Dodge ram truck 3500 1996 Service Manual page 1198

I - 208 5.IL (DIESEL) ENGINE -
BR
CLEANING AND INSPECTION
(Continued)
Measure the piston skirt diameter (Fig. 135). I f the
piston is out of limits, replace the piston.
1 2 mm (1 / 2 inch)
PISTON
101 .823 mm
4 . 0 0 8 8 inch
J 9 1 0 9 - 6 3
Fig. 135 Piston Skirt Diameter
The upper groove only needs to be inspected for
damage.
Use a new piston ring to measure the clearance in
the intermediate ring groove (Fig. 136). I f the clear­
ance of the intermediate ring exceeds 0.152 mm
(0.006 inch), replace the piston.
Use a new oil ring to measure the clearance in the
oil groove (Fig. 136). I f the clearance exceeds 0.127
mm (0.005 inch), replace the piston.
FEELER GAUGE
J9109-64
Fig. 136 Intermediate and Oil Ring Clearances
Measure the pin bore (Fig. 137). The maximum
diameter is 40.025 mm (1.5758 inch). I f the bore is
over limits, replace the piston.
Inspect the piston pin for nicks, gouges and exces­
sive wear.
Measure the pin diameter (Fig. 138). The mini­
mum diameter is 39.990 mm (1.5744 inch). I f the
diameter is out of limits, replace the pin.
Inspect the rod for damage and wear. The I-Beam
section of the connecting rod cannot have dents or
other damage. Damage to this part can cause stress
risers which will progress to breakage.
Measure the connecting rod pin bore (Fig. 139).
The maximum diameter is 40.042 mm (1.5764 inch).
If out of limits, replace the connecting rod.
J 9 1 0 9 - 6 5
Fig. 137 Piston Pin Bore
PISTON
'PIN
J 9 1 0 9 - 6 6
Fig. 138 Piston Pin Diameter
CONNECTING
ROD
J 9 1 0 9 - 6 7
Fig. 139 Connecting Rod Pin Bore
CRANKSHAFT
CLEANING AND INSPECTION
Clean the crankshaft oil galley holes with a nylon
brush.
Rinse in clean solvent and dry with compressed air.