Chrysler New Yorker. Manual — part 234
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
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). Cylin-
der bores should be measured halfway down the cyl-
inder bore and transverse to the engine crankshaft
center line. Refer to Cylinder Bore and Piston Spec-
ification
Chart.
Pistons
and
cylinder
bores
should be measured at normal room tempera-
ture, 70°F (21°C).
CYLINDER BORE AND PISTON SPECIFICATION CHART
ENGINE
STANDARD CYLINDER
BORE
MAXIMUM
OUT-OF-ROUND
MAXIMUM TAPER
STANDARD PISTON
SIZE
3.5L
96.0 mm
6
0.0076 mm
(3.780 in.
6
0.0003 in.)
0.076 mm
(0.003 in.)
0.051 mm
(0.002 in.)
95.980
6
0.019 mm
(3.7788
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
300M
3.5L ENGINE
9 - 19
DIAGNOSIS AND TESTING (Continued)
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).
Fig. 6 Piston Measurements
Fig. 7 Check Gap on Piston Rings
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:
0.23 - 0.50 mm
(0.0091 - 0.0197 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:
0.035 - 0.085 mm
(0.0014 - 0.0034 in.)
0.10 mm
(0.004 in.)
Intermediate
Ring:
0.035 - 0.085 mm
(0.0014 - 0.0034 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
9 - 20
3.5L ENGINE
300M
SERVICE PROCEDURES (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.
Fig. 9 Piston Ring—Installation
Fig. 10 Side Rail—Installation
Fig. 11 Upper and Intermediate Rings—Installation
Fig. 12 Piston Ring End Gap Position
300M
3.5L ENGINE
9 - 21
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.
CRANKSHAFT MAIN BEARING FITTING
The main bearings are a “select fit” to achieve
proper oil clearances. For main bearing selection, the
block
and
crankshaft
have
grade
identification
marks.
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
Fig. 15 Connecting Rod Side Clearance Measuring
CONNECTING ROD SIDE CLEARANCE CHART
New Part:
0.13 to 0.38 mm
(0.005 to 0.015 in.)
Wear Limit:
0.40 mm (0.0157 in.)
9 - 22
3.5L ENGINE
300M
SERVICE PROCEDURES (Continued)
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