Replace cylinder in bottom boom on hiranger bucket truck

TORQUE SPECIFICATIONS
All readings in ft. lbs.
Year Engine Displacement Liters Engine VIN Cylinder Head Bolts Main Bearing Bolts Rod Bearing Bolts Crankshaft Damper Bolts Flywheel Bolts Manifold Spark Plugs Oil Pan Drain Plug Intake Exhaust 2008 3.3 H - - - 40 70 - 17 13 20 3.8 P - - - 40 70 - 17 13 20 4.0 X - - - 70 70 - 17 20 20 2009 3.3 H - - - 40 70 - 17 13 20 3.8 P - - - 40 70 - 17 13 20 4.0 X - - - 70 70 - 17 20


Main Bearing Torque Sequence


3.3L & 3.8L Engines Specific to:
Chrysler Town & Country 2008-2009
Dodge Grand Caravan 2008-2009

NOTE
Only one main bearing should be selectively fitted while all the other main bearing caps are properly tightened.

1.Before servicing the vehicle, refer to the Precautions Section.
2.Start a bearing in place, and insert Main Bearing Tool C-3059 into the oil hole of the crankshaft.
3.Slowly rotate the crankshaft counterclockwise sliding the bearing into position. Remove Special Main Bearing Tool C-3059.
4.Inspect the main cap bolts for stretching. Replace the bolts that are stretched.
NOTE
The main cap bolts should be examined before reuse. Bolt stretch can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale, the bolt must be replaced.

5.Install each main cap and tighten the bolts finger tight.
6.Tighten number 1, 3, and 4 main cap bolts to 30 ft. lbs. (41 Nm), plus 1 / 4 turn.
7.Rotate the crankshaft until the number 6 piston is at Top Dead Center (TDC).
8.To ensure correct thrust bearing alignment, the following procedure must be done:
A.Move the crankshaft all the way to the rear of its travel.
B.Then, move the crankshaft all the way to the front of its travel.
C.Wedge an appropriate tool between the rear of the cylinder block and the rear crankshaft counterweight. This will hold the crankshaft in its most forward position.
D.Tighten the No. 2 Thrust Bearing cap bolts to 30 ft. lbs. (41 Nm), plus

I got this free Pdf manual from reliable-store for free and I don't think Ive visited a mechanic or fixya for help for more than 3-4 times out of the 20 times I fixed the chipper in these 4 years

Sounds like you need the hydraulic cylinder rebuilt.

Could it be a F-150 instead?
Ford Engine Bolt Torque Chart Bolt Torque Spec Chart for Ford Engines

These specs are for stock-type bolts with light engine oil applied to the threads and the underside of the bolt head. Moly and other lubes offer reduced friction and increased bolt tension, which will affect the torque figure. If you use after-market performance bolts like ARP's, you should follow the recommended torque specifications.

260, 289, 302 Torque Spec.
Fastener Type Torque Spec Main cap bolts 60-70 ft-lbs Outer main cap bolts 35-40 ft-lbs. Connecting rod bolts (40-45 ft-lbs. for 289 HP & Boss 302) Cylinder head bolts 65-72 ft-lbs. Rocker arms 17-23 ft-lbs. Intake manifold bolts 23-25 ft-lbs Oil pump bolt 23-28 ft-lbs. Cam bolts 40-45 ft-lbs. Cam thrust plate bolts 8-10 ft-lbs. Harmonic damper bolts 70-90 ft-lbs. Flywheel / flex-plate bolts 75-85 ft-lbs. Pressure plate bolts 35 ft-lbs. Front cover bolts 12-15 ft-lbs. 351W Torque Spec.
Fastener Type Torque Spec Main cap bolts 95-105 ft-lbs Connecting rod bolts 40-45 ft-lbs. Cylinder head bolts 90-100 ft-lbs. Rocker arms 17-23 ft-lbs. Intake manifold bolts 23-25 ft-lbs. Oil pump bolts 23-28 ft-lbs. Cam bolts 40-45 ft-lbs. Cam thrust plate bolts 8-10 ft-lbs. Harmonic damper bolt 70-90 ft-lbs. Flywheel / flex-plate bolts 75-85 ft-lbs. Pressure plate bolts 35 ft-lbs. Front cover bolts 12-15 ft-lbs. 351C, 351M Torque Spec.
Fastener Type Torque Spec Main cap bolts 95-105 ft-lbs. Connecting rod bolts 40-45 ft-lbs. (45-50 ft-lbs. For Boss 351C) Cylinder head bolts 105 ft-lbs. (125 ft-lbs. For Boss 351C) Rocker arms (non-adjustable) Rocker arms (non-adjustable) 5/16in. intake manifold bolts 21-25 ft-lbs. 3/8in. intake manifold bolts 28-23 ft-lbs Oil pump bolt 25 ft-lbs. Cam bolts 40-45 ft-lbs. Cam thrust plate bolts 9-12 ft-lbs. Harmonic damper bolt 70-90 ft-lbs. Flywheel / flex-plate bolts 75-85 ft-lbs. Pressure plate bolts 35 ft-lbs. Front cover bolts 12-18 ft-lbs. 360, 390, 406, 427, 428FE Torque Spec.
Fastener Type Torque Spec Main cap bolts 95-105 ft-lbs. Crossbolts for 406-427 40 ft-lbs. Connecting rod bolts 40-45 ft-lbs. (53-58 ft-lbs. For 406 and 427) Cylinder head bolts 80-90 ft-lbs. (100-110 ft-lbs. For 1963-67 427) Rocker arm shaft bolts 40-45 ft-lbs. Intake manifold bolts 32-35 ft-lbs. Oil pump bolt 12-15 ft-lbs. Cam bolts 40-45 ft-lbs. Harmonic damper bolt 70-90 ft-lbs. Flywheel / flex-plate bolts 75-85 ft-lbs. Pressure plate bolts 35 ft-lbs. Front cover bolts 12-15 ft-lbs. 429-460 Torque Spec.
Fastener Type Torque Spec Main cap bolts 95-105 ft-lbs Connecting rod bolts 40-45 ft-lbs. Cylinder head bolts 140 ft-lbs. Rocker arms (non-adjustable) 18-22 ft-lbs. Intake manifold bolts 25-30 ft-lbs. Oil pump bolt 25 ft-lbs. Cam bolts 40-45 ft-lbs. Harmonic damper bolt 70-90 ft-lbs. Flywheel / flex-plate bolts 75-85 ft-lbs. Pressure plate bolts 35 ft-lbs. Front cover bolts 12-18 ft-lbs.

Ford Engine Bolt Torque Chart Bolt Torque Spec Chart for Ford Engines

These specs are for stock-type bolts with light engine oil applied to the threads and the underside of the bolt head. Moly and other lubes offer reduced friction and increased bolt tension, which will affect the torque figure. If you use after-market performance bolts like ARP's, you should follow the recommended torque specifications.

260, 289, 302 Torque Spec.
Fastener Type Torque Spec Main cap bolts 60-70 ft-lbs Outer main cap bolts 35-40 ft-lbs. Connecting rod bolts (40-45 ft-lbs. for 289 HP & Boss 302) Cylinder head bolts 65-72 ft-lbs. Rocker arms 17-23 ft-lbs. Intake manifold bolts 23-25 ft-lbs Oil pump bolt 23-28 ft-lbs. Cam bolts 40-45 ft-lbs. Cam thrust plate bolts 8-10 ft-lbs. Harmonic damper bolts 70-90 ft-lbs. Flywheel / flex-plate bolts 75-85 ft-lbs. Pressure plate bolts 35 ft-lbs. Front cover bolts 12-15 ft-lbs. 351W Torque Spec.
Fastener Type Torque Spec Main cap bolts 95-105 ft-lbs Connecting rod bolts 40-45 ft-lbs. Cylinder head bolts 90-100 ft-lbs. Rocker arms 17-23 ft-lbs. Intake manifold bolts 23-25 ft-lbs. Oil pump bolts 23-28 ft-lbs. Cam bolts 40-45 ft-lbs. Cam thrust plate bolts 8-10 ft-lbs. Harmonic damper bolt 70-90 ft-lbs. Flywheel / flex-plate bolts 75-85 ft-lbs. Pressure plate bolts 35 ft-lbs. Front cover bolts 12-15 ft-lbs. 351C, 351M Torque Spec.
Fastener Type Torque Spec Main cap bolts 95-105 ft-lbs. Connecting rod bolts 40-45 ft-lbs. (45-50 ft-lbs. For Boss 351C) Cylinder head bolts 105 ft-lbs. (125 ft-lbs. For Boss 351C) Rocker arms (non-adjustable) Rocker arms (non-adjustable) 5/16in. intake manifold bolts 21-25 ft-lbs. 3/8in. intake manifold bolts 28-23 ft-lbs Oil pump bolt 25 ft-lbs. Cam bolts 40-45 ft-lbs. Cam thrust plate bolts 9-12 ft-lbs. Harmonic damper bolt 70-90 ft-lbs. Flywheel / flex-plate bolts 75-85 ft-lbs. Pressure plate bolts 35 ft-lbs. Front cover bolts 12-18 ft-lbs. 360, 390, 406, 427, 428FE Torque Spec.
Fastener Type Torque Spec Main cap bolts 95-105 ft-lbs. Crossbolts for 406-427 40 ft-lbs. Connecting rod bolts 40-45 ft-lbs. (53-58 ft-lbs. For 406 and 427) Cylinder head bolts 80-90 ft-lbs. (100-110 ft-lbs. For 1963-67 427) Rocker arm shaft bolts 40-45 ft-lbs. Intake manifold bolts 32-35 ft-lbs. Oil pump bolt 12-15 ft-lbs. Cam bolts 40-45 ft-lbs. Harmonic damper bolt 70-90 ft-lbs. Flywheel / flex-plate bolts 75-85 ft-lbs. Pressure plate bolts 35 ft-lbs. Front cover bolts 12-15 ft-lbs. 429-460 Torque Spec.
Fastener Type Torque Spec Main cap bolts 95-105 ft-lbs Connecting rod bolts 40-45 ft-lbs. Cylinder head bolts 140 ft-lbs. Rocker arms (non-adjustable) 18-22 ft-lbs. Intake manifold bolts 25-30 ft-lbs. Oil pump bolt 25 ft-lbs. Cam bolts 40-45 ft-lbs. Harmonic damper bolt 70-90 ft-lbs. Flywheel / flex-plate bolts 75-85 ft-lbs. Pressure plate bolts 35 ft-lbs. Front cover bolts 12-18 ft-lbs.

you may have to get specialist hydraulics for this. ON most boom and cylinder systems there is a flow control valve on the bottom side of the cylinder to stop uncontrolled fall in the event of hose failure. If the flow rate is too high the valve closes off and locks the ram in the position that the hose failed in. To unlock it you have to extend the ram in question and lower it slowly. Bent rams will also cause the fault as there is normally no downward hydraulic action as the ram moving back in relies on weight so any bent /jamming bush will not result in a ram return or slow ram return

YOU NEED TO MAKE 3 PASS FIRST PAST TORQUE CYLINDER BOLTS 44 FT LBS. SECOND PASS TORQUE CYLINDER BOLTS 59 FT LBS. IF YOU HAVE 17MM HEAD BOLTS TORQUE TO 70 FT LBS.THE THIRD PASS TIGHTEN ALL CYLINDER BOLTS ADDITIONAL 90 DEGREES. ROD BEARING BOLT TORQUE TO 35 FT LBS.

CYLINDER HEAD BOATS TORQUE FIRST PASS 29.5 FT LBS SECOND PASS 44 FT LBS.THEN TIGHTEN ADDITIONAL 90 DEGREES FOR MAIN BEARINGS 15 FT LBS TIGHTEN EACH BOAT ADDITIONAL 70 DEGREES ROD BEARINGS 15 FT LB TIGHTEN ADDITIONAL 70 DEGREES. CRANKSHAFT DAMPER BOLTS 130 FT LBS.

install:

1. The cylinder head should be cleaned and inspected prior to installation.
2. Lightly oil all bolt and stud bolt threads before installation.
3. Clean all gasket mating surfaces thoroughly.
4. Install a new head gasket on the cylinder block. WARNING Always use new cylinder head bolts when installing the cylinder head or damage to the engine may occur.
5. Install the cylinder head on the cylinder block.
6. Tighten the cylinder head bolts in reverse of the removal sequence. Tighten the 2004 cylinder head bolts to 18 ft. lbs. (25 Nm). Tighten an additional 70°, plus 70°, plus another 50°. Tighten 2005 bolts to 18 ft. lbs. (25 Nm). Tighten an additional 60°, plus 60°, plus another 10°.
7. Install the right engine mount. Tighten the engine mount attaching bolts to 22 ft. lbs. (30 Nm).
8. Install or connect the following:
   • Intake manifold
   • Intake manifold support bracket. Tighten the bolts to 18 ft. lbs. (25 Nm).
   • Throttle cable
   • Surge tank coolant hose
   • Heater hose to cylinder head
   • Fuel feed line at the fuel rail
   • All vacuum hoses
   • Exhaust manifold
   • Rear timing belt cover
   • Timing belt tensioner. Tighten the bolts to 18 ft. lbs. (25 Nm).
   • Idler pulley. Tighten the bolts to 18 ft. lbs. (25 Nm).
   • Intake and exhaust camshaft gears. Tighten the bolts to 49 ft. lbs. (68 Nm).
9. Apply a small amount of gasket sealant to the corners of the front camshaft caps and the top of the rear camshaft cover-to-cylinder head seal.
10. Install the valve cover using a new gasket
11. Align the timing marks on the camshaft gears.
12. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.
13. Install the timing belt and rotate the water pump clockwise to apply tension to the timing belt.
14. Tighten the water pump bolts to 89 inch lbs. (10 Nm).
15. Adjust the timing belt tension.
16. Install or connect the following:
    • Spark plug wires
    • Upper and lower timing belt coversCrankshaft pulley. Tighten the bolt to 70 ft. lbs. (95 Nm), plus an additional 30°, then another 15°.
    • Accessory drive belt
    • Air cleaner housing
    • Radiator hoses
    • Front splash shield
    • Right front wheel
    • Coolant temperature sensor
    • Fuel feed line from fuel rail
    • IAT sensor
    • Intake manifold pressure sensor
    • DIS coil connector
    • Fuel injector connectors
    • ECM ground terminal
    • Negative battery cable
17. Fill the engine with oil and coolant.
18. Start the engine and check for leak
    

Cylinder Head Removal

1. Disconnect the battery ground cable
2. Relieve the fuel pressure.
3. Drain the cooling system. Disconnect the three way catalytic converter Loosen the water pump pulley bolts.
4. Remove the drive belt.
5. Remove the water pump pulley, fan and clutch assembly.
6. Remove the intake manifolds
7. Remove the ignition wires from the spark plugs .
8. Remove the spark plugs; .
9. Remove the oil level indicator tube
• Remove the bolt.
• Remove the oil level indicator tube.
• Remove the EGR valve to exhaust manifold tube
1. Remove the valve cover
1. Remove the drive belt .
1. Recover the A/C refrigerant; refer to Disconnect the engine control wiring from the A/C compressor
2. Remove the A/C compressor mounting bracket (2882) with the power steering pump (3A674) attached and position out of the way.
3. Disconnect the engine control sensor wiring connector from the generator
4. Disconnect the (1) lower radiator hose and the (2) water pump inlet tube
5. Remove the upper radiator hose
6. Remove the water pump inlet tube.
   • Remove the bolts.
   • Remove the water pump inlet tube.
7. Remove the generator.
   • Remove the bolts.
   • Remove the generator.
8. Remove the generator mounting bracket.
   • Remove the bolts.
   • Remove the bracket.
1. Remove the ignition wire and bracket; refer to Section 303-07A .
1. Remove the outer timing belt cover; refer to the procedure in this section.
1. Remove the timing chain/belt (6268); refer to Timing Drive Components—Timing Belt in this section.
1. Remove the exhaust manifold (9430); refer to Exhaust Manifold in this section.
1. Remove the cylinder head .
   • Remove the bolts and discard. (should get new ones)
   • Remove the cylinder head.
   • Remove the head gasket and discard.

Installation

1. Clean all gasket mating surfaces.

1. Install new gaskets as necessary.
   • Use new cylinder head bolts.

1. Follow the removal procedure in reverse order.

1. Tighten the bolts in sequence, in three stages, to 70 Nm (51 lb/ft).
   • Stage 1: Tighten all bolts to 70 Nm.
   • Stage 2: Retighten all bolts to 70 Nm.
   • Stage 3: Tighten all bolts an additional 90-100 degrees.
2. Install generator bracket. Install bolts in four stages.
   • Stage 1: Hand-start bolt 1.
   • Stage 2: Install and tighten bolt 2.
   • Stage 3: Install and tighten bolt 3.
   • Stage 4: Tighten bolt 1.
3. Install the A/C compressor mounting bracket. Install the bolts and the stud.
   • Tighten the M10 bolts and stud to 48 Nm (35 lb/ft).
   • Tighten the M8 bolt to 25 Nm (18 lb/ft).