Removal and Installation
REMOVAL1. Remove engine assembly.
2. Remove structural collar from oil pan to transaxle housing.
3. Separate transaxle from engine.
4. Remove flex plate/flywheel.
5. Mount engine on a suitable repair stand.
6. Remove oil filter and adapter from bedplate.
7. Remove oil pan.
8. Remove crankshaft sprocket and oil pump.
Figure 95:
9. Remove all main bearing cap and bedplate bolts from the engine block (Fig. 95).
10. Using a mallet 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 and bedplate alignment.
11. Bedplate should be removed evenly from the cylinder block dowel pins.
Figure 94:
12. Lift out crankshaft from cylinder block (Fig.94). Be sure not to damage the main bearings or journals when removing the crankshaft.
CRANKSHAFT MAIN BEARINGS LOCATION
Figure 96:
The crankshaft is supported in five main bearings. All upper bearing shells in the crankcase have oil grooves. All lower bearing shells installed in the (bedplate) main bearing cap are plain. Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal (Fig. 96).
NOTE: The upper and lower main Bearing shells are Not interchangeable. The lower shells have a revised tab to prevent improper installation.
CRANKSHAFT MAIN JOURNALS INSPECTION
The crankshaft journals should be checked for excessive wear, taper and scoring. 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 Number 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 used it is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine.
Upper and lower Number 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine (Fig. 96). 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
Figure 97:
1. Install the main bearing shells with the lubrication groove in the cylinder block. Install O-ring into recess in the block (Fig. 97).
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 and install crankshaft and O-ring in cylinder block.
CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine.
Figure 98:
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. 98).
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 oil threads with clean engine oil, wipe off any excess oil.
Figure 99:
7. Install main bearing bedplate to engine block bolts 11, 17 and 20 finger tight. Tighten this bolts down together until the bedplate contacts the cylinder block. Torque bolts to 30 Nm (22 ft. lbs.) (Fig. 99).
8. Install main bearing bedplate to engine block bolts (1-10) and torque each bolt to 81 Nm (60 ft. lbs.) in sequence shown.
9. Install main bearing bedplate to engine block bolts (11-20), with baffle studs in positions 12, 13 and 16 and torque each bolt to 30 Nm(22 ft. lbs.) in sequence shown.
10. After the main bearing bedplate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 Nm (60 inch lbs.).
11. Install oil pump. If crankshaft end play is to be checked, refer to End Play.
12. Install crankshaft sprocket.
13. Install oil filter adapter and filter.
14. Install oil pan.
15. Remove engine from repair stand and position on Special Tools 6135 and 6710 Engine Dolly and Cradle. Install safety straps around the engine to cradle and tighten and lock them into position.
16. Install crankshaft rear oil seal.
17. Install flex plate/flywheel. Apply Mopar(R) Lock & Seal Adhesive to bolt threads and tighten to 95 Nm (70 ft. lbs.).
18. Install transaxle to engine.
19. Install structural collar.
20. Install engine assembly.
21. Perform camshaft and crankshaft timing relearn procedure as follows:
- Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel; near the steering column.
- Turn the ignition switch on and access the "miscellaneous" screen.
- Select "re-learn cam/crank" option and follow directions on DRB screen.