Dodge ram truck 3500 1996 Service Manual page 1177

5 J L (DSESEL) ENGINE I - 187
R E M O V A L A N D I N S T A L L A T I O N (Continued)
Follow this procedure to install the assembly so that
it corresponds to TDC for cylinder No.l.
(1) Look through the hole in the gear housing and
rotate the engine until the hole in the cam gear can
be seen.
(2) Remove the injector nozzles from all of the cyl­
inders. This step is important to vent the cylinders so •
the crankshaft can be rotated smoothly to locate TDC
for cylinder No.l.
(3) Temporarily install the vibration damper.
(4) Fabricate and install a wire pointer (Fig. 62).
This can be done by forming a piece of wire that can
be tighten under one of the gear housing capscrews.
The wire should extend from the gear cover to a
place on the crankshaft vibration damper that is eas­
ily seen.
Fig. 62 Fabricated Wire Pointer
(5) Rotate the crankshaft one-quarter rotation in
the direction of engine rotation.
(6) Tighten the adjusting screw for the No.l intake
valve to zero lash plus 5 turns.
CAUTION: Use extreme care when rotating the
crankshaft. Use of too much force could damage
the valve or push rod (Fig. 63).
(7) Rotate the crankshaft slowly in the opposite
direction of normal engine rotation until the piston
touches the intake valve (Fig. 63).
(8) Mark the vibration damper at the wire pointer
(Fig. 63).
(9) Rotate the crankshaft in the direction of nor­
mal engine rotation until the piston touches the
intake valve (Fig. 64). Make sure that the piston
touches the intake valve with approximately
the same amount of force as in the previous
step (Fig. 64).
(10) Mark the vibration damper at the wire
pointer (Fig. 64).
Fig. 63 Locate and Mark Vibration Damper—First
Mark
'J9409-119
Fig. 64 Mark Vibration Damper—Second Mark
(11) Measure the distance and mark the vibration
damper at one-half that distance between the two
marks. This mark is the TDC mark (Fig. 65).
Fig. 65 Location of Top Dead Center (TDC)
(12) Completely loosen the intake valve adjusting
screw. I f not done, damage to the intake valve or
push rod could occur when the crankshaft is rotated.