Chrysler RAM TRUCK 2500 1994 Service Manual page 875

9 - 154 5.9L (DIESEL) ENGINE
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J9109-88
Fig. 2 Main Bearing Cap Removal
(6) Lift the crankshaft and gear from the cylinder
block (Fig. 3).
CAUTION: Crankshaft must be lifted straight off the
bearings to prevent damage to the thrust bearings.
C R A N K S H A F T
J9109-89
Fig. 3 Lifting Crankshaft out of Cylinder Block
( 7 ) Remove the main bearings from the block and
the main caps.
(8) Remove the piston cooling nozzles by using a
3/16 inch pin punch to push them out (Fig. 4).
PISTON
C O O L I N G
N O Z Z L E
CLEANING AND INSPECTION
Clean the crankshaft oil galley holes with a nylon
brush.
Rinse in clean solvent and dry with compressed air.
Inspect the front and rear seal contact areas of the
crankshaft for scratches or grooving.
The service seal k i t will position the seal slightly
deeper into the seal bore so i t will contact the crank­
shaft at a different location. I f this has already been
done and the crankshaft has two worn areas, install
a wear sleeve to provide a new contact surface for
the seal.
Inspect the rod and main journal for deep scores,
signs of overheating and other abnormal marks.
CRANKSHAFT REWORK
Crankshaft main and rod journals may be ground
in increments of 0.25 mm (0.0098 inch) up to a total
of 1.00 mm (0.0394 inch).
The only exception is the main journal thrust
width surface. This journal must be ground i n incre­
ments of 0.50 mm (0.019/7 inch) up to a total of 1.00
mm (0.0394 inch). The thrust surface is located on
the No.6 main bearing. When the thrust surface re­
quires grinding, the main journal must be ground to
the same undersize dimension.
MAIN
J O U R N A L
A l l main journals are to be ground i n the opposite
direction of engine rotation (clockwise as viewed from
the front of crankshaft). Polish the journals i n the
same direction as engine rotation.
The main bearing grinding specifications are shown
i n Fig. 5.
Fig. 4 Piston Cooling Nozzles
STANDARD MAIN. JOURNAL DIAMETER
83.000 +0.013 mm
(3.2677 ± 0.0005 inch)
W O R N MAIN J O U R N A L DIAMETER LIMIT
82.962 (3.2662 inch)
U N D E R S I Z E S REGRIND T O
0.25 mm
(0.0098 inch)
82.750 ± 0 . 0 1 3 mm
(3.2579 ± 0.0005 inch)
0.50 mm
(0.0197 inch)
82.500 + 0 . 0 1 3 mm
(3.2480 ± 0.0005 inch)
0.75 mm
(0.0295 inch)
82.250 + 0 . 0 1 3 mm
(3.2381 ± 0 . 0 0 0 5 inch)
1.00 mm
(0.0394 inch)
82.000 + 0 . 0 1 3 mm
(3.2283 + 0 . 0 0 0 5 inch)
O U T - O F R O U N D & TAPER (MAX.)
0.005 mm (0.0002 inch)
ALL M A I N J O U R N A L S ARE T O BE PARALLEL
TO THE FRONT AND REAR M A I N S WITHIN:
0.030 mm (0.001 inch)
J9109-125
Fig. 5 Crankshaft Main Journal Dimensions