Dodge Dakota (R1). Manual — part 531
(10) Install the fan and fan shroud, Torque fan to
56 N·m (41 ft. lbs.).
(11) If equipped, evacuate and charge the air con-
ditioning system. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/REFRIGERANT
-
STANDARD PROCEDURE).
(12) Connect the negative battery cable.
(13) Fill the cooling system. Check for leaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(14) Operate the engine with the radiator cap off.
Inspect for leaks and continue operating the engine
until the thermostat opens. Add coolant, if required.
VIBRATION DAMPER
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the fan and set fan inside fan shroud
then remove fan shroud and fan as an assembly.
(3) Remove the accessary drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(4) Remove the vibration damper nut.
(5) Install special tool VM.1000-A to remove vibra-
tion damper.
INSTALLATION
(1) Install the vibration damper and align with
key way.
(2) Install the vibration damper nut. Torque nut to
196 N·m (147 ft. lbs.).
(3) Install the accessary drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(4) Connect the negative battery cable.
CAMSHAFT BEARINGS
REMOVAL
This procedure requires that the engine is removed
from the vehicle.
(1) With
the
engine
completely
disassembled,
remove camshaft rear plate and o-ring.
(2) Install the proper size adapters and horseshoe
washers (part of Crankshaft Bearing Remover/In-
staller Tool VM-1002) at back of each bearing shell.
Drive out the bearing shells.
INSTALLATION
(1) Install the new camshaft bearings with Cam-
shaft Bearing Remover/Installer Tool C3131–A by
sliding the new camshaft bearing shell over proper
adapter.
(2) Position the rear bearing in the tool. Install
horseshoe lock and by reversing removal procedure,
carefully drive bearing shell into place.
(3) Install the remaining bearings in the same
manner. The Bearings must be carefully aligned
to bring oil holes into full register with oil pas-
sages from the main bearing. If the camshaft
bearing shell oil holes are not in exact align-
ment, remove and install them correctly.
(4)
Install a new rear plate o-ring at the rear of
camshaft. Be sure this seal does not leak.
INTERNAL VACUUM PUMP
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the timing gear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(3) Align all the timing marks before removing the
vacuum pump (Fig. 46).
(4) Remove the vacuum pump retaining bolts.
(5) Remove the internal vacuum pump.
INSTALLATION
(1) To install the vacuum pump, align with timing
marks on gear set and install (Fig. 46). Torque bolts
to 27.5 N·m (20 ft. lbs.).
(2) Install the timing gear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(3) Connect the negative battery cable.
9a - 42
ENGINE 2.5L VM DIESEL INTERNATIONAL
R1
CAMSHAFT (Continued)
PISTON AND CONNECTING
ROD
STANDARD PROCEDURE - MEASURING
PISTON PROTRUSION
(1) Use special tool VM.1010 with dial indicator
special tool VM.1013 (Fig. 47).
(2) Bring the piston of cylinder no. 1 exactly to top
dead center.
(3) Zero the dial indicator on the cylinder block
mating surface.
(4) Setup the dial indicator on the piston crown
(above the center of the piston pin) 5mm (1/8 in.)
from the edge of the piston and note the measure-
ment, see the following chart.
PISTON PROTRUSION CHART
Measured dimension (mm)
0.53-0.62
Cyl. head gasket thickness (mm)
1.41
Piston clearance (mm)
0.80-0.89
Measured dimension (mm)
0.63-0.72
Cyl. head gasket thickness (mm)
1.51
Piston clearance (mm)
0.80-0.89
Measured dimension (mm)
0.73-0.82
Cyl. head gasket thickness (mm)
1.61
Piston clearance (mm)
0.80-0.89
(5) Repeat the procedure with the rest of the cyl-
inders.
(6) Establish the thickness of the steel gasket for
all four cylinder heads on the basis of the greatest
piston protrusion (Fig. 26).
CAUTION: Gaskets are to be installed DRY. DO NOT
use a gasket sealing compound on the gasket.
REMOVAL
PISTONS AND CONNECTING ROD ASSEMBLY
(1) Disconnect the battery cable.
(2) Remove cylinder heads, (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(3) Raise vehicle on host.
(4) Remove oil pan, (Refer to 9 - ENGINE/EN-
GINE BLOCK/WINDAGE TRAY / STRUCT SUP-
PORT - REMOVAL).
(5) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block. Be sure to keep tops of pistons
covered during this operation. Mark piston with
matching cylinder number.
(6) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(7) Remove connecting rod cap. Install connecting
rod bolt protectors on connecting rod bolts. Push each
piston and rod assembly out of cylinder bore.
NOTE: Be careful not to nick crankshaft journals.
(8) After removal, install bearing cap on the mat-
ing rod.
Fig. 46 Timing Marks
1 - VACUUM PUMP
2 - CAMSHAFT
3 - INJECTION PUMP
4 - TIMING MARKS
5 - OIL PUMP
6 - CRANKSHAFT
Fig. 47 Measuring Piston Protrusion
R1
ENGINE 2.5L VM DIESEL INTERNATIONAL
9a - 43
INTERNAL VACUUM PUMP (Continued)
PISTON PIN
(1) Secure connecting rod in a soft jawed vice.
(2) Remove 2 clips securing piston pin.
(3) Push piston pin out of piston and connecting
rod (Fig. 48).
PISTON RING
(1) ID mark on face of upper and intermediate pis-
ton rings must point toward piston crown.
(2) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 49).
(3) Remove the upper oil ring side rail, lower oil
ring side rail and then oil ring expander from piston.
(4) Carefully clean carbon from piston crowns,
skirts and ring grooves ensuring the 4 oil holes in
the oil control ring groove are clear.
INSPECTION
PISTONS
(1) Piston Diameter: Size: 91.93-91.94mm (3.6191-
3.6196 in.) Maximum wear limit .05mm (.0019 in.).
(2) Check piston pin bores in piston for roundness.
Make 3 checks at 120° intervals. Maximum out of
roundness .05mm (.0019in.).
(3) The
piston
diameter
should
be
measured
approximately 15 mm (.590 in.) up from the base.
(4) Skirt wear should not exceed 0.1 mm (.00039
in.).
(5) The clearance between the cylinder liner and
piston should not exceed 0.25 mm (.0009 in.).
(6) Make sure the weight of the pistons does not
differ by more than 5 g.
CONNECTING ROD
(1) Assemble bearing shells and bearing caps to
their respective connecting rods ensuring that the
serrations on the cap and reference marks are
aligned.
(2) Tighten bearing cap bolts to 29N·m (21 ft. lbs.)
plus 60°.
(3) Check and record internal diameter of crank
end of connecting rod.
NOTE: When changing connecting rods, all five
must have the same weight and be stamped with
the same number. Replacement connecting rods
will only be supplied in sets of five.
Connecting rods are supplied in sets of five since
they all must be of the same weight category. Max
allowable weight difference is 18 gr.
NOTE: On one side of the big end of the con-rod
there is a two-digit number which refers to the
weight category. On the other side of the big end
there is a four digit number on both the rod and the
cap. These numbers must both face the camshaft
as well as the recess on the piston crown (Fig. 51).
Lightly heat the piston in oven. Insert piston pin in
position and secure it with provided snap rings.
Fig. 48 Piston Assembly
Fig. 49 Piston Rings—Removing and Installing
9a - 44
ENGINE 2.5L VM DIESEL INTERNATIONAL
R1
PISTON AND CONNECTING ROD (Continued)
The Four digit numbers marked on con rod
big end and rod cap must be on the same side
as the camshaft (Fig. 50) (Fig. 51). After having
coated threads with Molyguard, tighten con rod bolts
to 29 N·m (21 ft. lbs.) plus 60°.
PISTON PIN
(1) Measure the diameter of piston pin in the cen-
ter and both ends.
(2) Piston pin diameter is 29.990 to 29.996mm
(1.1807 to 1.1809 in.).
CRANKSHAFT JOURNALS
(1) Using a micrometer, measure and record crank-
shaft connecting rod journals, take reading of each
journal 120° apart. Crankshaft journal diameter is
53.84 to 53.955mm (2.1196 to 2.1242 in.).
(2) Crankshaft journals worn beyond limits or
show signs of out of roundness must be reground or
replaced. Minimum reground diameter is 53.69mm
(2.1137 in.).
BEARING-TO-JOURNAL CLEARANCE
Compare internal diameters of connecting rod with
crankshaft journal diameter. Maximum clearance
between connecting rod and crankshaft journals .022
to .076mm (.0008 to .0029 in.) (Fig. 52).
INSTALLATION
PISTON RING FITTING
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 in.) from bottom of
cylinder bore. Check gap with feeler gauge. Top com-
pression ring gap .25 to .50mm (.0098 to .0196 in.).
Second compression ring gap .25 to .35mm (.0098 to
.0137 in.). Oil control ring gap .25 to .58mm (.0098 to
.0228 in.) (Fig. 53).
Fig. 50 Connecting Rod Identification
1 - CAMSHAFT SIDE
2 - 2–DIGIT NUMBER FOR WEIGHT CATEGORY
3 - 4–DIGIT REFERENCE NUMBERS FOR CORRECT
ASSEMBLING
Fig. 51 Piston and Connecting Rod Assembly
Fig. 52 Bearing Clearance
R1
ENGINE 2.5L VM DIESEL INTERNATIONAL
9a - 45
PISTON AND CONNECTING ROD (Continued)
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