Chrysler RAM TRUCK 2500 1994 Service Manual page 813

9 - 92 5.9L ENGINE
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(2) Insert a 3.175 mm (1/8 inch) finish wire or
equivalent into passage.
(3) Plug should be 190.0 to 195.2 mm (7-1/2 to
7-11/16 inches) from machined surface of block (Fig.
11). I f plug is too high, use a suitable flat dowel drift
to position properly.
RI G HT OIL G A L L E R Y
P A S S A G E
TO CAMSHAFT
R E A R BEARING
P L U G
CRANKSHAFT
OIL F R O M F I L T E R
TO S Y S T E M
OIL TO F I L T E R
FROM OIL P U M P
J9109-229
Fig. 11 Oil Line Plug
(4) I f plug is off position, remove oil pan and rear
main bearing cap. Use suitable flat dowel to remove
plug. Coat outside diameter of plug with Mopar (stud
and bearing mount adhesive), or equivalent. Plug
should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 inches)
from bottom of the block.
(5) Assemble engine and check oil pressure.
ENGINE CORE, OIL AND CAMSHAFT PLUGS
Engine core plugs have been pressed into the oil
galleries behind the camshaft thrust plate (Fig. 12).
This will reduce internal leakage and help maintain
higher oil pressure at idle.
REMOVAL
(1) Using a blunt tool such as a drift or a screw­
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 13).
(2) With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig.
13).
CLEANING
Thoroughly clean inside of cup plug hole i n cylinder
block or head. Be sure to remove old sealer.
Make certain the new plug is cleaned of all oil or
grease.
^RH157p
Fig. 12 Location of Cup Plugs in Oil Galleries
SECOND
REMOVE PLUG
WITH PLI E RS
FI R ST
STRIKE HERE
WITH HAMMER
DRIFT
9209-41
Fig. 13 Core Hole Plug Removal
INSTALLATION
(1) Coat edges of plug and core hole with Mopar
Gasket Maker, or equivalent.
CAUTION: DO NOT drive cup plug into the casting
a s restricted coolant flow can result and cause s e ­
rious engine problems.
(2) Using proper drive plug, drive plug into hole.
The sharp edge of the plug should be at least 0.50
mm (0.020 inch) inside the lead-in chamfer.
I t is not necessary to wait for curing of the sealant.
The cooling system can be filled and the vehicle
placed i n service immediately.
ASSEMBLE
(1) Install the piston/connecting rod assembly.
(2) Install the oil pan.
(3) Install the cylinder head.
(4) Install the engine into the vehicle.