Removal and Installation

REMOVAL

NOTE: Crankshaft can not be removed when engine is in vehicle.

1. Remove engine assembly from vehicle.
2. Separate engine from transaxle.
3. Remove drive plate and crankshaft rear oil seal.
4. Mount engine on a repair stand.
5. Remove oil filter and oil pan.
6. Remove Timing Belt Cover, Timing Belt and Oil Pump.
7. Remove Balance Shafts Assembly.
8. Remove all main bearing cap bedplate bolts from the engine block.
9. 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.

10. Bedplate should be removed evenly from the cylinder block dowel pins to prevent damage to the dowel pins and thrust bearing.
11. Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the crankshaft.

INSTALLATION

Figure 84:

1. Install the main bearing shells with the lubrication groove in the cylinder block (Fig. 84).
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 may effect 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.

Figure 85:

4. Apply 1.5 to 2.0 mm (0.059 to 0.078 inch) bead of Mopar(R) Torque Cure Gasket Maker to cylinder block as shown (Fig. 85).
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 Top Dead Center (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.

Figure 86:

- Step 5: Install and tighten bolts (1 - 10) in sequence shown (Fig. 86) 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.
10. Install main bearing bedplate to engine block: bolts (11 through 20), and torque each bolt to 28 Nm, (20 ft. lbs.) in sequence shown.
11. After the main bearing bedplate is installed, check the crankshaft turning torque. The turning: torque should not exceed 5.6 Nm (50 inch lbs.).
12. Install balance shaft assembly.
13. Install oil pump, timing belt and covers.
14. Install oil pan and oil filter.
15. Install crankshaft rear oil seal.
16. Install drive plate. Apply Mopar(R) Lock & Seal Adhesive to bolt threads and tighten to 95 Nm (70 ft. lbs.).
17. Attach transaxle to engine. Tighten attaching bolts to 101 Nm (75 ft. lbs.).
18. Install engine assembly.