Chrysler RAM TRUCK 2500 1994 Service Manual page 861

9 - 140 5.9L (DIESEL) ENGINE
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(6) Rotate the engine i n the opposite direction un­
t i l the piston contacts the plate.
(7) Mark the vibration damper (Fig. 11).
(8) Mark the vibration damper for TDC. TDC will
be one-half the distance between the first two marks
(Fig. 11).
(9) Remove the plate and rotate the engine i n the
direction of rotation until the pointer aligns with the
TDC mark.
(10) Look for the timing pin hole i n the camshaft
gear. I f i t is not visible, rotate the crankshaft one
complete rotation. Align the pointer with the TDC
mark.
(11) Install the timing pin housing assembly with a
new gasket.
(12) Apply a coat of Loctite 59241 liquid teflon, or
equivalent to the threads of the torx head bolts.
(13) Push the pin into the hole i n the cam gear to
align the timing pin housing.
(14) Hold the pin i n while tightening the torx head
bolts to 5 N-m (44 in. lbs.) torque. Be sure timing pin
is disengaged before rotating the engine.
(15) Remove the vibration damper and wire
pointer.
TIPPET
REMOWAL
(1) Remove the camshaft.
(2) Insert a trough the full length of the cam bore
(Fig. 1). Cummins Tappet Changing Tool 3822513 is
available for this job.
(3) Make sure the trough is positioned so i t will
catch the tappet when the wooden dowel is removed.
(4) Identify the location of each tappet as i t is re­
moved. The tappets must be installed i n their origi­
nal locations.
(5) Only remove one tappet at a time. Remove the
rubber band from the two companion tappets, secur­
ing the tappet not to be removed with the rubber
band.
(6) Pull the wooden dowel from the tappet bore al­
lowing the tappet to fall into the trough (Fig. 1).
(7) Normally the tappet will fall over when i t drops
into the trough. Use a flashlight to determine this. I f
the tappet does not fall over, shake the trough gently
to get i t to do so.
(8) Special care should be taken, when removing
the No.6 cylinder tappets. DO NOT knock or shake
the tappet over the end barrier of the trough.
(9) Carefully pull the trough and tappet from the
cam bore and remove the tappet. Repeat the process
until all tappets are removed.
INSPECTION
Inspect the tappet socket, stem and face for exces­
sive wear, cracks and other damage (Fig. 2).
T R O U G H
Fig. 1 Tappet Remowal using a Trough
The minimum tappet stem diameter is 15.925 mm
(0.627 inch) - (Fig. 2). I f the tappet is out of limits,
replace the tappet.
NORMAL
WEAR
S T E M
DIAMETER-
ABNORMAL
WEAR
J9109-152
Fig. 2 Tappet Inspection
INSTALLATION
(1) Insert the trough the full length of the cam
bore.
(2) Feed the installation tool down the tappet bore
and into the trough (Fig. 3).
(3) Feed the installation tool cord through the cam
bores. Carefully pull the trough and installation tool
out the front. The barrier at the rear of the trough
will assure the tool will be pulled out with i t .
(4) Lubricate the tappets with Lubriplate 105, or
equivalent.
(5) Insert the installation tool into the tappet (Fig.
4). To aid i n removing the installation tool after the
tappets is installed, work the tool i n and out of the
tappet several times before installing the tappets.
(6) Place the tappet and tool i n the trough and
slide the trough back into the cam bore (Fig. 4).
(7) Pull the tool/tappet through the cam bore and
up into the tappet bore (Fig. 5).
(8) Difficulty could be experienced i n getting the
tappet to make the bend from the trough up to the