Chrysler New Yorker. Manual — part 241
tion. The pilot tool remains on crankshaft during seal
installation.
(3) Using Special Tool 6926-2 Installer, and C-4171
Handle (Fig. 83), drive seal into the retainer housing
until seal is flush with housing surface.
(4) Install drive plate and transaxle.
CRANKSHAFT OIL SEAL RETAINER—REAR
REMOVAL
(1) Remove crankshaft rear oil seal and oil pan.
Refer to procedure outlined in this section.
(2) Remove seal retainer attaching screws.
(3) Remove seal retainer (Fig. 84).
NOTE: Seal
retainer
gasket
is
bonded
to
the
retainer and must be replaced as an assembly.
INSTALLATION
(1) Clean all sealing surfaces. Replace retainer
assembly if gasket is torn or damaged.
(2) Install seal retainer to block, but do not tighten
attaching screws at this time.
NOTE: The following steps must be performed to
prevent oil leaks at sealing joints.
(3) Attach Special Tools 8225 to pan rail using the
oil pan fasteners.
NOTE: Make sure that the marking “3.2/3.5L” on
Special Tools 8225, is facing towards the cylinder
block pan rail surface (notch on tool is towards the
seal retainer).
(4) While applying firm pressure to the seal
retainer against Special Tools 8225 (Fig. 85), tighten
seal retainer screws to 12 N·m (105 in. lbs.)
(5) Install crankshaft rear oil seal and oil pan.
Refer to procedures outlined in this section.
CRANKSHAFT MAIN BEARINGS
Bearing caps are not interchangeable and are
marked to insure correct assembly (Fig. 86). Upper
and lower bearing halves are NOT interchangeable.
Fig. 82 Rear Crankshaft Oil Seal Removal—Typical
Fig. 83 Crankshaft Rear Seal—Installation
Fig. 84 Oil Seal Retainer
300M
3.5L ENGINE
9 - 47
REMOVAL AND INSTALLATION (Continued)
CRANKSHAFT MAIN JOURNALS
The crankshaft journals should be checked for
excessive wear, taper and scoring. Limits of taper or
out-of-round on any crankshaft journals should be
held to 0.025 mm (0.001 in.). Journal grinding should
not exceed 0.305 mm (0.012 inch.) under the stan-
dard journal diameter. DO NOT grind thrust faces of
Number 2 main bearing. DO NOT nick crank pin or
bearing fillets. After grinding, remove rough edges
from crankshaft oil holes and clean out all passages.
CAUTION:
With a forged steel crankshaft it is
important that the final paper or cloth polish after
any journal regrind be in the same direction as nor-
mal rotation in the engine.
The crankshaft thrust is controlled with thrust
washers located at the upper No. 2 main bearing
bulk head (Fig. 87). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
before installation. Bearing shells are available in
standard and the following undersize: 0.025 mm
(0.001 in.) and 0.254 mm (0.010 in.). Never install an
undersize bearing that will reduce clearance below
specifications.
REMOVAL
(1) Remove oil pan, pick-up tube, and windage
tray. Refer to procedures outlined in this section.
Identify bearing caps before removal.
(2) Remove bearing caps one at a time. Remove
upper half of bearing by inserting Special Main Bear-
ing Tool C-3059 (Fig. 88) into the oil hole of crank-
shaft.
(3) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
INSTALLATION
CAUTION: Main bearings are select fit. Refer to
Crankshaft Main Bearing Fitting in this section for
proper bearing selection.
Fig. 85 Rear Crankshaft Seal Retainer Alignment
Fig. 86 Main Bearing Cap Identification
Fig. 87 Main Bearing Identification
9 - 48
3.5L ENGINE
300M
REMOVAL AND INSTALLATION (Continued)
NOTE:
Only one main bearing should be selec-
tively fitted while all other main bearing caps are
properly tightened.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Lubricate main bearing with clean engine oil.
(2) Start bearing in place, and insert Main Bearing
Tool C-3059 into oil hole of crankshaft (Fig. 88).
(3) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Special Main
Bearing Tool C-3059.
NOTE: Lubricate
main
bearing
cap
bolts
with
engine oil before installation.
(4) Lubricate and install lower bearing half and
main cap Tighten bolts finger tight.
(5) For installing thrust washers at the No. 2 main
bearing location, use the following procedure:
(a)
Move crankshaft forward to limit of travel.
Lubricate and install the front thrust washer by
rolling
the
washer
onto
the
machined
shelf
between the No. 2 upper main bulk head and
crankshaft thrust surface (Fig. 89).
(b) Move crankshaft rearward to limit of travel.
Lubricate and install the rear thrust washer by
rolling
the
washer
onto
the
machined
shelf
between the No. 2 upper main bulk head and
crankshaft thrust surface.
The main bearing cap bolts must be tightened in
the proper sequence. First the inner main cap bolts,
secondly the windage tray bolts, lastly the main cap
tie (horizontal) bolts.
(6) Install each main bearing cap and tighten
inner bolts finger tight.
(7) Tighten inner main bearing cap bolts to 20 N·m
+ 1/4 turn (15 ft. lbs. + 1/4 turn).
(8) Measure crankshaft end play. Refer to Service
Procedures in this section.
(9) Install windage tray. Lubricate bolts with
engine oil and tighten to 27 N·m + 1/4 turn (20 ft.
lbs. + 1/4 turn).
(10) Install the main cap tie (horizontal) bolts and
tighten to 28 N·m (250 in. lbs.).
(11) Install oil pump pick-up tube and oil pan.
(12) Fill engine crankcase with proper oil to cor-
rect level.
OIL FILTER
NOTE:
When servicing the oil filter, avoid deform-
ing the filter can. Install the remove/install tool band
strap against the base lock seam. The lock seam
joining the can to the base is reinforced by the
base plate.
(1) Using Tool C-4065, unscrew filter from base
and discard (Fig. 90).
(2) Wipe base clean, then inspect gasket contact
surface.
(3) Lubricate gasket of new filter with clean
engine oil.
(4) Install and tighten filter to 20 N·m (15 ft. lbs.)
of torque after gasket contacts base. Use filter
wrench if necessary.
(5) Start engine and check for leaks.
OIL PUMP
REMOVAL
It is necessary to remove the oil pan, oil pickup
and oil pump body to service the oil pump rotors. The
oil pump pressure relief valve can be serviced by
removing the oil pan.
(1) Drain cooling system and remove fan module.
Refer to Group 7, Cooling Systems for procedures.
Fig. 88 Removing and Installing Upper Main Bearing
With Special Tool C- 3059
Fig. 89 Thrust Washer Installation
300M
3.5L ENGINE
9 - 49
REMOVAL AND INSTALLATION (Continued)
(2) Remove the accessory drive belts. Refer to
Group 7, Cooling System for procedure.
(3) Remove the crankshaft damper and timing belt
covers. Refer to procedures in this section.
(4) Remove timing belt. Refer to procedure in this
section.
(5) Remove crankshaft sprocket. Refer to Crank-
shaft Oil Seal—Front procedure in this section.
(6) Remove oil pan. Refer to procedure in this sec-
tion.
(7) Remove oil pickup tube.
(8) Remove oil pump fasteners. Remove pump and
gasket from engine (Fig. 91).
INSTALLATION
(1) Prime oil pump before installation by filling
rotor cavity with engine oil.
(2) Install oil pump and gasket carefully over the
crankshaft. Position pump onto block and tighten
bolts to 28 N·m (250 in. lbs.)
(3) Install new O-ring on oil pickup tube.
(4) Install oil pickup tube.
(5) Install oil pan. Refer to procedure in this sec-
tion.
(6) Install crankshaft sprocket. Refer to Crank-
shaft Oil Seal—Front procedure in this section.
(7) Install timing belt. Refer to procedure in this
section.
(8) Install the timing belt covers and crankshaft
damper. Refer to procedures in this section.
(9) Install the accessory drive belts and fan mod-
ule. Refer to Group 7, Cooling System for procedures.
(10) Fill cooling system. Refer to Group 7, Cooling
System for procedure.
PISTON AND CONNECTING ROD
REMOVAL
(1) Remove cylinder heads and oil pan. Refer to
procedures in this section.
(2) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block. Be sure to keep tops of pistons
covered during this operation. Pistons and con-
necting rods must be removed from top of cyl-
inder
block.
When
removing
piston
and
connecting rod assemblies from the engine,
rotate crankshaft so that each connecting rod
is centered in cylinder bore.
(3) Inspect connecting rods and connecting rod
caps for cylinder identification. Identify them if nec-
essary (Fig. 92).
(4) Remove connecting rod cap. Install protectors
on connecting rod bolts (Fig. 93). Push each piston
and rod assembly out of cylinder bore.
NOTE: Be careful not to nick crankshaft journals.
Fig. 90 Oil Filter
Fig. 91 Oil Pump—Removal and Installation
Fig. 92 Identify Connecting Rod to Cylinder
9 - 50
3.5L ENGINE
300M
REMOVAL AND INSTALLATION (Continued)
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