Dodge dakota 2002 Service Manual page 1581

9 - 332 ENGINE 5.9L DIESEL
PISTON & CONNECTING ROD (Continued)
Inspect the piston pin for nicks, gouges and exces-
sive wear. Measure the pin diameter (Fig. 93). The
minimum diameter is 39.990 mm (1.5744 inch), max-
imum 40.003 mm (1.5749 inch). If the diameter is out
of limits, replace the pin.
Fig. 93 Piston Pin Diameter
1 - PISTON PIN
INSPECTION—CONNECTING ROD
Inspect the connecting 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. 94). The
maximum diameter is 40.042 mm (1.5765 inch), min-
imum diameter is 40.019 mm (1.5756 inch). If out of
limits, replace the connecting rod.
Fig. 94 Connecting Rod Pin Bore
1 - CONNECTING ROD
INSTALLATION
(1) Lubricate the cylinder bores with clean engine
oil.
(2) Generously lubricate the rings and piston
skirts with clean engine oil.
(3) Compress the rings using a piston ring com-
pressor tool (Fig. 95). If using a strap-type ring com-
pressor, make sure the inside end of the strap does
not hook on a ring gap and break the ring.
Fig. 95 Piston Ring Compressor Tool
1 - PISTON RING COMPRESSOR TOOL
(4) Bar the crankshaft so the rod journal for the
piston to be installed is at BDC (Bottom Dead Cen-
ter) - (Fig. 96).
Fig. 96 Piston/Rod Assembly at BDC
(5) Make sure the front of the piston is oriented
properly according to the marking on the top of the
piston and the numbers on the rod and cap are ori-
ented as illustrated.
(6) Position the piston and rod assembly into the
cylinder bore with the front of the piston oriented
properly according to the stamping in the top of the
piston. In this position the numbers on the connect-
ing rod should be facing the intake or camshaft side
of the engine, and the rod bolt hex heads toward the
oil cooler. Use care when you install the piston and
connecting rod so the cylinder bore is not damaged. If
a fractured split connecting rod is being installed, the
long side of the connecting rod must be installed on
the intake side of the engine.
(7) Push the piston into the bore until the top of
the piston is approximately 50 mm (2 inch) below the
top of the block. Carefully pull the connecting rod
onto the crankshaft journal.
DR