Dodge RAM TRUCK 1500 1995 Service Manual page 1022

Bit
5.9L (DIESEL) ENGINE 9 - 183
M I N .
82.962 mm (3.2662 inch)
M A X . 83.103 mm 13.2682 inch)
J9109-93
Fig. 21 Crankshaft Main Journal Diameter
limits, replace the main bearings. If not within spec­
ifications, grind the crankshaft to next size and use
oversize bearings.
CRANKSHAFT GEAR - REPLACEMENT
Remove the crankshaft gear using a heavy duty
puller.
Remove all burrs and make sure the gear surface
on the end of the crankshaft is smooth.
If removed, install a new alignment pin. Drive the
pin in using a ball-peen hammer, leaving it protrud­
ing 1.60 mm (0.063 inch) to 2.39 mm (0.094 inch)
above the crankshaft (Fig. 22).
Fig. 22 Installing Alignment Pin
Heat the crankshaft gear for 45 minutes at a tem­
perature of 121°C (250°F).
CAUTION: DO NOT heat the gear longer than 45
minutes.
WARNING: W E A R PROTECTIVE G L O V E S TO P R E ­
VENT INJURY.
Position the gear with the timing mark out and in­
stall it on the crankshaft using the alignment pin.
Make sure the gear contacts the shoulder.
INSTALLATION
CAUTION: Use only hand force to push the nozzle
in place. If driven with a hammer, the nozzle will be
damaged.
(1) Use a center punch to push the piston cooling
nozzle into place. Install nozzles so they are even
with or slightly below the saddle surface.
(2) Make sure the saddle surface is clean and dry.
Install the upper main bearings.
(3) Install the combination thrust/main bearing in
the number six main bearing location.
(4) Lubricate the bearings with Lubriplate 105, or
equivalent.
WARNING: TO AVOID INJURY, U S E A HOIST TO IN­
STALL THE CRANKSHAFT.
(5) Install the crankshaft.
CAUTION: Crankshaft must be lowered onto the
bearings straight to prevent damage to thrust bear­
ings.
(6) Install the ring dowels in the main bearing
caps (Fig. 23).
J9109-95
Fig. 23 Install Ring Dowels
(7) Install the lower main bearings in the caps.
(8) Lubricate the bearings with Lubriplate, or
equivalent.
(9) Numbers on the main bearings caps face the oil
cooler side of the engine with number one at the
front of the engine.
(10) Place the caps in their respective positions.
(11) Lubricate the main bearing bolt threads and
underside of the bolt head with clean engine oil.