Chrysler RAM TRUCK 2500 1994 Service Manual page 864

• S J L (DIESEL) ENGINE 9 - 143
CAUTION: The camshaft gear w i l l be p e r m a n e n t l y
d i s t o r t e d . If overheated. The o v e n t e m p e r a t u r e
s h o u l d never exceed 177°C (350°F).
(5) Heat the gear i n an oven at 177°C (350°F) for
45 minutes.
WARNING: WEAR PROTECTIVE GLOVES TO H A N ­
DLE THE HOT GEAR.
(6) Install the gear with the timing marks visible.
Be sure the gear is seated against the camshaft
shoulder.
(7) I f the camshaft is not to be used immediately,
lubricate the lobes and journals to prevent rust.
INSTALLATION
(1) Apply a coat of Lubriplate 105 to the camshaft
bores.
(2) Lubricate the camshaft lobes, journals and
thrust washer with Lubriplate 105, or equivalent.
CAUTION: W h e n Installing t h e camshaft, DO NOT
p u s h it in farther t h a n it w i l l g o w i t h t h e t h r u s t
washer in place. Pushing it t o o far can d i s l o d g e t h e
p l u g in t h e rear of t h e camshaft bore a n d c a u s e an
o i l leak.
(3) Install the camshaft/thrust washer. Align the
timing marks as illustrated (Fig. 7).
(4) Install the thrust washer bolts and tighten to
24 N-m (18 ft. lbs.) torque.
(5) Verify the camshaft has the correct amount of
backlash and end clearance (Fig. 11).
BACKLASH - 0 . 0 8 0 - 0 . 3 3 0 mm
( 0 . 0 0 3 - 0 . 0 1 3 inch)
C L E A R A N C E - 0 . 1 5 2 - 0 . 2 5 4 mm
( 0 . 0 0 6 - 0 . 0 1 0 inch)
Fig. 11 Camshaft Backlash and End Clearance
(6) Install the following parts:
• Lift pump
• Gear housing cover
• Vibration damper
• Fan hub assembly
• Drive belt
• Push rods
• Rocker lever assemblies
• Valve covers
(7) Install the engine i n the vehicle.
(8) Operate the engine at idle for five to ten min­
utes and check for leaks and loose parts.
CYLINDEH BL0CI
REMOVAL
(1) Remove the engine assembly from the vehicle.
(2) Remove the cylinder head from the block.
(3) Remove the camshaft.
(4) Remove the piston/connecting rod assemblies.
INSPECTION
Measure the combustion deck face using a straight
edge and a feeler gauge (Fig. 1). The distortion of the
combustion deck face is not to exceed 0.010 mm
(0.0004 inch) i n any 50.00 mm (2.0 inch) diameter.
Overall variation end to end or side to side is 0.075
mm (0.003 inch).
I f the surface exceeds the limit, refer to Cylinder
Block Refacing.
Fig. 1 Combustion Deck Face Measurement
Inspect the cylinder bores for damage or excessive
wear.
Measure the cylinder bores (Fig. 2). I f the cylinder
bores exceeds the limit, refer to Cylinder Bore Re­
pair.
Inspect the camshaft bores for scoring or excessive
wear.
Measure the camshaft bores (Fig. 3). Limit for the
No.l bore applies to the ID of the bushing.
I f a bore exceeds the limit, refer to Camshaft Bore
Repair.
Inspect the tappet bores for scoring or excessive
wear (Fig. 4).
I f out of limits, replace the cylinder block.
CYLINDER BORES—DE-GLAZE
(1) New piston rings may not seat i n glazed cylin­
der bores.