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Fig. 2 Removing Rear Crankshaft Oil Seal

(2)Place Special Tool C-4681 on crankshaft (Fig. 3).

(3)Lightly coat seal O.D. with Loctite Stud N' Bearing Mount or equivalent.

(4)Place seal over Tool C-4681 and tap in place with a plastic hammer.

Fig. 3 Installing Rear Crankshaft Oil Seal

REAR CRANKSHAFT SEAL RETAINER AND OIL SEAL

When retainer removal is required, use Mopar Gasket Maker applied as shown in (Fig. 4) to provide retainer to block sealing during re-installation.

FRONT CRANKSHAFT SEAL RETAINER

See Timing System and Seals Section for timing belt covers, belt crankshaft sprocket and oil seals removal and installation.

(1) Remove retainer screws (Fig.5).

Fig. 4 Rear Crankshaft Seal Retainer Sealing

Fig. 5 Front Crankshaft Oil Seal Retainer

Fig. 6 Front Crankshaft Seal Retainer Sealing

For reassembly Mopar Gasket Maker is applied to the retainer as shown in (Fig. 6). This material cures in the absence of air providing retainer to block sealing.

(2) Install retainer and tighten screws to 12 Nzm (105 in. lbs.).

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CRANKSHAFT SERVICE

CRANKSHAFT MAIN BEARINGS

Bearing caps are not interchangeable and should be marked at removal to insure correct assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of 1, 2, 4 and 5 are interchangeable. Upper main bearing halves of 1, 2, 4 and 5 are interchangeable (Fig. 7).

CRANKSHAFT MAIN JOURNALS

The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out-of-round on ny crankshaft journals should be held to .025mm (.001 inch). Journal grinding should not exceed .305mm (.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. 7). 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: 0.025mm (.001 inch), .051mm (.002 inch), .076mm (.003 inch),

.254mm (.010 inch), and .305mm (.012 inch). Never install an undersized bearing that will reduce clearance below specifications.

Fig. 7 Main Bearing Identification

2.2/2.5L ENGINES 9 - 43

MAIN BEARING SERVICE−CRANKSHAFT NOT REMOVED

REMOVAL

(1)Remove oil pan and identify bearing caps before removal.

(2)Remove bearing caps one at a time. Remove upper half of bearing by inserting Special Main Bearing Tool C-3059 (Fig.8) into the oil hole of crankshaft.

(3)Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell.

Fig. 8 Removing and Installing Upper Main Bearing

With Special Tool C-3059

INSTALLATION

Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened.

When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side.

(1)Start bearing in place, and insert Main Bearing Tool C-3059 into oil hole of crankshaft (Fig. 8).

(2)Slowly rotate crankshaft counter-clockwise sliding the bearing into position. Remove Special Main Bearing Tool C-3059.

CHECKING CRANKSHAFT END PLAY

(1)Mount a dial indicator to front of engine, locating probe on nose of crankshaft (Fig. 9).

(2)Move crankshaft all the way to the rear of its travel.

(3)Zero the dial indicator.

(4)Move crankshaft all the way to the front and read the dial indicator. Refer to (Fig. 10) for specifications.

OPTIONAL CRANKSHAFT END PLAY CHECK

(1) Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing

Fig. 9 Checking Crankshaft End Play

cap and a crankshaft cheek, using care not to damage any bearing surface. Do not loosen main bearing cap.

(2) Use a feeler gauge between number three thrust bearing and machined crankshaft surface to determine end play.

Fig. 10 Crankshaft Specifications

CRANKSHAFT BEARING CLEARANCE

(1) Refer to Measuring Main, Connecting Rod Bearing Clearance in Standard Service Procedures. Refer to (Fig. 10) for specifications.

CAUTION: Do not rotate crankshaft or the Plastigage may be smeared.

(2) Install the main bearing shells with the lubrication groove in the cylinder block (Fig. 12). The 1, 2, 4 and 5 main bearings are full groove to provide

Fig. 11 Checking Crankshaft Oil Clearance with Plastigage

Fig. 12 Installing Main Bearing Upper Shell

full time oiling to the connecting rod. Only the number 3 is half-groove.

(3)Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots.

(4)Oil the bearing and journals and install crank-

shaft.

(5)Install main bearing cap No.1 on timing belt

end.

(6)Install main bearing cap No. 5 on transmission

end.

Since the main bearing bolts are torqued using a new procedure they should be examined BEFORE reuse. If the threads are necked down the bolts should be replaced (Fig. 15).

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Fig. 13 Main Bearing Caps

Fig. 14 Installing Main Bearing Caps

Necking can be checked by holding a scale or straight edge against the threads or by running a

M11 x 1.50 nut the full length of the thread. If all the threads do not contact the scale or if the nut does not run down smoothly the bolt should be replaced.

(7)Before installing the bolts the threads should be oiled with engine oil.

(8)Install both bolts in each cap finger tight, then alternately torque each bolt to assemble the cap properly.

(9)Tighten the bolts to 41 Nzm plus 1/4 turn (30 ft. lbs. plus 1/4 turn). (Fig. 14)

2.2/2.5L ENGINES 9 - 45

BALANCE SHAFTS

2.2L Turbo III and 2.5L engines are equipped with two balance shafts installed in a carrier attached to the lower crankcase (Fig. 1).

The shafts are interconnected through gears to rotate in opposite directions. These gears are driven by a short chain from the crankshaft, to rotate at two times crankshaft speed. This counterbalances certain engine reciprocating masses.

REMOVAL

Refer to Engine Lubrication and Timing System and Seals Service of this group for removal procedure of necessary components to repair balance shafts.

Fig. 16 Chain Cover, Guide and Tensioner

(1)Remove chain cover, guide and tensioner (Fig. 16). Also see Carrier Assembly Removal for service procedures requiring only temporary relocation of assembly.

(2)Remove balance shaft gear and chain sprocket retaining screws and crankshaft chain sprocket torx screws. Remove chain and sprocket assembly. (Fig. 17)

(3)Remove gear cover retaining stud (double ended to also retain chain guide). Remove cover and balance shaft gears (Fig. 18).

(4)Remove carrier rear cover and balance shafts. (Fig. 19).

(5)Remove six carrier to crankcase attaching bolts to separate carrier (Fig. 1).

Fig. 17 Drive Chain and Sprockets

Fig. 18 Gear Cover and Gears

BALANCE SHAFTS CARRIER ASSEMBLY

REMOVAL

The following components will remain intact during carrier removal. Gear cover, gears, balance shafts and the rear cover.

(1)Remove chain cover and driven balance shaft chain sprocket screw.

(2)Loosen tensioner pivot and adjusting screws, move driven balance shaft inboard through driven chain sprocket. Sprocket will hang in lower chain loop.

(3)Remove carrier to crankcase attaching bolts to remove carrier.

Fig. 19 Balance Shaft(s) Remove/Install

INSTALLATION

Balance shaft and carrier assembly installation is the reverse of the removal procedure. During installation crankshaft to balance shaft timing must be established.

TIMING

(1)With balance shafts installed in carrier (Fig. 19) position carrier on crankcase and install six attaching bolts and tighten to 54 Nzm (40 ft. lbs.).

(2)Turn balance shafts until both shaft key ways are up Parallel to vertical centerline of engine. Install short hub drive gear on sprocket driven shaft and long hub gear on gear driven shaft. After installation gear and balance shaft keyways must be up with gear timing marks meshed as shown in (Fig. 20).

(3)Install gear cover and tighten double ended stud/washer fastener to 12 Nzm (105 in. lbs.).

(4)Install crankshaft sprocket and tighten socket head torx screws to 13 Nzm (130 in. lbs.).