Chrysler Town, Dodge Caravan. Manual — part 1095
CRANKSHAFT
DESCRIPTION
The crankshaft is a forged steel type design with
five main bearing journals. The crankshaft is located
at the bottom of the engine block and is held in place
with three main bearing supports (Fig. 34).
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or
flexplate.
STANDARD PROCEDURE - CHECKING
CRANKSHAFT END PLAY
(1) Mount a dial indicator to a stationary point at
rear of engine. Locate the probe perpendicular
against the flywheel (Fig. 35).
(2) Move the crankshaft all the way to the front of
its travel.
(3) Zero the dial indicator.
(4) Move the crankshaft all the way to the rear
and read dial indicator. For crankshaft end play
clearances (Refer to 9 - ENGINE - SPECIFICA-
TIONS) .
Fig. 34 CRANKSHAFT ASSEMBLY TYPICAL
1 - CRANKSHAFT SUPPORT HALVE
2 - MAIN BEARING HALVE
3 - CRANKSHAFT
4 - MAIN BEARING HALVE
5 - CRANKSHAFT SUPPORT HALVE
6 - MAIN BEARING SUPPORT BOLTS
7 - WASHERS
Fig. 35 CHECKING CRANKSHAFT END PLAY
1 - DIAL INDICATOR
2 - ADAPTER PLATE
3 - REAR MAIN BEARING SUPPORT
4 - SEALING RING
5 - SEALING RING
6 - ALIGNMENT PIN
7 - CRANKSHAFT
8 - RELUCTOR WHEEL
9 - RELUCTOR WHEEL RETAINING BOLT
10 - REAR MAIN BEARING SUPPORT RETAINING BOLTS
11 - FLYWHEEL
12 - FLYWHEEL BOLTS
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ENGINE
9 - 33
REMOVAL
(1) Remove engine from vehicle (Refer to 9 -
ENGINE - REMOVAL).
(2) Mount engine on an engine stand.
(3) Drain engine oil and remove oil filter.
(4) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(5) Remove timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
(6) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(7) Remove cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(8) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(9) Remove flywheel.
(10) Remove rear main bearing support/adapter
plate retaining bolts and remove adapter plate (Fig.
36).
(11) Remove rear main bearing support by thread-
ing two retaining bolts in holes provided. Tighten
bolts equally to push main bearing support out of
block (Fig. 37).
(12) Remove front engine cover (Refer to 9 -
ENGINE/ENGINE
BLOCK/ENGINE
COVER
-
REMOVAL).
(13) Remove crankshaft sprocket.
(14) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(15) Remove oil pump pickup tube (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - REMOVAL).
(16) Remove balance shaft assembly (Refer to 9 -
ENGINE/VALVE
TIMING/BALANCE
SHAFT
-
REMOVAL).
(17) Remove oil jets (Refer to 9 - ENGINE/LUBRI-
CATION/OIL JET - REMOVAL).
(18) Remove piston and connecting rod assemblies
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON &
CONNECTING ROD - REMOVAL).
(19) Slide special tool VM.1069 on crankshaft (Fig.
38).
(20) Using special tool VM.1054, remove crank-
shaft support retainers (Fig. 39).
(21) Slide crankshaft out rear of engine block.
INSTALLATION
NOTE: Before installing crankshaft in engine block,
be sure the notches in the crankshaft supports are
facing towards the front of the engine.
Fig. 36 REAR MAIN BEARING SUPPORT
1 - ADAPTER PLATE
2 - REAR MAIN BEARING SUPPORT
3 - CRANKSHAFT
4 - REAR MAIN BEARING SUPPORT RETAINING BOLTS
Fig. 37 REAR MAIN BEARING SUPPORT REMOVAL
1 - BOLTS
2 - REAR MAIN BEARING SUPPORT
3 - CRANKSHAFT
9 - 34
ENGINE
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CRANKSHAFT (Continued)
(1) Install crankshaft in engine block. Be sure to
align oil holes in crankshaft supports and
engine block.
NOTE: Before installing the crankshaft support
retainers/balance shaft oil feed be sure that special
tool VM 1079, alignment pins are installed (Fig. 40).
(2) Install crankshaft support retainers using spe-
cial tool VM 1054. (Fig. 39).
(3) Install crankshaft support retainers O-rings.
(4) Remove special tool VM.1069 from crankshaft
(Fig. 38).
(5) Install crankshaft sprocket.
(6) Install
front
engine
cover
(Refer
to
9
-
ENGINE/ENGINE
BLOCK/ENGINE
COVER
-
INSTALLATION).
(7) Install rear main bearing support in engine
block. Be sure to align oil hole in rear main
bearing support with hole in block.
(8) Install adapter plate and retaining bolts (Fig.
36). Torque bolts to 27.5N·m.
(9) Install flywheel.
(10) Install piston and connecting rod assemblies
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON &
CONNECTING ROD - INSTALLATION).
(11) Install oil jets (Refer to 9 - ENGINE/LUBRI-
CATION/OIL JET - INSTALLATION).
Fig. 38 CRANKSHAFT SLEEVE VM.1069
1 - CRANKSHAFT SLEEVE VM.1069
2 - ENGINE BLOCK
Fig. 39 CRANKSHAFT SUPPORT RETAINERS/
BALANCE SHAFT OIL FEED
1 - CRANKSHAFT SUPPORT RETAINERS/BALANCE SHAFT OIL
FEED
2 - O-RINGS (3)
3 - ENGINE BLOCK
4 - CRANKSHAFT SUPPORT RETAINER/BALANCE SHAFT OIL
FEED REMOVER - INSTALLER VM.1054
Fig. 40 CRANKSHAFT SUPPORT RETAINERS/
BALANCE SHAFT OIL FEED ALIGNMENT PINS
1 - ENGINE BLOCK
2 - ALIGNMENT PINS VM 1079
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ENGINE
9 - 35
CRANKSHAFT (Continued)
(12) Install balance shaft assembly (Refer to 9 -
ENGINE/VALVE
TIMING/BALANCE
SHAFT
-
INSTALLATION).
(13) Install oil pump pickup tube (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - INSTALLA-
TION).
(14) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(15) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(16) Install cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - INSTALLATION).
(17) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(18) Install timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - INSTALLATION).
(19) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(20) Install engine in vehicle.
(21) Fill engine oil with proper oil to correct level.
CYLINDER LINERS
DESCRIPTION
The cylinder wall liner used on this engine is of
the wet design. O-rings are used to seal the liner to
the engine block.
REMOVAL
(1) Remove engine from vehicle.
(2) With engine completely disassembled, use spe-
cial tool VM.1001 to remove liner assembly (Fig. 41).
(3) Tighten bolt on VM.1001 to remove liner from
block (Fig. 42).
(4) Remove shims from cylinder liner or cylinder
block recess. Keep shims with each cylinder liner.
INSPECTION
The cylinder walls should be checked for out-of-
round and taper with a dial bore gauge. The cylinder
bore out-of-round is 0.100 mm (.0039 in.) maximum
and cylinder bore taper is 0.100 mm (.0039 in.) max-
imum. If the cylinder walls are badly scuffed or
scored, new liners should be installed and honed, and
new pistons and rings fitted.
Fig. 41 CYLINDER LINER REMOVER
Fig. 42 CYLINDER LINER REMOVAL
1 - SPECIAL TOOL VM.1001
2 - CYLINDER LINER
3 - ENGINE BLOCK
9 - 36
ENGINE
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CRANKSHAFT (Continued)
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