Dodge ram truck 3500 1996 Service Manual page 1164

9 - 174 5.9L (DIESEL) ENGINE
- B R
S E R V I C E P R O C E D U R E S ( C o n t i n u e d )
CYLINDER BLOCK CUP PLUG REPLACEMENT
(1) Remove the cup plugs from the oil passages
(Fig. 24).
(2) Apply a bead of Loctite 277 around the outside
diameter of the oil passage cup plugs.
(3) Drive the cup plugs in until they bottom in the
bore (Fig. 24).
(4) Fill the - engine with oil. Run the engine and
check for leaks.
(5) Stop the engine and check the oil level with the
dipstick.
Fig. 24 Cup Plug Locations in Cylinder Block
CONNECTING ROD BEARING AND CRANKSHAFT
JOURNAL CLEARANCE
Measure the connecting rod bore with the bearings
installed and the bolts tightened to 100 N-m (73 ft.
lbs.) torque.
Record the smaller diameter.
Measure the diameter of the rod journal at the
location shown (Fig. 25). Calculate the average diam­
eter for each side of the journal.
The clearance is the difference between the con­
necting rod bore (smallest diameter) and the average
diameter for each side of the crankshaft journal.
If the crankshaft is within limits, replace the bear­
ing. I f the crankshaft is out of limits, grind the
crankshaft to the next smaller size and use oversize
rod bearings.
PISTON GRADING PROCEDURE
(1) Install any of the original connecting rod and
piston assemblies into the No.l cylinder. DO NOT
install the piston rings.
(2) Install the upper bearing shell in the connect­
ing rod with the tang of the bearing in the slot of the
connecting rod. The connecting rod bearing shell
must be installed in the original connecting rod and
M I N . 68.962 mm (2.715 inch)
MAX. 69.013 mm (2.717 inch)
Out-of-Round - M a x .
0.050
mm
(0.002
inch)
Taper - M a x .
0.013 mm (0.0005 inch)
Bearing Clearance - M a x .
0.089
mm
(0.0035
inch)
J 9 1 0 9 - 9 1
Fig. 25 Connecting Rod Journal Diameter Limits
cap. Use clean lubricating oil to coat the inside diam­
eter of the connecting rod bearing shell.
(3) Install the bearing shell in the connecting rod
cap with the tang of the bearing in the slot to the
cap. Use clean lubricating oil to coat the inside diam­
eter of the bearing shell.
(4) The four digit number stamped on the connect­
ing rod and cap at the parting line must match and
be installed on the oil cooler side of the engine.
Install the connecting rod cap and capscrews.
Tighten the capscrews to 35 N-m (26 ft. lbs.) torque.
(5) Use a fine grit stone to remove any burrs from
the cylinder block head deck. Zero the dial indicator
to the cylinder block head deck.
(6) Move the dial indicator directly over the piston
pin to eliminate any side-to-side movement.
(7) Rotate the crankshaft to top dead center
(TDC). Rotate the crankshaft clockwise and counter­
clockwise to find the highest dial indicator reading.
Record the reading.
(8) Remove the piston and connecting rod assem­
bly from the N o . l cylinder and install the assembly
into the No.2 cylinder. Repeat the procedure for every
cylinder using the same piston and connecting rod
assembly.