Dodge Caliber. Manual — part 1054
ROD-PISTON & CONNECTING
DESCRIPTION
The pistons are made of a cast aluminum alloy. The pistons have pressed-in pins attached to forged connecting
rods. The pistons pin is offset 0.8 mm (0.0314 in.) towards the thrust side of the piston. The connecting rods are a
cracked cap design and are not repairable. The pistons with rings and connecting rods are serviced as an assembly.
STANDARD PROCEDURE
PISTON TO CYLINDER BORE FITTING
NOTE: Pistons and cylinder bores should be mea-
sured at normal room temperature, 21°C (70°F).
Piston and cylinder wall must be clean and dry. Piston
diameter should be measured 90 degrees to piston
pin (1).
1. Measurement should be taken approximately 16
mm (0.629 in.) from the bottom of the skirt (2) as
shown in.
NOTE: Correct piston to bore clearance must be
established in order to assure quiet and economi-
cal operation.
2. Cylinder bores should be measured halfway down
the cylinder bore and transverse (measurement
location B) to the engine crankshaft center line
shown in. Refer to for Engine Specifications (Refer
to 9 - ENGINE - SPECIFICATIONS).
REMOVAL
NOTE: Pistons, rings, and rods are serviced as an assembly.
CAUTION: All four piston/rod assemblies must be replaced as a set or engine damage may result.
1. Remove engine (Refer to 9 - ENGINE - REMOVAL).
2. Separate engine from transaxle.
3. Remove cylinder head (Refer to 9 - ENGINE/CYLINDER HEAD - REMOVAL).
PM
ENGINE 1.8L WORLD
9 - 1503
4. Remove oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
5. Remove balance shaft assembly.
NOTE: Remove any carbon build up prior to piston removal.
6. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be
sure to keep tops of pistons covered during this operation.
7. Rotate crankshaft so that each connecting rod is centered in cylinder bore.
8. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap.
CAUTION: DO NOT use a number stamp or a punch to mark connecting rods, as damage to connecting rod
could occur.
CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage
many occur.
9. Remove connecting rod bolts and cap.
NOTE: Do not reuse connecting rod bolts.
10. Carefully push each piston and rod assembly out of cylinder bore. Re-install bearing cap on the mating rod.
11. Repeat procedure for each piston and connecting rod assembly.
INSTALLATION
1. Install piston rings on piston (Refer to 9 - ENGINE/
ENGINE BLOCK/PISTON RINGS - INSTALLA-
TION).
2. Before
installing
pistons
and
connecting
rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line
with oil ring rail gap.
3. Before installing the ring compressor, make sure
the oil ring expander ends are butted and the rail
gaps located as shown above. As viewed from the
top of the piston.
4. Immerse the piston head and rings in clean engine
oil, slide the ring compressor, over the piston. Be
sure position of rings does not change during
this operation.
5. The directional arrow stamped on the piston should face toward the front of the engine.
6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate connecting
rod journal with clean engine oil.
NOTE: There are three different size rod bearings, perform rod bearing selection procedure.
7. The rod bearing sizes are indicated on the nose of the crankshaft.
8. Install connecting rod upper bearing half into connecting rod.
9. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into posi-
tion on connecting rod journal.
NOTE: The connecting rod cap bolts should NOT be reused.
10. Before installing the NEW bolts, the threads should be coated with clean engine oil.
11. Install connecting rod lower bearing half into connecting rod cap. Install connecting rod cap.
12. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly.
13. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values:
9 - 1504
ENGINE 1.8L WORLD
PM
CAUTION: Do not use a torque wrench for the second step.
1. Tighten the bolts to 27 N·m (20 ft. lbs.).
2. Tighten the connecting rod bolts an additional 1/4 TURN.
14. Using a feeler gauge, check connecting rod side clearance. (Refer to 9 - ENGINE - SPECIFICATIONS) for
connecting rod side clearance.
15. Install the ladder frame.
16. Install oil pump/Balance Shaft Carrier Assembly
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT CARRIER - INSTALLATION).
17. Install oil pan (Refer to 9 - ENGINE/LUBRICA-
TION/OIL PAN - INSTALLATION).
18. Install cylinder head (Refer to 9 - ENGINE/CYLIN-
DER HEAD - INSTALLATION).
PM
ENGINE 1.8L WORLD
9 - 1505
BEARINGS-CRANKSHAFT MAIN
STANDARD PROCEDURE - MAIN BEARING SELECTION
NOTE: There are three different possibilities for the upper main bearings and five different lower main bear-
ings. The upper and lower bearing shells are not interchangeable.
The lower main bearing identification is stamped in the nose of the crankshaft (1). There are 5 different bearing
sizes available 0 through 4.
CRANKSHAFT IDENTIFICATION
LOWER CRANKSHAFT BEARING SELECTION
JOURNAL DIAMETER
GRADE
DIMENSION
LOWER MAIN BEARING
SIZE CLASSIFICATION
LOWER MAIN BEARING
DIMENSION
0
52 mm
0 (Pink or Red)
2 mm
1
52 mm
1 (Black)
2 mm
2
52 mm
2 (No Color)
2 mm
3
52 mm
3 (Green)
2 mm
4
52 mm
4 (Blue)
2 mm
The upper main bearing shell identification is located in the middle of cylinder block on the right side of the engine
when viewing from the flywheel. There are three different size bearings available.
UPPER MAIN BEARING SELECTION
CYLINDER BLOCK IDENTIFICATION
UPPER CRANKSHAFT BEARING SELECTION
MAIN BEARING GRADE
DIMENSION
UPPER MAIN BEARING
SIZE CLASSIFICATION
UPPER MAIN BEARING
DIMENSION
1
56 mm
1 (Black)
2 mm
2
56 mm
2 (No Color)
2 mm
3
56 mm
3 (Green)
2 mm
9 - 1506
ENGINE 1.8L WORLD
PM
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст