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Removal And Installation: Installation

GC0098631Courtesy of CHRYSLER GROUP, LLC
  1. If required, select and fit new crankshaft main bearings to the engine block. Refer to BEARING(S), CRANKSHAFT, MAIN .
  2. If required, select and fit new bearings to the connecting rod. Refer to BEARING(S), CONNECTING ROD .
  3. If removed, install the target wheel to the crankshaft with four new screws. Ensure the threaded holes in the crankshaft are free of residual thread lock adhesive. Tighten the screws in the sequence shown in illustration to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
    GC0098630Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The crankshaft is supported in five main bearings. All upper bearing shells (2) in the crankcase have oil grooves and holes. All lower bearing shells (1) are smooth. Crankshaft end play is controlled by a two piece thrust bearing (3) on the second main bearing journal.

  4. Clean the main bearing cap bolt holes with Mopar® brake parts cleaner or equivalent and blow out with compressed air.
  5. Install the main bearing upper shells (2) with the lubrication groove and oil hole in the engine block.
  6. Make certain the oil holes in the block line up with oil the hole in bearings and bearing tabs seat in the block tab slots.
    GC0098632Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Apply a light coating of petroleum jelly to the thrust bearings to hold the bearings in the block.

    NOTE:

    The thrust bearings must be installed with the notches facing the crankshaft.

  7. Install the thrust bearings (2) in the block (1).
    CAUTION:

    Do not get oil on the ladder frame mating surface. It will affect the ability of the RTV to seal the ladder frame to cylinder block.

    NOTE:

    Ensure that the main bearing cap bolt holes in the block are clean, dry (free of residual oil or coolant), and the threads are not damaged.

  8. Oil the bearings and journals. Install the crankshaft in the engine block.
  9. Install the lower main bearings into the main bearing caps. Make sure the bearing tabs are seated into the bearing cap slots.
  10. Install the main bearing caps to the engine block.
    NOTE:

    Main bearing caps are stamped 1 - 5 front to rear. Arrows on the caps must point towards the front of the engine.

    GC0104468Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    The main bearing cap bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

  11. Check the main bearing cap bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
  12. Before installing the bolts the threads should be clean and dry.
  13. Loosely install the main bearing cap bolts. Temporarily install main bearing cap bolts (M10 x 1.25 x 76.5) into the unsupported No. 2, 3 and 5 main bearing caps hand tight until the bearing beam can be installed.
    GC0152767Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Typical I4 engine configuration shown in illustration.

  14. Install the piston and connecting rod assemblies (1) in the engine block, if removed. Refer to ROD, PISTON AND CONNECTING, REMOVAL AND INSTALLATION .
  15. Install the bearing shell (7) on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
  16. Rotate the crankshaft while guiding the connecting rod into position over the rod journal.
  17. Install the bearing shell (5) on the connecting rod cap (3) with the tang inserted into the machined groove in the cap. Lubricate the bearing surface with clean engine oil.
    CAUTION:

    The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.

    NOTE:

    Do not lubricate the threads of the connecting rod cap bolts (4).

  18. Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten the NEW  connecting rod cap bolts (4) to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
  19. If required, check the connecting rod side clearance. Refer to ROD, PISTON AND CONNECTING .
  20. Repeat the previous steps for each connecting rod bearing cap being installed.
    GC0169583Courtesy of CHRYSLER GROUP, LLC
  21. Remove the temporarily installed cap bolts from main bearing caps 2, 3 and 5. Install the bearing beam (1) with its longer bolts so that the <FRT indication (2) is pointing to the front of the engine.
    GC0162220Courtesy of CHRYSLER GROUP, LLC
  22. Tighten the ten main bearing cap bolts in the sequence shown, following this 3 step torque plus angle method. Tighten according to the following torque values:
    • Step 1: All to 15 N.m (11 ft. lbs.)
    • Step 2: All to 45 N.m (33 ft. lbs.)
    • Step 3: All an additional 45° Turn Do not use a torque wrench for this step. 
  23. Check the crankshaft end play. Refer to BEARING(S), CRANKSHAFT, MAIN .
  24. Install the crankshaft position sensor. Refer to SENSOR, CRANKSHAFT POSITION, REMOVAL AND INSTALLATION .
  25. Install the cylinder head, if removed. Refer to CYLINDER HEAD, REMOVAL AND INSTALLATION .
  26. Install the crankshaft sprockets and timing chain. Refer to CHAIN AND SPROCKETS, TIMING, REMOVAL AND INSTALLATION .
  27. Install the ladder frame, balance shaft/oil pump assembly, engine timing cover, oil pan and cylinder head cover. Refer to FRAME, LADDER, REMOVAL AND INSTALLATION .
  28. Install the spark plugs and ignition coils. Refer to SPARK PLUG, REMOVAL AND INSTALLATION .
  29. Install a new rear crankshaft oil seal. Refer to SEAL, CRANKSHAFT OIL, REAR, REMOVAL AND INSTALLATION .
  30. Install the transmission to the engine and install the engine in the vehicle. Refer to REMOVAL AND INSTALLATION .
  31. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to OIL .
  32. Fill the transmission. Refer to STANDARD PROCEDURES .
  33. Fill the cooling system. Refer to STANDARD PROCEDURE .
  34. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
  35. Evacuate and charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  36. Start engine and check for leaks.
  37. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
NOTE:

The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.

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