Chrysler RG Voyager. Manual — part 474
(16) Remove coolant recovery pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - REMOVAL).
(17) Remove thermostat housing to upper radiator
hose pipe (Fig. 16).
(18) Remove turbocharger outlet to charge air
cooler pipe (Fig. 16).
(19) Remove exhaust manifold heat shield (Fig.
17).
(20) Remove exhaust manifold retaining nuts (Fig.
17).
(21) Slide exhaust manifold and turbocharger off of
exhaust manifold studs (Fig. 17).
(22) Remove cylinder head bolts.
(23) Remove cylinder head assembly from engine
block (Fig. 18).
CLEANING
Thoroughly clean the engine cylinder head and cyl-
inder block mating surfaces. Clean the intake and
exhaust manifold and engine cylinder head mating
surfaces. Remove all gasket material and carbon.
Check to ensure that no coolant or foreign material
has fallen into the tappet bore area.
Remove the carbon deposits from the combustion
chambers and top of the pistons.
INSPECTION
Use a straightedge and feeler gauge to check the
flatness of the engine cylinder head and block mating
surfaces.
The minimum cylinder head thickness is 89.95mm
(3.541 in.).
INSTALLATION
CAUTION: Piston protrusion must be measured to
determine cylinder head gasket thickness if one or
more cylinder liners have been replaced (Refer to 9
- ENGINE/CYLINDER HEAD - STANDARD PROCE-
DURE).
Fig. 16 TURBOCHARGER AND COOLANT PIPES
1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT
2 - TURBOCHARGER OUTLET PIPE
3 - ADAPTOR HOSE
4 - HOSE CLAMPS
5 - TURBOCHARGER INLET PIPE RETAINING BOLT
6 - TURBOCHARGER INLET PIPE
7 - ADAPTOR HOSE
8 - HOSE CLAMPS
9 - EGR VALVE TO INTAKE AIR INLET PIPE
10 - CLAMP
11 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE PIPE
Fig. 17 EXHAUST MANIFOLD AND
TURBOCHARGER
1 - TURBOCHARGER OIL SUPPLY BANJO BOLT
2 - COPPER WASHER
3 - EXHAUST MANIFOLD GASKET
4 - COPPER WASHER
5 - TURBOCHARGER
6 - HEAT SHIELD RETAINING BOLT
7 - ENGINE LIFT HOOK
8 - LIFT HOOK RETAINING BOLT
9 - EXHAUST MANIFOLD RETAINING NUT
10 - TURBOCHARGER RETURN HOSE
11 - EXHAUST MANIFOLD STUD
9 - 28
ENGINE
RG
CYLINDER HEAD (Continued)
NOTE: If cylinder liner(s) have not been removed,
the same thickness head gasket that was removed
can be used.
(1) Clean and inspect gasket mating surfaces.
(2) Position correct head gasket on engine block.
(3) Place cylinder head on engine block (Fig. 18).
CAUTION: New cylinder head bolts must be used.
(4) Tighten cylinder head bolts following procedure
below:
• Lubricate the new cylinder head bolts with
engine oil.
• Torque bolts to 30N·m in numerical starting
with bolt #1 (Fig. 19).
• Tighten all bolts an additional 75°, starting with
bolt #4 then 5-6-7-8-9-10-1-2-3 (Fig. 19).
• Tighten all bolts an additional 50° in numerical
order starting with bolt #11 then 12-13-14-15-16-
17-18 (Fig. 19).
• Without loosening any bolts tighten all bolts an
additional 75° in the following sequence: 4-5-6-7-8-9-
10-1-2-3-11-12-13-14-15-16-17-18.
(5) Slide exhaust manifold and turbocharger on
exhaust manifold studs (Fig. 20).
(6) Install exhaust manifold retaining nuts. Torque
nuts to 32.4N·m.
(7) Install exhaust manifold heat shield (Fig. 20).
Torque bolts to 27.5N·m.
(8) Install turbocharger outlet to charge air cooler
pipe (Fig. 21).
(9) Install thermostat housing to upper radiator
hose pipe (Fig. 21). Install retaining bolt and torque
to 47.1N·m.
(10) Install coolant recovery pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - INSTALLATION).
(11) Connect glow plug and coolant temperature
sensor electrical connectors.
(12) Install new cylinder head cover/intake mani-
fold gasket.
(13) Install rocker arm and lifter assemblies.Be
sure to put rocker arm and lifter assemblies in
same location as removed.
(14) Install cylinder head cover/intake manifold
(Fig. 15)(Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(15) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(16) Install timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - INSTALLATION).
(17) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
Fig. 18 CYLINDER HEAD ASSEMBLY
1 - VALVE SPRING
2 - CYLINDER HEAD BOLT
3 - GLOW PLUG
4 - COOLANT TEMPERATURE SENSOR
5 - CYLINDER HEAD ALIGNMENT DOWEL
6 - CYLINDER BLOCK
7 - CYLINDER LINER
8 - ENGINE BLOCK DECK
9 - CYLINDER HEAD GASKET
10 - CYLINDER HEAD
11 - ROCKER ARM AND LIFTER ASSEMBLY
Fig. 19 CYLINDER HEAD TORQUE SEQUENCE
RG
ENGINE
9 - 29
CYLINDER HEAD (Continued)
(18) Remove crankshaft and both camshaft
locking pins at this time (Refer to 9 - ENGINE/
VALVE TIMING - STANDARD PROCEDURE) .
(19) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(20) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(21) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(22) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(23) Install air cleaner housing assembly.
(24) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(25) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(26) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER
MODULE
-
INSTALLATION).
(27) Connect negative battery cable.
CAMSHAFT(S)
DESCRIPTION
The camshafts are made of gray cast iron with
eight machined lobes and four bearing journals (Fig.
22).
Fig. 20 EXHAUST MANIFOLD AND
TURBOCHARGER
1 - TURBOCHARGER OIL SUPPLY BANJO BOLT
2 - COPPER WASHER
3 - EXHAUST MANIFOLD GASKET
4 - COPPER WASHER
5 - TURBOCHARGER
6 - HEAT SHIELD RETAINING BOLT
7 - ENGINE LIFT HOOK
8 - LIFT HOOK RETAINING BOLT
9 - EXHAUST MANIFOLD RETAINING NUT
10 - TURBOCHARGER RETURN HOSE
11 - EXHAUST MANIFOLD STUD
Fig. 21 TURBOCHARGER AND COOLANT PIPES
1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT
2 - TURBOCHARGER OUTLET PIPE
3 - ADAPTOR HOSE
4 - HOSE CLAMPS
5 - TURBOCHARGER INLET PIPE RETAINING BOLT
6 - TURBOCHARGER INLET PIPE
7 - ADAPTOR HOSE
8 - HOSE CLAMPS
9 - EGR VALVE TO INTAKE AIR INLET PIPE
10 - CLAMP
11 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE PIPE
Fig. 22 CAMSHAFTS
1 - INTAKE CAMSHAFT
2 - EXHAUST CAMSHAFT
9 - 30
ENGINE
RG
CYLINDER HEAD (Continued)
OPERATION
When the camshaft rotates the lobes actuate the
hydraulic lifters and rocker arms, forcing downward
on the rocker arms which opens the valves.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER
MODULE
-
REMOVAL).
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Remove air cleaner housing.
(6) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(7) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(8) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
(9) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - 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)
(10) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(11) Remove timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
(12) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(13) Remove cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(14) With cylinder head cover/intake manifold on
work bench, remove plugs at rear of cylinder head
cover/intake manifold.
(15) Remove camshaft oil seals (Fig. 23).
(16) Remove snapring and thrust washer from
camshaft (Fig. 23).
(17) Slide camshaft through access hole at rear of
cylinder head cover/intake manifold.
INSTALLATION
(1) Lubricate the camshafts with Mopar
t Engine
Oil Supplement, or equivalent.
(2) Carefully install camshafts into access holes in
rear of cylinder head cover/intake manifold.
(3) Install thrust washer, snap ring, and camshaft
oil seal (Fig. 23).
(4) After camshafts are properly installed in cylin-
der head cover check end play of camshafts with a
dial indicator. The end play should be between .10
mm – .55 mm.
NOTE: If the camshaft end play is not within speci-
fication, measure thickness of the camshaft spacer.
Camshaft spacer thickness should be 2.8 ± .02mm.
(5) Install access hole plugs and gaskets at rear of
cylinder head cover/intake manifold. Torque plugs to
80N·m.
(6) Install cylinder head cover/intake manifold on
engine block (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION).
(7) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
Fig. 23 CAMSHAFT ASSEMBLY
1 - INTAKE CAMSHAFT
2 - SNAPRING
3 - CAMSHAFT OIL SEAL
4 - THRUST WASHER
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
6 - EXHAUST MANIFOLD
RG
ENGINE
9 - 31
CAMSHAFT(S) (Continued)
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст