Chrysler RAM TRUCK 2500 1994 Service Manual page 870

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5.9L (DIESEL) ENGINE 9 - 149
Measure the piston skirt diameter (Fig. 2). I f the
piston is out of limits, replace the piston.
12 mm (1/2 inch)
PISTON
_
H
M l l l l ' l l l !
m
MIN. DIAMETER
101.823 mm
4.0088 inch
J9109-63
Fig. 2 Piston Skirt Diameter
The upper groove only needs to be inspected for
damage.
Use a new piston ring to measure the clearance i n
the intermediate ring groove (Fig. 3). I f the clearance
of the intermediate ring exceeds 0.152 mm (0.006
inch), replace the piston.
Use a new oil ring to measure the clearance i n the
oil groove (Fig. 3). I f the clearance exceeds 0.127 mm
(0.005 inch), replace the piston.
FEELER GAUGE
PISTON
J 9 1 0 9 - 6 4
Fig. 3 Intermediate and Oil Ring Clearances
Measure the pin bore (Fig. 4). The maximum diam­
eter is 40.025 mm (1.5758 inch). I f the bore is over
limits, replace the piston.
Inspect the piston pin for nicks, gouges and exces­
sive wear.
Measure the pin diameter (Fig. 5). The minimum
diameter is 39.990 mm (1.5744 inch). I f the diameter
is out of limits, replace the pin.
Inspect the 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. 6). The
maximum diameter is 40.042 mm (1.5764 inch). I f
out of limits, replace the connecting rod.
J9109-65
Fig. 4 Piston Pin Bore
P I S T O N
PIN
J9109-66
Fig. 5 Piston Pin Diameter
CONNECTING
ROD
J9109-67
Fig. 6 Connecting Rod Pin Bore
CONNECTING R O D BEARING / CRANKSHAFT
JOURNAL CLEARANCE
Measure the connecting rod bore with the bearings
installed and the bolts tightened to 100 N«m (73 ft.
lbs.) torque.
Record the smaller diameter.