Dodge dakota 2002 Service Manual page 1510

DR
PISTON & CONNECTING ROD (Continued)
PISTON MEASUREMENT CHART
PISTON A DIA = PISTON
SIZE DIAMETER
MIN.
mm
(in.)
A —
B 101.580
(3.9992)
C 101.592
(3.9997)
D 101.605
(4.0002)
E —
DESCRIPTION
PISTON PIN BORE
RING GROOVE
HEIGHT
OIL RAIL
COMPRESSION
RAIL
TOTAL FINISHED
WEIGHT
REMOVAL
(1) Remove the engine from the vehicle (Refer to 9
- ENGINE - REMOVAL).
(2) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(3) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(4) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block. Be sure to keep tops of pistons covered
during this operation.
(5) Be sure each connecting rod and connecting rod
cap is identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
BORE
DIAMETER
MAX. MIN.
mm mm mm (in.)
(in.) (in.)
— —
101.592 101.605 101.618
(3.9997) (4.0002) (4.0007)
101.605 101.618 101.630
(4.0002) (4.0007) (4.0012)
101.618 101.630 101.643
(4.0007) (4.0012) (4.0017)
— —
SPECIFICATION
25.007 - 25.015 mm
(.9845 - .9848 in.)
4.033 - 4.058 mm
(.1588 - .1598 in.)
1.529 - 1.554 mm
(.0602 - .0612 in.)
470.8 ± 2 grams
(16.607 ± .0706 ounces)
(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing the
assemblies from the engine, rotate crankshaft so that
the connecting rod is centered in cylinder bore and at
BDC. Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mat-
MAX.
ing rod.
CLEANING
Clean the piston and connecting rod assembly
—
using a suitable solvent.
INSPECTION
Check the connecting rod journal for excessive
wear, taper and scoring (Refer to 9 - ENGINE/EN-
GINE BLOCK/CONNECTING ROD BEARINGS -
STANDARD PROCEDURE).
Check the connecting rod for signs of twist or bend-
ing.
Check the piston for taper and elliptical shape
before it is fitted into the cylinder bore (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECT-
—
ING ROD - STANDARD PROCEDURE).
Check the piston for scoring, or scraping marks in
the piston skirts. Check the ring lands for cracks
and/or deterioration.
INSTALLATION
(1) Be sure that compression ring gaps are stag-
gered so that neither is in line with oil ring rail gap.
(2) Before installing the ring compressor, be sure
the oil ring expander ends are butted and the rail
gaps located properly (Fig. 39).
1 - OIL RING SPACER GAP
2 - SECOND COMPRESSION RING GAP OIL RING RAIL GAP
(TOP)
3 - OIL RING RAIL GAP (BOTTOM)
4 - TOP COMPRESSION RING GAP
ENGINE - 5.9L
Fig. 39 Proper Ring Installation
9 - 261