Chrysler RG Voyager. Manual — part 480
(3) Top ring gap must be positioned at the #3 posi-
tion (looking at the piston crown from above) (Fig.
68).
(4) Second piston ring gap should be positioned at
the #1 position (Fig. 68).
(5) Oil control ring gap should be positioned at the
#2 position (Fig. 68).
(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 arrow on top of piston toward front of
engine. Therefore, the numbers stamped on connect-
ing rod big end should face toward the injection
pump side of engine. To insert piston into cylinder
use a ring compressor (VM.1065) as shown in (Fig.
69).
INSTALLATION
(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. 68).
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted together.
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
and tighten (Fig. 69). Ensure position of rings
does not change during this operation.
NOTE: Be sure arrow on top of piston faces
towards front of engine and the connecting rod
pawl faces the rear (flywheel) side of the engine.
NOTE: Be careful not to nick crankshaft journals.
(4) 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.
(5) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
Fig. 67 PISTON RINGS-INSTALLATION
Fig. 68 PISTON RING GAP LOCATION
1 - SECOND COMPRESSION RING GAP POSITION
2 - OIL CONTROL RING GAP POSITION
3 - TOP COMPRESSION RING GAP POSITION
Fig. 69 PISTON INSTALLATION USING VM.1065
1 - PISTON
2 - PISTON RING COMPRESSOR VM.1065
3 - ENGINE BLOCK
9 - 52
ENGINE
RG
PISTON & CONNECTING ROD (Continued)
NOTE: Connecting rod bolts must be replaced when
disassembled. DO NOT lubricate new connecting
rod bolts as they are already coated.
(6) Install connecting rod caps (Fig. 70). Install rod
bolts and tighten each bolt to 10N·m (89 lbs. in..).
Tighten each bolt again to 30N·m (22 lbs. ft.) plus
40°. Then torque to 88N·m (65 ft.lb).
(7) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(8) Install balance shaft assembly (Refer to 9 -
ENGINE/VALVE
TIMING/BALANCE
SHAFT
-
INSTALLATION).
(9) Install oil pump pickup tube (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - INSTALLA-
TION).
(10) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(11) Connect negative battery cable.
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner housing.
(3) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
(4) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(5) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(6) Remove
vibration
damper/crankshaft
pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(7) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(8) Remove timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
(9) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
NOTE: Crankshaft hub retaining bolt has LHD
thread.
(10) Remove crankshaft hub (Fig. 71).
(11) Remove front engine cover (Fig. 71) (Refer to
9 - ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL) .
(12) With cover on work bench, pry out old seal.
INSTALLATION
CAUTION: Do Not use a hammer to install the
crankshaft oil seal.
NOTE: To prevent potential oil leaks, DO NOT touch
the front crankshaft inner seal. Always handle the
seal from the outer diameter.
(1) Clean engine block and front engine cover seal-
ing surfaces.
(2) Install crankshaft oil seal on VM.1061 (Fig.
72).
(3) Place sleeve for VM.1061 on press bench as
shown (Fig. 72).
Fig. 70 PISTON AND CONNECTING ROD
INSTALLATION
1 - PISTON AND CONNECTING ROD ASSEMBLY
2 - PAINTED CYLINDER IDENTIFIER
3 - CONNECTING ROD BOLT
4 - PAINTED CYLINDER IDENTIFIER
RG
ENGINE
9 - 53
PISTON & CONNECTING ROD (Continued)
(4) Press the new seal into front engine cover.
(5) Install front engine cover using VM 1061 as a
guide, care must be taken not to damage the seal
(Fig. 73).
(6) Install crankshaft hub and retaining bolt.
Torque bolt to 304N·m (224 lbs. ft.).
(7) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(8) Install timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - INSTALLATION).
(9) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(10) Install
vibration
damper/crankshaft
pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(11) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(12) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(13) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(14) Install air cleaner housing.
(15) Connect negative battery cable.
Fig. 71 ENGINE COVER - FRONT
1 - CRANKSHAFT HUB RETAINING BOLT
2 - FRONT ENGINE COVER RETAINING BOLTS
3 - ENGINE BLOCK
4 - FRONT ENGINE COVER ALIGNMENT DOWELS
5 - FRONT ENGINE COVER
6 - CRANKSHAFT HUB
Fig. 72 VM.1061 PLACEMENT
1 - VM.1061
2 - FRONT ENGINE COVER
3 - PRESS BENCH
4 - SLEEVE FROM VM.1061
Fig. 73 ENGINE FRONT COVER
1 - ENGINE BLOCK
2 - FRONT ENGINE COVER
3 - VM.1061
9 - 54
ENGINE
RG
CRANKSHAFT OIL SEAL - FRONT (Continued)
VIBRATION DAMPER
REMOVAL
(1) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(3) Remove vibration damper retaining bolts and
damper (Fig. 74).
INSTALLATION
(1) Install vibration damper and retaining bolts
(Fig. 74). Torque bolts to 27.5N·m.
(2) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(3) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
ENGINE COVER - FRONT
DESCRIPTION
The front engine cover on this engine is a stamped
steel cover which covers the oil pump and vacuum
pump.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner housing.
(3) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
(4) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(5) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(6) Remove
vibration
damper
(Refer
to
9
-
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(7) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
CAUTION: Before removing the cylinder head cover/
intake manifold or timing belt the engine must put
at 90° after TDC. Failure to do so could result in
valve and/or piston damage during reassembly.
(Refer to 9 - ENGINE/VALVE TIMING - STANDARD
PROCEDURE)
(8) Remove timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
(9) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
NOTE: Crankshaft hub has LHD thread.
(10) Remove crankshaft hub.
(11) Remove front engine cover (Fig. 75).
INSTALLATION
(1) Clean engine block and front engine cover seal-
ing surfaces.
(2) Apply a continous 3mm bead of Silicone Sealer
to cover, install within 10 minutes (Fig. 75). Torque
bolts to 11.8N·m.
Fig. 74 VIBRATION DAMPER
1 - BELT TENSIONER RETAINING BOLT
2 - BELT TENSIONER
3 - IDLER PULLEY
4 - VIBRATION DAMPER/CRANKSHAFT PULLEY
5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING
BOLTS
RG
ENGINE
9 - 55
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