Chrysler RAM TRUCK 2500 1994 Service Manual page 848

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5.9L (DIESEL) ENGINE 9 - 127
(28) Install the radiator (refer to Group 7, Cooling
System).
(29) Connect the lower radiator hose.
(30) Install the fan shroud.
(31) Install the fan.
(32) Connect the top radiator hose.
(33) Install the radiator overflow bottle.
(34) Install the washer bottle.
(35) I f equipped, install the condenser.
(36) Install the A/C compressor with the lines at­
tached.
(37) Evacuate and charge the air conditioning sys­
tem, i f equipped (refer to Group 24, Heating and Air
Conditioning for service procedures).
(38) Install the transmission oil cooler.
(39) Install the upper crossmember and top core
support.
(40) Install the serpentine belt (refer to Group 7,
Cooling System).
(41) Fill the cooling system with a mixture of 50%
water and 50% ethylene-glycol base antifreeze (refer
Group 7, Cooling System for the proper procedure).
(42) Fill the engine with the required amount of
clean engine lubricating oil (refer to Group 0, Lubri­
cation and Maintenance).
(43) Install the battery and connect the battery ca­
bles.
(44) Check the oil level after the engine has run
for 2 or 3 minutes. Oil held i n the oil filter and oil
passages will cause the oil level i n the pan to be
lower.
(45) Operate the engine at idle for 5 to 10 minutes
and check for leaks and loose parts.
ROCKER LEVERS / PUSH RODS
REMOVAL
(1) Remove the valve covers.
(2) Loosen the adjusting screw locknuts. Loosen
the adjusting screws until they stop (Fig. 1).
(3) Remove the bolts from the rocker lever pedes­
tals. Remove the pedestals and rocker lever assem­
blies (Fig. 1).
(4) Remove the push rods. The rear two push rods
must be raised through holes i n cab overhang.
DISASSEMBLE—ROCKER LEVERS
(1) Remove the retaining rings and thrust washers
(Fig. 1).
(2) Remove the rocker levers (Fig. 1). DO NOT dis­
assemble the rocker lever shaft and pedestal. The
pedestal and shaft must be replaced as an assembly.
(3) Remove the locknut and adjusting screw (Fig.
1).
(4) Clean all parts i n a strong solution of laundry
detergent i n hot water.
(5) Use compressed air to dry the parts after rins­
ing i n clean hot water. The pedestals are made from
L O C K N U T A D J U S T I N G
J 9 1 0 9 - 3 1
Fig. 1 Location of Rocker Lever Components
powdered metal and may continue to show wetness
after they have been cleaned and dried.
(6) Inspect for excessive wear i n the bore and the
contact surface for the valve stem.
(7) Measure the rocker lever bore diameter. The
maximum diameter is 19.05 mm (0.75 inch). Replace
i f out of limits.
(8) Inspect the pedestal and shaft.
(9) Measure the shaft diameter. The minimum di­
ameter is 18.94 mm (0.746 inch). Replace i f out of
limits.
ASSEMBLE—ROCKER LEVERS
(1) Install the adjusting screw and locknut.
(2) Lubricate the shaft with clean engine oil. Be
sure to assemble the intake and exhaust rocker le­
vers i n the correct location.
(3) Position the levers on the rocker shaft. Install
the thrust washers.
(4) Clean the push rods i n the hot soapy water.
(5) Inspect the push rod ball and socket for signs
of scoring or cracks where the ball and the socket are
pressed into the tube.
(6) Check the push rods for roundness and
straightness.
(7) Install the push rods into the sockets of the
valve tappets. Lubricate the push rod sockets with
clean engine oil.
(8) Make sure the rocker lever adjusting screws
are completely backed out.
INSTALLATION
(1) Make sure the dowel rings i n the pedestals are
installed into the dowel bores i n the cylinder head.
(2) I f the push rod is holding pedestal off head, bar
the engine until the pedestal will set on the head
surface without interference.
(3) Use clean engine oil to lubricate the cylinder
head bolt threads and under the bolt heads.
(4) Install the long bolts (12 mm) into the rocker
lever pedestals. Tighten the bolts as follows: