Dodge Ram Truck 1500-2500-3500. Manual — part 1421

INSTALLATION

1. Insert the trough (1) the full length of the camshaft

bore. Again, make sure the cap end goes in first
and the open side faces up (towards tappets).

2. Lower the tappet installation tool through the push

rod hole and into the trough.

3. Retrieve the tappet installation tool using the

hooked rod provided with the tool kit

.

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4. Lubricate the tappet with clean engine oil or suit-

able equivalent and install the tappet to the instal-
lation tool.

5. Pull the tappet up and into position. If difficulty is

experienced getting the tappet to make the turn
into the tappet bore, wiggle the trough while gently
pulling up on the tappet.

6. With the tappet in place, rotate the trough one half

turn so the open side is down (toward crankshaft).

7. Remove the tappet installation tool from the tappet.

8. Re-install a dowel rod and secure the rod with a

rubber band.

9. Rotate the trough one half turn and repeat the pro-

cedure for the remaining tappets.

10. Install the camshaft (Refer to 9 - ENGINE/EN-

GINE

BLOCK/CAMSHAFT

&

BEARINGS

(IN

BLOCK) - INSTALLATION).

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PISTON & CONNECTING ROD

DESCRIPTION

PISTONS

The piston is constructed of aluminum and is gravity
cast, free floating design. The piston incorporates a
centrally located high swirl combustion bowl, and uti-
lizes a “keystone” style top compression ring, and a
“Tapered Face” intermediate ring, for superior cylinder
wall scraping. Piston cooling nozzles cool the piston
and pin with engine oil supplied by the crankshaft
main journals. High horsepower pistons are gallery
cooled and utilize J-jet piston cooling nozzles. Pistons
are directional in order to provide clearance to piston
cooling nozzles.

CONNECTING RODS

The connecting rods are a split angle design. They
have a pressed-in-place wrist pin bushing that is lubri-
cated by piston cooling nozzle oil spray.

Machined connecting rods are no longer used in
the diesel engine. Do not install machined con-
necting rods into an engine that has fractured split
connecting rods.

Fractured split connecting rods are first manufactured as a single piece and then fractured into two pieces. Frac-
tured split connecting rods can be identified by a rough and irregular surface at the connecting rod split face. To
properly assemble the rod cap to the connecting rod, the bearing tangs on the connecting rod and cap must be
located on the same side of the rod. The long end of the connecting rod must be assembled on the intake or
camshaft side of the engine.

Each matched fractured split connecting rod and cap is an assembly and are not interchangeable. If a connecting
rod or cap is damaged, the entire assembly must be replaced.

STANDARD PROCEDURE - HEAD GASKET SELECTION

1. Measure piston protrusion for all six pistons.

2. Calculate the average piston protrusion. Maximum allowable protrusion is 0.516 mm (0.020 inch).

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NOTE: There are two different head gaskets available. One gasket is for Average piston protrusion less than
0.30 mm (0.011 inch). The other gasket is for Average piston protrusion greater than 0.30 mm (0.011 inch)

REMOVAL

1. Disconnect the battery cables.

2. Remove the cylinder head (Refer to 9 - ENGINE/CYLINDER HEAD - REMOVAL).

3. Remove the oil pan and suction tube (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).

4. Remove bolts and the block stiffener.

5. Using Miller Tool 7471-B crankshaft barring tool, rotate the crankshaft so all of the pistons are below TDC.

6. Before removing the piston(s) from the bore(s):

a. Remove any carbon ridge formations or deposits at the top of the bore with a dull scraper or soft wire brush.

b. If cylinder bore wear ridges are found, use a ridge reamer to cut the ridge from the bore. DO NOT remove

more metal than necessary to remove the ridge.

7. Remove the J-jet cooling nozzles, if equipped.

NOTE: If cylinders have ridges, the cylinders are oversize and will more than likely need boring.

8. Using a hammer and steel stamp, stamp the cylinder number in the top of each piston. The front of the piston

is identified by a stamping on the top of the piston. DO NOT stamp in the outside 5 mm (.197 in.) of the piston
diameter. DO NOT stamp over the piston pin.

9. Mark the connecting rod and cap with the corresponding cylinder numbers.

10. Remove the connecting rod bolts and rod caps. Use care so the cylinder bores and connecting rods are not

damaged.

11. Use a hammer handle or similar object to push the piston and connecting rod through the cylinder bore.

12. Store the piston/rod assemblies in a rack.

CLEANING—PISTON AND CONNECTING ROD

CAUTION: DO NOT use bead blast to clean the pistons. DO NOT clean the pistons and rods in an acid tank.

PISTON

Clean the pistons and pins in a suitable solvent, rinse in hot water and blow dry with compressed air. Soaking the
pistons over night will loosen most of the carbon build up. De-carbon the ring grooves with a broken piston ring and
again clean the pistons in solvent. Rinse in hot water and blow dry with compressed air.

CONNECTING ROD

Clean the connecting rods in a suitable solvent, rinse in hot water and blow dry with compressed air.

INSPECTION

INSPECTION - PISTONS

PISTON SKIRT DIAMETER (MIN.)

101.775 mm (4.006 in. )

Inspect the pistons for damage and excessive wear. Check top of the piston, ring grooves, skirt and pin bore. Mea-
sure the piston skirt diameter. If the piston is out of limits, replace the piston.

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