Dodge ram truck 3500 1996 Service Manual page 1180

i - 190 5.9L (DIESEL) E N G I N E
BR
R E M O V A L AND INSTALLATION (Continued)
G E A R R E P L A C E M E N T
(1) Press the camshaft out of the gear.
(2) Remove all burrs and smooth any rough sur­
faces caused by removing the gear.
(3) Install the camshaft key.
(4) Lubricate the camshaft surface with Lubriplate
105, or equivalent.
CAUTION: The camshaft gear will be permanently
distorted if overheated. The oven temperature
should never exceed 177°C (350°F).
(5) Heat the gear in an oven at 177°C (350°F) for
45 minutes.
WARNING: WEAR PROTECTIVE G L O V E S TO HAN­
D L E THE HOT G E A R .
(6) Install the gear with the timing marks visible.
Be sure the gear is seated against the camshaft
shoulder.
(7) I f the camshaft is not to be used immediately,
lubricate the lobes and journals to prevent rust.
INSTALLATION
(1) Apply a coat of Lubriplate 105 to the camshaft
bores.
(2) Lubricate the camshaft lobes, journals and
thrust washer with Lubriplate 105, or equivalent.
CAUTION: When installing the camshaft, DO NOT
push it in farther than it will go with the thrust
washer in place. Pushing it too far can dislodge the
plug in the rear of the camshaft bore and cause an
oil leak.
(3) Install the camshaft/thrust washer. Align the
timing marks as illustrated (Fig. 70).
(4) Install the thrust washer bolts and tighten to
24 N-m (18 ft. lbs.) torque.
(5) Verify the camshaft has the correct amount of
backlash and end clearance (Fig. 73).
(6) Install the following parts:
• Lift pump
• Gear housing cover
• Vibration damper
• Fan hub assembly
• Drive belt
• Push rods
• Rocker lever assemblies
• Valve covers
(7) Install the engine in the vehicle.
(8) Operate the engine at idle for five to ten min­
utes and check for leaks and loose parts.
BACKLASH - 0 . 0 8 0 - 0 . 3 3 0 mm
( 0 . 0 0 3 - 0 . 0 1 3 inch)
CLEARANCE - C U 5 2 - 0 . 2 5 4 mm
( 0 . 0 0 6 - 0 . 0 1 0 inch)
Fig. 73 Camshaft Backiash and End Clearance
TAPPET
REMOVAL
(1) Remove the camshaft.
(2) Insert a trough the full length of the cam bore
(Fig. 74). Cummins Tappet Changing Tool 3822513 is
available for this job.
(3) Make sure the trough is positioned so i t will
catch the tappet when the wooden dowel is removed.
(4) Identify the location of each tappet as it is
removed. The tappets must be installed in their orig­
inal locations.
(5) Only remove one tappet at a time. Remove the
rubber band from the two companion tappets, secur­
ing the tappet not to be removed with the rubber
band.
(6) Pull the wooden dowel from the tappet bore
allowing the tappet to fall into the trough (Fig. 74).
(7) Normally the tappet will fall over when i t
drops into the trough. Use a flashlight to determine
this. I f the tappet does not fall over, shake the trough
gently to get it to do so.
(8) Special care should be taken, when removing
the No.6 cylinder tappets. DO NOT knock or shake
the tappet over the end barrier of the trough.
(9) Carefully pull the trough and tappet from the
cam bore and remove the tappet. Repeat the process
until all tappets are removed.
INSTALLATION
(1) Insert the trough the full length of the cam
bore.
(2) Feed the installation tool down the tappet bore
and into the trough (Fig. 75).
(3) Feed the installation tool cord through the cam
bores. Carefully pull the trough and installation tool