Page 333 of 1216
ENGINE <1.8L Ennine> -Rocker Arms, Rocker Arm Shafts and Camshaft&49
MD9984431
6EN245
IFuel pump
3EN287
r
0
Camheight6EN0184
hl,
3EN153, Oil seal
MD998364
DEN632
SERVICE POINTS OF DISASSEMBLYNWLFM.
9. REMOVAL OF ROCKER ARM AND SHAFT ASSEMBLYBefore removing the rocker arm and shaft assembly, use
the special tool to ensure that the lash adjuster doesn’t fall
out.
Caution
Put the rocker arms and lash adjusters in order in
cylinder No. separated places with clear distinction
between the intake and exhaust ones to prevent
confusion.
INSPECTION
CAMSHAFT
NOBLCDDI
(1) Visually check the camshaft journal surfaces and replace if
damage or seizure is evident.
If the journal is seized, check the cylinder head for possibledamage. Check also for clogged oil holes in the cylinder
head.
(2) Check cams for excessive wear and damage and replace if
defects are evident. Measure the cam height and replace ifthe limit is not reached.
Standard value: 35.91 mm (1.4138 in.)
Limit: 35.41 mm (1.3941 in.)SERVICE POINTS OF
INSTALLATIONNOSLQACa
11. INSTALLATION OF OIL SEAL
(1) Apply engine oil to oil seal lip.
(2) Using the special tool, drive the camshaft oil seal into
the cylinder head.
Page 334 of 1216
S-50 ENGINE 4.8L Engine> -Rocker Arms, Rocker Arm Shafts and Camshaft
MD998443Lash adjuster
6EN248Apply sealant
DEN230
10 mm
3EN0044
9.INSTALLATION OF ROCKER ARM AND SHAFT ASSEM-
BLY(1) Insert the lash adjuster from below as illustrated, being
*-careful not to spill the diesel oil inside it. Then use the
+special tool to prevent adjuster from falling while
installing it.
(2) Place the rocker arm and shaft assembly on the cylinderhead and tighten the bearing cap bolt.
(3) Remove the special tool.
8.APPLICATION OF SEALANT TO SEMI-CIRCULAR PACK-
ING
Apply sealant on the periphery of the semi-circular packing.
Specified sealant: MOPAR Part No.4318034 or equiva-
lent
Page 339 of 1216
ENGINE - Cylinder Head and Valve9-55
3EN026
w -w===j=Margin , EN034
Squareness
IFree length
INSPECTION
CYLINDER HEADNosocAMl Check the cylinder head for cracks, damage and engine
coolant leakage.l
Remove the scale, sealing compound and carbon deposits
completely. After cleaning oil passages, apply compressedair to make certain that the passages are clear.
l Check the cylinder head gasket surface for flatness by
using a straight edge in the direction of A, B, . . . as shown. Ifthe flatness exceeds the limit in any direction, either
resurface or replace the cylinder head.
Flatness of cylinder head gasket surface:
Standard dimension
Limit
Overall height:
Limit
Caution
Less than 0.05 mm (0020 in.)
0.2 mm (008 in.)
88.5 mm (3.484 in.)
88.3 mm (3.478 in.)
If cylinder block gasket surface has already been
ground, thickness of the removed stock should be
included in the grinding limit of -0.2 mm
(-,008 in.).
VALVESNo9PGMa
(1) Check each valve for wear, damage and deformation of
head and stem at
B. Correct or replace excessively worn,
damaged or deformed valves.
(2) If stem tip A is pitted, correct with an oil stone or other
means. The correction must be limited to a minimum. Also
reface the valve.
(3) Replace the valve if the margin has decreased to less than
the limit.
Margin:
Standard dimension
Intake1.0 mm (.039 in.)
Exhaust0.7 mm (028 in.)
Limit
Intake0.7 mm (.028 in.)
Exhaust0.5 mm LO20 in.)
VALVE SPRINGSNOWGh
(1) Check the valve spring for free length and load. If they
exceed the limits, replace the spring.
(2) Using a square, check the squareness of each spring. If thespring is out of square beyond the limit, replace.
Valve spring:
Standard dimension
Free length
49.2 mm (1.937 in.)
Load274.6 N (62 Ibs.) at installed height
Installed height37.3 mm (1.469 in.)
Out of square
Less than 2”
Limit
Free length48.2 mm (1.888 in.)
Installed height38.3 mm (1.516 in.)
Out of square4”
Page 340 of 1216
9-56ENGINE <1.8L Engine> - Cylinder Head and ValveStem O.D.
YEN323
3EN0039
-I
VALVE GUIDESCheck the valve stem-to-guide clearance. If the clearance
exceeds the limit, replace the valve guide with a next higher
7-c.oversize guide.“I
Valve stem-to-guide clearance:
Standard dimension
Intake0.03-0.06 mm (.0012-.0024 in.)
Exhaust0.05-0.08 mm (.0020-.0035 in.)
Limit
Intake0.10 mm (004 in.)
Exhaust0.15 mm (.006 in.)
Valve Guide OversizesSize mm
(in.)0.05
l.002) OS.0.25
LOlO) OS.
0.50
i.020) OS.
Size markValve guide fitting holediameter mm (in.)
513.05-13.068(.5138-.5145)
2513.25-13.268(.5216-.5244)
5015.5-13.518(.5315-.5323)
SERVICE POINTS OF REASSEMBLY
15./ 13. INSTALLATION OF VALVE STE,M SEAL/l6./14.
VALVE SPRING SEAT
Install the spring seat, then using the special tool, install the-stem seal by lightly tapping the tool. Seal is installed in
-dspecified position using the special tool.
Caution
1. Incorrect installation of the seal without using the
special tool will result in poor sealing and cause oil
leakage down valve guide.
2. Do not reuse stem seal.
12.18. INSTALLATION OF EXHAUST, INTAKE VALVEApply engine oil to each valve. Insert valves into the valve
guides. Avoid inserting the valve into the seal with force.
After insertion, check to see if the valve moves smoothly.PL
Page 342 of 1216
9-58ENGINE <1.8L Engine> -Front Case, Oil Pump and Silent Shaft
FRONT CASE, OIL PUMP AND SILENT SHAFTrl
L
I1
26:
25
15-18 Nm
11-13 ftlbs.DISASSEMBLY AND REASSEMBLY8-12 Nm
6.0-8.5 ft.lbs.15-22 Nm11-15 ft.lbs.
Disassembly steps
l +1. Oil filter~~ l +2. Oil pressure switch
3. Oil pressure gauge unit4. Oil filter bracket
5. Gasket
6. Drain plug
7. Drain plug gasket
+e*+ 8. Oil pan
9. Oil screen10. Oil screen gasket
11. Oil pump cover18-25
Nm/13-18 ftlbs.
8-8 Nm
4-8 ft.lbs.
l + 12. Oil pump oil seall + 13. Oil pump gasket
~~ l + 14. Flange boltI)+ 15. Oil pump driven geare+ 16. Oil pump drive gear
+e l + 17. Front case18. Plug
19. Relief spring20. Relief plunger
l + 21.Silent shaft oil seal
l + 22.Crankshaft front oil seal
35-45 Nm25-33 ftlbs.23.
Front case gasket
24. Silent shaft, right
25. Silent shaft, left
4* l + 26.Silent shaft front bearing~~ l + 27.Silent shaft rear bearing
i=G.NogRF-A.r
3EN0088
NOTE(1) Reverse the disassembly procedures to reassemble.(2) +e : Refer to “Service Points of Disassembly”.(3) l + : Refer to “Service Points of Reassembly”.(4) 0 : Non-reusable parts
Page 343 of 1216
7Luooo5ENGINE
-Front Case, Oil Pump and Silent Shaft9-59SERVICE POINTS OF DISASSEMBLY
Nom&
2. REMOVAL OF PRESSURE SWITCH(1) Disconnect the oil pressure switch terminal.
(2) Using the special tool, remove the oil pressure switch.
Caution
Sealant is coated on the threaded part, so be careful
not to damage when removing.
MD9982823EN041
8. REMOVAL OF OIL PAN
(1) Remove the all oil pan bolts.
(2) Drive in the special tool between the cylinder block and
oil pan.
NOTE
Never use a screwdriver or chisel, instead of the special
tool, as a deformed oil pan flange will result, resulting inoil leakage.
14. REMOVAL OF FLANGE BOLTWhen loosening the oil pump driven gear flange bolt, first
insert a Phillips screwdriver [shank diameter 8 mm (32 in.)]into the plug hole on the left side of cylinder block to block
the silent shaft.
17. REMOVAL OF FRONT CASE
The front case may be sticking to the cylinder block. In sucha case, insert a screwdriver into the slot shown in the
illustration and pry up. Never attempt to pry at any other
positions where flange is thinner. Also avoid applying
impact to the front case for removal.
26. REMOVAL OF SILENT SHAFT FRONT BEARINGSUsing the special tool, remove the front bearing from
cylinder block.
Page 344 of 1216
S-60ENGINE <1.8L Engine> -Front Case, Oil Pump and Silent Shaft
3EN040
7LUOOO6
27. REMOVAL OF SILENT SHAFT REAR BEARINGUsing the special tool, remove the rear bearing from
A=cylinder block..i
INSPECTION
SILENT SHAFTNOSRUEl(1) Check oil holes for clogging.
(2) Check journal for seizure, damage, and contact with
bearing. If there is anything wrong with the journal, replace
silent shaft, bearing or front case assembly.
(3) Check the silent shaft oil clearance. If the clearance is
excessively due to wear, replace the silent shaft bearing
silent shaft or front case assembly.
Standard value:
Front
Right
0.030-0.060 mm (.0012-.0024 in.)
LeftO.O20-0.064 mm (.OOOS-.0021 in.)
Rear
Right
Left
0.050-0.091 mm (.0020-.0036 in.) rt
0.050-0.091 mm (.0020-.0036 in.1-4FRONT CASE
(1) Check oil holes for clogging and clean if necessary.
(2) Check left silent shaft front bearing section for wear,
damage and seizure. If there is anything wrong with the
section, replace the front case.
(3) Check the front case for cracks and other damage. Replacecracked or damaged front case.
OIL SEALNOORCMAO
(1) Check the oil seal lip for wear and damage. Replace oil sealif
necessan/.(2) Check the oil seal lip for deterioration. Replace oil seal if
necessary.
OIL PRESSURE SWITCH
(1) Connect a tester (ohm range) between the terminal and thebody and check for conductivity. If there is no conductivity,
replace the switch.
Page 345 of 1216
ENGINE <1.8L Engine> -Front Case, Oil Pump and Silent Shaft9-61
Fine
7LUOOO7
3LUOOOl
3LUOOO2
I
1(2) Next insert a very fine wedge through the oil hole, pushing
it slightly. There should be no conductivity (resistance
should be infinite). If there is conductivity even when
wedge is pushed, replace the switch.
(3) Or, if there is no conductivity when a 50
kPa (71 psi)
pressure is placed through the oil hole, the switch is
operating properly. Check at this time to see that there is
no air pressure leakage. If there is air pressure leakage, thediaphragm is broken, and the switch should be replaced.
OIL PUMPNomcGH
(1)Install the oil pump gears in the front case and check the tipclearance of each gear using a thickness gauge.
Standard value:
Drive gear
0.06-0.12 mm (.0024-.0047 in.)
Driven gear0.04-0.12 mm (.0039-.0079 in.)
Limit:
Drive gear0.20 mm (.079 in.)
Driven gear0.18 mm (.071 in.)
NOTECheck the tip clearance of each gear at position indicated
by an arrow.
(2) Check the side clearance of each gear.
Standard value:
Drive gear
0.10-0.16 mm (.0039-.0063 in.)
Driven gear0.02-0.05 mm (.0008-.0020 in.)
Limit:Drive gear0.20 mm (308 in.)
Driven gear0.15 mm (AI66 in.)(3) Check for ridge wear on the surface of the oil pump cover
that are in contact with the pump gear side.
