Dodge RAM TRUCK 1500 1995 Service Manual page 961

I - 120 8 J L ENGINE
B R
(16) Remove the EGR tube. Discard the gasket, for
right side only.
(17) Remove lower intake manifold. Discard the
flange side gaskets and the front and,rear cross-over
gaskets.
(18) Disconnect exhaust pipe from exhaust mani­
fold (refer to Group 11, Exhaust System and Intake
Manifold). •
(19) Remove exhaust manifolds and gaskets (refer
to Group 11, Exhaust System and Intake Manifold).
(20) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(21) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin­
der head gasket.
(21) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads. Be sure material does not fall into the lifters
and surrounding valley.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
Clean the exhaust manifold to cylinder head mat­
ing areas.
INSPECTION
Inspect ail surfaces with a straightedge if there is
any reason to suspect leakage. The out-of-flatness
specifications are 0.0007 mm/mm (0.0004 inch/inch),
0.127 mm/152 mm (0.005 inch/6 inches) any direction
or 0.254 mm (0.010 inch) overall across head. If ex­
ceeded, either replace head or lightly machine the
head surface.
The cylinder head surface finish should be
1.78-4.57 microns (15-80 microinches).
Inspect push rods. Replace worn or bent rods.
Inspect rocker arms. Replace if worn or scored.
INSTALLATION
(1) Position the new cylinder head gaskets onto the
cylinder block.
(2) Position the cylinder heads onto head gaskets
and cylinder block.
(8) Tighten the cylinder head bolts in two steps
(Fig. 7):
• Step 1—Tighten all cylinder head bolts, in se­
quence, to 58 N e m (43 ft. lbs.) torque.
• Step 2—Tighten all cylinder head bolts, in se­
quence, to 148 N-m (105 ft. lbs.) torque.
CAUTION; When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the waives and piston could
occur.
Jf409-14
Fig. 7 Cylinder Head Bolt Tightening Sequence
(4) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 N-m
(21 ft. lbs.) torque.
(5) Install the side intake manifold gaskets. Re
sure that the locator dowels are positioned in the
head (Fig. 8).
Fig. 8 Intake Manifold Flange Gasket Alignment
(6) Peel off the protective paper (blue - rear and
brown - front) and press firmly onto the block (Fig.
9). BE SURE THE B L O C K IS O I L FREE*. Align­
ing slots in end seals with notches in intake manifold
gaskets.
{BLUE PEEL-OFF) J9409-63
Fig. 9 Intake Manifold-to-Block Seals