Dodge ZB 2005 Service Manual page 723

9 - 62 ENGINE
CONNECTING ROD BEARINGS (Continued)
The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and
caps.
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.013 mm (0.0005 in.).
Bearings are available in 0.025 mm (0.001 in.), 0.051
mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 mm
(0.010 in.) and 0.305 mm (0.012 in.) undersize.
Install the bearings in pairs. Do not use a new
bearing half with an old bearing half. Do not
file the rods or bearing caps.
(1) (Refer to 9 - ENGINE/ENGINE BLOCK/CON-
NECTING ROD BEARINGS - STANDARD PROCE-
DURE) - Measuring
Clearance to determine bearing clearance.
(2) Before installing the connecting rod cap bolts,
the bolt threads should be oiled with engine oil.
(3) Install bolts finger tight, then alternately
torque each bolt to assemble the cap properly.
(4) Tighten the connecting rod bolts to 68 N·m (50
ft. lbs.).
MEASURING CONNECTING ROD BEARING
CLEARANCE
Fig. 102 Placement of Plastigage in Bearing Shell
1 - PLASTIGAGE
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage (1) or equivalent. The fol-
lowing is the recommended procedure for the use of
Plastigage:
(1) Rotate the crankshaft until the connecting rod
to be checked is at the bottom of its stroke.
(2) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(3) Place a piece of Plastigage (1) across the entire
width of the bearing shell in the bearing cap approx-
imately 6.35 mm (1/4 inch.) off center and away from
the oil hole (Fig. 102). In addition, suspect areas can
be checked by placing plastigage in the suspect area.
(4) Before assembling the rod cap with Plastigage
in place, the crankshaft must be rotated until the
connecting rod being checked starts moving toward
Connecting Rod Bearing
the top of the engine. Only then should the cap be
assembled and torqued to specifications. Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.
Fig. 103 Clearance Measurement
(5) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 103) with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
(Refer to 9 - ENGINE - SPECIFICATIONS). Plasti-
gage generally is accompanied by two scales.
One scale is in inches, the other is a metric
scale.
(6) Plastigage is available in a variety of clearance
ranges. The 0.025-0.076 mm (.001-.003 inch) is usu-
ally the most appropriate for checking engine bearing
proper specifications.
CRANKSHAFT DAMPER
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove left and right engine mount to frame
nuts (Fig. 104).
(3) Lower vehicle.
(4) Remove air cleaner housing (Refer to 9 -
ENGINE/AIR INTAKE
HOUSING - REMOVAL).
(5) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove crankshaft pulley.
(7) Support engine with floor jack and wooden
block on oil pan. Raise engine with floor jack enough
to allow removal of crankshaft damper.
(8) Remove crankshaft damper bolt.
(9) Install crankshaft insert, Special Tool 8194
(Fig. 105). Lubricate the end of Special Tool 8194
with wheel bearing grease or equivalent.
SYSTEM/AIR CLEANER
ZB