Dodge ram truck 3500 1996 Service Manual page 1183

BR 5.9L (DIESEL) ENGINE 9 - 193
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 )
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Fig. 80 Piston/Rod Assembly at BDC
top of the block. Carefully pull the connecting rod
onto the crankshaft journal.
(8) Use clean engine oil to lubricate the threads
and under the heads of the connecting rod bolts.
(9) The 4 digit number stamped on the rod cap at
the parting line must match and be installed towards
the oil cooler side of the engine (Fig. 81).
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Fig. 81 Correct Rod Cap Installation
(10) Install the rod cap and bolts to the connecting
rod. Tighten the connecting rod and bolt evenly in 3
steps.
• Tighten the bolts to 35 N-m (26 ft. lbs.) torque.
• Tighten the bolts to 70 N-m (51 ft. lbs.) torque.
• Tighten the bolts to 100 N-m (73 ft. lbs.) torque.
(11) The crankshaft must rotate freely. Check for
freedom of rotation as the caps are installed. If the
crankshaft does not rotate freely, check the installa­
tion of the rod bearing and the bearing size.
(12) Measure the side clearance between the con­
necting rod and the crankshaft (Fig. 82). DO NOT
measure the clearance between the cap and crank­
shaft.
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SIDE CLEARANCE LIMITS
M I N .
0 . 1 0 0 mm ( 0 . 0 0 4 inch)
M A X
0 . 3 0 0 mm ( 0 . 0 1 2 inch)
Fig. 82 Side Ciearance between Connecting
Rod/Crankshaft
(13) Install the suction tube and oil pan.
(14) Install the cylinder head onto the block.
(15) Install the engine assembly into the vehicle.
CRANKSHAFT
REMOVAL
(1) Remove the rear crankshaft seal housing.
(2) Remove the gear housing.
(3) Rotate the engine to a horizontal position and
remove the main bearing bolts.
(4) The main bearing caps should be numbered. If
they are not, be sure to mark them, beginning with
number one at the front and ending with number
seven at the rear (Fig. 83).
M A I N
BEARING
CAP
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Fig. 83 Numbering Main Bearing Caps
CAUTION: DO NOT pry on the main caps to free
them from the cylinder block.