Dodge ram truck 3500 1996 Service Manual page 1178

i?EH©WAL im® INSTALLATION (Continued)
(13) 'Rotate the crankshaft in the direction of nor­
mal engine rotation until the pointer is aligned with
the TDC mark. Rotate crankshaft one additional
turn.
(14) The timing pin hole in the cam gear should be
visible or felt through the back side of the gear hous­
ing. I f not, the crankshaft must be rotated one revo­
lution in the direction of engine rotation.
(15) Apply a coat of Loctite® 59241 (Liquid
Teflon), or equivalent to the threads of the Torx head
bolts. Install the timing pin assembly and new
O-ring.
(16) Hold the timing pin in the hole to align the
housing and install the Torx head bolts. Tighten the
Torx bolts to 5 N-m (44 in. lbs.) torque.
(17) Install the remaining rocker lever pedestal
assemblies. Tighten the rocker lever pedestal mount­
ing capscrews.
(18) Adjust the valves.
(19) Install the injectors and bleed the fuel system
(refer to Group 14, Fuel System).
(20) Install the fuel pump (refer to Group 14, Fuel
System). •
(21) Install the gear cover.
(22) Remove the pointer. Install the crankshaft
vibration, damper.
INSTALLATION—CYLINDER HEAD REMOVED
The timing pin assembly is precisely located on the
gear housing to correspond to TDC for Cylinder No.l.
The timing pin assembly must be relocated i f the
gear housing is interchanged.
(1) Temporarily install the vibration damper and a
fabricated wire pointer (Fig. 66). Put a flat washer
between the pointer and gear housing to prevent
damage to the gear housing.
Fig, 68 Fabricated Wire Pointer
(2) Fabricate a steel plate (Fig. 67).
(3) Use two flywheel housing bolts to assemble the
plate over No.l cylinder (Fig. 68).
50.8 mm
Fig. 67 Fabricated Steel Plate
Fig, 68 Fabricated Plate Location on NoJ Cylinder
(4) Rotate the crankshaft In the direction of rota­
tion until the piston contacts the plate.
(5) Mark the vibration damper (Fig. 65).
(6) Rotate the engine in the opposite direction
until the piston contacts the plate.
(7) Mark the vibration damper (Fig. 65).
(8) Mark the vibration damper for TDC. TDC will
be one-half the distance between the first two marks
(Fig. 65).
(9) Remove the plate and rotate the engine In the
direction of rotation until the pointer aligns with the
TDC mark.
(10) Look for the timing pin hole in the camshaft
gear. I f i t is not visible, rotate the crankshaft one
complete rotation. Align the pointer with the TDC
mark.
(11) Install the timing pin housing assembly with
a new gasket.
(12) Apply a coat of Loctite 59241 liquid teflon, or
equivalent to the threads of the torx head bolts.
(13) Push the pin into the hole in the cam gear to
align the timing pin housing.
(14) Hold the pin in while tightening the torx head
bolts to 5 N-m (44 In. lbs.) torque. Be sure timing pin
is disengaged before rotating the engine.
(15) Remove the vibration damper and wire pointer.