compression ratio DODGE DURANGO 1998 1.G User Guide

Downloaded from www.Manualslib.com manuals search engine DESCRIPTION SPECIFICATION
PISTON PIN
Clearance in Piston 0.00635 ± 0.01905 mm
(0.00025 ± 0.00075 in.)
Diameter 24.996 ± 25.001 mm
(0.9841 ± 0.9843 in.)
End Play NONE
Length 75.946 ± 76.454 mm
(2.990 ± 3.010 in.)
PISTON RINGS
Ring Gap
Compression Rings 0.254 ± 0.508 mm
(0.010 ± 0.020 in.)
Oil Control (Steel Rails) 0.254 ± 1.270 mm
(0.010 ± 0.050 in.)
Ring Side Clearance
Compression Rings 0.038 ± 0.076 mm
(0.0015 ± 0.0030 in.)
Oil Ring (Steel Rails) 0.06 ± 0.21 mm
(0.002 ± 0.008 in.)
Ring Width
Compression rings 1.971 ± 1.989 mm
(0.0776 ± 0.0783 in.)
Oil Ring (Steel Rails) ±
Max.3.848 ± 3.975 mm
(0.1515 ± 0.1565 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) 21É
Opens (BBDC) 60É
Duration 264É
Intake Valve
Closes (ATDC) 61É
Opens (BBDC) 10É
Duration 250É
Valve Overlap 31ÉOVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
U/S-O/S Item Identification Identification
Location
U/S Rod/ R or M R-1-4
ect.Milled flat on
No.8
.0254
mmMain (indicating
No. 1crankshaft
(0.001
in.)Journal and 4
connectingcounterweight.
rod journal)
and/or
M-2-3 ect.
(indicating
No. 2
and 3 main
bearing
journal)
O/S HydrauliclDiamond-
shaped
.2032
mmTappets stamp top pad
-
(.008 in.) front of engine
and flat
ground
on outside
surface of
each
O/S tappet
bore.
O/S Valve X Milled pad
.127 mm Stems adjacent to
two
(.005 in.) tapped holes
(3/8 in.) on
each
end of
cylinder
head.
DN5.2L ENGINE 9 - 131
SPECIFICATIONS (Continued)

Downloaded from www.Manualslib.com manuals search engine 5.9L ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ENGINE...............................136
ENGINE LUBRICATION SYSTEM............136
EXHAUST MANIFOLD....................139
INTAKE MANIFOLD......................139
CYLINDER HEAD COVER GASKET..........140
CYLINDER HEAD........................140
VALVES AND VALVE SPRINGS.............140
ENGINE OIL PAN........................140
CRANKSHAFT OIL SEALS.................140
PISTON AND CONNECTING ROD...........140
CRANKSHAFT MAIN BEARINGS............141
CRANKSHAFT..........................141
DIAGNOSIS AND TESTING
ENGINE DIAGNOSISÐINTRODUCTION.......141
SERVICE DIAGNOSISÐGASOLINE ENGINES . . 142
INTAKE MANIFOLD LEAKAGE DIAGNOSIS....145
CYLINDER COMPRESSION PRESSURE TEST . 145
CYLINDER HEAD GASKET FAILURE
DIAGNOSIS...........................146
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST.......................146
INSPECTION (ENGINE OIL LEAKS IN
GENERAL)...........................147
REAR SEAL AREA LEAKSÐINSPECTION.....147
HYDRAULIC TAPPETS....................148
ENGINE OIL PRESSURE..................148
SERVICE PROCEDURES
FORM-IN-PLACE GASKETS................149
ENGINE PERFORMANCE.................149
ENGINE OIL............................150
REPAIR DAMAGED OR WORN THREADS.....151
CYLINDER BOREÐHONING...............152
HYDROSTATIC LOCK.....................152
VALVE TIMING..........................153
VALVE SERVICE........................153
MEASURING TIMING CHAIN STRETCH.......155
PISTONSÐFITTING......................156
PISTON RINGSÐFITTING.................156
CONNECTING ROD BEARINGSÐFITTING.....157
CRANKSHAFT MAIN BEARINGSÐFITTING....157
REMOVAL AND INSTALLATION
ENGINE FRONT MOUNTS.................158ENGINE REAR SUPPORT.................160
ENGINE ASSEMBLY......................161
INTAKE MANIFOLD......................163
EXHAUST MANIFOLD....................165
CYLINDER HEAD COVER.................165
ROCKER ARMS AND PUSH RODS..........166
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE.............166
CYLINDER HEAD........................167
VALVES AND VALVE SPRINGS.............167
HYDRAULIC TAPPETS....................168
VIBRATION DAMPER.....................168
TIMING CHAIN COVER...................169
TIMING CHAIN..........................170
CAMSHAFT............................170
CAMSHAFT BEARINGS...................172
DISTRIBUTOR DRIVE SHAFT BUSHING......172
CRANKSHAFT MAIN BEARINGS............174
OILPAN...............................174
PISTON AND CONNECTING ROD ASSEMBLY . . 175
CRANKSHAFT..........................176
OIL PUMP.............................177
CRANKSHAFT OIL SEALÐFRONT...........178
CRANKSHAFT OIL SEALSÐREAR...........179
ENGINE CORE OIL AND CAMSHAFT PLUGS . . 180
DISASSEMBLY AND ASSEMBLY
OIL PUMP.............................181
CLEANING AND INSPECTION
CYLINDER HEAD COVER.................182
CYLINDER HEAD ASSEMBLY..............182
PISTON AND CONNECTING ROD ASSEMBLY . . 182
OILPAN...............................182
OIL PUMP.............................182
CYLINDER BLOCK.......................185
INTAKE MANIFOLD......................185
EXHAUST MANIFOLD....................185
SPECIFICATIONS
5.9L ENGINE SPECIFICATIONS.............185
SPECIFICATIONS........................189
SPECIAL TOOLS
5.9L ENGINE...........................189
DN5.9L ENGINE 9 - 135

Downloaded from www.Manualslib.com manuals search engine CRANKSHAFT MAIN BEARINGS
DESCRIPTION
Main bearings are located in the cylinder block.
One half of the main bearing is located in the crank-
shaft main bore the other half of the matching bear-
ing is located in the main bearing cap (Fig. 9). There
are five main bearings. Number three main bearing
is flanged, this flange controls crankshaft thrust.
OPERATION
The main bearings encircle the crankshaft main
bearing journals, this aligns the crankshaft to the
centerline of the engine and allows the crankshaft to
turn without wobbling or shaking therefore eliminat-
ing vibration. The main bearings are available in
standard and undersizes.
CRANKSHAFT
DESCRIPTION
The crankshaft is of a cast nodular steel splayed
type design, with five main bearing journals. The
crankshaft is located at the bottom of the engine
block and is held in place with five main bearing
caps. The number 3 counterweight is the location for
journal size identification (Fig. 10).
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or
flexplate.
DIAGNOSIS AND TESTING
ENGINE DIAGNOSISÐINTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Service DiagnosisÐMechanical Chart
and the Service DiagnosisÐPerformance Chart, for
possible causes and corrections of malfunctions. Refer
to FUEL SYSTEM for the fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
²Lash Adjuster (Tappet) Noise Diagnosis
²Engine Oil Leak Inspection
Fig. 9 Main Bearing Orientation
Fig. 10 Crankshaft with Journal Size Identification
DN5.9L ENGINE 9 - 141
DESCRIPTION AND OPERATION (Continued)

Downloaded from www.Manualslib.com manuals search engine CONDITION POSSIBLE CAUSES CORRECTION
OIL LEAKS 1. Misaligned or
deteriorated gaskets1. Replace gasket
2. Loose fastener,
broken or porous metal
part2. Tighten, repair or replace the part
3. Front or rear
crankshaft oil seal
leaking3. Replace seal
4. Leaking oil gallery
plug or cup plug4. Remove and reseal threaded plug. Replace cup style plug
5. Leaking intake 5. Replace gaskets
manifold cross-over
gaskets
EXCESSIVE OIL
CONSUMPTION
OR SPARK
PLUGS OIL
FOULED1. PCV System
malfunction1. Refer to group 25, Emission Control System for correct
operation
2. Intake manifold 2. Replace plenum
plenum pan gasket pan gasket
failure
3. Defective valve 3. Replace seals
stem seal(s)
4. Worn or broken
piston rings4. Hone cylinder bores. Install new rings
5. Scuffed pistons/
cylinder walls5. Hone cylinder bores and replace pistons as required
6. Carbon in oil control
ring groove6. Remove rings and de-carbon piston
7. Worn valve guides 6. Repair as
necessary
8. Piston rings fitted 8. Remove rings and
too tightly in grooves check ring end gap
and side clearance.
Replace if necessary
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPMs, the area of the suspected
leak has been found.
(4) Repair as required.
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
DN5.9L ENGINE 9 - 145
DIAGNOSIS AND TESTING (Continued)

Downloaded from www.Manualslib.com manuals search engine Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise, the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs.
(3) Secure the throttle in the wide-open position.
(4) Disconnect the ignition coil.
(5) Insert a compression pressure gauge and rotate
the engine with the engine starter motor for three
revolutions.
(6) Record the compression pressure on the third
revolution. Continue the test for the remaining cylin-
ders.
Refer to Engine Specifications for the correct
engine compression pressures.
CYLINDER HEAD GASKET FAILURE DIAGNOSIS
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
²Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
²Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test in this
section. An engine cylinder head gasket leaking
between adjacent cylinders will result in approxi-
mately a 50±70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing)
²Leaks between adjacent cylinders or into water
jacket
²Any causes for combustion/compression pressure
loss
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM HOT COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn OFF the
engine.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.
Perform the test procedure on each cylinder accord-
ing to the tester manufacturer's instructions. While
testing, listen for pressurized air escaping through
the throttle body, tailpipe or oil filler cap opening.
Check for bubbles in the radiator coolant.
9 - 146 5.9L ENGINEDN
DIAGNOSIS AND TESTING (Continued)

Downloaded from www.Manualslib.com manuals search engine (2) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
(3) Remove the air inlet hose.
(4) Remove cylinder head cover and gasket. The
gasket may be used again.
INSTALLATION
(1) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas-
ket. Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(3) Install closed crankcase ventilation system and
evaporation control system.
(4) Install the air inlet hose.
(5) Connect the negative cable to the battery.
ROCKER ARMS AND PUSH RODS
REMOVAL
(1) Remove cylinder head cover and gasket. Refer
to Cylinder Head Cover in this section for correct
procedure.
(2) Remove the rocker arm bolts and pivots (Fig.
49). Place them on a bench in the same order as
removed.
(3) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
(1) Rotate the crankshaft until the ªV8º mark lines
up with the TDC mark on the timing chain case
cover. This mark is located 147É ATDC from the No.1
firing position.
(2) Install the push rods in the same order as
removed.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker arm bolts
to 28 N´m (21 ft. lbs.) torque.
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(4) Install cylinder head cover.
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE
(1) Remove the air cleaner.
(2) Remove cylinder head covers and spark plugs.
(3) Remove coil wire from distributor and secure to
good ground to prevent engine from starting.
(4) Using suitable socket and flex handle at crank-
shaft retaining bolt, turn engine so the No.1 piston is
at TDC on the compression stroke.
(5) Remove rocker arms.
(6) With air hose attached to an adapter installed
in No.1 spark plug hole, apply 620-689 kPa (90-100
psi) air pressure.
(7) Using Valve Spring Compressor Tool
MD-998772A with adaptor 6716A, compress valve
spring and remove retainer valve locks and valve
spring.
(8) Install seals on the exhaust valve stem and
position down against valve guides.
(9) The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the
valve stem as a guide. DO NOT force seal against top
of guide. When installing the valve retainer locks,
compress the spring only enough to install the locks.
(10) Follow the same procedure on the remaining 7
cylinders using the firing sequence 1-8-4-3-6-5-7-2.
Make sure piston in cylinder is at TDC on the valve
spring that is being removed.
(11) Remove adapter from the No.1 spark plug
hole and install spark plugs.
(12) Install rocker arms.
(13) Install covers and coil wire to distributor.
(14) Install air cleaner.
(15) Road test vehicle.
Fig. 48 Cylinder Head Cover Gasket
1 ± CYLINDER HEAD COVER GASKET
Fig. 49 Rocker Arms
1 ± ROCKER ARMS
2 ± CYLINDER HEAD
9 - 166 5.9L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine 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. 70).
(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.
CRANKSHAFT
A crankshaft which has undersize journals will be
stamped with 1/4 inch letters on the milled flat on
the No.3 crankshaft counterweight (Fig. 71).
FOR EXAMPLE:R2 stamped on the No.3 crank-
shaft counterweight indicates that the No.2 rod jour-
nal is 0.025 mm (0.001 in) undersize. M4 indicates
that the No.4 main journal is 0.025 mm (0.001 in)
undersize. R3 M2 indicates that the No.3 rod journal
and the No.2 main journal are 0.025 mm (0.001 in)
undersize.
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.
(2) Remove the oil pump from the rear main bear-
ing cap.
(3) Remove the vibration damper.
(4) Remove the timing chain cover.
(5) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time.
(6) Lift the crankshaft out of the block.
Fig. 70 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
Fig. 71 Location of Crankshaft Identification
1 ± 1/4º LETTERS
2 ± (ROD)
3 ± (MAIN)
CRANKSHAFT IDENTIFICATION MARK
LOCATION CHART
UNDERSIZE JOURNAL IDENTIFICATION
STAMP
0.025 mm (0.001 in.)
(ROD)R1-R2-R3 or R4
0.025 mm (0.001 in.)
(MAIN)M1-M2-M3-M4 or M5
9 - 176 5.9L ENGINEDN
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine CYLINDER BLOCK
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
²The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
²The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
²The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coor-
dinated with the fitting of pistons and rings so spec-
ified clearances may be maintained.
Refer to Standard Service Procedures in the begin-
ning of this Group for the proper honing of cylinder
bores.
INTAKE MANIFOLD
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
EXHAUST MANIFOLD
CLEANING
Clean mating surfaces on cylinder head and mani-
fold, wash with solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks, Inspect mating sur-
faces of manifold for flatness with a straight edge.
Seal surfaces must be flat within 0.1 mm (0.004 inch)
overall.
SPECIFICATIONS
5.9L ENGINE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Engine Type 90É V-8 OHV
Bore and Stroke 101.6 x 90.9 mm
(4.00 x 3.58 in.)
Displacement 5.9L (360 c.i.)
Compression Ratio 9.1:1
Firing Order 1±8±4±3±6±5±7±2
Lubrication Pressure Feed ±
Full Flow Filtration
Cooling System Liquid Cooled ±
Forced Circulation
Cylinder Block Cast Iron
Cylinder Head Cast Iron
Crankshaft Nodular Iron
Camshaft Nodular Cast Iron
Combustion Chambers Wedge -
High Swirl Valve
Shrouding
Pistons Aluminum Alloy w/strut
Connecting Rods Forged Steel
Cylinder Compression 689.5 kPa
Pressure (Min.) (100 psi)
DESCRIPTION SPECIFICATION
CAMSHAFT
Bearing Diameter
No. 1 50.800 ± 50.825 mm
(2.000 ± 2.001 in.)
No. 2 50.394 ± 50.419 mm
(1.984 ± 1.985 in.)
No. 3 50.013 ± 50.038 mm
(1.969 ± 1.970 in.)
No. 4 49.606 ± 49.632 mm
(1.953 ± 1.954 in.)
No. 5 39.688 ± 39.713 mm
(1.5625 ± 1.5635 in.)
DN5.9L ENGINE 9 - 185
CLEANING AND INSPECTION (Continued)

Downloaded from www.Manualslib.com manuals search engine DESCRIPTION SPECIFICATION
PISTONS
Clearance at Top of Skirt 0.013 ± 0.038 mm
(0.0005 ± 0.0015 in.)
Land Clearance (Diam.) 0.508 ± 0.660 mm
(0.020 ± 0.026 in.)
Piston Length 81.03 mm (3.19 in.)
Piston Ring Groove
DepthÐ
#1&2 4.761 ± 4.912 mm
(0.187 ± 0.193 in.)
Piston Ring Groove
DepthÐ
#3 3.996 ± 4.177 mm
(0.157 ± 0.164 in.)
Weight 582 ± 586 grams
(20.53 ± 20.67 oz.)
PISTON PINS
Clearance in Piston 0.006 ± 0.019 mm
(0.00023 ± 0.00074 in.)
Diameter 25.007 ± 25.015 mm
(0.9845 ± 0.9848 in.)
End Play NONE
Length 67.8 ± 68.3 mm
(2.67 ± 2.69 in.)
PISTON RINGS
Ring Gap
Compression Ring (Top) 0.30 ± 0.55 mm
(0.012 ± 0.022 in.)
Compression Ring (2nd) 0.55 ± 0.80 mm
(0.022 ± 0.031 in.)
Oil Control (Steel Rails) 0.381 ± 1.397 mm
(0.015 ± 0.055 in.)
Ring Side Clearance
Compression Rings 0.040 ± 0.085 mm
(0.0016 ± 0.0033 in.)
Oil Ring (Steel Rails) 0.05 ± 0.21 mm
(0.002 ± 0.008 in.)
Ring Width
Compression rings 1.530 ± 1.555 mm
(0.060 ± 0.061 in.)DESCRIPTION SPECIFICATION
Oil Ring (Steel Rails) ±
Max.0.447 ±0.473 mm
(0.018 ± 0.019 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) 33É
Opens (BBDC) 56É
Duration 269É
Intake Valve
Closes (ATDC) 62É
Opens (BBDC) 7É
Duration 249É
Valve Overlap 41É
OVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
ITEM U/S
(O/S)IDENTI-
FICATIONIDENTI-
FICATION
LOCATION
Crank-
shaft
Journals0.0254
mm
(0.001
in.) U/SR or M M-2-3
ect.
(indicating
No. 2 and 3
main bearing
journal)
and/or R-1-4
ect.
(indicating
No. 1 and 4
connecting
rod journal)Milled flat on
No. 8
crankshaft
counterweight.
Hydraulic
Tappets0.2032
mm
(0.008
in.)
(O/S)lDiamond-
shaped stamp
top pad - front
of engine and
flat ground on
outside
surface of
each O/S
tappet bore.
Valve
Stems0.127
mm
(0.005
in.)
(O/S)X Milled pad
adjacent to
two tapped
holes (3/8 in.)
on each end
of cylinder
head.
9 - 188 5.9L ENGINEDN
SPECIFICATIONS (Continued)