Dodge ram truck 3500 1996 Service Manual page 1052

9 - 32 5.2L ENGINE
SEHWiCE PftOCEBtfRES
(Continued)
(8) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam­
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(10) Slide both sprockets evenly over their respec­
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 7).
Fig. 7 Alignment of Timing Marks
(11) Install the camshaft bolt. Tighten the bolt to
47 N-m (35 f t . lbs.) torque.
(12) Check camshaft end play. The end play should
be 0.051-0.152 m m (0.002-0.006 inch) with a new
thrust plate a n d up to 0.254 mm (0.010 inch) with a
used thrust plate. I f not within these limits install a
new thrust plate.
FITTING
PISTONS
Piston
a n d
cylinder
w a l l
must be clean and dry.
Specified clearance between the piston and the cylin­
der
w a l l
is 0.013-0.038
m m
(0.0005-0.0015 inch) at
21°C (70°F).
Piston diameter should be measured at the top of
skirt, 90° to piston pin axis location A in (Fig. 8). Cyl­
inder bores should b e measured halfway down the
cylinder bore and transverse to the engine crankshaft
center' line.
Pistons and cylinder bores should be measured at
normal room temperature, 2PC (70°F).
FITTING PISTON ilNGS
(1) Measurement o f end gaps:
(a) Measure piston ring gap 2 inches from bot­
tom o f cylinder bore. An inverted piston can be
u s e d t o p u s h t h e
rings
d o w n t o
ensure positioning
rings squarely i n t h e cylinder bore before measur­
i n g .
(b) Insert
feeler
gauge
i n t h e g a p .
The top com­
pression ring g a p 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
m m
(0.020-
0.030
i n c h ) . T h e o i l
ring
g a p
should be 0.254-1.270
m m (0.010-0.050 i n c h ) .
PISTON PIN BORE DIAMETER
A
PISTON
SIZE
A DIA = PISTON DIAMETER BORE DIAMETER
PISTON
SIZE
MIN. mm (IN.) < MAX. mm (IN.) MIN. mm (IN.)
M A I . mm (IN.)
A
99.280 (3.9087)
99.294 (3.9092) 99.306 (3.9097) 99.319(3.9102)
B 99.294 (3,9092) 99,306 (3.9097)
99.319(3.9102) 99.332 (3.9107)
C
99.306 (3.9097) 99.319(3.9102) 99.332 (3.9107) 99.344(3,9112)
D
99.319(3.9102) 99,332 (3,9107)
99.344(3.9112) 99.357 (3.9117)
E 99,332 (3.9107) 99.344 (3.9112) 99.357(3.9117)
99.370(3.9122)
J9509-80
Fig. 8 Piston Measurements
(c) Rings with insufficient end gap may be prop­
erly filed to the correct dimension. Rings with,
excess 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. Install the oil control rings
according to instructions in the package, i t is not
necessary to use a tool to install the upper and
lower rails. Insert oil rail spacer first, then side
rails.
(b) Install the second compression rings using
Installation Tool C-4184. The compression rings
must be installed with the identification mark face
up (toward top of piston) and chamfer facing down.
An identification mark on the ring is a drill point,
a stamped letter
a
O", an oval depression or the
word TOP (Fig. 9) (Fig. 11).
(c) Using a ring installer, install the top com­
pression ring with the chamfer facing up (Fig. 10)
(Fig. 11), An identification mark on the ring is a
drill point, a stamped letter "O", an oval depression
or the word TOP facing up.
(d) Measure side clearance between piston ring
and ring land. Clearance should be 0.074-0.097 mm
(0.0029-0.0038 inch) for the compression rings. The
steel rail oil ring should be free in groove, but