1993 DODGE TRUCK Service Repair Manual

9
- 132 5.9L
(DIESEL) ENGINE
BORING
AND

HONING
DIAMETERS
BORING DIAMETER DIMENSION 1st REBORE
-
102.469
mm

(4.0342
inch)
2nd
REBORE
-
102.969
mm
(4.0539
inch)

HONING
DIAMETER DIMENSIONS
STANDARD
102.020
±0.020
mm
(4.0165
±
0.0008
inch)

1st REBORE
102.520
±
0.020
mm
(4.0362
±
0.0008
inch)
2nd
REBORE
103.020
±0.020
mm
(4.0559
±
0.0008
inch)

CHAMFER DIMENSIONS

Approx.
1.25 mm
(0.049
inch)
by
15°

J9109-119

Fig.
10 Cylinder
Bore
Dimensions
TOP
OF
BLOCK
Fig.
11
Crosshatch
Pattern
of Repaired
Sleeve(s)
Bore the block cylinder bore to 104.500-104.515
mm (4.1142-4.1148 inch) - (Fig. 12).
Repair sleeves can be replaced by using a boring
bar to bore out the old sleeve. DO NOT cut the cyl­
inder bore beyond the oversize limit.
BORE DIAMETER
BLOCK REBORE
FOR
REPAIR SLEEVE BORE
DIA. -
104.500
+0.015
mm

(4.1142
+0.0006
inch)

STEP
DIM. - 6.35 mm (0.25 inch)

J9109-120

Fig.
12
Block
Bore
for Repair
Sleeve
Dimensions

After machining the block for the new repair
sleeve, thoroughly clean the bore of all metal chips,
debris and oil residue before installing the sleeve.
Cool the repair sleeve(s) to a temperature of -12°C
(10°F) or below for a minimum of one hour. Be ready
to install the sleeve immediately after removing it
from the freezer.
Apply a coat of Loctite 620, or equivalent to the
bore that is to be sleeved. Wear protective gloves to push the cold sleeve into
the bore as far as possible.
Using a sleeve driver, drive the sleeve downward
until it contacts the step at the bottom of the bore (Fig. 13).
J9109-121

Fig.
13
Sleeve
Installation

•

5
9L
(DIESEL) ENGINE
9 - 133
A sleeve driver can be constructed as follows (Fig. 14).

DRIVE
-
ALUMINUM
HANDLE
-
STEEL A
= 127 mm (5 inch)

B
= 38 mm (1.5 inch)

C
= 6.35 mm (0.25 inch)

D
= 25.4 mm (1 inch)

E
= 101 mm
(3.976
inch)

F
=
107.343
mm
(4.226
inch)

J9109-122

Fig.
14
Sleeve
Driver Construction
Set up a boring bar and machine the sleeve to
101.956 mm (4.014 inch) - (Fig. 15). After removing the boring bar, use a honing stone to
chamfer the corner of the repair sleeve(s) - (Fig. 15).
SLEEVE DIAMETER
-
101.956
mm

(4.014
inch)

SLEEVE PROTRUSION MIN.
-
FLUSH
WITH
BLOCK MAX.
-
0.050
mm
(0.0019
inch)

SLEEVE CHAMFER APPROX.
1.25 mm
(0,049
inch)
BY
15° •
J9109-123

Fig.
15
Sleeve
Machining
Dimensions

A correctly honed surface will have a Crosshatch
appearance with the lines at 15° to 25° angles with
the top of the cylinder block. For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit
honing stones. Finished bore inside dimension is 102.020 ±0.020
mm (4.0165 ±0.0008 inch). A maximum of 1.2 micrometer (48 microinch) sur­
face finish must be obtained.
After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry detergent and hot water.
After rinsing, blow the block dry with compressed
air.
Wipe the bore with a white, lint-free, lightly oiled
cloth. Make sure there is no grit residue present. Apply a rust-preventing compound if the block will
not be used immediately.
A standard diameter piston and a piston ring set
must be used with a sleeved cylinder bore.
CAM
BORE REPAIR
The front cam bushing bore can be bored to 57.740
Mm ±0.018 mm (2.273 inch ±0.0007 inch) oversize.
DO NOT bore the intermediate or rear cam bore to
the front cam bore oversize dimensions. Intermediate and rear cam bores may be bored to 57.240 mm ±0.018 mm (2.253 inch ±0.0007 inch) oversize.
A surface finish of 2.3 micrometers (92 microinch)
must be maintained. Not more than 20% of an area
of any one bore may be 3.2 micrometers (126 micro-

inch).

Camshaft bores can be repaired individually. It is
not necessary to repair undamaged cam bores in or­
der to repair individually damaged cam bores. The standard front bushing cannot be used to repair in­
termediate or rear bores.
Install all cam bushings flush or below the front
cam bore surface. The oil hole must align to allow a 3.2 mm (0.125 inch) rod to pass through freely (Fig.
16). Fig.
16 Oil Hole
Alignment

CUP PLUG-REPLACEMENT
(1) Remove the cup plugs from the oil passages
(Fig. 17).
(2) Apply a bead of Loctite 277 around the outside
diameter of the oil passage cup plugs. (3) Drive the cup plugs in until they bottom in the
bore (Fig. 17).

9
- 134 5.9L
(DIESEL) ENGINE

• (4) Fill the engine with oil. Run the engine and
check for leaks.
(5) Stop the engine and check the oil level with the
dipstick.
CUP
PLUG

J9109-30

Fig.
17 Cup Plug Locations in Cylinder Block INSTALLATION
(1) Install the cylinder head onto the block.
(2) Install the engine assembly into the vehicle.

PISTON
/
CONNECTING ROD ASSEMBLY
The turbocharged intercooler piston has a Ni-Resist
insert with a keystone profile for the top compression
ring. The new piston has a new design bowl and a 7 mm longer piston pin. These pistons can not be in­
terchanged with earlier models.
REMOVAL (1) Remove the engine assembly from the vehicle.
(2) Remove the cylinder head from the block.
(3) Remove the oil pan and suction pump.
(4) If the cylinder bores have ridges, use a ridge
reamer to cut the ridge from the top of the cylinder
bore before removing the piston. Make sure the ridge reamer does not make a deep cut into the bore. DO
NOT remove more metal than is necessary to remove
the ridge.
(5) If cylinders have ridges, the cylinders are over­
size and will need boring. (6) Use a hammer and a steel stamp to mark the
cylinder number onto each connecting rod cap. Mark
the cylinder number onto the top of each piston. (7) Remove the connecting rod bolts and rod caps.
Use care so the cylinder bores and connecting rods
are not damaged. (8) Use a hammer handle or similar object to push
the piston and connecting rod through the cylinder

bore.
(9) Store the piston/rod assemblies in a rack.
DISASSEMBLE (1) Remove the retainer rings from the piston (Fig.

1).
(2) Remove the piston pin. Heating the piston is
not required. (3) Remove the piston rings (Fig. 1). RETAINER
RING

CONNECTING

ROD

PISTON

PISTON RIN RETAINER
RING J9109-62

Fig.
1 Retainer
Rings

CLEANING
CAUTION: DO NOT use bead
blast
to clean the
pis­

tons.
DO
NOT
clean the pistons and rods in an acid

tank.

Soak the pistons in cold parts cleaner. Soaking the
pistons overnight will usually loosen the carbon de­ posits.
Wash the pistons and rods in a strong solution of
laundry detergent and hot water.
Clean the remaining deposits from the ring grooves
with the square end of a broken ring. DO NOT use a
ring groove cleaner and be sure not to scratch the
ring sealing surface in the piston groove.
Wash the pistons again in a detergent solution or
solvent.
Rinse the pistons. Use compressed air to dry.
INSPECTION Inspect the rod journals for deep scratches, indica­
tion of overheating and other damage.
Inspect the pistons for damage and excessive wear.
Check top of the piston, ring grooves, skirt and pin

bore.

Measure the piston skirt diameter (Fig. 2). If the
piston is out of limits, replace the piston.
The upper groove only needs to be inspected for
damage.
Use a new piston ring to measure the clearance in
the intermediate ring groove (Fig. 3). If 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 in the
oil groove (Fig. 3). If the clearance exceeds 0.127 mm (0.005 inch), replace the piston.

•
5.9L
(DIESEL) ENGINE
9 - 135 -j^u mm 11/2 inch)
MIN. DIAMETER
101.823 mm
4.0088 inch
J9109-63

Fig. 2 Piston Skirt Diameter PISTON

•
PIN FEELER GAUGE
J910<

PISTON J9109-64
Fig. 3 Intermediate and Oil Ring Clearances
Measure the pin bore (Fig. 4). The maximum diam­
eter is 40.025 mm (1.5756 inch). If the bore is over
limits,
replace the piston,
PISTON

J9109-65

Fig. 4 Piston Pin Bore
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). If 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. -66 Fig. 5 Piston Pin Diameter
Measure the connecting rod pin bore (Fig. 6). The
maximum diameter is 40.092 mm (1.5784 inch). If
out of limits, replace the connecting rod.
CONNECTING
Fig. 6 Connecting Rod Pin Bore
CONNECTING ROD 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.
Measure the diameter of the rod journal at the lo­
cation shown (Fig. 7). Calculate the average diame­
ter for each side of the journal.
The clearance is the difference between the con­
necting rod bore (smallest diameter) and the average
diameter for each side of the crankshaft journal.
If the crankshaft is within limits, replace the bear­
ing. If the crankshaft is out of limits, grind the
crankshaft to the next smaller size and use oversize
rod bearings.

ASSEMBLE
(1) Be sure the FRONT marking on the piston and
the numbers on the rod and cap are oriented (Fig. 8).

9
- 136 5.9L
(DIESEL)
ENGINE

• MIN.
68.962 mm (2.715
inch)
MAX. 69.013 mm (2.717 inch)
Out-of-Round - Max.
0.050
mm (0.002 inch)
Taper - Max. 0.013 mm (0.0005 inch)
Bearing Clearance - Max.

0.089
mm (0.0035 inch)
J9109-91

Fig.
7
Connecting
Rod
Journal
Diameter Limits
Install the retaining ring into the pin groove on the
FRONT side of the piston.
Fig.
8 Proper Markings on the
Piston
and

Connecting
Rod (2) Lubricate the pin and bore with engine oil.
(3) Install the piston pin in the opposite side of the
installed retaining pin. Pistons do not require heat­
ing to install the pin, however, the piston does need
to be at room temperature or above.
(4) Determine the piston diameter and obtain the
appropriate ring set. The piston rings can be identi­
fied as shown in Fig. 9. TOP RING INTERMEDIATE
RING
OIL CONTROL RING TOP J9109-69

Fig.
9
Piston
Ring
Identification

(5) Position each ring in the cylinder and use a
piston to square it with the bore at a depth of 89.0 mm (3.5 inch) - (Fig. 10). (6) Use a feeler gauge to measure the piston ring
gap (Fig. 11).
Fig.
10 Position of
Ring
in Cylinder
Bore

MINIMUM MAXIMUM
TOP
0.400
mm
(0.0160 inch)
0.700
mm
(0.0275 inch)
INTERMEDIATE
0.250
mm
(0.0100 inch)
0.550
mm
(0.0215 inch)
OIL CONTROL
0.250
mm
(0.0100 inch)
0.550
mm
(0.0215 inch)
J9109-71
Fig.
11
Piston
Ring
Gap

•

5.9L (DIESEL) ENGINE
9 - 137 (7) The top surface of all of the rings are identified
with the word TOP or the supplier's MARK. Assem­
ble the rings with the word TOP or the supplier's MARK up.
(8) Position the oil ring expander in the oil control
ring groove (bottom groove). (9) Install the oil control ring with the end gap
OPPOSITE the ends on the expander (Fig. 12). OIL CONTROL
RING
PISTON EXPANDER
J9109-72

Fig.
12 Oil Control
Ring/Expander
Location in
Groove
(10) Install the intermediate piston ring in the sec­
ond groove (Fig. 13).
(11) Install the top piston ring in the top groove
(Fig. 13). PISTON RING
INSTALLATION
TOOL J9109-74

Fig.
13
Piston
Ring
Installation
Tool (12) Position the rings as shown in Fig. 14.
(13) Install the original bearings as removed or in­
stall new bearings. If new bearings are used, be sure
to obtain the proper bearing clearance (Fig. 15). (14) DO NOT lubricate the side of the bearing that
is against the connecting rod or cap. Apply a coat of
Lubriplate 105, or equivalent to the new upper and
lower connecting rod bearings.

INSTALLATION
(1) Lubricate the cylinder bore with clean engine

oil.
(2) Generously lubricate the rings and piston
skirts with clean engine oil. (3) Compress the rings using a piston ring com- TOP
RING
INTERMEDIATE
RING
OIL CONTROL
RING

J9109-73

Fig.
14
Piston
Ring
Positioning
STANDARD
J9109-82
OVERSIZE
0.250 mm (.0098 in.
0.500 mm (.0197 in.
0.750 mm (.0295 in. 1.000 mm (.0394 in.

Fig.
15
Connecting
Rod Bearing
Size
Location pressor tool (Fig. 16). If using a strap-type ring com­
pressor, make sure the inside end of the strap does
not hook on a ring gap and break the ring.
PISTON
RING
COMPRESSOR TOOL J9109-83

Fig.
16
Piston
Ring
Compressor
Tool (4) Bar the crankshaft so the rod journal for the
piston to be installed is at BDC (Bottom Dead Cen­
ter) - (Fig. 17).
(5) Be sure the FRONT marking on the piston and
the numbers on tlie rod and cap are oriented as illus­
trated.
(6) Position the piston and rod assembly into the
cylinder bore with the word FRONT on the piston to­
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

9
- 138 5.9L
(DIESEL)
ENGINE

J9109-84

Fig.
17
Piston/Rod
Assembly
at BDC
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).
O
o

-—-—.—
f
'
-
ro o

O —

—"k

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 Nun (26 ft. lbs.)
torque. • Tighten
the
bolts
to 70 N*m (51 ft. lbs.)
torque.
• Tighten
the
bolts
to 100 Nun (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.
(14) Install
the
cylinder head onto
the
block.
(15) Install
the
engine assembly into
the
vehicle.
SIDE
CLEARANCE
LIMITS

MIN.
MAX. 0.100
mm

0.300
mm

(0.004 inch)
(0.012 inch)
Fig.
19
Side
Clearance between
Connecting
Rod/

Crankshaft

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).

MAIN BEARING

CAP

J9109-87

Fig.
1
Numbering
Main Bearing
Caps

CAUTION:
DO NOT pry on the
main
caps
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:
USE
A
HOIST
TO
AVOID
INJURY.

(6) Lift
the
crankshaft
and
gear from
the
cylinder
block
(Fig. 3).

•

5.9L
(DIESEL) ENGINE 9 - 139

Fig.
2 Main Beating Cap
Removal
CAUTION:
Crankshaft must be
lifted
straight
off the

bearings
to
prevent
damage
to the
thrust
bearings.

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).

Fig.
4
Piston
Cooling
Nozzles

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 kit will position the seal slightly
deeper into the seal bore so it will contact the crank­
shaft at a different location. If 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 in incre­ ments of 0.50 mm (0.0197 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
JOURNAL
All main journals are to be ground in the opposite
direction of engine rotation (clockwise as viewed
from the front of crankshaft). Polish the journals in
the same direction as engine rotation.
The main bearing grinding specifications are
shown in Fig. 5.

STANDARD
MAIN
JOURNAL
DIAMETER
83.000 +0.013 mm
(3.2677 ±0.0005 inch)

WORN
MAIN
JOURNAL
DIAMETER
LIMIT
82.962 (3.2662
inch)

UNDERSIZES
REGRIND
TO
0.25 mm
(0.0098
inch)
82.750 ±0.013 mm
(3.2579 ±0.0005
inch)

0.50 mm
(0.0197
inch)
82.500 +0.013 mm
(3.2480 +0.0005
inch)

0.75 mm
(0.0295
inch)
82.250 +0.013 mm
(3.2381 ±0.0005
inch)

1.00 mm
(0.0394 inch) 82.000 +0.013 mm
(3.2283 ±0.0005 inch)

OUT-OF
ROUND
&
TAPER
(MAX.)
0.005 mm (0.0002 inch)

ALL
MAIN
JOURNALS
ARE
TO
BE
PARALLEL

TO
THE
FRONT
AND
REAR
MAINS
WITHIN:
0.030
mm
(0.001 inch)
J9109-125

Fig.
5 Crankshaft Main
Journal
Dimensions

Thrust journals can be ground in the same incre­
ments and using the same specifications as all other main journals. The main journal radius may be ground using either the preferred or the alternative