Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 318
CONNECTING RODS
INSTALLATION OF CONNECTING ROD BEAR-
INGS
Fit all rods on one bank until complete.
The bearing caps are not interchangeable and should
be marked at removal to insure correct assembly.
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 .025mm (.001 inch). Bear-
ings are available in .025mm (.001 inch),.051mm (.002
inch),.076mm (.003 inch),.254mm (.010 inch) and
.305mm (.012 inch) 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. 16).
The rod bearing bolts should be examined be-
fore reuse. If the threads are necked down the
bolts should be replaced (Fig. 19).
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.
(2) Before installing the nuts the threads should be
oiled with engine oil.
(3) Install nuts on each bolt finger tight then alter-
nately torque each nut to assemble the cap properly.
(4) Tighten the nuts to 54 N
Im PLUS 1/4 turn (40 ft.
lbs. PLUS 1/4 turn).
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 17). Refer to (Fig. 18) for specifications.
CRANKSHAFT SERVICE
CRANKSHAFT MAIN BEARINGS
Bearing caps are not interchangeable and should be
marked at removal to insure correct assembly. (Fig. 1)
Upper and lower bearing halves are NOT interchange-
able. Lower main bearing halves of 1, 3 and 4 are
interchangeable. Upper main bearing halves of 1, 3
and 4 are interchangeable.
CRANKSHAFT MAIN JOURNALS
The crankshaft journals should be checked for exces-
sive wear, taper and scoring. (Fig. 6) Limits of taper or
out-of-round on any crankshaft journals should be held
to .025mm (.001 inch). Journal grinding should not
exceed .305mm (.012 inch) under the standard journal
diameter. Do NOT grind thrust faces of Number 2 main
bearing. Do NOT nick crank pin or bearing fillets. After
grinding, remove rough edges from crankshaft oil holes
and clean out all passages.
CAUTION: With the nodular cast iron crankshafts
used it is important that the final paper or cloth polish
after any journal regrind be in the same direction as
normal rotation in the engine.
Upper and lower Number 2 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves in
the engine (Fig. 2). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
before installation. Bearing shells are available in
Fig. 17 Checking Connecting Rod Side Clearance
Fig. 18 Connecting Rod Specifications
Fig. 19 Check for Stretched Rod Bolts
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standard and the following undersizes: 0.025mm (.001
inch), .051mm (.002 inch), .076mm (.003 inch), .254mm
(.010 inch), and .305mm (.012 inch). Never install an
undersize bearing that will reduce clearance below
specifications.
REMOVAL
(1) Remove oil pan and identify bearing caps before
removal.
(2) Remove bearing caps one at a time. Remove
upper half of bearing by inserting Special Main Bear-
ing Tool C-3059. (Fig. 3) into the oil hole of crankshaft.
(3) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
INSTALLATION
Only one main bearing should be selectively
fitted while all other main bearing caps are prop-
erly tightened.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Main Bearing
Tool C-3059 into oil hole of crankshaft (Fig. 3).
(2) Slowly rotate crankshaft counter-clockwise slid-
ing the bearing into position. Remove Special Main
Bearing Tool C-3059.
(3) Install each main cap and tighten bolts finger
tight.
(4) Tighten number 1, 3 and 4 main cap bolts to 41
N
Im + 1/4 Turn (30 ft. lbs.+ 1/4 Turn).
(5) Rotate the crankshaft until number 6 piston is at
TDC.
(6) To ensure correct thrust bearing alignment the
following procedure must be done:
(a) Move crankshaft all the way to the rear of its
travel.
(b) Then, move crankshaft all the way to the front
of its travel.
(c) Wedge a appropriate tool between the rear of
the cylinder block and rear crankshaft counter-
weight. This will hold the crankshaft in it’s most
forward position.
(d) Tighten the #2 Thrust Bearing cap bolts to 41
N
Im + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove the
holding tool.
CHECKING CRANKSHAFT END PLAY
(1) Mount a dial indicator to front of engine, locating
probe on nose of crankshaft (Fig. 4).
(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. 5) for specification.
CRANKSHAFT END PLAY CHECK—OPTIONAL
(1) Move crankshaft all the way to the rear of its
travel using a screwdriver or other lever inserted
between a main bearing cap and a crankshaft cheek us-
Fig. 1 Main Bearing Cap Identification
Fig. 2 Main Bearing Identification
Fig. 3 Removing and Installing Upper Main Bearing
With Special Tool C-3059
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ing care not to damage any bearing surface.Do not-
loosen main bearing cap.
(2) Use a feeler gauge between number 2 thrust
bearing and machined crankshaft surface to determine
end play. Refer to (Fig. 5) for specification.
CRANKSHAFT OIL CLEARANCE
(1) Measure the journal outside diameter as shown
in (Fig. 6). Refer to specification (Fig. 5).
PLASTIGAGE (OIL CLEARANCE) MEASURE-
MENT
(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. 7). Refer to
specification (Fig. 5) for proper clearances. If the clear-
ance exceeds the specified limits. Replace the main
bearing(s) and if necessary have the crankshaft ma-
chined to next undersize. Also see Measuring Main and
Connecting Rod Bearing Clearance in Standard Ser-
vice Procedures.
CAUTION: Do not rotate crankshaft or the Plastigage
may be smeared.
Fig. 4 Checking Crankshaft End Play
Fig. 5 Crankshaft specification
Fig. 6 Measure Crankshaft Journal O.D.
Fig. 7 Measuring Bearing Clearance with Plastigage
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CRANKSHAFT OIL SEALS SERVICE
REMOVAL
Pry out rear seal with screwdriver. Be careful not to
nick or damage crankshaft flange seal surface or re-
tainer bore (Fig. 8).
INSTALLATION
(1) Place Special Seal Pilot Tool C-4681 on crank-
shaft (Fig. 9).
(2) Lightly coat seal O.D. with Loctite Stud N’ Bear-
ing Mount or equivalent.
(3) Place seal over Special Seal Pilot Tool C-4681 and
tap in place with a plastic hammer.
REAR CRANKSHAFT SEAL RETAINER
When retainer removal is required, remove retainer
clean engine block and retainer of old gasket. Make
sure surfaces are clean and free of oil. Install new
gasket and tighten screws to 12 N
Im (105 in. lbs.).
Fig. 9 Installing Rear Crankshaft Oil Seal
Fig. 8 Removing Rear Crankshaft Oil Seal
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