Dodge ram truck 3500 1996 Service Manual page 1100

I - 110 5.9L ENGINE
B R
REMOVAL AND INSTALLATION (Continued)
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing . Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 36).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
Fig. 86 Upper Main Bearing Removal and
Installation with Tool C-3059
INSTALLATION
Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight­
ened. A l l bearing capbolts removed during service
procedures are to be cleaned and oiled before instal­
lation.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 36).
(2) Slowly rotate crankshaft counterclockwise slid­
ing the bearing into position. Remove Tool C-3059.
(3) Install the bearing cap. Clean and oil the bolts.
Tighten the capbolts to 115 N-m (85 ft. lbs.) torque.
(4) Install the oil pump.
(5) Install the oil pan.
PISTON AND CONNECTING HOD ASSEMBLY
REMOVAL
(1) Remove the engine from the vehicle.
(2) Remove the cylinder head.
(3) Remove the oil pan.
(4) Remove top ridge of cylinder bores with a reli­
able ridge reamer before removing pistons from cyl­
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 nick 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. 37).
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. 37 Proper Ring Installation
(3) Immerse the piston head and rings i n 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 during 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.