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.
•
5.9L
(DIESEL)
ENGINE
9 - 123 (6) Remove the bolts that hold the gear cover to
the gear housing. (7) Gently pry the cover away from the housing,
taking care not to mar the gasket surfaces (Fig. 5). (8) Clean the old gasket residue from the back of
the gear cover and front of the gear housing.
Fig.
5 Gear
Housing
and
Cover
INSTALLATION
(1) Lubricate the front gear train with clean en
gine oil.
(2) Thoroughly clean the front seal area of the
crankshaft. The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks.
(3) Install the gear housing cover and a new gas
ket.
(4) Install the bolts but DO NOT tighten them at
this time.
(5) Use the alignment/installation tool from the
seal kit to align the cover to the crankshaft (Fig. 6). (6) Tighten the gear housing cover bolts to 24 N*m
(18 ft. lbs.) torque.
Fig.
6 Alignment/Installation Tool
(7) Remove the alignment/installation tool. Always
use a seal pilot when you install a seal.
(8) Apply a bead of Loctite 277 to the outside di
ameter of the seal. Install the pilot from the seal kit onto the crankshaft. Install the seal onto the pilot
and start into the gear housing cover. Remove the pi
lot. (9) Use the alignment/installation tool and a plas
tic hammer to install the seal to the correct depth.
To prevent damage to the seal carrier, hit the align ment/installation tool alternately at the 12, 3, 6 and 9 o'clock positions.
(10) Install the oil fill tube and mounting bolts.
Tighten the bolts to 43 N*m (32 ft. lbs.) torque. (11) Install the vibration damper. DO NOT tighten
the bolts to the correct torque valve at this time.
(12) Install the belt tensioner. Tighten the mount
ing bolts to 43 Nnn (32 ft. lbs.) torque. (13) Raise the belt tensioner to install the belt.
(14) Tighten the vibration damper bolts to 125
N*m (92 ft. lbs.) torque. Use an engine barring tool to keep the engine from rotating during tightening op
eration.
TIMING
PIN TIMING PIN REPLACEMENT The timing pin can be replaced without removing
the assembly from the gear housing. (1) Remove the timing pin by prying the retaining
ring out with a small screwdriver. Replace the re
taining ring if it is damaged during removal.
(2) If timing pin assembly is removed from gear
housing, it must be precisely reset to obtain exact
TDC.
(3) Install a new O-Ring, lubricate the pin and po
sition in the housing (Fig. 7). Install the new retain
ing ring to 1.5 mm (0.059 inch).
Fig.
7
Engine
Timing Pin Location
TIMING PIN HOUSING ASSEMBLY/ GASKET
REMOVAL
(1) Locate TDC for cylinder No.l.
(2) Remove the timing pin housing assembly and
gasket.
(3) Clean any gasket material from the gear hous-
