Chrysler RAM TRUCK 2500 1994 Service Manual page 770

(16) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(17) Remove exhaust manifolds.
(18) Remove rocker arm assemblies and push rods.
Identify to ensure installation i n original locations.
(19) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin­
der head gasket.
(20) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge i f there is
any reason to suspect leakage. I f out-of-flatness ex­
ceeds 0.00075 mm/mm (0.00075 inch/inch) times the
span length i n inches i n any direction, either replace
head or lightly machine the head surface.
FOR EXAMPLES A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept­
able.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
(1) Apply Perfect Sealant No.5, or equivalent, to
both sides of the gasket (Fig. 5).
Fig. 5 Sealant Location on Cylinder Head Gasket
(2) Position the new cylinder head gaskets onto the
cylinder block.
(3) Position the cylinder heads onto head gaskets
and cylinder block.
(4) Starting at top center, tighten all cylinder head
bolts, i n sequence, to 68 N-m (50 ft. lbs.) torque (Fig.
6). 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. 6 Cylinder Head Bolt Tightening Sequence
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
T D C . Contact between the valves and piston could
occur.
(5) Install push rods and rocker arm assemblies i n
their original position. Tighten the bolts to 28 N-m
(21 ft. lbs.) torque.
(6) Install the intake manifold and throttle body
assembly (refer to Group 11, Exhaust System and In­
take Manifold).
(7) Install exhaust manifolds. Tighten the bolts
and nuts to 34 N-m (25 ft. lbs.) torque.
(8) Adjust spark plugs to specifications (refer to
Group 8D, Ignition System). Install the plugs and
tighten to 41 N-m (30 ft. lbs.) torque.
(9) Install coil wires.
(10) Connect heat indicator sending unit wire.
(11) Connect the heater hoses and bypass hose.
(12) Install distributor cap and wires.
(13) Hook up the return spring.
(14) Connect the accelerator linkage and i f so
equipped, the speed control and transmission kick-
down cables.
(15) Install the fuel lines.
(16) Install the generator and drive belt. Tighten
generator mounting bolt to 41 N-m (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 N-m
(200 in. lbs.) torque. Refer to Group 7, Cooling Sys­
tem for adjusting the belt tension.
(17) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.