Dodge ram truck 3500 1996 Service Manual page 1188

9 • 198 5.9L (DIESEL) ENGINE
B R
R E M O V A L
AND INSTALLATION
( C o n t i n u e d )
If removed, install a new alignment pin. Drive the
pin in using a ball- peen hammer, leaving i t protrud­
ing 1.60 mm (0.063 Inch) to 2.39 mm (0.094 inch)
above the crankshaft (Fig. 98).
Fig. 98 Installing Alignment Pin
Heat the crankshaft gear for 45 minutes at a tem­
perature of 121°C (250°F).
CAUTION: DO NOT heat the gear longer than 45
minutes.
WARNING: WEAR PROTECTIVE GLOVES TO PRE­
VENT INJURY.
Position the gear with the timing mark out and
install i t on the crankshaft using the alignment pin.
Make sure the gear contacts the shoulder.
OIL P U i P
The non-intercooled turbocharged engine oil pumps
can not be used on intercooled engines.
REMOVAL
(1) Remove the radiator (refer to Group 7, Cooling
System for the proper procedure).
(2) Loosen the crankshaft vibration damper and
remove the drive belt.
(3) Remove the fan clutch assembly.
(4) Remove the fan hub.
(5) Remove the oil fill tube.
(6) Remove the crankshaft vibration damper.
(7) Remove the gear housing cover.
(8) Remove the four mounting bolts and pull the
pump from the bore in the cylinder block (Fig. 99).
INSTALLATION
(1) Lubricate the pump with clean engine oil. Fill­
ing the pump with clean engine oil during installa­
tion will help to prime the pump at engine start up.
Make sure the idler gear pin is installed in the
locating bore in the cylinder block.
(2) Install the pump. Tighten the oil pump mount­
ing bolts in two steps and in the sequence shown
(Fig. 99).
Fig. 99 Oil Pump Removal
® Step 1—Tighten to 5 N-m (44 in. lbs.) torque.
o Step 2—Tighten to 24 N-m (18 ft. lbs.) torque.
(3) The back plate on the pump seats against the
bottom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump
will not touch the cylinder block.
(4) Measure the idler gear to pump drive gear
backlash and the idler gear to crankshaft gear back­
lash (Fig. 100). The backlash should be 0.080- 0.330
mm (0.003-0.013 inch). I f the backlash is out of lim­
its, replace the oil pump drive gear and the idler
gear.
(5) I f the adjoining gear moves when you measure
the backlash, the reading will be incorrect.
Fig. 100 Idler Gear to Pump Drive Gear and
Crankshaft Gear Backlash
OIL FILTER BYPASS WALWE
REMOVAL
(1) Remove the oil cooler cover (Fig. 101).
(2) Remove the valve from the cooler cover (Fig.
101).
INSTALLATION
(1) Drive the new valve in until i t bottoms against
the step in the bypass valve bore (Fig. 102).