Dodge RAM TRUCK 1500 1995 Service Manual page 1015

i - 176 5.9L (DIESEL) ENGINE
B R
TOP
R I N G
INTERMEDIATE
RING
N O I L C O N T R O L
R I N G
/ J m 09-73
Fig. 17 Piston Ring Positioning
J9109-82
0.250 mm (.0098 in.
0.500 mm (.0197 in.
0.750 mm (.0295 in.
1.000 mm .0394 in.
Fig. 18 Connecting Rod Bearing Size Location
(3) Compress the rings using a piston ring com­
pressor tool (Fig. 19). If using a strap-type ring com­
pressor, make sure the inside end o
f
the strap does
not hook on a ring gap and break the ring.
PISTON
R I N G
C O M P R E S S O R TOOL
J9109-83
Fig. 19 Piston Ring Compressor Tool
(4) Bar the crankshaft so the rod journal for the
piston to be installed is at BDC (Bottom Dead Cen­
ter) - (Fig.
20).
(5) Be sure the FRONT marking on the piston and
the numbers on the rod and cap are oriented as illus­
trated.
(6) Position the piston and rod assembly into the
cylinder bore with the word FRONT on the piston to­
wards the front of the cylinder block. Use care when
you install the piston and connecting rod so the cyl­
inder bore is not damaged.
(7) Push the piston into the bore until the top of
the piston is approximately 50 mm (2 inch) below the
J9109-84
Fig. 20 Piston/Rod Assembly at BDC
top of the block. Carefully pull the connecting rod
onto the crankshaft journal.
(8) Use clean engine oil to lubricate the threads
and under the heads of the connecting rod bolts.
(9) The 4 digit number stamped on the rod cap at
the parting line must match and be installed towards
the oil cooler side of the engine (Fig. 21).
J9109-85
Fig. 21 Correct Rod Cap Installation
(10) Install the rod cap and bolts to the connecting
rod. Tighten the connecting rod and bolt evenly in 3
steps.
• Tighten the bolts to 35 N-m (26 ft. lbs.) torque.
© Tighten the bolts to 70 N-m (51 ft. lbs.) torque.
• Tighten the bolts to 100 N-m (73 ft. lbs.) torque.
(11) The crankshaft must rotate freely. Check for
freedom of rotation as the caps are installed. If the
crankshaft does not rotate freely, check the installa­
tion of the rod bearing and the bearing size.
(12) Measure the side clearance between the con­
necting rod and the crankshaft (Fig. 22). DO NOT
measure the clearance between the cap and crank­
shaft.
(13) Install the suction tube and oil pan.
(14) Install the cylinder head onto the block.
(15) Install the engine assembly into the vehicle.