A. LX (RWD and AWD) Engine Inspection

1. Open the trunk lid or tailgate.

2. Raise the cargo floor panel to access the battery.

3. Disconnect the battery.

NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure.

4. Open the hood.

5. Remove the engine oil dipstick.

6. Remove the generator upper support bracket.

7. Remove the dipstick tube mounting bolt and remove the dipstick tube from the engine oil pan.

8. Lock the steering wheel in the straight ahead position.

9. Raise the vehicle on a suitable hoist.

10. Remove the lower plastic splash shield from under the engine.

11. Drain engine oil and remove the engine oil filter.

12. Install the engine oil drain plug into the engine oil pan and tighten.

13. For AWD models:

a. Lower the vehicle part way to perform suspension operations.

b. Remove the right and left front wheel and tire assembly.





c. Remove the right and left vehicle speed sensors from the steering knuckle (Figure 1).

d. Remove the right and left upper control arm ball joint bolt and separate the steering knuckle from the upper control arm (Figure 2).

e. Remove the right and left brake calipers. Set them aside.

CAUTION:
Do not let the calipers hang by the brake hose.

f. Remove the right and left brake pads and set them aside for reuse.

g. Remove the right and left hub nuts holding the right and left axle shafts to the hubs.





h. Remove the right and left sway bar link bolts to the strut clevis brackets and locate the sway bar and links away from the lower control arm (Figure 2).

i. Separate the left axle shaft from the steering knuckle.

j. Separate left axle shaft from the differential extension housing.

k. Remove the left axle shaft from the vehicle.

l. Remove the left tie-rod end from the steering knuckle.

m. Remove the left strut to lower control arm bolt and separate the strut from the arm.





n. Remove the differential extension (Figure 3).

o. Separate the right axle shaft from the steering knuckle.

p. Remove the right axle shaft from the vehicle.

q. Remove the right tie rod end from the steering knuckle.

r. Remove the right strut to lower control arm bolt and separate the strut from the arm.

s. Apply a paint alignment mark to the propeller and front differential flange.

t. Remove the four bolts holding the propeller shaft from the transfer case to the front differential assembly.

u. Plug front differential openings to prevent fluid leakage.





v. Remove front differential and secure it to the engine cradle away from the engine oil pan (Figure 4).

14. Raise the vehicle.

15. Remove the engine oil cooler/filter nipple and set oil cooler aside.

NOTE:
Do not remove the oil cooler coolant hoses from the engine oil cooler.

16. For RWD model:
a. Mark the steering column coupler in relation to the steering gear.





b. Remove the steering column bolt at the coupler and separate the steering column coupler from the steering gear (Figure 5).

c. Remove the two bolts holding the steering rack to the sub frame and allow the steering rack to hang freely.





17. Remove the drive plate access cover to gain access to the rear two engine oil pan bolts (Figure 6).

18. Remove the two rear engine oil pan retaining bolts.

19. Remove the four rear engine oil pan to transmission bell housing bolts.

20. Remove the metal dust shield at the right rear side of oil pan.

21. Remove the remaining oil pan bolts and nuts.

22. Using a putty knife, separate the oil pan from the oil pan gasket. Carefully remove the oil pan. The oil pan gasket should remain attached to the block.

NOTE:
If the oil pan gasket is attached to the block at all four corners, be careful not to dislodge the gasket while completing this section.





23. Remove the oil pickup tube (Figure 7).

24. Remove the stamped metal windage tray. Note which direction the windage tray is facing for installation later (Figure 7).

25. Rotate the crankshaft clockwise until the # 2 connecting rod is at Bottom Dead Center (BDC).





26. Paint mark one side of the # 2 connecting rod bearing cap and connecting rod before removal. This is to aide in the correct orientation during assembly (Figure 8).

27. Remove the # 2 connecting rod cap.








28. Inspect the crankshaft journal and connecting rod bearing shell. A good bearing is shown in Figure 9. A failed bearing is shown in Figure 10. If any of the following conditions are observed, continue with Section C LX Engine Replacement.

a. Significant damage or wear to the connecting rod bearing from any of the following:

> Galling
> Embedded debris
> Tab misalignment
> Fine machining lines are not visible
> Any bronze or copper coloration.
> Fine burrs on the edge of the bearing oil hole.

NOTE:
For detailed color images of acceptable and failed bearings, view this CSN through TechCONNECT.








b. Significant damage to the crankshaft journal for any of the following (Figures 11 & 12):

> Chips or burrs in the oil hole.
> Chips or burrs in oil hole chamfer.
> Finger nail scratch test across the face of the journal surface detects a surface anomaly on an otherwise uniform smooth surface.

NOTE:
For detailed color images of acceptable and failed bearings, view this CSN through TechCONNECT.

29. Check that the connecting rod bearing in the cap is fully seated and the tab is aligned properly.

NOTE:
The joint face of the connecting rod surface and the bearing must be free of particles.

30. Check the upper bearing shell that it is correctly seated in the connecting rod and the bearing tab is properly engaged.

NOTE:
Do not nick the polished crankshaft journal with the connecting rod or any tools.

31. Lubricate the rod bearing with clean 10W30 engine oil.

32. Install the connecting rod cap to the connecting rod with the paint marks of Step 26 aligned. Hand seat the connecting rod bolts. Tighten the connecting rod fasteners to 20 ft. lbs. (27 N.m).





33. Once the proper torque is reached, wipe clean the screw head and connecting rod cap of oil. Draw a line with a paint pen between connecting rod cap and the connecting rod screw head to indicate that each bolt torque was verified (Figure 13).

34. Tighten both rod bolts another 90 degrees (1/4 turn).

35. Install windage tray in the direction noted in Step 24. Lubricate windage tray bolts with engine oil and finger tighten all bolts. Tighten the windage tray bolts to 20 ft. lbs. (27 N.m).

36. Paint mark each windage tray bolt at the bolt flange to the windage tray.

37. Beginning with any center windage tray bolt, turn the bolt clockwise until the paint mark shows it has rotated 90� from the initial position.

38. Repeat Step 37 with each windage tray bolt in a circular sequence ending with the outer most bolts.

39. Inspect the oil pick-up tube "O" ring for damage. If damaged replace with P/N 04792068.

40. Install oil pickup tube and tighten bolt to 21 ft. lbs. (28 N.m).

CAUTION:
Do not to damage the oil pick up tube O-ring during installation. Make sure it is correctly seated in the hole.

41. Clean the engine oil pan.

42. If the oil pan gasket is still attached to the engine at all four corners, use a clean shop cloth and wipe the oil pan gasket surfaces and continue with Step 47. If the engine oil pan gasket was removed or has come loose, continue with Step 43.

CAUTION:
Do not use any cleaning fluids (such as brake cleaner) to clean gasket surfaces. Damage to the gasket will result.

43. Clean the block oil pan gasket surface.

44. Obtain new oil pan gasket: P/N 04792869AA





45. Apply a 1/8 inch bead of Mopar Engine RTV (PN 82300234) at the parting line of the oil pump housing and the rear seal retainer (Figure 14).

46. Align the engine oil pan gasket onto the engine oil pan.





47. Raise the oil pan to the engine and hand-start one 8 mm oil pan bolt into the engine block at the rear most position and one nut at the diagonal front corner stud (Figure 15).

48. Hand-start one 8 mm oil pan bolt into the engine block at the other rear most position and one nut at the remaining diagonal front corner stud (Figure 15).

49. Push the engine rear face of the oil pan flush against the transmission bell housing and hand tighten the two outer rear oil pan bolts and two front nuts until the pan is snug (Figure 15).





50. Install one engine oil pan to transmission bell housing 10 mm bolt at the right lower hole (Figure 16).

51. Install one engine oil pan to transmission bell housing 10 mm bolt at the left lower hole (Figure 16).

52. Pre-tighten the two engine oil pan to transmission bell housing 10 mm bolts installed in Step 50 and 51 to 12 in. lbs. (1.4 N.m ).

53. Hand-start each of the remaining engine oil pan bolts and nuts.

54. Tighten the oil pan bolts as follows:

a. Tighten the right rear engine oil pan bolt first to 20 ft. lbs. (28 N.m) (Figure 15).

b. Tighten the left rear engine oil pan bolt to 20 ft. lbs. (28 N.m) (Figure. 15).

c. Tighten the two 6 mm engine oil pan bolt located in the access opening to 105 in. lbs (12 N.m) (Figure 15).

55. Tighten the remaining 8 mm oil pan bolts and nuts to 20 ft. lbs. (28 N.m).

56. Position the metal dust shield at the right rear side of oil pan and hand-start the two remaining engine oil pan to transmission bell housing bolts.

57. Tighten the four 10 mm engine oil pan to transmission bell housing bolts to 40 ft. lbs. (55 N.m).

58. Install the torque converter access cover (Figure 16) and tighten the fastener to 97 in. lbs. (11 N.m).

59. Wipe clean both the upper engine oil cooler sealing "O" ring and the oil filter sealing surface.

60. Position oil cooler to fitting on oil pan. The notch in the engine oil pan oil cooler pad must fit into the cut-out of the oil cooler.

61. While holding the engine oil cooler in position, install the oil cooler/filter nipple and tighten to 45 ft. lbs. (61 N.m).

NOTE:
Do not over tighten. Damage to the oil cooler will occur.

62. Install a new oil filter and tighten to 106 in. lbs. (12 N.m).

63. For AWD models:

a. Lower the vehicle part way to perform suspension operations.





b. Install the front differential and tighten bolts to 47 ft. lbs. (64 N.m) (Figure 17).

c. Remove the opening plugs from the differential.

d. Align the propeller shaft to the differential flange to the mark made in Step 13(s). Install the four bolts and tighten to 47 ft. lbs. (64 N.m).

e. Install the right strut to the lower control arm. Tighten the bolt to 84 ft. lbs. (114 N.m).

f. Install the right tie rod end to the steering knuckle and tighten the nut to 60 ft. lbs. (81 N.m).

g. Install the right axle shaft into the differential housing.

h. Install the right axle shaft into the steering knuckle.





i. Install the differential extension housing (left side of vehicle) to the engine oil pan and tighten bolts to 48 ft. lbs. (65 N.m) (Figure 18).

j. Install the left strut to lower control arm and tighten bolt to 84 ft. lbs. (114 N.m).

k. Install the left tie-rod end to the steering knuckle and tighten nut to 60 ft. lbs. (81 N.m).

l. Install axle shaft into the differential extension housing.

m. Install axle shaft into the steering knuckle.





n. Install left and right sway bar link bolts to the strut clevis brackets and tighten bolt to 95 ft. lbs. (128 N.m) (Figure 19).

o. Install right and left hub nuts to right and left axles and tighten to 157 ft. lbs. (213 N.m).

p. Install right and left brake pads and calipers. Tighten caliper bolts to 44 ft. lbs. (60 N.m).

q. Install right and left upper control arm ball joint to steering knuckle. Tighten the bolt to 35 ft. lbs. (47 N.m) + 90° (Figure 19).





r. Install right and left vehicle speed sensors to the steering knuckle. Tighten bolts to 96 in. lbs. (11 N.m) (Figure 20).

s. Install right and left front wheel and tire assembly and tighten the lug nuts to 110 ft. lbs. (149 N.m).

t. Check the front differential for proper differential oil level. Adjust as needed.

64. For RWD models:

a. Install the steering rack to the sub-frame and tighten the bolts to 75 ft. lbs. (102 N.m).

b. Align the steering coupler to the steering gear using the mark made in Step 16 (a).

c. Install the steering coupler bolt and tighten to 40 ft. lbs. (54 N.m).

65. Install the lower plastic splash shield underneath the engine.

66. Lower the vehicle to the ground.

67. Inspect the dipstick tube "O" ring for damage. Replace the "O" if necessary (PN 05003905AA).

68. Install the dipstick tube into the oil pan.

69. Install the dipstick tube mounting bolt and tighten to 30 ft. lbs. (41 N.m).

70. Install the generator upper support bracket and tighten bolts to 48 ft. lbs. (65 N.m).

71. Install the engine dipstick.

72. Install six new quarts of 10W30 engine oil into the engine.

73. Connect the battery.

74. Verify the seating of the cargo floor panel.

75. Start the vehicle and inspect for leaks.

76. Return vehicle to the customer.