Chrysler RAM TRUCK 2500 1994 Service Manual page 759

DISASSEMBLE
(1) Remove the cylinder head.
(2) Remove the oil pan.
(3) Remove the piston/connecting rod assembly.
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
• The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
• The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
• The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely co­
ordinated with the fitting of pistons and rings so
specified clearances may be maintained.
Refer to Standard Service Procedures i n the begin­
ning of this Group for the proper honing of cylinder
bores.
OIL LINE PLUG
The oil line plug is located i n the vertical passage
at the rear of the block between the Oil-To-Filter and
Oil-From-Filter passages (Fig. 11). Improper installa­
tion or plug missing could cause erratic, low or no oil
pressure.
(1) Remove oil pressure sending unit from back of
block.
(2) Insert a 3.175 mm (1/8 inch) finish wire or
equivalent into passage.
(3) Plug should be 192.0 to 195.2 mm (7-1/2 to
7-11/16 inches) from machined surface of block (Fig.
11). I f plug is too high, use a suitable flat dowel drift
to position properly.
(4) I f plug is off position, remove oil pan and rear
main bearing cap. Use suitable flat dowel to remove
plug. Coat outside diameter of new plug with Mopar
(stud and bearing mount adhesive), or equivalent.
Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16
inches) from bottom of the block.
(5) Assemble engine and check oil pressure.
ENGINE COItE OIL I CAMSHAFT PLUGS
Engine core plugs have been pressed into the oil
galleries behind the camshaft thrust plate (Fig. 12).
This will reduce internal leakage and help maintain
higher oil pressure at idle.
RIGHT OIL GALLERY
© \ CYLINDER
Fig. 12 Location of Cup Plugs in Oil Galleries
REMOVAL
(1) Using a blunt tool such as a drift or a screw­
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 13).
(2) With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig.
13).
CLEANING
Thoroughly clean inside of cup plug hole i n cylinder
block or head. Be sure to remove old sealer.
Make certain the new plug is cleaned of all oil or
grease.