Chrysler RAM TRUCK 2500 1994 Service Manual page 756

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3.9L ENGINE 9 - 35
U n d e r s i z e J o u r n a l
I d e n t i f i c a t i o n Stamp
ROD - 0.025mm (0.001 in.) Rl -R2-R3-Etc.
M A I N - 0.025mm (0.001 in.) M 1 - M 2 - M 3 o r M 4
STEEL STAMP IDENTIFICATION
R (ROD) A N D / O R M (MAIN) F O L L O W E D
BY THE R O D OR M A I N NUMBER
# 5 # 4 # 3 # 2 - ^
#1
J 9 2 0 9 - 1 3 4
Fig. 6 Location of Crankshaft Identification
bearings. Therefore, selective fitting of the bearings
is not required when a crankshaft and bearings are
replaced.
REMOVAL
(1) Remove
(2) Remove
ing cap.
(3) Remove
(4) Remove
(5) Identify
bearing caps
(6) Lift the
(7) Remove
seals.
(8) Remove
seal.
the oil pan.
the oil pump from the rear main bear-
the vibration damper,
the timing chain cover.
bearing caps before removal. Remove
and bearings one at a time,
crankshaft out of the block.
and discard the crankshaft rear oil
and discard the front crankshaft oil
INSPECTION OF J O U R N A L S
The crankshaft connecting rod and main journals
should be checked for excessive wear, taper and scor­
ing. The maximum taper or out-of-round on any
crankshaft journal is 0.025 mm (0.001 inch).
Journal grinding should not exceed 0.305 mm
(0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.3 main bearing. DO
NOT nick crank pin or bearing fillets. After grinding,
remove rough edges from crankshaft oil holes and
clean out all oil passages.
CAUTION: After any journal grind, it is important
that the final paper or cloth polish be in the same
direction a s the engine rotates.
CLEANING
Clean Loctite 515 residue and sealant from the cyl­
inder block and rear cap mating surface. Do this be­
fore applying the Loctite drop and the installation of
rear cap.
INSTALLATION
(1) Lightly oil the new upper seal lips with engine
oil.
(2) Install the new upper rear bearing oil seal with
the yellow paint facing towards the rear of the en­
gine.
(3) Position the crankshaft into the cylinder block.
(4) Lightly oil the new lower seal lips with engine
oil.
(5) Install the new lower rear bearing oil seal into
the bearing cap with the yellow paint facing towards
the rear of the engine.
(6) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap
(Fig. 7). DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing
cap to cylinder block immediately after sealant appli­
cation.
t MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTSs
^ L O C T I T E
515 (OR EQUIVALENT)^
C A P
A L I G N M E N T
SLOT
REAR M A I N
B E A R I N G C A P
J9309-72
Fig. 7 Sealant Application to Bearing Cap
(7) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
(8) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 N-m (85 ft. lbs.) torque.
(9) Install oil pump.
(10) Install the timing chain cover.
(11) Install the vibration damper.
(12) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 8). Ap­
ply enough sealant until a small amount is squeezed
out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove.
(13) Install new front crankshaft oil seal.
(14) Immediately install the oil pan.
CRANKSHAFT MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly.