Standard Procedure - Measuring Piston Protrusion - Dodge Sprinter 2006 Manual

VA
Distance between middle
connecting rod bore to
connecting rod bushing
bore
Allowable out-of-round-
ness and taper of basic
bore
Allowable twist of con-
necting rod bearing bore
to connecting rod bush-
ing bore over a length of
100 mm
Allowable variation of
axial parallelism of con-
necting rod bearing bore
to connecting rod bush-
ing bore over a length of
100 mm
Allowable difference in
weight of complete con-
necting rod of an engine
Connecting rod inner
bushing
Connecting rod outer
bushing
Connecting rod basic
bore
Piston pin play in con-
necting rod
Peak-to-Valley height
(Rz) of connecting rod
bushing on inside
Connecting rod bolt
thread
STANDARD PROCEDURE - MEASURING PIS-
TON PROTRUSION
Aft er r epla cin g t h e pist on s/con n ect in g r ods or
m a ch in in g t h e en gin e block con t a ct su r fa ce, it is t h en
n ecessa r y t o m ea su r e t h e pist on pr ot r u sion .
Mea su r e pr ot r u sion bet ween pist on cr own a n d cyl-
in der h ea d con t a ct su r fa ce wit h ou t t h e h ea d ga sket
in st a lled. Th e m ea su r m en t m u st be ca r r ied ou t in
t h e dir ect ion of t h e pist on pin in or der t o elim in a t e
pist on r ock.
(1) Mea su r e pist on pr ot r u sion a t t h e t wo m ea su r-
in g poin t s (a r r ows) (F ig. 39).
P ist on pr ot r u sion wit h n ew cr a n kca se sh ou ld be
0.38 - 0.62 m m .
148.970 mm to 149.030
mm
.020 mm
.100 mm
.045 mm
2g
30.018 to 30.024 mm
32.575 mm to 32.600
mm
32.500 mm to 32.525
mm
.018 mm to.024 mm
5
M8 x 1
Fig. 39 MEASURING PISTON PROTRUSION
1 - PISTON PROTRUSION MEASUREMENT
REMOVAL
(1) Discon n ect t h e n ega t ive ba t t er y ca ble.
(2) Rem ove t h e en gin e (Refer t o 9 - E NGINE -
RE MOVAL).
(3) Rem ove t h e cylin der
E NGINE /CYLINDE R H E AD - RE MOVAL).
(4) Rem ove t h e oil pa n (Refer t o 9 - E NGINE /LU-
BRICATION/OIL PAN - RE MOVAL).
(5) P u sh ba ck on t h e ch a in t en sion er a n d r em ove
t h e oil pu m p ch a in fr om t h e oil pu m p.
(6) Rem ove t h e oil pu m p.
NOTE: Mark the connecting rod and connecting rod
bearing cap to each other at the inlet side.
(7) Rem ove t h e con n ect in g r od bea r in g ca p.
NOTE: Do Not mix up the top and bottom connect-
ing rod bearing shells.
(8) Ma r k t h e con n ect in g r od bea r in g sh ell a n d t h e
con n ect in g r od bea r in g ca p t o ea ch ot h er.
ENGINE 9 - 47
h ea d (Refer t o 9 -