Customer Satisfaction Notification F35 Engine Connecting Rod Bearing Debris Service Campaign Bulletin
Total Page：16
File Type：pdf, Size：1020Kb
9/23/2019 Printer Friendly View CarMax Store #7249 2006 Chrysler Pacifica 3.5L Eng VIN 4 Limited Service Manual: CUSTOMER SATISFACTION Print Date: 9/23/2019 NOTIFICATION F35 ENGINE CONNECTING ROD BEARING DEBRIS CUSTOMER SATISFACTION NOTIFICATION F35 ENGINE CONNECTING ROD BEARING DEBRIS SERVICE CAMPAIGN BULLETIN Reference Number(s): F35, Date of Issue: September 2006 CHRYSLER: 2006 LX Chrysler 300, Dodge Magnum and Charger; 2006 CS Chrysler Pacifica NOTE: Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal RRT #06-025 has been cancelled. MODELS 2006 LX Chrysler 300, Dodge Magnum and Charger 2006 CS Chrysler Pacifica NOTE: This notification applies only to the above vehicles equipped with a 3.5L engine ("G", "V" or "4" in the 8th VIN position) with engine build date codes from 900586 through 900766. IMPORTANT: Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery . Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. https://www1.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=true&ymms=false&selectorMode=&className=&hideOption… 1/73 9/23/2019 Printer Friendly View SUBJECT The engines in about 11,200 of the above vehicles may have been assembled with sand-like debris on the number two connecting rod bearing journal of the crankshaft. This can cause excessive rod bearing wear and result in engine failure. REPAIR The number two connecting rod bearing and crankshaft journal must be inspected. If either the connecting rod bearing or crankshaft journal is damaged, a long block engine must be installed. ALTERNATE TRANSPORTATION Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that engine replacement is required and the vehicle must be held overnight. PARTS INFORMATION IMPORTANT: Due to the small number of vehicles requiring engine replacement, engine and gasket packages should only be ordered as determined by the inspection procedure in Section A or Section B. All engine long block assemblies must be ordered through the STAR center. LONG BLOCK PARTS NUMBERS Part Number Quantity Description 68020620AA 1 Engine, 3.5L (LX) Long Block 68020619AA 1 Engine, 3.5L (CS) Long Block LX LONG BLOCK PACKAGE PARTS INFORMATION Part Number Description CEA0F352 LX Long Block Parts Package Each package contains the following components: LX PACKAGE COMPONENTS INFORMATION Quantity Description 1 Gasket, EGR Valve to Cylinder Head 1 Gasket, EGR Valve to EGR tube 2 Gasket, Exhaust Manifold to Cylinder Head https://www1.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=true&ymms=false&selectorMode=&className=&hideOption… 2/73 9/23/2019 Printer Friendly View 8 Bolt, Drive Plate to Crankshaft CS LONG BLOCK PACKAGE PARTS INFORMATION Part Number Description CEA0F351 CS Long Block Parts Package Each package contains the following components: CS LONG BLOCK PACKAGE COMPONENTS INFORMATION Quantity Description 1 Gasket, EGR Valve to Cylinder Head 1 Gasket, EGR Valve to EGR Tube 2 Gasket, Exhaust Manifold to Cylinder Head 1 Gasket, Crossover pipe, Crossover to Front Exhaust Manifold 1 Gasket, Crossover pipe, Crossover to Rear Exhaust Manifold 1 Gasket, Exhaust Manifold to Front Catalytic Converter 8 Bolt, Drive Plate to Crankshaft SPECIAL TOOLS The following existing special tools may be required to perform this repair: SPECIAL TOOLS Tool Number Description C-4685-C1 Screw, Forcing 6792 Installer, Crank Sprocket 9365 Holding Fixture, Damper L-4407A Puller, Gear 8874 CS Suspension Cradle Fixture StarSCAN Tool CH9401 https://www1.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=true&ymms=false&selectorMode=&className=&hideOption… 3/73 9/23/2019 Printer Friendly View CH9404 StarSCAN Vehicle Cable 8631 CS Steering Coupling Pin Removal 8874 CS Suspension Cradle Support Fixture 8534 Engine Lift Kit SERVICE PROCEDURE A. LX (RWD And AWD) Engine Inspection 1. Open the trunk lid or tailgate. 2. Raise the cargo floor panel to access the battery. 3. Disconnect the battery. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Open the hood. 5. Remove the engine oil dipstick. 6. Remove the generator upper support bracket. 7. Remove the dipstick tube mounting bolt and remove the dipstick tube from the engine oil pan. 8. Lock the steering wheel in the straight ahead position. 9. Raise the vehicle on a suitable hoist. 10. Remove the lower plastic splash shield from under the engine. 11. Drain engine oil and remove the engine oil filter. 12. Install the engine oil drain plug into the engine oil pan and tighten. 13. For AWD models: a. Lower the vehicle part way to perform suspension operations. b. Remove the right and left front wheel and tire assembly. c. Remove the right and left vehicle speed sensors from the steering knuckle (Figure 1 ). https://www1.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=true&ymms=false&selectorMode=&className=&hideOption… 4/73 9/23/2019 Printer Friendly View d. Remove the right and left upper control arm ball joint bolt and separate the steering knuckle from the upper control arm (Figure 2 ). e. Remove the right and left brake calipers. Set them aside. CAUTION: Do not let the calipers hang by the brake hose. f. Remove the right and left brake pads and set them aside for reuse. g. Remove the right and left hub nuts holding the right and left axle shafts to the hubs. h. Remove the right and left sway bar link bolts to the strut clevis brackets and locate the sway bar and links away from the lower control arm (Figure 2 ). i. Separate the left axle shaft from the steering knuckle. j. Separate left axle shaft from the differential extension housing. https://www1.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=true&ymms=false&selectorMode=&className=&hideOption… 5/73 9/23/2019 Printer Friendly View k. Remove the left axle shaft from the vehicle. l. Remove the left tie-rod end from the steering knuckle. m. Remove the left strut to lower control arm bolt and separate the strut from the arm. n. Remove the differential extension (Figure 3 ). o. Separate the right axle shaft from the steering knuckle. p. Remove the right axle shaft from the vehicle. q. Remove the right tie rod end from the steering knuckle. https://www1.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=true&ymms=false&selectorMode=&className=&hideOption… 6/73 9/23/2019 Printer Friendly View r. Remove the right strut to lower control arm bolt and separate the strut from the arm. s. Apply a paint alignment mark to the propeller and front differential flange. t. Remove the four bolts holding the propeller shaft from the transfer case to the front differential assembly. u. Plug front differential openings to prevent fluid leakage. v. Remove front differential and secure it to the engine cradle away from the engine oil pan (Figure 5 ). 14. Raise the vehicle. 15. Remove the engine oil cooler/filter nipple and set oil cooler aside. NOTE: Do not remove the oil cooler coolant hoses from the engine oil cooler. https://www1.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=true&ymms=false&selectorMode=&className=&hideOption… 7/73 9/23/2019 Printer Friendly View 16. For RWD model: a. Mark the steering column coupler in relation to the steering gear. b. Remove the steering column bolt at the coupler and separate the steering column coupler from the steering gear (Figure 5 ). c. Remove the two bolts holding the steering rack to the sub frame and allow the steering rack to hang freely. https://www1.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=true&ymms=false&selectorMode=&className=&hideOption… 8/73 9/23/2019 Printer Friendly View 17. Remove the drive plate access cover to gain access to the rear two engine oil pan bolts (Figure 6 ). 18. Remove the two rear engine oil pan retaining bolts. 19. Remove the four rear engine oil pan to transmission bell housing bolts. 20. Remove the metal dust shield at the right rear side of oil pan. 21. Remove the remaining oil pan bolts and nuts. https://www1.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=true&ymms=false&selectorMode=&className=&hideOption… 9/73 9/23/2019 Printer Friendly View https://www1.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=true&ymms=false&selectorMode=&className=&hideOptio… 10/73 9/23/2019 Printer Friendly View 22. Using a putty knife, separate the oil pan from the oil pan gasket. Carefully remove the oil pan. The oil pan gasket should remain attached to the block. NOTE: If the oil pan gasket is attached to the block at all four corners, be careful not to dislodge the gasket while completing this section. 23. Remove the oil pickup tube (Figure 7 ). 24. Remove the stamped metal windage tray. Note which direction the windage tray is facing for installation later (Figure 7 ). 25. Rotate the crankshaft clockwise until the #2 connecting rod is at Bottom Dead Center (BDC). 26. Paint mark one side of the #2 connecting rod bearing cap and connecting rod before removal. This is to aide in the correct orientation during assembly (Figure 8 ). 27. Remove the #2 connecting rod cap. https://www1.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=true&ymms=false&selectorMode=&className=&hideOptio… 11/73 9/23/2019 Printer Friendly View 28.