Dodge ram truck 3500 1996 Service Manual page 1093

mm
5.9L ENGINE 9 - 103
i E i i M L l^m I I S T 1 L L A K O I ( C o n t i n u e d )
VALVE SPRING AND STEIVI SEAL REPLACEMENT-
IN VEHICLE
(1) Set engine basic timing to Top Dead Center
(TDC).
(2) Remove the air cleaner.
(3) Remove cylinder head covers and spark plugs.
(4) Remove coil wire from distributor and secure to
good ground to prevent engine from starting.
(5) Using suitable socket and flex handle at crank­
shaft retaining bolt, turn engine so the No.l piston is
at TDC on the compression stroke.
. (6) Remove rocker arms.
(7) With air hose attached to an adapter installed
in N o . l spark plug hole, apply 620-689 kPa (90-100
psi) air pressure.
(8) Using Valve Spring Compressor Tool
MD-998772A with adaptor 6633, compress valve
spring and remove retainer valve locks and valve
spring.
(9) Install seals on the exhaust valve stem and
position down against valve guides.
(10) The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the
valve stem as a guide. DO NOT force seal against top
of guide. When installing the valve retainer locks,
compress the spring only enough to install the locks.
(11) Follow the same procedure on the remaining 7
cylinders using the firing sequence 1-8-4-3-6-5-7-2.
Make sure piston in cylinder is at TDC on the valve
spring that is being removed.
(12) Remove adapter from the No.l spark plug
hole.
(13) Install rocker arms.
(14) Install covers and coil wire to distributor.
(15) Install air cleaner.
(16) Road test vehicle.
CYLINDER HEADS
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (refer to Group 7, Cooling
System for the proper procedures).
(3) Remove the intake manifold-to-generator
bracket support rod. Remove the generator.
(4) Remove closed crankcase ventilation system.
(5) Disconnect the evaporation control system.
(6) Remove the air cleaner.
(7) Disconnect the fuel lines.
(8) Disconnect accelerator linkage and i f so
equipped, the speed control and transmission kick-
down cables.
(9) Remove the return spring.
(10) Remove distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect heat indicator sending unit wire.
(13) Disconnect heater hoses and bypass hose.
(14) Remove cylinder head covers and gaskets.
(15) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(16) Remove exhaust manifolds.
(17) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(18) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin­
der head gasket.
(19) Remove spark plugs.
INSTALLATION
(1) Position the new cylinder head gaskets onto
the cylinder block.
(2) Position the cylinder heads onto head gaskets
and cylinder block.
(3) Starting at top center, tighten all cylinder head
bolts, i n sequence, to 68 N-m (50 ft. lbs.) torque (Fig.
20). Repeat procedure, tighten all cylinder head bolts
to 143 N-m (105 ft. lbs.) torque. Repeat procedure to
confirm that all bolts are at 143 N-m (105 ft. lbs.)
torque.
Fig. 20 Cylinder Head Bolt Tightening Sequence
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(4) Install push rods and rocker arm assemblies i n
their original position. Tighten the bolts to 28 N-m
(21 ft. lbs.) torque.
(5) Install the intake manifold and throttle body
assembly (refer to Group 11, Exhaust System and
Intake Manifold).
(6) Install exhaust manifolds. Tighten the bolts
and nuts to 34 N-m (25 ft. lbs.) torque.