D. Replace Cylinder Block Core Plugs

1. Remove the exhaust crossover pipe.





2. Remove the front engine mount bracket (Figure 34).

3. Remove the starter and set it aside.

NOTE:
It is not necessary to disconnect the starter wires.

4. Reinstall an engine mount bolt back into the transmission support bracket.

5. Remove the driveplate cover.





6. Mark the torque converter for reassembly ease and then remove the converter to driveplate bolts (Figure 35). Rotate the engine clockwise to line up the converter bolts.

7. Remove the crank position sensor.

8. Remove the upper and lower transaxle bell housing bolts and separate the transaxle from the engine. Set the transaxle aside.

9. Remove the driveplate from the engine crankshaft.

10. Remove the A/C condenser bracket and the generator as an assembly.








11. Remove the eight (8) cylinder block core plugs (3 on front side of block (Figure 36), 3 on rear side of block, and 2 on transaxle end of block (behind driveplate) (Figure 37)) as follows:





^ Using a blunt tool such as a drift or a screwdriver and a hammer, strike the bottom edge of the core plug (Figure 38).

^ With the core plug rotated, grasp it firmly with pliers or another suitable tool and remove the plug.

CAUTION:
Do not drive the core plug into the casting as restricted cooling can result and cause serious cooling problems.

12. Install eight new cylinder block core plugs as follows:

^ Thoroughly remove all rust and clean the inside of the core plug hole in the cylinder head. Be sure to remove all of the old sealer.

^ Lightly coat the side of the new core plug with sealer such as Mopar Gasket Maker (PN 4318083).

^ Using the proper sized plug driver or socket, drive the plug into the hole so that the sharp edge of the plug is between 0.020" - 0.040" (0.5 mm - 1.0 mm) inside the lead in chamfer (Figure 38).

13. Install the A/C compressor bracket and generator assembly. Tighten the bolts to 40 ft-lbs (54 N.m).

14. Install the driveplate. Tighten the driveplate bolts to 70 ft-lbs (95 N.m).

15. Install the transaxle onto the engine. Tighten the transaxle bell housing bolts to 70 ft-lbs (95 N.m).


16. Line up the torque converter with the driveplate and install the converter bolts (Figure 35). Tighten the bolts to 55 ft-lbs (75 N.m). Rotate the engine clockwise to line up the converter bolts.


17. Install the crank position sensor.


18. Install the driveplate cover.


19. Install the starter. Tighten the starter bolts to 40 ft-lbs (54 N.m).


20. Remove the engine mount bolt that was reinstalled in the transmission support bracket.


21. Install the front engine mount bracket. Tighten the upper bolt to 45 ft-lbs (61 N.m). Tighten the four (4) lower bolts to 80 ft-lbs (110 N.m).


22. Install the exhaust crossover pipe. Tighten the bolts to 275 in-lbs (31 N.m).


23. Install the power steering pump bracket. Tighten the bolts to 40 ft-lbs (54 N.m).


24. Continue with Section "E" -- Install Engine and Transmission Assembly.