Chrysler New Yorker. Manual — part 218
valve is a one-piece forging, while the exhaust valve
has a forged head with a welded stem for lock groove
hardenability. Both valves employ a three-groove lock
design.
VALVE SPRINGS
Valve springs are unique for intake versus exhaust.
Both are made from chrome silicon alloy wire and
incorporate a “bee-hive” design. Valve spring retain-
ers and locks are common. The valve spring seat is
integral with the valve stem oil seal, which incorpo-
rates a garter spring to maintain consistent lubrica-
tion control to the valve stem.
INTAKE MANIFOLD
The composite intake manifold is a cross-flow type
with long runners to improve air charge inertia. An
active Short Runner Valve (SRV) opens during cer-
tain operating conditions to improve top end perfor-
mance. A Manifold Tuning Valve (MTV) connects the
plenums at specific engine speeds to maximize low
RPM torque without reducing high RPM power.
EXHAUST MANIFOLDS
Both manifolds are a log style made of ductile cast
iron. The outlets are designed for V-Band clamp
attachment of close coupled catalytic converters.
ENGINE LUBRICATION
System is a full-flow filtration, pressure feed type.
The oil pump body is mounted to the engine block.
The pump inner rotor is driven by the crankshaft. A
windage tray, integral with the oil pan gasket,
increases power by minimizing oil windage at high
engine RPM. For increased oil cooling, an oil-to-cool-
ant oil cooler is used. This cooler is mounted inside
the radiator tank.
DIAGNOSIS AND TESTING
HYDRAULIC LASH ADJUSTER
The hydraulic lash adjusters are precision units
installed in machined openings in the valve actuating
ends of the rocker arms. Do not disassemble the
hydraulic lash adjuster from the rocker arm
assembly (Fig. 3). Damage to the adjuster and
rocker arm will occur.
CHECKING ENGINE OIL PRESSURE
Check oil pressure using gauge at oil pressure
switch location. Oil pressure should be 34 kPa (5 psi)
at idle or 205 to 550 kPa (30 to 80 psi.) at 3000 RPM.
(1) Remove pressure sending unit. The pressure
sending unit is located on the left front of engine
near the oil filter.
(2) Install oil pressure gauge.
CAUTION:
If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM.
(3) Warm engine to normal operating temperature.
TESTING VALVE SPRINGS
VALVE SPRING IDENTIFICATION
The valve springs are of two different lengths and
are wound in different directions. The valve springs
are color coded, intake spring is right hand coil direc-
tion with orange dye on the top coils and the exhaust
spring is left hand coil direction with a green dye on
the top coils (Fig. 4).
TESTING VALVE SPRINGS
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested (Fig. 5). As an example; the compression
length of the spring to be tested is 38.00 mm (1.496
inches.). Turn table of Tool C-647 until surface is in
line with the 38.00 mm (1.496 inches.) mark on the
threaded stud and the zero mark on the front. Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjust-
ments. Refer to Specifications Section to obtain
Fig. 3 Hydraulic Lash Adjuster
Fig. 4 Valve Spring Identification
LH
3.2L ENGINE
9 - 67
DESCRIPTION AND OPERATION (Continued)
specified height and allowable tensions. Replace
springs that do not meet specifications.
SERVICE PROCEDURES
PISTONS
Pistons are machined to two different weight spec-
ifications and matched to rods based on weight. All
piston and rod assemblies weigh the same, to main-
tain engine balance.
FITTING PISTONS
Piston and cylinder wall must be clean and dry.
Piston diameter should be measured 90 degrees to
piston pin at size location shown in (Fig. 6). Cylinder
bores should be measured halfway down the cylinder
bore and transverse to the engine crankshaft center
line. Refer to Cylinder Bore and Piston Specification
Chart. Pistons and cylinder bores should be
measured at normal room temperature, 70°F
(21°C).
PISTON PINS
The piston pin is full floating and is held in place
by lock rings. Pistons and rods are weight matched
for balance. Do Not switch pistons with other
rods. Piston and Rods are serviced as an assembly
for balance.
FITTING PISTON RINGS
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 inch.) from bottom
of cylinder bore. Check gap with feeler gauge (Fig. 7).
Refer to Piston Ring Specification Chart.
(2) Check piston ring to groove clearance: (Fig. 8).
Refer to Piston Ring Specification Chart.
PISTON RINGS—INSTALLATION
(1) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Insure that the No. 2 ring is
installed with manufacturers I.D. mark (dot) facing
up, towards top of the piston (Fig. 9).
CYLINDER BORE AND PISTON SPECIFICATION CHART
ENGINE
STANDARD
CYLINDER BORE
MAXIMUM
OUT-OF-ROUND
MAXIMUM TAPER
STANDARD
PISTON SIZE
3.2L
92.0 mm (3.622 in.)
0.076 mm (0.003
in.)
0.051 mm (0.002
in.)
91.980
6
0.019 mm
(3.6213
6
0.0008 in.)
Piston to Bore Clearance: -0.007 to +0.047 mm (-0.0003 to 0.0018 in.) Measurement taken at Piston Size
location.
Fig. 5 Testing Valve Spring with Tool C-647
Fig. 6 Piston Measurements
Fig. 7 Check Gap on Piston Rings
9 - 68
3.2L ENGINE
LH
DIAGNOSIS AND TESTING (Continued)
CAUTION:
Install piston rings in the following
order:
(2) Oil ring expander.
(3) Upper oil ring side rail.
(4) Lower oil ring side rail.
(5) No. 2 Intermediate piston ring.
(6) No. 1 Upper piston ring.
(7) Install the side rail by placing one end between
the piston ring groove and the expander. Hold end
firmly and press down the portion to be installed
until side rail is in position. Do not use a piston
ring expander during this step (Fig. 10).
(8) Install upper side rail first and then the lower
side rail.
(9) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 11).
(10) Position piston ring end gaps as shown in
(Fig. 12).
(11) Position oil ring expander gap at least 45°
from the side rail gaps but not on the piston pin cen-
ter or on the thrust direction. Staggering ring gap is
important for oil control.
INSTALLATION OF CONNECTING ROD BEARINGS
Fit all rods on one bank until complete.
The bearing caps are not interchangeable and
should be marked at removal to insure correct
assembly.
PISTON RING SPECIFICATION CHART
RING
POSITION
RING GAP
WEAR LIMIT
Upper Ring:
0.20 - 0.36 mm
(0.008 - 0.014
in.)
0.56 mm
(0.0221 in.)
Intermediate
Ring:
0.22 - 0.49 mm
(0.087 - 0.0193
in.)
0.8 mm (0.031
in.)
Oil Control
Ring:
0.25 - 0.76 mm
(0.010 - 0.030
in.)
1.0 mm (0.039
in.)
RING
POSITION
GROOVE
CLEARANCE
MAXIMUM
CLEARANCE
Upper Ring:
0.04 - 0.08 mm
(0.0016 -
0.0031 in.)
0.10 mm (0.004
in.)
Intermediate
Ring:
0.04 - 0.08 mm
(0.0016 -
0.0031 in.)
0.10 mm (0.004
in.)
Oil Control
Ring-Three
Piece:
0.038 - 0.184
mm (0.0015 -
0.0073 in.)
0.211 mm
(0.0084 in.)
Fig. 8 Measuring Piston Ring Side Clearance
Fig. 9 Piston Ring—Installation
Fig. 10 Side Rail—Installation
LH
3.2L ENGINE
9 - 69
SERVICE PROCEDURES (Continued)
The bearing shells must be installed with the
tangs inserted into the machined grooves in the rods
and caps. Install cap with the tangs on the same side
as the rod.
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 in.).
Bearings are available in 0.025 mm (0.001 in.), 0.076
mm (0.003 in.), and 0.254 mm (0.010 in.) undersize.
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.
(1) Follow procedure specified in the Standard Ser-
vice Procedure Section for Measuring Main Bearing
Clearance and Connecting Rod Bearing Clearance
(Fig. 13). Refer to Connecting Rod Bearing Oil Clear-
ance Chart for specifications.
NOTE: The rod bearing bolts should be examined
before reuse. If the threads are necked down the
bolts should be replaced (Fig. 14).
(2) Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
(3) Before installing the nuts the threads should
be oiled with engine oil.
(4) Install nuts on each bolt finger tight then alter-
nately torque each nut to assemble the cap properly.
(5) Tighten the nuts to 54 N·m PLUS 1/4 turn (40
ft. lbs. PLUS 1/4 turn).
(6) Using a feeler gauge, check connecting rod side
clearance (Fig. 15). Refer to Connecting Rod Side
Clearance Chart for specifications.
Fig. 11 Upper and Intermediate Rings—Installation
Fig. 12 Piston Ring End Gap Position
Fig. 13 Checking Connecting Rod Bearing
Clearance—Typical
CONNECTING ROD BEARING OIL CLEARANCE
CHART
New Part:
0.019 to 0.087 mm
(0.0008 to 0.0034 in.)
Wear Limit:
0.095 mm (0.0037 in.)
Fig. 14 Check for Stretched Bolts
9 - 70
3.2L ENGINE
LH
SERVICE PROCEDURES (Continued)
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