set clock DODGE TRUCK 1993 Service Repair Manual

e - 4
CLUTCH

•
7/16 - 20
THREAD
NUT
10 INCHES LONG J9006-25

CLUTCH
HOUSING

BORE
J9006-26

Fig.
2 Checking Clutch Housing Bore Runout
.000
CLUTCH
HOUSING

qroe {Smm READINGS) J9006-27

Fig.
3
Housing
Bore Measurement Points And Sample Readings
MEASURING
CLUTCH
HOUSING FACE
RUNOUT (GAS AND DIESEL ENGINES) (1) Reposition the dial indicator plunger on the
housing face (Fig. 5). Place the indicator plunger at
the rim of the housing bore as shown.
(2) Rotate the crankshaft until the indicator
plunger is at the 10 O'clock position on the bore.
Then zero the dial indicator.
SLOT SHOWS DIRECTION OFFSET
DOWEL
DOWEL SELECTION
TIR
VALUE OFFSET DOWEL

REQUIRED
0.011
-0.021
inch
0.007
inch

0.022
-
0.035
inch
0.014
inch

0.036
-
0.052
inch
0.021
inch

J9206-7
Fig.
4
Housing
Bore
Alignment
Dowel
Selection

(3)
Measure and record face runout at four points
90° apart around the housing face (Fig. 6). Perform
the measurement at least twice for accuracy.

(4)
Subtract the lowest reading from the highest to
determine total runout. As an example, refer to the
sample readings shown in Figure 6. If the low read­
ing was minus
0.004
in. and the highest reading was
plus
0.009
in., total runout is actually
0.013
inch.

(5)
Total allowable face runout is 0.010 inch. If
runout exceeds this figure, runout will have to be
corrected. Refer to Correcting Clutch Housing Face
Runout.

CORRECTING CLUTCH HOUSING FACE
RUNOUT

Housing face runout, on gas or diesel engines, can
be corrected by installing shims between the clutch
housing and transmission (Fig. 7). The shims can be made from shim stock or similar materials of the re­
quired thickness.
As an example, assume that face runout is the
same as shown in Figure 6 and in step (4) above. In
this case, three shims will be needed. Shim thick­
nesses should be
0.009
in. (at the
0.000
corner),
0.012
in. (at the
-0.003
corner) and
0.013
in. (at the
-0.004

corner).
After installing the clutch assembly and housing,
tighten the housing bolts nearest the alignment dow­ els first.
Clutch housing preferred bolt torques are:
• 41 N-m (30 ft. lbs.) for 3/8 in. diameter bolts
• 68 Nnn (50 ft. lbs.) for 7/16 in. diameter bolts
• 47 Nth (35 ft. lbs.) for diesel clutch housing bolts During final transmission installation, install the
shims between the clutch housing and transmission at the appropriate bolt locations.

•

COOLING SYSTEM
7 - 15
SERVICE
PROCEDURES

INDEX
page
Coolant
26
Coolant Reserve/Overflow System
30

Cooling System Cleaning/Reverse Flushing
28

Cooling System Fan—Diesel Engine
. 37

Cooling System
Fan—Gas
Engines
36

Cooling System
Hoses
34
Draining Cooling System
27

Pressure
Testing
Radiator
Caps
............. 32

Radiator Pressure
Cap 31

Radiators
32

Refilling
the
Cooling System
28

WATER PUMPS—EXCEPT DIESEL
A centrifugal water pump circulates coolant
through the water jackets, passages, intake manifold,
radiator core, cooling system hoses and heater core.
The pump is driven from the engine crankshaft by a drive belt. The water pump impeller is pressed onto the rear
of a shaft that rotates in a bearing pressed into the
water pump body. The body has a small hole for ven­
tilation. The water pump seals are lubricated by an­
tifreeze in the coolant mixture. Additional lubrication is not necessary. A quick test to determine if pump is working is to
check if heater warms properly. A defective water
pump will not be able to circulate heated coolant
through the long heater hose to the heater core. The water pump on all models can be removed
without discharging the air conditioning system (if equipped).
REMOVAL The water pump on all gas powered engines is
bolted directly to the engine timing chain case/cover.
A gasket is used as a seal between the water pump
and timing chain case/cover.
If water pump is replaced because of bearing/shaft
damage or leaking shaft seal, the mechanical cooling
fan assembly should also be inspected. Inspect for fa­ tigue cracks, loose blades or loose rivets that could
have resulted from excessive vibration. Replace fan if any of these conditions are found. Also check condi­
tion of the thermal viscous fan drive. Refer to Vis­
cous Fan Drive in this group. (1) Disconnect negative battery cable from battery.
(2) Drain cooling system. Refer to Draining Cool­
ing System in this group. Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
(3)
Disconnect throttle cable from clip at top of fan
shroud.
page

Testing
Cooling System
for
Leaks
. 29

Thermostat
22

Transmission
Oil
Cooler—Diesel
35

Transmission
Oil
Cooler—Except Diesel
35

Transmission Oil-To-Air Cooler
36
Viscous
Fan
Drive
38

Water
Pump
Bypass
Hose—All
Gas
Powered
Engines
.............................. 19

Water
Pumps—5.9L Diesel
18

Water
Pumps—Except Diesel
15
(4) Unsnap coolant reserve/overflow tank (up and
out) from the T-slots on side of fan shroud (Fig. 1) and lay aside. Do not disconnect hose or drain cool­
ant from tank.
(5) Remove the fan shroud from the radiator. Do
not remove shroud from vehicle at this time.
FAN

SHROUD
J9107-67

Fig.
1 Fan
Shroud—Except
Diesel

(6) Remove upper radiator hose at radiator. Special
Clamp Tool number 6094 (Fig. 2) may be used to re­
move the constant tension clamps.
(7) The thermal viscous fan drive is attached
(threaded) to the water pump hub shaft (Fig. 3). Re­
move the fan/fan drive assembly from water pump by
turning the mounting nut counterclockwise (as viewed from front). Threads on the fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool
Set number 2017DSP) can be used. Place a bar or
screwdriver between the water pump pulley bolts (Fig. 3) to prevent the pulley from rotating.
If water pump is being replaced, do not unbolt fan
blade assembly (Fig. 3) from the thermal control fan drive.

7 - 36
COOLING
SYSTEM

• (4) Connect coolant hoses to cooler.

(5)
Connect battery cable to battery.

(6)
Fill cooling system. Refer to Refilling Cooling
System in this section. (7) Check transmission oil level and fill as neces­
sary.

TRANSMISSION
OIL/TO-AIR
COOLER
Oil to air transmission coolers are mounted ahead
of the radiator and operate in conjunction with the
main cooler (Figs, 52 or 53). The transmission oil is
routed through the main cooler first, then the auxil­ iary cooler, before returning to the transmission.
FRONT
OIL-TO-AIR
COOLER

RADIATOR
RADIATOR GRILL SUPPORT RETURN JO

_
TRANSMISSION

*
PRESSURE

(FROM BOTTOM COOLER)
VIEW
IN
CIRCLE J9007-75 Fig.
52
Transmission
Oil-to-Air Cooler—Except

Diesel—
Typical

AUXILIARY
OIL TO AIR
COOLER
J9107-73
Fig.
53
Transmission
Oil-to-Air
Cooler—Diesel

Engine—Typical
COOLING
SYSTEM FAN—GAS ENGINES

Also refer to Viscous Fan Drive in this group for
additional information.
REMOVAL (1) Disconnect negative battery cable from battery.
(2) Remove throttle cable at top of fan shroud.
(3) Unsnap coolant reserve/overflow tank from fan
shroud and lay aside. The tank is held to shroud
with T-shaped slots. Do not disconnect hose or drain
coolant from tank.
(4) The thermal Viscous Fan Drive/Fan Blade As­
sembly is attached (threaded) to water pump hub
shaft (Fig. 54). Remove fan blade/viscous fan drive
assembly from water pump by turning mounting nut
counterclockwise as viewed from front. Threads on
viscous fan drive are RIGHT HAND. A Snap-On 36
MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be
used. Place a bar or screwdriver between water pump
pulley bolts (Fig. 54) to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive as­
sembly from vehicle at this time.
FAN BLADE

ASSEMBLY

THREADED NUT WATER
PUMP

PULLEY
PULLEY
BOLTS
WATER PUMP
THREADED SHAFT
(WATER PUMP HUB)
VISCOUS
FAN DRIVE CRANKSHAFT
PULLEY
J9307-32

Fig.
54 Fan
Blade/Viscous
Fan
Drive—Gas
Engines
Do not unbolt fan blade assembly (Fig. 54) from
viscous fan drive at this time.
(5) Remove fan shroud attaching hardware (two
bolts at bottom-two clips at top). (6) Remove fan shroud and fan blade/viscous fan
drive assembly as a complete unit from vehicle.
After removing fan blade/viscous fan drive assem­
bly, do not place viscous fan drive in horizontal po­ sition. If stored horizontally, silicone fluid in the
viscous fan drive could drain into its bearing assem­
bly and contaminate lubricant.

•

COOLING
SYSTEM
7 - 37
CAUTION:
Do not
remove
water
pump pulley-to-wa­

ter
pump
bolts
(Fig. 54), This
pulley
is
under spring
tension.

(7) Remove four bolts securing fan blade assembly
to viscous fan drive (Fig. 54).
INSPECTION The fan cannot be repaired. If fan is damaged, it
must be replaced. Inspect fan as follows:
(1) Remove fan blade and viscous fan drive as an
assembly from the engine. Refer to preceding Re­
moval procedure.
(2) Remove fan blade assembly from viscous fan
drive unit (four bolts).
(3) Lay fan on a flat surface with leading edge fac­
ing down. With tip of blade touching flat surface, re­
place fan if clearance between opposite blade and surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm (.090 inch). Test all blades in this manner.

WARNING:
DO NOT
ATTEMPT
TO
BEND
OR
STRAIGHTEN
FAN
BLADES
IF NOT
WITHIN
SPECI­
FICATIONS.

(4) Inspect fan assembly for cracks, bends, loose
rivets or broken welds. Replace fan if any damage is
found,

CAUTION:
If fan
blade assembly
is
replaced
be­

cause
of
mechanical damage,
water
pump
and
vis­

cous
fan
drive should
also
be
inspected. These

components
could have been damaged
due to ex­

cessive
vibration.

INSTALLATION (1) Install fan blade assembly to viscous fan drive.
Tighten bolts (Fig. 48) to 23 N*m (17 ft. lbs.) torque. (2) Position fan shroud and fan blade/viscous fan
drive assembly to vehicle as a complete unit.
(3) Install fan shroud.
(4) Install fan blade/viscous fan drive assembly to
water pump shaft (Fig. 54). (5) Install coolant reserve/overflow tank to fan
shroud. Snaps into position.
(6) Install throttle cable to fan shroud.
(7) Connect negative battery cable.

COOLING
SYSTEM
FAN-DIESEL ENGINE

REMOVAL (1) Disconnect negative battery cable from battery.
(2) Remove the fan shroud mounting bolts. Posi­
tion fan shroud towards engine.

CAUTION:
Do not
remove
the fan
puHey bolts. This pulley
is
under spring tension.
(3) The thermal viscous fan drive/fan blade assem­
bly is attached (threaded) to the fan hub shaft (Fig.
55).
Remove the fan blade/fan drive assembly from
fan pulley by turning the mounting nut clockwise (as
viewed from front). Threads on the viscous fan drive are LEFT HAND. A Snap-On 36 MM Fan Wrench
(number SP346 from Snap-On Cummins Diesel Tool
Set number 2017DSP) can be used. Place a bar or
screwdriver between the fan pulley bolts to prevent
pulley from rotating.

THREADED
Fig.
55 Fan
Blades/Viscous
Fan Drive-5.9L
Diesel
(4) Remove the fan shroud and the fan blade/vis­
cous drive as an assembly from vehicle.
(5) Remove fan blade-to-viscous fan drive mount­
ing bolts.
Inspect the fan for cracks, loose rivets, loose or
bent fan blades.
INSPECTION The fan cannot be repaired. If the fan is damaged,
it must be replaced. Inspect the fan as follows:
(1) Remove fan blade and thermal viscous fan
drive assembly from engine. Refer to the preceding
Removal procedure.
(2) Remove fan blade assembly from thermal vis­
cous fan drive unit (four bolts). (3) Lay fan on a flat surface with leading edge fac­
ing down. With tip of blade touching flat surface, re­
place fan if clearance between opposite blade and surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm (.090 inch). Test all blades in this manner.

8D
- 24
IGNITION
SYSTEMS

•
.040
GAUGE

SPARK

"PLUG

J908D-10
Fig.
16 Setting
Spark Plug
Gap—Typical

SPARK
PLUG
SECONDARY
CABLES
CAUTION:
When disconnecting
a
high voltage cable
from
a
spark plug
or
from
the
distributor cap, twist
the rubber boot slightly
(1/2
turn)
to
break
it
loose.
Grasp
the
boot
(not
the
cable)
and
pull
it off
with
a

steady,
even force.

Install cables into
the
proper engine cylinder firing
order (Figs.
17 or 18).

FRONT OF
ENGINE
CLOCKWISE
ROTATION

1-6-5-4-3-2
J9314-80

Fig.
17
Engine
Firing Order—3.9L V-6
Engine

When replacing
the
spark plug
and
coil cables,
route
the
cables correctly
and
secure
in the
proper a

FRONT OF
ENGINE
CLOCKWISE
ROTATION

1-8-4-3-6-5-7-2
J9314-79

Fig.
18
Engine
Firing Order—5.2U5.9L V-8
Engines

retainers. Failure
to
route
the
cables properly
can
cause
the
radio
to
reproduce ignition noise.
It
could
also cause cross ignition
of the
plugs,
or
short circuit
the cables
to
ground.
When installing
new
cables, make sure
a
positive
connection
is
made.
A
snap should
be
felt when
a

good connection
is
made between
the
plug cable
and

the distributor
cap
tower.
Spark plug cable boot heat shields
are
pressed into
the cylinder head
to
surround each cable boot
and
spark plug
(Fig. 19).
These shields protect
the
spark
plug boots from damage
(due to
intense engine heat generated
by the
exhaust manifolds)
and
should
not

be removed. After
the
spark plug cable
has
been
in­
stalled,
the lip of the
cable boot should have
a
small
air
gap to the top of the
heat shield
(Fig. 19).
SPARK
PLUG BOOT

-
HEAT SHIELD
J9314-94

Fig.
19 Heat
Shields

THROTTLE
POSITION
SENSOR
(TPS) For removal
and
installation, refer
to
Throttle
Po­

sition Sensor
in
Group
14,
Fuel Systems.

•

INSTRUMENT PANEL
AND
GAUGES
8E - 3
MALFUNCTION INDICATOR (CHECK ENGINE)

Fig.
5
Distance Sensor
If
the
input from
one of the
following sensors fails
an internal Powertrain Control Module
(PCM)
self
check,
the PCM
turns
on the
Check Engine Lamp. The
PCM
then substitutes
a
modified signal
in
place
of
the one
that failed until
a
repair
is
made:
• Manifold Absolute Pressure (MAP) Sensor
• Throttle Position Sensor
• Coolant Temperature Sensor
• Battery Voltage Sense
• Battery Voltage
Too
High
Refer
to the
appropriate Powertrain Diagnostic
Test Procedures manual
for
further information.

ELECTRONIC DIGITAL CLOCK
The electronic digital clock
is in the
radio.
The

clock
and
radio each
use the
display panel built into
the radio.
A
digital readout indicates
the
time
in

hours
and
minutes whenever
the
ignition switch
is in

the
ON or ACC
position. When
the
ignition switch
is in the OFF
position
or

when
the
radio frequency
is
being displayed, time keeping
is
accurately maintained. The procedure
for
setting
the
clock varies slightly
with each radio.
The
correct procedure
is
described under
the
individual radio operating instructions
re­

ferred
to in the
Owner Manual supplied with
the ve­

hicle.

MESSAGE CENTER—GAS ENGINE

The message center
(Fig. 6),
located above
the

Heater-A/C controls, includes warning lamps
for the:

• brake systems (parking
and
service)
•
ABS
brakes • liftgate open (Ramcharger only)
• maintenance required.

O/D
BRAKE
(P)(7

GATE OPEN

MAINT
REQD.

J938E-54
Fig.
6
Message Center—Gas Engine

EMISSIONS
MAINTENANCE REMINDER
This system
is
designed
to act as a
reminder that
scheduled vehicle emissions maintenance should
be

performed.
It is not
intended
to
indicate
a
warn­
ing
or
that
a
state
of
emergency exists which must
be
corrected
to
insure safe vehicle opera­
tion.
The
components covered
by the
system include
the
EGR
system,
PCV
valve,
and
oxygen sensor. Refer
to
Group
25 -
Emissions,
for
further informa­
tion.

ABS
WARNING
LIGHT
This light monitors
the ABS
Brake System. This
light will come
on
when
the
ignition
key is
turned
to

the
ON
position
and may
stay
on for as
long
as

thirty seconds.
If the ABS
light remains
on or
comes on during driving,
it
indicates that
the ABS
portion
of
the
brake system
is not
functioning. Refer
to
Group
5 -
Brakes
for
further information.

BRAKE
SYSTEM WARNING
LIGHT
The dual brake system provides
a
reserve braking
capability
in the
event
of a
failure
to a
portion
of the

hydraulic system. Failure
of
either
of the
dual sys­
tem
is
indicated
by the
brake warning light which
will glow when
the
service brake pedal
is
depressed.
The light will remain
on
until
the
cause
is
corrected. The light will also come
on
when
the
parking
brake
is
applied with
the
ignition
in the ON
position.
Refer
to
Group
5 -
Brakes
for
further information.

8K
- 6
WINDSHIELD WIPER
AND
WASHER SYSTEMS
• INTERMITTENT WINDSHIELD WIPER FUNCTION
AND
SWITCH TESTING
PROCEDURES

INTERMITTENT
WIPER
FUNCTION
TESTING

PROCEDURES
The intermittent wipe and standard two speed mo­
tors are identical. Refer to previous sections for diag­
nosis of system problems which do not involve the
DELAY function. If problem occurs only in the DE­ LAY mode, the following tests are to be performed.
These tests involve disconnecting the intermittent wipe control unit which can be found on the steering column support bracket (Fig. 2).
CONDITION Excessive delay (more than 30 seconds) or in­
adequate variation in delay.
PROCEDURE Variations in delay should be as follows: (1) Minimum delay (delay control to extreme coun­
terclockwise position before first detent) 1/2 to 2 sec­
onds.

(2) Maximum delay (delay control to extreme
clockwise position before off detent) 10 to 30 seconds.
(3) If there is excessive delay or no variations in
delay proceed to intermittent wipe switch test.
CONDITION In DELAY mode wipers run continually when
wash is operated but do not provide an extra
wipe when the wash control is released.
PROCEDURE Replace the control unit.
CONDITION ' Wipers start erratically during DELAY mode.
PROCEDURE (1) Verify that the ground connection at the in­
strument panel is making good connection (free from
paint) and is tight.
(2) Verify that the motor ground strap is making
good contact and that the motor mounting bolts are
tight.
(3) Verify that the wiring ground connections for
the intermittent wipe control unit and the wiper switch are tight.
(4) If condition is not corrected, replace control
unit.

MULTIFUNCTION (INTERMITTENT WIPER) SWITCH

TESTING
PROCEDURES
Refer to Multifunction (Two Speed Wiper) Switch
Testing Procedures using the following continuity chart.
i

24 23 22
21 20 19

17 16 15 14
/V~\M3
12 11 10 9 8
7
6 V5^4 3
.
2 1

EZJ
CZ3 CZ3 C3 Jr

L
JT

MULTIFUNCTION
SWITCH
PINS

SWITCH

POSITION
CONTINUITY

BETWEEN

OFF
PIN
6 AND PIN 7

DELAY
PIN 8 AND PIN 9
PIN 2 AND PIN 4
PIN
1
AND PIN 2
PIN
1
AND PIN 4
LOW PIN 4 AND PIN 6

HIGH
PIN 4 AND PIN 5

WASH
PIN 3 AND PIN 4

*
RESISTANCE
AT
AAAXIMUM
DELAY
POSITION
SHOULD
BE
BETWEEN
270,000
OHMS
AND
330,000
OHMS.

•RESISTANCE
AT
MINIMUM
DELAY
POSITION
SHOULD
BE
ZERO
WITH
OHMMETER
SET ON
HIGH
OHM
SCALE.

918J-4

Fig.
11ntermittent
Wipe
Switch
Continuity Chart

INTERMITTENT WIPE MODULE LOCATION
The intermittent wipe module is located to the
right of the steering column on the back side of the instrument panel (Fig. 2).
BUZZER

MODULE

INTERMITTENT

WIPE
MODULE
Fig.
2
Intermittent
Wipe
Module
Location

(5) Be sure the connecting rod and connecting rod
cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston and connecting rod assemblies from the engine, ro­
tate crankshaft so that the connecting rod is centered in cylinder bore and at BDC. Be careful not to nick
crankshaft journals.
(7) After removal, install bearing cap on the mat­
ing rod.

INSPECTION
Check the crankshaft connecting rod journal for ex­
cessive wear, taper and scoring. Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.
Check the pistons for taper and elliptical shape be­
fore they are fitted into the cylinder bore (Fig. 12).
DIAMETER
(D)

SHOULD BE

0.0000-0.0152
mm

(0.0000-0.0006
in.)
LARGER
THAN
(C).
98.704-98.831
mm

-(3.886-3.891
in.)-
98.577-98.704
mm-
(3.881-3.886
in.) (a) Measure piston ring gap 2 inches from bot­
tom of cylinder bore. An inverted piston can be used to push the rings down to ensure positioning
rings squarely in the cylinder bore before measur­ ing.
(b) Insert feeler gauge in the gap. The top com­
pression ring gap should be between 0.254-0.508
mm (0.010-0.020 inch). The second compression
ring gap should be between 0.508-0.762 mm (0.020- 0.030 inch). The oil ring gap should be 0.254-1.270
mm (0.010-0.050 inch).
(c) Rings with insufficient end gap may be prop­
erly filled to the correct dimension. Rings with ex­
cess gaps should not be used.
(2) Install rings and confirm ring side clearance: (a) Install oil rings being careful not to nick or
scratch the piston.
(b) Install the compression rings using Installa­
tion Tool C-4184. The top compression may be in­ stalled with either side up. The second compression
ring must be installed with the identification mark
face up (toward top of piston) and the chamfer should face down. An identification mark on the
ring is a drill point, a stamped letter "O", an oval
depression or the word TOP.
(c) Measure side clearance between piston ring
and ring land (Fig. 13). Clearance should be 0.038-
0.076 mm (0.0015-0.0030 inch) for the compression

rings.
The steel rail oil ring should be free in groove, but should not exceed 0.203 mm (0.0080 inch) side clearance.
FEELER
GAUGE
ELLIPTICAL SHAPE
OF
THE PISTON

SKIRT
SHOULD
BE
0.254-0.304
mm

(0.010-0.012
in.)
LESS
AT DIAMETER
(A)
THAN
ACROSS
THE THRUST
FACES
AT DIAMETER
(B).

J9309-9
Fig.
12
Piston
Measurements

FITTING
PISTONS
Piston and cylinder wall must be clean and dry.
Specified clearance between the piston and the cylin­
der wall is 0.013-0.038 mm (0.0005-0.0015 inch). Piston diameter should be measured at the top of
skirt, 90° to piston pin axis. Cylinder bores should be
measured halfway down the cylinder bore and trans­
verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21°C (70°F).

FITTING
RINGS
(1) Measurement of end gaps: J9209-136

Fig.
13
Measuring
Piston
Ring Side
Clearance (d) Pistons with insufficient or excessive side
clearance should be replaced. (3) Orient the rings:
(a) Arrange top compression ring 90° counter­
clockwise from the oil ring rail gap (Fig. 14). (b) Arrange second compression ring 90° clock­
wise from the oil ring rail gap (Fig. 14).

CAUTION:
Th© plunger and
tappet
bodies are not
interchangeable. The plunger and valve must al­

ways
be
fitted
to the
original
body. It is advisable to

work
on one
tappet
at a
time
to avoid
mixing
of parts. Mixed
parts
are not
compatible.
DO NOT
dis­

assemble
a
tappet
on a
dirty
work
bench,

DISASSEMBLE
(1) Pry out plunger retainer spring clip (Fig. 17).
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, check valve, check valve spring, check valve
retainer and plunger spring (Fig. 17). Check valve could be flat or ball.

ASSEMBLE

(1) Clean all tappet parts in a solvent that will re­
move all varnish and carbon.
(2) Replace tappets that are unfit for further ser­
vice with new assemblies.
(3) If plunger shows signs of scoring or wear, in­
stall a new tappet assembly. If valve is pitted, or
valve seat on end of plunger is prevented from seat­
ing, install a new tappet assembly. (4) Assemble tappets (Fig. 17).
PLUNGER
CHECK

BALL
PLUNGER
RETAINER
SPRING CLIP
ROLLER
TAPPET BODY RETAINER I PLUNGER
CHECK VALVE
SPRING PLUNGER
CAP
J9109-220
Fig.
17 Hydraulic
Tappet
Assembly

INSTALLATION
(1) Lubricate tappets.
(2) Install tappets and push rods in their original
positions. Ensure that the oil feed hole in the side of
the tappet body faces up (away from the crankshaft). (3) Install aligning yokes with ARROW toward
camshaft. (4) Install yoke retainer. Tighten the bolts to 23
N»m (200 in. lbs.) torque. Install intake manifold. (5) Install push rods in original positions.
(6) Install rocker arm.
(7) Install cylinder head cover.
(8) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To
prevent
damage to valve mechanism,
engine must not be run above
fast
idle
until
all hy­
draulic
tappets
have
filled
with
oil and have become
quiet.
VALVE
TIMING

(1) Turn crankshaft until the No.6 exhaust valve
is closing and No.6 intake valve is opening. (2) Insert a 6.350 mm (1/4 inch) spacer between
rocker arm pad and stem tip of No.l intake valve. Allow spring load to bleed tappet down giving in ef­
fect a solid tappet. (3) Install a dial indicator so plunger contacts
valve spring retainer as nearly perpendicular as pos­
sible.
Zero the indicator. (4) Rotate the crankshaft clockwise (normal run­
ning direction) until the valve has lifted 0.254 mm (0.010 inch). The timing of the crankshaft should
now read from 10° before top dead center to 2° after
top dead center. Remove spacer.

CAUTION:
DO NOT
turn
crankshaft any
further

clockwise as valve spring
might
bottom
and
result
in serious
damage.

(5) If reading is not within specified limits: (a) Check sprocket index marks.
(b) Inspect timing chain for wear.
(c) Check accuracy of DC mark on timing indica­
tor.

VIBRATION DAMPER
REMOVAL (1) Disconnect the negative cable from the battery.
(2) Remove fan shroud retainer bolts and set
shroud back over engine.
(3) Remove the cooling system fan.
(4) Remove the serpentine belt (refer to Group 7,
Cooling System).
(5) Remove the vibration damper pulley. (6) Remove vibration damper bolt and washer from
end of crankshaft. (7) Install bar and screw from Puller Tool Set
C-3688. Install 2 bolts with washers through the
puller tool and into the vibration damper (Fig. 1).
(8) Pull vibration damper off of the crankshaft.
J9209-81

Fig.
1
Vibration
Damper
Assembly

9
- 88 5.9L
ENGINE

•
CAUTION:
The
plunger
and
tappet
bodies
are not

interchangeable,.
The
plunger
and
valve must
al­

ways
be
fitted
to the
original
body,
It is
advisable
to

work
on one
tappet
at a time to
avoid mixing
of
parts. Mixed parts
are not
compatible.
DO
NOT dis­

assemble
a
tappet
on a dirty
work bench.

DISASSEMBLE (1) Pry out plunger retainer spring clip (Fig. 17).
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, check valve, check valve spring, check valve
retainer and plunger spring (Fig, 17). Check valve
could be flat or ball.

ASSEMBLE
(1) Clean all tappet parts in a solvent that will re­
move all varnish and carbon. (2) Replace tappets that are unfit for further ser­
vice with new assemblies.
(3) If plunger shows signs of scoring or wear, in­
stall a new tappet assembly. If valve is pitted, or
valve seat on end of plunger is prevented from seat­ ing, install a new tappet assembly.
(4) Assemble tappets (Fig. 17).
SPiING
CAP J9109-220

Fig.
17 Hydraulic
Tappet
Assembly INSTALLATION

(1) Lubricate tappets.
(2) Install tappets and push rods in their original
positions. Ensure that the oil feed hole In the side of
the tappet body faces up (away from the crankshaft). (3) Install rocker arm and shaft assembly.
(4) Install vent cover.
(5) Install distributor, start engine and reset tim­
ing.

CAUTION:
To
prevent damage
to
valve mechanism,
engine must
not be run
above
fast
idle
until
all hy­

draulic tappets have
filled
with oil and
have become
quiet.

¥AL¥E
TIMING
(1) Turn crankshaft until the No.6 exhaust valve
is closing and No.6 intake valve Is opening. (2) Insert a 6.350 mm (1/4 inch) spacer between
rocker arm pad and stem tip of No.l intake valve.
Allow spring load to bleed tappet down giving in ef­
fect a solid tappet. (3) Install a dial indicator so plunger contacts
valve spring retainer as nearly perpendicular as pos­
sible.
Zero the Indicator.
(4) Rotate the crankshaft clockwise (normal run­
ning direction) until the valve has lifted 0.863 mm (0.034 inch). The timing of the crankshaft should
now read from 10° before top dead center to 2° after
top dead center. Remove spacer.

CAUTION:
DO NOT
turn crankshaft
any
further

clockwise
as
valve spring might bottom
and
result
in serious damage.

(5) If reading is not within specified limits: (a) Check sprocket index marks.
(b) Inspect timing chain for wear.
(c) Check accuracy of DC mark on timing indica­
tor. -

¥IBRATI0N
PAMPER
REMOVAL (1) Disconnect the negative cable from the battery.
(2) Remove fan shroud retainer bolts and set
shroud back over engine. (3) Remove the cooling system fan.
(4) Remove the serpentine belt (refer to Group 7,
Cooling System). (5) Remove the vibration damper pulley. (6) Remove vibration damper bolt and washer from
end of crankshaft. (7) Install bar and screw from Puller Tool Set
C-3688. Install 2 bolts with washers through the
puller tool and into the vibration damper (Fig. 1).
J9209-81

Fig.
1
Vibration
Damper
Assembly
(8) Pull vibration damper off of the crankshaft.
INSTALLATION (1) Position the vibration damper onto the crank­
shaft.