B. CS (FWD & AWD) Engine Inspection
1. Open the hood.2. Disconnect the battery.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure.
3. Remove engine trim cover.
4. Remove engine oil dipstick.
5. Remove dipstick tube mounting bolt and remove the dipstick tube from the engine oil pan.
6. Remove serpentine belt.
7. Raise the vehicle on a suitable hoist.
8. Remove the right wheel well lower splash shield.
9. Remove the four air conditioning compressor bolts. Set the compressor aside and secure.
10. Remove the air conditioning compressor mounting bracket.
11. Remove the power steering return hose bracket and set aside.
12. AWD models: Remove the powertrain structural collar bracket between the engine oil pan and the transmission (Figure 21).
13. Drain engine oil and remove the oil filter.
14. Install the engine oil drain plug into the engine oil pan and tighten.
15. Remove the access cover for the transmission torque converter drive plate bolts (Figure 22).
16. Remove the oil pan bolts and nuts.
17. 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.
18. Remove oil pickup tube (Figure 23).
19. Remove the stamped metal windage tray. Note which direction the windage tray is facing for installation later (Figure 23).
20. Rotate the crankshaft clockwise until the # 2 connecting rod is at Bottom Dead Center (BDC).
21. Paint mark one side of the connecting rod bearing cap and connecting rod before removal. This is to aide in the correct positioning of the connecting rod cap to the connecting rod during assembly (Figure 24).
22. Remove the # 2 connecting rod bearing bolts and rod cap.
23. Inspect the crankshaft journal and connecting rod bearing shell. A good bearing is shown in Figure 25. A failed bearing is shown in Figure 26. If any of the following conditions are observed, continue with Section D - CS 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 27 and 28):
> 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.
24. Check that the connecting rod bearing in the cap is fully seated in the connecting rod cap and the tab is aligned properly.
NOTE:
The joint face of the connecting rod surface and the bearing must be free of particles.
25. Check that the upper bearing shell that it is correctly seated and the bearing tab is properly engaged.
NOTE:
Do not nick the crankshaft journal with the connecting rod or any tools.
26. Lubricate the rod bearing with clean 10W30 engine oil.
27. Install the connecting rod cap to the connecting rod with the paint marks of Step 21 aligned. Hand seat the connecting rod bolts. Tighten the connecting rod fasteners to 20 ft. lbs. (27 N.m).
28. 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 29).
29. Tighten both rod bolts another 90 degrees (1/4 turn).
30. Install windage tray in the direction noted in Step 19. Lubricate windage tray bolts with engine oil and finger tighten all bolts. Tighten the windage tray bolts to 20 ft. lbs. (27 Nm).
31. Paint mark each windage tray bolt at the bolt flange to the windage tray.
32. Beginning with any center windage tray bolt, turn the bolt clockwise until the paint mark shows it has rotated 90� from the initial position.
33. Repeat Step 33 with each windage tray bolt in a circular sequence ending with the outmost bolts.
34. Inspect the oil pick-up tube "O" ring for damage. If damaged, install a new "O" ring P/N 04792068.
35. 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. Make sure it is correctly seated in the hole.
36. Clean the engine oil pan.
37. 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 43. If the engine oil pan gasket was removed or has come loose, continue with Step 39.
CAUTION:
Do not use any cleaning fluids (such as brake cleaner) to clean gasket surfaces. Damage to the gasket will result.
38. Clean the block oil pan gasket surface.
39. Obtain new oil pan gasket P/N 04892072AA.
40. 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 30).
41. Align the oil pan gasket onto the engine oil pan.
42. Install the engine oil pan and hand start the bolts and nuts.
43. Tighten the 8 mm oil pan bolts and nuts to 20 ft. lbs. (28 N.m).
44. Tighten the two 6 mm engine oil pan bolt located in the rear of the engine oil pan to 105 in. lbs. (12 N.m).
45. Install the access cover for the transmission torque converter bolts and tighten the bolts to 97 in. lbs. (11 N.m).
46. For AWD models: Install the powertrain structural bracket between the engine oil pan and the transmission. Tighten the bolts to 40 ft. lbs. (54 N.m).
47. Install the air conditioning mounting bracket and hand start the four bolts. Then tighten the bolts to 30 ft. lbs. (41 N.m) in the sequence as follows (Figure 31):
a. Tighten the upper rear bolt.
b. Tighten the upper front bolt.
c. Tighten the bottom rear bolt.
d. Tighten the bottom front bolt.
NOTE:
Steps 48 and 59 must be followed exactly to minimize belt squealing due to air conditioning compressor pulley miss alignment.
48. Locate the power steering return hose bracket to the upper left A/C compressor clearance hole. Install the four air conditioning compressor bolts snug tight.
49. Install a new engine oil filter.
50. Lower the vehicle.
51. Install the serpentine belt.
52. Inspect the dipstick tube "O" ring for damage. If damaged, install a new "O" ring (PN 05003905AA).
53. Install dipstick tube into the engine oil pan and tighten the mounting bolt to 30 in. lbs. (41 N.m).
54. Connect the battery.
55. Install 5-1/2 quarts of new 10W30 oil into the engine.
56. Start the engine.
57. Check for oil leaks.
58. Raise the engine rpms several times to align the air conditioning compressor to the serpentine belt.
59. Raise the vehicle while the engine is idling.
60. Carefully tighten ONLY THE LOWER TWO air conditioning compressor bolts to 200 in. lbs. (23 N.m).
WARNING:
Keep hands and tools away from the moving serpentine belt while tightening the air conditioning compressor mounting bolts.
61. Lower the vehicle and turn off the ignition.
62. Raise the vehicle and torque the four bolts to the air conditioning compressor to 200 in. lbs. (23 N.m).
63. Install the right wheel well lower splash shield.
64. Lower the vehicle.
65. Install engine trim cover.
66. Return vehicle to the customer.