Dodge ram truck 3500 1996 Service Manual page 1138

9 - 148 8.0L ENGINE
BR
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 )
(11) Connect the negative cable to the battery.
(12) Fill crankcase with oil to proper level.
PISTON AND
C0NNECT1N0
iOD ASSEMBLY
REMOVAL
(1) Remove the engine from the vehicle (refer to
Engine Removal of this manual).
(2) Remove the valve cover, rocker arms, push rods
and cylinder head. Mark parts as removed.
(3) Remove the oil pan and oil pump pick-up tube.
( 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 center
the connecting rod in the cylinder bore and at BDC.
Be careful not to n i c k crankshaft journals* DO
MOT t r y to remove black coating on s k i r t ; This
is the dry film lubricant.
(7) After removal, install bearing cap on the mat­
ing rod.
INSTALLATION
(1) Check the crankshaft connecting rod journal
for excessive wear, taper and scoring.
(2) Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.
(3) Be sure that compression ring gaps are stag­
gered so that neither is in line with oil ring rail gap.
(4) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 48).
(5) 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 during this operation.
(6) Install connecting rod bolt protectors on rod
bolts, a long protector should be installed on the
numbered side of the connecting rod.
(7) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore in the
bottom dead center position. Be sure connecting rod
and cylinder bore number are the same. Insert rod
and piston into cylinder bore. Be sure the piston and
rod assemblies are installed in the proper orientation
(Fig. 49).
(8) The notch, groove or arrow on top of piston
must be pointing toward front of engine. The larger
TOP COMPRESSION RING GAP
UPPER OIL RING GAP
t if /
SPACER
GAP
2ND COMPRESSION RING GAP
LOWER OIL RAIL GAP J9409-77
Fig. 48 Proper Ring instailation
FRONT I.D.
TOWARDS THIS SIDE
ORIENTATION BUTTON ORIENTATION BUTTON
TOWARDS FRONT TOWARDS REAR
(L.H. ONLY) (R.H. ONLY)
1 , 3 , 5 , 7 , 9 2, 4, 6, 8, 10
J9409-78
Fig. 49 Piston and Rod Orientation
chamfer of the connecting rod bore must be installed
toward crankshaft journal fillet.
(9) While tapping the piston down in cylinder bore
with the handle of a hammer, guide the connecting
rod over the crankshaft journal.
(10) Install rod caps. Install nuts on cleaned and
oiled rod bolts and tighten nuts to 61 N-m (45 ft. lbs.)
torque.
(11) Install the oil pump pick-up tube and oil pan.