Dodge ram truck 3500 1996 Service Manual page 1066

I - 76
5.21
ENGINE
mm
R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d )
inder block. Be sure to keep tops of pistons covered
during this operation.
(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, rotate crankshaft to cen­
ter the connecting rod in the cylinder bore and at
BDC. Be careful not to n i c k crankshaft journals,
(7) After removal, install bearing cap on the mat­
ing rod.
INSTALLATION
(1) Be sure that compression ring gaps are stag­
gered so that neither is in-line with oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 40).
OIL RING
SPACER GAP
TOP
COMPRESSION
RING GAP
SECOND
COMPRESSION
RING GAP
OIL RING RAIL
GAP (TOP)
OIL RING RAIL
GAP (BOTTOM)
J9309-80
Fig. 40 Proper Ring installation
(3) Immerse the piston head and rings In clean
engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench
(part of Tool C-385). Be sure position of rings
does not change d u r i n g this operation.
(4) Install connecting rod bolt protectors on rod
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston Into cylinder bore and
.guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal.
(7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, con­
necting rod cap and cylinder bore number are the
same. Install nuts on cleaned and oiled rod bolts and
tighten nuts to 61 N-m (45 ft. lbs.) torque.
(9) Install the oil pan.
(10) Install the cylinder head.
(11) Install the engine into the vehicle.
CRANKSHAFT
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap.
(3) Remove the vibration damper.
(4) Remove the timing chain cover.
(5) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time.
(6) Lift the crankshaft out of the block.
(7) Remove and discard the crankshaft rear oil
seals.
(8) Remove and discard the front crankshaft oil
seal.
INSTALLATION
(1) Clean Loctite 518 residue and sealant from the
cylinder block and rear cap mating surface. Do this
before applying the Loctite drop and the installation
of rear cap.
(2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine
oil.
(6) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
. (7) Apply 5 mm (0.20 in) drop of Loctite 518, or
equivalent, on each side of the rear main bearing cap
(Fig. 41). DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing
cap to cylinder block immediately after sealant appli­
cation.
(8) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
(9) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 N-m (85 ft. lbs.) torque.
(10) Install oil pump.
(11) Install the timing chain cover.
(12) Install the vibration damper.