Dodge ram truck 3500 1996 Service Manual page 1190

9 - 210 5.9L (DIESEL) ENGINE —
DISASSEMBLY AND ASSEMBLY
(Continued)
(4) Clean all parts in a strong solution of laundry
detergent in hot water.
(5) Use compressed air to dry the parts after rins­
ing in clean hot water. The pedestals are made from
powdered metal and may continue to show wetness
after they have been cleaned and dried.
(6) Inspect for excessive wear in the bore and the
contact surface for the valve stem.
(7) Measure the rocker lever bore diameter. The
maximum diameter is 19.05 mm (0.75 inch). Replace
if out of limits.
(8) Inspect the pedestal and shaft.
(9) Measure the shaft diameter. The minimum
diameter is 18.94 mm (0.746 inch). Replace i f out of
limits.
ASSEMBLE
(1) Install the adjusting screw and locknut.
(2) Lubricate the shaft with clean engine oil. Be
sure to assemble the intake and exhaust rocker
levers in the correct location.
(3) Position the levers on the rocker shaft. Install
the thrust washers.
(4) Clean the push rods in the hot soapy water.
(5) Inspect the push rod ball and socket for signs
of scoring or cracks where the ball and the socket are
pressed into the tube.
(6) Check the push rods for roundness and
straightness.
(7) Install the push rods into the sockets of the
valve tappets. Lubricate the push rod sockets with
clean engine oil.
(8) Make sure the rocker lever adjusting screws
are completely backed out.
PISTON AND CONNECTING ROD ASSE1BLY
DISASSEMBLE
(1) Remove the retainer rings from the piston (Fig.
106) .
(2) Remove the piston pin. Heating the piston is
not required.
(3) Remove the piston rings (Fig. 106).
ASSEMBLE
(1) Be sure the FRONT marking on the piston and
the numbers on the rod and cap are oriented (Fig.
107) . Install the retaining ring into the pin groove on
the FRONT side of the piston.
(2) Lubricate the pin and bore with engine oil.
(3) Install the piston pin in the opposite side of the
installed retaining pin. Pistons do not require heat­
ing to install the pin, however, the piston does need
to be at room temperature or above.
(4) Determine the piston diameter and obtain the
appropriate ring set. The piston rings can be identi­
fied as shown in (Fig. 108).
BR
Fig. 106 Retainer Rings
Fig. 107 Proper Markings on the Piston and
Connecting Rod
TOP RING ' T O P
I N T E R M E D I A T E
R I N G
O I L C O N T R O L
R I N G
J 9 1 0 9 - 6 9
Fig. 108 Piston Ring identification
(5) Position each ring in the cylinder and use a
piston to square i t with the bore at a depth of 89.0
mm (3.5 inch) - (Fig. 109).
(6) Use a feeler gauge to measure the piston ring
gap (Fig.
1 1 0 ) .
(7) The top surface of all of the rings are identified
with the word TOP or the supplier's MARK. Assem­
ble the rings with the word TOP or the supplier's
MARK up.