DODGE TRUCK 1993 Service Repair Manual

i - 68 5.2L
ENGINE

RH180
Fig.
10
Measuring
Clearance Over Rotors If oil pressure was low and pump is within specifi­
cations, inspect for worn engine bearings or other
reasons for oil pressure loss. NBV y%L
RETAINER CAP
COTTER KEY CHAMFER RN98
Fig.
11 Proper Installation of Retainer Cap
ASSEMBLE
(1) Install pump rotors and shaft, using new parts
as required. (2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N»m (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin. (4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling ro­
tor cavity with engine oil.
INSTALLATION (1) Install oil pump. During installation slowly ro­
tate pump body to ensure driveshaft-to-pump rotor shaft engagement. (2) Hold the oil pump base flush against mating
surface on No.4 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
Nnn (30 ft. lbs.) torque.
(3) Install the oil pan.
PISTON
/
CONNECTING ROD
ASSEMBLY

The pistons are elliptically turned so that the di­
ameter at the pin boss is less than its diameter
across the thrust face. This allows for expansion un­
der normal operating conditions. Under operating
temperatures, expansion forces the pin bosses away from each other, causing the piston to assume a more
nearly round shape. All pistons are machined to the same weight, re­
gardless of size, to maintain piston balance. The piston pin rotates in the piston only and is re­
tained by the press interference fit of the piston pin
in the connecting rod.
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. Re 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 from the engine, ro­
tate crankshaft so that the connecting rod is centered in 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 crankshaft connecting rod journal for ex­
cessive 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 be­
fore they are fitted into the cylinder bore (Fig. 12).
FITTING PISTONS* Piston and cylinder wall must be clean and dry.
Specified clearance between the piston and the cylin­
der wall is 0.013-0.038 mm (0.0005-0.0015 inch).
Piston diameter should be measured at the top of
skirt, 90° to piston pin axis. Cylinder bores should be
measured halfway down the cylinder bore and trans­
verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21°C (70°F).
FITTING RINGS (1) Measurement of end gaps:
(a) Measure piston ring gap 2 inches from bot­
tom of cylinder bore. An inverted piston can be

•
5.2L
ENGINE
I - 67
DIAMETER
(D)

SHOULD
BE

0.0000-0.0152
mm

(0.0000-0.0006
in.)
LARGER
THAN
(C).
98.704-98.831
mm
•
(3.886-3.891
in.)-
FEELER
GAUGE

62.230
mm (2.45 in.)
1
26.543
mm

(1.045
in.)

±c

ELLIPTICAL
SHAPE
OF
THE
PISTON

SKIRT
SHOULD
BE
0.254-0.304
mm

(0.010-0.012
in.)
LESS AT
DIAMETER
(A)
THAN
ACROSS
THE
THRUST
FACES
AT
DIAMETER
(B).

J9309-9
Fig.
12
Piston
Measurements
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).
(c) Rings with insufficient end gap may be prop­
erly filled to the correct dimension. Rings with ex­ cess 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.
(b) Install the compression rings using Installa­
tion Tool C-4184. The top compression may be in­ stalled with either side up. The second compression
ring must be installed with the identification mark
face up (toward top of piston) and the chamfer should face down. An identification mark on the
ring is a drill point, a stamped letter "O", an oval
depression or the word TOP.
(c) Measure side clearance between piston ring
and ring land (Fig. 13). Clearance should be 0.038-
0.076 mm (0.0015-0.0030 inch) for the compression

rings.
The steel rail oil ring should be free in
groove, but should not exceed 0.203 mm (0.0080
inch) side clearance.
(d) Pistons with insufficient or excessive side
clearance should be replaced. (3) Arrange ring gaps 90° apart as shown in Fig.
RING

GROOVE

J9209-136

Fig.
13
Measuring
Piston
Ring
Side
Clearance
OIL
RING

SPACER
GAP
TOP
COMPRESSION
RING
GAP
SECOND
COMPRESSION
RING
GAP

OIL
RING
RAIL
GAP (TOP) OIL
RING
RAIL

GAP
(BOTTOM)
J9309-80
14. Fig.
14 Proper
Ring
Installation

CONNECTING
ROD
BEARINGS
Fit all rods on a bank until completed. DO NOT al­
ternate from one bank to another, because connect­ ing rods and pistons are not interchangeable from
one bank to another.
The bearing caps are not interchangeable and
should be marked at removal to ensure correct as­
sembly.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing shell, make certain that the V-groove in the shell is
in line with the V-groove in the cap. This provides
lubrication of the cylinder wall in the opposite bank.
The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and
caps.

Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 inch). Bearings are available in 0.025 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under­
size.
Install the bearings in pairs. DO NOT use a
new bearing half with an old bearing
half.
DO
NOT file the rods or bearing caps.

9
- 68 5.2L
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. 14).
(3) Immerse the piston head and rings in clean en­
gine 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.8 crankshaft counterweight (Fig. 15).
FOR
EXAMPLE: R2 stamped on the No.8 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.Q01 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) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time. (4) Lift the crankshaft out of the block.
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
#8
CRANKSHAFT

COUNTERWEIGHT
(ROD)

(MAIN)
f
J9209-138

Fig.
15 Location of Crankshaft
Identification

(5) Remove and discard the crankshaft rear oil

seals.
(6) Remove and discard the front crankshaft oil
seal.
INSPECTION OF JOURNALS The crankshaft connecting rod and main journals
should be checked for excessive wear, taper and scor­
ing. The maximum taper or out-of-round on any crankshaft journal is 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 mm
(0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.3 main bearing. DO
NOT nick crank pin or bearing fillets. After grind­ ing, remove rough edges from crankshaft oil holes
and clean out all oil passages.

CAUTION:
After any journal
grind,
it is important

that
the
final
paper or cloth
polish
be in the
same
direction as the engine rotates.
INSTALLATION (1) Lightly oil the new upper seal lips with engine

oil.
(2) Install the new upper rear bearing oil seal with
the yellow paint facing towards the rear of the en­
gine.
(3) Position the crankshaft into the cylinder block.
(4) Lightly oil the new lower seal lips with engine

oil.

(5) Install the new lower rear bearing oil seal into
the bearing cap with the yellow paint facing towards
the rear of the engine.

(6)
Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap (Fig. 16). Do not over apply sealant or allow the seal­
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica­ tion.

5.2L ENGINE
9 - 69

BEARING
CAP
J9309-72

Fig.
16 Sealant Application to Bearing Cap (7) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more
than 2 times for proper engagement.
(8) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 Nnn (85 ft. lbs.) torque.
(9) Install oil pump.
(10) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­
ply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove.
(11) Install new front crankshaft oil seal.
(12) Immediately install the oil pan.
MOPAR SILICONE SEALANT

RUBBER
ADHESIVE APPLIED
Fig.
17
Apply
Sealant to Bearing Cap to
Block
Joint

CRANKSHAFT
MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter­ changeable. Lower main bearing halves of No.2 and

4
are interchangeable. Upper and lower No.3 bearing halves are flanged
to carry the crankshaft thrust loads. They are NOT interchangeable with any other bearing halves in the
engine (Fig. 18). Bearing shells are available in stan­
dard and the following under
sizes:
0.25 mm (0.001

inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
Never install an undersize bearing that will reduce
clearance below specifications.

Fig.
18 Main Bearing
Identification

REMOVAL (1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap.
(3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 19).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
Fig.
19 Upper Main Bearing
Removal
and

Installation
with
Tool C-3059

INSTALLATION

Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight­ ened. All bearing capbolts removed during service
procedures are to be cleaned and oiled before instal­ lation. When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 19).
(2) Slowly rotate crankshaft counterclockwise slid­
ing the bearing into position. Remove Tool C-3059.
(3) Install the bearing cap. Clean and oil the bolts.
Tighten the capbolts to 115 N»m (85 ft. lbs.) torque.
(4) Install the oil pump.
(5) Install the oil pan.

CRANKSHAFT REAR
OIL
SEALS
The service seal is a 2 piece, viton seal. The upper
seal half can be installed with crankshaft removed
from engine or with crankshaft installed. When a
new upper seal is installed, install a new lower seal.
The lower seal half can only be installed with the rear main bearing cap removed.
UPPER SEAL REPLACEMENT (CRANKSHAFT
REMOVED) (1) Remove the crankshaft. (2) Lightly oil the new upper seal lips with engine

oil.

(3) Install the new upper rear bearing oil seal with
the yellow paint facing towards the rear of the en­
gine.

(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine

oil.

(6) Install the new lower rear bearing oil seal into
the bearing cap with the yellow paint facing towards the rear of the engine. (7) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap (Fig. 16). Do not over apply sealant or allow the seal­
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica­
tion.
(8) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more
than 2 times for proper engagement.
(9) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately tighten to 115 N*m (85 ft. lbs.) torque. (10) Install oil pump.
(11) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­ ply enough sealant until a small amount is squeezed
out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove. (12) Install new front crankshaft oil seal.
(13) Immediately install the oil pan.

UPPER SEAL
REPLACEMENT (CRANKSHAFT

INSTALLED)
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap.
(3) Remove the rear main bearing cap. Remove
and discard the old lower oil seal.

(4)
Carefully remove and discard the old upper oil
seal.
(5)
Lightly oil the new upper seal lips with engine

oil.
To allow ease of installation of the seal, loosen at
least the 2 main bearing caps forward of the rear
bearing cap.
(6) Rotate the new upper seal into the cylinder
block being careful not to shave or cut the outer sur­ face of the seal. To assure proper installation, use the installation tool provided with the kit. Install the
new seal with the yellow paint facing towards the
rear of the engine.
(7) Install the new lower rear bearing oil seal into
the bearing cap with the yellow paint facing towards
the rear of the engine.
(8) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap (Fig. 16). Do not over apply sealant or allow the seal­
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica­
tion. Be sure the yellow paint faces toward the rear of the engine. (9) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more than 2 times for proper engagement. (10) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten ALL cap
bolts to 115 N*m (85 ft. lbs.) torque. (11) Install oil pump.
(12) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­
ply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove. (13) Immediately install the oil pan.
LOWER SEAL REPLACEMENT (1) Remove the oil pan.
(2)
Remove the oil pump from the rear main bear­
ing cap. (3) Remove the rear main bearing cap and discard
the old lower seal.

•

5.2L
ENGINE
9 - 71
(4)
Carefully install
a
new
upper seal
(refer
to
Up­
per Seal Replacement
-
Crankshaft
Installed
proce­ dure above).
(5) Lightly
oil the
new
lower
seal lips
with
engine

oil.

(6) Install
a new
lower seal
in
bearing
cap
with
yellow paint facing
the
rear
of
engine.
(7) Apply
5
mm (0.20
in)
drop
of Loctite 515,
or

equivalent,
on
each side
of
the rear main bearing cap (Fig. 16). Do not over apply sealant or allow the seal­
ant
to
contact the rubber seal. Assemble bearing
cap

to cylinder block immediately after sealant applica­
tion.

(8)
To align
the
bearing
cap,
use
cap slot, align­
ment dowel and cap bolts. Do
not
remove
excess
ma­

terial after assembly. Do
not
strike
rear
cap
more
than
2
times
for
proper engagement. (9) Install
the
rear main bearing cap
with
cleaned

and oiled cap bolts. Alternately tighten the
cap
bolts
to 115 N-m (85
ft.
lbs.) torque*.
(10)
Install
oil
pump.

(11)
Apply
Mopar
Silicone Rubber Adhesive
Seal­

ant,
or
equivalent,
at
bearing
cap to
block joint
to

provide cap
to
block and oil pan sealing (Fig. 17). Ap­ ply enough sealant until
a
small amount
is
squeezed
out. Withdraw nozzle and wipe excess sealant
off
the

oil
pan
seal groove. (12) Immediately install
the oil
pan.

CYLINDER BLOCK
Remove
the
engine assembly from
the
vehicle.
DISASSEMBLE
(1)
Remove
the
cylinder head.

(2)
Remove
the oil
pan.

(3)
Remove
the
piston/connecting
rod
assembly.

CLEANING
Clean cylinder block thoroughly
and
check
ail
core
hole plugs for evidence
of
leaking.
INSPECTION
Examine
block
for
cracks or fractures.
The cylinder walls
should
be
checked
for
out-of-

bound and taper with
Cylinder
Bore Indicator Tool
C-119. The
cylinder block should
be
bored
and
honed
with new pistons
and
rings fitted
if:

•
The cylinder bores show more than 0.127
mm
(0.005
inch) out-of-round.

•
The
cylinder bores show
a
taper
of
more than
0.254
mm
(0.010
inch).

•
The cylinder walls are badly scuffed
or
scored. Boring
and
honing
operation should
be
closely
co­

ordinated with
the
fitting
of
pistons
and
rings
so

specified clearances
may
be
maintained.

Refer
to
Standard Service Procedures
in the
begin­
ning
of
this
Group
for the
proper
honing
of
cylinder

bores.
OIL
LINE PLUG
The oil
line
plug
is
located in
the
vertical passage
at
the
rear of the
block
between
the Oil-To-Filter and
Oil-From-Filter passages (Fig, 20). Improper installa­
tion
or
plug missing could cause erratic, low
or no oil
pressure.
(1) Remove
oil
pressure sending unit from back
of

block.
(2) Insert
a 3.175 mm (1/8
inch) finish wire
or

equivalent into passage.
(3) Plug should
be 192.0 to 195.2 mm
(7-1/2
to

7-11/16 inches) from machined surface
of
block (Fig.

20).
If
plug
is
too high, use
a
suitable flat dowel drift
to position properly.

RIGHT
OIL
GALLERY
CRANKSHAFT FROM
OIL
PUMP
J9209-147
Fig,
20
Oil
Line
Plug

(4)
If
plug
is off
location, remove
oil pan and
rear
main bearing cap. Use suitable flat dowel
to
remove
plug. Coat outside diameter
of
plug with Mopar (stud and bearing mount adhesive),
or
equivalent. Plug
should
be 54.0 to 57.7 mm
(2-1/8
to
2-5/16 inches)
from bottom
of
the block.
(5) Assemble engine
and
check
oil
pressure.

ENGINE CORE,
OIL AND
CAMSHAFT PLUGS
Engine core plugs have been pressed into
the oil

galleries behind
the
camshaft thrust plate (Fig.
21).

This
will
reduce internal leakage
and
help maintain higher
oil
pressure
at
idle.

REMOVAL (1)
Using
a
blunt tool such
as a
drift
or a
screw­
driver
and a
hammer, strike
the
bottom edge
of the

cup plug (Fig.
22).

9
- 72 5.2L
ENGINE

Fig. 21 Location of Cup Plugs in Oil Galleries
(2) With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig.
22).
CLEANING

Thoroughly clean inside of cup plug hole in cylin­
der block or head. Be sure to remove old sealer.
Make certain the new plug is cleaned of all oil or
grease.
CYLINDER

"
BLOCK
' /

DRIFT
9209-41

Fig. 22 Core Hole Plug Removal

INSTALLATION
(1) Coat edges of plug and core hole with Mopar
Gasket Maker, or equivalent.
CAUTION:
DO NOT drive cup
plug
into the
casting

as
restricted coolant flow can result and
cause
se­
rious
engine
problems.

(2) Using proper drive plug, drive plug into hole.
The sharp edge of the plug should be at least 0.50
mm (0.020 inch) inside the lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be filled and the vehicle
placed in service immediately.

ASSEMBLE
(1) Install the piston/connecting rod assembly.
(2) Install the oil pan. (3) Install the cylinder head.
(4) Install the engine into the vehicle.

SPECIFICATIONS—5.2L
ENGINE

ENGINE SPECIFICATIONS

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)
Diametrical Clearance 0.0254-0.0762 mm (0.001-0.003 in)
Max. Allowable 0.127 mm (0.005 in)
End Play. . .... 0.051-0.254 mm (0.002-0.010 in)
Bearing Journal Diameter
No.
1....................... . 50.749-50.775 mm (1.998-1.999 in)

No.
2 50.343-50.368 mm

(1.982-1.983
in)

No.
3... 49.962-49.987 mm (1.967-1.968 in)

No.
4. ......... .......... 49.555-49.581 mm (1.951-1.952 in)

No.
5 39.637-39.662 mm
(1.5605-1.5615 in)

Connecting
Rods
Bearing Clearance 0.0127-0.0559 mm (0.0005-0.0022 in)
Piston Pin Bore Diameter . 24.966-24.978 mm (0.9829-0.9834 in)
Side Clearance (Two Rods) ......... 0.152-0.356 mm (0.006-0.014 in)
Total Weight (Less Bearing) ......... 726 grams (25.61 oz)

Crankshaft

Connect Rod Journal Diameter ....... 53.950-53.975 mm (2.124-2.125 in)
Out-of-Round (Max.) ............ 0.0254 mm (0.001 in)
Taper (Max.) .... ...... 0.0254 mm (0.001 in)
Diametrical Clearance
No.
1 0.0127-0.0381 mm (0.0005-0.0015 in)

Nos.
2, 3, 4 and 5 ............. 0.0127-0.0508 mm (0.0005-0.0020 in)
Max. Allowable (Nos. 2, 3,4&5) 0.0635 mm (0.0025 in) End Play 0.051-0.178 mm
(0.002-0.007 in)
Max. Allowable 0.254 mm (0.010 in)
Main Bearing Journals Diameter ..................... 63.487-63.513 mm (2.4995-2.5005 in)
Out-of-Round (Max.) 0.0254 mm (0.001 in)
Taper (Max.) 0.0254 mm (0.001 in)

Cylinder
Block

Cylinder Bore Diameter 99.314-99.365 mm (3.910-3.912 in)
Out-of-Round (Max.) ............ 0.127 mm (0.005 in)
Taper (Max.) 0.254 mm (0.010 in)
Oversize (Max.) ................ 1.016 mm (0.040 in)
Distributor Lower Drive Shaft Bushing (Press Fit in Block) 0.0127-0.3556 mm (0.0005-0.0140 in)
Shaft-to-Bushing Clearance ........ 0.0178-0.0686 mm (0.0007-0.0027 in)
Tappet Bore Diameter ......... 22.99-23.01 mm (0.9051-0.9059 in)

Cylinder
Head
Compression Pressure 689 kPa (100 psi)
Gasket Thickness (Compressed) ......
1.2065
mm (0.0475 in)
Valve Seat Angle. .... 44.25° - 44.75° Runout (Max.) .......... ... 0.0762 mm (0.003 in)
Width (Finish) - Intake
1.016-1.524
mm
(0.040-0.060 in)
Width (Finish) - Exhaust. .........
1.524-2.032
mm (0.060-0.080 in)

Hydraulic
Tappets Body Diameter 22.949-22.962 mm (0.9035-0.9040 in)
Clearance in Block . 0.0279-0.0610 mm (0.0011-0.0024 in)

Dry
Lash
1.524-5.334
mm (0.060-0.210 in)
Push Rod Length ............. 172.57-173.08 mm (6.794-6.814 in)
J9309-97

ENGINE
SPECIFICATIONS
(CONT*)

Oil Pump
Clearance Over Rotors (Max.)..... 0.1016 mm (0.004 in)
Cover
Out-of-Flat
(Max.).. ... 0.0381 mm (0.0015 in)

Inner
Rotor
Thickness (Min.) 20.955 mm (0.825 in)

Outer
Rotor
Clearance (Max.)............. 0.3556 mm
(0.014 in)

Diameter
(Min.) 62.7126 mm (2.469 in)
Thickness (Min.) 20.955 mm
(0.825 in)
Tip Clearance
Between
Rotors (Max). . 0.2032 mm
(0.008 in)
Oil Pressure
At Curb
Idle
Speed*
41.4 kPa
(6 psi)
At 3000 rpm 207-552 kPa (30-80 psi)
Oil Pressure
Switch
Actuating
Pressure (Min.) . 34.5-48.3 kPa (5-7 psi)

*CAUTION:
If pressure is
ZERO
at
curb
idle,
DO
NOT run
engine
at 3,000 rpm.
Oil
Filter
Bypass
Valve
Setting
............
62-103 kPa
(9-15 psi)
Pistons
Clearance at Top of
Skirt
.... 0.0127-0.0381 mm (0.0005-0.0015 in)
Land Clearance
(Diametrical)
..... 0.635-1.016 mm (0.025-0.040 in)
Piston
Length
.................
86.360 mm
(3.40 in)
Piston Ring Groove
Depth

Nos.
1 and 2 4.572-4.826 mm (0.180-0.190 in)

No.
3 3.810-4.064 mm (0.150-0.160 in)

Weight
592.6-596.6 grams
(20.90-21.04 oz) Piston Pins
Clearance In Piston . 0.00635-0.01905 mm (0.00025-0.00075 in)
In Rod
(interference)
..........
0.0178-0.0356 mm (0.0007-0.0014 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) 3.848-3.975 mm (0.1515-0.1565 in)

V®hr©s
Face Angle 43.25° - 43.75°
Head
Diameter
Intake
.....................
48.666 mm (1.916 in)
Exhaust 41.250 mm (1.624 in)

Length
(Overall)
Intake
. 124.28-125.92 mm (4.893-4.918 in)
Exhaust . 124.64-125.27 mm (4.907-4.932 in)

Lift
(Zero
Lash) 10.973 mm (0.432 in)
Stem
Diameter
7.899-7.925 mm (0.311-0.312 in)

Stem-to-Guide
Clearance......... 0.0254-0.0762 mm (0.001-0.003 in)

Max.
Allowable
(Rocking Method). . 0.4318 mm
(0.017 in)
Guide Bore
Diameter
(Std) 7.950-7.976 mm (0.313-0.314 in)
J9309-32

ENGINE SPECIFICATIONS (CONT,)

Valve Springs Free
Length
(Approx.)
49.962
mm
(1.967
in)

Spring Tension
.
@ 41.66 mm
= 378 N
(Valve
Closed)
(@ 1.64 in . 85 lbs)

Spring Tension
.
@ 30.89 mm
=
890
N (Valve Open) (@
1.212
in =
200
lbs)

Number
of
Coils
............... 6.8
Installed Height
41.66
mm (Spring Seat to Retainer)
(1.64
in)
Wire Diameter .
4.50
mm
(0.177
in)
Valve Timing

Exhaust Valve
Closes
(ATC)
16°

Opens
(BBC)
52° Duration
248°

Intake Valve
Closes
(ABC)
50°

Opens
(BTC)
. 10° Duration .
240°

Valve Overlap ... 26°

J9309-33

OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
CONDITION

IDENTIFICATION

LOCATION
OF
IDENTIFICATION

CRANKSHAFT JOURNALS (UNDERSIZE)

0.0254 mm (0.001
in.) RorM

M-2-3
etc. (indicating no. 2 and 3 main bearing journal)
and/or
R-l-4 etc.
(indicating no.
1
and 4 connecting rod journal) Milled flat on no. 8 crankshaft counterweight.

HYDRAULIC TAPPETS (OVERSIZE)

0.2032
mm
(0.008
in.) •
Diamond-shaped stamp top pad - front of
engine and flat ground on outside surface of
each O/S tappet bore.

VALVE
STEMS
(OVERSIZE)
0.127 mm (0.005
in.) X
Milled pad adjacent to two tapped holes

(3/8
in.) on each end of cylinder head.

J9309-82