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5.2L/5.9L ENGINE
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CYLINDER BLOCK
PISTON
REMOVAL
(1) Remove top ridge of cylinder bores w i t h a r e l i -
able ridge reamer before r e m o v i n g pistons f r o m cyl-
inder block. Be sure t o keep tops o f pistons covered
d u r i n g t h i s operation. Pistons a n d connecting rods
must be removed f r o m top o f cylinder block. W h e n
removing piston and connecting r o d assemblies
from
the engine, rotate crankshaft so t h a t each connecting
rod is centered i n cylinder bore.
(2) Inspect connecting rods a n d connecting rod caps
for cylinder identification. I d e n t i f y t h e m i f necessary.
(3) Remove connecting r o d cap. I n s t a l l connecting
rod bolt guide set on connecting r o d bolts. Push each
piston a n d r o d assembly o u t o f cylinder bore. Be
careful not to nick crankshaft j o u r n a l s .
(4) After removal, i n s t a l l b e a r i n g cap on the mat-
i n g rod.
CLEANING AND
INSPECTION
(1) Clean cylinder block t h o r o u g h l y a n d check a l l
core hole plugs for evidence o f l e a k i n g .
(2) I f new core plugs are i n s t a l l e d , coat edges of
p l u g and core hole w i t h M O P A R Gasket M a k e r or
equivalent. Drive t h e core p l u g i n so t h a t t h e r i m
lies at least 0.397 m m (1/64 inch) below the lead-in
chamfer.
(3) E x a m i n e block for cracks or fractures.
CYLINDER
BORE
INSPECTION
The
cylinder walls should be checked
for out-
of-bound and taper w i t h Tool C-119. I f the cylinder
bores show more t h a n 0.127 m m (0.005 inch) out-of-
round, or a taper of more t h a n 0.254 m m (0.010 inch)
or i f the cylinder w a l l s are badly scuffed or scored,
the cylinder block should be bored a n d honed, a n d
new pistons and rings fitted. Whatever type of boring
equipment
is used, boring a n d h o n i n g operation
should be closely coordinated w i t h t h e fitting o f pis-
tons and rings i n order t h a t specified clearances may
be m a i n t a i n e d .
ENGINE CORE OIL AND CAM PLUGS
REMOVAL
U s i n g a b l u n t tool such as a d r i f t or a screwdriver
and a hammer, s t r i k e t h e b o t t o m edge o f the cup
p l u g (Fig. 1). W i t h the cup p l u g r o t a t e d , grasp
firmly
w i t h pliers or other suitable tool a n d remove p l u g
(Fig. 1).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious en-
gine problems.
Fig.
1 Core Hole
Plug
INSTALLATION
Thoroughly clean inside o f cup p l u g hole i n c y l i n -
der block or head. Be sure t o remove o l d sealer.
L i g h t l y coat inside o f cup p l u g hole w i t h Loctite S t u d
N ' B e a r i n g M o u n t or equivalent. M a k e certain t h e
new p l u g is cleaned of a l l o i l or grease. U s i n g proper
drive p l u g , drive p l u g i n t o hole so t h a t t h e sharp
edge o f the p l u g is a t least 0.50 m m (0.020 inch) i n -
side the lead-in chamfer.
I t is not necessary t o w a i t for c u r i n g of the sealant.
The cooling system can be filled a n d t h e vehicle
placed i n service i m m e d i a t e l y .
PISTONS, PINS AND RINGS
The pistons are cam g r o u n d so t h a t the diameter a t
the p i n boss is less t h a n i t s diameter across t h e
t h r u s t face. This allows for expansion under n o r m a l
operating conditions. U n d e r operating temperatures,
expansion forces t h e p i n bosses away
from
each
other, t h u s , causing t h e piston t o assume a more
nearly r o u n d shape. I t is i m p o r t a n t t h a t pistons be
checked for taper and e l l i p t i c a l shape before they are
fitted i n t o t h e cylinder bore (Figs. 2 and 3).
SHAPE OF THE PISTON SKIRT
.000 TO .0006 INCH (.0152 mm)
SHOULD BE .010 TO .012 IN.
LARGER THAN (C)
(.254 TO .304 mm) LESS AT DIAMETER
(A) THAN ACROSS THE THRUST
FACES AT DIAMETER (B)
8909-62
Fig. 2 Piston Measurements—5.2L
Engine
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