DODGE TRUCK 1993 Service Repair Manual

9
- 126 5.9L
(DIESEL) ENGINE

•
(5)
Only remove one tappet at a time. Remove the
rubber band from the two companion tappets, secur­ ing the tappet not to be removed with the rubber
band.
(6) Pull the wooden dowel from the tappet bore al­
lowing the tappet to fall into the trough (Fig. 1).
(7) Normally the tappet will fall over when it
drops into the trough. Use a flashlight to determine

this.
If the tappet does not fall over, shake the
trough gently to get it to do so.
(8) Special care should be taken, when removing
the No.6 cylinder tappets. DO NOT knock or shake
the tappet over the end barrier of the trough.
(9) Carefully pull the trough and tappet from the
cam bore and remove the tappet. Repeat the process
until all tappets are removed.

Fig.
1
Tappet
Removal
using
a Trough

INSPECTION
Inspect the tappet socket, stem and face for exces­
sive wear, cracks and other damage (Fig. 2).
The minimum tappet stem diameter is 15.925 mm
(0.627 inch) - (Fig. 2). If the tappet is out of limits,
replace the tappet.

NORMAL
WEAR

STEM DIAMETER-
ABNORMAL

WEAR

J9109-152

Fig.
2
Tappet
Inspection
INSTALLATION

(1) Insert the trough the full length of the cam

bore.
(2) Feed the installation tool down the tappet bore
and into the trough (Fig. 3).

J9109-153
Fig.
3
Tappet
Installation
Tool
(3) Feed the installation tool cord through the cam

bores.
Carefully pull the trough and installation tool out the front. The barrier at the rear of the trough
will assure the tool will be pulled out with it.
(4) Lubricate the tappets with Lubriplate 105, or
equivalent. (5) Insert the installation tool into the tappet (Fig.

4).
To aid in removing the installation tool after the
tappets is installed, work the tool in and out of the
tappet several times before installing the tappets. (6) Place the tappet and tool in the trough and
slide the trough back into the cam bore (Fig. 4).
J9109-155'

Fig.
4 Insert
Installation
Tool
into
Tappet
(7) Pull the tool/tappet through the cam bore and
up into the tappet bore (Fig. 5).
(8) Difficulty could be experienced in getting the
tappet to make the bend from the trough up to the tappet bore (due to the webbing of the block). If this
occurs, pull the trough out enough to allow the tap-

•
5.9L
(DIESEL) ENGINE
9 - 127

Fig.
5 Pull
Tappet/Tool
into
Position pet to drop down and align
itself.
Now pull the tap­
pet up into the bore carefully. (9) After the tappet has been pulled up into posi­
tion, slide the trough back into the cam bore and ro­ tate it 1/2 turn. This will position the round side of
the trough up, which will hold the tappet in place.
(10) Remove the installation tool from the tappet. (11) Install a wooden dowel into the top of the tap­
pet and secure it with a rubber band.
(12) Repeat this process until all tappets have been
installed. (13) Install the camshaft.

CAMSHAFT
REMOVAL (1) Remove the following parts:
• Valve covers
• Rocker lever assemblies
• Push rods • Drive belt
• Fan hub assembly • Vibration damper
• Gear housing cover
• Lift pump (2) Insert the dowels through the push tube holes
and into the top of each tappet. When properly in­
stalled, the dowels can be used to pull the tappets up (Fig. 6).
(3) Pull the tappets up and wrap a rubber band
around the top of the dowel rods (Fig. 6). This will
prevent the tappets from dropping down.
(4) Rotate the crankshaft to align the crankshaft
to camshaft timing marks (Fig. 7).
(5) Remove the bolts from the thrust plate (Fig. 8)
(6) Remove the camshaft, gear and thrust plate.

INSPECTION
Inspect the lift pump lobe, valve lobes and bearing
journals for wear, cracking, pitting and other dam­
age.
DOWEL
TOOL
Fig.
6
Holding
Tappets in Place
(Cummins
Tool 3822513)
J9109-51

Fig.
7
Align
Crankshaft to Camshaft
Fig.
8 Thrust
Plate
Bolt
Location
Clean the camshaft and gear with solvent and a
lint free cloth.
Inspect the gear teeth for wear and damage. Look
for cracks at the root of the teeth. Measure the bearing journals, lift pump lobe and
valve lobes (Fig. 9).

9
- 128 5.9L
(DIESEL)
ENGINE

•

CAMSHAFT

JOURNAL
CAMSHAFT
JOURNAL
DIAMETER
(MIN.

53.962 mm (2.1245
inch)

VALVE
LOBE
HEIGHT
(MIN..)
INTAKE
- 47.040 mm (1.852
inch)

EXHAUST
- 46.770 mm (1.841
inch)

LIFT
PUMP
LOBE
DIAMETER
(MIN.)

35.500 mm (1.398
inch)

J9109-53

Fig.
9 Bearing Journal/Valve
Lobe
Measurements

CAMSHAFT
BUSHING-REPLACEMENT
(1) Measure the diameter of each bore. (The limit
for the bushing in the No.l bore is the same as for
the other bores without bushings). The limit of the inside diameter is 54.133 mm (2.1312 inch). If the
camshaft bore for the first cam bushing is worn be­
yond the limit, install a new service bushing. Inspect the rest of the camshaft bores for damage or exces­ sive wear.
(2) If the bores without a bushing are worn beyond
the limit, the engine must be removed for machining and installation of service bushings. If badly worn,
replace the cylinder block.
(3) Remove the bushing from the No.l bore, using
a universal cam bushing tool.
(4) Mark the cylinder block so you can align the
oil hole in the cylinder block with the oil hole in the
bushing.
(5) Use a universal cam bushing installation tool
and install the bushing so that it is even with the
front face of the cylinder block. The oil hole must .be aligned. A 3.2 mm (0.128 inch) diameter rod must be able to pass through the hole (Fig. 10). (6) Measure the installed bushing. The limit of the
inside diameter is 54.133 mm (2.1312 inch).

CAMSHAFT
GEAR-REPLACEMENT
(1) Press the camshaft out of the gear. J9109-54

Fig.
10 Oil Hole
Alignment

(2) Remove all burrs and smooth any rough sur­
faces caused by removing the gear. (3) Install the camshaft key.
(4) Lubricate the camshaft surface with Lubriplate

105,
or equivalent.
(5) Heat the gear in an oven at 121°C (250°F) for
45 minutes.

WARNING:
WEAR
PROTECTIVE
GLOVES
TO
HAN­
DLE
THE HOT
GEAR.

(6) Install the gear with the timing marks visible.
Be sure the gear is seated against the camshaft shoulder.
(7) If the camshaft is not to be used immediately,
lubricate the lobes and journals to prevent rust.

INSTALLATION
(1) Apply a coat of Lubriplate 105 to the camshaft

bores.
(2) Lubricate the camshaft lobes, journals and
thrust washer with Lubriplate 105, or equivalent.

CAUTION:
When
installing
the
camshaft,
DO NOT

push
it in
farther
than
it
will
go
with
the
thrust

washer
in
place.
Pushing
it too far
can
dislodge
the
plug
in the
rear
of the
camshaft
bore
and
cause
an

oil
leak.

(3) Install the camshaft/thrust washer. Align the
timing marks as illustrated (Fig. 11). (4) Install the thrust washer bolts and tighten to
24 N-m (18 ft. lbs.) torque.
(5) Verify the camshaft has the correct amount of
backlash and end clearance (Fig. 12).
(6) Install the following parts:
• Lift pump • Gear housing cover
• Vibration damper
• Fan hub assembly
• Drive belt
• Push rods
• Rocker lever assemblies
• Valve covers (7) Install the engine in the vehicle.

•
BACKLASH - 0.080-0.330 mm (0.003-0.013 inch)
CLEARANCE - 0.152-0.254 mm (0.006-0.010 inch)
Fig.
12 Camshaft
Backlash
and End Clearance
(8) Operate the engine at idle for five to ten min­
utes and check for leaks and loose parts.

CYLINDER BLOCK

REMOVAL (1) Remove the engine assembly from the vehicle.
(2) Remove the cylinder head from the block.
(3) Remove the camshaft.
(4) Remove the piston/connecting rod assemblies.

INSPECTION
Measure the combustion deck face using a straight
edge and a feeler gauge (Fig. 1). The distortion of the
combustion deck face is not to exceed 0.010 mm (0.0004 inch) in any 50.00 mm (2.0 inch) diameter.
Overall variation end to end or side to side is 0.075
mm (0.003 inch).
If the surface exceeds the limit, refer to Cylinder
Block Refacing. 5.9L
(DIESEL) ENGINE
9 - 129

Fig.
1
Combustion
Deck
Face Measurement Inspect the cylinder bores for damage or excessive
wear.
Measure the cylinder bores (Fig. 2). If the cylinder
bores exceeds the limit, refer to Cylinder Bore Re­
pair. MIN. 102.0 mm (4.0157 inch)
MAX. 102.1 16 mm (4.0203 inch)
Out-of-Round 0.038 mm (0.0015 inch)
Taper 0.0 76 mm (0.003 inch) Oversize pistons and rings are
available for bored cylinder blocks.

J9209-167

Fig.
2 Cylinder
Bore
Diameter
Inspect the camshaft bores for scoring or excessive
wear.
Measure the camshaft bores (Fig. 3). Limit for the
No.l bore applies to the ID of the bushing.
If a bore exceeds the limit, refer to Camshaft Bore
Repair.
Inspect the tappet bores for scoring or excessive
wear (Fig. 4). If out of limits, replace the cylinder block.

CYLINDER BORES—DE-GLAZE
(1) New piston rings may not seat in glazed cylin­
der bores.
(2) De-glazing gives the bore the correct surface
finish required to seat the rings. The size of the bore
is not changed by proper de-glazing.

9
- 130 5.9L
(DIESEL) ENGINE

• CAMSHAFT BORE DIAMETER
MAX.
54.133
mm
(2.1312
inch)
J9109-78

Fig.
3 Camshaft
Bores

BORE DIAMETER
MAX. 16.055 mm (0.632 inch)
J9109-79

Fig.
4
Tappet
Bore
Diameter
(3) Cover the lube holes in the top of the block
with waterproof tape.
(4) A correctly honed surface will have a cross-
hatch appearance with the lines at 15° to 25° angles (Fig. 5). For the rough hone, use 80 grit honing
stones. To finish hone, use 280 grit honing stones.
(5) Use a drill, a fine grit Flexi-hone and a mix­
ture of equal parts of mineral spirits and SAE 30W engine oil to de-glaze the bores.
(6) The Crosshatch angle is a function of drill speed
and how fast the hone is moved vertically (Fig. 6).
TOP
OF
BLOCK
Fig.
5 Cylinder
Bore
Crosshatch
Pattern
(7) Vertical strokes MUST be smooth continuous
passes along the full length of the bore (Fig. 6).
1
STROKE
(f+|)/PER
SECOND

Fig.
6 De-Glazing Drill
Speed
and
Vertical
Speed
(8) Inspect the bore after 10 strokes.
(9) Use a strong solution of hot water and laundry
detergent to clean the bores. Clean the cylinder bores
immediately after de-glazing.
(10) Rinse the bores until the detergent is removed
and blow the block dry with compressed air. (11) Check the bore cleanliness by wiping with a
white, lint free, lightly oiled cloth. If grit residue is still present, repeat the cleaning process until all res­
idue is removed. Wash the bores and the complete
block assembly with solvent and dry with compressed air.
(12) Be sure to remove the tape covering the lube
holes after the cleaning process is complete.

CYLINDER BLOCK REFACING
(1) The combustion deck can be refaced twice. The
first reface should be 0.15 mm (0.0059 inch). If addi­
tional refacing is required, an additional 0.35 mm (0.0138 inch) can be removed. Total allowed refacing
is 0.50 mm (0.0197 inch) - (Fig. 7).
(2) The upper right corner of the rear face of the
block must be stamped with a X when the block is refaced to 0.15 mm (0.0059 inch). A second X must

•
5.9L (DIESEL) ENGINE
9 - 131

1st REFACE
0.15 mm

(0.0058
inch)

2nd REFACE
0.35 mm
(0.0138

inch)

®
Total
0.50
mm
(0.0197

inch)

®
Standard
323.00
mm ±0.10 mn i

(12.7165
inch
±0.0039
inch)

1st
RE
FACE
322.85 mm ±0.10 mm

(12.7106
inch
±0.0039
inch)
2nd
REFACE
322.50
mm ±0.10 mn i

(12.6968
inch
±0.0039
inch)
J9109-118
Fig.
7 Refacing
Dimensions
of the Cylinder
Block

1st REFACE
X

2nd REFACE
XX
J9109-116

Fig.
8
Stamp
Block
after
Reface
be stamped beside the first when the block is refaced
to 0.50 mm (0.0197 inch) - (Fig. 8). (3) Consult the parts catalog for the proper head
gaskets which must be used with refaced blocks to
ensure proper piston-to-valve clearance (Fig. 9).
CYLINDER BORE REPAIR Cylinder bore(s) can be repaired by one of two
methods:

•
Method
1:—Over
boring and using oversize pistons and rings.
GASKET
FOR

0.15 mm

(0.0058
inch)
REFACE
GASKET FOR
0.50
mm

(0.0197
inch)
REFACE
Fig.
9 Proper Head
Gasket
•
Method 2:—Boring and installing a repair sleeve
to leturn the bore to standard dimensions.

METHOD 1-0WERS1ZE
BORE
Oversize pistons and rings are available in two
sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393

inch).

Any combination of standard, 0.50 mm (0.0197
inch) or 1.00 mm (0.0393 inch) overbore may be used
in the same engine.
If more than 1.00 mm (0.0393 inch) overbore is
needed, a repair sleeve can be installed (refer to
Method 2—Repair Sleeve).
Cylinder block bores may be bored twice before use
of a repair sleeve is required (Fig. 10). The first bore
is 0.50 mm (0.0197 inch) oversize. The second bore is 1.00 mm (0.0393 inch) oversize.
After boring to size, use a honing stone to chamfer
the edge of the bore (Fig. 10). A correctly honed surface will have a Crosshatch
appearance with the lines at 15° to 25° angles with
the top of the cylinder block (Fig. 11). For the rough
hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones. A maximum of 1.2 micrometer (48 microinch) sur­
face finish must be obtained. After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry detergent and hot water. After rinsing, blow the block dry. Check the bore cleanliness by wiping with a white,
lint-free, lightly-oiled cloth. There should be no grit
residue present. If the block is not to be used right away, coat it
with a rust-preventing compound.

METHOD 2—REPAIR
SLEEWE
If more than a 1.00 mm (0.03937 inch) diameter
oversize bore is required, the block must be bored and a repair sleeve installed.

9
- 132 5.9L
(DIESEL) ENGINE
BORING
AND

HONING
DIAMETERS
BORING DIAMETER DIMENSION 1st REBORE
-
102.469
mm

(4.0342
inch)
2nd
REBORE
-
102.969
mm
(4.0539
inch)

HONING
DIAMETER DIMENSIONS
STANDARD
102.020
±0.020
mm
(4.0165
±
0.0008
inch)

1st REBORE
102.520
±
0.020
mm
(4.0362
±
0.0008
inch)
2nd
REBORE
103.020
±0.020
mm
(4.0559
±
0.0008
inch)

CHAMFER DIMENSIONS

Approx.
1.25 mm
(0.049
inch)
by
15°

J9109-119

Fig.
10 Cylinder
Bore
Dimensions
TOP
OF
BLOCK
Fig.
11
Crosshatch
Pattern
of Repaired
Sleeve(s)
Bore the block cylinder bore to 104.500-104.515
mm (4.1142-4.1148 inch) - (Fig. 12).
Repair sleeves can be replaced by using a boring
bar to bore out the old sleeve. DO NOT cut the cyl­
inder bore beyond the oversize limit.
BORE DIAMETER
BLOCK REBORE
FOR
REPAIR SLEEVE BORE
DIA. -
104.500
+0.015
mm

(4.1142
+0.0006
inch)

STEP
DIM. - 6.35 mm (0.25 inch)

J9109-120

Fig.
12
Block
Bore
for Repair
Sleeve
Dimensions

After machining the block for the new repair
sleeve, thoroughly clean the bore of all metal chips,
debris and oil residue before installing the sleeve.
Cool the repair sleeve(s) to a temperature of -12°C
(10°F) or below for a minimum of one hour. Be ready
to install the sleeve immediately after removing it
from the freezer.
Apply a coat of Loctite 620, or equivalent to the
bore that is to be sleeved. Wear protective gloves to push the cold sleeve into
the bore as far as possible.
Using a sleeve driver, drive the sleeve downward
until it contacts the step at the bottom of the bore (Fig. 13).
J9109-121

Fig.
13
Sleeve
Installation

•

5
9L
(DIESEL) ENGINE
9 - 133
A sleeve driver can be constructed as follows (Fig. 14).

DRIVE
-
ALUMINUM
HANDLE
-
STEEL A
= 127 mm (5 inch)

B
= 38 mm (1.5 inch)

C
= 6.35 mm (0.25 inch)

D
= 25.4 mm (1 inch)

E
= 101 mm
(3.976
inch)

F
=
107.343
mm
(4.226
inch)

J9109-122

Fig.
14
Sleeve
Driver Construction
Set up a boring bar and machine the sleeve to
101.956 mm (4.014 inch) - (Fig. 15). After removing the boring bar, use a honing stone to
chamfer the corner of the repair sleeve(s) - (Fig. 15).
SLEEVE DIAMETER
-
101.956
mm

(4.014
inch)

SLEEVE PROTRUSION MIN.
-
FLUSH
WITH
BLOCK MAX.
-
0.050
mm
(0.0019
inch)

SLEEVE CHAMFER APPROX.
1.25 mm
(0,049
inch)
BY
15° •
J9109-123

Fig.
15
Sleeve
Machining
Dimensions

A correctly honed surface will have a Crosshatch
appearance with the lines at 15° to 25° angles with
the top of the cylinder block. For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit
honing stones. Finished bore inside dimension is 102.020 ±0.020
mm (4.0165 ±0.0008 inch). A maximum of 1.2 micrometer (48 microinch) sur­
face finish must be obtained.
After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry detergent and hot water.
After rinsing, blow the block dry with compressed
air.
Wipe the bore with a white, lint-free, lightly oiled
cloth. Make sure there is no grit residue present. Apply a rust-preventing compound if the block will
not be used immediately.
A standard diameter piston and a piston ring set
must be used with a sleeved cylinder bore.
CAM
BORE REPAIR
The front cam bushing bore can be bored to 57.740
Mm ±0.018 mm (2.273 inch ±0.0007 inch) oversize.
DO NOT bore the intermediate or rear cam bore to
the front cam bore oversize dimensions. Intermediate and rear cam bores may be bored to 57.240 mm ±0.018 mm (2.253 inch ±0.0007 inch) oversize.
A surface finish of 2.3 micrometers (92 microinch)
must be maintained. Not more than 20% of an area
of any one bore may be 3.2 micrometers (126 micro-

inch).

Camshaft bores can be repaired individually. It is
not necessary to repair undamaged cam bores in or­
der to repair individually damaged cam bores. The standard front bushing cannot be used to repair in­
termediate or rear bores.
Install all cam bushings flush or below the front
cam bore surface. The oil hole must align to allow a 3.2 mm (0.125 inch) rod to pass through freely (Fig.
16). Fig.
16 Oil Hole
Alignment

CUP PLUG-REPLACEMENT
(1) Remove the cup plugs from the oil passages
(Fig. 17).
(2) Apply a bead of Loctite 277 around the outside
diameter of the oil passage cup plugs. (3) Drive the cup plugs in until they bottom in the
bore (Fig. 17).

9
- 134 5.9L
(DIESEL) ENGINE

• (4) Fill the engine with oil. Run the engine and
check for leaks.
(5) Stop the engine and check the oil level with the
dipstick.
CUP
PLUG

J9109-30

Fig.
17 Cup Plug Locations in Cylinder Block INSTALLATION
(1) Install the cylinder head onto the block.
(2) Install the engine assembly into the vehicle.

PISTON
/
CONNECTING ROD ASSEMBLY
The turbocharged intercooler piston has a Ni-Resist
insert with a keystone profile for the top compression
ring. The new piston has a new design bowl and a 7 mm longer piston pin. These pistons can not be in­
terchanged with earlier models.
REMOVAL (1) Remove the engine assembly from the vehicle.
(2) Remove the cylinder head from the block.
(3) Remove the oil pan and suction pump.
(4) If the cylinder bores have ridges, use a ridge
reamer to cut the ridge from the top of the cylinder
bore before removing the piston. Make sure the ridge reamer does not make a deep cut into the bore. DO
NOT remove more metal than is necessary to remove
the ridge.
(5) If cylinders have ridges, the cylinders are over­
size and will need boring. (6) Use a hammer and a steel stamp to mark the
cylinder number onto each connecting rod cap. Mark
the cylinder number onto the top of each piston. (7) Remove the connecting rod bolts and rod caps.
Use care so the cylinder bores and connecting rods
are not damaged. (8) Use a hammer handle or similar object to push
the piston and connecting rod through the cylinder

bore.
(9) Store the piston/rod assemblies in a rack.
DISASSEMBLE (1) Remove the retainer rings from the piston (Fig.

1).
(2) Remove the piston pin. Heating the piston is
not required. (3) Remove the piston rings (Fig. 1). RETAINER
RING

CONNECTING

ROD

PISTON

PISTON RIN RETAINER
RING J9109-62

Fig.
1 Retainer
Rings

CLEANING
CAUTION: DO NOT use bead
blast
to clean the
pis­

tons.
DO
NOT
clean the pistons and rods in an acid

tank.

Soak the pistons in cold parts cleaner. Soaking the
pistons overnight will usually loosen the carbon de­ posits.
Wash the pistons and rods in a strong solution of
laundry detergent and hot water.
Clean the remaining deposits from the ring grooves
with the square end of a broken ring. DO NOT use a
ring groove cleaner and be sure not to scratch the
ring sealing surface in the piston groove.
Wash the pistons again in a detergent solution or
solvent.
Rinse the pistons. Use compressed air to dry.
INSPECTION Inspect the rod journals for deep scratches, indica­
tion of overheating and other damage.
Inspect the pistons for damage and excessive wear.
Check top of the piston, ring grooves, skirt and pin

bore.

Measure the piston skirt diameter (Fig. 2). If the
piston is out of limits, replace the piston.
The upper groove only needs to be inspected for
damage.
Use a new piston ring to measure the clearance in
the intermediate ring groove (Fig. 3). If the clearance of the intermediate ring exceeds 0.152 mm (0.006

inch),
replace the piston.
Use a new oil ring to measure the clearance in the
oil groove (Fig. 3). If the clearance exceeds 0.127 mm (0.005 inch), replace the piston.

•
5.9L
(DIESEL) ENGINE
9 - 135 -j^u mm 11/2 inch)
MIN. DIAMETER
101.823 mm
4.0088 inch
J9109-63

Fig. 2 Piston Skirt Diameter PISTON

•
PIN FEELER GAUGE
J910<

PISTON J9109-64
Fig. 3 Intermediate and Oil Ring Clearances
Measure the pin bore (Fig. 4). The maximum diam­
eter is 40.025 mm (1.5756 inch). If the bore is over
limits,
replace the piston,
PISTON

J9109-65

Fig. 4 Piston Pin Bore
Inspect the piston pin for nicks, gouges and exces­
sive wear. Measure the pin diameter (Fig. 5). The minimum
diameter is 39.990 mm (1.5744 inch). If the diameter
is out of limits, replace the pin.
Inspect the rod for damage and wear. The I-Beam
section of the connecting rod cannot have dents or
other damage. Damage to this part can cause stress
risers which will progress to breakage. -66 Fig. 5 Piston Pin Diameter
Measure the connecting rod pin bore (Fig. 6). The
maximum diameter is 40.092 mm (1.5784 inch). If
out of limits, replace the connecting rod.
CONNECTING
Fig. 6 Connecting Rod Pin Bore
CONNECTING ROD BEARING / CRANKSHAFT
JOURNAL CLEARANCE
Measure the connecting rod bore with the bearings
installed and the bolts tightened to 100 N*m (73 ft.
lbs.) torque. Record the smaller diameter.
Measure the diameter of the rod journal at the lo­
cation shown (Fig. 7). Calculate the average diame­
ter for each side of the journal.
The clearance is the difference between the con­
necting rod bore (smallest diameter) and the average
diameter for each side of the crankshaft journal.
If the crankshaft is within limits, replace the bear­
ing. If the crankshaft is out of limits, grind the
crankshaft to the next smaller size and use oversize
rod bearings.

ASSEMBLE
(1) Be sure the FRONT marking on the piston and
the numbers on the rod and cap are oriented (Fig. 8).