Dodge ram truck 3500 1996 Service Manual page 1182

9 - 192 5 J L (DIESEL) ENGINE
BR
REMOVAL AND INSTALLATION (Continued)
(7) Drain the used engine oil. Dispose of the used
oil properly.
(8) Remove oil pan bolts, lower pan slightly and
remove oil suction tube.
(9) Remove oil pan.
GASKET
Fig, 78 Oii Pan, Suction Tube and Gasket
INSTALLATION
(1) Clean the sealing surface.
(2) Install the suction tube and gasket. Tighten
the bolts to 24 N-m (18 ft. lbs.) torque.
(3) Fill the joint between the pan rail/gear housing
and pan rail/rear cover with sealant. Use Three Bond
1207-C, or equivalent.
(4) Install the pan and gasket (Fig. 78). Tighten
the bolts to 24 N-m (18 ft. lbs.) torque.
(5) Install the drain plug with a new sealing
washer and tighten to 80 N-m (60 ft. lbs.) torque.
(6) Fill the engine with clean lubrication oil. Run
the engine and check for leaks.
(7) Stop the engine and let It set for five minutes.
Check the oil level, and add oil i f needed.
PISTON IND CONNECTING iOD ASSEMBLY
The turbocharged intercooler piston has a Ni-Re-
sist Insert with a keystone profile for the top com­
pression ring. The new piston has a new design bowl
and a 7 mm longer piston pin. These pistons can not
be interchanged with earlier models.
REMOVAL
(1) Remove the engine assembly from the vehicle.
(2) Remove the cylinder head from the block.
(3) Remove the oil pan and suction pump.
(4) I f the cylinder bores have ridges, use a ridge
reamer to cut the ridge from the top of the cylinder
bore before removing the piston. Make sure the ridge
reamer does not make a deep cut into the bore. DO
NOT remove more metal than is necessary to remove
the ridge.
(5) I f cylinders have ridges, the cylinders are over­
size and will need boring.
(6) Use a hammer and a steel stamp to mark the
cylinder number onto each connecting rod cap. Mark
the cylinder number onto the top of each piston.
(7) Remove the connecting rod bolts and rod caps.
Use care so the cylinder bores and connecting rods
are not damaged.
(8) Use a hammer handle or similar object to push
the piston and connecting rod through the cylinder
bore.
(9) Store the piston/rod assemblies in a rack.
(10) I f a piston must be replaced, replace with the
same part number (grading) that was removed.
I N S T A L L A T I O N
(1) Lubricate the cylinder bore with clean engine
oil.
(2) Generously lubricate the rings and piston
skirts with clean engine oil.
(3) Compress the rings using a piston ring com­
pressor tool (Fig. 79). I f using a strap-type ring com­
pressor, make sure the inside end of the strap does
not hook on a ring gap and break the ring.
PISTON
RING
COMPRESSOR TOOL
J 9 ]
09-83
Fig. 79 Piston Ring Compressor Tool
(4) Bar the crankshaft so the rod journal for the
piston to be installed is at BDC (Bottom Dead Cen­
ter) - (Fig. 80).
(5) Be sure the FRONT marking on the piston and
the numbers on the rod and cap are oriented as illus­
trated.
(6) Position the piston and rod assembly into the
cylinder bore with the word FRONT on the piston
towards the front of the cylinder block. Use care
when you install the piston and connecting rod so the
cylinder bore is not damaged.
(7) Push the piston into the bore until the top of
the piston is approximately 50 mm (2 inch) below the