Dodge Sprinter 2006 - Page 1571

ENGINE
TAB LE O F CO NTE NTS
page page
ENGINE
DESCRIPTION ..........................2
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE ......................3
STANDARD PROCEDURE - CYLINDER
LEAK DOWN TEST .....................3
STANDARD PROCEDURE - DETERMINING
CYLINDER PRESSURE LOSS .............4
REMOVAL
REMOVAL - ENGINE COVER .............4
REMOVAL ............................5
INSTALLATION
INSTALLATION - ENGINE COVER ..........9
INSTALLATION ........................9
SPECIFICATIONS - TORQUE
SPECIFICATIONS .....................11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 17
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
AIR CLEANER HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
HEAD BOLT INSPECTION . . . . . . . . . . . . . . . 22
STANDARD PROCEDURE - MEASURE
CYLINDER HEAD SURFACE . . . . . . . . . . . . . 22
REMOVAL
REMOVAL - CYLINDER HEAD . . . . . . . . . . . . 23
REMOVAL - CYLINDER HEAD FRONT
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL - CYLINDER HEAD GUIDE RAIL . . 26
INSTALLATION
INSTALLATION - CYLINDER HEAD . . . . . . . . 26
INSTALLATION - CYLINDER HEAD FRONT
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION - CYLINDER HEAD GUIDE
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CAMSHAFT(S)
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING
CAMSHAFT POSITION . . . . . . . . . . . . . . . . . 28
STANDARD PROCEDURE - INSPECTING
TAPPET CLEARANCE . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
CYLINDER HEAD COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
VALVE STEM SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
VALVE SPRINGS
REMOVAL
REMOVAL - VALVE SPRINGS . . . . . . . . . . . . 35
REMOVAL - VALVES . . . . . . . . . . . . . . . . . . . 36
INSTALLATION
INSTALLATION - VALVE SPRINGS . . . . . . . . 36
INSTALLATION - VALVES . . . . . . . . . . . . . . . 37
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - REPLACING
ENGINE CORE AND OIL GALLERY PLUGS . . 37
STANDARD PROCEDURE - MEASURING
CYLINDER BORES . . . . . . . . . . . . . . . . . . . . 38
CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
STANDARD PROCEDURE - MEASURE
CRANKSHAFT AND BLOCK JOURNALS . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
FLYWHEEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION - CRANKSHAFT LOCK . . . . . 44
PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 45
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING AND
REPAIRING CONNECTING RODS . . . . . . . . . 46
STANDARD PROCEDURE - MEASURING
PISTON PROTRUSION . . . . . . . . . . . . . . . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54
VA ENGINE 9 - 1