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(5)Turn crankshaft until number one cylinder is at Top Dead Center (TDC). The timing marks on the chain sprocket should line up with the parting line on the left side of number one main bearing cap. (Fig. 21).

(6)Place chain over crankshaft sprocket so that the nickel plated link of the chain is over the timing mark on the crankshaft sprocket (Fig. 21).

(7)Place balance shaft sprocket into the timing chain (Fig. 17) so that the timing mark on the sprocket (yellow dot) mates with the (lower) nickel plated link on the chain.

(8)With balance shaft keyways pointing up (12 o'clock) slide the balance shaft sprocket onto the nose of the balance shaft. The balance shaft may have to be pushed in slightly to allow for clearance.

Fig. 21 Balance Shaft Timing

THE TIMING MARK ON THE SPROCKET, THE (LOWER) NICKEL PLATED LINK, AND THE ARROW ON THE SIDE OF THE GEAR COVER SHOULD LINE UP WHEN THE BALANCE SHAFTS ARE TIMED CORRECTLY.

(9) If the sprockets are timed correctly install the balance shaft bolts and tighten to 28 Nzm (250 in. lbs.). A wood block placed between crankcase and crankshaft counterbalance will prevent crankshaft and gear rotation.

CHAIN TENSIONING

(1)Install chain tensioner loosely assembled.

(2)Position guide on double ended stud making sure tab on the guide fits into slot on the gear cover. Install and tighten nut/washer assembly to 12 Nzm (105 in. lbs.).

(3)Place a shim 1mm (.039 inch) thick x 70mm (2.75 inch) long or between tensioner and chain. Push tensioner and shim up against the chain. Apply firm pressure (5.5 to 6.6 lbs.) directly behind the adjustment slot to take up all slack (chain must have shoe radius contact as shown in Fig. 22).

(4)With the load applied, tighten top tensioner bolt first, then bottom pivot bolt. Tighten bolts to 12 Nzm (105 in. lbs.), Remove shim.

(5)Install carrier covers and tighten screws to 12 Nzm (105 in. lbs.).

Fig. 22 Chain Tensioner Adjustment

INTERMEDIATE SHAFT SERVICE

REMOVAL

CAUTION: The oil pump and distributor must be removed before attempting to remove intermediate shaft.

(1)Hold sprocket with Tool C-4687 and adaptor Tool C-4687-1 when removing or installing screw (Fig. 23).

(2)See Timing System and Seals for intermediate seal removal and replacement.

(3)Remove retainer screws (Fig. 24).

(4)Remove retainer and lay aside.

(5)Remove intermediate shaft.

Fig. 23 Removing/Installing Intermediate Shaft

Sprocket

Fig. 24 Intermediate Shaft Retainer

Fig. 25 Intermediate Shaft Retainer Sealing

INSTALLATION

(1)Lubricate distributor drive gear when install-

ing.

(2)Apply Mopar Gasket Maker as shown in (Fig.

25)and install intermediate shaft retainer.

Fig. 26 Intermediate Shaft Bushing, Front

Fig. 27 Intermediate Shaft Bushing−Rear

Fig. 28 Intermediate Shaft Journal Specifications

(3) Install retaining screws and torque to 12 Nzm (105 in. lbs.).

INTERMEDIATE SHAFT BUSHING SERVICE

(1)Remove front bushing using Special Tool C-4697-2 with Special Tool Handle C-4171 (Fig.26).

(2)Install front bushing using Special Tool C-4697-1 and Special Tool Handle C-4171 until tool is flush with block.

(3)Remove rear bushing using Special Tool C-4686-2 and Special Tool Handle C-4171 (Fig. 27).

(4)Install rear bushing using Special Tool C-4686-1 and Special Tool Handle C-4171 until tool is flush with block.

PISTON AND CONNECTOING ROD−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. Mark piston with matching cylinder number (Fig. 2).

Fig. 2 Piston Marking

(2)Remove oil pan. Ensure connecting rods and connecting rod caps for cylinder identification. Identify them if necessary (Fig. 3).

(3)Valve relief toward manifold side of engine. Turbocharged engine pistons will have arrow towards front of engine.

Fig. 3 Identify Connecting Rod to Cylinder

(4)Squirt hole on connecting rod must face timing belt end of engine.

(5)Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore.

(6)Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts (Fig. 4). Push each piston and rod assembly out of cylinder bore.

Be careful not to nick crankshaft journals.

(7)After removal, install bearing cap on the mating

rod.

Fig. 4 Connecting Rod Protectors

CYLINDER BLOCK 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, Refer to Engine Core Oil and Cam Plugs.

(3)Examine block and cylinder bores for cracks or fractures.

CYLINDER BORE INSPECTION

The cylinder walls should be checked for out-of- round and taper with Tool C-119 (Fig. 5). The cylinder bore out-of-round is 0.050 mm (.002 inch) maximum and cylinder bore taper is .125 mm (.005 inch) maximum. 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 Cylin-

Fig. 5 Checking Cylinder Bore Size

der Bores outlined in the Standard Service Procedures for specification and procedures.

Measure the cylinder bore at three levels in directions A and B (Fig. 5). Top measurement should be 10mm (3/8 inch.) down and bottom measurement should be 10mm (3/8 inch.) up from bottom of bore. Refer to (Fig. 6) for specifications.

SIZING 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. 7). Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in (Fig. 5). Refer to (Fig. 6) for specifica-

Fig. 7 Piston Installation and Sizing Information

Fig. 8 N.A. (Naturally Aspirated) Pistons

tions. Correct piston to bore clearance must be established in order to assure quiet and economical operation.

Fig. 9 2.2L Turbo III and 2.5L Turbo I Pistons

Chrysler engines use pistons designed specifically for each engine model. Clearance and sizing locations vary with respect to engine model.

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

Fig. 10 Piston Pin Lock Ring Removal

Notch−Turbocharged Engine

9 - 52 2.2/2.5L ENGINES

PISTON PINS

DISASSEMBLY

Turborcharged engine piston-pin-connecting rod assemblies should not be disassembled unless a malfunction is present or a damaged assembly component is to be replaced.

WARNING: APPROVED SAFETY GLASSES MUST BE WORN DURING PISTON LOCK RING REMOVAL OR INSTALLATION TO PREVENT POSSIBLE INJURY FROM FLYING PARTS.

Fig. 11 Engine Piston Pins−Turbo and N.A.

(1)Carefully, remove piston pin lock rings from piston, using a small screwdriver in removal notch (Fig. 10).

(2)Discard used lock ring.

(3)Following lock ring removal, attempt to slide pin out of piston. If pin does not slide out freely by hand;

²Check for burr on outer edge of lock ring groove. If one is present, carefully scrape burr away with a knife or other hand tool, being careful not to damage lock ring retaining groove.

(4)Slide out piston pin to complete disassembly.

(5)Inspect components, discard damaged or excessively worn parts refer to specifications (Fig. 12). If a piston is replaced, a new pin should be used.

PISTON PINS

REASSEMBLY

(1) Two different lock rings are used for turbocharged engine applications. Consult the Service

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Note, provided with the lock ring service package, to select the correct lock rings from the package for your application.

(2)Carefully, install one NEW lock ring with gap towards piston top in lock ring groove. Do not reinstall used lock rings.

(3)Position connecting rod and slide in lightly oil piston pinch

(4)Install second NEW lock ring with gap towards piston top in lock ring groove, use small screwdriver if needed.

CAUTION: BOTH lock rings must be FULLY SEATED in lock ring grooves or engine failure will occur.

(5) Check piston pin end play pin movement between lock rings in assembly.

Fig. 12 Piston Pin Specifications

Fig. 13 Piston Rings−Removing and Installing

PISTON RING−REMOVAL

(1)ID mark on face of upper and intermediate piston rings must point toward piston crown.

(2)Using a suitable ring expander, remove upper and intermediate piston rings (Fig. 13).

(3)Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston.

(4)Clean ring grooves of any carbon deposits.

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Fig. 14 Piston Ring Gap

Fig. 15 Piston Ring Groove Clearance

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. 14). Refer to specifications (Fig. 16, 17 and 18).

(2)Check piston ring to groove clearance: (Fig. 15). Refer to specification (Fig. 17).

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. 13).

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.

2.2/2.5L ENGINES 9 - 53

Fig. 16 Piston Ring Specifications−Turbo III

Fig. 17 Piston Ring Groove Specifications

Fig. 18 Piston Ring Gap Specifications

(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. 19).

(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. 8).

Fig. 19 Installing Side Rail

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

20).

(6)Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control.

Fig. 20 Piston Ring End Gap Position

PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION

(1)Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap.

(2)Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in (Fig. 20).

(3)Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston

Fig. 21 Installing Piston

and tighten with the special wrench (Fig. 21). Be sure position of rings does not change during this operaiton.

Fig. 22 Piston Markings

(4)The valve cut should be toward the manifold side of the engine (Fig. 22 ).

(5)Install connecting rod bolt protectors on rod bolts (Fig. 4).

(6)Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal.

(7)Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.

(8)Intall rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 Nzm (40 ft. lb.) Plus 1/4 turn.