check oil CHRYSLER CARAVAN 2002 Owners Manual
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Page 1344 of 2399
INSTALLATION
(1) Clean relief valve, spring and bore.
NOTE: Lubricate relief valve with clean engine oil
before installing.
(2) Install relief valve and spring into housing.
(3) Install new retainer cap until flush with seal-
ing surface.
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Fill crankcase with proper oil to correct level.
OIL PRESSURE SWITCH
DESCRIPTION
The engine oil pressure switch is located on the
lower left front side of the engine. It screws into the
oil filter adapter. The normally closed switch provides
an input through a single wire to the low pressure
indicator light on the instrument cluster.
OPERATION
The oil pressure switch provides a ground for the
instrument cluster low oil pressure indicator light.
The switch receives oil pressure input from the
engine main oil gallery. When engine oil pressure is
greater than 27.5 Kpa (4 psi), the switch contacts
open, providing a open circuit to the low pressure
indicator light. For wiring circuits and diagnostic
information, (Refer to Appropriate Wiring/Diagnostic
Information).
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect electrical connector from switch.
(3) Remove oil pressure switch (Fig. 110).
INSTALLATION
(1) Install oil pressure switch. Torque oil pressure
switch to 23 N´m (200 in. lbs.) (Fig. 110).
(2) Connect electrical connector to switch.
(3) Lower the vehicle.
(4) Start engine and check for leaks.
(5) Check engine oil level. Adjust as necessary.
OIL PUMP
DESCRIPTION
The oil pump is located in the timing chain cover.
It is driven by the crankshaft.
REMOVAL
The oil pump is contained within the timing chain
cover housing (Fig. 111).
(1) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(2) Remove the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(3) Disassemble oil pump from timing chain cover.
(Refer to 9 - ENGINE/LUBRICATION/OIL PUMP -
DISASSEMBLY)
(4) Clean and Inspect oil pump components. (Refer
to 9 - ENGINE/LUBRICATION/OIL PUMP - CLEAN-
ING) (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - INSPECTION)
Fig. 110 OIL FILTER ADAPTER
1 - SEAL
2 - OIL FILTER ADAPTER
3 - OIL FILTER
4 - BOLT
5 - OIL PRESSURE SWITCH
6 - BOLT
RSENGINE 3.3/3.8L9 - 143
OIL PRESSURE RELIEF VALVE (Continued)
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Page 1345 of 2399
DISASSEMBLY
(1) Remove oil pump cover screws, and lift off
cover (Fig. 111).
(2) Remove oil pump rotors (Fig. 111).
(3) Clean and inspect oil pump components. (Refer
to 9 - ENGINE/LUBRICATION/OIL PUMP - CLEAN-
ING) (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - INSPECTION)
CLEANING
(1) Clean all parts thoroughly in a suitable sol-
vent.
INSPECTION
(1) Inspect mating surface of the chain case cover.
Surface should be smooth. Replace cover if scratched
or grooved.
(2) Lay a straightedge across the pump cover sur-
face (Fig. 112). If a 0.025 mm (0.001 in.) feeler gauge
can be inserted between cover and straight edge,
cover should be replaced.
(3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 7.64 mm (0.301 in.)
or less (Fig. 113), or if the diameter is 79.95 mm
(3.148 in.) or less, replace outer rotor.
(4) If inner rotor thickness measures 7.64 mm
(0.301 in.) or less, replace inner rotor (Fig. 114).
(5) Install outer rotor into chain case cover. Press
rotor to one side with fingers and measure clearance
between rotor and chain case cover (Fig. 115). If mea-
surement is 0.39 mm (0.015 in.) or more, replace
chain case cover, only if outer rotor is in specification.
(6) Install inner rotor into chain case cover. If
clearance between inner and outer rotors (Fig. 116) is
0.203 mm (0.008 in.) or more, replace both rotors.
(7) Place a straightedge across the face of the
chain case cover, between bolt holes. If a feeler gauge
of 0.10 mm (0.004 in.) or more can be inserted
between rotors and the straightedge, replace pump
assembly (Fig. 117).ONLYif rotors are in specs.
Fig. 111 OIL PUMP
1 - TIMING CHAIN COVER
2 - SCREWS
3 - INNER ROTOR
4 - OUTER ROTOR
5 - COVER
Fig. 112 Checking Oil Pump Cover Flatness
1 - FEELER GAUGE
2 - OIL PUMP COVER
3 - STRAIGHT EDGE
9 - 144 ENGINE 3.3/3.8LRS
OIL PUMP (Continued)
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Page 1351 of 2399
(11) Install air cleaner and air inlet hose assembly.
(12) Connect the inlet air temperature (IAT) sen-
sor electrical connector.
(13) Connect battery negative cable.
INTAKE MANIFOLD - LOWER
REMOVAL - LOWER INTAKE MANIFOLD
(1) Perform fuel system pressure release procedure
(before attempting any repairs).(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(3) Remove the upper intake manifold. (Refer to 9
- ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
(4) Remove the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL LINES - STANDARD
PROCEDURE) (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE)
(5) Remove ignition coil and bracket (Fig. 125).
(6) Disconnect heater supply hose and engine cool-
ant temperature sensor (Fig. 126).
(7) Disconnect the fuel injector wire harness.
(8) Remove the fuel injectors and rail assembly
(Fig. 125).
(9) Remove radiator upper hose.
(10) Remove the intake manifold bolts.
(11) Remove lower intake manifold (Fig. 127).
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(12) Remove intake manifold seal retainers screws
(Fig. 127). Remove intake manifold gasket.
(13) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/
INTAKE MANIFOLD - CLEANING)
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
Check for:
²Damage and cracks of each section.
²Clogged water passages in end cross-overs (if
equipped).
²Check for cylinder head mounting surface distor-
tion using a straightedge and thickness gauge. (Refer
to 9 - ENGINE/CYLINDER HEAD - INSPECTION)
INSTALLATION - LOWER INTAKE MANIFOLD
(1) Place a bead (approximately 1/4 in. diameter)
of MopartEngine RTV GEN II onto each of thefour
manifold to cylinder head gasket corners (Fig. 128).
(2) Carefully install the new intake manifold gas-
ket (Fig. 127). Tighten end seal retainer screws to 12
N´m (105 in. lbs.).
(3) Install lower intake manifold (Fig. 127). Install
the bolts and torque to 1 N´m (10 in. lbs.). Then
torque bolts to 22 N´m (200 in. lbs.) in sequence
shown in (Fig. 129). Then torque again to 22 N´m
(200 in. lbs.). After intake manifold is in place,
inspect to make sure seals are in place.
(4) Install the fuel injectors and rail assembly.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL RAIL - INSTALLATION)
(5) Connect fuel injector electrical harness.
Fig. 125 FUEL RAIL AND IGNITION COIL &
BRACKET
1 - FUEL RAIL
2 - BOLT - FUEL RAIL
3 - NUT - IGNITION COIL
4 - BOLT - IGNITION COIL
5 - IGNITION COIL
6 - BRACKET - IGNITION COIL
7 - STUD - IGNITION COIL
8 - SEPARATOR - SPARK PLUG CABLE
9 - BRACKET - SPARK PLUG CABLE SEPARATOR
10 - BOLT - SEPARATOR BRACKET
11 - BRACKET - SPARK PLUG CABLE SEPARATOR
9 - 150 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - UPPER (Continued)
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ENGINE
TABLE OF CONTENTS
page page
ENGINE 2.5L TURBO DIESEL
DESCRIPTION
DESCRIPTION - 2.5L COMMON RAIL
DIESEL ENGINE.......................2
DESCRIPTION - ENGINE COVER..........3
REMOVAL
REMOVAL - 2.5L DIESEL ENGINE..........3
REMOVAL - ENGINE COVER.............6
INSTALLATION
INSTALLATION - 2.5L TURBO DIESEL
ENGINE..............................7
INSTALLATION - ENGINE COVER..........7
SPECIFICATIONS
SPECIFICATIONS - 2.5L COMMON RAIL
DIESEL ENGINE.......................8
SPECIFICATIONS - TORQUE............10
SPECIAL TOOLS.......................12
CYLINDER HEAD
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE
SERVICE............................17
STANDARD PROCEDURE - MEASURING
PISTON PROTRUSION.................18
REMOVAL.............................19
CLEANING............................21
INSPECTION..........................21
INSTALLATION.........................21
CAMSHAFT(S)
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................23
CYLINDER HEAD COVER(S)
DESCRIPTION.........................24
REMOVAL.............................24
INSTALLATION.........................25
CAMSHAFT OIL SEAL(S)
REMOVAL.............................27
INSTALLATION.........................27
ROCKER ARMS
DESCRIPTION.........................27
OPERATION...........................27
REMOVAL.............................27
INSTALLATION.........................28
HYDRAULIC LIFTERS
DESCRIPTION.........................29
REMOVAL.............................29
INSPECTION..........................30
INSTALLATION.........................30ENGINE BLOCK
DESCRIPTION.........................30
CRANKSHAFT
DESCRIPTION.........................30
OPERATION...........................30
STANDARD PROCEDURE - CHECKING
CRANKSHAFT END PLAY...............31
REMOVAL.............................31
INSTALLATION.........................32
CYLINDER LINERS
DESCRIPTION.........................33
REMOVAL.............................33
INSPECTION..........................34
INSTALLATION.........................34
INTERNAL VACUUM PUMP
DESCRIPTION.........................35
REMOVAL.............................35
INSTALLATION.........................35
PISTON & CONNECTING ROD
DESCRIPTION.........................36
STANDARD PROCEDURE - PISTON RING
FITTING.............................36
REMOVAL.............................36
INSPECTION..........................38
INSTALLATION.........................39
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................41
INSTALLATION.........................41
VIBRATION DAMPER
REMOVAL.............................42
INSTALLATION.........................42
ENGINE COVER - FRONT
DESCRIPTION.........................43
REMOVAL.............................43
INSTALLATION.........................43
CRANKSHAFT MAIN BEARINGS
REMOVAL.............................44
INSTALLATION.........................45
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................46
INSTALLATION.........................46
OIL PAN
REMOVAL.............................46
INSTALLATION.........................46
OIL PUMP
REMOVAL
REMOVAL...........................47
REMOVAL...........................47
RGENGINE9a-1
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(17) Remove battery shield.
(18) Remove charge air cooler outlet hose.
(19) Remove charge air cooler inlet hose (Fig. 6).
(20) Disconnect upper radiator hose at engine (Fig.
7).
(21) Disconnect lower radiator hose at engine (Fig.
7).
(22) Disconnet brake booster vacuum supply hose.
(23) Disconnect heater core return hose at engine.
(24) Disconnect egr solenoid vacuum line at brake
booster check valve.
(25) Disconnect fuel injector, cam sensor, boost
pressure/intake air temp sensor, fuel rail high pres-
sure, and egr solenoid connectors (Fig. 8).
(26) Disconnect generator electrical connectors.
(27) Disconnect coolant temp sensor and glow plug
electrical connectors.
(28) Disconnect injection pump and A/C compres-
sor electrical connectors.
(29) Disconnect starter electrical connectors.
(30) Disconnect ground wires at engine block.
(31) Raise vehicle on hoist.
(32) Disconnect oil temp sensor, oil pressure sen-
sor, engine speed sensor, and vehicle speed sensor
electrical connector (Fig. 9).(33) Remove front wheels.
(34) Remove the suspension cradle assembly (Refer
to 13 - FRAME & BUMPERS/FRAME/ENGINE
CRADLE CROSSMEMBER - REMOVAL).
(35) Remove both axle shaft assemblies (Refer to 3
- DIFFERENTIAL & DRIVELINE/HALF SHAFT -
REMOVAL).
(36) Disconnect the clutch slave cylinder quick dis-
connect line (RHD only)(Refer to 6 - CLUTCH/SLAVE
CYLINDER - REMOVAL).
(37) Disconnect reverse lamp connector.
(38) Disconnect shifter cables at the tranmission
(Refer to 21 - TRANSMISSION/TRANSAXLE/MAN-
UAL/GEAR SHIFT CABLE - REMOVAL).
(39) Disconnect exhaust pipe from the turbo-
charger downpipe and reposition to right side of vehi-
cle.
(40) Disconnect cabin heater coolant line (Refer to
24 - HEATING & AIR CONDITIONING/CABIN
HEATER/HEATER UNIT - REMOVAL).
(41) Remove front engine mount bracket retaining
bolts from lower radiator support
(42) Lower vehicle. Evacuate the A/C system
(Refer to 24 - HEATING & AIR CONDITIONING/
Fig. 6 CHARGE AIR COOLER HOSES
1 - COOLING MODULE
2 - BYPASS HOSE
3 - UPPER RADIATOR HOSE
4 - CHARGE AIR COOLER OULET HOSE
5 - CHARGE AIR COOLER INLET HOSE
6 - LOWER RADIATOR HOSE
7 - CHARGE AIR COOLER
Fig. 7 UPPER AND LOWER RADIATOR HOSES
1 - COOLANT BYPASS HOSE
2 - RADIATOR ASSEMBLY
3 - UPPER RADIATOR HOSE
4 - COOLING FAN
5 - LOWER RADIATOR HOSE
6 - CHARGE AIR COOLER
7 - RADIATOR BRACKET
RGENGINE9a-5
ENGINE 2.5L TURBO DIESEL (Continued)
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Page 1382 of 2399
(23) Remove cylinder head assembly from engine
block (Fig. 18).
CLEANING
Thoroughly clean the engine cylinder head and cyl-
inder block mating surfaces. Clean the intake and
exhaust manifold and engine cylinder head mating
surfaces. Remove all gasket material and carbon.
Check to ensure that no coolant or foreign material
has fallen into the tappet bore area.
Remove the carbon deposits from the combustion
chambers and top of the pistons.
INSPECTION
Use a straightedge and feeler gauge to check the
flatness of the engine cylinder head and block mating
surfaces.
The minimum cylinder head thickness is 89.95mm
(3.541 in.).
INSTALLATION
CAUTION: Piston protrusion must be measured to
determine cylinder head gasket thickness if one or
more cylinder liners have been replaced (Refer to 9
- ENGINE/CYLINDER HEAD - STANDARD PROCE-
DURE).
NOTE: If cylinder liner(s) have not been removed,
the same thickness head gasket that was removed
can be used.
(1) Clean and inspect gasket mating surfaces.
(2) Position correct head gasket on engine block.
(3) Place cylinder head on engine block (Fig. 18).
CAUTION: New cylinder head bolts must be used.
(4) Tighten cylinder head bolts following procedure
below.
Cylinder Head Bolt Torquing Procedure
(1) Lubricate cylinder head bolts with engine oil.
(2) Torque bolts to 30N´m in numerical starting
with bolt #1 (Fig. 19).
(3) Tighten all bolts an additional 75É, starting
with bolt #4 then 5-6-7-8-9-10-1-2-3 (Fig. 19).
(4) Tighten all bolts an additional 50É in numerical
order starting with bolt #11 then 12-13-14-15-16-
17-18 (Fig. 19).
(5) Without loosening any bolts tighten all bolts an
additional 75É in the following seguence: 4-5-6-7-8-9-
10-1-2-3-11-12-13-14-15-16-17-18.
Fig. 18 CYLINDER HEAD ASSEMBLY
1 - VALVE SPRING
2 - CYLINDER HEAD BOLT
3 - GLOW PLUG
4 - COOLANT TEMPERATURE SENSOR
5 - CYLINDER HEAD ALIGNMENT DOWEL
6 - CYLINDER BLOCK
7 - CYLINDER LINER
8 - ENGINE BLOCK DECK
9 - CYLINDER HEAD GASKET
10 - CYLINDER HEAD
11 - ROCKER ARM AND LIFTER ASSEMBLY
Fig. 19 CYLINDER HEAD TORQUE SEQUENCE
RGENGINE9a-21
CYLINDER HEAD (Continued)
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Page 1384 of 2399
CAUTION: Before removing the cylinder head cover/
intake manifold or timing belt the engine must put
at 90É after TDC. Failure to do so could result in
valve and/or piston damage during reassembly.
(Refer to 9 - ENGINE/VALVE TIMING - STANDARD
PROCEDURE)
(10) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(11) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(12) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(13) Remove cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(14) With cylinder head cover/intake manifold on
work bench, remove plugs at rear of cylinder head
cover/intake manifold.
(15) Remove camshaft oil seals (Fig. 21).
(16) Remove snapring and thrust washer from
camshaft (Fig. 21).
(17) Slide camshaft through access hole at rear of
cylinder head cover/intake manifold.
INSTALLATION
(1) Lubricate the camshafts with MopartEngine
Oil Supplement, or equivalent.
(2) Carefully install camshafts into access holes in
rear of cylinder head cover/intake manifold.
(3) Install thrust washer, snapring, and camshaft
oil seal (Fig. 21).
CHECKING CAMSHAFT ENDPLAY
(1) After camshafts are properly installed in cylin-
der head cover check end play of camshafts with a
dial indicator. The end play should be between .10
mm ± .30 mm.
NOTE: If the camshaft endplay is not within speci-
fication, measure thickness of the camshaft spacer.
Camshaft spacer thickness should be 2.8 .02mm.
(4) Install access hole plugs and gaskets at rear of
cylinder head cover/intake manifold. Torque plugs to
80N´m.
(5) Install cylinder head cover/intake manifold on
engine block (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION).
(6) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).(7) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(8) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(9) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(10) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(11) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(12) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Install air cleaner housing.
(14) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(15) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(16) Connect negative battery cable.
Fig. 21 CAMSHAFT ASSEMBLY
1 - INTAKE CAMSHAFT
2 - SNAPRING
3 - CAMSHAFT OIL SEAL
4 - THRUST WASHER
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
6 - EXHAUST CAMSHAFT
RGENGINE9a-23
CAMSHAFT(S) (Continued)
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STANDARD PROCEDURE - CHECKING
CRANKSHAFT END PLAY
(1) Mount a dial indicator to a stationary point at
rear of engine. Locate the probe perpendicular
against the flywheel (Fig. 35).
(2) Move the crankshaft all the way to the front of
its travel.
(3) Zero the dial indicator.
(4)
Move the crankshaft all the way to the rear and
read dial indicator. For crankshaft end play clearances
(Refer to 9 - ENGINE - SPECIFICATIONS).
REMOVAL
(1) Remove engine from vehicle (Refer to 9 -
ENGINE - REMOVAL).
(2) Mount engine on an engine stand.
(3) Drain engine oil and remove oil filter.
(4) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(5) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(6) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(7) Remove cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(8) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(9) Remove flywheel.
(10) Remove rear main bearing support/adapter
plate retaining bolts and remove adapter plate (Fig.
36).
Fig. 35 CHECKING CRANKSHAFT END PLAY
1 - DIAL INDICATOR
2 - ADAPTER PLATE
3 - REAR MAIN BEARING SUPPORT
4 - SEALING RING
5 - SEALING RING
6 - ALIGNMENT PIN
7 - CRANKSHAFT
8 - RELUCTOR WHEEL
9 - RELUCTOR WHEEL RETAINING BOLT
10 - REAR MAIN BEARING SUPPORT RETAINING BOLTS
11 - FLYWHEEL
12 - FLYWHEEL BOLTSFig. 36 REAR MAIN BEARING SUPPORT
1 - ADAPTER PLATE
2 - REAR MAIN BEARING SUPPORT
3 - CRANKSHAFT
4 - REAR MAIN BEARING SUPPORT RETAINING BOLTS
RGENGINE9a-31
CRANKSHAFT (Continued)
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Page 1397 of 2399
(10) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(11) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(12) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Install air cleaner housing.
(14) Connect negative battery cable.
PISTON & CONNECTING ROD
DESCRIPTION
The pistons are of a free floating design. Oil jets in
the engine block lubricate and cool the piston and pin
assembly. The connecting rods have a pressed in
place wrist pin bushing which is lubricated by the oil
jets (Fig. 48).
STANDARD PROCEDURE - 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 (Fig. 49). Check gap with feeler gauge.
Top compression ring gap .30 to .45mm (.0118 to
.0177 in.). Second compression ring gap .30 to .45mm(.0118 to .0177 in.). Oil control ring gap .25 to .50mm
(.0098 to .0196 in.).
(2) If ring gaps exceed dimension given, new rings
or cylinder liners must be fitted. Keep piston rings in
piston sets.
(3) Check piston ring to groove clearance (Fig. 50).
Top compression ring gap .080 to .130mm (.0031 to
.0051 in.). Second compression ring gap .070 to
.110mm (.0027 to .0043 in.). Oil control ring gap .040
to .080mm (.0015 to .0031 in.).
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
Fig. 47 VACUUM PUMP COMPONENTS
1 - VACUUM PUMP BODY
2 - VACUUM PUMP BLADE TAPERED EDGE
3 - VACUUM PUMP BLADE
Fig. 48 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN
2 - PISTON
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
6 - CONNECTING ROD BEARING
7 - CONNECTING ROD
8 - SNAP RING
9a - 36 ENGINERG
INTERNAL VACUUM PUMP (Continued)
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Page 1399 of 2399
PISTON RING - REMOVAL
(1) ID mark on face of top and second piston rings
must point toward piston crown.
(2) Using a suitable ring expander, remove top and
second piston rings (Fig. 52).
(3) Remove upper oil ring side rail, lower oil ring
side rail and then the oil 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: 91.912-91.928mm
(3.6185-3.6192 in.) Maximum wear limit .05mm
(.0019 in.).
(2) Check piston pin bores in piston for roundness.
Make 3 checks at 120É 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 0.065-0.083 mm
(.0025-.0032 in.).
(6) Make sure the weight of the pistons does not
differ by more than 5 g.
CONNECTING RODS
(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 connecting cap bolts to 29 N´m (21 ft.
lbs.) plus 60É.
(3) Without loosening connecting rod bolts, tighten
all bolts to 88N´m.(4) Check and record internal diameter of crank
end of connecting rod.
NOTE: When changing connecting rods, all four
must have the same weight and be stamped with
the same number. Replacement connecting rods
will only be supplied in sets of four.
Connecting rods are supplied in sets of four since
they all must be of the same weight category. Max
allowable weight difference is 5 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 injection
pump side of the block (Fig. 53). Lightly heat the
piston in oven. Insert piston pin in position and
secure it with provided snap rings.
The Four digit numbers marked on con rod
big end and rod cap must be on the same side
as the injection pump (Fig. 53).After having
coated threads with Molyguard, tighten con rod bolts
to 29 N´m (21 ft. lbs.) plus 60É.
PISTON PINS
(1) Measure the diameter of piston pin in the cen-
ter and both ends.
(2) Piston pin diameter is 29.992 to 29.996mm
(1.1807 to 1.1809 in.).
Fig. 52 PISTON RINGS - REMOVAL/INSTALLATION
Fig. 53 CONNECTING ROD IDENTIFICATION
1 - SMALL END OF CONNECTING ROD
2 - 2 DIGIT NUMBER LOCATION
3 - 4 DIGIT NUMBER LOCATION
9a - 38 ENGINERG
PISTON & CONNECTING ROD (Continued)
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