Page 1689 of 5267

INSPECTION
1. It is mandatory to use a dial bore gauge to mea-
sure each cylinder bore diameter. To correctly
select the proper size piston, a cylinder bore
gauge, capable of reading in 0.003 mm (.0001 in.)
INCREMENTS is required. If a bore gauge is not
available, do not use an inside micrometer.
2. Measure the inside diameter of the cylinder bore at
three levels below top of bore. Start perpendicular
(across or at 90 degrees) to the axis of the crank-
shaft and then take two additional reading.
3. Measure the cylinder bore diameter crosswise to
the cylinder block near the top of the bore. Repeat
the measurement near the middle of the bore, then
repeat the measurement near the bottom of the
bore.
4. Determine taper by subtracting the smaller diame-
ter from the larger diameter.
5. Rotate measuring device 90° and repeat steps
above.
6. Determine out-of-roundness by comparing the dif-
ference between each measurement.
7. If cylinder bore taper does not exceed 0.025 mm (0.001 inch) and out-of-roundness does not exceed 0.015 mm
(0.0006 inch), the cylinder bore can be honed. If the cylinder bore taper orout- of-round condition exceeds these
maximum limits, the cylinder block must be replaced. A slight amount of taper always exists in the cylinder bore
after the engine has been in use for a period of time.
Page 1690 of 5267
BEARINGS - CONNECTING ROD
STANDARD PROCEDURE - CONNECTING ROD BEARING FITTING
Inspect the connecting rod bearings for scoring. Check
the bearings for normal wear patterns, scoring, groov-
ing, fatigue and pitting. Replace any bearing that
shows abnormal wear.
Inspect the connecting rod journals for signs of scor-
ing, nicks and burrs.
Misaligned or bent connecting rods can cause abnor-
mal wear on pistons, piston rings, cylinder walls, con-
necting rod bearings and crankshaft connecting rod
journals. If wear patterns or damage to any of these
components indicate the probability of a misaligned connecting rod, inspect it for correct rod alignment. Replace
misaligned, bent or twisted connecting rods.
1. Wipe the oil from the connecting rod journal.
2. Lubricate the upper bearing insert (2) and install in
connecting rod (1).Center bearing insert (2) in
connecting rod.
Page 1691 of 5267
3. Use piston ring compressor (3) and Guide Pins
Special Tool 8507 (4) to install the rod and piston
assemblies. The oil slinger slots in the rods must
face front of the engine. The “F”’s near the piston
wrist pin bore should point to the front of the
engine.
4. Install the lower bearing insert in the bearing cap
Center bearing insert (2) in connecting rod (1)..
The lower insert must be dry. Place strip of Plasti-
gage across full width of the lower insert at the
center of bearing cap. Plastigage must not crumble
in use. If brittle, obtain fresh stock.
Page 1692 of 5267

5. Install bearing cap and connecting rod on the jour-
nal and tighten bolts to 27 Nꞏm (20 ft. lbs.) plus a
90° turn. DO NOT rotate crankshaft. Plastigage will
smear, resulting in inaccurate indication.
6. Remove the bearing cap and determine amount of
bearing-to-journal clearance by measuring the
width of compressed Plastigage (2). Refer to
Engine Specifications for the proper clearance.
Plastigage should indicate the same clearance
across the entire width of the insert. If the
clearancevaries,itmaybecausedbyeithera
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
7. If the correct clearance is indicated, replacement of
the bearing inserts is not necessary. Remove the
Plastigage (2) from crankshaft journal and bearing insert. Proceed with installation.
Bearing Mark SIZE USED WITH
JOURNAL SIZE
.025 US.025 mm 50.983-50.967 mm
(.001 in.) (2.0073-2.0066 in.)
Std.STANDARD 50.992-51.008 mm
(2.0076-2.0082 in.)
.250 US.250 mm 50.758-50.742 mm
(.010 in.) (1.9984-1.9978 in.)
8. If bearing-to-journal clearance exceeds the specification, determine which service bearing set to use, using the
chart above.
CAUTION: Connecting Rod Bolts are Torque to
Yield Bolts and Must Not Be Reused. Always
replace the Rod Bolts whenever they are loosened
or removed.
9. Repeat the Plastigage measurement to verify your
bearing selection prior to final assembly.
10. Once you have selected the proper insert, install
the insert and cap. Tighten the connecting rod
bolts to 27 Nꞏm (20 ft. lbs.) plus a 90° turn.
Slide snug-fitting feeler gauge between the connecting
rod and crankshaft journal flange. Refer to Engine
Specifications for the proper clearance. Replace the
connecting rod if the side clearance is not within
specification.
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PLUGS - CORE
REMOVAL
1. Drain the cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
2. Using a blunt tool such as a drift or a screw driver
and a hammer, strike the bottom edge of the cup
plug (5).
3. Using a suitable pair of pliers, grasp the core plug
(5) and remove.
INSTALLATION
NOTE: Thoroughly clean core plug bore, remove all of the old sealer.
1. Coat the edges of the engine core plug and the core plug bore with Mopar Gasket Maker, or equivalent.
NOTE: It is not necessary to wait for the sealant to cure on the core plugs. The cooling system can be filled
and the vehicle returned to service immediately.
2. Using proper plug driver, drive core plug into the core plug bore. The sharp edge of the core plug should be at
least 0.50 mm (0.020 in.) inside the lead in chamfer.
3. Refill the cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
Page 1694 of 5267

CRANKSHAFT
DESCRIPTION
The crankshaft is constructed of nodular cast iron. The crankshaft is a crosshaped four throw design with eight
counterweights for balancing purposes. The crankshaft is supported by five select fit main bearings with the number
three serving as the thrust washer location. The main journals of the crankshaft are cross drilled to improve rod
bearing lubrication. The number eight counterweight has provisions for crankshaft position sensor target wheel
mounting. The select fit main bearing markings are located on the rear sideof the target wheel. The crankshaft oil
seals are one piece design. The front oil seal is retained in the timing chain cover, and the rear seal is pressed in
to a bore formed by the cylinder block and the bedplate assembly.
REMOVAL
NOTE: To remove the crankshaft from the engine, the engine must be removed from the vehicle.
1. Remove the engine. (Refer to 9 - ENGINE - REMOVAL).
2. Remove the engine oil pump. (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - REMOVAL).
CAUTION: DO NOT pry on the oil pan gasket when removing the oil pan, The oil pan gasket is mounted to
the cylinder block in three locations and will remain attached to block when removing oil pan. Gasket can
not be removed with oil pan.
3. Remove oil pan. (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
4. Remove the oil pump pickup tube and oil pan gasket /windage tray.
5. Remove the bedplate mounting bolts. Note the location of the three stud bolts for installation.
6. Remove the connecting rods from the crankshaft.
CAUTION: The bedplate to cylinder block mating
surface is a critical sealing surface. Do not pry on
or damage this surface in anyway.
NOTE: The bedplate contains the lower main bear-
ing halves. Use care when handling bedplate as
not to drop or damage bearing halves. Installing
main bearing halves in the wrong position will
cause sever damage to the crankshaft.
NOTE: The bedplate has pry points cast into it.
Use these points only. The pry points are on both
the left and right sides, only the left side is shown.
7. Carefully pry on the pry points to loosen the bed-
plate then remove the bedplate.
CAUTION: When removing the crankshaft, use
care not to damage bearing surfaces on the crankshaft.
8. Remove the crankshaft.
Page 1695 of 5267

INSPECTION
NOTE: Thoroughly inspect the connecting rod bearing bores and main bearing bores for scoring, blueing or
severe scratches. Further disassembly may be required.
If connecting rod bearing bores show damage, the cylinder heads must be removed to service the piston and rod
assemblies. If the bedplate or the cylinder block main bearing bores show damage the engine must be replaced.
1. If required, remove the main bearing halves from the cylinder block and bedplate.
2. Thoroughly clean the bedplate to cylinder block sealing surfaces and main bearing bores. Remove all oil and
sealant residue.
3. Inspect the bedplate main bearing bores for cracks, scoring or severe blueing. If either condition exists the
engine must be replaced.
4. Inspect the crankshaft thrust washers for scoring, scratches, wear or blueing. If either condition exist replace the
thrust washer.
5. Inspect the oil pan gasket/windage tray for splits, tears or cracks in the gasket sealing surfaces. Replace gasket
as necessary.
INSTALLATION
CAUTION: Main bearings are select fit. (Refer to 9
- ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE) for proper
bearing selections.
1. Lubricate upper main bearing halves with clean
engine oil.
CAUTION: When installing crankshaft, use care
not to damage bearing surfaces on the crankshaft.
2. Position crankshaft in cylinder block.
3. Install the thrust washers (1).
Page 1696 of 5267
CAUTION: The bedplate to cylinder block mateing
surface must be coated with sealant prior to
installation. Failure to do so will cause severe oil
leaks.
NOTE: The installation time to install the bedplate
after the sealant has been applied is critical.
NOTE: Make sure that the bedplate and cylinder
block sealing surfaces are clean and free of oil or
other contaminants. Contaminants on the sealing
surfaces may cause main bearing distortion and/or
oil leaks.
4. Apply a 2.5mm (0.100 inch) bead of Mopar
Gen II
Silicone Rubber Adhesive sealant (2) to the cylin-
der block-to-bedplate mating surface (1) as shown.
5. Coat the crankshaft main bearing journals with
clean engine oil and position the bedplate onto the
cylinder block.