Chrysler DODGE D150 1993 Service Manual page 643

9 - 38 3.9L ENGINE
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OIL RING
S P A C E R G A P
TOP
C O M P R E S S I O N
R I N G G A P
S E C O N D
C O M P R E S S I O N
RING G A P
OIL RING RAiL
G A P (TOP)
OIL RING RAIL
G A P (BOTTOM) J9309-80
Fig. 14 Proper Ring Installation
CONNECTING ROD BEARINGS
Fit all rods on a bank until completed. DO NOT al­
ternate from one bank to another, because connect­
ing rods and pistons are not interchangeable from
one bank to another.
The bearing caps are not interchangeable and
should be marked at removal to ensure correct as­
sembly.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing
shell, make certain t h a t the V-groove in the shell is
in line with the V-groove in the cap. This provides
lubrication of the cylinder wall in the opposite bank.
The bearing shells must be installed so t h a t the
tangs are in the machined grooves in the rods and
caps.
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 inch).
Bearings are available in 0.025 mm (0.001 inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under-
size. Install the bearings in pairs. DO NOT u s e a
n e w bearing half with an old bearing half. DO
NOT file the rods or bearing caps.
INSTALLATION
(1) Be sure t h a t compression ring gaps are stag­
gered so t h a t neither is in-line with oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 14).
(3) Immerse the piston head and rings in clean en­
gine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench
(part of Tool C-385). B e sure position of rings d o e s
not c h a n g e during this operation.
(4) Install connecting rod bolt protectors on rod
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so t h a t the connecting rod
journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal.
(7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, con­
necting rod cap and cylinder bore number are the
same. Install nuts on cleaned and oiled rod bolts and
tighten nuts to 61 N»m (45 ft. lbs.) torque.
(9) Install the oil pan.
(10) Install the cylinder head.
(11) Install the engine into the vehicle.
CRANKSHAFT
A crankshaft which has undersize journals will be
stamped with 1/4 inch letters near the notch of the
No.6 crankshaft counterweight (Fig. 15).
FOR EXAMPLE:R2 stamped on the No.6 crank­
shaft counterweight indicates t h a t the No.2 rod jour­
nal is 0.025 mm (0.001 in) undersize. M4 indicates
t h a t the No.4 main journal is 0.025 mm (0.001 in)
undersize. R3 M2 indicates t h a t the No.3 rod journal
and the No.2 main journal are 0.025 mm (0.001 in)
undersize.
Undersize Journal
Identification Stamp
ROD - 0.025mm (0.001 in.)
Rl-R2-R3-Etc.
MAIN - 0.025mm (0.001 in.)
M1-M2-M3 or M4
STEEL STAMP IDENTIFICATION
R (ROD) A N D / O R M (MAIN) FOLLOWED
BY THE ROD OR M A I N NUMBER
Fig. 15 Location of Crankshaft Identification
When a crankshaft is replaced, all main and con­
necting rod bearings should be replaced with new
bearings. Therefore, selective fitting of the bearings
is not required when a crankshaft and bearings are
replaced.
REMOVAL
(1) Remove the oil pan.