Dodge ram truck 3500 1996 Service Manual page 1176

9 - 186 5.9L (DIESEL) ENGINE
B R
REMOVAL AND
I N S T A L L A T I O N
(Continued)
(2) Remove the front end components and the gear
housing cover (refer to Gear Housing Cover Removal
for the proper procedures).
( 3 ) Remove the following:
• Camshaft
• Gear driven accessories
• Fuel injection pump (refer to Group 14, Fuel
System)
• Fan hub assembly (refer to Group 7, Cooling
System)
(4) Remove the gear housing and gasket (Fig. 59).
(5) Clean the gasket material from the cylinder
block.
GEAR
HOUSING
J9109-103
Fig. 59 Gear Housing/Gasket
INSTALLATION
(1) Install a new gasket and the gear housing.
Tighten the bolts to 24 N-m (18 ft. lbs.) torque.
(2) Install the camshaft. Make sure the alignment
marks on the camshaft and crankshaft gears are
aligned (Fig. 60).
J9109-104
Fig. 60 Camshaft/Crankshaft Gear Aiignment
(3) I f a new housing is installed, the timing pin
assembly must be accurately located.
(4) Install the following:
• Fan hub assembly (refer to Group 7, Cooling
System)
• Fuel injection pump (refer to Group 14, Fuel
System)
4
• Gear driven accessories
(5) Install the gear housing cover (refer to Gear
Housing Cover Installation for the proper proce­
dures).
(6) Install the front end components.
(7) Install the engine assembly into the vehicle.
TIMING PIN
The timing pin can be replaced without removing
the assembly from the gear housing.
REMOVAL
(1) Remove the timing pin by prying the retaining
ring out with a small screwdriver. Replace the retain­
ing ring i f i t is damaged during removal.
INSTALLATION
(1) I f timing pin assembly is removed from gear
housing, i t must be precisely reset to obtain exact
TDC.
(2) Install a new O-Ring, lubricate the pin and
position i n the housing (Fig. 61). Install the new
retaining ring to 1.5 mm (0.059 inch).
CAMSHAFT
GEAR
O-RING
ENGINE
TIMING PIN
RETAINER
RING
g j " 1.5 mm (0.059 inch)
GEAR HOUSING
J9109-46
Fig. 61 Engine Timing Pin Location
TIMING PIN HOUSING ASSEMBLY
REMOVAL
(1) Locate TDC for cylinder No.l.
(2) Remove the timing pin housing assembly and
gasket.
(3) Clean any gasket material from the gear hous­
ing and from the timing pin housing assembly.
INSTALLATION—CYLINDER HEAD ON
The location of the timing pin assembly on the
gear housing is critical for correct engine adjustment.