Content .. 540 541 542 543 ..

Dodge Dakota (R1). Manual - part 542

PISTON MEASUREMENT CHART

PISTON

A DIA = PISTON

BORE

SIZE

DIAMETER

MIN.

MAX.

MIN.

MAX.

(in.)

mm (in.)

—

101.580

101.592

101.605

101.618

(3.9992)

(3.9997)

(4.0002)

(4.0007)

101.592

101.605

101.618

101.630

(3.9997)

(4.0002)

(4.0007)

(4.0012)

101.605

101.618

101.630

101.643

(4.0002)

(4.0007)

(4.0012)

(4.0017)

—

DESCRIPTION

SPECIFICATION

PISTON PIN BORE

25.007 - 25.015 mm

(.9845 - .9848 in.)

RING GROOVE

HEIGHT

(OIL RAIL)

4.033 - 4.058 mm

(.1588 - .1598 in.)

(COMPRESSION

RAIL)

1.529 - 1.554 mm

(.0602 - .0612 in.)

TOTAL FINISHED

470.8 ± 2 grams

WEIGHT

(16.607 ± .0706 ounces)

REMOVAL

(1) Remove the engine from the vehicle.
(2) Remove the cylinder head.
(3) Remove the oil pan.
(4) Remove top ridge of cylinder bores with a reli-

able ridge reamer before removing pistons from cyl-
inder block. Be sure to keep tops of pistons covered
during this operation.

(5) Be sure the connecting rod and connecting rod

cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.

(6) Pistons and connecting rods must be removed

from top of cylinder block. When removing piston and
connecting rod assemblies, rotate crankshaft to cen-
ter the connecting rod in the cylinder bore and at
BDC. Be careful not to nick crankshaft journals.

(7) After removal, install bearing cap on the mat-

ing rod.

INSPECTION

Check the connecting rod journal for excessive

wear, taper and scoring.

Check the cylinder block bore for out-of-round,

taper, scoring and scuffing.

Check the pistons for taper and elliptical shape

before they are fitted into the cylinder bore (Fig. 35).

PISTON MEASUREMENT CHART

PISTON

A DIA = PISTON

BORE

SIZE

DIAMETER

MIN.

MAX.

MIN.

MAX.

(in.)

mm (in.)

—

101.580

101.592

101.605

101.618

(3.9992)

(3.9997)

(4.0002)

(4.0007)

101.592

101.605

101.618

101.630

(3.9997)

(4.0002)

(4.0007)

(4.0012)

101.605

101.618

101.630

101.643

(4.0002)

(4.0007)

(4.0012)

(4.0017)

—

DESCRIPTION

SPECIFICATION

PISTON PIN BORE

25.007 - 25.015 mm

(.9845 - .9848 in.)

RING GROOVE

HEIGHT

(OIL RAIL)

4.033 - 4.058 mm

(.1588 - .1598 in.)

(COMPRESSION

RAIL)

1.529 - 1.554 mm

(.0602 - .0612 in.)

TOTAL FINISHED

470.8 ± 2 grams

WEIGHT

(16.607 ± .0706 ounces)

9a - 86

ENGINE 5.2L INTERNATIONAL

PISTON & CONNECTING ROD (Continued)

INSTALLATION

(1) Be sure that compression ring gaps are stag-

gered so that 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. 36).

(3) Immerse the piston head and rings in clean

engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench
(part of Tool C-385). Be sure position of rings
does not change 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 that 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.

PISTON RINGS

STANDARD PROCEDURE - PISTON RINGS -
FITTING

(1) Measurement of end gaps:

(a) Measure piston ring gap 2 inches from bot-

tom of cylinder bore. An inverted piston can be
used to push the rings down to ensure positioning
rings squarely in the cylinder bore before measur-
ing.

(b) Insert feeler gauge in the gap. The top com-

pression ring gap should be between 0.254-0.508
mm (0.010-0.020 inch). The second compression
ring gap should be between 0.508-0.762 mm (0.020-
0.030 inch). The oil ring gap should be 0.254-1.270
mm (0.010-0.050 inch).

erly filed to the correct dimension. Rings with
excess gaps should not be used.
(2) Install rings, and confirm ring side clearance:

(a) Install oil rings being careful not to nick or

scratch the piston. Install the oil control rings
according to instructions in the package. It is not
necessary to use a tool to install the upper and
lower rails. Insert oil rail spacer first, then side
rails.

(b) Install the second compression rings using

Installation Tool C-4184. The compression rings
must be installed with the identification mark face
up (toward top of piston) and chamfer facing down.
An identification mark on the ring is a drill point,
a stamped letter “O”, an oval depression, or the
word “TOP” (Fig. 37) (Fig. 39).

pression ring with the chamfer facing up (Fig. 38)
(Fig. 39). An identification mark on the ring is a
drill point, a stamped letter “O”, an oval depression
or the word “TOP” facing up.

(d) Measure side clearance between piston ring

and ring land. Clearance should be 0.074-0.097 mm
(0.0029-0.0038 inch) for the compression rings. The
steel rail oil ring should be free in groove, but
should not exceed 0.246 mm (0.0097 inch) side
clearance.

(e) Pistons with insufficient or excessive side

clearance should be replaced.

Fig. 36 Proper Ring Installation

1 - OIL RING SPACER GAP
2 - SECOND COMPRESSION RING GAP OIL RING RAIL GAP
(TOP)
3 - OIL RING RAIL GAP (BOTTOM)
4 - TOP COMPRESSION RING GAP

ENGINE 5.2L INTERNATIONAL

9a - 87

PISTON & CONNECTING ROD (Continued)

VIBRATION DAMPER

REMOVAL

(1) Disconnect the negative cable from the battery.
(2) Remove fan shroud retainer bolts and set

shroud back over engine.

(3) Remove the cooling system fan.
(4) Remove the serpentine belt (Refer to 7 - COOL-

ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).

(5) Remove the vibration damper pulley.
(6) Remove vibration damper bolt and washer from

end of crankshaft.

(7) Install bar and screw from Puller Tool Set

C-3688. Install 2 bolts with washers through the
puller tool and into the vibration damper (Fig. 40).

(8) Pull vibration damper off of the crankshaft.

INSTALLATION

(1) Position the vibration damper onto the crank-

shaft.

(2) Place installing tool, part of Puller Tool Set

C-3688 in position and press the vibration damper
onto the crankshaft (Fig. 41).

Fig. 37 Second Compression Ring Identification

(Typical)

1 - SECOND COMPRESSION RING (BLACK CAST IRON)
2 - CHAMFER
3 - TWO DOTS

Fig. 38 Top Compression Ring Identification

(Typical)

1 - TOP COMPRESSION RING (GRAY IN COLOR)
2 - CHAMFER
3 - ONE DOT

Fig. 39 Compression Ring Chamfer Location

(Typical)

1 - CHAMFER
2 - TOP COMPRESSION RING
3 - SECOND COMPRESSION RING
4 - PISTON
5 - CHAMFER

Fig. 40 Vibration Damper Assembly

1 - SPECIAL TOOL C-3688

Fig. 41 Installing Vibration Damper

1 - SPECIAL TOOL C-3688

9a - 88

ENGINE 5.2L INTERNATIONAL

PISTON RINGS (Continued)

(3) Install the crankshaft bolt and washer. Tighten

the bolt to 183 N·m (135 ft. lbs.) torque.

(4) Install the crankshaft pulley. Tighten the pul-

ley bolts to 23 N·m (200 in. lbs.) torque.

(5) Install the serpentine belt (Refer to 7 - COOL-

ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).

(6) Install the cooling system fan. Tighten the

bolts to 23 N·m (17 ft. lbs.) torque.

(7) Position the fan shroud and install the bolts.

Tighten the retainer bolts to 11 N·m (95 in. lbs.)
torque.

(8) Connect the negative cable to the battery.

FRONT MOUNT

REMOVAL

On 4WD vehicles the engine front support brackets

attach directly to engine block and the axle housing.
The brackets provide a solid interconnection for these
units (Fig. 42) (Fig. 43). Engine must be supported
during any service procedures involving the front
support assemblies.

(1) Disconnect the negative cable from the battery.
(2) Raise vehicle on hoist.
(3) Install engine lifting (support) fixture.
(4) Remove front axle assembly.(Refer to 3 - DIF-

FERENTIAL & DRIVELINE/FRONT AXLE - C205F
- REMOVAL).

(5) Left mount insulator only. Remove starter

wires and starter motor assembly.

(6) Remove insulator to frame through bolt (Fig.

44).

(7) Raise engine slightly.
(8) Remove upper insulator to support bracket

stud nut and insulator to support through bolt.

(9) Remove engine mount insulator (Fig. 42) (Fig.

43).

(10) If engine support bracket is to be removed/re-

placed, remove support bracket to transmission bell
housing bolt(s) and three (3) support bracket to
engine block bolts. Remove support bracket (Fig. 42)
(Fig. 43).

INSTALLATION

(1) If engine support brackets were removed,

install them and their fasteners (Fig. 42) (Fig. 43).
Tighten support bracket to block bolts to 41 N·m (30
ft. lbs.). Tighten support bracket to transmission bell
housing bolt(s) to 88 N·m (65 ft. lbs.).

(2) Install Engine mount insulator and tighten

insulator to support bracket nut to 41 N·m (30 ft.
lbs.). Tighten insulator to support bracket through
bolt nut to 102 N·m (75 ft. lbs.).

(3) Lower engine and install insulator to frame

through bolt and nut (Fig. 44). Tighten nut to 95 N·m
(70 ft. lbs.).

Fig. 42 Right Engine Mount Insulator and Support

Bracket

1 - ENGINE SUPPORT BRACKET
2 - INSULATOR
3 - FRONT AXLE

ENGINE 5.2L INTERNATIONAL

9a - 89

VIBRATION DAMPER (Continued)

Content .. 540 541 542 543 ..