Dodge ram truck 3500 1996 Service Manual page 1087

B R
5.9L ENGINE I -17
SERVICE PROCEDURES (Continued)
imaginary center line through both camshaft and
crankshaft bores.
(7) Place timing chain around both sprockets.
(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 ft. lbs.) torque.
(12) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and 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 and cylinder wall must be clean and dry.
Specified clearance between the piston and the cylin­
der wall is 0.013-0.038 mm (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. Cylinder bores should be
measured halfway down the cylinder bore and trans­
verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21°C (70°F).
Check the pistons for taper and elliptical shape
before they are fitted into the cylinder bore (Fig. 8).
FITTING PISTON RINGS
( 1 ) Measurement of end gaps:
PISTON PIN BORE DIAMETER
A
PISTON
SIZE
A DIA = PISTON DIAMETER
BORE DIAMETER
PISTON
SIZE MIN.
m m
(IN.)
MAX. mm
(IN.) MIN.
m m
(IN.) MAX. m m
(IN.)
A
B 101.580 (3.9992) 101.592 (3.9997) 101.605 (4.0002) 101.618(4.0007)
C 101.592 (3.9997) 101.605 (4.0002) 101.618(4.0007) 101.630 (4.0012)
D 101.605 (4.0002) 101.618(4.0007) 101.630 (4.0012) 101.643 (4.0017)
E
J9509-79
Fig. 8 Piston Measurements
(a) Measure piston ring gap 2 inches from bot­
tom of cylinder bore. An inverted piston can be
used to push the rings down to ensure positioning
rings squarely in the cylinder bore before measur­
ing.
(b) Insert feeler gauge in the gap. The top com­
pression ring gap 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 mm (0.020-
0.030 inch). The oil ring gap should be 0.254-1.270
mm (0.010-0.050 inch).
(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. It 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 Instal­
lation 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