Dodge Dakota (R1). Manual — part 532
(2) If ring gaps exceed dimension given, new rings
or cylinder liners must be fitted. Keep piston rings in
piston sets.
(3) Check piston ring to groove clearance (Fig. 54).
Top compression ring gap .08 to .130mm (.0031 to
.0051 in.). Second compression ring gap .070 to
.102mm (.0027 to .0040 in.). Oil control ring gap .040
to .072mm (.0015 to .0028 in.).
PISTON RINGS
(1) Install rings on the pistons using a suitable
ring expander (Fig. 55).
(2) Top compression ring is tapered and chromium
plated. The second ring is of the scraper type and
must be installed with scraping edge facing bottom of
the piston (Fig. 56). The third is an oil control ring.
Ring gaps must be positioned, before inserting piston
into the liners, as follows (Fig. 57).
(3) Top ring gap must be positioned at 30 degrees
to the right of the combustion chamber recess (look-
ing at the piston crown from above).
(4) Second piston ring gap should be positioned on
the opposite side of the combustion chamber recess.
(5) Oil control ring gap to be located 30 degrees to
the left of combustion chamber recess.
Fig. 53 Ring Gap Measurement
1 - FEELER GAUGE
Fig. 54 Piston Ring to Groove Clearance
Fig. 55 Piston Rings—Removing and Installing
Fig. 56 Piston Ring Identification
9a - 46
ENGINE 2.5L VM DIESEL INTERNATIONAL
R1
PISTON AND CONNECTING ROD (Continued)
(6) When assembling pistons check that compo-
nents are installed in the same position as before dis-
assembly, determined by the numbers stamped on
the crown of individual pistons. Engine cylinders are
numbered starting from gear train end of the engine.
Face chamber recess side of piston towards
camshaft. Therefore, the numbers stamped on con
rod big end should also face in the same direction. To
insert piston into cylinder use a ring compressor as
shown in (Fig. 55).
PISTON PIN
(1) Secure connecting rod in soft jawed vice.
(2) Lubricate piston pin and piston with clean oil.
(3) Position piston on connecting rod.
CAUTION: Ensure combustion recess in piston
crown and the bearing cap numbers on the con-
necting rod are on the same side.
(4) Install piston pin.
(5) Install clips in piston to retain piston pin.
(6) Remove connecting rod from vice.
PISTONS AND CONNECTING ROD
(1) Before installing pistons, and connecting rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 57).
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 57).
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
and tighten with the special wrench (Fig. 58).
Ensure position of rings does not change dur-
ing this operation.
(4) Face chamber recess side of piston towards
camshaft.
CAUTION: During piston and rod removal. DO NOT
rotate piston and connecting rod or damage to the
oil jets extending out into the cylinder bore will
occur (Fig. 59).
NOTE: Be careful not to nick crankshaft journals.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. 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 connecting rod journal.
(7) Install rod caps. Install rod bolts and tighten to
29 N·m (21 ft. lb.) plus 60°.
Fig. 57 Piston Ring Gap Location
Fig. 58 Installing Piston
Fig. 59 Oil Jets
1 - CYLINDER BLOCK
2 - OIL COOLING JETS (4)
3 - FASTENER
4 - O-RING
R1
ENGINE 2.5L VM DIESEL INTERNATIONAL
9a - 47
PISTON AND CONNECTING ROD (Continued)
CYLINDER WALL LINER
ASSEMBLY
REMOVAL
(1) Remove cylinder heads.
(2) Remove Oil pan.
(3) Remove pistons.
(4) Use tool VM-1001 to remove liners (Fig. 60).
(5) Remove shims from cylinder liner or cylinder
block recess. Keep shims with each cylinder liner.
INSPECTION
The cylinder walls should be checked for out-of-
round and taper with dail bore gauge. The cylinder
bore out-of-round is 0.100 mm (.0039 inch) maximum
and cylinder bore taper is 0.100 mm (0.0039 inch)
maximum. If the cylinder walls are badly scuffed or
scored, new liners should be installed and honed, and
new pistons and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 61). Top measurement should be
10 mm ( 3/8 inch) down and bottom measurement
should be 10 mm ( 3/8 inch.) up from bottom of bore.
INSTALLATION
(1) Carefully clean residual LOCTITE from liner
and crankcase, and degrease the crankcase where it
comes into contact with the liners. Install the liners
in the crankcase as shown (A), rotating them back
and forth by 45° in order to guarantee correct posi-
tioning (Fig. 62).
(2) Measure the liner recess relative to block deck
with a dial indicator mounted on a special tool
VM-1010 A. All the measurements must be taken
on camshaft side. Zero dial gauge on block deck.
(3) Move dial gauge to cylinder liner record read-
ing on dial gauge.
(4) Remove liner and special tool.
(5) Then select the correct shim thickness to give
proper protrusion (0.01 - 0.06 mm).
(6) Fit the shim and the O-rings onto the liner.
(7) Lubricate the lower liner location in the block.
Apply LOCTITE AVX to the corner of the liner seat.
Apply LOCTITE AVX uniformly to the upper part of
the liner at area.
(8) Fit the liners in the crankcase making sure
that the shim is positioned correctly in the seat. Lock
the liners in position using special tool (VM-1016)
and bolts (Fig. 63). Clean the residual LOCTITE on
the upper surface of the block deck.
(9) Recheck the liner protrusion. It should be 0.01
- 0.06 mm.
NOTE: A period of six hours must elapse between
the liners being installed and engine start-up. If
engine assembly is not continued after liner instal-
lation, the liners need to be clamped for twelve
hours minimum.
Fig. 60 Liner Removal Tool
Fig. 61 Liner Inspection
9a - 48
ENGINE 2.5L VM DIESEL INTERNATIONAL
R1
CRANKSHAFT MAIN
BEARINGS
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the engine from vehicle (Refer to 9 -
ENGINE - REMOVAL).
(3) Install the engine on an engine stand.
(4) Remove the accessary drive system.
(5) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(6) Remove the rocker arm assemblies and push
rods (Refer to 9 - ENGINE/CYLINDER HEAD/
ROCKER ARMS - REMOVAL).
(7) Remove the intake manifold, exhaust manifold
and turbocharger (Refer to 11 - EXHAUST SYSTEM/
TURBOCHARGER
SYSTEM/TURBOCHARGER
-
REMOVAL).
(8) Remove the water manifold.
(9) Remove the oil feed lines to rocker arms.
(10) Remove the cylinder heads (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(11) Remove the oil pan and oil pick-up.
(12) Remove the pistons and connecting rods.
(13) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(14) Remove the timing gear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(15) Remove the oil pump and vacuum pump from
block.
(16) Install special tool VM.1004 onto crankshaft
over gear (Fig. 64).
(17) Remove the main bearing oil feed and crank-
shaft carrier locators from block.
(18) Remove the flywheel and adaptor plate from
engine block.
(19) Remove the thrust bearings from rear main
bearing carrier.
Fig. 62 Liner Installation
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ENGINE 2.5L VM DIESEL INTERNATIONAL
9a - 49
CYLINDER WALL LINER ASSEMBLY (Continued)
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