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Home >> Fiat >> 2016 >> 500 Turbo, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 25 (1.4L 16-Valve Turbo Engine (Service Information) 500) >> Engine Block >> Seal, Crankshaft Oil, Rear >> Installation >> With Manual Transmission

With Manual Transmission

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Fig 1: Crankshaft Seal Surface & Sealant Locations
GC0152683Courtesy of CHRYSLER GROUP, LLC
CAUTION:

Whenever the crankshaft is replaced, the rear crankshaft oil seal must also be replaced. Failure to do so may result in engine fluid leakage.

  1. Inspect the crankshaft to make sure there are no nicks or burrs on the seal surface (1).
  2. Clean the seal retainer, cylinder block and bedplate mating surfaces with isopropyl alcohol in preparation for sealant application.
    CAUTION:

    Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Engine Sealant RTV Silicone Rubber Adhesive may result in engine fluid leakage.

    CAUTION:

    Following the application of Mopar® Engine Sealant RTV Silicone Rubber Adhesive to the gasket surfaces, the components must be assembled within 10 minutes and the attaching fasteners must be tightened to specification within the next 10 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.

  3. Apply a 2 to 3 mm wide bead of Mopar® Engine Sealant RTV Silicone Rubber Adhesive (1) to the two cylinder block to bedplate T-joints as shown in illustration.
    Fig 2: Alignment Fixture & Bolts
    GC0152685Courtesy of CHRYSLER GROUP, LLC
  4. Attach the (special tool #8225, Alignment Fixture) (1) to the oil pan mounting flange using the oil pan bolts (2). Tighten the bolts to 9 N.m (80 in. lbs.).
    NOTE:

    Make sure that the "2.7L" stamped on the alignment fixture is facing the cylinder block (flat side of tools against oil pan mounting flange).

    Fig 3: Rear Crankshaft Oil Seal Guide, Garter Spring & Rear Seal Retainer
    GC0152680Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    It is not necessary to lubricate the seal or the crankshaft when installing the seal retainer. Residual oil following installation can be mistaken for seal leakage.

  5. Carefully install the (special tool #10306, Guide, Rear Crankshaft Oil Seal) (1) into the rear seal retainer (3).
    NOTE:

    Make sure that the garter spring (2) is intact around the inside of the oil seal lip.

    Fig 4: Rear Seal Installed
    GC0081633Courtesy of CHRYSLER GROUP, LLC
  6. Carefully position the seal retainer and seal installer on the crankshaft and push firmly into place on the engine block (during this step, the seal installer will be pushed from the oil seal as a result of installing the seal retainer).
  7. Verify that the seal lip (2) on the retainer is uniformly curled inward toward the engine on the crankshaft (1).
    Fig 5: Seal Retainer Flange Tightening Sequence
    GC0152684Courtesy of CHRYSLER GROUP, LLC
  8. Allow the seal retainer to center itself on the crankshaft and position the seal retainer so that the distance between the seal retainer flange and the alignment fixture is equal on both sides (1).
    NOTE:

    Do not force the seal retainer flange down against the alignment fixture.

  9. While maintaining this alignment, install the six seal retainer bolts. Tighten the six bolts in two steps following the sequence shown in illustration:
    • Step 1: All to 5 N.m (44 in. lbs.).
    • Step 2: All to 9 N.m (80 in. lbs.).
    Fig 6: Oil Pan Sealant Locations
    GC0152689Courtesy of CHRYSLER GROUP, LLC
  10. Clean the oil pan, engine block, oil pump and rear seal retainer mating surfaces with isopropyl alcohol in preparation for sealant application.
    CAUTION:

    Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Engine Sealant RTV Silicone Rubber Adhesive may result in engine fluid leakage.

    CAUTION:

    Following the application of Mopar® Engine Sealant RTV Silicone Rubber Adhesive to the gasket surfaces, the components must be assembled within 10 minutes and the attaching fasteners must be tightened to specification within the next 10 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.

  11. Apply a 2 to 3 mm wide bead of Mopar® Engine Sealant RTV Silicone Rubber Adhesive to the oil pan as shown in illustration in the following locations:
    • Oil pan to engine block flange (1)
    • Two oil pump to engine block T-joints (3)
    • Two rear seal retainer to engine block T-joints (2)
    Fig 7: Oil Pan Flange Fasteners
    GC0152688Courtesy of CHRYSLER GROUP, LLC
  12. Install the oil pan with fourteen bolts (1), two studs and two nuts (2) hand tight.
    Fig 8: Oil Pan Fastener Tightening Sequence
    GC0152690Courtesy of CHRYSLER GROUP, LLC
  13. Tighten the sixteen oil pan fasteners in two steps following the sequence shown in illustration:
    • Step 1: All to 4 N.m (35 in. lbs.).
    • Step 2: All to 9 N.m (80 in. lbs.).
    Fig 9: Crankshaft Position Sensor (CKP), Sensor Locator Boss & 5 mm Hex Head Driver
    GC0158824Courtesy of CHRYSLER GROUP, LLC
  14. Install the crankshaft position sensor (1) with mounting screw.
    CAUTION:

    Make sure the CKP sensor is firmly seated against the alignment boss prior to rotating the fastener. The sensor will be damaged if the fastener is used to align or draw the sensor into position.

  15. Tighten the mounting screw to 4 N.m (35 in. lbs.).
    Fig 10: Tone Wheel & Alignment Pin
    GC0168968Courtesy of CHRYSLER GROUP, LLC
  16. Position the slot over the alignment pin (2) and install the tone wheel (1) on the crankshaft.
    Fig 11: Pressure Plate Bolts
    GC0155963Courtesy of CHRYSLER GROUP, LLC
  17. Install the flywheel and clutch. Refer to FLYWHEEL, INSTALLATION .
    Fig 12: Flywheel Dust Covers & Bolts
    GC0156336Courtesy of CHRYSLER GROUP, LLC
  18. Install the flywheel dust covers (2 and 3) with two bolts (1) tightened to 9 N.m (80 in. lbs.).
    Fig 13: Upper Bell Housing Bolts
    GC0156315Courtesy of CHRYSLER GROUP, LLC
  19. Install the manual transmission in the vehicle. Refer to INSTALLATION .
    Fig 14: Lower Air Dam/Belly Pan
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  20. Fill the transmission with the proper fluid to the correct level. Refer to FLUID .
  21. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to STANDARD PROCEDURE .
  22. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
  23. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
  24. Start and run the engine until it reaches normal operating temperature.
    NOTE:

    The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system. For example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to appropriate Engine Electrical Diagnostics article.

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