200 ENGINE ASSEMBLY

Refer to Figure 6-13.

8.Using dial bore gauge J 5347-B or equivalent, check the cylinder sleeve for outof-round and taper limit. Take readings in two directions, 90 degrees apart, at each of three levels.

Cylinder sleeve ID maximum: 4.877 inches (123.876 mm).

Cylinder sleeve ID minimum: 4.875 inches (123.825 mm), cylinder sleeve ID may be minimum 4.872 inches (123.749 mm) due to close-in from press fit.

Engines produced since mid-year 1992 have finer, more precisely finished cylinder sleeves. Because of the finer finish, honing is NOT recommended. Particles from the honing process which become wedged in the pattern are impossible to completely remove and can cause further damage.

Page 6-13

200 Engine Assembly

[219 RV] PISTON COOLING SPRAY NOZZLE Description

Refer to Figure 6-14.

The piston cooling system consists of an oil pump, oil passages drilled in the cylinder block, and an oil spray-nozzle assembly for each piston. The piston cooling nozzles are attached to the main oil gallery. Oil is discharged through the nozzles and into the underside of each piston. This spray provides additional piston cooling. The oil returns, by gravity, to the crankcase oil pan. Inside the crankcase at each cylinder is a drilled oil passage from the main oil gallery and one threaded hole for the retaining screw.

Beginning with 1991 E7 engine production, piston cooling nozzle hardware and nozzle spray positioning tool changes have been made. The two-piece piston design uses two types of cooling. A unique splash and forced piston cooling system first appeared on the 1991 E7 engine. Precise targeting of the piston cooling spray provides adequate cooling to the piston crown and fills the four oil reservoirs located in the top of the piston skirt.

The piston cooling nozzle bracket is thicker on the piston cooling nozzles beginning on 1991 E7 production engines. Also, “310” is etched on the pre-1991 piston cooling nozzle, and “316” began in 1991 E7 production. These parts are not interchangeable with 1989/1990 production.

Special Tools Required

Piston Cooling Nozzle Spray Position Set

J 37721-A (for 1989/1990 production)

Two-Piece Piston Cooling Nozzle Aimer

J 39045 (for 1991 and later production)

Installation

Refer to Figure 6-15.

1.Using a liberal amount of lubricant, install elastomer sleeve (7) on locator tube (6).

2.Install a retaining screw (4) in the spray nozzle bracket (3).

3.Position spray nozzle locator tube (6) in cylinder block oil passage (2) and torque retaining screw to 15 lb-ft (20 N m) using torque wrench J 24406 or equivalent.