Chrysler DODGE D150 1993 Service Manual page 733

9 - 128 5.9L (DIESEL) ENGINE
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CAMSHAFT
JOURNAL
CAMSHAFT JOURNAL DIAMETER (MIN.
53.962 mm (2.1245 inch)
VALVE LOBE HEIGHT (MIN..)
INTAKE - 47.040 mm (1.852 inch)
EXHAUST - 46.770 mm (1.841 inch)
LIFT PUMP LOBE DIAMETER (MIN.)
35.500 mm (1.398 inch)
J9109-53
Fig. 9 Bearing Journal/Valve Lobe Measurements
CAMSHAFT BUSHING-REPLACEMENT
(1) Measure the diameter of each bore. (The limit
for the bushing in the No.l bore is the same as for
the other bores without bushings). The limit of the
inside diameter is 54.133 mm (2.1312 inch). If the
camshaft bore for the first cam bushing is worn be­
yond the limit, install a new service bushing. Inspect
the rest of the camshaft bores for damage or exces­
sive wear.
(2) If the bores without a bushing are worn beyond
the limit, the engine must be removed for machining
and installation of service bushings. If badly worn,
replace the cylinder block.
(3) Remove the bushing from the No.l bore, using
a universal cam bushing tool.
(4) Mark the cylinder block so you can align the
oil hole in the cylinder block with the oil hole in the
bushing.
(5) Use a universal cam bushing installation tool
and install the bushing so t h a t it is even with the
front face of the cylinder block. The oil hole must .be
aligned. A 3.2 mm (0.128 inch) diameter rod must be
able to pass through the hole (Fig. 10).
(6) Measure the installed bushing. The limit of the
inside diameter is 54.133 mm (2.1312 inch).
CAMSHAFT GEAR-REPLACEMENT
(1) Press the camshaft out of the gear.
J9109-54
Fig. 10 Oil Hole Alignment
(2) Remove all burrs and smooth any rough sur­
faces caused by removing the gear.
(3) Install the camshaft key.
(4) Lubricate the camshaft surface with Lubriplate
105, or equivalent.
(5) Heat the gear in an oven at 121°C (250°F) for
45 minutes.
W A R N I N G : W E A R P R O T E C T I V E G L O V E S T O H A N ­
D L E T H E HOT G E A R .
(6) Install the gear with the timing marks visible.
Be sure the gear is seated against the camshaft
shoulder.
(7) If 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.
C A U T I O N : When installing the camshaft, D O N O T
push it in farther than it will g o with the thrust
washer in place. Pushing it too far can dislodge the
plug in the rear of the camshaft bore and cause an
oil leak.
(3) Install the camshaft/thrust washer. Align the
timing marks as illustrated (Fig. 11).
(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. 12).
(6) Install the following parts:
• Lift pump
• Gear housing cover
• Vibration damper
• F a n hub assembly
• Drive belt
• Push rods
• Rocker lever assemblies
• Valve covers
(7) Install the engine in the vehicle.