Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 310
PLASTIGAGE MEASUREMENT
(1) Remove oil from journal and bearing shell.
(2) Install crankshaft.
(3) Cut plastigage to same length as width of the
bearing and place it in parallel with the journal axis.
(Fig. 7).
(4) Install the main bearing cap carefully and
tighten the bolts to specified torque.
CAUTION: Do not rotate crankshaft or the plastigage
will be smeared.
(5) Carefully remove the bearing cap and measure
the width of the plastigage at the widest part using the
scale on the plastigage package (Fig. 8). Refer to
specification (Fig. 6) for proper clearances. Also see
Measuring Main and Connecting Rod Bearing Clear-
ance in Standard Service Procedures.
CRANKSHAFT BEARINGS
INSTALLATION
(1) Install upper main bearing shells making certain
oil holes are in alignment, and bearing tabs seat in
block tabs. All upper bearings have oil grooves (Fig. 9).
THRUST BEARINGS. Crankshaft thrust bearings
(washers) are installed at journal #3 separately from
the radial bearings. Thrust bearings shown in (Fig. 9)
are
different,
one
has
end
positioning
tabs,
Fig. 3 Rear Seal Assembly
Fig. 4 Measure Crankshaft Journal O.D.
Fig. 5 Measure Main Bearing I.D.
Fig. 6 Crankshaft Clearance Specification
Fig. 7 Measure Oil Clearance with Plastigage
.
3.0L ENGINE
9 - 71
while the other is plain. One pair of each thrust
washers are installed into the block and one pair into
the main bearing cap (Fig. 9).
(2) Apply a thin film of grease to plain side of thrust
washers and position them on each side of number
three main bearing. Grooved surface towards crank-
shaft.
(3) Oil the bearings and journals and install crank-
shaft.
(4) Install lower main bearing shells without oil
grooves in monoblock cap.
(5) Install one pair of thrust washers in cap. Refer to
Thrust Bearings (Fig. 9).
(6) Carefully install bearing cap with arrows (Fig.
10) toward timing belt end.
(7) Oil the bearing cap bolt threads, install and
tighten bolts progressively in sequence shown in (Fig.
9) to 80 N
Im (60 ft. lbs.) torque.
CHECKING CRANKSHAFT END PLAY
(1) Mount a dial indicator to front of engine, locating
probe on nose of crankshaft (Fig. 11).
(2) Move crankshaft all the way to the rear of its
travel. (3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and read
the dial indicator. Refer to (Fig. 6) for specification.
CRANKSHAFT OIL SEALS SERVICE
REAR CRANKSHAFT SEAL RETAINER
(1) Install rear crankshaft oil seal in housing with
Special Tool MD998718 (Fig. 12).
(2) Apply (Mopar Silicone Rubber Adhesive Sealant
or equivalent) to oil seal housing (Fig. 13) per proce-
dure detailed in form-in-place gasket section in Stan-
dard Service Procedures.
(3) Apply light coating of engine oil to the entire
circumference of oil seal lip.
Fig. 9 Install Main Bearings
Fig. 8 Measuring Clearance
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3.0L ENGINE
.
(4) Install seal assembly on cylinder block and
tighten bolts to 12 N
Im (104 in. lbs.).
FRONT CRANKSHAFT OIL PUMP AND OIL
SEAL
(1) Install oil pump gasket and oil pump case (Figs.
1 and 14).
CAUTION: Install bolts, depending on length in loca-
tions shown in (Fig. 14).
(2) Using front crankshaft oil seal installer Special
Tool MB998306 install oil seal in oil pump (Fig. 15).
CYLINDER BLOCK
Inspect cylinder block for scratches, cracks and rust
or corrosion, and repair or replace as required.
(1) Clean cylinder block and check top surface for
distortion with a straight edge and thickness gauge
(Fig. 16).
(2) Top surface must be flat within:
• Standard Value: 0.05 mm (.002 inch)
Fig. 10 Crankshaft Main Bearing Cap
Fig. 11 Checking Crankshaft End Play
Fig. 12 Install Crankshaft Rear Oil Seal
.
3.0L ENGINE
9 - 73
• Service Limit 0.1 mm (.003 inch)
CAUTION: Maximum of 0.2mm (.008 inch) is permit-
ted. This is a combined total dimension of stock
removal from cylinder head (if any) and block top
surface.
BORING CYLINDER
Examine cylinder walls for scuffs, scoring and mea-
sure cylinder bore for out-of-round or taper. If defec-
tive, bore cylinder to oversize. Measure at points shown
in (Fig. 17).
Four oversize pistons are available (0.25mm (.010
inch) 0.50mm (.020 inch) 0.75mm (.030 inch) and
1.0mm (.039 inch). Determine oversize piston on basis
of largest cylinder bore.
(1) Bore to specified clearance between the piston
O.D. and cylinder. The measuring point of the piston
O.D. is shown in (Fig. 18).
(2) Based on measured piston O.D., calculate boring
finish dimension. Boring finish dimension equals pis-
ton O.D. plus 0.03 to 0.05 mm (.0012 to .002 inch)
(clearance between piston O.D. and cylinder) minus
0.02 mm which is the boring margin.
Fig. 13 Apply Sealant to Oil Seal Housing
Fig. 14 Oil Pump
Fig. 15 Crankshaft Front Oil Seal
Fig. 16 Distortion Check
Fig. 17 Measure Cylinder Bore
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3.0L ENGINE
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