Материал: 92FWD_9

9 - 112 3.3/3.8L ENGINE

Fig. 5 Alignment of Timing Marks

(4)Position oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats (Fig. 6).

(5)Install cover onto crankshaft. Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result.

(6)Install chain case cover screws and torque to 27 Nzm (20 ft. lbs.).

(7)Install crankshaft oil seal (Fig. 7).

(8)Install crankshaft pulley (Fig. 8).

Fig. 6 Timing Chain Case Cover Gaskets and

O-Rings

(9)Install engine bracket (Fig. 2) torque screws to 54 Nzm (40 ft. lbs.).

(10)Install idler pulley on engine bracket.

(11)Install cam sensor Refer to Ignition System Group 8D for installation procedure.

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Fig. 7 Install Crankshaft Oil Seal

Fig. 8 Installing Crankshaft Pulley

(12)Install A/C compressor mounting bracket.

(13)Install A/C compressor.

(14)Install drive belt Refer to Cooling System Group 7 for installation procedure.

(15)Install inner splash shield and wheel.

(16)Install oil pump pick-up and oil pan and transmission inspection cover if removed.

(17)Install engine mount.

(18)Fill crankcase with oil to proper level.

(19)Fill cooling system Refer to Cooling System Group 7 for procedure.

(3)Connect battery.

TIMING CHAIN COVER EXTERNAL OIL SEAL

REMOVAL

(1)Raise vehicle on hoist. Remove right wheel and inner splash shield.

(2)Remove drive belt. (Refer to Cooling System Group 7) for procedure.

(3)Remove crankshaft pulley (Fig. 1).

(4) Using Tool C-4991 to remove oil seal (Fig 9). Be careful not to damage that crankshaft seal surface of cover.

Fig. 9 Removing Crankshaft Oil Seal

INSTALLATION

(1)Install new seal by using Tool C-4992 (Fig. 7).

(2)Place seal into opening with seal spring towards the inside of engine. Install seal until flush with cover.

(3)Install crankshaft pulley using plate L-4524. Thurst Bearing/washer and 5.9 inch screw (Fig. 8).

(4)Install drive belt (Refer to Cooling System Group 7) for installation procedure.

(5)Install inner splash shield and wheel.

CAMSHAFT

REMOVAL−ENGINE REMOVED FROM VEHICLE

Remove intake manifold, cylinder head covers, cylinder heads, timing chain case cover and timing chain.

(1)Remove rocker arm and shaft assemblies.

(2)Remove push rods and tappets; identify so each part will be replaced in its original location.

(3)Remove camshaft thrust plate (Fig 10).

(4)Install a long bolt into front of camshaft to facilitate removal of the camshaft; remove camshaft, being careful not to damage cam bearing with the cam lobes.

INSTALLATION

(1) Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 2 inches of its final position in cylinder block.

Fig. 10 Camshaft Thrust Plate

Fig. 11 Camshaft and Sprocket Assembly

Whenever an engine has been rebuilt or a new camshaft or tappets have been installed, add one pint of Chrysler Crankcase Conditioner or equivalent to engine oil to aid in break in. The oil mixture should be left in engine for a minimum of 805km (500 miles) and drained at the next normal oil change.

(2)Install camshaft thrust plate with two screws as shown in (Fig. 10). Tighten to 12 Nzm (105 in. lbs.) torque.

(3)Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores.

(4)Place timing chain around both sprockets.

(5)Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in camshaft sprocket.

(6)Lift sprockets and chain keep sprockets tight against the chain in position as described.

(7)Slide both sprockets evenly over their respective shafts use a straightedge to check alignment of timing marks (Fig. 12).

(8)Install the camshaft bolt. Tighten bolt to 54 Nzm (40 ft. lbs.).

(9)Rotate crankshaft 2 revolutions. Timing marks should line up. If timing marks do not line up, remove cam sprocket and realign.

(10)Measure camshaft end play. End Play should measure .0127 to .304 mm (.005 to .012 inches.) .310 mm (.012 inch. Max.). If not within limits install a new thrust plate.

(11)Each tappet reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the tappets must be replaced.

Fig. 12 Alignment of Timing Marks

CAMSHAFT BEARINGS−ENGINE REMOVED FROM VEHICLE

REMOVAL

(1)With engine completely disassembled, drive out rear cam bearing core hole plug.

(2)Install proper size adapters and horseshoe washers (part of Tool C-3132-A) at back of each bearing shell to be removed and drive out bearing shells (Fig. 13).

INSTALLATION

(1)Install new camshaft bearings with Tool C-3132-A by sliding the new camshaft bearing shell over proper adapter.

(2)Position rear bearing in the tool. Install horseshoe lock and by reversing removal procedure, carefully drive bearing shell into place.

(3)Install remaining bearings in the same manner. Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing. Number two bearing must index with the oil passage to the left cylinder head and Number three bearing must index with the oil passage to the right cylinder head. If the camshaft bearing shell oil holes are not in exact alignment, remove and reinstall them correctly. Install a new core hole plug at the rear of camshaft. Be sure this plug does not leak.

Fig. 13 Removed Installation of Camshaft Bearings

with Tool C-3132AÐTypical

ENGINE CORE OIL AND CAM PLUGS

REMOVAL

Using a blunt tool such as a drift and a hammer, strike the bottom edge of the cup plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug (Fig. 14).

CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious engine problems.

Fig. 14 Core Hole Plug Removal

INSTALLATION

Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with Loctite Stud N' Bearing Mount or equivalent. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5mm (.020 inch) inside the lead-in chamfer.

It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately.

Fig. 2 Identify Connecting Rod to Cylinder

CYLINDER BLOCK

PISTON−REMOVAL

(1)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. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore.

(2)Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if necessary. (Fig. 2)

(3)Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts (Fig. 3).

Fig. 3 Connecting Rod Protectors

Push each piston and rod assembly out of cylinder bore.

Be careful not to nick crankshaft journals.

(4) After removal, install bearing cap on the mating rod.

CLEANING AND INSPECTION

(1)Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking.

(2)If new core plugs are installed, see Engine Core Oil and Cam Plugs.

(3)Examine block for cracks or fractures.

Fig. 4 Checking Cylinder Bore Size

CYLINDER BORE INSPECTION

The cylinder walls should be checked for out-of- round and taper with Tool C-119 (Fig. 4). If the cylinder walls are badly scuffed or scored, the cylinder block should be rebored and honed, and new pistons and rings fitted. Whatever type of boring equipment is used, boring and honing operation should be closely coordinated with the fitting of pistons and rings in order that specified clearances may be maintained.

Refer to Honing Cylinder Bores outlined in the Standard Service Procedures for specification and procedures.

Measure the cylinder bore at three levels in directions A and B (Fig. 4). Top measurement should be 12mm (.50 inch) down and bottom measurement should be 12mm (.50 inch.) up from bottom of bore. Refer to (Fig. 5) for specifications.

FINISHED PISTONS

All pistons are machined to the same weight in grams, to maintain piston balance. For cylinder bores which have been honed, new pistons and connecting rod assemblies are available for service.

FITTING PISTONS

Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin at size location shown in (Fig. 6). Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in (Fig. 4). Refer to (Fig. 5) for specifications.

Pistons and cylinder bores should be measured at normal room temperature, 70°F. (21°C).

Fig. 5 Cylinder Bore and Piston Specifications

Fig. 6 Piston Measurements

PISTON PINS

The piston pin rotates in the piston only, and is retained by the press interference fit of the piston pin in the connecting rod. The piston pin is not to be removed damage to the piston may result.

FITTING RINGS

(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 12mm (.50 inch) from bottom of cylinder bore. Check gap with feeler gauge (Fig. 7).

Refer to specifications (Fig. 8).

(2)Check piston ring to groove clearance: (Fig. 9). Refer to specification (Fig. 8).

Fig. 7 Check Gap on Piston Rings

Fig. 8 Piston Ring Specifications

Fig. 9 Measuring Piston Ring Side Clearance

PISTON RINGS−INSTALLATION

(1) The No. 1 and No. 2 piston rings have a different cross section. Install rings with manufacturers I.D. mark facing up, to the top of the piston (Fig. 10).

CAUTION: Install piston rings in the following order:

(a)Oil ring expander.

(b)Upper oil ring side rail.

(c)Lower oil ring side rail.

(d)No. 2 Intermediate piston ring.

(e)No. 1 Upper piston ring.

(2)Install the side rail by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander. (Fig. 11).

Fig. 10 Piston Ring Installation

(3)Install upper side rail first and then the lower side rail.

(4)Install No. 2 piston ring and then No. 1 piston ring (Fig. 12).

Fig. 11 Installing Side Rail

(5) Position piston ring end gaps as shown in (Fig. 13).