Chrysler RAM TRUCK 2500 1994 Service Manual page 860

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5.9L (DIESEL) ENGINE 9 - 139
5 ) ) ) / ROTATE
VIBRATION
H A M P E R
E X H A U S T ' ^ T ^
= p V A L V E / 2 N D MARK
'J9409-119
Fig. 10 Mark Vibration Damper—Second Mark
T D C
1ST
MARK
2ND MARK
J 9 1 0 9 - 5 0
Fig. 11 Location of Top Dead Center (TDC)
(15) Apply a coat of Loctite™ 59241 (Liquid Te­
flon), or equivalent to the threads of the Torx head
bolts. Install the timing pin assembly and new
O-ring.
(16) Hold the timing pin i n the hole to align the
housing and install the Torx head bolts. Tighten the
Torx bolts to 5 N-m (44 i n . lbs.) torque.
(17) Install the remaining rocker lever pedestal as­
semblies. Tighten the rocker lever pedestal mounting
capscrews.
(18) Adjust the valves.
(19) Install the injectors and bleed the fuel system
(refer to Group 14, Fuel System).
(20) Install the fuel pump (refer to Group 14, Fuel
System).
(21) Install the gear cover.
(22) Remove the pointer. Install the crankshaft v i ­
bration damper.
INSTALLATION (CYLINDER HEAD OFF)
The timing pin assembly is precisely located on the
gear housing to correspond to TDC for Cylinder No.l.
The timing pin assembly must be relocated i f the
gear housing is interchanged.
(1) Temporarily install the vibration damper and a
fabricated wire pointer (Fig. 12). Put a flat washer
between the pointer and gear housing to prevent
damage to the gear housing.
(2) Fabricate a steel plate (Fig. 13).
FABRICATED
WIRE
POINTER
VIBRATION
DAMPER
J 9 1 0 9 - 1 0 7
Fig. 12 Fabricated Wire Pointer
1 4 . 2 8 8 mm ( . 5 6 2 5 inch)
12.7 mm
(.5 inch)
1 5 3 . 9 8 8 mm
( 6 . 0 6 2 5 inch)
5 0 . 8 mm
(2 inch)
J 9 1 0 9 - 1 0 5
Fig. 13 Fabricated Steei Plate
(3) Use two flywheel housing bolts to assemble the
plate over N o . l cylinder (Fig. 14).
(4) Rotate the crankshaft i n the direction of rota­
tion until the piston contacts the plate.
(5) Mark the vibration damper (Fig. 11).
FLYWHEEL
H O U S I N G
BOLT
F A B R I C A T E
P L A T E
Fig. 14 Fabricated Plate Location on No.1 Cylinder