RAM 3500 Truck 4WD L6-5.9L DSL Turbo VIN C (2002)
Piston: Procedures
STANDARD PROCEDURE - PISTON GRADING
When rebuilding an engine with the original cylinder block, crankshaft and pistons, make sure the pistons are installed in their original cylinder.
If replacing the piston(s), make sure the replacement piston(s) are the same grade as the one being replaced.
If a new cylinder block and/or crankshaft is used, the piston grading procedure MUST be performed to determine the proper piston grade for each
cylinder.
1. Install any of the original connecting rod and piston assemblies into the No.1 cylinder. DO NOT install the piston rings.
2. Install the upper bearing shell in the connecting rod with the tang of the bearing in the slot of the connecting rod. The connecting rod bearing shell
must be installed in the original connecting rod and cap. Use clean lubricating oil to coat the inside diameter of the connecting rod bearing shell.
3. Install the bearing shell in the connecting rod cap with the tang of the bearing in the slot to the cap. Use clean lubricating oil to coat the inside
diameter of the bearing shell.
4. The four digit number stamped on the connecting rod and cap at the parting line must match and be installed on the oil cooler side of the engine.
Install the connecting rod cap and cap screws. Tighten the cap screws to 35 Nm (26 ft. lbs.) torque.
5. Use a fine grit stone to remove any burrs from the cylinder block head deck. Zero the dial indicator to the cylinder block head deck.
6. Move the dial indicator directly over the piston pin to eliminate any side-to-side movement.
7. Rotate the crankshaft to Top Dead Center (TDC). Rotate the crankshaft clockwise and counterclockwise to find the highest dial indicator reading.
Record the reading.
8. Remove the piston and connecting rod assembly from the No.1 cylinder and install the assembly into the No.2 cylinder. Repeat the procedure for
every cylinder using the same piston and connecting rod assembly
Figure 126
Figure 127
9. Determine the grade of the piston being used by referring to the Piston Protrusion Chart below. Four digits on top of the piston can be cross
referenced to a DaimlerChrysler part number for replacement (Fig. 126). If the number on the piston cannot be seen, measure from the top of the
piston to the top of the piston pin to see what grade piston is used (Fig. 127).
NOTE: NEVER INTERMIX PISTONS FROM ONE ENGINE APPLICATION TO ANOTHER ENGINE APPLICATION. SEVER
DRIVEABILITY CONCERNS MAY RESULT.
