Removal and Replacement
REMOVALNOTE: Crankshaft can not be removed when engine is in vehicle.
1. Remove engine assembly from vehicle.
2. Separate engine from transaxle.
3. Remove flex plate and crankshaft rear oil seal.
4. Mount engine on a repair stand.
5. Drain engine oil and remove oil filter.
6. Remove the oil pan.
7. Remove the timing belt covers.
8. Remove the timing belt.
9. Remove the oil pump.
10. Remove balance shafts and housing assembly.
11. Remove all bedplate bolts from the engine block (Fig. 42).
12. Using a mallet gently tap the bedplate loose from the engine block dowel pins.
CAUTION: Do not pry up on one side of the bedplate. Damage may occur to cylinder block to bedplate alignment and thrust bearing.
13. Bedplate should be removed evenly from the cylinder block dowel pins to prevent damage to the dowel pins and thrust bearing.
14. Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the crankshaft.
INSPECTION
The crankshaft journals should be checked for excessive wear, taper and scoring (Fig. 43). Limits of taper or out of round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. DO NOT grind thrust faces of No. 3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts, it is important that the final paper or cloth polish be in the same direction as normal rotation in the engine.
Upper and lower No. 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine (Fig. 47). All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. Bearing shells are available in standard and the following undersized: 0.016 mm (0.0006 inch), 0.032 mm (0.0012 inch), 0.250 mm (0.010 inch). Never install an undersize bearing that will reduce clearance below specifications.
INSTALLATION
1. Install the main bearing shells with the lubrication groove in the cylinder block (Fig. 44).
2. Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots.
CAUTION: Do not get oil on the bedplate mating surface. It will affect the sealer ability to seal the bedplate to cylinder block.
3. Oil the bearings and journals. Install crankshaft.
CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine.
4. Apply 1.5 to 2.0 mm (0.059 to 0.078 inch) bead of Mopar Bed Plate Sealant to cylinder block as shown in (Fig. 45).
5. Install lower main bearings into main bearing cap/bedplate. Make certain the bearing tabs are seated into the bedplate slots. Install the main bearing/bedplate into engine block.
6. Before installing the bolts the threads should be oiled with clean engine oil, wipe off any excess oil.
7. Install main bearing bedplate to engine block bolts 11, 17, and 20 finger tight. Tighten these bolts down together until the bedplate contacts the cylinder block.
8. To ensure correct thrust bearing alignment, perform the following steps:
- Step 1: Rotate crankshaft until number 4 piston is at TDC.
- Step 2: Move crankshaft rearward to limits of travel.
- Step 3: Then, move crankshaft forward to limits of travel.
- Step 4: Wedge an appropriate tool between the rear of the cylinder block (NOT BED PLATE) and the rear crankshaft counterweight. This will hold the crankshaft in its furthest forward position.
- Step 5: Install and tighten bolts (1-10) in sequence shown in (Fig. 46) to 41 Nm (30 ft. lbs.).
- Step 6: Remove wedge tool used to hold crankshaft.
9. Tighten bolts (1-10) again to 41 Nm (30 ft. lbs.) +1/4 turn in sequence shown in (Fig. 46).
10. Install main bearing bedplate to engine block bolts (11-20), and torque each bolt to 28 Nm (20 ft. lbs.) in sequence shown in (Fig. 46).
11. After the main bearing bedplate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 Nm (50 in. lbs.).
12. Install balance shafts and housing assembly.
13. Install the oil pump.
14. Install the timing belt rear cover.
15. Install the timing belt.
16. Install the timing belt front covers.
17. Install engine support bracket.
18. Install the oil pan.
19. Install the oil filter.
20. Install crankshaft rear oil seal.
21. Install flex plate. Apply Mopar Lock & Seal Adhesive to bolt threads and tighten to 95 Nm (70 ft. lbs.).
22. Attach transaxle to engine. Tighten attaching bolts to 101 Nm (76 ft. lbs.).
23. Install the engine assembly.