Dodge ram truck 3500 1996 Service Manual page 1105

B R 5 J L ENGINE I - 1 1 5
REMOVAL AND INSTALLATION (Continued)
CYLINDER
DRIFT 9209-41
Fig. 47 Core Hole Plug Removal
CLEANING
Thoroughly clean inside of cup plug hole in cylin­
der block or head. Be sure to remove old, sealer.
Make certain the new plug is cleaned of all oil or grease.
INSTALLATION
(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 inch) 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. 48).
(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. 48). 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. 48).
SPRING CAP J9109-220
Fig. 48 Hydraulic Tappet Assembly
CYLINDER B L 0 C I
DISASSEMBLE
(1) Remove the cylinder head.
(2) Remove the oil pan.
(3) Remove the piston/connecting rod assembly.
OIL LINE PLUG
The oil line plug is located in the vertical passage at the
rear of the block between the Oil-To-Filter and Oil-From-
Filter passages (Fig. 49). Improper installation or plug
missing could cause erratic, low or no oil pressure.
(1) Remove oil pressure sending unit from back of block.
(2) Insert a 3.175 mm (1/8 inch) finish wire or
equivalent into passage.
(3) Plug should be 190.0 to 195.2 mm (7-1/2 to
7-11/16 inches) from machined surface of block (Fig.
49). I f plug is too high, use a suitable flat dowel drift
to position properly.
RIGHT OIL GALLERY
J9109-229
Fig. 49 Oii Line Plug