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Disassembly And Reassembly Following Inspection - 2.4L: Disassembly

GC0164047Courtesy of CHRYSLER GROUP, LLC
  1. Remove the screws (1) and remove the splash shield.
    GC0169024Courtesy of CHRYSLER GROUP, LLC
  2. Mark chain link (1) corresponding to crankshaft sprocket timing mark (2).
    NOTE:

    If the timing chain plated links (1) can no longer be seen, the timing chain links corresponding to the timing marks (2) must be marked prior to removal if the chain is to be reused.

    GC0165462Courtesy of CHRYSLER GROUP, LLC
  3. Mark the chain link (1) corresponding to balance shaft/oil pump sprocket timing mark.
    GC0084902Courtesy of CHRYSLER GROUP, LLC
  4. Reset the balance shaft/oil pump chain tensioner by pushing the plunger inward and installing a pin to hold the plunger in the retracted position.
    GC0169243Courtesy of CHRYSLER GROUP, LLC
  5. Remove the two bolts (4) and the tensioner (3).
  6. Remove the tensioner arm bolt (2) and the tensioner arm (1).
  7. Remove the fixed chain guide bolts (5) and the chain guide (6).
    GC0164673Courtesy of CHRYSLER GROUP, LLC
  8. Remove the screws (1a), disengage the chain from the engine oil pump control and remove the oil pump assembly - balancing assembly (1b).
    GC0169512Courtesy of CHRYSLER GROUP, LLC
  9. Remove the crankshaft sprocket (1).
    GC0098645Courtesy of CHRYSLER GROUP, LLC
  10. Insert a flat bladed screwdriver (7) between the dust lip (8) and the metal case (4) of the crankshaft seal (1). Angle the screwdriver through the dust lip against the metal case of the seal. Pry out the seal.
    CAUTION:

    Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of the screwdriver blade against crankshaft edge (chamfer) is permitted.

  11. Check to make sure the seals garter spring is also removed and is not on the crankshaft.
    GC0164450Courtesy of CHRYSLER GROUP, LLC
  12. Loosen the clamps and disconnect the water supply and return hoses (1) to the engine oil cooler.
    GC0164262Courtesy of CHRYSLER GROUP, LLC
  13. Unlock the engine oil filter and remove it using an appropriate oil filter wrench (1).
    GC0164226Courtesy of CHRYSLER GROUP, LLC
  14. Remove the screws and remove the heat shield (1).
    GC0165352Courtesy of CHRYSLER GROUP, LLC
  15. Unscrew the filler (1) and remove the motor oil cooler.
    GC0169267Courtesy of CHRYSLER GROUP, LLC
  16. Remove the mounting bolt (2) and remove the knock sensor (1).
    GC0169562Courtesy of CHRYSLER GROUP, LLC
  17. Remove the mounting bolt (3) and remove the Crankshaft Position (CKP) sensor (1).
    GC0156354Courtesy of CHRYSLER GROUP, LLC
  18. Remove the oil pressure sensor (2).
    GC0165881Courtesy of CHRYSLER GROUP, LLC
  19. Remove the nuts (1) securing the coolant tube to the water pump body (2b).
  20. Remove the bolts (2a) and the water pump body (2b).
  21. Remove and discard the gasket.
    GC0166167Courtesy of CHRYSLER GROUP, LLC
  22. If necessary, remove the bolts (1) and the water pump.
    GC0169358Courtesy of CHRYSLER GROUP, LLC
  23. Remove the three bolts (2) and the generator mounting bracket (1) from the engine.
    GC0169431Courtesy of CHRYSLER GROUP, LLC
  24. Remove the three bolts (2) and the intermediate shaft bearing support (1) from the engine, if equipped.
    GC0121277Courtesy of CHRYSLER GROUP, LLC
  25. Remove the ladder frame bolts and separate the ladder frame from the engine block.
    GC0162220Courtesy of CHRYSLER GROUP, LLC
  26. Loosen the ten main bearing cap bolts.
  27. Remove the bearing beam bolts (1 - 6) and remove the bearing beam. 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.
    GC0081705Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.

    CAUTION:

    DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur.

  28. Mark connecting rod and bearing cap positions (1) using a permanent ink marker or scribe tool.
    GC0152767Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Typical I4 engine configuration shown in illustration.

  29. If necessary, remove the top ridge of the cylinder bores with a reliable ridge reamer before removing the pistons from the engine block. Be sure to keep the tops of pistons covered during this operation.  Pistons and connecting rods must be removed from the top of the engine block. When removing piston and connecting rod assemblies from the engine, rotate the crankshaft CW so that each connecting rod is centered in the cylinder bore.
  30. Remove the connecting rod cap bolts (4) and the connecting rod cap (3). Discard the cap bolts (4).
    CAUTION:

    Care must be taken not to nick crankshaft journals, as engine damage may occur.

  31. Install the special tool (#10281, Pins, Connecting Rod Guide) (6) on the connecting rod being removed.
    CAUTION:

    Avoid contact with the piston oil cooler jet(s). Positioning of the oil cooler jet(s) is critical for proper engine operation.

  32. Remove the connecting rod and piston assembly (1) complete with upper bearing shell (7) from the cylinder bore.
  33. Repeat the previous steps for each piston being removed.
  34. Immediately after piston and connecting rod removal, reinstall the bearing cap (3) on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
  35. If required, remove the piston rings. Refer to RING(S), PISTON, REMOVAL AND INSTALLATION .
    GC0081626Courtesy of CHRYSLER GROUP, LLC
  36. Measure the crankshaft end play and compare it to the specification. Refer to TECHNICAL SPECIFICATIONS .
    NOTE:

    Crankshaft thrust bearings are not selectable and are only available in a single thickness.

    CAUTION:

    DO NOT use a number stamp or a punch to mark main bearing caps, as damage to main bearings could occur.

  37. Mark the main bearing cap positions using a permanent ink marker or a scribe tool.
    NOTE:

    Main bearing caps are not interchangeable and are marked to insure correct assembly.

  38. Remove the main bearing cap bolts and remove the main bearing caps.
    GC0144295Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Do not rest the crankshaft on the target wheel (1). Damaged or bent target wheel teeth will destroy the target wheels ability to correctly relay crankshaft position to the crankshaft position sensor.

  39. Lift the crankshaft from the cylinder block. Do not damage the main bearings or journals when removing the crankshaft.
  40. If required, remove the four screws (2) and the target wheel (1) from the crankshaft.
  41. Remove the lower main bearing shells from the main bearing caps.
  42. Remove the upper main bearing shells from the engine block.
  43. Remove the crankshaft thrust bearings.
    GC0084060Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Rear plug shown in illustration, other plugs are similar.

  44. Remove the water galley and oil galley plugs (2).
    GC0103050Courtesy of CHRYSLER GROUP, LLC
  45. Remove the bolt (1) and the piston oil cooler jets (2).
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