(3) Immerse the piston head and rings in clean
engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench
(part of Tool C-385). Be sure position of rings
does not change during this operation.
(4) Install connecting rod bolt protectors on rod
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal.
(7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, con-
necting rod cap and cylinder bore number are the
same. Install nuts on cleaned and oiled rod bolts and
tighten nuts to 61 N·m (45 ft. lbs.) torque.
(9) Install the oil pan.
(10) Install the cylinder head.
(11) Install the engine into the vehicle.
CRANKSHAFT
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-
ing cap.
(3) Remove the vibration damper.
(4) Remove the timing chain cover.
(5) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time.
(6) Lift the crankshaft out of the block.
(7) Remove and discard the crankshaft rear oil
seals.
(8) Remove and discard the front crankshaft oil
seal.
INSTALLATION
(1) Clean Loctite 518 residue and sealant from the
cylinder block and rear cap mating surface. Do this
before applying the Loctite drop and the installation
of rear cap.
(2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine
oil.
(6) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of Loctite 518, or
equivalent, on each side of the rear main bearing cap
(Fig. 40). DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing
cap to cylinder block immediately after sealant appli-
cation.
(8) To align the bearing cap, use cap slot, align-
ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
(9) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 N·m (85 ft. lbs.) torque.
(10) Install oil pump.
(11) Install the timing chain cover.
(12) Install the vibration damper.
(13) Apply Mopar
t
Silicone Rubber Adhesive Seal-
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 41).
Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
(14) Install new front crankshaft oil seal.
(15) Immediately install the oil pan.
OIL PUMP
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from rear main bearing
cap.
INSTALLATION
(1) Install oil pump. During installation slowly
rotate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
Fig. 40 Sealant Applicationto Bearing Cap
.25 DROP OF LOCTITE 515
ON BOTH SIDES OF REAR
MAIN CAP
ZG
5.9L ENGINE
9 - 107
REMOVAL AND INSTALLATION (Continued)
Summary of Contents for 1997 Grand Cherokee
Page 6: ...FASTENER IDENTIFICATION 4 INTRODUCTION ZG GENERAL INFORMATION Continued ...
Page 9: ...METRIC CONVERSION ZG INTRODUCTION 7 GENERAL INFORMATION Continued ...
Page 12: ......
Page 58: ......
Page 180: ......
Page 228: ......
Page 274: ......
Page 282: ...COOLING SYSTEM DIAGNOSIS DIESEL ENGINE 7 8 COOLING SYSTEM ZG DIAGNOSIS AND TESTING Continued ...
Page 283: ...ZG COOLING SYSTEM 7 9 DIAGNOSIS AND TESTING Continued ...
Page 284: ...7 10 COOLING SYSTEM ZG DIAGNOSIS AND TESTING Continued ...
Page 285: ...ZG COOLING SYSTEM 7 11 DIAGNOSIS AND TESTING Continued ...
Page 286: ...7 12 COOLING SYSTEM ZG DIAGNOSIS AND TESTING Continued ...
Page 290: ...SERPENTINE DRIVE BELT DIAGNOSIS 7 16 COOLING SYSTEM ZG DIAGNOSIS AND TESTING Continued ...
Page 318: ......
Page 330: ......
Page 340: ......
Page 402: ......
Page 423: ...VIC Initial Set Up ZG INSTRUMENT PANEL SYSTEMS 8E 21 SERVICE PROCEDURES Continued ...
Page 424: ...VIC Reset 8E 22 INSTRUMENT PANEL SYSTEMS ZG SERVICE PROCEDURES Continued ...
Page 436: ......
Page 454: ......
Page 468: ......
Page 470: ......
Page 510: ......
Page 520: ......
Page 532: ......
Page 560: ......
Page 572: ......
Page 580: ......
Page 596: ......
Page 610: ......
Page 622: ......
Page 680: ......
Page 700: ......
Page 712: ......
Page 752: ......
Page 772: ......
Page 780: ......
Page 842: ......
Page 852: ......
Page 868: ......
Page 872: ......
Page 890: ......
Page 908: ......
Page 974: ......
Page 1056: ......
Page 1090: ......
Page 1104: ......
Page 1106: ......
Page 1118: ......
Page 1136: ......
Page 1176: ......
Page 1196: ......
Page 1208: ......
Page 1248: ......
Page 1268: ......
Page 1270: ......
Page 1271: ......
Page 1272: ......
Page 1273: ......
Page 1274: ......
Page 1276: ......
Page 1338: ......
Page 1348: ......
Page 1364: ......
Page 1368: ......
Page 1386: ......
Page 1404: ......
Page 1470: ......
Page 1492: ......
Page 1542: ......
Page 1552: ......
Page 1584: ......
Page 1598: ......
Page 1655: ...Fig 3 Oil Lubrication System ZG 5 2L ENGINE 9 57 DESCRIPTION AND OPERATION Continued ...
Page 1684: ...TORQUE 9 86 5 2L ENGINE ZG SPECIFICATIONS Continued ...
Page 1689: ...Fig 3 Oil Lubrication System ZG 5 9L ENGINE 9 91 DESCRIPTION AND OPERATION Continued ...
Page 1723: ...DIAGNOSIS AND TESTING SERVICE DIAGNOSIS DIESEL PERFORMANCE ZG ENGINE 9 3 ...
Page 1724: ...9 4 ENGINE ZG DIAGNOSIS AND TESTING Continued ...
Page 1725: ...ZG ENGINE 9 5 DIAGNOSIS AND TESTING Continued ...
Page 1726: ...9 6 ENGINE ZG DIAGNOSIS AND TESTING Continued ...
Page 1727: ...ZG ENGINE 9 7 DIAGNOSIS AND TESTING Continued ...
Page 1728: ...9 8 ENGINE ZG DIAGNOSIS AND TESTING Continued ...
Page 1729: ...SERVICE DIAGNOSIS DIESEL MECHANICAL ZG ENGINE 9 9 DIAGNOSIS AND TESTING Continued ...
Page 1730: ...9 10 ENGINE ZG DIAGNOSIS AND TESTING Continued ...
Page 1731: ...ZG ENGINE 9 11 DIAGNOSIS AND TESTING Continued ...
Page 1762: ...SPECIFICATIONS ENGINE SPECIFICATIONS 9 42 ENGINE ZG ...
Page 1763: ...ZG ENGINE 9 43 SPECIFICATIONS Continued ...
Page 1862: ......
Page 1930: ......
Page 1934: ......
Page 2114: ......
Page 2122: ...DIAGNOSIS AND TESTING NV231 DIAGNOSIS 21 8 TRANSMISSION AND TRANSFER CASE ZG ...