Chrysler DODGE D150 1993 Service Manual page 646

• 3.9L ENGINE 9 - 41
(3) Remove the rear main bearing cap. Remove
and discard the old lower oil seal.
(4) Carefully remove and discard t h e old upper oil
seal.
(5) Lightly oil the new upper seal lips with engine
oil. To allow ease of installation of t h e seal, loosen at
least the 2 main bearing caps forward of the rear
bearing cap.
(6) Rotate the new upper seal into the cylinder
block being careful not to shave or cut the outer sur­
face of the seal. To assure proper installation, use the
installation tool provided with the kit. Install the
new seal with the yellow paint facing towards the
rear of the engine.
(7) Install the new lower rear bearing oil seal into
the bearing cap with the yellow paint facing towards
the rear of the engine.
(8) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap
(Fig. 16). Do not over apply sealant or allow the seal­
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica­
tion. Be sure the yellow paint faces toward the rear
of the engine.
(9) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more
than 2 times for proper engagement.
(10) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten ALL cap
bolts to 115 N-m (85 ft. lbs.) torque.
(11) Install oil pump.
(12) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­
ply enough sealant until a small amount is squeezed
out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove.
(13) Immediately install the oil pan.
LOWER SEAL REPLACEMENT
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap.
(3) Remove the rear main bearing cap and discard
the old lower seal.
(4) Carefully install a new upper seal (refer to Up­
per Seal Replacement - Crankshaft Installed proce­
dure above).
(5) Lightly oil the new lower seal lips with engine
oil.
(6) Install a new lower seal in bearing cap with
yellow paint facing the rear of engine.
(7) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap
(Fig. 16). Do not over apply sealant or allow the seal­
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica­
tion.
(8) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more
t h a n 2 times for proper engagement.
(9) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten the cap bolts
to 115 Nnn (85 ft. lbs.) torque.
(10) Install oil pump.
(11) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­
ply enough sealant until a small amount is squeezed
out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove.
(12) Immediately install the oil pan.
CYLINDER BLOCK
Remove the engine assembly from the vehicle.
DISASSEMBLE
(1) Remove the cylinder head.
(2) Remove the oil pan.
(3) Remove the piston/connecting rod assembly.
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
• The cylinder bores show more t h a n 0.127 mm
(0.005 inch) out-of-round.
• The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
• The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely co­
ordinated with the fitting of pistons and rings so
specified clearances may be maintained.
Refer to Standard Service Procedures in the begin­
ning of this Group for the proper honing of cylinder
bores.
OIL LINE PLUG
The oil line plug is located in the vertical passage
at the rear of the block between the Oil-To-Filter and
Oil-From-Filter passages (Fig. 20). Improper installa­
tion or plug missing could cause erratic, low or no oil
pressure.
(1) Remove oil pressure sending unit from back of
block.