Complete removal and replacement of the crankshaft, requiring engine removal from vehicle, full disassembly of rotating assembly, and precision measurement during installation.

Warnings

Tools required

Parts

• Crankshaft (new or machined) × 1 — Use OEM specification
• Main bearing set (standard or oversized as needed) × 1 — Use OEM specification
• Rod bearing set (standard or oversized as needed) × 1 — Use OEM specification
• Thrust bearing set × 1 — Use OEM specification
• Complete gasket set × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Harmonic balancer bolt × 1 — Use OEM specification
• Main bearing cap bolts × 10 — Use OEM specification
• Rod bearing cap bolts × 12 — Use OEM specification
• Flexplate/flywheel bolts × 8 — Use OEM specification
• Piston ring set (if reusing pistons) × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Mopar engine assembly lube × 1 — Use OEM specification
• RTV silicone sealant (Mopar approved) × 1 — Use OEM specification

Fluids

• Mopar 5W-20 Synthetic Blend — 6.5 qt
• Mopar OAT Coolant (Purple) — 13 qt
• Mopar ATF+4 — 10 qt

Preparation

1. Position vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 2 minutes
3. Remove engine cover and air intake system completely
4. Drain engine oil and coolant into appropriate containers
5. Drain automatic transmission fluid if equipped
6. Remove hood and support with blankets to prevent damage
7. Remove radiator, cooling fans, and all coolant hoses
8. Disconnect all electrical connectors from engine and transmission, labeling each
9. Disconnect fuel lines after relieving fuel system pressure
10. Remove serpentine belt and all accessory brackets
11. Raise vehicle on lift and remove skid plates
12. Disconnect exhaust system at manifolds
13. Mark and disconnect driveshafts from transfer case
14. Support transmission with transmission jack
15. Remove transmission-to-engine bolts and separate transmission
16. Attach engine hoist with chains to factory lift points
17. Remove engine mount bolts
18. Carefully lift engine from vehicle and secure to engine stand
19. Clean exterior of engine thoroughly before disassembly

Procedure

1. 1

   Remove external engine components
   With engine on stand, remove alternator, A/C compressor, power steering pump, starter motor, and all remaining accessories. Remove valve covers, intake manifold, and exhaust manifolds. Label and bag all bolts by component.
   Torque spec

   Mounting Bolts54 Nm (40 lb-ft)

   Gasket Bolts23 Nm (17 lb-ft)
2. 2

   Remove timing components
   Remove timing chain cover after removing harmonic balancer using puller tool. Remove timing chains, guides, and tensioners. Remove camshaft position sensors. Keep all timing components organized for inspection.
   ⚠Do not use impact tools on harmonic balancer bolt. Use breaker bar with flywheel holding tool to prevent crankshaft damage.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)

   Sensor Bolts12 Nm (9 lb-ft)
3. 3

   Remove cylinder heads
   Remove cylinder head bolts in reverse of tightening sequence (consult service manual for pattern). Lift cylinder heads carefully and place on clean surface with valves facing up. Inspect head gasket surface for damage or warping.
   ℹ️Cylinder head bolts are torque-to-yield and must be replaced during reassembly.
   Torque spec

   Gasket Surface Bolts23 Nm (17 lb-ft)
4. 4

   Remove oil pan and oil pump
   Remove oil pan bolts and carefully separate oil pan from engine block. Remove oil pickup tube. Remove oil pump mounting bolts and extract oil pump assembly. Clean all gasket material from mating surfaces.
   Torque spec

   Mounting Bolts54 Nm (40 lb-ft)

   Gasket Bolts23 Nm (17 lb-ft)
5. 5

   Mark and remove connecting rod caps
   Rotate crankshaft to position each piston at top dead center individually. Use permanent marker to number each rod and cap (1-6) with cylinder number and orientation arrow pointing toward front of engine. Remove rod cap bolts and caps, pushing pistons up into bores. Keep each rod cap with its corresponding bolts.
   ⚠Rod caps MUST be reinstalled in exact same position and orientation. Mixing caps will cause immediate engine failure.
6. 6

   Mark and remove main bearing caps
   Mark each main bearing cap with position number (1-4) and directional arrow pointing to front of engine. Caps are numbered from front to back. Remove main bearing cap bolts in sequence from outer caps toward center. Carefully lift caps and keep with their respective bolts. Note thrust bearing position (typically cap #3).
   ⚠Main bearing caps are machined in place and not interchangeable. Installing caps incorrectly will destroy engine.
7. 7

   Remove crankshaft
   Carefully lift crankshaft straight up out of engine block using both hands. Avoid dragging journals across block. Place crankshaft on clean padded surface. Remove and keep all upper main bearings, noting their positions.
   ℹ️Crankshaft weighs approximately 60 lbs. Use proper lifting technique.
8. 8

   Inspect and measure crankshaft
   Clean all crankshaft journals thoroughly with solvent. Inspect journals for scoring, heat discoloration, or damage. Measure all main and rod journals with outside micrometer at multiple points. Main journals should measure 2.519-2.520 inches, rod journals 2.283-2.284 inches. Out-of-round or taper exceeding 0.0002 inches requires machining. Check for cracks using magnetic particle or dye penetrant inspection.
   ⚠Crankshaft with damaged journals must be machined to next undersize or replaced. Installing damaged crankshaft will cause immediate failure.
9. 9

   Inspect engine block bearing bores
   Clean all main bearing bores in block thoroughly. Inspect for scoring or damage. Measure each main bearing bore with inside micrometer. Bores should measure 2.696-2.697 inches. Check bore alignment using straightedge and feeler gauge. Maximum out-of-line tolerance is 0.002 inches.
   ⚠Block with damaged or misaligned bearing bores requires machine shop align-honing or replacement.
10. 10

    Install new main bearings in block
    Ensure block bearing bores are perfectly clean and dry. Install new upper main bearings, ensuring bearing tabs engage notches in block. Apply thin coat of assembly lube to bearing surfaces. Verify thrust bearing is installed in correct position (typically #3 main). Do not allow bearings to rotate in bores.
    ℹ️Bearings must be installed dry in bores - no oil on bearing backs. Oil only the bearing surfaces.
11. 11

    Install crankshaft and check bearing clearances
    Carefully lower crankshaft into block, aligning with main bearings. Place Plastigage strip across each journal (do not rotate crank after placement). Install lower bearing shells in caps without oil. Install caps in correct positions with arrows pointing forward. Install new main cap bolts and torque in sequence from center outward to 15 ft-lbs, then to final specification plus angle per service manual. Remove caps and measure Plastigage width. Clearance should be 0.0007-0.0023 inches for mains.
    ⚠Do not rotate crankshaft with Plastigage installed. This will give false readings.
    ⚠Clearances outside specification require different bearing sizes or crankshaft machining.
12. 12

    Permanently install crankshaft
    Remove main caps again and clean off all Plastigage residue. Apply assembly lube generously to all bearing surfaces. Reinstall crankshaft and main caps with lubricated bearings. Install new main cap bolts and torque in proper sequence per service manual specifications (typically 20 ft-lbs, then 90 degrees additional). Verify crankshaft rotates freely with no binding. Check crankshaft endplay with dial indicator - should be 0.002-0.010 inches.
    ⚠Excessive endplay indicates incorrect thrust bearing installation. Insufficient endplay will cause bearing failure.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)
13. 13

    Install connecting rods and pistons
    If pistons were removed, install new rings with gaps staggered per specifications. Apply assembly lube to rod bearings and install in rods. Install ring compressor on each piston. Insert each piston/rod assembly into correct cylinder with orientation marks facing front. Tap piston crown gently with wooden hammer handle to seat. Guide rod onto crankshaft journal. Install rod bearing caps in correct orientation with new bolts. Torque rod bolts to specification (typically 20 ft-lbs plus 90 degrees).
    ⚠Ensure rod cap is installed on correct rod in correct orientation. Mixing rods will cause immediate failure.
    ℹ️Ring gaps must be staggered - consult service manual for proper positions.
14. 14

    Install rear main seal and oil pump
    Install new rear main seal using seal installation tool, ensuring seal is square and seated to proper depth. Apply RTV sealant to oil pump mating surface and install oil pump with new gasket. Verify pump engages crankshaft properly. Install oil pump mounting bolts and torque to specification.
    ⚠Rear main seal must be installed square. Cocked seal will leak immediately.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)

    Gasket Bolts23 Nm (17 lb-ft)
15. 15

    Install oil pan and prepare for timing components
    Apply RTV sealant or new gasket to oil pan mating surface per specifications. Install oil pan and torque bolts in crisscross pattern to specification. Install new front crankshaft seal. Rotate crankshaft to verify smooth rotation with all components installed. Prime oil pump using priming tool before installing timing components.
    ⚠Engine must be primed with oil before startup to prevent bearing damage during initial cranking.
    Torque spec

    Gasket Bolts23 Nm (17 lb-ft)

Reassembly

1. Install timing chains, guides, and tensioners with crankshaft and camshafts in correct timing positions per service manual
2. Install timing chain cover with new gasket, ensuring proper seal alignment
3. Install harmonic balancer using installer tool - never hammer onto crankshaft
4. Install new harmonic balancer bolt and torque to specification plus angle per service manual
5. Install cylinder heads with new gaskets and new head bolts, torquing in proper sequence
6. Install exhaust manifolds, intake manifold, and valve covers with new gaskets
7. Install all accessories including alternator, A/C compressor, power steering pump, and starter
8. Install flexplate/flywheel with new bolts torqued to specification
9. Carefully lower engine into vehicle and align with transmission
10. Install transmission-to-engine bolts and torque to specification
11. Install engine mount bolts and remove engine hoist
12. Reconnect driveshafts, exhaust system, and all electrical connectors
13. Install radiator, cooling system components, and serpentine belt
14. Fill engine with specified oil quantity, install new oil filter
15. Fill cooling system with specified coolant mixture
16. Refill transmission with ATF+4 to proper level
17. Install hood, air intake system, and engine cover

Verification

• Perform final visual inspection of all connections, bolts, and hoses
• Verify all electrical connectors are properly seated and locked
• Check all fluid levels including oil, coolant, transmission, transfer case, and differentials
• Verify serpentine belt routing is correct and tensioner operates properly
• Disconnect fuel pump relay and crank engine for 10 seconds to build oil pressure before fuel delivery
• Reconnect fuel pump relay and start engine, monitoring oil pressure gauge immediately
• Oil pressure should rise within 3-5 seconds - if not, shut down immediately and investigate
• Allow engine to warm to operating temperature, monitoring for leaks, unusual noises, or vibrations
• Check for coolant, oil, and transmission fluid leaks throughout warm-up
• Verify cooling fans operate and engine reaches normal operating temperature
• After warm-up, shut down and recheck all fluid levels when cool
• Test drive vehicle and verify normal operation, smooth idle, and proper power delivery
• After 50-100 miles, retorque cylinder head bolts if specified by service manual
• Change engine oil and filter after initial 500 mile break-in period

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