Chrysler RAM TRUCK 2500 1994 Service Manual page 874

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5.9L (DIESEL) ENGINE 9 - 153
J9109-84
Fig. 17 Piston/Rod Assembly at BDC
wards the front of the cylinder block. Use care when
you install the piston and connecting rod so the cyl­
inder bore is not damaged.
(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.
(8) Use clean engine oil to lubricate the threads
and under the heads of the connecting rod bolts.
(9) The 4 digit number stamped on the rod cap at
the parting line must match and be installed towards
the oil cooler side of the engine (Fig. 18).
J9109-85
Fig. 18 Correct Rod Cap Installation
(10) Install the rod cap and bolts to the connecting
rod. Tighten the connecting rod and bolt evenly in 3
steps.
• Tighten the bolts to 35 N-m (26 ft. lbs.) torque.
• Tighten the bolts to 70 N-m (51 ft. lbs.) torque.
• Tighten the bolts to 100 N-m (73 ft. lbs.) torque.
(11) The crankshaft must rotate freely. Check for
freedom of rotation as the caps are installed. If the
crankshaft does not rotate freely, check the installa­
tion of the rod bearing and the bearing size.
(12) Measure the side clearance between the con­
necting rod and the crankshaft (Fig. 19). DO NOT
measure the clearance between the cap and crank­
shaft.
(13) Install the suction tube and oil pan.
J9109-86
SI D E C L E A R A N C E L I M I T S
MIN.
M A X .
0.100 mm
0.300 mm
(0.004 inch)
(0.012 inch)
Fig. 19 Side Clearance between Connecting
Rod/Crankshaft
(14) Install the cylinder head onto the block.
(15) Install the engine assembly into the vehicle.
CRANKSHAFT
REMOVAL
(1) Remove the rear crankshaft seal housing.
(2) Remove the gear housing.
(3) Rotate the engine to a horizontal position and
remove the main bearing bolts.
(4) The main bearing caps should be numbered. If
they are not, be sure to mark them, beginning with
number one at the front and ending with number
seven at the rear (Fig. 1).
M A I N
BEARI N G
C A P
J9109-87
Fig. 1 Numbering Main Bearing Caps
CAUTION: DO NOT pry on the main c a p s to free
them from the cylinder block.
(5) Use two of the main bearing cap bolts to "wig­
gle" the main cap loose, being careful not to damage
the bolt threads (Fig. 2). Remove the caps.
WARNING: U S E A HOIST T O AVOID INJURY.