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Home >> Jeep >> 2021 >> Renegade Limited >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> 1.3L Engine (Service Information) >> Disassembly And Assembly >> Disassembly And Reassembly Following Inspection - 1.3L

Disassembly And Reassembly Following Inspection - 1.3L

DISASSEMBLY 

GC0208165Courtesy of CHRYSLER GROUP, LLC
  1. Remove the bolts (1a) and remove the mounting bracket (1b) with the auxiliary coolant pump attached.
    GC0208004Courtesy of CHRYSLER GROUP, LLC
  2. Remove the bolts and the knock sensors (1).
  3. Remove the bolt and the Crankshaft Position (CKP) sensor (2).
  4. Remove the oil pressure sensor (3).
  5. Remove the retaining clips (4).
    GC0208164Courtesy of CHRYSLER GROUP, LLC
  6. Remove the bolt (1) and the coolant pump drive sprocket.
    GC0208163Courtesy of CHRYSLER GROUP, LLC
  7. Remove the bolt (1) and the timing chain tensioner arm.
  8. Remove the bolts (2) and the timing chain tensioner.
    GC0208162Courtesy of CHRYSLER GROUP, LLC
  9. Remove the bolt (1) and the accessory belt tensioner.
    GC0208161Courtesy of CHRYSLER GROUP, LLC
  10. Remove the seal (1).
    GC0208160Courtesy of CHRYSLER GROUP, LLC
  11. Remove the oil filter (1).
    GC0208003Courtesy of CHRYSLER GROUP, LLC
  12. Remove the nut (1) securing the bedplate to the engine stand bracket.
  13. Remove the bolts (2) securing the bedplate to the engine block.
    GC0208002Courtesy of CHRYSLER GROUP, LLC
  14. Use the 1870718000 tool (1) to break the sealant bond.
    GC0208001Courtesy of CHRYSLER GROUP, LLC
  15. Using the pry points shown in illustration, release the bedplate (1) from the sealant and remove it, complete with the lower crankshaft main bearing halves.
    GC0208159Courtesy of CHRYSLER GROUP, LLC
  16. Remove the bolts (1a) and remove the connecting rod cap (1b) complete with connecting rod bearing halves.
    GC0208158Courtesy of CHRYSLER GROUP, LLC
  17. Use a suitable tool on the connecting rod to remove the connecting rod-piston assembly (1).
  18. Repeat the process to remove the remaining connecting rod-piston assemblies.
    GC0208000Courtesy of CHRYSLER GROUP, LLC
  19. Remove the (Special Tool No. 1860815000, Tool, Crankshaft Rotating) from the crankshaft.
  20. Remove the crankshaft (1).
    GC0189973Courtesy of CHRYSLER GROUP, LLC
  21. Remove the rear oil seal from the crankshaft (1).
    GC0190227Courtesy of CHRYSLER GROUP, LLC
  22. Remove the upper engine crankshaft main bearings (1b) and the two thrust bearings (1a).
    GC0208157Courtesy of CHRYSLER GROUP, LLC
  23. Remove the bolt (1a) and the piston oil cooler jet (1b).
  24. Repeat the procedure to remove the other piston oil cooler jets.
  25. Remove the engine block from the engine stand and place on a workbench.
  26. Drill and remove the water and oil galley plugs from the engine block to allow for cleaning of the internal passages.
  27. Wash and inspect the disassembled components.
  28. Install the water and oil galley plugs to the engine block, using appropriate tools.

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 torque 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.
    GC0207999Courtesy 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 N. m (9 ft. lbs.).
    • Step 2: M10 bolts 11 - 20 to 25 N. m (18 ft. lbs.).
    • Step 3: M10 bolts 11 - 20 to 30 N. m (22 ft. lbs.) plus an additional 40° turn.
    • Step 4: M8 bolts 1 - 10 to 25 N. m (18 ft. lbs.).
    GC0208156Courtesy 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.
    GC0207998Courtesy 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 N. m (9 ft. lbs.).
    • Step 2: M10 bolts 11 - 20 to 25 N. m (18 ft. lbs.).
    • Step 3: M10 bolts 11 - 20 to 30 N. m (22 ft. lbs.) plus an additional 40° turn.
    • Step 4: M8 bolts 1 - 10 to 25 N. m (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 No. 1860815000, Tool, Crankshaft Rotating).
    GC0207997Courtesy 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).
    GC0208154Courtesy 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 torque 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.

    GC0208153Courtesy 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 torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0207996Courtesy of CHRYSLER GROUP, LLC
  42. Rotate the engine on the engine stand.
  43. Remove the (Special Tool No. 1860815000, Tool, Crankshaft Rotating) and install the (Special Tool No. 2063700090, Locking, Crankshaft) timing tool (1).
  44. Install the timing chain tensioner arm and timing chain tensioner and tighten the bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  45. Install the water pump drive sprocket and tighten the bolt to the proper torque 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 No. 2031300091, Tool, Alignment Cylinder Head to Block) (1).
    Fig 1: Cylinder Head Bolt Tightening Sequence
    GC0191641Courtesy of CHRYSLER GROUP, LLC
    GC0191641Courtesy of CHRYSLER GROUP, LLC
  48. Install and tighten the NEW  cylinder head bolts (1) in the sequence shown, to the proper torque 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.
    Fig 2: Camshaft Bearing Cap Bolts Tightening Sequence
    GC0207995Courtesy of CHRYSLER GROUP, LLC
  54. Tighten the bolts in the sequence shown to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0207994Courtesy of CHRYSLER GROUP, LLC
  55. Install the (Special Tool No. 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 torque 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.
    Fig 3: VVAA Retaining Bolts Tightening Sequence
    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 torque specification. Refer to TORQUE SPECIFICATIONS  .
  62. Remove the tools from the VVAA.
    GC0190155Courtesy of CHRYSLER GROUP, LLC
  63. Install the (Special Tool No. 2031600091, Pin, Centering) (1) in the locations shown on the cylinder head.
    GC0207992Courtesy of CHRYSLER GROUP, LLC
  64. Apply a 2-mm thick continuous sealant strip to the lower crankcase and cylinder head surfaces.
    GC0207991Courtesy 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 in the sequence shown. Refer to TORQUE SPECIFICATIONS  .
  68. Tighten the M10 bolts (2b) 14-17 to the initial in the sequence shown. Refer to TORQUE SPECIFICATIONS  .
  69. Tighten the M10 bolts (2b) 14-17 to the final in the sequence shown. Refer to TORQUE SPECIFICATIONS  .
  70. Tighten the M6 bolts (2a) 1-13 to the final in the sequence shown. Refer to TORQUE SPECIFICATIONS  .
  71. Remove the (Special Tool No. 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).
    Fig 4: Cylinder Head Cover Bolts Tightening Sequence
    GC0207989Courtesy of CHRYSLER GROUP, LLC
  75. Install the cylinder head cover and tighten the bolts in the sequence shown to the proper torque 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 torque specification. Refer to TORQUE SPECIFICATIONS  .
  78. Install engine oil pick-up tube and tighten the bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0208136Courtesy 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 torque 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 No. 2064000090, Locking, Pulley) tool (2) above the damper pulley and securely tighten the bolts.
  84. Tighten the vibration damper bolt (3) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  85. Remove the (Special Tool No. 2064000090, Locking, Pulley), (Special Tool No. 2063700090, Locking, Crankshaft) and (Special Tool No. 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 torque specification. Refer to TORQUE SPECIFICATIONS  .
  88. Install the ignition coils and tighten the bolts to the proper torque 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 torque specification. Refer to DRAINING AND FILLING THE COOLING SYSTEM - 1.3L .
    GC0188843Courtesy of CHRYSLER GROUP, LLC
  91. Install a NEW  gasket (1) to the water pump.
    Fig 5: Water Pump Cover Bolts Tightening Sequence
    GC0188782Courtesy of CHRYSLER GROUP, LLC
  92. Install the water pump cover and tighten the bolts using the sequence shown, to the proper torque 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 torque 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 torque specification. Refer to TORQUE SPECIFICATIONS .
  96. Install the A/C compressor with the pipe retainer bracket and tighten the bolts to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  97. Install the generator and tighten the bolts to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  98. Install the accessory drive belt and release the tensioner.
  99. Using the (Special Tool No. 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 torque specification. Refer to TORQUE SPECIFICATIONS  .
  101. Install a new seal on the thermostat.
  102. Install the thermostat and tighten the bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
  103. Install the high pressure fuel pump with roller tappet and tighten the bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    Fig 6: Engine Oil Cooler Bolts Tightening Sequence
    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 torque 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 torque 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 torque 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 torque specification. Refer to TORQUE SPECIFICATIONS  .
  113. Install the Crankshaft Position (CKP) sensor and tighten the new bolt to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
  114. Install the new engine oil pressure sensor and tighten it to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  115. Install the auxiliary coolant pump mounting bracket with the pump attached and tighten the bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    Fig 7: Intake Manifold Bolts Tightening Sequence
    GC0190141Courtesy of CHRYSLER GROUP, LLC
  116. Install the intake manifold with new gaskets and tighten the bolts in the sequence shown to the proper torque 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 torque 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 torque specification. Refer to TORQUE SPECIFICATIONS  .
  128. Install a new seal and tighten the catalytic converter to the turbocharger collar bolt to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
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