Dodge ram truck 3500 1996 Service Manual page 1073

BR 5.2L ENGINE 9 - 83
DISASSEMBLY AND ASSEMBLY
( C o n t i n u e d )
OIL PUMP ASSEMBLY
SPRING
COTTER PIN
RELIEF VALVE
* RETAINER CAP
RH174
Fig. 58 Oii Pressure Relief Valve
INNER ROTOR
AND SHAFT
DISTRIBUTOR DRIVESHAFT
BODY (REFERENCE)
OUTER ROTOR
COVER
BOLT
COTTER PIN
RETAINER
CAP
LARGE CHAMFERED
EDGE
SPRING
RY10B
Fig. 59 Oil Pump
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling
rotor cavity with engine oil.
CYLINDER BLOCK
DISASSEMBLE
Engine assembly removed from vehicle:
(1) Remove the cylinder head.
(2) Remove the oil pan.
(3) Remove the piston and connecting rod assem­
blies.
ASSEMBLE
(1) Install the piston and connecting rod assembly.
(2) Install the oil pan.
(3) Install the cylinder head.
(4) Install the engine into the vehicle.
C L E A H 1 H G AMD I ^ S P E C Y I C M
CYLINDER HEADS
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge i f there is
any reason to suspect leakage. I f out-of-flatness
exceeds 0.00075 mm/mm (0.00075 inch/inch) times
the span length in inches in any direction, either
replace head or lightly machine the head surface.
FOR EXAMPLE: A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept­
able.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 micro inches).
Inspect push rods. Replace worn or bent rods.
PISTON AND CONNECTING ROD ASSEMBLY
INSPECTION
Check the crankshaft connecting rod journal for
excessive wear, taper and scoring.
Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.
Check the pistons for taper and elliptical shape
before they are fitted into the cylinder bore (Fig. 60).
CRANKSHAFT INSPECTION OF JOURNALS
The crankshaft connecting rod and main journals
should be checked for excessive wear, taper and scor­
ing. The maximum taper or out-of-round on any
crankshaft journal is 0.025 mm (0.001 inch).
Journal grinding should not exceed 0.305 mm
(0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.3 main bearing. DO
NOT nick crank pin or bearing fillets. After grinding,
remove rough edges from crankshaft oil holes and
clean out all oil passages.
CAUTION: After any journal grind, it is important
that the final paper or cloth polish be in the same
direction as the engine rotates.
OIL PAN
CLEANING
Clean the block and pan gasket surfaces.