS
Engine core plugs have been pressed into the oil
galleries behind the camshaft thrust plate (Fig. 46).
This will reduce internal leakage and help maintain
higher oil pressure at idle.
Fig. 46 Location of Cup Plugs in Oil Galleries
REMOWAL
(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. 47).
(2) With the cup plug rotated, grasp firmly with pliers
or other suitable tool and remove plug (Fig. 47).