Chrysler New Yorker. Manual — part 214
PISTON AND CONNECTING ROD—
INSTALLATION
(1) Before installing piston and connecting rod
assemblies into the bore, ensure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 83).
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor over the piston
and tighten with the special wrench. Ensure posi-
tion of rings does not change during this oper-
ation.
CAUTION: Ensure the hole in bearing half aligns
with hole in connecting rod, as damage to engine
may occur.
(4) Position bearing onto connecting rod. Ensure
that hole in bearing half is aligned to hole in con-
necting rod. Lubricate bearing surface with clean
engine oil.
(5) Install Special Tools 8189 Connecting Rod
Guides into connecting rod (Fig. 79).
(6) The pistons are marked on top with an arrow
and with an “F” (Front) above the pin boss. These
marks must be pointing toward the front of engine
on both cylinder banks. The connecting rod oil squirt
Fig. 81 Side Rail—Installation
Fig. 82 Upper and Intermediate Rings—Installation
Fig. 83 Piston Ring End Gap Position
Fig. 84 Piston and Connecting Rod—Installation
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2.7L ENGINE
9 - 51
REMOVAL AND INSTALLATION (Continued)
hole faces the major thrust (right) side of the block
(Fig. 85).
(7) 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 (Fig. 84).
CAUTION: Do Not interchange piston assemblies
bank to bank, as engine damage may occur.
(8) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(9) Lubricate rod bolts and bearing surface with
engine oil. Install connecting rod cap and bearing.
Tighten bolts to 27 N·m (20 ft. lbs.) Plus 1/4 turn.
ENGINE CORE AND OIL PLUGS
REMOVAL
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 86).
CAUTION:
Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
Fig. 85 Piston and Connecting Rod Positioning
Fig. 86 Core Hole Plug Removal
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2.7L ENGINE
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopar
t
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 inch.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
DISASSEMBLY AND ASSEMBLY
OIL PUMP
(1) Remove the pressure relief valve by remove the
threaded retaining cap from the oil pump housing.
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 87) or engine damage
may occur.
(2) Remove spring and relief valve.
(3) Remove oil pump cover screws and lift off cover
plate (Fig. 88).
(4) Remove pump rotors.
(5) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
(6) Tighten cover screws to 12 N·m (105 in. lbs.)
(Fig. 88). Tighten oil pressure relief valve retaining
cap to 12 N·m (105 in. lbs.) (Fig. 87).
CLEANING AND INSPECTION
CYLINDER HEAD
CLEANING
(1) Use a gasket removal compound to soften the
old gasket material.
CAUTION:
When cleaning the cylinder head and
block mating surfaces, do not use a metal scraper
because the sealing surfaces could be cut or
ground. Instead, use a wooden or plastic scraper.
(2) Make sure the gasket and/or foreign material
does not enter the oil feed hole or the oil return
holes.
INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 89).
(4) Cylinder head must be flat within:
• Standard dimension = less than 0.05 mm (0.002
inch.)
• Service Limit = 0.2 mm (0.008 inch.)
• Grinding Limit = Maximum of 0.2 mm (0.008
inch.) is permitted.
CAUTION:
0.20 mm (0.008 in.) MAX is a combined
total dimension of the stock removal limit from cyl-
inder head and block top surface (Deck) together.
Fig. 87 Oil Pressure Relief Valve
Fig. 88 Oil Pump
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2.7L ENGINE
9 - 53
REMOVAL AND INSTALLATION (Continued)
CAMSHAFT FOLLOWER
Inspect the cam follower assembly for wear or
damage (Fig. 90). Replace as necessary.
VALVE INSPECTION
(1) Clean valves thoroughly and replace burned,
warped and cracked valves.
(2) Measure valve stems for wear (Fig. 91). Refer
to Valve Specification.
NOTE: Valve stems are chrome plated and should
not be polished (Fig. 91).
(3) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
CHECKING VALVE GUIDES
(1) Measure valve stem-to-guide clearance as fol-
lows:
(2) Install valve into cylinder head so it is 15 mm
(0.590 inch.) off the valve seat. A small piece of hose
may be used to hold valve in place.
(3) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 92).
(4) Move valve to and from the indicator. Refer to
Valve Guide Specification Chart.
VALVE GUIDES
NOTE:
Replace cylinder head if stem-to-guide
clearance exceeds specifications, or if guide is
loose in cylinder head.
OIL PUMP
INSPECTION AND REPAIR
(1) Clean all parts thoroughly. Mating surface of
the oil pump housing should be smooth. Replace
pump cover if scratched or grooved.
(2) Lay a straightedge across the pump cover sur-
face (Fig. 93). If a 0.025 mm (0.001 inch.) feeler
gauge can be inserted between cover and straight
edge, cover should be replaced.
Fig. 89 Checking Cylinder Head Flatness—Typical
Fig. 90 Cam Follower Assembly
Fig. 91 Intake and Exhaust Valves
Fig. 92 Measuring Valve Guide Wear—Typical
VALVE GUIDE SPECIFICATION CHART
Valve Guide Dial
Indicator Reading
(Maximum).
Intake Valve
Exhaust Valve
0.290 mm
(0.0114 in.)
0.370 mm
(0.0146 in.)
9 - 54
2.7L ENGINE
LH
CLEANING AND INSPECTION (Continued)
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