Chrysler RAM TRUCK 2500 1994 Service Manual page 801

REMOVAL
(1) Remove the air cleaner.
(2) Remove cylinder head cover.
(3) Remove rocker assembly and push rods. Iden­
tify push rods to ensure installation i n original loca­
tion.
(4) Remove intake manifold.
(5) Remove yoke retainer and aligning yokes.
(6) Slide Hydraulic Tappet Remover/Installer Tool
C-4129-A through opening i n cylinder head and seat
tool firmly i n the head of tappet.
(7) Pull tappet out of bore with a twisting motion.
I f all tappets are to be removed, identify tappets to
ensure installation i n original location.
(8) I f the tappet or bore i n cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to
next oversize. Replace with oversize tappet.
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must al­
w a y s be fitted to the original body. It is advisable to
work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. DO NOT dis­
assemble a tappet on a dirty work bench.
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets and push rods i n their original
positions. Ensure that the oil feed hole i n the side of
the tappet body faces up (away from the crankshaft).
(3) Install rocker arm and shaft assembly.
(4) Install vent cover.
(5) Install distributor, start engine and reset tim­
ing.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all hy­
draulic tappets have filled with oil and have become
quiet.
¥AL¥E TIMING
(1) Turn crankshaft until the No.6 exhaust valve is
closing and No.6 intake valve is opening.
(2) Insert a 6.350 mm (1/4 inch) spacer between
rocker arm pad and stem tip of No.l intake valve. A l ­
low spring load to bleed tappet down giving i n effect
a solid tappet.
(3) Install a dial indicator so plunger contacts
valve spring retainer as nearly perpendicular as pos­
sible. Zero the indicator.
(4) Rotate the crankshaft clockwise (normal run­
ning direction) until the valve has lifted 0.863 mm
(0.034 inch). The timing of the crankshaft should
now read from 10° before top dead center to 2° after
top dead center. Remove spacer.
CAUTION: DO NOT turn crankshaft any further
clockwise a s valve spring might bottom and result
in serious damage.
(5) I f reading is not within specified limits:
(a) Check sprocket index marks.
(b) Inspect timing chain for wear.
(c) Check accuracy of DC mark on timing indica­
tor.
VIBRATION DAMPER
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove fan shroud retainer bolts and set
shroud back over engine.
(3) Remove the cooling system fan.
(4) Remove the serpentine belt (refer to Group 7,
Cooling System).
(5) Remove the vibration damper pulley.
(6) Remove vibration damper bolt and washer from
end of crankshaft.
(7) Install bar and screw from Puller Tool Set
C-3688. Install 2 bolts with washers through the
puller tool and into the vibration damper (Fig. 1).
J9209-81
Fig. 1 Vibration Damper Assembly
(8) Pull vibration damper off of the crankshaft.
INSTALLATION
(1) Position the vibration damper onto the crank­
shaft.
(2) Place installing tool, part of Puller Tool Set
C-3688 i n position and press the vibration damper
onto the crankshaft (Fig. 2).
(3) Install the crankshaft bolt and washer. Tighten
the bolt to 183 N-m (135 ft. lbs.) torque.
(4) Install the crankshaft pulley. Tighten the pul­
ley bolts to 23 N-m (200 i n . lbs.) torque.
(5) Install the serpentine belt (refer to Group 7,
Cooling System).
(6) Install the cooling system fan. Tighten the bolts
to 23 N-m (17 ft. lbs.) torque.
(7) Position the fan shroud and install the bolts.
Tighten the retainer bolts to 11 N-m (95 in. lbs.)
torque.
(8) Connect the negative cable to the battery.