Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 303
OIL PAN
A formed steel oil pan provides lower engine protec-
tion as well as serving as the engine oil reservoir (Fig.
2). Pan side flanges to block are sealed with gaskets.
The 2.5L engine pickup is unsupported and the lower
end has a box type strainer (Fig. 4).
PRESSURE LUBRICATION
Oil drawn up through the pickup tube is pressurized
by the pump and routed through the full flow filter to
the main oil gallery running the length of the cylinder
block (Fig. 1). Modified oil pickup, pump and check
valve provide increased oil flow to the main oil gallery.
MAIN/ROD BEARINGS
A diagonal hole in each bulkhead feeds oil to each
main bearing. Drilled passages within the crankshaft
route oil from main bearing journals to crankpin jour-
nals (Fig. 1).
ACCESSORY SHAFT
Two separate holes supply oil to the accessory shaft.
BALANCE SHAFTS
For 2.5L engine balance shafts lubrication an addi-
tional hole interconnects with a passage in one leg of
the balance shaft carrier to route oil down to the carrier
oil gallery. This gallery directly supplies the balance
shafts front bearings and internal machined passages
in the shafts routes oil from front to rear shaft bearing
journals.
CAMSHAFT/HYDRAULIC LIFTERS
A vertical hole at the number five bulkhead routes
(through a restrictor) pressurized oil up past a cylinder
head bolt to an oil gallery running the length of the
cylinder head. Hydraulic adjusters are supplied di-
rectly from this gallery while diagonal holes supply oil
to the camshaft journals. The camshaft journals are
partially slotted to allow a predetermined amount of
pressurized oil to pass into the bearing cap cavities
with small holes directed to spray lubricate the cam-
shaft lobes.
SPLASH LUBRICATION
Oil returning to the pan from pressurized compo-
nents supplies lubrication to the valve stems. Cylinder
bores and wrist pins are splash lubricated from di-
rected holes in the connecting rods.
OIL PAN
REMOVAL
(1) Drain engine oil and remove oil pan.
(2) Clean oil pan and all gasket surfaces.
OIL PAN RAIL TO BLOCK SEALING
2.5L engines use side gaskets for rail sealing (Fig. 2).
INSTALLATION
(1) Apply Mopar Silicone Rubber Adhesive Sealant
or equivalent at the front seal retainer parting line
(Fig. 3).
(2) Install the oil pan side gaskets to the block. Use
heavy grease or Mopar Silicone Rubber Adhesive Seal-
ant or equivalent to hold in place.
(3) Apply Mopar Silicone Rubber Adhesive Sealant
or equivalent to ends of new oil pan end seals at
junction of cylinder block pan rail gasket (Fig. 3).
(4) Install pan and tighten screws to 23 N
Im (200 in.
lbs.).
OIL PUMP SERVICE
OIL PICKUP
(1) Remove screw on pump cover holding oil pick-up
tube to oil pump (Fig. 4).
(2) Remove oil pick-up tube. When reinstalling
make sure to use a new O-Ring on pickup tube.
Fig. 3 Sealing, Front and Rear End Seals
Fig. 4 Oil Pick-Up
.
2.5L ENGINE
9 - 43
REMOVAL
(1) Remove two (2) screws holding oil pump to cylin-
der block assembly (Fig. 5).
INSTALLATION
(1) Apply Mopar Gasket Maker to pump body-to-
block interface (machined surface).
(2) Lubricate oil pump rotor & shaft and drive gear.
(3) Turn crankshaft and intermediate shaft until
markings on sprockets are in line (arrows Fig. 6).
(4) Slot in oil pump shaft must be parallel to center
line of crankshaft when intermediate shaft and crank-
shaft are properly timed (Fig. 7).
(5) Install pump full depth and rotate back and forth
slightly to ensure proper positioning and alignment
through full surface contact of pump and block ma-
chined interface surfaces (Fig. 5).
CAUTION: Pump must be held in fully seated position
(described above) while installing screws.
(6) Tighten screws to 23 N
Im (200 in. lbs.).
INSPECTION
(1) Check rotor end clearance with feeler gauge as
shown in (Fig. 8).
(2) Limits:
• 0.03mm (.001 inch) min
• 0.09mm (.0035 inch) max.
(3) Thickness: 23.96mm (.9435 inch) min. Outer Di-
ameter: 62.7mm (2.469 inch) min (Fig. 9).
(4) Install with large chamfered edge in pump body
(Fig. 9).
Clearance: 0.20mm (.008 inch) max. (Fig. 10)
Clearance: 0.35mm (.014 inch) max. (Fig. 11)
Clearance: 0.076mm (.003 inch) max. (Fig. 12)
Oil pressure relief valve spring: Free length: 49.5mm
(1.95 inch). Load: 89 N at 34mm. Load: (20 lbs. at 1.34
inch) (Fig. 13).
Thickness: 23.96mm (.9435 inch) Minimum (Fig. 14).
Fig. 5 Oil Pump Assembly
Fig. 6 Crankshaft and Intermediate Shaft Timing
Fig. 7 Oil Pump Shaft Alignment
9 - 44
2.5L ENGINE
.
Fig. 8 Checking Rotor End Clearance
Fig. 9 Measuring Outer Rotor
Fig. 10 Clearance Between Rotors
Fig. 11 Outer Rotor Clearance
Fig. 12 Oil Pump Cover
.
2.5L ENGINE
9 - 45
CHECKING ENGINE OIL PRESSURE
(1) Remove pressure sending unit and install Spe-
cial Tool S-94 with gauge assembly C-3292 (Fig. 15).
(2) Warm engine at high idle until thermostat opens.
CAUTION: If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM
(3) Oil Pressure: Curb Idle 25 kPa (4 psi) minimum
3000 RPM 170-550 kPa (25-80 psi).
OIL FILTER
ANTI-DRAIN BACK VALVE
Installation: Apply liquid (Teflon Type) sealant to
valve-to-block threads (Fig. 16). Tighten assembly to
55 N
Im (40 ft. lbs.).
FILTER
CAUTION: When servicing the oil filter (Fig. 16) avoid
deforming
the
filter
can
by
installing
the
remove/install tool band strap against the can-to-
base lockseam. The lockseam joining the can to the
base is reinforced by the base plate.
(1) Turn counter clockwise to remove.
(2) To install, lubricate new filter gasket. Check
filter mounting surface. The surface must be smooth,
flat and free of debris or old pieces of rubber. Screw
filter on until gasket contacts base. Tighten to 1 turn.
Fig. 13 Oil Pressure Relief Valve
Fig. 14 Measuring Inner Rotor Thickness
Fig. 15 Checking Oil Pump Pressure—Typical
Fig. 16 Engine Oil Filter and Antidrain Back Valve
9 - 46
2.5L ENGINE
.
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