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Home >> Jeep >> 2019 >> Renegade High Altitude, 4WD >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> 1.3L Engine (Service Information) >> Disassembly And Assembly >> Disassembly And Reassembly Following Inspection - 1.3L >> Reassembly

Disassembly And Reassembly Following Inspection - 1.3L: Reassembly

  1. Lubricate all internal engine components with clean engine oil.
  2. Check that the cylinder head support surface does not have cracks or surface grooves.
  3. Remove sealant residues from the mating surfaces of the removed parts.
  4. Install the engine block on the 1871000000 engine stand.
  5. Install the piston oil cooler jets and tighten the new bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  6. Measure the flatness of the cylinder head mounting surface on the engine block and compare it to the specification. Refer to SPECIFICATIONS  .
    NOTE:

    If the flatness is not within specification, resurface the cylinder head mounting surface.

  7. Measure the diameter of the cylinder bores and compare it to the specification. Refer to SPECIFICATIONS  .
    NOTE:

    If the diameters are not within specification, bore the cylinders to the appropriate oversize.

    NOTE:

    If cylinder boring is required, all cylinder bores must be bored to the same size.

  8. Measure the roundness of the cylinder bores and compare it to the specification. Refer to SPECIFICATIONS  .
    NOTE:

    If the roundness is not within specification, bore the cylinders to the appropriate oversize.

    NOTE:

    If cylinder boring is required, all cylinder bores must be bored to the same size.

  9. Measure the taper of the cylinder bores and compare it to the specification. Refer to SPECIFICATIONS  .
    NOTE:

    If the taper is not within specification, bore the cylinders to the appropriate oversize.

    NOTE:

    If cylinder boring is required, all cylinder bores must be bored to the same size.

  10. Measure the crankshaft main bearing journal diameters and verify that they are within specification. Refer to SPECIFICATIONS  .
  11. If the crankshaft main bearing journal diameters do not fall within the specifications, correct by refinishing the diameter of the journal to the appropriate undersize.
    NOTE:

    The crankshaft has a nitride treatment; Therefore, after refinishing the crankshaft should again be nitrided and subjected to a subsequent dimensional inspection.

  12. Measure the crankshaft rod bearing journal diameters and verify that they are within specification. Refer to SPECIFICATIONS  .
  13. If the crankshaft rod bearing journal diameters do not fall within the specifications, correct by refinishing the diameter of the journal to the appropriate undersize.
    NOTE:

    The crankshaft has a nitride treatment; Therefore, after refinishing the crankshaft should again be nitrided and subjected to a subsequent dimensional inspection.

  14. Select main bearings to achieve the proper bearing clearance. Do not attempt to perform any adaptation to the bearing shells. If you encounter any scratches or traces of engagement, replace the bearing shells.
    NOTE:

    The upper main bearing shells have oil lubrication holes, the lower main bearing shells do not. Crankshaft thrust washers are integral to the center upper main bearing shell.

    GC0189478Courtesy of CHRYSLER GROUP, LLC
  15. Install the upper main bearing shells and crankshaft (1) into the engine block.
  16. Apply the calibrated wire (Plastigage) across the surface of the bearing journals (2).
  17. Install the lower main bearing shells into the bedplate.
  18. Install the bedplate on the engine block.
    G00594697Courtesy of CHRYSLER GROUP, LLC
  19. Install the bedplate to engine block bolts and tighten in the sequence shown following the 4 step torque plus angle method. Tighten according to the following torque values:
    • Step 1: M8 bolts 1 - 10 to 12 Nm (9 ft. lbs.).
    • Step 2: M10 bolts 11 - 20 to 25 Nm (18 ft. lbs.).
    • Step 3: M10 bolts 11 - 20 to 30 Nm (22 ft. lbs.) plus an additional 40° turn.
    • Step 4: M8 bolts 1 - 10 to 25 Nm (18 ft. lbs.).
    G00594698Courtesy of CHRYSLER GROUP, LLC
  20. Remove the bedplate and using a graduated measuring guide (1) determine the bearing clearance indicated by the calibrated wire.
  21. Perform the measurement on the remaining journals taking care not to rotate the crankshaft.
    GC0189522Courtesy of CHRYSLER GROUP, LLC
  22. After verifying all main bearing clearances are within specification, apply a continuous bead of sealant (1) with a thickness of 2 mm, to the bedplate sealing surface.
    G00594697Courtesy of CHRYSLER GROUP, LLC
  23. Install the bedplate to engine block bolts and tighten in the sequence shown following this 4 step torque plus angle method. Tighten according to the following torque values:
    • Step 1: M8 bolts 1 - 10 to 12 Nm (9 ft. lbs.).
    • Step 2: M10 bolts 11 - 20 to 25 Nm (18 ft. lbs.).
    • Step 3: M10 bolts 11 - 20 to 30 Nm (22 ft. lbs.) plus an additional 40° turn.
    • Step 4: M8 bolts 1 - 10 to 25 Nm (18 ft. lbs.).
  24. Make sure that the piston outer diameter is within specification. Refer to SPECIFICATIONS  .
    NOTE:

    Pistons not within specification should be replaced complete with rings and pin.

  25. Using a feeler gauge, check that the piston to cylinder bore clearances are within specification. Refer to SPECIFICATIONS  .
    NOTE:

    Measure 7 mm up from the bottom edge of the piston skirt, perpendicular to the piston pin bore.

  26. Verify that the internal diameter of the pistons pin bores are within specification. Refer to SPECIFICATIONS  .
    NOTE:

    Pistons not within specification should be replaced.

  27. Make sure that the outer diameter of the piston pins are within specification. Refer to SPECIFICATIONS  .
    NOTE:

    Piston pins not within specification should be replaced.

  28. Check that the thickness of the piston rings are within specification. Refer to SPECIFICATIONS  .
  29. Insert the piston rings in the cylinder bore and using a feeler gauge, check that the end gaps are within specification. Refer to SPECIFICATIONS  .
    NOTE:

    Piston rings not within specification should be replaced.

    GC0208155Courtesy of CHRYSLER GROUP, LLC
  30. Using a feeler gauge (1a), check that the axial clearance between the rings (1b) and ring grooves on the piston are within specification. Refer to SPECIFICATIONS  .
  31. Verify that the diameter of the connecting rod big end is within specification. Refer to SPECIFICATIONS  .
  32. Check that the diameter of the connecting rod small end bushings are within specification. Refer to SPECIFICATIONS  .
    NOTE:

    The connecting rod small end bushings are not available separately, therefore the entire connecting rod must be replaced.

  33. Install the (special tool #1860815000, Tool, Crankshaft Rotating).
    G00594699Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The connecting rod and cap are of the fractured type and therefore are not interchangeable and must remain as a matched set.

  34. The arrow on the piston crown points to the front (timing) side of the engine.
  35. Install the rod and piston complete with bearing shell using a ring compressor (1).
    G00594700Courtesy of CHRYSLER GROUP, LLC
  36. Apply the calibrated wire (Plastigage) across the surface of the bearing journals (1).
  37. Check that the components are free of burrs, stamps, scratches or any other surface defects. Thoroughly clean and dry the pieces before assembly.
  38. Fit the bearing caps complete with bearing shells and tighten the bearing cap bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    NOTE:

    The connecting rod caps must be assembled so that the number stamped on them is facing the same side as the one stamped on the big end.

    G00594701Courtesy of CHRYSLER GROUP, LLC
  39. Remove the bearing caps previously installed and using the graduated measuring guide (1) determine the bearing clearance indicated by the calibrated wire.
  40. Perform the measurement on the remaining journals taking care not to rotate the crankshaft.
    NOTE:

    If the measured value is not within specification, replace the bearing shells with the proper dimension.

  41. Fit all bearing caps complete with bearing shells and tighten all bearing cap bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    G00594702Courtesy of CHRYSLER GROUP, LLC
  42. Rotate the engine on the engine stand.
  43. Remove the (special tool #1860815000, Tool, Crankshaft Rotating) and install the (special tool #2063700090, Locking, Crankshaft) timing tool (1).
  44. Install the timing chain tensioner arm and timing chain tensioner and tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  45. Install the water pump drive sprocket and tighten the bolt to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  46. Install the locating dowels and install a new cylinder head gasket on the crankcase.
    GC0190306Courtesy of CHRYSLER GROUP, LLC
  47. Install the cylinder head in position using the (special tool #2031300091, Tool, Alignment Cylinder Head to Block) (1).
    GC0191641Courtesy of CHRYSLER GROUP, LLC
  48. Install and tighten the NEW  cylinder head bolts (1) in the sequence shown, to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    GC0189940Courtesy of CHRYSLER GROUP, LLC
  49. Install the hydraulic tappets in the cylinder head.
  50. Install the camshaft (1) on the cylinder head.
  51. Apply "LOCTITE (red) 5203" under the rear camshaft bearing cap (2).
  52. Install the rear camshaft bearing cap (2) on the locating bushings.
  53. Install the other camshaft caps (3a) following the numbers (3b) marked on them (from timing end to flywheel end) and keeping the arrows (3c) pointing to the timing end and install the bolts (3d) hand tight.
    GC0207995Courtesy of CHRYSLER GROUP, LLC
  54. Tighten the bolts in the sequence shown to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    GC0207994Courtesy of CHRYSLER GROUP, LLC
  55. Install the (special tool #2063500090, Locking, Camshaft) timing tool (1) on the vacuum pump mounting surface and securely tighten the bolts.
  56. Install the timing drive chain and crankshaft sprocket.
  57. Install the timing chain guides and tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  58. Hold the tensioner arm against the tensioner piston, remove the lock pin and release the tensioner arm. Check that the piston is in contact with the tensioner arm.
    GC0207993Courtesy of CHRYSLER GROUP, LLC
  59. Install a new Variable Valve Actuation Assembly (VVAA) gasket on the cylinder head.
  60. Install the VVAA (1) on the cylinder head over the two centering pins (2) located in positions 12 and 14.
  61. Install and tighten the VVAA retaining bolts (3) in the sequence shown to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  62. Remove the tools from the VVAA.
    GC0190155Courtesy of CHRYSLER GROUP, LLC
  63. Install the (special tool #2031600091, Pin, Centering) (1) in the locations shown on the cylinder head.
    G00594703Courtesy of CHRYSLER GROUP, LLC
  64. Apply a 2-mm thick continuous sealant strip to the lower crankcase and cylinder head surfaces.
    G00594704Courtesy of CHRYSLER GROUP, LLC
  65. Install the timing cover (1).
  66. Install NEW  M6 (2a) 1-13 and M10 (2b) 14-17 bolts finger tight.
  67. Tighten the M6 bolts (2a) 1-13 to the initial specification in the sequence shown. Refer to TORQUE SPECIFICATIONS  .
  68. Tighten the M10 bolts (2b) 14-17 to the initial specification in the sequence shown. Refer to TORQUE SPECIFICATIONS  .
  69. Tighten the M10 bolts (2b) 14-17 to the final specification in the sequence shown. Refer to TORQUE SPECIFICATIONS  .
  70. Tighten the M6 bolts (2a) 1-13 to the final specification in the sequence shown. Refer to TORQUE SPECIFICATIONS  .
  71. Remove the (special tool #2031600091, Pin, Centering) from the cylinder head.
  72. Using the installation tool supplied with the spare part, fit the new timing cover oil seal.
    GC0207990Courtesy of CHRYSLER GROUP, LLC
  73. Install new gaskets on the cylinder head cover.
  74. Apply sealant to the six locations shown (1).
    GC0207989Courtesy of CHRYSLER GROUP, LLC
  75. Install the cylinder head cover and tighten the bolts in the sequence shown to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  76. Rotate the engine 180° on the engine stand.
  77. Install the windage tray and tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  78. Install engine oil pick-up tube and tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    G00594705Courtesy of CHRYSLER GROUP, LLC
  79. Apply sealant to the engine oil pan mounting surface.
  80. Install the engine oil pan and tighten the bolts in the sequence shown to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    GC0207988Courtesy of CHRYSLER GROUP, LLC
  81. Rotate the engine 180° on the engine stand.
    82. NOTE:

    The damper bolt is a left-hand thread.

  82. Install the vibration damper (1) on the crankshaft and hand tighten the bolt (3).
  83. Install the (special tool #2064000090, Locking, Pulley) tool (2) above the damper pulley and securely tighten the bolts.
  84. Tighten the vibration damper bolt (3) to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  85. Remove the (special tool #2064000090, Locking, Pulley), (special tool #2063700090, Locking, Crankshaft) and (special tool #2063500090, Locking, Camshaft) timing tools.
    86. NOTE:

    Do not rotate the crankshaft using the damper bolt, the bolt has left-hand threads and can be inadvertently loosened resulting in loss of camshaft timing. Only rotate the damper itself in a clockwise direction (as viewed from the front).

  86. Rotate the crankshaft clockwise (as viewed from the front) through two complete revolutions and refit the timing tools to verify correct camshaft timing.
  87. Install the spark plugs and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  88. Install the ignition coils and tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    GC0207987Courtesy of CHRYSLER GROUP, LLC
  89. Install the water pump (1a) with new ring seals (1b), engaging the pump drive (1c) to the drive gear (1d).
  90. Tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    GC0188843Courtesy of CHRYSLER GROUP, LLC
  91. Install a NEW  gasket (1) to the water pump.
    GC0188782Courtesy of CHRYSLER GROUP, LLC
  92. Install the water pump cover and tighten the bolts using the sequence shown, to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  93. Install the wiring duct and securely tighten the bolts.
  94. Install the accessory belt tensioner and tighten the bolt to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    GC0188686Courtesy of CHRYSLER GROUP, LLC
  95. Install the water pump inlet connector with a new seal (1) and tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  96. Install the A/C compressor with the pipe retainer bracket and tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS .
  97. Install the generator and tighten the bolts to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
  98. Install the accessory drive belt and release the tensioner.
  99. Using the (special tool #2031400091, Installer, Crank Seal - Rear), install the new rear crankshaft oil seal.
  100. Install the vacuum pump with a new gasket and tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  101. Install a new seal on the thermostat.
  102. Install the thermostat and tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  103. Install the high pressure fuel pump with roller tappet and tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    GC0190078Courtesy of CHRYSLER GROUP, LLC
  104. Install the engine oil cooler with a new gasket and tighten the bolts in the sequence shown to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  105. Install the engine oil cooler pipe intermediate brackets to the crankcase and securely tighten the bolts.
  106. Install a new turbocharger heat shield/gasket.
  107. Install the turbocharger with engine oil supply and return pipes attached, and tighten the nuts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  108. Install the turbocharger engine oil supply and return pipes to the crankcase and tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  109. Install the turbocharger heat shield and securely tighten the bolts and nut.
  110. Install the Camshaft Position (CMP) sensor with the heat shield in place and securely tighten the bolt.
  111. Install the engine oil pump displacement control solenoid valve and securely tighten the bolt.
  112. Install the knock sensors and tighten the new bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  113. Install the Crankshaft Position (CKP) sensor and tighten the new bolt to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  114. Install the new engine oil pressure sensor and tighten it to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  115. Install the auxiliary coolant pump mounting bracket with the pump attached and tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    GC0190141Courtesy of CHRYSLER GROUP, LLC
  116. Install the intake manifold with new gaskets and tighten the bolts in the sequence shown to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  117. Connect the quick coupling for the oil vapor pipe to the cylinder head cover.
  118. Install the fuel rail with the fuel injectors. Refer to RAIL, FUEL, REMOVAL AND INSTALLATION .
  119. Install a new high pressure fuel pipe from the pressure pump to the fuel rail and tighten the connectors to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  120. Connect the quick coupling of the high pressure pump fuel supply pipe and install the fuel pump heat shield.
  121. Install the turbocharger air intake tube and tighten the band clamp.
  122. Install the air outlet pipe from turbocharger to throttle body with new gaskets and securely tighten the screws and nuts.
  123. Install the oil filler cap with integral dipstick.
  124. Install the wire harness mounting brackets and securely tighten the bolts.
  125. Install the engine wire harness:
    • Connect the A/C compressor wire harness connectors.
    • Connect the turbocharger by-pass solenoid valve wire harness connector.
    • Connect the turbocharger actuator wire harness connector.
    • Connect the air supercharging sensor wire harness connector.
    • Connect the air temperature sensor wire harness connector.
    • Engage the wiring duct retaining clips and securely tighten the cylinder head cover bolts.
    • Connect the engine oil pump displacement control solenoid valve wire harness connector.
    • Connect the oil pressure sensor wire harness connector.
    • Engage the in-line connector to the retaining bracket.
    • Connect the knock sensor wire harness connectors.
    • Connect the CKP sensor wire harness connector.
    • Connect the auxiliary coolant pump wire harness connector.
    • Connect the air temperature and pressure sensor wire harness connector.
    • Connect the fuel vapor purge solenoid wire harness connector.
    • Connect the throttle body wire harness connector.
    • Connect the fuel injector wire harness connectors.
    • Connect the VVAA oil temperature sensor wire harness connector.
    • Connect the fuel pressure sensor wire harness connector.
    • Connect the VVAA actuator wire harness connectors.
    • Connect the ignition coil wire harness connectors.
    • Install the ground wires and securely tighten the bolts.
    • Connect the pressure pump wire harness connector.
    • Connect the engine coolant level sensor wire harness connector.
    • Connect the engine water heating coil wire harness connector.
    • Connect the CMP sensor wire harness connector.
    • Connect the turbocharger intake air temperature sensor wire harness connector.
    • Engage the engine harness in the retaining clips.
  126. Install the catalytic converter with new seal and securely tighten the nuts to the crankcase mounting bracket.
  127. Tighten the bolts for the side support brackets to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  128. Install a new seal and tighten the catalytic converter to the turbocharger collar bolt to the proper specification. Refer to TORQUE SPECIFICATIONS  .
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