Turn JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 3±wire, solid-state engine oil pressure sensor
(sending unit) is located in an engine oil pressure
gallery.
OPERATION
The oil pressure sensor uses three circuits. They
are:
²A 5±volt power supply from the Powertrain Con-
trol Module (PCM)
²A sensor ground through the PCM's sensor
return
²A signal to the PCM relating to engine oil pres-
sure
The oil pressure sensor has a 3±wire electrical
function very much like the Manifold Absolute Pres-
sure (MAP) sensor. Meaning different pressures
relate to different output voltages.
A 5±volt supply is sent to the sensor from the PCM
to power up the sensor. The sensor returns a voltage
signal back to the PCM relating to engine oil pres-
sure. This signal is then transferred (bussed) to the
instrument panel on either a CCD or PCI bus circuit
(depending on vehicle line) to operate the oil pressure
gauge and the check gauges lamp. Ground for the
sensor is provided by the PCM through a low-noise
sensor return.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise vehicle on hoist.
(3) Remove front splash shield.
(4) Disconnect oil pressure sender wire (Fig. 78).
(5) Remove the pressure sender (Fig. 78).
INSTALLATION
(1) Install oil pressure sender.
(2) Connect oil pressure sender wire.
(3) Install front splash shield.
(4) Lower vehicle.
(5) Connect the negative battery cable.
OIL PUMP
REMOVAL
(1) Remove the oil pan and pick-up tube (Refer to
9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(2) Remove the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(3) Remove the timing chains and tensioners
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL).
(4) Remove the four bolts, primary timing chain
tensioner and the oil pump.
DISASSEMBLY
(1) Remove oil pump cover screws and lift off cover
plate.
(2) Remove pump inner and outer rotors.
NOTE: Once the oil pressure relief valve, cup plug,
and pin are removed, the pump assembly must be
replaced.
(3) If it is necessary to remove the pressure relief
valve, drive the roll pin from pump housing and
remove cup plug, spring and valve.
Fig. 78 Oil Pressure Sending Unit
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
KJENGINE - 3.7L 9 - 65

ENGINE - 2.4L
DESCRIPTION
The 2.4 Liter (148 cu. in.) in-line four cylinder
engine is a double over head camshaft with hydraulic
lifters and four valve per cylinder design. The engine
is free-wheeling; meaning it has provisions for piston-
to-valve clearance. However valve-to-valve interference
can occur, if camshafts are rotated independently.
The cylinders are numbered from front of the
engine to the rear. The firing order is 1±3±4±2.
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.WARNING: DO NOT REMOVE THE PRESSURE CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the pressure cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.
Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.
(4) Remove the Auto Shutdown (ASD) relay from
the PDC.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gage adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0±500 psi (Blue) pressure
transducer with cable adaptors to the DRBIIIt.
Fig. 1 ENGINE IDENTIFICATION
1 - ENGINE IDENTIFICATION
KJENGINE9s-3

(7) Crank engine until maximum pressure is
reached on gage. Record this pressure as #1 cylinder
pressure.
(8) Repeat the previous step for all remaining cyl-
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
INSPECTION
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair as necessary.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.
(5)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
²Disconnect the fresh air hose (make-up air) at
the cylinder head cover and plug or cap the nipple on
the cover.
²Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
²Attach an air hose with pressure gauge and reg-
ulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.²Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
²If the leakage occurs at the crankshaft rear oil
seal area, refer to the section, Inspection for Rear
Seal Area Leak.
(6) If no leaks are detected, turn off the air supply.
Remove the air hose, all plugs, and caps. Install the
PCV valve and fresh air hose (make-up air). Proceed
to next step.
(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
NOTE: If oil leakage is observed at the dipstick tube
to block location; remove the tube, clean and reseal
using MoparTStud & Bearing Mount (press fit tube
applications only), and for O-ring style tubes,
remove tube and replace the O-ring seal.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area, remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crank-
case as previously described.
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
9s - 4 ENGINEKJ
ENGINE - 2.4L (Continued)

DESCRIPTION SPECIFICATION
Valve Springs
Free Length (Approx.) 48.4 mm
(1.905 in.)
Nominal Force (Valve
Closed)338 N @ 38.0 mm
(75.98 lbs. @ 1.496 in.)
Nominal Force (Valve
Open)607 N @ 29.75 mm
(136 lbs. @ 1.172 in.)
Installed Height 38.00 mm
(1.496 in.)
Number of Coils 7.82
Wire Diameter 3.86 mm
(1.496 in.)
Oil Pump
Clearance Over Rotors
(Max.)0.10 mm
(0.004 in.)
Cover Out-of-Flat (Max.) 0.025 mm
(0.001 in.)
Inner Rotor Thickness
(Min.)9.40 mm
(0.370 in.)
Outer Rotor Thickness
(Min.)9.40 mm
(0.370 in.)
Outer Rotor Clearance
(Max.)0.039 mm
(0.015 in.)
Outer Rotor Diameter
(Min.)79.95 mm
(3.148 in.)
Tip Clearance Between
Rotors (Max.)0.20 mm
(0.008 in.)
Oil Pressure
At Curb Idle Speed* 25 kPa
(4 psi)
At 3000 rpm 170±550 kPa
(25±80 psi)
CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.SPECIFICATIONS - TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Balance Shaft Carrier to
BlockÐBolts54 40 Ð
Balance Shaft Gear
CoverÐDouble Ended
Fastener12 Ð 105
Balance Shaft SprocketÐ
Bolt28 Ð 250
Balance Shaft Chain
TensionerÐBolts12 Ð 105
Balance Shaft Carrier
CoverÐBolts12 Ð 105
Camshaft SprocketÐBolt 101 75 Ð
Connecting Rod
CapÐBolts54 +
1¤4
turn40
+1¤4
turnÐ
Crankshaft Main Bearing
Cap/Bedplate
ÐM8 Bolts 34 250
ÐM11 Bolts 41 +
1¤4
Turn30
+1¤4
TurnÐ
Crankshaft Damper 136 100 Ð
Cylinder HeadÐBolts (Refer to 9 - ENGINE/
CYLINDER HEAD -
INSTALLATION)
Cylinder Head CoverÐ
Bolts12 Ð 105
Flex Plate to Crankshaft 95 70 Ð
Flywheel Mounting Bolts 81 60 Ð
Engine Mount Bracket
RightÐBolts61 45 Ð
Engine MountingÐBolts (Refer to 9 ENGINE/
ENGINE MOUNTING)
Exhaust Manifold to
Cylinder HeadÐBolts23 Ð 200
Exhaust Manifold Heat
ShieldÐBolts12 Ð 105
Intake Manifold - Lower
ÐBolts28 Ð 250
Oil Filter 20 15 Ð
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pump to BlockÐBolts 28 Ð 250
9s - 16 ENGINEKJ
ENGINE - 2.4L (Continued)

Remove all gasket material from cylinder head and
block (Refer to 9 - ENGINE - STANDARD PROCE-
DURE). Be careful not to gouge or scratch the alumi-
num head sealing surface.
Clean all engine oil passages.
INSPECTION
(1) Cylinder head must be flat within 0.1 mm
(0.004 in.) (Fig. 6).
(2) Inspect camshaft bearing journals for scoring.
(3) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(4) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 7). (Refer to 9 - ENGINE - SPECIFICA-
TIONS) Replace guides if they are not within
specification.
(5) Check valve guide height (Fig. 8).
INSTALLATION - CYLINDER HEAD
NOTE: The Cylinder head bolts should be examined
BEFORE reuse. If the threads are necked down, the
bolts must be replaced (Fig. 9).
Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale, the bolt should be replaced.
(1) Before installing the bolts, the threads should
be coated with engine oil.
(2) Position cylinder head gasket on engine block
(Fig. 10).
(3) Install cylinder head on engine block.
(4) Tighten the cylinder head bolts in the sequence
shown in (Fig. 11). Using the 4 step torque turn
method, tighten according to the following values:
²First All to 34 N´m (25 ft. lbs.)
²Second All to 68 N´m (50 ft. lbs.)
Fig. 6 Checking Cylinder Head Flatness
1 - FEELER GAUGE
2 - STRAIGHT EDGE
Fig. 7 Checking Wear on Valve GuideÐTypical
1-TOP
2 - MIDDLE
3 - BOTTOM
4 - CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS
Fig. 8 Valve Guide Height
1 - VALVE GUIDE
2 - 13.25 - 13.75 MM (.521 - .541 IN.)
3 - SPRING SEAT
Fig. 9 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
KJENGINE9s-21
CYLINDER HEAD (Continued)

²Third All to 68 N´m (50 ft. lbs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
²Fourth Turn an additional 1/4 Turn,
(5) Install rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - INSTALLA-
TION)
(6) Install camshafts. (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(7) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(8) Install timing belt rear cover and timing belt
idler pulley. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - INSTALLA-
TION)
(9) Install timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
(10) Connect cam sensor and fuel injectors wiring
connectors.(11) Install ignition coil and wires. Connect igni-
tion coil wiring connector.
(12) Install accessary drive bracket.
(13) Install power steering pump to cylinder head.
(14) Raise vehicle and install the exhaust pipe to
the manifold.
(15) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(16) Install heater tube support bracket to cylinder
head.
(17) Install intake manifold.
(18) Connect all vacuum lines, electrical wiring,
ground straps and fuel line.
(19) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(20) Connect battery negative cable.
CAMSHAFT OIL SEAL(S)
REMOVAL
(1) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(2) Hold each camshaft sprocket with Special Tool
6847 while removing center bolt (Fig. 12).
(3) Remove camshaft sprockets.
(4) Remove exhaust camshaft target ring.
(5) Remove exhaust camshaft sensor.
CAUTION: Inspect sensor and target ring for exces-
sive wear. Clean sensor face and install new spacer
pad.
(6) Remove rear timing belt cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(7) Remove camshaft seal using Special Tool
C-4679-A (Fig. 13).
CAUTION: Do not nick shaft seal surface or seal
bore.
INSTALLATION
NOTE: Clean and inspect sensor and target ring for
excessive wear. Clean sensor face and always
install a new spacer pad.
(1) Shaft seal surface must be free of varnish, dirt
or nicks. Polish with 400 grit paper if necessary.
(2) Install camshaft seals into cylinder head using
Special Tool MD-998306 until flush with head (Fig.
14).
Fig. 10 Cylinder Head Gasket Positioning
1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER
Fig. 11 Cylinder Head Tightening Sequence
9s - 22 ENGINEKJ
CYLINDER HEAD (Continued)

(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
(4) Low oil pressure.
(5) The oil restrictor (integral to the head gasket)
in the vertical oil passage to the cylinder head is
plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
b. Remove suspected lash adjusters, and replace as
necessary.
REMOVAL
NOTE: This procedure is for in-vehicle service with
camshafts installed.
(1) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(2) Remove the camshafts (Refer to 9 - ENGINE/
CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).
(3) Remove rocker arm. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - REMOVAL)
(4) Remove hydraulic lifter (Fig. 30).(5) Repeat removal procedure for each hydraulic
lifter.
(6) If reusing, mark each hydraulic lifter for reas-
sembly in original position. Lifters are serviced as an
assembly.
INSTALLATION
(1) Install hydraulic lifter (Fig. 30). Ensure the
lifters are at least partially full of engine oil. This is
indicated by little or no plunger travel when the
lifter is depressed.
(2) Install rocker arm. (Refer to 9 - ENGINE/CYL-
INDER HEAD/ROCKER ARMS - INSTALLATION)
(3) Repeat installation procedure for each hydrau-
lic lifter.
(4) Install camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(5) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
ROCKER ARMS
REMOVAL
NOTE: This procedure is for in-vehicle service with
camshafts installed.
(1) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(2) Remove fuel rail. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - REMOVAL)
(3) Remove spark plugs.
(4) Rotate engine until the camshaft lobe, on the
follower being removed, is position on its base circle
(heel). Also, the piston should be a minimum of 6.3
mm (0.25 in) below TDC position.
Fig. 29 Checking Spring Installed Height and Valve
Tip Height Dimensions
1 - GARTER SPRING
2 - VALVE SPRING SEAT
3 - CYLINDER HEAD SURFACE
Fig. 30 Hydraulic Lash Adjuster
KJENGINE9s-29
HYDRAULIC LIFTERS (Continued)

INSPECTION
ENGINE BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are to be installed, (Refer to 9
- ENGINE - STANDARD PROCEDURE - ENGINE
CORE AND OIL GALLERY PLUGS).
(3) Examine block and cylinder bores for cracks or
fractures.
(4) Check block deck surfaces for flatness. Deck
surface must be within service limit of 0.1 mm (0.004
in.).
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
The cylinder walls should be checked for out-of-
round and taper with Tool C119 or equivalent (Fig.
37) (Refer to 9 - ENGINE - SPECIFICATIONS). If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 37). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
(Refer to 9 - ENGINE - SPECIFICATIONS).
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING
(1) For measuring connecting rod bearing clear-
ance procedure and use of Plastigage(Refer to 9 -
ENGINE - STANDARD PROCEDURE). For bearing
clearance refer to Engine Specifications. (Refer to 9 -
ENGINE - SPECIFICATIONS)
NOTE: The rod bearing bolts should not be reused.
(2) Before installing theNEWbolts the threads
should be oiled with clean engine oil.
(3) Install each bolt finger tight then alternately
torque each bolt to assemble the cap properly.
(4) Tighten the bolts to 27 N´m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn)Do not use a torque
wrench for last step.
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 38). Refer to clearance specifications
(Refer to 9 - ENGINE - SPECIFICATIONS).
CRANKSHAFT
DESCRIPTION
The crankshaft is made of nodular cast iron and
includes five main bearing journals and four connect-
ing rod journals (Fig. 39). The number three journal
is the location for the thrust bearing. The mains and
connecting rod journals have undercut fillet radiuses
that are rolled for added strength. To optimize bear-
ing loading, eight counterweights are used.
Fig. 37 Checking Cylinder Bore Size
Fig. 38 Connecting Rod Side Clearance
9s - 32 ENGINEKJ
ENGINE BLOCK (Continued)

(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 cylin-
der block.
(8) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 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 it's furthest forward position.
²Step 5: Install and tighten bolts (1±10) in
sequence shown in (Fig. 45) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1±10) again to 41 N´m (30 ft.
lbs.) +1/4 turn in sequence shown in (Fig. 45).
(10) Install main bearing bedplate to engine block
bolts (11±20), and torque each bolt to 28 N´m (20 ft.
lbs.) in sequence shown in (Fig. 45).
(11) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
(12) Install balance shafts and housing assembly.
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - INSTALLATION)
(13) Install the oil pump and pickup tube. (Refer
to 9 - ENGINE/LUBRICATION/OIL PUMP -
INSTALLATION)
(14) Install the timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(15) Install the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
(16) Install the timing belt front covers. (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(17) Install engine support bracket.
(18) Install the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION)
(19) Install the oil filter.
(20) Install crankshaft rear oil seal. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - INSTALLATION)
(21) Install flex plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten to 95 N´m (70
ft. lbs.).(22) Install the engine assembly. (Refer to 9 -
ENGINE - INSTALLATION)
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - MAIN BEARING -
FITTING
For crankshaft specifications (Refer to 9 - ENGINE
- SPECIFICATIONS).
CRANKSHAFT MAIN BEARINGS
The crankshaft is supported in five main bearings.
All upper and lower bearing shells in the crankcase
have oil grooves. Crankshaft end play is controlled by
a flanged bearing on the number three main bearing
journal (Fig. 46).
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. 46). 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: 0.025 mm
(0.001 in.) and 0.250 mm (0.010 in.). Never install an
undersize bearing that will reduce clearance below
specifications. Replace or machine the crankshaft as
necessary to obtain proper bearing clearances.
MAIN BEARING INSTALLATION
(1) Install the main bearing shells with the lubri-
cation groove in the cylinder block (Fig. 47).
Fig. 46 Main Bearing Identification
1 - OIL GROOVE
2 - MAIN BEARINGS
3 - OIL HOLE
KJENGINE9s-35
CRANKSHAFT (Continued)

(2) Make certain oil holes in block line up with oil
holes in bearings. Bearing tabs must seat in the
block tab slots.
CAUTION: Do not get oil on the bedplate mating
surface. It will may effect the sealer ability to seal
the bedplate to cylinder block.
(3) Oil the bearings and journals and install
crankshaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine. Ensure that both cylinder block and bed-
plate surfaces are clean.
(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead
of anaerobic sealer MopartBed Plate Sealant to cyl-
inder block as shown in (Fig. 48).(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots.
(6) Position the main bearing/bedplate onto the
engine block.
(7) Before installing bolts, lubricate the threads
with clean engine oil, wipe off any excess oil.
(8) Install main bearing bedplate to engine block
bolts 11, 17 and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(9) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 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 it's furthest forward position.
²Step 5: Install and tighten bolts (1±10) in
sequence shown in (Fig. 49) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(10) Tighten bolts (1±10) again to 41 N´m (30 ft.
lbs.)PLUS1/4 turn in sequence shown in (Fig. 49).
(11) Install main bearing bedplate to engine block
bolts (11±20), and torque each bolt to 28 N´m (20 ft.
lbs.) in sequence shown in (Fig. 49).
(12) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
Fig. 47 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
Fig. 48 Main Bearing Caps/Bedplate Sealing
Fig. 49 Main Bearing Caps/Bedplate Tightening
Sequence
9s - 36 ENGINEKJ
CRANKSHAFT MAIN BEARINGS (Continued)