Dodge Caliber. Manual — part 1107
6. Install thrust bearings (3) in block.
CAUTION: Do not get oil on the ladder frame mat-
ing surface. It will affect the ability of the RTV to
seal the ladder frame to cylinder block.
7. Oil the bearings and journals. Install crankshaft in
engine block.
8. Install lower main bearings (1) into main bearing
cap. Make certain the bearing tabs are seated into
the bearing cap slots.
9. Before installing the bolts the threads should be
clean and dry.
10.
Install main bearing caps to engine block, install
bolts finger tight.
11. To ensure correct thrust bearing alignment, per-
form the following steps:
•
Step 1: Rotate crankshaft until number 4 piston is at 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 and the rear crankshaft counter-
weight. This will hold the crankshaft in it’s furthest forward position.
12. Tighten bolts (1–10) again to 41 N·m (30 ft. lbs.) in sequence shown.
13. Remove wedge tool used to hold crankshaft.
14.
Check the crankshaft turning torque, it should not exceed 5.6 N·m (50 in. lbs.).
15. Check crankshaft end play (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT - STANDARD PROCE-
DURE).
16. Install connecting rod bearings and caps. Do Not Reuse Connecting Rod Bolts. Torque connecting rod bolts
to 27 N·m (20 ft. lbs.) plus 1/4 turn.
17. Install the ladder frame assembly (Refer to 9 - ENGINE/ENGINE BLOCK/LADDER FRAME - INSTALLATION).
18. Install the balance shaft module (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - INSTALLATION).
19. Install the oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION).
20. Install crankshaft position sensor.
21. Install cylinder head if it was removed (Refer to 9 - ENGINE/CYLINDER HEAD - INSTALLATION).
22. Install front crankshaft sprocket.
23. Install the timing chain (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS -
INSTALLATION).
24. Install the timing chain front cover.
25. Install front crankshaft oil seal.
26. Install engine mount support bracket.
27. Install crankshaft vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLA-
TION).
28. 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.
29. Install crankshaft rear oil seal (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR -
INSTALLATION).
30. Install drive plate/flex plate. Apply Mopar
T
Lock & Seal Adhesive to bolt threads and tighten to 95 N·m (70 ft.
lbs.).
31. Attach transaxle to engine. Tighten attaching bolts to 101 N·m (75 ft. lbs.).
32. Install the engine assembly (Refer to 9 - ENGINE - INSTALLATION).
33. Install new oil filter and fill with oil.
34. Start engine and check for leaks.
PM
ENGINE 2.4L WORLD
9 - 1715
SEAL-FRONT CRANKSHAFT OIL
REMOVAL
1. Remove the crankshaft vibration damper (Refer to
9
-
ENGINE/ENGINE
BLOCK/VIBRATION
DAMPER - REMOVAL).
2. Remove front crankshaft oil seal (1) by prying out
with a screw driver (2). Be careful not to damage
the cover seal surface.
INSTALLATION
1. Place seal (1) onto Seal installer 9506 (2) with seal
spring towards the inside of engine.
9 - 1716
ENGINE 2.4L WORLD
PM
2. Install new seal (1) by using Seal installer 9506 (2)
and crankshaft damper bolt (3).
3. Press seal into front cover until Seal Installer 9506
(1) seats against timing chain cover (3).
4. Remove seal installer 9506 (1).
5. Install crankshaft vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION.
PM
ENGINE 2.4L WORLD
9 - 1717
SEAL- REAR CRANKSHAFT OIL
REMOVAL
1. Remove transaxle
2. Remove flex plate bolts and discard.
3. Remove flex plate (1).
4. Insert a 3/16 flat bladed screwdriver (7) between
the dust lip (8) and the metal case (4) of the crank-
shaft seal (1). Angle the screwdriver through the
dust lip against metal case of the seal. Pry out
seal.
CAUTION: Do not permit the screwdriver blade to
contact crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (cham-
fer) is permitted.
9 - 1718
ENGINE 2.4L WORLD
PM
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