Dodge ram truck 3500 1996 Service Manual page 1192

I - 202 5.9L (DIESEL) ENGINE
B R
DISASSEMBLY
A N D
ASSEMBLY
( C o n t i n u e d )
(14) DO NOT lubricate the side of the bearing that
is against the connecting rod or cap. Apply a coat of
Lubriplate 105, or equivalent to the new upper and
lower connecting rod bearings.
J9109-82
STANDARD
OVERSIZE
0.250 mm (.0098
in.)
0.500 mm (.0197
in.)
0.750 mm (.0295
in.)
1.000 mm (.0394
in.)
Fig. 114 Connecting Rod Bearing Size Location
C L E A N I N G AND I N S P E C T I O N
OIL COOLER ELEMENT AND GASKET
CLEANING AND INSPECTION
Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. I f the element leaks, replace the
element.
CYLINDER HEAD
INSPECTION
Remove the cup plugs and inspect the coolant pas­
sages. A large build up of rust and lime will require
removal of the cylinder block for cleaning in a hot
tank.
Inspect the cylinder bores for damage or excessive
wear. Rotate the crankshaft so the piston is at Bot­
tom Dead Center (BDC) to inspect the bores.
Measure the cylinder bores (Fig. 115). DO NOT
proceed with in-chassis repair i f the bores are dam­
aged or worn beyond the limits (refer to Cylinder
Bore Repair - Cylinder Block).
Check the top surface for damage caused by the
cylinder head gasket leaking between cylinders.
Inspect the block and head surface for nicks, ero­
sion, etc.
Check the head distortion (Fig. 116). The distortion
of the combustion deck face is not to exceed 0.010
mm (0.0004 inch) in any 50.8 mm (2.00 inch) diame­
ter. Overall variation end to end or side to side 0.30
mm (0.012 inch).
DO NOT proceed with the in-chassis overhaul i f
the cylinder head or block surface is damaged or not
flat (within specifications).
MIN. 102.0 mm (4.0157 inch)
MAX. 102.1 16 mm (4 0203 inch)
Out-of-Round 0.038 mm (0.0015 inch)
Taper 0.76 mm (0.003 inch)
Oversize pistons and rings are
available for bored cylinder blocks.
J9109-75
Fig. 115 Cylinder Bore Diameter
Fig. 116 Cylinder Head Combustion Deck Face
Measurement
REFACING HEAD SURFACE
The cylinder head combustion deck may be refaced
in whatever increments necessary to clean up the
surface and maintain the surface finish and flatness
tolerances. The combined total of stock removed must
not exceed 1.00 mm (0.03937 inch). The amount of
stock removed each time must be steel stamped
above combustion deck edge, on the lower right hand
corner of the rear face (Fig. 117). Check valve protru­
sion after head surface refacing.
Surface finish requirements are 1.5-3.2 microme­
ters (60-126 microinch).