Disassembly
When removing parts, refer to the figure "Crankshaft, flywheel and torque converter drive plate".
Note: For ease of installation, position the removed parts (connecting rod caps, connecting rod and main bearing shells) in order of their correspondence to cylinder numbers and installation direction.
Examination
Crankshaft
1. Check the main and connecting rod journals of the crankshaft for damage (snags and grips), excessive wear and cracks. Also, check the oil passage holes for clogging. Repair or replace the defective part.
2. Check the taper and out-of-roundness of the main and connecting rod journals of the crankshaft.
- Rated value:
- 2.0L/2.4L engines:
- Main journal diameter: 56.982-57.000 mm
- Crankpin diameter: 44.980-45.000 mm
- Taper and out-of-roundness of main journals and crankpins: 0.003 mm or less
- Engine 2.7L:
- Main journal diameter: 61.982-62.000 mm
- Crankpin diameter: 47.982-48.000 mm
- The ovality of the connecting rod and main journals of the shaft: no more than 0.003 mm
- The taper of the connecting rod and main journals of the shaft: no more than 0.005 mm
- Limit value: 0.1 mm
Engine 2.7 l. |
Measuring the clearance in a connecting rod bearing using a plastic gauge
Note: The use of this method greatly simplifies the procedure for determining the clearances in the crankshaft bearings.
1. Check that the alignment marks on the connecting rod and connecting rod cap are in line (to ensure correct assembly).
2. Turn away nuts of fastening of a cover of a rod.
3. Remove the connecting rod cap and one of the connecting rod bearing shells.
4. Clean the crankshaft journals and liners from oil and dirt.
5. Cut a piece of plastic gauge equal to the width of the bushing and place it parallel to the axis of the shaft journal away from the oil passage hole.
6. Install the bearing and connecting rod cap and tighten the nuts to the specified torque.
Caution: Do not rotate the crankshaft during this procedure.
7. Remove the connecting rod cover and, using the scale printed on the package of gauges, determine the clearance in the bearing.
Rated value:
- 2.0L/2.4L engines: 0.015-0.048 mm
- Engine 2.7L: 0.018-0.036mm
- Limit value: 0.1 mm
Engines 2.0 l / 2.4 l.
Note:
- Do not machine the bearing or connecting rod cap to adjust clearance.
- If it is impossible to adjust the clearance to the nominal value using liners, then replace the crankshaft and liners with new ones.
Determination of the clearance in the main bearing of the crankshaft using a plastic gauge
Note: The use of this method greatly simplifies the procedure for determining the clearances in the crankshaft bearings.
1. Clean the surfaces of the cylinder block and main bearing caps, crankshaft main journals and bearing shells from oil deposits, grease and other contaminants.
2. Carefully place the crankshaft into the cylinder block.
3. Cut a piece of calibrated plastic wire the length of which matches the width of the neck, then place it on the crankshaft journal along the axis of the crankshaft.
4. Carefully install the crankshaft bed (engines 2.0 l / 2.4 l) or bearing caps (engine 2.7 l) and tighten the fastening bolts to the rated torque.
Caution: Do not rotate the crankshaft during this procedure.
Torque:
- Engine 2.7L:
- M8 (bolts №9-6): 10-12 Nm
- M10 (bolts #1-8): 14 -16 Nm
- 2.0l/2.4l engines: 25 Nm + 90°
5. Turn away bolts of fastening, carefully remove a cover.
6. Measure the width of the crushed plastic gauge wire at its widest point using the scale printed on the plastic gauge package.
- Engines 2.0L/2.4L:
- Main bearing clearance:
- Rated value:
- #1, 2, 4, 5: 0.018-0.036 mm
- No. 3: 0.024-0.042 mm
- Limit value: #1, 2, 4, 5: 0.1mm
- Engine 2.7L:
- Main bearing clearance:
- Rated value: 0.004-0.022mm
- Limit value: 0.1 mm
Note:
- Do not machine the bearing or bearing cap to adjust clearance.
- If it is impossible to adjust the clearance to the nominal value using liners, then replace the crankshaft and liners with new ones.
Crankshaft seals
Check the front and rear crankshaft oil seals for damage or wear on the sealing lips. Replace defective oil seal.
Crankshaft bed (engines 2.0 l / 2.4 l)
After installing the crankshaft bed (main bearing caps) check that the crankshaft rotates smoothly and the crankshaft end play is within specification. If the axial clearance exceeds the maximum allowable value, then replace the thrust half-rings of the bearing and / or bearing shells.
- Rated value: 0.05-0.25mm
- Limit value: 0.40 mm
Assembly
1. Install the upper main bearing shells (with oil groove) in the bed of the crankshaft on the cylinder block.
2. Install the bottom bushings (without grooves) in bed crankshaft (main bearing caps).
Engines 2.0 l / 2.4 l.
Note: (2.0L / 2.4L engines) Center bearing shells (combined with thrust bearing) crankshaft without oil grooves.
Engine 2.7 l.
3. Apply engine oil to the main and connecting rod journals of the crankshaft. Install the crankshaft.
4. Install the main bearing caps (crankshaft bed - engines 2.0 l / 2.4 l) so that the mark in the form of an arrow is directed towards the front of the engine.
5. Tighten bolts of fastening of covers of radical bearings (engine 2.7 l) or crankshaft bed (engines 2.0 l / 2.4 l) rated torque in the sequence shown in the corresponding figure.
Attention: the cover fastening bolts should be tightened gradually in four or five steps with increasing torque, then tighten to the rated torque.
Torque:
- Engine 2.7L:
- M7 (bolts #9 - 16): 10-12 Nm
- M10 (bolts #1 - 8): 14 -16 Nm
- 2.0 l/2.4 l engines: 25 Nm + 90°
Engine 2.7 l. | Engines 2.0 l / 2.4 l. |
6. Check up smoothness of rotation of a cranked shaft and measure an axial backlash of a shaft.
- Engine 2.7L:
- Rated value: 0.07-0.25mm
- Limit value: 0.40 mm
- Engines 2.0 l / 2.4 p:
- Rated value: 0.05-0.25mm
- Limit value: 0.40 mm
Engines 2.7 liters.
7. With special tool (mandrel for installing the crankshaft rear oil seal) Install the crankshaft rear oil seal into the oil seal housing.
Attention:
- The installation of a used stuffing box is not allowed.
- (2.0L / 2.4L engines) Install the seal so that the hole (arrow in the picture) oil separator pointing downwards (to the oil pan).
Engines 2.0 l / 2.4 l. |
8. (2.7L engine) Apply sealant to the stuffing box at the locations shown in the illustration. Install the oil seal housing to the cylinder block and tighten the rear oil seal housing bolts.
- Tightening torque: 10-12 Nm
9. (2.0L / 2.4L engines) Install the seal housing assembly on the new gasket.
- Tightening torque: 10-12 Nm
10. (Except models with automatic transmission - engines 2.0 l / 2.4 l) Establish a back plate of the block of cylinders.
11. (Models with manual transmission) Install the flywheel assembly and tighten the bolts of its fastening to the nominal torque.
Torque:
- 2.0L / 2.4L engines: 130-140 Nm
- 2.7L engine: 73-77 Nm
Engine 2.7 l.
12. (Models with automatic transmission, engines 2.0 l / 2.4 l) Install the crankshaft bushing and adapter plate to the cylinder block, then install the automatic transmission torque converter drive plate and tighten its mounting bolts to the specified torque.
- Tightening torque: 130-140 Nm
13. (Models with automatic transmission, 2.7 l engine) Install the adapter plate and the automatic transmission torque converter drive plate.
- Tightening torque: 73-77 Nm
Engine 2.7 l.