Dodge ram truck 3500 1996 Service Manual page 1172

9 - 182 5.9L (DIESEL) ENGINE
REMOVAL AND INSTALLATION (Continued)
(40) Fill the cooling system with a mixture of 50%
water and 50% ethylene-glycol base antifreeze (refer
Group 7, Cooling System for the proper procedure).
(41) Fill the engine with the required amount of
clean engine lubricating oil (refer to Group 0, Lubri­
cation and Maintenance).
(42) install the battery and connect the battery
cables.
(43) Check the oil level after the engine has run
for 2 or 3 minutes. Oil held in the oil filter and oil
passages will cause the oil level in the pan to be
lower than normal for a short period of time.
(44) Operate the engine at idle for 5 to 10 minutes
and check for leaks and loose parts.
ROCIER LEWERS IND PUSH iODS
REMOVAL
(1) Remove the valve covers.
(2) Loosen the adjusting screw locknuts. Loosen
the adjusting screws until they stop (Fig. 45).
(3) Remove the bolts from the rocker lever pedes­
tals. Remove the pedestals and rocker lever assem­
blies (Fig. 45).
(4) Remove the push rods. The rear two push rods
must be raised through holes in cab overhang.
LOCKNUT ADJUSTING
J9109-31
Fig. 45 Location of Rocker Lever Components
INSTALLATION
(1) Make sure the dowel rings in the pedestals are
installed into the dowel bores in the cylinder head.
(2) I f the push rod is holding pedestal off head, bar
the engine until the pedestal will set on the head
surface without interference.
(3) Use clean engine oil to lubricate the cylinder
head bolt threads and under the bolt heads.
(4) Install the long bolts (12 mm) into the rocker
lever pedestals. Tighten the bolts as follows:
• Step 1—Tighten the bolts, in sequence (Fig. 46),
to 90 N-m (66 ft. lbs.) torque. Check the torque. I f
lower than 90 N-m (66 ft. lbs.), tighten to this torque.
• Step 2—Tighten the bolts, in sequence (Fig. 46), to
120 N-m (89 ft. lbs.) torque. Check the torque. I f lower
than 120 N-m (89 ft. lbs.), tighten to this torque.
• Step 3—Tighten the bolts, in sequence (Fig. 46),
an additional 90°.
C = * FRONT
J9109-32
Fig. 46 Rocker Lever (Head Botts) Tightening
Sequence
(5) Tighten the 8 mm bolts to 24 N-m (18 ft. lbs.)
torque.
(6) Install the valve cover. Tighten the valve cover
bolt to 24 N-m (18 ft. lbs.) torque.
CYLINDER HEAD
These cylinder heads can only be used on engines
with an intercooler. DO NOT interchange with ear­
lier models.
REMOVAL .
(1) Drain the coolant. DO NOT waste reusable
coolant. I f the solution is clean, drain the coolant into
a clean container for reuse.
(2) Drain the engine oil. Dispose of the used oil
properly.
(3) Disconnect the radiator and heater hoses (refer
to Group 7, Cooling System).
(4) Remove the turbocharger.
(5) Remove the exhaust manifold (Fig. 47).
Fig. 47 Exhaust Manifold