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ENGINE

1. 80c41fbO Fig 86 INTAKE MANIFOLD 1 THROTTLE BODY 2 INTAKE MANIFOLD 3 INTAKE PORT GASKETS REMOVAL 1 Disconnect negative cable from battery 2 Remove resonator assembly and air inlet hose 3 Disconnect throttle and speed control cables 4 Disconnect electrical connectors for the follow ing components Refer to FUEL SYSTEM for compo nent locations e Manifold Absolute Pressure MAP Sensor e Intake Air Temperature IAT Sensor e Throttle Position TPS Sensor e Coolant Temperature CTS Sensor e Idle Air Control IAC Motor 5 Disconnect vapor purge hose brake booster hose speed control servo hose positive crankcase ventilation PCV hose 6 Disconnect generator electrical connections 7 Disconnect air conditioning compressor electri cal connections 8 Disconnect left and right radio suppressor straps 9 Disconnect and remove ignition coil towers 10 Remove top oil dipstick tube retaining bolt and ground strap K INTAKE MANIFOLD Continued 11 Bleed fuel system Refer to FUEL SYSTEM 12 Remove fuel rail 13 Remove throttle body assembly and mounting bracket 14 Drain cooling system below coolant tempera ture level Refer to COOLING SYSTEM 15 Remove the heater hoses from the engine front cover and the heater core 16 Undip and remove heater hoses and tubes from intake manifold 17 Remove coolant temperature sensor Refer to FUEL SYSTEM 18
2. _a_ _ _ _ _ KJ ENGINE 3 7L Continued Puller 1026 Rear Crankshaft Seal Installer 8349 Crankshaft Damper Removal Insert 8513 Rear Crankshaft Seal Remover 8506 Connecting Rod Guides 8507 Chall Tensioner WENDE 9879 Crankshaft Damper Installer 8512 Chain Tensioner Pins 8514 Kj ENGINE 3 7L 9 17 ENGINE 3 7L Continued Remover Rocker Arm 8516 ENGINE LIFTING FIXTURE 8427 Idler Shaft Remover 8517 CAMSHAFT HOLDER 8428 9 Valve Spring Compressor Adapters 8519 9 18 ENGINE 3 7L ENGINE 3 7L Continued INSTALLER REMOVER COUNTER BALANCE SHAFT 8641 801194420 Dial Indicator C 3339 Valve Spring Compressor C 3422 B 8011c9fa Bore Size Indicator C 119 Oil Pressure Gauge C 3292 Piston Ring Compressor C 385 Bloc Chek Kit C 3685 A K K AIR CLEANER ELEMENT REMOVAL 3 7L Housing removal is not necessary for element fil ter replacement 1 Pry up 2 spring dips Fig 3 from front of housing cover spring clips retain cover to housing 2 Release housing cover from 4 locating tabs located on rear of housing and remove cover 3 Remove air cleaner element filter from hous ing 4 Clean inside of housing before replacing ele ment 80090655 Fig 3 AIR CLEANER ELEMENT 3 7L AIR INTAKE HOSE HOSE CLAMP COVER CLIPS 2 RO DP INSTALLATION 3 7L 1 Install eleme
3. eee ee 57 OPERATION u npe OW dae alia a ew are 58 KJ DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING ENGINE OIL LEAK o eread aa ti e ia 60 DIAGNOSIS AND TESTING ENGINE OIL PRESSURE uns zw fr RR v ES es 60 DIAGNOSIS AND TESTING REAR SEAL AREA LEAKS ooo 61 OIL STANDARD PROCEDURE ENGINE OIL 61 OIL FILTER REMOVAL sanos nas ren 63 INSTALLATION 2 eee ee ee 63 OIL PAN DESCRIPTION eee ee 63 REMOVAL count ea ei ee 63 CLEANING 22 22 63 INSPECTION ee 63 INSTALLATION memes eee ee 64 OIL PRESSURE SENSOR SWITCH DESCRIPTION zs ssces dot xk RE RR I EE es 65 OPERATION szzxakaecexcerk RR ae 65 REMOVAL vesoronodin rada ARP 65 INSTALLATION cade enue RE ARE ERE 65 OIL PUMP REMOVAL ease x Re REESE EX UE od 65 DISASSEMBLY eee iai ee 65 INSPECTION cere 66 ASSEMBLY 4 sine d SkA A ee a 67 INSTALLATION occ 67 INTAKE MANIFOLD DESCRIPTION cce eed RR RR 68 DIAGNOSIS AND TESTING INTAKE MANIFOLD LEAKS occ 68 REMOVAL rasen eee he Pe eee ees 68 INSTALLATION 1 eee BB 69 EXHAUST MANIFOLD DESCRIPTION eee ee 69 REMOVAL usa 2 0 xe Ree CE ES RE een 69 INSTALLATION sseee ee 70 VALVE TIMING DESCRIPTION cesos a HERR 71 OPERATION aereas ras ia 71 STANDARD PROCEDURE MEASURING TIMING CHAIN WEAR 71 SERVICE PROCEDURES 72 BALANCE SHAFT REMOVAL rasanten 74 INSTALLATION 2 eee ee 74 TIMING BELT CHAIN COVER S REMOVAL 2l14 9 kd RIBERA
4. 1 Lubricate camshaft journals with clean engine oil NOTE Position the right side camshaft so that the camshaft sprocket dowel is near the 10 o clock position This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps 2 Position the camshaft into the cylinder head 3 Install the camshaft bearing caps hand tighten the retaining bolts NOTE Caps should be installed so that the stamped numbers on the caps are in numerical order 1 thru 4 from the front to the rear of the engine All caps should be installed so that the stamped arrows on the caps point toward the front of the engine 4 Working in 1 2 turn increments tighten the bearing cap retaining bolts starting with the middle cap working outward Fig 23 5 Torque the camshaft bearing cap retaining bolts to 11 N m 100 in Ibs 9 34 ENGINE 3 7L CAMSHAFT S Continued SUUM E A Roda carr NS 808a1e9b Fig 23 Camshaft Bearing Caps Tightening Sequence 6 Position the camshaft drive gear into the tim ing chain aligning the V6 mark between the two marked chain links Two links marked during remov al 7 Using Special Tool 8428 Camshaft Wrench rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket Install the sprocket onto the camshaft CAUTION Remove excess oil from camshaft sprocket bolt Failure to do so can cause bolt over torque
5. 2 Install the crankshaft tone wheel Torque the mounting screws to 22 N m 21 ft Ibs 3 Position crankshaft in cylinder block 4 Install the thrust washers Fig 42 CAUTION The bedplate to cylinder block mating surface must be coated with Mopar Engine RTV sealant prior to installation Failure to do so will cause severe oil leaks NOTE Make sure that the bedplate and cylinder block sealing surfaces are clean and free of oil or other contaminants Contaminants on the sealing surfaces may cause main bearing distortion and or oil leaks 5 Apply a 2 5mm 0 100 inch bead of Mopar Engine RTV sealant to the cylinder block to bedplate mating surface as shown 6 Coat the crankshaft main bearing journals with clean engine oil and position the bedplate onto the cylinder block 9 44 ENGINE 3 7L CRANKSHAFT Continued K MATING SURFACE O e O O O ig PRY PRY POINT POINT BES E a EJ MATING SURFACE A 2 e O 80c06e9f Fig 41 BEDPLATE PRY POINT LOCATION 80b77054 Fig 42 Crankshaft Thrust Washer Installation 1 CRANKSHAFT THRUST WASHER NOTE Lubricate the bedplate retaining bolts with clean engine oil prior to installation 7 Install the bedplate retaining bolts making sure to place the stud bolts in the correct location Torque the bolts in the sequence shown Fig 43 e Hand tighten bolts 1D 1G and 1F until the bed plate contacts the block e Tight
6. 6 Replace as necessary 7 Inspect and replace as necessary 8 Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL REMOVAL 9 Refer to Engine Tlming in this section 1 ENGINE MISSES ON ACCELERATION 1 Spark plugs dirty or incorrectly gapped 2 Dirt in fuel system 3 Burned warped or pitted valves 4 Faulty coil 1 Refer to 8 ELECTRICAL IGNITION CONTROL SPARK PLUG CLEANING 2 Clean fuel system 3 Replcae as necessary 4 Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL REMOVAL 1 ENGINE MISSES AT HIGH SPEED 1 Spark plugs dirty or incorrectly gapped 2 Faulty coil 3 Dirt or water in fuel system 1 Refer to 8 ELECTRICAL IGNITION CONTROL SPARK PLUG CLEANING 2 Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL REMOVAL 3 Clean system and replace fuel filter 9 6 ENGINE 3 7L ENGINE 3 7L Continued DIAGNOSIS AND TESTING ENGINE DIAGNOSIS MECHANICAL CONDITION POSSIBLE CAUSES K CORRECTIONS NOISY VALVES 1 High or low oil level in crankcase 2 Thin or diluted oil 3 Low oil pressure 4 Dirt in lash adjusters 5 Worn rocker arms 7 Worn valve guides 8 Excessive runout of valve seats on valve faces 1 Refer to LUBRICATION amp MAINTENANCE FLUID TYPES SPECIFICATIONS 2 Change oil and filter 3 Check oil pump if Ok check rod and main bearings for excessive wear 4
7. KJ 4 Remove radiator core support bracket 5 Remove fan shroud with electric fan assembly 6 Remove mechanical cooling fan 7 Remove drive belt NOTE lt is NOT necessary to discharge the A C system to remove the engine 8 Remove A C compressor and secure away from engine with lines attached 9 Remove generator engine and secure away from NOTE Do NOT remove the phenolic pulley from the P S pump lt is not required for P S pump removal 10 Remove power steering pump with lines attached and secure away from engine 11 Drain cooling system 12 Remove coolant bottle 13 Disconnect the heater hoses from the engine 14 Disconnect heater hoses from heater core and remove hose assembly 15 Disconnect throttle and speed control cables 16 Remove upper radiator hose from engine 17 Remove lower radiator hose from engine 18 Disconnect the engine to body ground straps at the left side of cowl 19 Disconnect the engine wiring harness at the following points e Intake air temperature IAT sensor Fuel Injectors Throttle Position TPS Switch Idle Air Control LAC Motor Engine Oil Pressure Switch Engine Coolant Temperature ECT Sensor Manifold Absolute Pressure MAP Sensor Camshaft Position CMP Sensor Coil Over Plugs e Crankshaft Position Sensor 20 Remove coil over plugs 21 Release fuel rail pressure 22 Remove fuel rail and secure away from engine NOTE It is not necessary to release the
8. NOTE Check for sharp edges on the keeper grooves Remove any burrs from the valve stem before removing the valve from the cylinder head 7 Remove the valve from the cylinder head NOTE The valve stem seals are common between intake and exhaust 8 Remove the valve stem seal Mark the valve for proper installation 9 28 ENGINE 3 7L K INTAKE EXHAUST VALVES amp SEATS Continued TESTING VALVE SPRINGS NOTE Whenever the valves are removed from the cylinder head it is recommended that the valve springs be inspected and tested for reuse Inspect the valve springs for physical signs of wear or damage Turn table of tool C 647 until surface is in line with the 40 69 mm 1 602 in mark on the threaded stud and the zero mark on the front Place spring over the stud on the table and lift compress ing lever to set tone device Pull on torque wrench until Ping is heard Take reading on torque wrench at this instant Multiply this reading by two This will give the spring load at test length Fractional measurements are indicated on the table for finer adjustments Refer to Specifications Section to obtain specified height and allowable tensions Replace any springs that do not meet specifications Fig 19 9209 37 Fig 19 Testing Valve Springs 1 SPECIAL TOOL C 647 INSTALLATION 1 coat the valve stem with clean engine oil and insert it into the cylinder head 2 Install the valve stem seal make sure th
9. 39 Remove the structural cover 40 Remove torque convertor bolts and mark location for reassembly 41 Remove transmission bellhousing to engine bolts 42 Loosen left and right engine mount thru bolts NOTE It is not necessary to completely remove engine mount thru bolts for engine removal 43 Lower the vehicle 44 Support the transmission with a suitable jack 45 Connect a suitable engine hoist to the engine lift plate 46 Remove engine from vehicle INSTALLATION 1 Position the engine in the vehicle 2 Install both left and right side engine mounts onto engine 3 Raise the vehicle ENGINE 3 7L 9 11 4 Install the transmission bellhousing to engine mounting bolts Tighten the bolts to 41 N m 30ft Ibs 5 Tighten the engine mount thru bolts 6 Install the torque convertor bolts 7 Connect the ground straps on the left and right side of the engine 8 Install the starter 9 Connect the crankshaft position sensor 10 Install the engine block heater power cable if equipped CAUTION The structural cover requires a specific torque sequence Failure to follow this sequence may cause severe damage to the cover 11 Install the structural cover NOTE New clamps must be used on exhaust man ifold flanges Failure to use new clamps may result in exhaust leaks 12 Install the left and right exhaust pipes 13 Connect the left and right oxygen sensors 14 Lower veh
10. ENGINE LUBRICATION OIL PAN REMOVAL 2 Remove the timing chain cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 3 Remove the timing chains and tensioners Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 4 Remove the four bolts primary timing chain tensioner and the oil pump DISASSEM BLY 1 Remove oil pump cover screws and lift off cover plate 2 Remove pump inner and outer rotors NOTE Once the oil pressure relief valve cup plug and pin are removed the pump assembly must be replaced 3 If it is necessary to remove the pressure relief valve drive the roll pin from pump housing and remove cup plug spring and valve 9 66 ENGINE 3 7L OIL PUMP Continued INSPECTION CAUTION Oil pump pressure relief valve and spring should not be removed from the oil pump If these components are disassembled and or removed from the pump the entire oil pump assem bly must be replaced 1 Clean all parts thoroughly Mating surface of the oil pump housing should be smooth If the pump cover is scratched or grooved the oil pump assembly should be replaced 2 Lay a straight edge across the pump cover sur face Fig 79 If a 0 025 mm 0 001 in feeler gauge can be inserted between the cover and the straight edge the oil pump assembly should be replaced 3 Measure the thickness of the outer rotor Fig 80 If the outer rotor thickness measures at 12 00
11. 3 Right Cylinder Head 4 Counterbalance Shaft Rear Journal Crankshaft Main Journals Crankshaft Rod Journals Crankshaft Number One Main Journal Left Cylinder Head Right Cylinder Head 1 Front Timing Chain Idler Shaft 2 Counterbalance Shaft Front Journal 3 Both Secondary Chain Tensioners Refer to Engine Lubrication Flow Chart Cylinder Heads Table 2 Refer to Engine Lubrication Flow Chart Cylinder Heads Table 2 The cylinder head gaskets have an oil restricter to control oil flow to the cylinder heads ENGINE LUBRICATION FLOW CHART CYLINDER HEADS TABLE 2 Cylinder Head Oil Port in bolt hole Main Oil Gallery drilled through head from rear to front Base of Camshaft Towers Diagonal Cross Drilling to Main Oil Gallery 1 Base of Camshaft Towers 2 Lash Adjuster Towers Vertical Drilling Through Tower to Camshaft Bearings Lash Adjuster Towers Diagonal Drillings to Hydraulic Lash Adjuster Pockets The number three camshaft bearing journal feeds oil into the hollow camshaft tubes Oil is routed to the intake lobes which have oil passages drilled into them to lubricate the rocker arms Kj ENGINE 3 71 9 59 LUBRICATION Continued 80bbb21e Fig 69 LUBRICATION OIL FLOW 1 OIL FLOW TO RIGHT CYLINDER HEAD 8 OIL PUMP OUTLET TO CYLINDER BLOCK 2 CYLINDER BLOCK MAIN OIL GALLERY 9 OIL PUMP 3 LEFT CYLINDER HEAD OIL GALLERY 10 OIL FLOW TO CRANKSHAFT MAIN JOURNALS 4 OIL FLO
12. 9 Remove the crankshaft tone wheel INSPECTION NOTE Thoroughly inspect the connecting rod bear ing bores and main bearing bores for scoring blue ing or severe scratches Further disassembly may be required If connecting rod bearing bores show damage the cylinder heads must be removed to service the piston and rod assemblies If the bedplate or the cylinder ENGINE 3 7L 9 43 block main bearing bores show damage the engine must be replaced 1 If required remove the main bearing halves from the cylinder block and bedplate 2 Thoroughly clean the bedplate to cylinder block sealing surfaces and main bearing bores Remove all oil and sealant residue 3 Inspect the bedplate main bearing bores for cracks scoring or severe blueing If either condition exists the engine must be replaced 4 Inspect the crankshaft thrust washer for scor ing scratches or blueing If either condition exist replace the thrust washer 5 Inspect the oil pan gasket windage tray for splits tears or cracks in the gasket sealing surfaces Replace gasket as necessary INSTALLATION CAUTION Main bearings are select fit Refer to Crankshaft Main Bearings in this section for proper bearing selections CAUTION When insialling crankshaft use care not to damage bearing surfaces on the crankshaft NOTE Apply sealant to the tone wheel retaining screws prior to installation 1 Lubricate upper main bearing halves with clean engine oil
13. ELECTRICAL IGNITION CONTROL SPARK PLUG CLEANING 6 Incorrect right bank cam timing 7 Dirt or water in fuel system 8 Faulty fuel pump relay or wiring 9 Faulty cam or crank sensor 6 Refer to engine timing in this section 7 Clean system and replace fuel filter 8 Repair or replace as necessary 9 Refer to Ignition system ENGINE STALLS OR ROUGH IDLE 1 Vacuum leak 2 Faulty crank position sensor 4 Faulty coil 1 Inspect intake manifold and vacuum hoses repair or replace as necessary 2 Replace crank position sensor 4 Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL REMOVAL K ENGINE 3 7L Continued CONDITION POSSIBLE CAUSE ENGINE 3 7L 9 5 CORRECTION 5 Incorrect cam timing 5 Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 1 ENGINE LOSS OF POWER 1 Dirty or incorrectly gapped spark plugs 2 Dirt or water in fuel system 3 Faulty fuel pump 4 Blown cylinder head gasket 5 Low compression 6 Burned warped or pitted valves 7 Plugged or restricted exhaust system 8 Faulty coil 9 Incorrect cam timing 1 Refer to 8 ELECTRICAL IGNITION CONTROL SPARK PLUG CLEANING 2 Clean system and replace fuel filter 3 Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL PUMP DIAGNOSIS AND TESTING 4 Replace cylinder head gasket 5 Refer to 9 ENGINE DIAGNOSIS AND TESTING repair as necessary
14. Plastigage must not crumble in use If brittle obtain fresh stock 5 Install bearing cap and connecting rod on the journal and tighten bolts to 27 N m 20 ft Ibs plus a 9 50 ENGINE 3 7L PISTON amp CONNECTING ROD Continued 90 turn DO NOT rotate crankshaft Plastigage will smear resulting in inaccurate indication 6 Remove the bearing cap and determine amount of bearing to journal clearance by measuring the width of compressed Plastigage Refer to Engine Specifications for the proper clearance Plastigage should indicate the same clearance across the entire width of the insert If the clearance var ies it may be caused by either a tapered jour nal bent connecting rod or foreign material trapped between the insert and cap or rod 7 If the correct clearance is indicated replace ment of the bearing inserts is not necessary Remove the Plastigage from crankshaft journal and bearing insert Proceed with installation 8 If bearing to journal clearance exceeds the specification determin which services bearing set to use the bearing sizes are as follows USED WITH JOURNAL SIZE Bearing Mark 025 US 025 mm 001 in 57 871 57 879 mm 2 2783 2 2786 in Std STANDARD 57 896 57 904 mm 2 2793 2 2810 in 250 mm 010 in 57 646 57 654 mm 2 2695 2 2698 in 9 Repeat the Plastigage measurement to verify your bearing selection prior to final assembly 10 Once you have sele
15. Remove intake manifold retaining fasteners in reverse order of tightening sequence 19 Remove intake manifold INSTALLATION 1 Install intake manifold gaskets 2 Install intake manifold 3 Install intake manifold retaining bolts and tighten in sequence shown in to 12 N m 105 in Ibs 4 Install left and right radio suppressor straps 5 Install throttle body assembly 6 Install throttle cable bracket 7 Connect throttle cable and speed control cable to throttle body 8 Install fuel rail 9 Install ignition coil towers 10 Position and install heater hoses and tubes onto intake manifold 11 Install the heater hoses to the heater core and engine front cover 12 Connect electrical connectors for the following components e Manifold Absolute Pressure MAP Sensor Intake Air Temperature IAT Sensor Throttle Position TPS Sensor Coolant Temperature CTS Sensor Idle Air Control IAC Motor Ignition coil towers Fuel injectors 13 Install top oil dipstick tube retaining bolt and ground strap 14 Connect generator electrical connections 15 Connect Vapor purge hose Brake booster hose Speed control servo hose Positive crankcase ventilation PCV hose 16 Fill cooling system 17 Install resonator assembly and air inlet hose 18 Connect negative cable to battery ENGINE 3 7L 9 69 EXHAUST MANIFOLD DESCRIPTION The exhaust manifolds Fig 87 are log style with a patented flow
16. Use a brush to wash parts with a solution of hot water and deter gent Dry parts thoroughly Use a clean white lint free cloth to check that the bore is clean Oil the bores after cleaning to prevent rusting CLEANING Thoroughly clean the oil pan and engine block gas ket surfaces Use compressed air to clean out e The galley at the oil filter adaptor hole e The front and rear oil galley holes e The feed holes for the crankshaft main bearings 9 40 ENGINE 3 7L ENGINE BLOCK Continued Once the block has been completely cleaned apply Loctite PST pipe sealant with Teflon 592 to the threads of the front and rear oil galley plugs Tighten the plugs to 34 N m 25 ft Ibs torque INSPECTION 1 It is mandatory to use a dial bore gauge to measure each cylinder bore diameter To correctly select the proper size piston a cylinder bore gauge capable of reading in 0 003 mm 0001 in INCRE MENTS is required If a bore gauge is not available do not use an inside micrometer Fig 33 A 805dd884 Fig 33 Bore Gauge Typical FRONT BORE GAUGE CYLINDER BORE 38 MM 1 5 in Bom 2 Measure the inside diameter of the cylinder bore at three levels below top of bore Start perpen dicular across or at 90 degrees to the axis of the crankshaft and then take two additional reading 3 Measure the cylinder bore diameter crosswise to the cylinder block near the top of the bore Repeat the meas
17. Using Special Tool 8387 Valve Spring Compres sor compress the valve spring 5 Install the two spring retainer lock halves NOTE the valve spring is under tension use care when releasing the valve spring compressor 6 Remove the valve spring compressor 7 Disconnect the shop air to the cylinder 8 Install the spark plug for the cylinder the valve spring and seal was installed on 9 Using Special Tool 8516 Valve Spring Compres sor install the rocker arms and the hydraulic lash adjusters 10 Install the cylinder head cover Refer to Cylin der Head Cover in this Section K ENGINE BLOCK DESCRIPTION The cylinder block is made of cast iron The block is a dosed deck design with the left bank forward To provide high rigidity and improved NVH an enhanced compacted graphite bedplate Fig 31 is bolted to the block The block design allows coolant flow between the cylinders bores and an internal coolant bypass to a single poppet inlet thermostat is included in the cast aluminum front cover 80c41 fad Fig 31 CYLINDER BLOCK BEDPLATE 1 Cylinder Block Bedplate 2 Crankshaft Position Sensor 3 Crankshaft Main Bearing Caps STANDARD PROCEDURE CYLINDER BORE HONING Before honing stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area 1 Used carefully the Cylinder Bore Sizing Hone C 823 equipped with 220 grit ston
18. chain tensioner 12 Remove Special Tool 8429 13 Install the timing chain cover 14 Install the crankshaft damper damper bolt 175 N m 130 Ft Lbs 15 Install the power steering pump 16 Install the fan blade assembly and fan shroud 17 Install the cylinder head cover 18 Install the intake manifold Tighten 19 Refill the cooling system 20 Raise the vehide 21 Install the exhaust pipe onto the left exhaust manifold 22 Lower the vehide 23 Connect the negative cable to the battery 24 Start the engine and check for leaks CAMSHAFT S DESCRIPTION The camshafts consist of powdered metal steel lobes which are sinter bonded to a steel tube Four bearing journals are machined into the camshaft Camshaft end play is controlled by two thrust walls that border the nose piece journal Engine oil enters the hollow camshafts at the third journal and lubri cates every intake lobe rocker through a drilled pas sage in the intake lobe 9 24 ENGINE 3 7L CAMSHAFT S Continued REMOVAL CAUTION When the timing chain is removed and the cylinder heads are still installed DO NOT force fully rotate the camshafts or crankshaft indepen dently of each other Severe valve and or piston damage can occur CAUTION When removing the cam sprocket timing chains or camshaft Failure to use Special Tool 8379 will result in hydraulic tensioner ratchet over extension requiring timing chain cover removal t
19. reesen Ring Width Bearing Journal Diameter 25 975 25 995 mm Top Compression Ring 1 472 1 490 mm 1 0227 1 0235 in 0 057 0 058 in Bearing Clearance 0 025 0 065 mm Second Compression 1 472 1 490 mm 0 001 0 0026 in Ping 0 057 0 058 in Bearing Clearance MAX 0 065 mm 0 0026 in Oil Ring Steel Rails 0 445 0 470 mm End Play 075 200 mm 0 017 0 018 in 0 003 0 0079 in End Play MAX 200 mm 0 0079 in Top Compression Ring 0 0146 0 0249 in 9 14 ENGINE 3 7L ENGINE 3 7L Continued DESCRIPTION SPECIFICATION VALVE TIMING Opens ATDC Closes ATDC Duration exhaust J VALVES Face Angle Head Diameter Intake Exhaust Length Overall Intake Exhaust Stem Diameter Intake Exhaust Stem to Guide 45 45 5 48 52 48 78 mm 1 9103 1 9205 in 36 87 37 13 mm 1 4516 1 4618 in 113 45 114 21 mm 4 4666 4 4965 114 92 115 68 mm 4 5244 4 5543 in 6 931 6 957 mm 0 2729 0 2739 in 6 902 6 928 mm 0 2717 0 2728 in K DESCRIPTION SPECIFICATION Valve Lift Zero Lash Intake Exhaust 12 00 mm 0 472 in 10 90 mm 0 4292 in VALVE SPRING Free Lenght Approx Intake and Exhaust 48 92 mm 1 9260 in Spring Force Valve Closed Intake and Exhaust Spring Force Valve Open Intake and Exhaust Number of Coils Wire Diameter Intake and Exhaust Installed Height Spring Seat to Bo
20. the insulator mount Fig 67 and Fig 68 AN PIDO 808c2c9d Fig 67 Engine Insulator Mount 3 7 Left MOUNT NUT WIRE RETAINER FASTENER BOLT THRU BOLT oarWN KJ FRONT MOUNT Continued NA 2 VEAS e I bp gt Ec P N WSZ f I d UI RO DR far iO IR gt Es A IE it 808c2ca2 Fig 68 Engine Insulator Mount 3 7 Right 1 MOUNT 2 THRU BOLT 3 BOLT 4 NUT INSTALLATION 1 Position the insulator mount and install the insulator mount through bolt 2 Lower the engine until the cylinder block to in sulator mount bolts can be installed 3 Remove the jack and block of wood 4 Torque the cylinder block to insulator mount bolts to 61 N m 45 ft Ibs 5 Install and torque the through bolt retaining nut to 61 Nm 45 ft Ibs 6 Install the fan blade fan clutch and fan shroud REAR MOUNT REMOVAL NOTE A resilient rubber cushion supports the transmission at the rear between the transmission extension housing and the rear support crossmem ber or skid plate 1 Disconnect negative cable from battery 2 Raise the vehicle and support the transmission 3 Remove the nuts holding the support cushion to the crossmember Remove the crossmember ENGINE 3 7L 9 57 MANUAL TRANSMISSION e Remove the support cushion nuts and remove the cushion e Remove the transmission support bracket bolts and remove the bracket from the transmi
21. 3 2 CYLINDER BLOCK Cylinder Bock 3 6619 0 0003 in Out of Round MAX 0 076 mm 0 003 in Taper MAX 0 051 mm 0 002 in kj ENGINE 3 71 9 13 ENGINE 3 7L Continued DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION PISTONS CONNECTING RODS Bearing Clearance 0 010 0 048 mm Be Side Clearance 0 10 0 35 mm No 1 83 73 83 97 mm Piston Pin Clearance 015 028 mm No 2 82 833 83 033 mm Bearing Bore Out of 0 004 mm 3 261 3 310 in Round 83 88 84 08 mm MAX 0 0002 in 3 302 3 310 in Total Weight Less 612 grams 21 588 Bearing ounces PISTON PINS CRANKSHAFT Floating Main BearingJournal Clearance In Piston 0 010 0 019 mm Diameter 63 488 63 512 mm 0 0004 0 0008 in 2 4996 2 5005 in Diameter 24 013 24 016 mm Bearing Clearance 0 002 0 034 mm 0 9454 0 9456 in PISTON RINGS Ring Ga Out of Round MAX 0 005 mm 0 0002 in SE Taper MAX 0 006 mm 0 0004 in 0 37 0 63 mm End Play 0 052 0 282 mm 0 0021 0 0112 in Second SE 0 37 0 63 mm End Play MAX 0 282 mm 0 0112 in 0 0146 0 0249 in Connecting Rod Oil Control Steel Rails 0 25 0 76 mm Journal PE 0 0099 0 30 in Diameter 57 904 57 896 mm Side Clearance Top Compression Ring 051 094 mm Bearing Clearance 0 010 0 048 mm 0 0020 0 0037 in Ring Taper MAX 0 006 mm 0 0002 in 0 0016 0 0031 in CAMSHAFT Oil Ring Steel Ring 019 229 mm 26 02 26 04 mm 7 01
22. 72 9400 9 Fig 72 Engine Oil Container Standard Notations OIL LEVEL INDICATOR DIPSTICK The engine oil level indicator is located on the right side of the the 3 7L engine CRANKCASE OIL LEVEL INSPECTION CAUTION Do not overfill crankcase with engine oil pressure loss or oil foaming can result KJ Inspect engine oil level approximately every 800 kilometers 500 miles Unless the engine has exhib ited loss of oil pressure run the engine for about five minutes before checking oil level Checking engine oil level on a cold engine is not accurate To ensure proper lubrication of an engine the engine oil must be maintained at an acceptable level The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick 1 Position vehicle on level surface 2 With engine OFF allow approximately ten min utes for oil to settle to bottom of crankcase remove engine oil dipstick 3 Wipe dipstick clean 4 Install dipstick and verify it is seated in the tube 5 Remove dipstick with handle held above the tip take oil level reading 6 Add oil if level is below the SAFE ZONE on dipstick ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules Run engine until achieving normal operating tem perature 1 Position the vehicle on a level surface and turn engine off 2 Remove oil fill cap 3 Hoist and support vehide on safety stan
23. 74 INSTALLATION ssee RI 76 IDLER SHAFT REMOVAL aee hotsa sisun ee 77 INSTALLATION ye nandai a i amai ea eee 77 TIMING BELT CHAIN AND SPROCKET S REMOVAL rue ante aana he 77 INSPEGTION usce caras re 79 INSTALLATION 1 eee ee 80 K ENGINE 3 7L DESCRIPTION ENGINE 3 7L 9 3 80ccc15e 3 7 L ENGINE The 3 7 liter 226 CID six cylinder engine is an 90 single overhead camshaft engine The cast iron cylinder block is made up of two different compo nents the first component is the cylinder bore and upper block the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings The cylinders are numbered from front to rear with the left bank being numbered 1 3 and 5 and the right bank being numbered 2 4 and 6 The firing order is 1 6 5 4 3 2 The engine serial num ber is located at the right front side of the engine block 9 4 ENGINE 3 7L ENGINE 3 7L Continued DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING ENGINE DIAGNOSIS INTRODUCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance These malfunctions may be classified as either per formance eg engine idles rough and stalls or mechanical e g a strange noise Refer to 9 ENGINE DIAGNOSIS AND TEST ING PERFORMANCE and Refer to 9 ENGINE DIAGNOSIS AND TESTING ME
24. 7L 9 71 shaft sprocket Primary chain motion is controlled by a pivoting leaf spring tensioner arm and a fixed guide The arm and the guide both use nylon plastic wear faces for low friction and long wear The pri mary chain receives oil splash lubrication from the secondary chain drive and designed oil pump leak age The idler sprocket assembly connects the pri mary chain drive secondary chain drives and the counterbalance shaft The idler sprocket assembly consists of two integral 26 tooth sprockets a 40 tooth sprocket and a helical gear that is press fit to the assembly The spline joint for the 40 tooth sprocket is a non serviceable press fit anti rattle type A spiral ring is installed on the outboard side of the fifty tooth sprocket to prevent spline disengagement The idler sprocket assembly spins on a stationary idler shaft The idler shaft is a light press fit into the cyl inder block A large washer on the idler shaft bolt and the rear flange of the idler shaft are used to con trol sprocket thrust movement Pressurized oil is routed through the center of the idler shaft to pro vide lubrication for the two bushings used in the idler sprocket assembly There are two secondary drive chains both are roller type one to drive the camshaft in each SOHC cylinder head There are no shaft speed changes in the secondary chain drive system Each secondary chain drives a 26 tooth cam sprocket directly from the 26 tooth sprocket on the
25. BLOCK CONNECTING ROD BEARINGS STANDARD PROCEDURE Check the connecting rod for signs of twist or bend ing Check the piston for taper and elliptical shape before it is fitted into the cylinder bore Refer to 9 ENGINE ENGINE BLOCK PISTON CONNECT ING ROD STANDARD PROCEDURE Check the piston for scoring or scraping marks in the piston skirts Check the ring lands for cracks and or deterioration INSTALLATION 1 Before installing piston and connecting rod assemblies into the bore install the piston rings 2 Immerse the piston head and rings in clean engine oil Position a ring compressor over the piston and rings Tighten ring compressor Ensure posi tion of rings do not change during this opera tion 3 Position bearing onto connecting rod Ensure that tabs in bearing shell aligns with slots in con necting rod Verify that parting line of bearing is aligned with parting line of connecting rod 4 Lubricate bearing surface with clean engine oil 5 Install Special Tool 8507 Connecting Rod Guides into connecting rod bolt threads Fig 55 6 The pistons are marked on the piston pin bore surface with an raised F indicating installation position This mark must be pointing toward the front of engine on both cylinder banks The connect ing rod oil slinger slot faces the front of the engine Fig 56 7 Wipe cylinder bore clean and lubricate with engine oil 8 Rotate crankshaft until connecting rod j
26. N m 30 ft Ibs torque 5 Remove the transmission support 6 Lower the vehicle 7 Connect negative cable to battery LUBRICATION DESCRIPTION The lubrication system is a full flow filtration pres sure feed type 9 58 ENGINE 3 7L LUBRICATION Continued OPERATION Oil from the oil pan is pumped by a gerotor type oil pump directly mounted to the crankshaft nose Oil pressure is controlled by a relief valve mounted inside the oil pump housing For lubrication flow refer to Fig 69 The camshaft exhaust valve lobes and rocker arms are lubricated through a small hole in the rocker arm oil flows through the lash adjuster then through the rocker arm and onto the camshaft lobe Due to the orentation of the rocker arm the camshaft intake K lobes are not lubed in the same manner as the exhaust lobes The intake lobes are lubed through internal passages in the camshaft Oil flows through a bore in the number 3 camshaft bearing bore and as the camshaft turns a hole in the camshaft aligns with the hole in the camshaft bore allowing engine oil to enter the camshaft tube The oil then exits through 1 6mm 0 063 in holes drilled into the intake lobes lubricating the lobes and the rocker arms ENGINE LUBRICATION FLOW CHART BLOCK TABLE 1 FROM TO Oil Pickup Tube Oil Pump Oil Pump Oil Filter Oil Filter Block Main Oil Gallery Block Main Oil Gallery 1 Crankshaft Main Journal 2 Left Cylinder Head
27. Nuts 3 Manifold Flange LEFT EXHAUST MANIFOLD 1 Disconnect the negative cable from the battery 2 Raise and support the vehicle 3 Remove the bolts and nuts attaching the exhaust pipe to the engine exhaust manifold 4 Lower the vehicle 5 Remove the exhaust heat shields Fig 90 6 Remove bolts nuts and washers attaching manifold to cylinder head 7 Remove manifold and gasket from the cylinder head INSTALLATION RIGHT EXHAUST MANIFOLD CAUTION If the studs came out with the nuts when removing the engine exhaust manifold install new studs Apply sealer on the coarse thread ends Water leaks may develop at the studs if this precau tion is not taken 80cb34c1 Fig 90 EXHAUST MANIFOLD LEFT 1 Heat Shield 2 Nuts 3 Manifold Flange K EXHAUST MANIFOLD Continued 1 Position the engine exhaust manifold and gas ket on the two studs located on the cylinder head Install conical washers and nuts on these studs 2 Install remaining conical washers Starting at the center arm and working outward tighten the bolts and nuts to 25 N m 18 ft Ibs torque 3 Install the exhaust heat shields 4 Raise and support the vehicle CAUTION Over tightening heat shield fasteners may cause shield to distort and or crack 5 Assemble exhaust pipe to manifold and secure with bolts nuts and retainers Tighten the bolts and nuts to 34 N m 25 ft Ibs torque L
28. belt tensioner assembly Refer to 7 COOLING ACCESSORY DRIVE BELT TENSIONERS INSTALLATION 9 Install radiator upper and lower hoses 10 Install both heater hoses 80cca006 Fig 100 TIMING COVER SEALANT 1 TIMING CHAIN COVER 2 WATER PASSAGE ORING 3 MOPAR ENGINE RTV SEALER TIMING CHAIN COVER ASSEMBLY 80b6b298 Fig 101 Timing Chain Cover Fasteners Typical 11 Install electric fan shroud and viscous fan drive assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 12 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 13 Connect the battery negative cable K IDLER SHAFT REMOVAL 1 Remove the primary and secondary timing chains and sprockets Refer to procedure in this sec tion NOTE To remove the idler shaft it is necessary to tap threads into the shaft to install the removal tool 2 Using a 12 mm X 1 75 tap cut threads in the idler shaft center bore 3 Cover the radiator core with a suitable cover CAUTION Use care when removing the idler shaft Do not strike the radiator cooling fins with the slide hammer 4 Using Special Tool 8517 Slide Hammer remove the idler shaft INSTALLATION 1 Thoroughly clean the idler shaft bore 2 Position the idler shaft in the bore NOTE The two lubrication holes in the idler shaft do not require any special alignment NOTE Before using the retaining bolt to install the idle
29. bolts in sequence using the follow ing steps and torque values e Step 1 Tighten bolts 1 10 20 N m 15 ft Ibs e Step 2 Tighten bolts 1 10 47 N m 35 ft lbs Tighten bolts 11 14 25 N m 18 ft Ibs e Step 3 Tighten bolts 1 10 90 degrees Tighten bolts 11 14 30 N m 22 ft Ibs CAUTION The nut on the right side camshaft sprocket should not be removed for any reason as the sprocket and camshaft sensor target wheel is serviced as an assembly If the nut was removed retorque nut to 5 N m 44 in Ibs 7 Position the secondary chain onto the camshaft drive gear making sure one marked chain link is on either side of the V6 mark on the gear then using Special Tool 8428 Camshaft Wrench position the gear onto the camshaft CAUTION Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt Fail ure to do so may cause over torquing of bolt result ing in bolt failure 8 Install the camshaft drive gear retaining bolt 9 Install the right side secondary chain guide 10 Install the cylinder head access plug 11 Reset and install the right side secondary chain tensioner 12 Remove Special Tool 8429 13 Install the timing chain cover 14 Install the crankshaft damper Tighten damper bolt 175 N m 130 Ft Lbs 15 Install accessory drive belt 16 Install the fan shroud 17 Install the cylinder head cover 18 Install the intake manifold K CYLINDER HEAD RIGHT C
30. enhancing design to maximize perfor mance The exhaust manifolds are made of high sili con molybdenum cast iron A perforated core graphite exhaust manifold gasket is used to improve sealing to the cylinder head The exhaust manifolds are cov ered by a three layer laminated heat shield for ther mal protection and noise reduction The heat shields Fig 88 are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold 80c41 fae Fig 87 EXHAUST MANIFOLDS 1 LEFT SIDE EXHAUST MANIFOLD 2 RIGHT SIDE EXHAUST MANIFOLD REMOVAL RIGHT EXHAUST MANIFOLD 1 Disconnect the negative cable from the battery 2 Raise and support the vehicle 3 Remove the bolts and nuts attaching the exhaust pipe to the engine exhaust manifold 4 Lower the vehicle 5 Remove the exhaust heat shield Fig 89 6 Remove bolts nuts and washers attaching manifold to cylinder head 7 Remove manifold and gasket from the cylinder head 9 70 ENGINE 3 7L EXHAUST MANIFOLD Continued 80c41faf Fig 88 EXHAUST MANIFOLD HEAT SHIELDS RIGHT SIDE EXHAUST MANIFOLD HEAT SHIELD RIGHT SIDE EXHAUST MANIFOLD FLANGE LEFT SIDE EXHAUST MANIFOLD HEAT SHIELD LEFT SIDE EXHAUST MANIFOLD FLANGE Dom K u gt LAT ZU S old eats Ae fat t LEON M Tees 80cb34c3 Fig 89 EXHAUST MANIFOLD RIGHT 1 Heat Shield 2
31. head bolt threads with clean engine oil and install the eight M11 bolts 5 Coat the four M8 cylinder head bolts with Mopar Lock and Seal Adhesive then install the bolts NOTE The cylinder head bolts are tightened using an angle torque procedure however the bolts are not a torque to yield design 6 Tighten the bolts in sequence using the follow ing steps and torque values e Step 1 Tighten bolts 1 10 27 N m 20 ft Ibs e Step 2 Verify that bolts 1 10 all reached 27 N m 20 ft Ibs by repeating step 1 without loosen ing the bolts Tighten bolts 11 thru 14 to 14 N m 10 ft Ibs e Step 3 Tighten bolts 1 10 90 degrees Fig 11 e Step 4 Tighten bolts 1 10 90 degrees again Tighten bolts 11 14 26 N m 19 ft Ibs 7 Position the secondary chain onto the camshaft drive gear making sure one marked chain link is on either side of the V6 mark on the gear then using Special Tool 8428 Camshaft Wrench position the gear onto the camshaft CAUTION Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt Fail ure to do so may cause over torqueing of bolt resulting in bolt failure 8 Install the camshaft drive gear retaining bolt 9 Install the left side secondary chain guide ENGINE 3 7L 9 23 LEFT BANK RIGHT BANK 80cb8871 Fig 11 CYLINDER HEAD TIGHTENING SEQUENCE 10 Install the cylinder head access plug 11 Reset and Install the left side secondary
32. idler sprocket assembly A fixed chain guide and a hydraulic oil damped ten sioner are used to maintain tension in each second ary chain system The hydraulic tensioners for the secondary chain systems are fed pressurized oil from oil reservoir pockets in the block Each tensioner incorprates a controled leak path through a device known as a vent disc located in the nose of the piston to manage chain loads Each tensioner also has a mechanical ratchet system that limits chain slack if the tensioner piston bleeds down after engine shut down The tensioner arms and guides also utilize nylon wear faces for low friction and long wear The secondary timing chains receive lubrication from a small orifice in the tensioners This orifice is pro tected from clogging by a fine mesh screen which is located on the back of the hydraulic tensioners STANDARD PROCEDURE MEASURING TIMING CHAIN WEAR NOTE This procedure must be performed with the timing chain cover removed 1 Remove the timing chain cover Refer to Timing Chain Cover in this section for procedure 9 72 ENGINE 3 7L VALVE TIMING Continued 2 To determine if the secondary timing chains are worn rotate the engine clockwise until maximum tensioner piston extension is obtained Measure the distance between the secondary timing chain ten sioner housing and the step ledge on the piston The measurement at point A must be less than 15mm 5906 inches 3 If the measurement exc
33. load 8 Starting at the outside working inward loosen the camshaft bearing cap retaining bolts 1 2 turn at a time Repeat until all load is off the bearing caps 80c41ef3 Fig 12 SECURING TIMING CHAIN TENSIONERS USING TIMING CHAIN WEDGE Typical 1 SPECIAL TOOL 8379 2 CAMSHAFT SPROCKET 3 CAMSHAFT SPROCKET BOLT N Y KD IS N 80ccc0a4 Fig 13 Special Tool 8428 1 Camshaft hole 2 Special Tool 8428 CAUTION DO NOT STAMP OR STRIKE THE CAM SHAFT BEARING CAPS SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS KJ CAMSHAFT S Continued NOTE When the camshaft is removed the rocker arms may slide downward mark the rocker arms before removing camshaft 9 Remove the camshaft bearing caps and the camshaft INSTALLATION 1 Lubricate camshaft journals with clean engine oil NOTE Position the left side camshaft so that the camshaft sprocket dowel is near the 1 o clock posi tion This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps 2 Position the camshaft into the cylinder head 3 Install the camshaft bearing caps hand tighten the retaining bolts NOTE Caps should be installed so that the stamped numbers on the caps are in numerical order 1 thru 4 from the front to the rear of the engine All caps should be installed so that the stamped arrows on the caps point toward the front of the engine 4 Work
34. not exceed 20 6 kPa 3 psi ENGINE 3 7L 9 61 5 If the leak is not detected very slowly turn the crankshaft and watch for leakage If a leak is detected between the crankshaft and seal while slowly turning the crankshaft it is possible the crankshaft seal surface is damaged The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth CAUTION Use extreme caution when crankshaft polishing is necessary to remove minor nicks or scratches The crankshaft seal flange is specially machined to complement the function of the rear oil seal 6 For bubbles that remain steady with shaft rotation no further inspection can be done until dis assembled Refer to 9 ENGINE DIAGNOSIS AND TESTING under the Oil Leak row for components inspections on possible causes and corrections 7 After the oil leak root cause and appropriate corrective action have been identified Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR REMOVAL OIL STANDARD PROCEDURE ENGINE OIL WARNING NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL CONTAMINANTS IN USED ENGINE OIL CAUSED BY INTERNAL COMBUSTION CAN BE HAZARDOUS TO YOUR HEALTH THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER DO NOT WASH SKIN WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROBLEMS CAN RESULT DO NOT POLLUTE DISPOSE OF USED ENGINE OIL PROPE
35. oil pressure sensor uses three circuits They are e A 5 volt power supply from the Powertrain Con trol Module PCM e A sensor ground through the PCM s sensor return e A signal to the PCM relating to engine oil pres sure The oil pressure sensor has a 3 wire electrical function very much like the Manifold Absolute Pres sure MAP sensor Meaning different pressures relate to different output voltages A 5 volt supply is sent to the sensor from the PCM to power up the sensor The sensor returns a voltage signal back to the PCM relating to engine oil pres sure This signal is then transferred bussed to the instrument panel on either a CCD or PCI bus circuit depending on vehide line to operate the oil pressure gauge and the check gauges lamp Ground for the sensor is provided by the PCM through a low noise sensor return REMOVAL 1 Disconnect the negative cable from the battery 2 Raise vehide on hoist 3 Remove front splash shield 4 Disconnect oil pressure sender wire Fig 78 5 Remove the pressure sender Fig 78 INSTALLATION 1 Install oil pressure sender 2 Connect oil pressure sender wire 3 Install front splash shield 4 Lower vehicle 5 Connect the negative battery cable ENGINE 3 7L 9 65 80b76fe9 Fig 78 Oil Pressure Sending Unit BELT OIL PRESSURE SENSOR OIL FILTER ELEC CONNECTOR ROD OIL PUMP REMOVAL 1 Remove the oil pan and pick up tube Refer to 9
36. plug breather cap nipple 2 Remove the PCV valve from the cylinder head cover Cap or plug the PCV valve grommet 3 Attach an air hose with pressure gauge and regulator to the dipstick tube CAUTION Do not subject the engine assembly to more than 20 6 kpa 3 PSI of test pressure 4 Gradually apply air pressure from 1 psi to 2 5 psi maximum while applying soapy water at the sus pected source Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source If the oil leak is detected and identified repair per service manual procedures 5 If the leakage occurs at the rear oil seal area refer to the section Inspection for Rear Seal Area Leak 6 If no leaks are detected turn off the air supply and remove the air hose and all plugs and caps Install the PCV valve and breather cap hose 7 Clean the oil off the suspect oil leak area using a suitable solvent Drive the vehicle at various speeds approximately 24 km 15 miles Inspect the engine for signs of an oil leak by using a black light KJ INSPECTION FOR REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine a more involved inspection is necessary The following steps should be followed to help pinpoint the source of the leak If the leakage occurs at the crankshaft rear oil seal area 1 Disconnect the battery 2 Raise the vehic
37. pressure than that required for non coated pistons The bonded coating on the piston will give the appearance of a lineto line fit with the cylinder bore e 80aaczao Fig 53 Moly Coated Piston Typical 1 MOLY COATED 2 MOLY COATED REMOVAL 1 Disconnect negative cable from battery 2 Remove the following components e Oil pan and gasket windage tray Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL e Cylinder head covers Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL and Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL e Timing chain cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL e Cylinder head s Refer to 9 ENGINE CYLIN DER HEAD REMOVAL and Refer to 9 ENGINE CYLINDER HEAD REMOVAL 3 If necessary remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block Be sure to keep tops of pis tons covered during this operation Pistons and connecting rods must be removed from top of cylinder block When removing piston and connecting rod K PISTON amp CONNECTING ROD Continued A 805dd884 Fig 54 Bore Gauge Typical 1 FRONT 2 BORE GAUGE 3 CYLINDER BORE 4 38 MM 1 5 in assemblies from the engine rotate crankshaft so the each connecting rod is centered in cylinder bore CAUTION DO NOT use a number stamp or a
38. procedures 10 Collapse and pin primary chain tensioner CAUTION Plate behind left secondary chain ten sioner could fall into oil pan Therefore cover pan Opening 11 Remove secondary chain tensioners 12 Remove camshaft position and crankshaft position sensors Fig 105 and Fig 106 9 78 ENGINE 3 7L K TIMING BELT CHAIN AND SPROCKET S Continued 80ca8813 Fig 102 Camshaft Sprocket V6 Marks 1 LEFT CYLINDER HEAD 2 RIGHT CYLINDER HEAD e EET rr N Ur lla M ST e Fig 104 Cylinder Head Access Plugs 1 RIGHT CYLINDER HEAD ACCESS PLUG 2 LEFT CYLINDER HEAD ACCESS PLUG AN e 5 17720 Fig 103 Engine Top Dead Center 1 TIMING CHAIN COVER 2 CRANKSHAFT TIMING MARKS K ENGINE 3 7L 9 79 TIMING BELT CHAIN AND SPROCKET S Continued 2 Ze ES 38 von SS E E SOR OS SS SER IS OSO Z TA S y 80cad7fa Fig 105 CAMSHAFT POSITION SENSOR 1 CYLINDER HEAD 2 CAMSAHFT POSITION SENSOR 2 SCREW um P 80cad603 Fig 106 Crankshaft Position Sensor 1 CRANKSHAFT POSITION SENSOR 2 CYLINDER HEAD COVER 3 CAMSHAFT POSITION SENSOR 4 RIGHT SIDE CYLINDER BLOCK CAUTION Care should be taken not to damage camshaft target wheel Do not hold target wheel while loosening or tightening camshaft sprocket Do not place the target wheel near a magnetic source of any kind A damaged or ma
39. punch to mark connecting rods or caps as damage to connecting rods could occur NOTE Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly 4 Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool CAUTION Care must be taken not to damage the fractured rod and cap joint face surfaces as engine damage may occur 5 Remove connecting rod cap Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed Remove piston from cylinder bore Repeat this procedure for each piston being removed CAUTION Care must be taken not to nick crank shaft journals as engine damage may occur 6 Immediately after piston and connecting rod removal install bearing cap on the mating connect ing rod to prevent damage to the fractured cap and rod surfaces ENGINE 3 7L 9 51 CLEANING CAUTION DO NOT use a wire wheel or other abra sive cleaning devise to clean the pistons or con necting rods The pistons have a Moly coating this coating must not be damaged 1 Using a suitable cleaning solvent clean the pis tons in warm water and towel dry 2 Use a wood or plastic scraper to clean the ring land grooves CAUTION DO NOT remove the piston pin from the piston and connecting rod assembly INSPECTION Check the connecting rod journal for excessive wear taper and scoring Refer to 9 ENGINE EN GINE
40. quick con nect fitting from the fuel supply line for engine removal 23 Remove the PCV hose 24 Remove the breather hoses 25 Remove the vacuum hose for the power brake booster 26 Disconnect knock sensors 27 Remove engine oil dipstick tube 28 Remove intake manifold 29 Install engine lift plate gt wa K ENGINE 3 7L Continued NOTE Recheck bolt torque for engine lift plate before removing engine 30 Secure the left and right engine wiring har nesses away from engine 31 Raise vehide 32 Disconnect oxygen sensor wiring 33 Disconnect crankshaft postion sensor 34 Disconnect the engine block heater power cable if equipped 35 Disconnect the front propshaft at the front differential and secure out of way NOTE It is necessary to disconnect the front prop shaft for access to the starter and left side exhaust flange 36 Remove the starter 37 Remove the ground straps from the left and right side of the block 38 Disconnect the right and left exhaust pipes at the manifolds and from the crossover and remove from the vehicle NOTE The exhaust clamps at the manifolds cannot be reused New clamps must be used or leaks may occur NOTE For manual transmission vehicles the trans mission must be removed from the vehicle before the engine can be removed The manual transmis sion will contact the floorpan before the engine clears the motor mounts so it must be removed
41. repair consists of e Drilling out worn or damaged threads 9 10 ENGINE 3 7L ENGINE 3 7L Continued e Tapping the hole with a special Heli Coil Tap or equivalent e Installing an insert into the tapped hole to bring the hole back to its original thread size STANDARD PROCEDURE ENGINE CORE AND OIL GALLERY PLUGS Using a blunt tool such as a drift and a hammer strike the bottom edge of the cup plug With the cup plug rotated grasp firmly with pliers or other suit able tool and remove plug Fig 2 9209 41 Fig 2 Core Hole Plug Removal CYLINDER BLOCK REMOVE PLUG WITH PLIERS STRIKE HERE WITH HAMMER DRIFT PUNCH CUP PLUG akon CAUTION Do not drive cup plug into the casting as restricted cooling can result and cause serious engine problems Thoroughly clean inside of cup plug hole in cylin der block or head Be sure to remove old sealer Lightly coat inside of cup plug hole with Mopar Stud and Bearing Mount Make certain the new plug is cleaned of all oil or grease Using proper drive plug drive plug into hole so that the sharp edge of the plug is at least 0 5 mm 0 020 in inside the lead in chamfer It is not necessary to wait for curing of the sealant The cooling system can be refilled and the vehicle placed in service immediately REMOVAL 1 Disconnect the battery negative cable 2 Remove hood Mark hood hinge location for reinstallation 3 Remove air cleaner assembly
42. resulting in bolt failure 8 Remove excess oil from camshaft sprocket bolt then install the camshaft sprocket retaining bolt and hand tighten 9 Remove timing chain wedge special tool 8379 10 Using Special Tool 6958 spanner wrench with adapter pins 8346 torque the camshaft sprocket retaining bolt to 122 N m 90 ft Ibs 11 Install the camshaft position sensor 12 Install the cylinder head cover CYLINDER HEAD COVER S REMOVAL 1 Disconnect battery negative cable 2 Remove air cleaner assembly resonator assem bly and air inlet hose 3 Drain cooling system below the level of the heater hoses Refer to COOLING SYSTEM KJ 4 Remove accessory drive belt 5 Remove air conditioning compressor retaining bolts and move compressor to the left 6 Remove heater hoses 7 Disconnect injector and ignition coil connectors 8 Disconnect and remove positive crankcase ven tilation PCV hose 9 Remove oil fill tube 10 Un clip injector and ignition coil harness and move away from cylinder head cover 11 Remove right rear breather tube and filter assembly 12 Remove cylinder head cover retaining bolts 13 Remove cylinder head cover INSTALLATION CAUTION Do not use harsh cleaners to clean the cylinder head covers Severe damage to covers may occur NOTE The gasket may be used again provided no cuts tears or deformation has occurred 1 Clean cylinder head cover and both seali
43. the equivalent This will maintain tension on chains to aid in installation Align the timing mark on the idler sprocket to the timing mark on the coun terbalance shaft drive gear then seat idler sprocket fully Fig 109 Before installing idler sprocket bolt lubricate washer with oil and tighten idler sprocket assembly retaining bolt to 34 N m 25 ft Ibs K ENGINE 3 7L 9 81 TIMING BELT CHAIN AND SPROCKET S Continued 80c413e9 Fig 109 COUNTERBALANCE SHAFT ALIGNMENT MARKS 1 COUNTERBALANCE SHAFT 2 TIMING MARKS 3 IDLER SPROCKET NOTE It will be necessary to slightly rotate cam shafts for sprocket installation 11 Align left camshaft sprocket L dot to plated link on chain 12 Align right camshaft sprocket R dot to plated link on chain CAUTION Remove excess oil from the camshaft sprocket bolt Failure to do so can result in over torque of bolt resulting in bolt failure 13 Remove Special Tool 8429 then attach both sprockets to camshafts Remove excess oil from bolts then Install sprocket bolts but do not tighten at this time 14 Verify that all plated links are aligned with the marks on all sprockets and the V6 marks on camshaft sprockets are at the 12 o clock position CAUTION Ensure the plate between the left sec ondary chain tensioner and block is correctly installed 15 Install both secondary chain tensioners Tighten bolts to 28 N m 250 in I
44. 0 reduction in compression pressure CYLINDER TO WATER JACKET LEAKAGE TEST WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRES SURE CAP REMOVED K CYLINDER HEAD RIGHT Continued VISUAL TEST METHOD With the engine cool remove the coolant pressure cap Start the engine and allow it to warm up until thermostat opens If a large combustion compression pressure leak amp ists bubbles will be visible in the coolant COOLING SYSTEM TESTER METHOD WARNING WITH COOLING SYSTEM TESTER IN PLACE PRESSURE WILL BUILD UP FAST EXCES SIVE PRESSURE BUILT UP BY CONTINUOUS ENGINE OPERATION MUST BE RELEASED TO A SAFE PRESSURE POINT NEVER PERMIT PRES SURE TO EXCEED 138 kPa 20 psi Install Cooling System Tester 7700 or equivalent to pressure cap neck Start the engine and observe the tester s pressure gauge If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident CHEMICAL TEST METHOD Combustion leaks into the cooling system can also be checked by using Bloc Chek Kit C 3685 A or equivalent Perform test following the procedures supplied with the tool kit REMOVAL 1 Disconnect battery negative cable 2 Raise the vehicle on a hoist 3 Disconnect the exhaust pipe at the right side exhaust manifold 4 Drain the engine coolant Refer to COOLING SYSTEM 5 Lower the vehicle 6 Remove the intake manifold Refer to proce dure 7 Remove the cylin
45. 41 5 e IQ a Y N CSS CAT N SH 80b77088 Fig 37 Piston and Connecting Rod Installation Typical 1 F TOWARD FRONT OF ENGINE 2 OIL SLINGER SLOT 3 RING COMPRESSOR 4 SPECIAL TOOL 8507 6 Remove the bearing cap and determine amount of bearing to journal clearance by measuring the width of compressed Plastigage Fig 38 Refer to Engine Specifications for the proper dearance Plas tigage should indicate the same clearance across the entire width of the insert If the clearance varies it may be caused by either a tapered journal bent connecting rod or foreign material trapped between the insert and cap or rod 7 If the correct clearance is indicated replace ment of the bearing inserts is not necessary Remove the Plastigage from crankshaft journal and bearing insert Proceed with installation 8 If bearing to journal clearance exceeds the specification determin which services bearing set to use the bearing sizes are as follows 9 42 ENGINE 3 7L CONNECTING ROD BEARINGS Continued K J9009 42 Fig 38 Measuring Bearing Clearance with Plastigage 1 PLASTIGAGE SCALE 2 COMPRESSED PLASTIGAGE Bearing USED WITH Mark JOURNAL SIZE 025 US 025 mm 001 in 50 983 50 967 mm 2 0073 2 0066 in Std STANDARD 50 992 51 008 mm 2 0076 2 0082 in 250 mm 010 in 50 758 50 742 mm 1 9984 1 9978 in 9 Repeat the Plast
46. 5 mm 0 4727 in or less the oil pump assembly must be replaced 4 Measure the diameter of the outer rotor If the outer rotor diameter measures at 85 925 mm 3 382 in or less the oil pump assembly must be replaced 5 Measure the thickness of the inner rotor Fig 81 If the inner rotor thickness measures at 12 005 mm 0 472 in or less then the oil pump assembly must be replaced 6 Slide outer rotor into the body of the oil pump Press the outer rotor to one side of the oil pump body and measure clearance between the outer rotor and the body Fig 82 If the measurement is 0 235mm 0 009 in or more the oil pump assembly must be replaced 7 Install the inner rotor in the into the oil pump body Measure the clearance between the inner and outer rotors Fig 83 If the clearance between the rotors is 150 mm 0 006 in or more the oil pump assembly must be replaced 8 Place a straight edge across the body of the oil pump between the bolt holes if a feeler gauge of 095 mm 0 0038 in or greater can be inserted between the straightedge and the rotors the pump must be replaced Fig 84 NOTE The 3 7 Oil pump is released as an assem bly There are no DaimlerChrysler part numbers for Sub Assembly components In the event the oil pump is not functioning or out of specification it must be replaced as an assembly K 9309 184 Fig 79 Checking Oil Pump Cover Flatness 1 STRAIGHT EDGE 2 FEELER GAUGE 3 O
47. 9 128 Fig 35 Locking Tab Inspection 1 ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS NOT FULLY SEATED OR BEING BENT UPPER J8909 129 Fig 36 Scoring Caused by Insufficient Lubrication or Damaged Crankshaft Journal Misaligned or bent connecting rods can cause abnormal wear on pistons piston rings cylinder walls connecting rod bearings and crankshaft con necting rod journals If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod inspect it for correct rod alignment Replace misaligned bent or twisted con necting rods 1 Wipe the oil from the connecting rod journal 2 Lubricate the upper bearing insert and install in connecting rod 3 Use piston ring compressor and Guide Pins Special Tool 8507 Fig 37 to install the rod and pis ton assemblies The oil slinger slots in the rods must face front of the engine The F s near the piston wrist pin bore should point to the front of the engine 4 Install the lower bearing insert in the bearing cap The lower insert must be dry Place strip of Plas tigage across full width of the lower insert at the cen ter of bearing cap Plastigage must not crumble in use If brittle obtain fresh stock 5 Install bearing cap and connecting rod on the journal and tighten bolts to 27 N m 20 ft Ibs plus a 90 turn DO NOT rotate crankshaft Plastigage will smear resulting in inaccurate indication ENGINE 3 7L 9
48. 95 Camshaft Sprocket V6 Marks 1 LEFT CYLINDER HEAD 2 RIGHT CYLINDER HEAD BALANCE SHAFT REMOVAL 1 Remove the primary and secondary timing chains Refer to TIMING CHAIN and SPROCKET NOTE The balance shaft and gear are serviced as an assembly Do not attempt to remove the gear from the balance shaft Remove the retaining bolt from the counterbalance shaft thrust plate Fig 96 2 Using Special Tool 8641 Counterbalance shaft remover installer tool remove the counterbalance shaft from the engine Fig 97 INSTALLATION NOTE The balance shaft and gear are serviced as an assembly Do not attempt to remove the gear from the balance shaft 1 Coat counterbalance shaft bearing journals with clean engine oil NOTE The balance shaft is heavy and care should be used when installing shaft so bearings are not damaged 2 Using Special Tool 8641 Counterbalance shaft remover installer tool carefully install counterbal ance shaft into engine 3 Install Counterbalance shaft thrust plate retaining bolt finger tight Do not tighten bolt at this time 4 Position the right side of the thrust plate with the right chain guide bolt install bolt finger tight 5 Torque the thrust plate retaining bolt to 28 N m 250 in lbs 6 Remove the chain guide bolt so that guide can be installed TIMING BELT CHAIN COVER S REMOVAL 1 Disconnect the battery negative cable 2 Drain cooling system Refer to 7 CO
49. CHANICAL for possible causes and corrections of malfunctions Refer to 14 FUEL SYSTEM FUEL DELIVERY DIAGNOSIS AND TESTING and Refer to 14 FUEL SYSTEM FUEL INJECTION DIAGNOSIS AND TESTING for the fuel system diagnosis K Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts Information concerning additional tests and diagno sis is provided within the following diagnosis e Cylinder Compression Pressure Test Refer to 9 ENGINE DIAGNOSIS AND TESTING e Cylinder Combustion Pressure Leakage Test Refer to 9 ENGINE DIAGNOSIS AND TEST ING e Engine Cylinder Head Gasket Failure Diagnosis Refer to 9 ENGINE CYLINDER HEAD DIAGNO SIS AND TESTING e Intake Manifold Leakage Diagnosis Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING ENGINE DIAGNOSIS PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1 Weak battery 2 Corroded or loose battery connections 3 Faulty starter 4 Faulty coil or control unit 5 Incorrect spark plug gap 1 Charge or replace as necessary 2 Clean and tighten battery connections Apply a coat of light mineral grease to the terminals 3 Refer to 8 ELECTRICAL STARTING DIAGNOSIS AND TESTING 4 Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL REMOVAL 5 Refer to 8
50. CRIPTION iras d Rated le ae 39 STANDARD PROCEDURE CYLINDER BORE HONING secre er nat 39 CLEANING scores aa pad e eee uns 39 INSPECTION sec tti Re ge 40 CONNECTING ROD BEARINGS STANDARD PROCEDURE CONNECTING ROD BEARING FITTING 40 CRANKSHAFT DESCRIPTION dixe reo ERR ens 42 REMOVAL 2ke9 R A dada ees dee oe 43 INSPECTION oe IR 43 INSTALLATION seerl IR 43 CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE MAIN BEARING FITTING 45 CRANKSHAFT OIL SEAL FRONT REMOVAL uy exceso er ra 46 INSTALLATION eser IR 47 CRANKSHAFT OIL SEAL REAR REMOVAL usura reed RR reb 48 INSTALLATION eeee IR 48 FLEX PLATE REMOVAL zik sar AREA REX EARS 49 INSTALLATION ooo 49 PISTON amp CONNECTING ROD DESCRIPTION iiseneerkxe midesi tiigi 49 STANDARD PROCEDURE CONNECTING ROD BEARING FITTING 49 STANDARD PROCEDURE PISTON FITTINGS ad at o atada 50 REMOVAL i212 dk ee 50 CLEANING ebrei RR eer Res 51 INSPECTION eseel IR 51 INSTALLATION ooo 51 PISTON RINGS STANDARD PROCEDURE PISTON RING ETTING lt ocro ire 52 VIBRATION DAMPER REMOVAL secciones ae ye 54 INSTALLATION ooo 55 STRUCTURAL COVER DESCRIPTION isses ieee daa 55 OPERATION sac etter eee cede sid D RES 55 REMOVAL iuris Re an ada 55 INSTALLATION Cocco 55 FRONT MOUNT REMOVAL sans nett 56 INSTALLATION ooo 57 REAR MOUNT REMOVAL isis co Rr da dae ES 57 INSTALLATION ooo 57 LUBRICATION DESCRIPTION
51. Clean or replace as necessary 5 Replace as necessary 7 Refer to 9 ENGINE CYLINDER HEAD INTAKE EXHAUST VALVES 8 SEATS STANDARD PROCEDURE 8 Service valves and valve seats Refer to 9 ENGINE CYLINDER HEAD INTAKE EXHAUST VALVES 8 SEATS STANDARD PROCEDURE ENGINE VIBRATION 1 Counter Balance Shaft not timed properly 1 Refer to Engine Timing in this section CONNECTING ROD NOISE 1 Insufficient oil supply 2 Low oil pressure 3 Thin or diluted oil 4 Excessive bearing clearance 5 Connecting rod journal out of round 6 Misaligned connecting rods 1 Refer to LUBRICATION amp MAINTENANCE FLUID TYPES SPECIFICATIONS 2 Check oil pump if Ok check rod and main bearings for excessive wear 3 Change oil and filter 4 Replace as necessary 5 Service or replace crankshaft 6 Replace bent connecting rods MAIN BEARING NOISE 1 Insufficient oil supply Low oil pressure Thin or diluted oil Excessive bearing clearance Crankshaft journal out of round 3 4 5 Excessive end play 6 7 Loose flywheel or torque converter 1 Refer to LUBRICATION amp MAINTENANCE FLUID TYPES SPECIFICATIONS 2 Check oil pump if Ok check rod and main bearings for excessive wear 3 Change oil and filter 4 Replace as necessary 5 Check thrust washers for wear 6 Service or replace crankshaft 7 Tighten to correct torque K ENGINE 3 7L
52. Continued DIAGNOSIS AND TESTING ENGINE DIAGNOSIS LUBRICATION CONDITION POSSIBLE CAUSES ENGINE 3 7L 9 7 CORRECTION OIL LEAKS 1 Gaskets and O Rings a Misaligned or damaged b Loose fasteners broken or porous metal parts 2 Crankshaft rear seal 3 Crankshaft seal flange Scratched nicked or grooved 4 Oil pan flange cracked 5 Timing chain cover seal damaged 6 Scratched or damaged vibration damper hub 1 a Replace as necessary b Tighten fasteners Repair or replace metal parts 2 Replace as necessary Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR REMOVAL 3 Polish or replace crankshaft 4 Replace oil pan Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL 5 Re seal timing cover 6 Polish or replace damper OIL PRESSURE DROP 1 Low oil level 2 Faulty oil pressure sending unit Low oil pressure Clogged oil filter Worn oil pump Thin or diluted oil 7 Excessive bearing clearance Oil pump relief valve stuck 9 Oil pump suction tube loose damaged or clogged 1 Check and correct oil level 2 Replace sending unit Refer to 9 ENGINE LUBRICATION OIL PRESSURE SENSOR SWITCH REMOVAL 3 Check oil pump and bearing clearance 4 Replace oil filter Refer to 9 ENGINE LUBRICATION OIL FILTER REMOVAL 5 Replace oil pump Refer to 9 ENGINE LUBRICATION OIL PUMP REMOVAL 6 Change oil an
53. EFT EXHAUST MANIFOLD CAUTION If the studs came out with the nuts when removing the engine exhaust manifold install new studs Apply sealer on the coarse thread ends Water leaks may develop at the studs if this precau tion is not taken 1 Position the engine exhaust manifold and gas ket on the two studs located on the cylinder head Install conical washers and nuts on these studs 2 Install remaining conical washers Starting at the center arm and working outward tighten the bolts and nuts to 25 N m 18 ft Ibs torque 3 Install the exhaust heat shields 4 Raise and support the vehicle CAUTION Over tightening heat shield fasteners may cause shield to distort and or crack 5 Assemble exhaust pipe to manifold and secure with bolts nuts and retainers Tighten the bolts and nuts to 34 N m 25 ft Ibs torque VALVE TIMING DESCRIPTION The timing drive system has been designed to pro vide quiet performance and reliability to support a non free wheeling engine Specifically the intake valves are non free wheeling and can be easily dam aged with forceful engine rotation if camshaft to crankshaft timing is incorrect The timing drive system consists of a primary chain two secondary timing chain drives and a counterbalance shaft drive OPERATION The primary timing chain is a single inverted tooth chain type The primary chain drives the large 40 tooth idler sprocket directly from a 20 tooth crank ENGINE 3
54. ER INSTAL LATION 3 Install radiator cooling fan and shroud Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLATION 4 Install upper radiator hose 5 Install A C compressor and tighten fasteners to 54 N m 40 ft lbs 6 Install accessory drive belt refer Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 7 Refill cooling system Refer to 7 COOLING STANDARD PROCEDURE 8 Connect negative cable to battery 9 48 ENGINE 3 7L CRANKSHAFT OIL SEAL REAR REMOVAL NOTE This procedure can be performed in vehicle 1 If being preformed in vehicle remove the transmission 2 Remove the flexplate Refer to 9 ENGINE ENGINE BLOCK FLEX PLATE REMOVAL NOTE The crankshaft oil seal CAN NOT be reused after removal NOTE The crankshaft rear oil seal remover Special Tool 8506 must be installed deeply into the seal Continue to tighten the removal tool into the seal until the tool can not be turned farther Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine 3 Using Special Tool 8506 Fig 48 remove the crankshaft rear oil seal AO S O Ds 80b76fa8 Fig 48 Crankshaft Rear Oil Seal Removal 1 REAR CRANKSHAFT SEAL 2 SPECIAL TOOL 8506 INSTALLATION 1 Position the magnetic seal guide Special Tool 8349 2 Fig 49 onto the crankshaft rear face Then position the crankshaft rear oil sea
55. IL PUMP COVER 9309 70 Fig 81 Measuring Inner Rotor Thickness KJ OIL PUMP Continued 80b6b3b1 Fig 82 Measuring Outer Rotor Clearance in 1 FEELER GAUGE 2 OUTER ROTOR MN O o 80b6b3b0 Fig 83 Measuring Clearance Between Rotors 1 OUTER ROTOR 2 FEELER GAUGE 3 INNER ROTOR ENGINE 3 7L 9 67 80b6b3b2 Fig 84 Measuring Clearance Over Rotors 1 STRAIGHT EDGE 2 FEELER GAUGE ASSEMBLY 1 Wash all parts in a suitable solvent and inspect carefully for damage or wear 2 Install inner and outer rotors 3 Install oil pump cover plate and install cover bolts and tighten them to 12 N m 105 in Ibs 4 Prime oil pump before installation by filling rotor cavity with engine oil 5 If oil pressure is low and pump is within spec ifications inspect for worn engine bearings or other causes for oil pressure loss INSTALLATION 1 Position the oil pump onto the crankshaft and install two oil pump retaining bolts 2 Position the primary timing chain tensioner and install the two retaining bolts 3 Tighten the oil pump and primary timing chain tensioner retaining bolts to 28 N m 250 in Ibs in the sequence shown Fig 85 4 Install the secondary timing chain tensioners and timing chains Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 5 Install the timing chain cover Refer to 9 ENGINENALVE TIMING TI
56. ION The valves are made of heat resistant steel and have chrome plated stems to prevent scuffing Each valve is actuated by a roller rocker arm which pivots on a stationary lash adjuster All valves use three bead lock keepers to retain the springs and promote valve rotation STANDARD PROCEDURE REFACING NOTE Valve seats that are worn or burned can be reworked provided that correct angle and seat width are maintained Otherwise the cylinder head must be replaced NOTE When refacing valves and valve seats it is important that the correct size valve guide pilot be used for reseating stones A true and complete sur face must be obtained 1 Using a suitable dial indicator measure the center of the valve seat Total run out must not exceed 0 051 mm 0 002 in 2 Apply a small amount of Prussian blue to the valve seat insert the valve into the cylinder head while applying light pressure on the valve rotate the K ENGINE 3 7L 9 27 INTAKE EXHAUST VALVES amp SEATS Continued valve Remove the valve and examine the valve face If the blue is transferred below the top edge of the valve face lower the valve seat using a 15 degree stone If the blue is transferred to the bottom edge of the valve face raise the valve seat using a 65 degree stone 3 When the seat is properly positioned the width of the intake seat must be 1 75 2 36 mm 0 0689 0 0928 in and the exhaust seat must be 1 71 2 32 mm 0 0673 0 0911
57. Idle 25 Kpa 4 psi minimum e 3000 rpm 170 550 KPa 25 80 psi 4 If oil pressure is O at idle shut off engine Check for a clogged oil pick up screen or a pressure relief valve stuck open K LUBRICATION Continued 7 D AQ O ROL A 7 S f qum SS Is CZ 6 e 80b76fe9 Fig 70 Oil Pressure Sending Unit Typical BELT OIL PRESSURE SENSOR OIL FILTER ELEC CONNECTOR om DIAGNOSIS AND TESTING REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine a more involved inspection is necessary The following steps should be followed to help pinpoint the source of the leak If the leakage occurs at the crankshaft rear oil seal area 1 Disconnect the battery 2 Raise the vehicle 3 Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil Use a black light to check for the oil leak a Circular spray pattern generally indicates seal leakage or crankshaft damage b Where leakage tends to run straight down possible causes are a porous block camshaft bore cup plugs oil galley pipe plugs oil filter runoff and main bearing cap to cylinder block mating sur faces See Engine for proper repair procedures of these tems 4 If no leaks are detected pressurized the crank Case as outlined in the section Inspection Engine oil Leaks in general CAUTION Do
58. KJ ENGINE 3 7L 9 1 ENGINE 3 7L TABLE OF CONTENTS page page ENGINE 3 7L INSTALLATION Cocco 26 DESCRIPTION pasarun dedi tapi e es 3 INTAKE EXHAUST VALVES amp SEATS DIAGNOSIS AND TESTING DESCRIPTION zasgzs RES v ERR ERR n 26 DIAGNOSIS AND TESTING ENGINE STANDARD PROCEDURE REFACING 26 DIAGNOSIS INTRODUCTION 4 REMOVAL zu 2 02 de Red ER are 27 DIAGNOSIS AND TESTING ENGINE INSTALLATION 1 eee ee 28 DIAGNOSIS PERFORMANCE 4 ROCKER ARM DIAGNOSIS AND TESTING ENGINE DESCRIPTION sese reeset RR Re 29 DIAGNOSIS MECHANICAL 6 VALVE GUIDE SEALS DIAGNOSIS AND TESTING ENGINE DESCRIPTION sasexkesteer awes e e 29 DIAGNOSIS LUBRICATION 7 VALVE SPRINGS DIAGNOSIS AND TESTING CYLINDER DESCRIPTION gensprawa naad ee 29 COMPRESSION PRESSURE 8 REMOVAL usa 29 DIAGNOSIS AND TESTING CYLINDER INSTALLATION eseer BB 29 COMBUSTION PRESSURE LEAKAGE 8 CYLINDER HEAD RIGHT STANDARD PROCEDURE DESCRIPTION STANDARD PROCEDURE ENGINE DESCRIPTION CYLINDER HEAD 30 GASKET SURFACE PREPARATION 9 DESCRIPTION VALVE GUIDES 30 STANDARD PROCEDURE REPAIR DESCRIPTION coco RR mE 30 DAMAGED OR WORN THREADS 9 DIAGNOSIS AND TESTING STANDARD PROCEDURE ENGINE CORE DIAGNOSIS AND TESTING HYDRAULIC AND OIL GALLERY PLUGS 10 LASH ADJUSTER 1 30 REMOVAL enter 10 DIAGNOSIS AND TESTING CY
59. L 1 Remove the cylinder head cover Refer to Cyl inder Head Cover in this Section 2 Using Special Tool 8516 Valve Spring Compres sor remove the rocker arms and the hydraulic lash adjusters 3 Remove the spark plug for the cylinder the valve spring and seal are to be removed from 4 Apply shop air to the cylinder to hold the valves in place when the spring is removed K NOTE All six valve springs and seals are removed in the same manner this procedure only covers one valve seal and valve spring 5 Using Special Tool 8387 Valve Spring Compres sor compress the valve spring NOTE It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed 6 Remove the two spring retainer lock halves NOTE the valve spring is under tension use care when releasing the valve spring compressor 7 Remove the valve spring compressor 8 Remove the spring retainer and the spring 9 Remove the valve stem seal NOTE The valve stem seals are common between intake and exhaust INSTALLATION NOTE All six valve springs and seals are removed in the same manner this procedure only covers one valve seal and valve spring 1 Apply shop air to the cylinder to hold the valves in place while the spring is installed NOTE The valve stem seals are common between intake and exhaust 2 Install the valve stem seal 3 Install the spring retainer and the spring 4
60. LINDER INSTALLATION iue ec Re 11 HEAD GASKET 4 eee wie ek 30 SPECIFICATIONS REMOVAL us onde de va peda de see hale TORQUE oesrrrrcar adria 12 CLEANING 3 LENGINE ssepe ropas 12 INSPECTION SPECIAL TOOLS INSTALLATION usa sur RR RR Rx 32 S LENGINE sessi na ki 15 CAMSHAFT S AIR CLEANER ELEMENT DESCRIPTION zu RR ae ae 33 REMOVAL 3 7L ee eee 19 REMOVAL unseren 33 INSTALLATION 3 7L 1 eee 19 INSTALLATION 1 eee ee 33 CYLINDER HEAD LEFT CYLINDER HEAD COVER S DESCRIPTION VALVE GUIDES 19 REMOVAL o12ese eg RR ee 34 DIAGNOSIS AND TESTING INSTALLATION sseer BI 34 DIAGNOSIS AND TESTING HYDRAULIC INTAKE EXHAUST VALVES amp SEATS LASH ADJUSTER ooo 19 STANDARD PROCEDURE REFACING 34 DIAGNOSIS AND TESTING CYLINDER REMOVAL sauna nenn 35 HEAD GASKET ooo 19 INSTALLATION I 36 REMOVAL iia ra yd Aor E E 20 ROCKER ARM CLEANING i rk E Wee na eae ata ald Russ 22 DESCRIPTION idees RR e dE Ren 37 INSTALLATION eeeer m BR 22 REMOVAL nassen sense ia Eyed 37 CAMSHAFT S INSTALLATION 1 eee oroi 37 DESCRIPTION ceeds panded rara pies 23 VALVE GUIDE SEALS REMOVAL ize eR eaa na 24 DESERIPTION zu 2422 iaa IDE SR 38 INSTALLATION eeeel m ee 25 VALVE SPRINGS CYLINDER HEAD COVER S DESCRIPTION seek Re Re Kis 38 DESCRIPTION sicario 25 REMOVAL cocaina Ee S 38 REMOVAL rss sr a p PA 25 INSTALLATION cect ea en 38 9 2 ENGINE 3 7L ENGINE BLOCK DES
61. MING BELT CHAIN COVER S INSTALLATION 6 Install the pick up tube and oil pan Refer to 9 ENGINE LUBRICATION OIL PAN INSTALLA TION 9 68 ENGINE 3 7L OIL PUMP Continued PRIMARY TIMING CHAIN Q TENSIONER ENGINE OIL PUMP ON 80b76faa Fig 85 Oil Pump and Primary Timing Chain Tensioner Tightening Sequence INTAKE MANIFOLD DESCRIPTION The intake manifold Fig 86 is made of a compos ite material and features 300 mm 11 811 in long runners which maximizes low end torque The intake manifold uses single plane sealing which consist of six individual press in place port gaskets to prevent leaks The throttle body attaches directly to the intake manifold Eight studs and two bolts are used to fasten the intake to the head DIAGNOSIS AND TESTING INTAKE MANIFOLD LEAKS An intake manifold air leak is characterized by lower than normal manifold vacuum Also one or more cylinders may not be functioning WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR THE FAN DO NOT WEAR LOOSE CLOTHING 1 Start the engine 2 Spray a small stream of water Spray Bottle at the suspected leak area 3 If engine RPM S change the area of the sus pected leak has been found 4 Repair as required K ie CASIO i EN VAPAATA e a HI
62. MOVAL NOTE To remove the crankshaft from the engine the engine must be removed from the vehicle 1 Remove the engine Refer to Engine Assembly in this section for procedure 2 Remove the engine oil pump Refer to Oil Pump in this section for procedure CAUTION DO NOT pry on the oil pan gasket when removing the oil pan The oil pan gasket is mounted to the cylinder block in three locations and will remain attached to block when removing oil pan Gasket can not be removed with oil pan 3 Remove oil pan bolts and oil pan 4 Remove the oil pump pickup tube and oil pan gasket windage tray 5 Remove the bedplate mounting bolts Note the location of the two stud bolts for installation 6 Remove the connecting rods from the crank shaft CAUTION The bedplate to cylinder block mating surface is a critical sealing surface Do not pry on or damage this surface in anyway NOTE The bedplate contains the lower main bear ing halves Use care when handling bedplate as not to drop or damage bearing halves Installing main bearing halves in the wrong position will cause sever damage to the crankshaft NOTE The bedplate has pry points cast into it Use these points only The pry points are shown below 7 Carefully pry on the pry points Fig 41 to loosen the bedplate then remove the bedplate CAUTION When removing the crankshaft use care not to damage bearing surfaces on the crankshaft 8 Remove the crankshaft
63. NOTE The valve stem seals are common between intake and exhaust INSTALLATION NOTE All six valve springs and seals are removed in the same manner this procedure only covers one valve seal and valve spring 1 Apply shop air to the cylinder to hold the valves in place while the spring is installed NOTE The valve stem seals are common between intake and exhaust 2 Install the valve stem seal 3 Install the spring retainer and the spring 4 Using Special Tool 8387 Valve Spring Compres sor compress the valve spring 5 Install the two spring retainer lock halves NOTE the valve spring is under tension use care when releasing the valve spring compressor 6 Remove the valve spring compressor 7 Disconnect the shop air to the cylinder 8 Install the spark plug for the cylinder the valve spring and seal was installed on 9 30 ENGINE 3 7L VALVE SPRINGS Continued 9 Using Special Tool 8516 Valve Spring Compres sor install the rocker arms and the hydraulic lash adjusters 10 Install the cylinder head cover Refer to Cylin der Head Cover in this Section CYLINDER HEAD RIGHT DESCRIPTION DESCRIPTION CYLINDER HEAD The cylinder heads are made of an aluminum alloy The cylinder head features two valves per cylinder with pressed in powdered metal valve guides The cylinder heads also provide enclosures for the timing chain drain necessitating unique left and right cylin der heads DESCRI
64. OLING STANDARD PROCEDURE 3 Remove electric cooling fan and fan shroud assembly 4 Remove fan and fan drive assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 5 Disconnect both heater hoses at timing cover 6 Disconnect lower radiator hose at engine K ENGINE 3 7L 9 75 TIMING BELT CHAIN COVER S Continued A Fig 96 COUNTERBALANCE SHAFT RETAINING PLATE 80c41ef1 IDLER SHAFT COUNTERBALANCE SHAFT THRUST PLATE COUNTERBALANCE SHAFT DRIVE GEAR RETAINING BOLT RO DP 7 Remove accessory drive belt tensioner assembly Fig 98 8 Remove crankshaft damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 9 Remove the generator Refer to 8 ELECTRI CAL CHARGING GENERATOR REMOVAL 10 Remove A C compressor Refer to 24 HEAT ING 6 AIR CONDITIONING PLUMBING A C COM PRESSOR REMOVAL CAUTION The 3 7L engine uses an anerobic sealer instead of a gasket to seal the front cover to the engine block from the factory For service Mopar Engine RTV sealant must be substituted NOTE It is not necessary to remove the water pump for timing cover removal 11 Remove the bolts holding the timing cover to engine block Fig 99 12 Remove the timing cover N O 80c41ef0 Fig 97 COUNTERBALANCE SHAFT REMOVAL INSTALLATION TOOL 1 COUNTERBALANCE SHAFT REMOVAL AND INSTALLATION TOOL 2 COUNTERBALANCE SHAFT THRUST PLATE RE
65. ON The valve guide seals are made of rubber and incorporate an integral steel valve spring seat The integral garter spring maintains consistent lubrica tion control to the valve stems VALVE SPRINGS DESCRIPTION The valve springs are made from high strength chrome silicon steel The springs are common for intake and exhaust applications The valve spring seat is integral with the valve stem seal which is a positive type seal to control lubrication REMOVAL 1 Remove the cylinder head cover Refer to Cyl inder Head Cover in this Section 2 Using Special Tool 8516 Valve Spring Compres sor remove the rocker arms and the hydraulic lash adjusters 3 Remove the spark plug for the cylinder the valve spring and seal are to be removed from 4 Apply shop air to the cylinder to hold the valves in place when the spring is removed NOTE All six valve springs and seals are removed in the same manner this procedure only covers one valve seal and valve spring 5 Using Special Tool 8387 Valve Spring Compres sor compress the valve spring NOTE It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed 6 Remove the two spring retainer lock halves NOTE the valve spring is under tension use care when releasing the valve spring compressor 7 Remove the valve spring compressor 8 Remove the spring retainer and the spring 9 Remove the valve stem seal
66. PTION VALVE GUIDES The valve guides are made of powered metal and are pressed into the cylinder head The guides are not replaceable or serviceable and valve guide ream ing is not recommended If the guides are worn beyond acceptable limits replace the cylinder heads DESCRIPTION The valves are made of heat resistant steel and have chrome plated stems to prevent scuffing Each valve is actuated by a roller rocker arm which pivots on a stationary lash adjuster All valves use three bead lock keepers to retain the springs and promote valve rotation DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING HYDRAULIC LASH ADJUSTER A tappet like noise may be produced from several items Check the following items 1 Engine oil level too high or too low This may cause aerated oil to enter the adjusters and cause them to be spongy 2 Insufficient running time after rebuilding cylin der head Low speed running up to 1 hour may be required 3 Turn engine off and let set for a few minutes before restarting Repeat this several times after engine has reached normal operating temperature 4 Low oil pressure 5 The oil restrictor in cylinder head gasket or the oil passage to the cylinder head is plugged with debris K 6 Air ingested into oil due to broken or cracked oil pump pick up 7 Worn valve guides 8 Rocker arm ears contacting valve spring retainer 9 Rocker arm loose adjuster stuck or at maxi mum extension
67. RLY ENGINE OIL SPECIFICATION CAUTION Do not use non detergent or straight mineral oil when adding or changing crankcase lubricant Engine failure can result API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certi fied MOPAR provides engine oils that conform to this service grade SAE VISCOSITY An SAE viscosity grade is used to specify the vis cosity of engine oil Use only engine oils with multi 9 62 ENGINE 3 7L OIL Continued ple viscosities such as 5W 30 or 10W 30 in the 3 7L engines These are specified with a dual SAE viscos ity grade which indicates the cold to hot temperature viscosity range Select an engine oil that is best suited to your particular temperature range and vari ation Fig 71 ENGINE OIL VISCOSITY GRADES 5W 30 Preferred F 20 0 10 20 32 60 80 100 C 29 18 12 7 0 16 27 38 Temperature range anticipated before next oil change 80b89880 Fig 71 Temperature Engine Oil Viscosity 3 7L Engine ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines The designation of ENERGY CON SERVING is located on the label of an engine oil con tainer CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans Fig
68. Raf gt 80b6b296 Fig 98 Accessory Drive Belt Tensioner 1 TENSIONER ASSEMBLY 2 FASTENER TENSIONER TO FRONT COVER 9 76 ENGINE 3 7L K TIMING BELT CHAIN COVER S Continued 4 INDICATES STUD LOCATIONS TIMING CHAIN COVER ASSEMBLY 80b6b298 Fig 99 Timing Chain Cover Fasteners Typical INSTALLATION CAUTION Do not use oil based liquids to clean tim ing cover or block surfaces Use only rubbing alco hol along with plastic or wooden scrapers Use no wire brushes or abrasive wheels or metal scrapers or damage to surfaces could result 1 Clean timing chain cover and block surface using rubbing alcohol CAUTION The 3 7L uses a special anerobic sealer instead of a gasket to seal the timing cover to the engine block from the factory For service repairs Mopar Engine RTV must be used as a substitute 2 Inspect the water passage o rings for any dam age and replace as necessary 3 Apply Mopar Engine RTV sealer to front cover Fig 100 4 Install cover Tighten fasteners in sequence as shown in Fig 101 to 54 N m 40 ft Ibs 5 Install crankshaft damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTALLATION 6 Install the A C compressor Refer to 24 HEAT ING amp AIR CONDITIONING PLUMBING A C COM PRESSOR INSTALLATION 7 Install the generator Refer to 8 ELECTRI CAL CHARGING GENERATOR INSTALLATION 8 Install accessory drive
69. TE Coat the rocker arms with clean engine oil prior to installation 1 For rocker arm installation on cylinders 4 Rotate the crankshaft until cylinder 1 is at TDC exhaust stroke 2 For rocker arm installation on cylinder 1 Rotate the crankshaft until cylinder 1 is at TDC compression stroke 3 For rocker arm installation on cylinders 2 and 8 Rotate the crankshaft until cylinder 1 is at BDC compression stroke 4 For rocker arm installation on cylinders and 6 Rotate the crankshaft until cylinder 1 is at BDC exhaust stroke 5 Using special tool 8516 press downward on the valve spring install rocker arm Fig 30 6 Install the cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION 9 38 ENGINE 3 7L ROCKER ARM Continued O S LEZ X gt x x LA y A 2 III o OS Bi 80b76fa5 Fig 30 Rocker Arm Installation 1 CAMSHAFT 2 SPECIAL TOOL 8516 VALVE GUIDE SEALS DESCRIPTION The valve guide seals are made of rubber and incorporate an integral steel valve spring seat The integral garter spring maintains consistent lubrica tion control to the valve stems VALVE SPRINGS DESCRIPTION The valve springs are made from high strength chrome silicon steel The springs are common for intake and exhaust applications The valve spring seat is integral with the valve stem seal which is a positive type seal to control lubrication REMOVA
70. URE LEAKAGE The combustion pressure leakage test provides an accurate means for determining engine condition Combustion pressure leakage testing will detect e Exhaust and intake valve leaks improper seat ing 1 Worn or damaged rings 1 Hone cylinder bores and replace rings 2 Replace rings Refer to 9 ENGINE ENGINE BLOCK PISTON RINGS STANDARD PROCEDURE 3 Replace rings Refer to 9 ENGINE ENGINE BLOCK PISTON RINGS STANDARD PROCEDURE 4 Ream guides and replace valves Refer to 9 ENGINE CYLINDER HEAD INTAKE EXHAUST VALVES amp SEATS STANDARD PROCEDURE 5 Replace valve guide seals e Leaks between adjacent cylinders or into water jacket e Any causes for combustion compression pressure loss 1 Check the coolant level and fill as required DO NOT install the radiator cap 2 Start and operate the engine until it attains normal operating temperature then turn the engine OFF 3 Remove the spark plugs 4 Remove the oil filler cap 5 Remove the air cleaner 6 Calibrate the tester according to the manufac turer s instructions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum and 552 kPa 80 psi recom mended 7 Perform the test procedures on each cylinder according to the tester manufacturer s instructions Set piston of cylinder to be tested at TDC compres sion While testing listen for pressurized air escaping throu
71. W TO BOTH SECONDARY TENSIONERS 11 CRANKSHAFT MAIN BEARING JOURNALS 5 OIL FLOW TO LEFT CYLINDER HEAD 12 RIGHT CYLINDER HEAD OIL GALLERY 6 OIL PRESSURE SENSOR LOCATION 7 OIL FLOW TO COUNTER BALANCE SHAFT 9 60 ENGINE 3 7L LUBRICATION Continued DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING ENGINE OIL LEAK Begin with a thorough visual inspection of the engine particularly at the area of the suspected leak If an oil leak source is not readily identifiable the following steps should be followed 1 Do not clean or degrease the engine at this time because some solvents may cause rubber to swell temporarily stopping the leak 2 Add an oil soluble dye use as recommended by manufacturer Start the engine and let idle for approximately 15 minutes Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light 3 Using a black light inspect the entire engine for fluorescent dye particularly at the suspected area of oil leak If the oil leak is found and identified repair per service manual instructions 4 If dye is not observed drive the vehicle at var ious speeds for approximately 24km 15 miles and repeat inspection If the oil leak source is not pos itively identified at this time proceed with the air leak detection test method Air Leak Detection Test Method 1 Disconnect the breather cap to air cleaner hose at the breather cap end Cap or
72. abnormal wear patterns and for metal or other foreign material imbedded in the lining Normal main bearing insert wear patterns are illustrated Inspect the back of the inserts for fractures scrap ings or irregular wear patterns Inspect the upper insert locking tabs for damage ENGINE 3 7L 9 45 80cbda4f wod Q FIN Fig 44 Main Bearing Markings on Target Wheel Typical 1 REARMOST CRANKSHAFT COUNTER WEIGHT 2 TARGET WHEEL 3 MAIN BEARING SELECT FIT MARKINGS Replace all damaged or worn bearing inserts 9 46 ENGINE 3 7L CRANKSHAFT MAIN BEARINGS Continued MAIN BEARING JOURNAL DIAMETER CRANKSHAFT REMOVED Remove the crankshaft from the cylinder block Refer to CRANKSHAFT Clean the oil off the main bearing journal Determine the maximum diameter of the journal with a micrometer Measure at two locations 90 apart at each end of the journal The maximum allowable taper is 0 008mm 0 0004 inch and maximum out of round is 0 005mm 0 002 inch Compare the measured diameter with the jour nal diameter specification Main Bearing Fitting Chart Select inserts required to obtain the specified bearing to journal clearance Install the crankshaft into the cylinder block Refer to CRANKSHAFT Check crankshaft end play Refer to CHECKING CRANKSHAFT END PLAY CRANKSHAFT MAIN BEARING SELECTION 1 Service main bearings are available in three grades The chart below identifies the three servic
73. and still leaves lash in the system 10 Oil leak or excessive cam bore wear in cylin der head 11 Faulty lash adjuster e Check lash adjusters for sponginess while installed in cylinder head and cam on camshaft at base cirde Depress part of rocker arm over adjuster Normal adjusters should feel very firm Spongy adjusters can be bottomed out easily e Remove suspected lash adjusters and replace e Before installation make sure adjusters are at least partially full of oil This can be verified by little or no plunger travel when lash adjuster is depressed DIAGNOSIS AND TESTING CYLINDER HEAD GASKET A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket Possible indications of the cylinder head gasket leaking between adjacent cylinders are e Loss of engine power e Engine misfiring e Poor fuel economy Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are e Engine overheating e Loss of coolant e Excessive steam white smoke emitting from exhaust e Coolant foaming CYLINDER TO CYLINDER LEAKAGE TEST To determine if an engine cylinder head gasket is leaking between adjacent cylinders follow the proce dures in Cylinder Compression Pressure Test Refer to 9 ENGINE DIAGNOSIS AND TESTING An engine cylinder head gasket leaking between adja cent cylinders will result in approximately a 50 7
74. ar K VALVE TIMING Continued 80c413e9 Fig 92 COUNTERBALANCE SHAFT ALIGNMENT MARKS 1 COUNTERBALANCE SHAFT 2 TIMING MARKS 3 IDLER SPROCKET 5 Using Special Tool 8428 Camshaft Wrench rotate the camshaft until the alignment dowel on the camshaft is aligned with the slot in the camshaft drive gear CAUTION Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt Fail ure to do so may cause over torqueing of bolt resulting in bolt failure 6 Position the camshaft drive gear onto the cam shaft remove oil from bolt then install the retaining bolt Using Special Tools Spanner Wrench 6958 with Adapter Pins 8346 and a suitable torque wrench Tighten retaining bolt to 122N m 90 ft Lbs 7 Remove Special Tool 8379 8 Rotate the crankshaft two full revolutions then reverify that the camshaft drive gear V6 marks are in fact aligned 9 Install the cylinder head covers Refer to Cylin der Head Cover in this section ENGINE 3 7L 9 73 80c41ef2 Fig 93 SECURING TIMING CHAIN TENSIONER USING TIMING CHAIN WEDGE 1 CYLINDER HEAD 2 SPECIAL TOOL 8379 2 TIMING CHAIN 80c41ef3 Fig 94 CAMSHAFT DRIVE GEAR REMOVAL INST 1 SPECIAL TOOL 8279 TIMING CHAIN WEDGE 2 CAMSHAFT DRIVE GEAR 3 RETAINING BOLT 4 CYLINDER HEAD 9 74 ENGINE 3 7L VALVE TIMING Continued K 80038813 Fig
75. ation CAUTION Do not hold or pry on the camshaft tar get wheel for any reason Severe damage will occur to the target wheel A damaged target wheel could cause a vehicle no start condition 4 Loosen but DO NOT remove the camshaft sprocket retaining bolt Leave bolt snug against sprocket NOTE The timing chain tensioners must be secured prior to removing the camshaft sprockets Failure to secure tensioners will allow the tension ENGINE 3 7L 9 33 ers to extend requiring timing chain cover removal in order to reset tensioners CAUTION Do not force wedge past the narrowest point between the chain strands Damage to the tensioners may occur 5 Position Special Tool 8379 timing chain wedge between the timing chain strands Tap the tool to securely wedge the timing chain against the ten sioner arm and guide 6 Remove the camshaft position sensor 7 Hold the camshaft with Special Tool 8428 Cam shaft Wrench while removing the camshaft sprocket bolt and sprocket 8 Starting at the outside working inward loosen the camshaft bearing cap retaining bolts 1 2 turn at a time Repeat until all load is off the bearing caps CAUTION DO NOT STAMP OR STRIKE THE CAM SHAFT BEARING CAPS SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS NOTE When the camshaft is removed the rocker arms may slide downward mark the rocker arms before removing camshaft 9 Remove the camshaft bearing caps and the camshaft INSTALLATION
76. ay Refer to 9 ENGINE LUBRICATION OIL PAN INSTALLA TION 12 Fill crankcase with proper engine oil to cor rect level 13 Connect negative cable to battery PISTON RINGS STANDARD PROCEDURE PISTON RING FITTING Before reinstalling used rings or installing new rings the ring clearances must be checked 1 Wipe the cylinder bore clean 2 Insert the ring in the cylinder bore NOTE The ring gap measurement must be made with the ring positioned at least 12mm 0 50 inch from bottom of cylinder bore 3 Using a piston to ensure that the ring is squared in the cylinder bore slide the ring downward into the cylinder 4 Using a feeler gauge check the ring end gap Fig 57 Replace any rings not within specification PISTON RING SIDE CLEARANCE KJ PISTON RINGS Continued 805dd892 Fig 57 Ring End Gap Measurement Typical 1 FEELER GAUGE NOTE Make sure the piston ring grooves are clean and free of nicks and burrs 5 Measure the ring side clearance as shown Fig 58 make sure the feeler gauge fits snugly between the ring land and the ring Replace any ring not within specification 805dd887 Fig 58 Measuring Piston Ring Side Clearance 1 FEELER GAUGE 6 Rotate the ring around the piston the ring must rotate in the groove with out binding ENGINE 3 7L 9 53 PISTON RING SPECIFICATION CHART Maximum Clearance 0 10mm 0 004 in Groove didi Las Clearance Upp
77. bs NOTE Left and right secondary chain tensioners are not common 16 Remove all locking pins 3 from tensioners CAUTION After pulling locking pins out of each tensioner DO NOT manually extend the tensioner s ratchet Doing so will over tension the chains resulting in noise and or high timing chain loads 17 Using Special Tool 6958 Spanner with Adap tor Pins 8346 tighten left Fig 110 and right Fig 111 camshaft sprocket bolts to 122 N m 90 ft Ibs a Fig 110 Tightening Left Side Camshaft Sprocket Bolt TORQUE WRENCH CAMSHAFT SPROCKET LEFT CYLINDER HEAD SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346 RO DP 18 Rotate engine two full revolutions Verify tim ing marks are at the follow locations e primary chain idler sprocket dot is at 12 o clock e primary chain crankshaft sprocket dot is at 6 o clock e secondary chain camshaft sprockets V6 marks are at 12 o dock e counterbalancer shaft drive gear dot is aligned to the idler sprocket gear dot 19 Lubricate all three chains with engine oil 9 82 ENGINE 3 7L KJ TIMING BELT CHAIN AND SPROCKET S Continued PO I sovz6taz Fig 111 Tightening Right Side Camshaft Sprocket Bolt TORQUE WRENCH SPECIAL TOOL 6958 WITH ADAPTER PINS 8346 LEFT CAMSHAFT SPROCKET RIGHT CAMSHAFT SPROCKET Pom 20 After installing all chains it is recommended that the idler gear e
78. ct the battery negative cable 43 Start the engine and check for leaks SPECIFICATIONS TORQUE DESCRIPTION Camshaft Non Oiled Sprocket Bolt Bearing Cap Bolts Timing Chain Cover Bolts Connecting Rod Cap Bolts PLUS 90 TURN Bed Plate Bolts Refer to Procedure Crankshaft Damper Bolt 175 130 Cylinder Head Bolts M11 Bolts M8 Bolts Cylinder Head Cover Bolts Exhaust Manifold Bolts Exhaust Manifold Heat Shield Nuts Flexplate Bolts Engine Mount Bracket to Block Bolts Refer Td rgcedure Generator Mounting Bolts M10 Bolts M8 Bolts Intake Manifold Bolts Refer to Procedure for Tightening Sequence DiFa moas Si 5 KJ DESCRIPTION Ft In Lbs Lbs Oil Pan Drain Plug 34 25 ON Pump Bota e Oi Pump Cover Bois 12 105 Oil Pickup Tube Bolt and 28 250 Nut Oil Dipstick Tube to Engine 15 130 Block Bolt Oil Fill Tube Bolts 12 105 Timing Chain Guide Bolts 250 EH Timing Chain Tensioner RAMI 150 HEM m Arm Special Pin Bolt 250 250 Hydraulic Tensioner Bolts Timing Chain Primary Tensioner Bolts Timing Drive Idler Sprocket Bolt 105 Thermostat Housing Bolts Walor Pumpe 0 3 7L ENGINE SPECIFICATIONS DESCRIPTION SPECIFICATION Engine Type 90 SOHC V 6 12 Valve Displacement 3 7 Liters 3700 cc Cubic Inches Lead Cylinder 1 Left Bank Firing Order 1 6 5 4
79. cted the proper insert install the insert and cap Tighten the connecting rod bolts to 27 N m 20 ft Ibs plus a 90 turn Slide snug fitting feeler gauge between the con necting rod and crankshaft journal flange Refer to Engine Specifications for the proper clearance Replace the connecting rod if the side clearance is not within specification STANDARD PROCEDURE PISTON FITTING 1 To correctly select the proper size piston a cyl inder bore gauge capable of reading in 0 003 mm 0001 in INCREMENTS is required If a bore gauge is not available do not use an inside micrometer 2 Measure the inside diameter of the cylinder bore at a point 38 0 mm 1 5 inches below top of bore Start perpendicular across or at 90 degrees to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B Fig 54 3 The coated pistons will be serviced with the piston pin and connecting rod pre assembled KJ 4 The coating material is applied to the piston after the final piston machining process Measuring the outside diameter of a coated piston will not pro vide accurate results Fig 53 Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY To correctly select the proper size piston a cylinder bore gauge capable of reading in 0 003 mm 0001 in increments is required 5 Piston installation into the cylinder bore requires slightly more
80. cylinder head gasket leaking between adja cent cylinders will result in approximately a 50 70 reduction in compression pressure CYLINDER TO WATER JACKET LEAKAGE TEST WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRES SURE CAP REMOVED VISUAL TEST METHOD With the engine cool remove the coolant pressure cap Start the engine and allow it to warm up until thermostat opens If a large combustion compression pressure leak amp ists bubbles will be visible in the coolant COOLING SYSTEM TESTER METHOD WARNING WITH COOLING SYSTEM TESTER IN PLACE PRESSURE WILL BUILD UP FAST EXCES SIVE PRESSURE BUILT UP BY CONTINUOUS ENGINE OPERATION MUST BE RELEASED TO A SAFE PRESSURE POINT NEVER PERMIT PRES SURE TO EXCEED 138 kPa 20 psi Install Cooling System Tester 7700 or equivalent to pressure cap neck Start the engine and observe the tester s pressure gauge If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident CHEMICAL TEST METHOD Combustion leaks into the cooling system can also be checked by using Bloc Chek Kit C 3685 A or equivalent Perform test following the procedures supplied with the tool kit K REMOVAL 1 Disconnect the negative cable from the battery 2 Raise the vehicle on a hoist 3 Disconnect the exhaust pipe at the left side exhaust manifold 4 Drain the engine coolant Refer to COOLING SYSTEM 5 Lower the vehide 6 Remo
81. d filter 7 Replace as necessary 8 Replace oil pump Refer to 9 ENGINE LUBRICATION OIL PUMP REMOVAL 9 Replace as necessary 9 8 ENGINE 3 7L ENGINE 3 7L Continued CONDITION POSSIBLE CAUSES KJ CORRECTION OIL PUMPING AT RINGS SPARK PLUGS FOULING 2 Carbon in oil ring slots 3 Incorrect ring size installed 4 Worn valve guides 5 Leaking valve guide seals DIAGNOSIS AND TESTING CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc tions Ensure the battery is completely charged and the engine starter motor is in good operating condition Otherwise the indicated compression pressures may not be valid for diagnosis purposes 1 Clean the spark plug recesses with compressed air 2 Remove the spark plugs 3 Secure the throttle in the wide open position 4 Disable the fuel system Refer to 14 FUEL SYSTEM FUEL DELIVERY DESCRIPTION 5 Remove the ASD relay Refer to 8 ELECTRI CAL IGNITION CONTROL AUTO SHUT DOWN RELAY REMOVAL 6 Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions 7 Record the compression pressure on the 3rd revolution Continue the test for the remaining cylin ders 8 Refer to 9 ENGINE SPECIFICATIONS for the correct engine compression pressures DIAGNOSIS AND TESTING CYLINDER COMBUSTION PRESS
82. der head cover Refer to proce dure 8 Remove the fan shroud Refer to COOLING SYSTEM 9 Remove oil fill housing from cylinder head 10 Remove accessory drive belt Refer to COOL ING SYSTEM 11 Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark 12 Verify the V6 mark on the camshaft sprocket is at the 12 o clock position Rotate the crankshaft one turn if necessary 13 Remove the crankshaft damper Refer to pro cedure 14 Remove the timing chain cover Refer to pro cedure 15 Lock the secondary timing chains to the idler sprocket using Special Tool 8429 Timing Chain Hold ing Fixture ENGINE 3 7L 9 31 NOTE Mark the secondary timing chain prior to removal to aid in installation 16 Mark the secondary timing chain one link on each side of the V6 mark on the camshaft drive gear 17 Remove the right side secondary chain ten sioner Refer to Timing Chain and Sprockets in this section 18 Remove the cylinder head access plug 19 Remove the right side secondary chain guide Refer to Timing Chain and Sprockets in this section CAUTION The nut on the right side camshaft sprocket should not be removed for any reason as the sprocket and camshaft sensor target wheel is serviced as an assembly If the nut was removed retorque nut to 5 N m 44 in Ibs 20 Remove the retaining bolt and the camshaft drive gear CAUTION Do not allow the engine to rotate sever
83. der heads and the black bolts retain the guides to the engine block 4 Install the left side chain guide Tighten the bolts to 28 N m 250 in lbs 5 Install left side chain tensioner arm Apply Mopar Lock N Seal to torx bolt tighten bolt to 28 N m 250 in lbs 6 Install the right side chain guide Tighten the bolts to 28 N m 250 in lbs 7 Install both secondary chains onto the idler sprocket Align two plated links on the secondary chains to be visible through the two lower openings on the idler sprocket 4 o dock and 8 o dock Once the secondary timing chains are installed position special tool 8429 to hold chains in place for installa tion 8 Align primary chain double plated links with the timing mark at 12 o clock on the idler sprocket Align the primary chain single plated link with the timing mark at 6 o clock on the crankshaft sprocket 9 Lubricate idler shaft and bushings with clean engine oil NOTE The idler sprocket must be timed to the counterbalance shaft drive gear before the idler sprocket is fully seated p 80b77056 Fig 108 Installing Idler Gear Primary and Secondary Timing Chains 1 SPECIAL TOOL 8429 2 PRIMARY CHAIN IDLER SPROCKET 3 CRANKSHAFT SPROCKET 10 Install all chains crankshaft sprocket and idler sprocket as an assembly Fig 108 After guid ing both secondary chains through the block and cyl inder head openings affix chains with a elastic strap or
84. ds 4 Place a suitable drain pan under crankcase drain 5 Remove drain plug from crankcase and allow oil to drain into pan Inspect drain plug threads for stretching or other damage Replace drain plug if damaged 6 Install drain plug in crankcase 7 Remove oil filter Refer to 9 ENGINE LUBRI CATION OIL FILTER REMOVAL 8 Install a new oil filter 9 Lower vehicle and fill crankcase with 5 quarts of the specified type of engine oil described in this section 10 Install oil fill cap 11 Start engine and inspect for leaks 12 Stop engine and inspect oil level USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine Refer to the WARNING at beginning of this section K OIL FILTER REMOVAL All engines are equipped with a high quality full flow disposable type oil filter DaimlerChrysler Cor poration recommends a Mopar or equivalent oil filter be used 1 Position a drain pan under the oil filter 2 Using a suitable oil filter wrench loosen filter 3 Rotate the oil filter counterclockwise Fig 73 to remove it from the cylinder block oil filter boss B 808a1b94 Fig 73 Oil Filter 3 7L Engine 1 ENGINE OIL FILTER 4 When filter separates from cylinder block oil filter boss tip gasket end upward to minimize oil spill Remove filter from vehide NOTE Make sure filter gask
85. e damage to the valve train can occur CAUTION Do not overlook the four smaller bolts at the front of the cylinder head Do not attempt to remove the cylinder head without removing these four bolts CAUTION Do not hold or pry on the camshaft tar get wheel for any reason A damaged target wheel can result in a vehicle no start condition NOTE The cylinder head is attached to the cylinder block with twelve bolts 21 Remove the cylinder head retaining bolts 22 Remove the cylinder head and gasket Discard the gasket CAUTION Do not lay the cylinder head on its gas ket sealing surface do to the design of the cylinder head gasket any distortion to the cylinder head sealing surface may prevent the gasket from prop erly sealing resulting in leaks CLEANING To ensure engine gasket sealing proper surface preparation must be performed especially with the use of aluminum engine components Fig 22 Refer to 9 ENGINE STANDARD PROCEDURE 9 32 ENGINE 3 7L CYLINDER HEAD RIGHT Continued 80b76eba Fig 22 Proper Tool Usage For Surface Preparation 1 PLASTIC WOOD SCRAPER INSPECTION 1 Inspect the cylinder head for out of flatness using a straightedge and a feeler gauge If measure ments exceed 0 0508 mm 0 002 in replace the cyl inder head 2 Inspect the valve seats for damage Service the valve seats as necessary 3 Inspect the valve guides for wear cracks or looseness If either c
86. e grades available Crankshaft JOURNAL SIZE SIZE mm in MARKING R Size 63 488 63 496 mm 2 4995 2 4998 in 63 496 63 500 mm 2 4998 2 4999 in T Size 63 500 63 504 mm 2 4999 2 501 in Bearing size and application Bearing Size Application Code Upper Bearing 2 443 2 447 Use with mm Cankshaft size R 0961 0963 in 2 439 2 443 mm c 2 435 2 439 mm 0958 0960 in Use with crankshaft S T Use with carnkshaft U Lower Bearing Main 1 and 4 2 441 2 447 mm 0961 0963 in 2 2 435 2 441 mm 0958 0962 in Use with crankshaft T U Use with carnkshaft R S K JOURNAL SIZE SIZE mm in Crankshaft MARKING Lower Main Bearing 2 and 3 a 2 429 2 435 mm 0956 0958 in 4 2 423 2 429 mm 0953 0956 in Use with crankshaft R S Use with crankshaft T U Bearing Clearances Main 1 4 Crankshaft R Crankshaft S Crankshaft eT Crankshaft MU Main 2 3 Crankshaft R Crankshaft S Crankshaft pU Crankshaft yr 004 034 mm 00015 0013 in 004 030 mm 00015 0011 in 006 032 mm 0002 0012 in 002 032 mm 00007 0012 in 016 064 mm 0 062 0025 in 016 042 mm 00062 016 in 018 044 mm 0007 0017 in 014 044 mm 0005 0017 in CRANKSHAFT OIL SEAL FRONT REMOVAL 1 Disconnect negat
87. e seal is fully seated and that the garter spring at the top of the seal is intact 3 Install the spring and the spring retainer Fig 20 4 Using the valve spring compressor compress the spring and install the two valve spring retainer hal ves 5 Release the valve spring compressor and make sure the two spring retainer halves and the spring retainer are fully seated D O I E c Fig 20 Valve Assembly Configuration VALVE LOCKS 3 BEAD RETAINER VALVE STEM OIL SEAL INTAKE VALVE EXHAUST VALVE VALVE SPRING AN GB 80b8983f O9 oV0ROWOD 6 lubricate the camshaft journal with clean engine oil then Position the camshaft with the sprocket dowel on the left camshaft at 11 o clock and the right camshaft at 12 o clock then position the camshaft bearing caps 7 Install the camshaft bearing cap retaining bolts Tighten the bolts 9 13 N m 100 in Ibs in Y turn increments in the sequence shown Fig 21 8 Position the hydraulic lash adjusters and rocker arms K ENGINE 3 7L 9 29 INTAKE EXHAUST VALVES amp SEATS Continued SUUM E A Roda carr NS 808a1e9b Fig 21 Camshaft Bearing Caps Tightening Sequence ROCKER ARM DESCRIPTION The rocker arms are steel stampings with an inte gral roller bearing The rocker arms incorporate a 2 8 mm 0 11 inch oil hole in the lash adjuster socket for roller and camshaft lubrication VALVE GUIDE SEALS DESCRIPTI
88. e tool to dean seal ing surface 3 Clean oil screen and tube thoroughly in dean solvent INSPECTION 1 Inspect oil drain plug and plug hole for stripped or damaged threads Repair as necessary 9 64 ENGINE 3 7L OIL PAN Continued 80ca56ed Fig 75 OIL PAN AND GASKET 1 OILPAN 2 WINDAGE TRAY AND INTEGRATED OIL PAN GASKET KJ 80ca56ed Fig 76 OIL PAN AND GASKET 1 OIL PAN 2 WINDAGE TRAY AND INTEGRATED OIL PAN GASKET 2 Inspect the oil pan mounting flange for bends or distortion Straighten flange if necessary INSTALLATION 1 Clean the oil pan gasket mating surface of the bedplate and oil pan 2 Inspect integrated oil pan gasket and replace as necessary 3 Position the integrated oil pan gasket windage tray assembly 4 Install the oil pickup tube 5 Install the mounting bolt and nuts Tighten nuts to 28 N m 20 ft Ibs 6 Position the oil pan and install the mounting bolts Tighten the mounting bolts to 15 N m 11 ft Ibs in the sequence shown Fig 77 7 Remove engine from engine stand 8 Install engine Refer to 9 ENGINE INSTAL LATION 80cc65e7 Fig 77 OIL PAN MOUNTING BOLT SEQUENCE K OIL PRESSURE SENSOR SWITCH DESCRIPTION The 3 wire solid state engine oil pressure sensor sending unit is located in an engine oil pressure gallery OPERATION The
89. e vehide 2 Install all bolts retaining the cover to engine DO NOT tighten the bolts at this time 3 Install the cover to transmission bolts Do NOT tighten at this time 9 56 ENGINE 3 7L STRUCTURAL COVER Continued STRUCTURAL COVER 80b897e3 Fig 65 Structural Cover 1 BOLT 2 BOLT 3 BOLT CAUTION The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence Failure to do so may cause damage to the cover 4 Starting with the two rear cover to engine bolts tighten bolts 1 Fig 66 to 54 N m 40 ft Ibs then tighten bolts 2 Fig 66 and 3 to 54 N m 40 ft lbs in the sequence shown STRUCTURAL COVER 80b897e3 KJ FRONT MOUNT REMOVAL 1 Disconnect the negative cable from the battery CAUTION Remove the fan blade fan clutch and fan shroud before raising engine Failure to do so may cause damage to the fan blade fan clutch and fan shroud 2 Remove the fan blade fan dutch and fan shroud Refer to COOLING SYSTEM for procedure 3 Remove the engine oil filter 4 Support the engine with a suitable jack and a block of wood across the full width of the engine oil pan 5 Remove the four 4 cylinder block to insulator mount bolts and the nut from the engine insulator mount through bolt 6 Using the jack raise the engine high enough to remove the engine insulator mount through bolt and
90. eeds the specification the secondary timing chains are worn and require replacement Refer to Timing Chain and Sprockets in this section for procedure SERVICE PROCEDURES TIMING VERIFICATION CAUTION The 3 7L is a non free wheeling design engine Therefore correct engine timing is critical NOTE Components referred to as left hand or right hand are as viewed from the drivers position inside the vehicle NOTE The blue link plates on the chains and the dots on the camshaft drive sprockets may not line up during the timing verification procedure The blue link plates are lined up with the sprocket dots only when re timing the complete timing drive Once the timing drive is rotated blue link to dot alignment is no longer valid Engine base timing can be verified by the following procedure 1 Remove the cylinder head covers Refer to the procedure in this section 2 Using a mirror locate the TDC arrow on the front cover Fig 91 Rotate the crankshaft until the mark on the crankshaft damper is aligned with the TDC arrow on the front cover The engine is now at TDC 3 Note the location of the V6 mark stamped into the camshaft drive gears If the V6 mark on each camshaft drive gear is at the twelve o clock position the engine is at TDC on the exhaust stroke If the V6 mark on each gear is at the six o dock position the engine is at TDC on the compression stroke Fig 95 4 If both of the camshaft drive gears are off in
91. en bolts 1 8 to 27 N m 20 ft Ibs e Tighten bolts 1A 1J to 20 N m 15 ft Ibs e Tighten bolts A E 8 Nm 6 ft lbs Turn bolts 1 8 an additional 66 Turn bolts 1D 1G and IF an additional 42 Turn bolts 1A 1B 1C 1E 1H ll and 1J an addi tional 36 e Turn bolts A E an additional 32 8 Measure crankshaft end play Refer to Crank shaft Main Bearings in this section for procedure 9 Install the connecting rods and measure side clearance Refer to Connecting Rod Bearings in this section for procedure 10 Position the oil pan gasket windage tray using a new o ring install the oil pickup tube Torque the bolt to 28N n 20 ft lbs torque the nuts to 28N m 20 ft lbs 11 Install the oil pan Torque the retaining bolts to 15 N m 11 ft lbs in the sequence shown 12 Install the engine K CRANKSHAFT Continued STUDS E DOWEL LOCATIONS e CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE MAIN BEARING FITTING SELECT FIT IDENTIFICATION The main bearings are select fit to achieve proper oil dearances For main bearing selection the crank shaft position sensor target wheel has grade identifi cation marks stamped into it Fig 44 These marks are read from left to right corresponding with jour nal number 1 2 3 4 and 5 The crankshaft position sensor target wheel is mounted to the number 8 counter weight on the crankshaft INSPECTION Wipe the inserts dean and inspect for
92. er Ring 051 094mm 0 0020 0037 in Intermediate 0 04 0 08mm Ring 0 0016 0 0031 in 019 229mm 0007 0090 in Ring Position Ring Gap Upper Ring 0 23 0 39mm 0 43mm 0 009 0 015 0 0017 in in 0 40 0 66mm 0 015 0 026 in 0 028 0 79mm 0 011 0 031 in 2bmm 0 010 in Oil Control Ring Steel Rails 0 74mm 0 029 in Intermediate Ring Oil Control Ring Steel Rail 1 55mm 0 061 in 7 The No 1 and No 2 piston rings have a differ ent cross section Ensure No 2 ring is installed with manufacturers I D mark Dot facing up towards top of the piston NOTE Piston rings are installed in the following order e Oil ring expander e Upper oil ring side rail e Lower oil ring side rail e No 2 Intermediate piston ring e No 1 Upper piston ring 8 Install the oil ring expander 9 Install upper side rail Fig 59 by placing one end between the piston ring groove and the expander ring Hold end firmly and press down the portion to be installed until side rail is in position Repeat this step for the lower side rail 10 Install No 2 intermediate piston ring using a piston ring installer Fig 60 11 Install No 1 upper piston ring using a piston ring installer Fig 60 12 Position piston ring end gaps as shown in Fig 61 It is important that expander ring gap is at least 45 from the side rail gaps but not on the pis ton pin center or on the thrust directi
93. er stuck or at maxi mum extension and still leaves lash in the system 10 Oil leak or excessive cam bore wear in cylin der head 11 Faulty lash adjuster e Check lash adjusters for sponginess while installed in cylinder head and cam on camshaft at base circle Depress part of rocker arm over adjuster Normal adjusters should feel very firm Spongy adjusters can be bottomed out easily e Remove suspected lash adjusters and replace e Before installation make sure adjusters are at least partially full of oil This can be verified by little or no plunger travel when lash adjuster is depressed DIAGNOSIS AND TESTING CYLINDER HEAD GASKET A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket 9 20 ENGINE 3 7L CYLINDER HEAD LEFT Continued Possible indications of the cylinder head gasket leaking between adjacent cylinders are e Loss of engine power e Engine misfiring e Poor fuel economy Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are e Engine overheating e Loss of coolant e Excessive steam white smoke emitting from exhaust e Coolant foaming CYLINDER TO CYLINDER LEAKAGE TEST To determine if an engine cylinder head gasket is leaking between adjacent cylinders follow the proce dures in Cylinder Compression Pressure Test Refer to 9 ENGINE DIAGNOSIS AND TESTING An engine
94. er to Specifications Section to obtain specified height and allowable tensions Replace any springs that do not meet specifications Fig 26 9209 37 Fig 26 Testing Valve Springs 1 SPECIAL TOOL C 647 INSTALLATION 1 coat the valve stem with clean engine oil and insert it into the cylinder head 2 Install the valve stem seal make sure the seal is fully seated and that the garter spring at the top of the seal is intact 3 Install the spring and the spring retainer 4 Using the valve spring compressor compress the spring and install the two valve spring retainer halves Fig 27 5 Release the valve spring compressor and make sure the two spring retainer halves and the spring retainer are fully seated W E c d Fig 27 Valve Assembly Configuration VALVE LOCKS 3 BEAD RETAINER VALVE STEM OIL SEAL INTAKE VALVE EXHAUST VALVE VALVE SPRING AN GB 80b8983f our wh 6 lubricate the camshaft journal with clean engine oil then Position the camshaft with the sprocket dowel on the left camshaft at 11 o clock and the right camshaft at 12 o clock then position the camshaft bearing caps 7 Install the camshaft bearing cap retaining bolts Tighten the bolts 9 13 N m 100 in lbs in Y turn increments in the sequence shown Fig 28 8 Position the hydraulic lash adjusters and rocker arms K ENGINE 3 7L 9 37 INTAKE EXHAUST VALVES amp SEATS Cont
95. es is the best tool for this job In addition to deglazing it will reduce taper and out of round as well as removing light scuffing scoring and scratches Usually a few strokes will clean up a bore and maintain the required lim its CAUTION DO NOT use rigid type hones to remove cylinder wall glaze 2 Deglazing of the cylinder walls may be done if the cylinder bore is straight and round Use a cylin der surfacing hone Honing Tool C 3501 equipped with 280 grit stones C 3501 3810 about 20 60 strokes depending on the bore condition will be suf ficient to provide a satisfactory surface Using honing ENGINE 3 7L 9 39 oil C 3501 3880 or a light honing oil available from major oil distributors CAUTION DO NOT use engine or transmission oil mineral spirits or kerosene 3 Honing should be done by moving the hone up and down fast enough to get a crosshatch pattern The hone marks should INTERSECT at 50 to 60 for proper seating of rings Fig 32 80861d41 Fig 32 Cylinder Bore Crosshatch Pattern 1 CROSSHATCH PATTERN 2 INTERSECT ANGLE 4 A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper cross hatch angle The number of up and down strokes per minute can be regulated to get the desired 50 to 60 angle Faster up and down strokes increase the cross hatch angle 5 After honing it is necessary that the block be cleaned to remove all traces of abrasive
96. et was removed with fil ter 5 With a wiping cloth dean the gasket sealing surface of oil and grime INSTALLATION 1 Lightly lubricate oil filter gasket with engine oil 2 Thread filter onto adapter nipple When gasket makes contact with sealing surface Fig 74 hand tighten filter one full turn do not over tighten 3 Add oil verify crankcase oil level and start engine Inspect for oil leaks ENGINE 3 7L 9 63 Fig 74 Oil Filter Sealing Surface Typical 1 SEALING SURFACE 2 RUBBER GASKET 3 OIL FILTER OIL PAN DESCRIPTION The engine oil pan is made of laminated steel and has a single plane sealing surface The sandwich style oil pan gasket has an integrated windage tray and steel carrier Fig 75 The sealing area of the gasket is molded with rubber and is designed to be reused as long as the gasket is not cut torn or ripped REMOVAL 1 Remove the engine Refer to 9 ENGINE REMOVAL 2 Position the engine in a suitable engine stand NOTE Do not pry on oil pan or oil pan gasket Gas ket is integral to engine windage tray and does not come out with oil pan Fig 76 3 Remove the oil pan mounting bolts and oil pan 4 Unbolt oil pump pickup tube and remove tube 5 Remove the oil pan gasket windage tray assemblyfrom engine CLEANING 1 Clean oil pan in solvent and wipe dry with a dean doth 2 Clean the oil pan gasket surface DO NOT use a grinder wheel or other abrasiv
97. g is placed onto the threaded rod The hard ened bearing surface of the bearing MUSTface the nut Then the hardened washer slides onto the threaded rod Fig 63 Once assembled coat the threaded rod s threads with Mopar Nickel Anti Seize or Loctite No 771 80bce9a4 Fig 63 Proper Assembly Method for Special Tool 8512 A BEARING NUT THREADED ROD BEARING HARDENED SURFACE FACING NUT HARDENED WASHER VPOmD 3 Using Special Tool 8512A press damper onto crankshaft Fig 64 4 Install then tighten crankshaft damper bolt to 175 N m 130 ft lbs 5 Install accessory drive belt Refer to 7 COOL ING ACCESSORY DRIVE DRIVE BELTS INSTAL LATION 6 Connect negative cable to battery ENGINE 3 7L 9 55 80b6b294 Fig 64 Crankshaft Damper Installation 1 SPECIAL TOOL 8512A STRUCTURAL COVER DESCRIPTION The structural dust cover is made of die cast alu minum and joins the lower half of the transmission bell housing to the engine bedplate OPERATION The structural cover provides additional power train stiffness and reduces noise and vibration REMOVAL 1 Raise vehicle on hoist 2 Remove the bolts retaining structural cover Fig 65 3 Remove the structural cover INSTALLATION CAUTION The structural cover must be installed as described in the following steps Failure to do so will cause severe damage to the cover 1 Position the structural cover in th
98. gh the throttle body tailpipe and oil filler cap opening Check for bubbles in the radiator coolant All gauge pressure indications should be equal with no more than 25 leakage FOR EXAMPLE At 552 kPa 80 psi input pres sure a minimum of 414 kPa 60 psi should be main tained in the cylinder Refer to CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART K ENGINE 3 7L Continued ENGINE 3 7L 9 9 CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION Intake valve bent burnt or not seated properly AIR ESCAPES THROUGH THROTTLE BODY AIR ESCAPES THROUGH TAILPIPE seated properly Exhaust valve bent burnt or not Inspect valve and valve seat Reface or replace as necessary Inspect valve springs Replace as necessary Inspect valve and valve seat Reface or replace as necessary Inspect valve springs Replace as necessary AIR ESCAPES THROUGH Head gasket leaking or cracked Remove cylinder head and inspect RADIATOR cylinder head or block Replace defective part MORE THAN 50 LEAKAGE FROM ADJACENT CYLINDERS MORE THAN 25 LEAKAGE AND AIR ESCAPES THROUGH OIL FILLER CAP OPENING ONLY cylinder wall STANDARD PROCEDURE STANDARD PROCEDURE ENGINE GASKET SURFACE PREPARATION To ensure engine gasket sealing proper surface preparation must be performed especially with the use of aluminum engine components and multi layer steel cylinder head gaskets Never use t
99. gnetized tar get wheel could cause a vehicle no start condition CAUTION Do not forcefully rotate the camshafts or crankshaft independently of each other Damaging intake valve to piston contact will occur Ensure negative battery cable is disconnected to guard against accidental starter engagement 13 Remove left and right camshaft sprocket bolts 14 While holding the left camshaft steel tube with Special Tool 8428 Camshaft Wrench remove the left camshaft sprocket Slowly rotate the camshaft approximately 5 degrees dockwise to a neutral posi tion 15 While holding the right camshaft steel tube with Special Tool 8428 Camshaft Wrench remove the right camshaft sprocket 16 Remove idler sprocket assembly bolt 17 Slide the idler sprocket assembly and crank sprocket forward simultaneously to remove the pri mary and secondary chains 18 Remove both pivoting tensioner arms and chain guides 19 Remove chain tensioner INSPECTION Inspect the following components e Sprockets for excessive tooth wear Some tooth markings are normal and not a cause for sprocket replacement e Idler sprocket assembly bushing and shaft for excessive wear e Idler sprocket assembly spline joint The joint should be tight with no backlash or axial movement e Chain guides and tensioner arms Replace these parts if grooving in plastic face is more than 1 mm 0 039 in deep If plastic face is severely grooved or melted the tensioner
100. he following to clean gasket surfaces e Metal scraper e Abrasive pad or paper to clean cylinder block and head e High speed power tool with an abrasive pad or a wire brush Fig 1 NOTE Multi Layer Steel MLS head gaskets require a scratch free sealing surface Only use the following for cleaning gasket surfaces e Solvent or a commercially available gasket remover e Plastic or wood scraper Fig 1 e Drill motor with 3M Roloc Bristle Disc white or yellow Fig 1 CAUTION Excessive pressure or high RPM beyond the recommended speed can damage the sealing surfaces The mild white 120 grit bristle disc is recommended If necessary the medium yellow 80 grit bristle disc may be used on cast iron surfaces with care Head gasket leaking or crack in cylinder head or block between adjacent cylinders Stuck or broken piston rings cracked piston worn rings and or Remove cylinder head and inspect Replace gasket head or block as necessary Inspect for broken rings or piston Measure ring gap and cylinder diameter taper and out of round Replace defective part as necessary 80c073f0 Fig 1 Proper Tool Usage For Surface Preparation 1 ABRASIVE PAD 2 3M ROLOC BRISTLE DISC 3 PLASTIC WOOD SCRAPER STANDARD PROCEDURE REPAIR DAMAGED OR WORN THREADS CAUTION Be sure that the tapped holes maintain the original center line Damaged or worn threads can be repaired Essen tially this
101. he top edge of the valve face lower the valve seat using a 15 degree stone If the blue is transferred to the bottom edge of the valve face raise the valve seat using a 65 degree stone 3 When the seat is properly positioned the width of the intake seat must be 1 75 2 36 mm 0 0689 0 0928 in and the exhaust seat must be 1 71 2 32 mm 0 0673 0 0911 in 4 Check the valve spring installed height after refacing the valve and seat The installed height for both intake and exhaust valve springs must not exceed 41 44 mm 1 6315 in 5 The valve seat and valve face must maintain a face angle of 44 5 45 degrees angle Fig 24 80b8983f Fig 24 Valve Assembly Configuration VALVE LOCKS 3 BEAD RETAINER VALVE STEM OIL SEAL INTAKE VALVE EXHAUST VALVE VALVE SPRING 0 R PDP REMOVAL NOTE The cylinder heads must be removed in order to perform this procedure 1 Remove rocker arms and lash adjusters Refer to procedures in this section Fig 25 N A RY X CE BALA zs 80b76fa5 Fig 25 Rocker Arm Removal 1 CAMSHAFT 2 SPECIAL TOOL 8516 2 Remove the camshaft bearing caps and the camshaft NOTE All six valve springs and valves are removed in the same manner this procedure only covers one valve and valve spring C 3422 B or C 3422 C 8519 3 Using Special Tool Valve Spring Compressor and Special tool Adapter compress the valve sp
102. icle 15 Remove the engine lift plate 16 Connect the knock sensors 17 Connect the engine to body ground straps at the left side of the cowl 18 Install the intake manifold 19 Install the engine oil dipstick tube 20 Install the power brake booster vacuum hose 21 Install the breather hoses 22 Install the PCV hose 23 Install the fuel rail 24 Install the coil over plugs 25 Connect the engine wiring harness at the fol lowing points Intake air temperature IAT sensor Fuel Injectors Throttle Position TPS Switch Idle Air Control IAC Motor Engine Oil Pressure Switch Engine Coolant Temperature ECT Sensor Manifold Absolute Pressure MAP Sensor Camshaft Position CMP Sensor Coil Over Plugs e Crankshaft Position Sensor 26 Connect lower radiator hose 27 Connect upper radiator hose 28 Connect throttle and speed control cables 29 Install the heater hose assembly 30 Install coolant recovery bottle 31 Install the power steering pump 32 Install the generator 33 Install the A C compressor 34 Install the drive belt A A m 9 12 ENGINE 3 7L ENGINE 3 7L Continued 35 Install the mechanical cooling fan 36 Install the fan shroud with the electric fan assembl y 37 Install the radiator core support bracket 38 Install the air deaner assembly 39 Refill the engine cooling system 40 Install the hood 41 Check and fill engine oil 42 Conne
103. igage measurement to verify your bearing selection prior to final assembly 10 Once you have selected the proper insert install the insert and cap Tighten the connecting rod bolts to 27 N m 20 ft Ibs plus a 90 turn Slide snug fitting feeler gauge between the con necting rod and crankshaft journal flange Fig 39 Refer to Engine Specifications for the proper clear ance Replace the connecting rod if the side clearance is not within specification CRANKSHAFT DESCRIPTION The crankshaft Fig 40 is constructed of nodular cast iron The crankshaft is a three throw split pin design with six counterweights for balancing pur poses The crankshaft is supported by four select fit main bearings with the number two serving as the thrust washer location The main journals of the crankshaft are cross drilled to improve rod bearing Fig 39 Checking Connecting Rod Side Clearance Typical lubrication The number six counterweight has provi sions for crankshaft position sensor target wheel mounting The select fit main bearing markings are located on the rear side of the target wheel The crankshaft oil seals are one piece design The front oil seal is retained in the timing chain cover and the rear seal is pressed in to a bore formed by the cylin der block and the bedplate assembly 80c411b3 Fig 40 CRANKSHAFT AND TARGET RING 1 CRANKSHAFT 2 CRANKSHAFT POSITION SENSOR TARGET RING K CRANKSHAFT Continued RE
104. in 4 Check the valve spring installed height after refacing the valve and seat The installed height for both intake and exhaust valve springs must not exceed 41 44 mm 1 6315 in 5 The valve seat and valve face must maintain a face angle of 44 5 45 degrees angle Fig 17 80b8983f Fig 17 Valve Assembly Configuration VALVE LOCKS 3 BEAD RETAINER VALVE STEM OIL SEAL INTAKE VALVE EXHAUST VALVE VALVE SPRING oo oUPODPD REMOVAL NOTE The cylinder heads must be removed in order to perform this procedure 1 Remove rocker arms and lash adjusters Refer to procedures in this section Fig 18 2 Remove the camshaft bearing caps and the camshaft DM AZ DR e za LIZA ANT RE SASS zs 80b76fa5 Fig 18 Rocker Arm Removal 1 CAMSHAFT 2 SPECIAL TOOL 8516 NOTE All six valve springs and valves are removed in the same manner this procedure only covers one valve and valve spring C 3422 B or C 3422 C 8519 3 Using Special Tool Valve Spring Compressor and Special tool Adapter compress the valve spring NOTE It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed 4 Remove the two spring retainer lock halves NOTE the valve spring is under tension use care when releasing the valve spring compressor 5 Remove the valve spring compressor 6 Remove the spring retainer and the spring
105. ing in turn increments tighten the bearing cap retaining bolts starting with the middle cap working outward Fig 14 OU ia Sara le II 808a1e9b Fig 14 Camshaft Bearing Caps Tightening Sequence ENGINE 3 7L 9 25 5 Torque the camshaft bearing cap retaining bolts to 11 N m 100 in Ibs 6 Position the camshaft drive gear into the tim ing chain aligning the V6 mark between the two marked chain links Two links marked during remov al 7 Using Special Tool 8428 Camshaft Wrench rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket Install the sprocket onto the camshaft CAUTION Remove excess oil from camshaft sprocket bolt Failure to do so can cause bolt over torque resulting in bolt failure 8 Remove excess oil from bolt then install the camshaft sprocket retaining bolt and hand tighten 9 Remove Special Tool 8379 timing chain wedge 10 Using Special Tool 6958 spanner wrench with adapter pins 8346 torque the camshaft sprocket retaining bolt to 122 N m 90 ft Ibs 11 Install the cylinder head cover CYLINDER HEAD COVER S DESCRIPTION The cylinder head covers are made of single layer stamped steel and are not interchangable from side to side Fig 15 REMOVAL 1 Disconnect negative cable from battery 2 Remove the resonator assemble and air inlet hose 3 Disconnect injector connectors and
106. inued 9 8 5 0 JU OU CU UO TOO NS 808a1e9b Fig 28 Camshaft Bearing Caps Tightening Sequence ROCKER ARM DESCRIPTION The rocker arms are steel stampings with an inte gral roller bearing The rocker arms incorporate a 2 8 mm 0 11 inch oil hole in the lash adjuster socket for roller and camshaft lubrication REMOVAL NOTE Disconnect the battery negative cable to pre vent accidental starter engagement 1 Remove the cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL 2 For rocker arm removal on cylinder 4 Rotate the crankshaft until cylinder 1 is at TDC exhaust stroke 3 For rocker arm removal on cylinder 1 Rotate the crankshaft until cylinder is at TDC compres sion stroke 4 For rocker arm removal on cylinders and 8 Rotate the crankshaft until cylinder 1 is at BDC compression stroke 5 For rocker arm removal on cylinders 5 and 6 Rotate the crankshaft until cylinder 1 is at BDC exhaust stroke 6 Using special tool 8516 Rocker Arm Remover press downward on the valve spring remove rocker arm Fig 29 DM AZ M Z ZA x D7 y AAS c ERE OY AS 80b76fa5 Fig 29 Rocker Arm Removal 1 CAMSHAFT 2 SPECIAL TOOL 8516 INSTALLATION CAUTION Make sure the rocker arms are installed with the concave pocket over the lash adjusters Failure to do so may cause severe damage to the rocker arms and or lash adjusters NO
107. is used to attach the piston to the connecting rod Fig 52 ENGINE 3 7L 9 49 80c41tac Fig 52 PISTON AND ROD ASSEMBLY Connecting Rod Piston Piston Pin Oil Slinger Slot STANDARD PROCEDURE CONNECTING ROD BEARING FITTING Inspect the connecting rod bearings for scoring and bent alignment tabs Check the bearings for normal wear patterns scoring grooving fatigue and pitting Replace any bearing that shows abnormal wear Inspect the connecting rod journals for signs of scoring nicks and burrs Misaligned or bent connecting rods can cause abnormal wear on pistons piston rings cylinder walls connecting rod bearings and crankshaft con necting rod journals If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod inspect it for correct rod alignment Replace misaligned bent or twisted con necting rods 1 Wipe the oil from the connecting rod journal 2 Lubricate the upper bearing insert and install in connecting rod 3 Use piston ring compressor and Guide Pins Special Tool 8507 to install the rod and piston assem blies The oil slinger slots in the rods must face front of the engine The F s near the piston wrist pin bore should point to the front of the engine 4 Install the lower bearing insert in the bearing cap The lower insert must be dry Place strip of Plas tigage across full width of the lower insert at the cen ter of bearing cap
108. ive cable from battery 2 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 3 Remove A C compressor mouning fasteners and set aside 4 Drain cooling system Refer to 7 COOLING STANDARD PROCEDURE 5 Remove upper radiator hose 6 Disconnect electrical connector for fan mounted inside radiator shroud 7 Remove radiator shroud attaching fasteners 8 Remove radiator cooling fan and shroud Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 9 Remove crankshaft damper bolt K ENGINE 3 7L 9 47 CRANKSHAFT OIL SEAL FRONT Continued 10 Remove damper using Special Tools 8513 Insert and 1026 Three J aw Puller Fig 45 80b6b292 Fig 45 Crankshaft Damper Removal 1 SPECIAL TOOL 8513 INSERT 2 SPECIAL TOOL 1026 11 Using Special Tool 8511 remove crankshaft front seal Fig 46 E ER Fig 46 Crankshaft Front Seal Removal 1 SPECIAL TOOL 8511 80b6b290 INSTALLATION CAUTION To prevent severe damage to the Crank shaft Damper or Special Tool 8512 thoroughly clean the damper bore and the crankshaft nose before installing Damper 1 Using Special Tool 8348 and 8512 install crankshaft front seal Fig 47 80b76fa1 Fig 47 Crankshaft Front Seal Installation 1 TIMING CHAIN COVER 2 SPECIAL TOOL 8348 3 SPECIAL TOOL 8512 2 Install vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMP
109. l onto the guide K O SS N ZOE LIA 2 Fig 49 Crankshaft Rear Oil Seal Guide Special Tool 8349 2 and Oil 1 REAR CRANKSHAFT SEAL 2 SPECIAL TOOL 8349 2 GUIDE 80b76fa9 2 Using Special Tools 8349 Crankshaft Rear Oil Seal Installer and C 4171 Driver Handle Fig 50 with a hammer tap the seal into place Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore 80b77050 Fig 50 Crankshaft Rear Oil Seal Installation 1 REAR CRANKSHAFT SEAL 2 SPECIAL TOOL 8349 1 INSTALLER 3 SPECIAL TOOL C 4171 HANDLE 3 Install the flexplate 4 Install the transmission K FLEX PLATE REMOVAL 1 Remove the transmission 2 Remove the bolts and flexplate INSTALLATION 1 Position the flexplate onto the crankshaft and install the bolts hand tight 2 Tighten the flexplate retaining bolts to 95 N m 70 ft Ibs in the sequence shown Fig 51 3 Install the transmission FRONT 80b6b397 Fig 51 Flexplate Tightening Sequence 1 FLEXPLATE PISTON amp CONNECTING ROD DESCRIPTION CAUTION Do not use a metal stamp to mark con necting rods as damage may result instead use ink or a scratch awl The pistons are made of a high strength aluminum alloy The top ring groove is coated with a anti seize coating The connecting rods are made of forged pow dered metal with a fractured cap design A full floating piston pin
110. le 3 Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil Use a black light to check for the oil leak a Circular spray pattern generally indicates seal leakage or crankshaft damage b Where leakage tends to run straight down possible causes are a porous block camshaft bore cup plugs oil galley pipe plugs oil filter runoff and main bearing cap to cylinder block mating sur faces 4 If no leaks are detected pressurize the crank case as outlined in the Inspection Engine oil Leaks in general CAUTION Do not exceed 20 6 kPa 3 psi 5 If the leak is not detected very slowly turn the crankshaft and watch for leakage If a leak is detected between the crankshaft and seal while slowly turning the crankshaft it is possible the crankshaft seal surface is damaged The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth CAUTION Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches The crankshaft seal flange is especially machined to complement the function of the rear oil seal 6 For bubbles that remain steady with shaft rotation no further inspection can be done until dis assembled DIAGNOSIS AND TESTING ENGINE OIL PRESSURE 1 Remove oil pressure sending unit Fig 70 and install gauge assembly C 3292 2 Run engine until thermostat opens 3 Oil Pressure e Curb
111. lts must be examined BEFORE reuse If the threads are necked down the bolts should be replaced The M8 head bolts should not be reused Use new M8 bolts Necking can be checked by holding a straight edge against the threads If all the threads do not contact the scale the bolt should be replaced Fig 9 CAUTION When cleaning cylinder head and cylin der block surfaces DO NOT use a metal scraper because the surfaces could be cut or ground Use only a wooden or plastic scraper 1 Clean the cylinder head and cylinder block mating surfaces Fig 10 KJ 80b76eba Fig 8 Proper Tool Usage For Surface Preparation 1 PLASTIC WOOD SCRAPER 9009 38 Fig 9 Checking Cylinder Head Bolts for Stretching Necking 1 STRETCHED BOLT 2 THREADS ARE NOT STRAIGHT ON LINE 3 THREADS ARE STRAIGHT ON LINE 4 UNSTRETCHED BOLT 2 Position the new cylinder head gasket on the locating dowels CAUTION When installing cylinder head use care not damage the tensioner arm or the guide arm 3 Position the cylinder head onto the cylinder block Make sure the cylinder head seats fully over the locating dowels NOTE The four smaller cylinder head mouniing bolts require sealant to be added to them before installing Failure to do so may cause leaks K CYLINDER HEAD LEFT Continued 80b76eba Fig 10 Proper Tool Usage For Surface Preparation 1 PLASTIC WOOD SCRAPER 4 Lubricate the cylinder
112. lube jet may be clogged The tensioner should be replaced e Secondary chain tensioner piston and ratcheting device Inspect for evidence of heavy contact between tensioner piston and tensioner arm If this condition exist the tensioner tensioner arm and chain should be replaced e Primary chain tensioner plastic faces Replace as required 9 80 ENGINE 3 7L K TIMING BELT CHAIN AND SPROCKET S Continued INSTALLATION 1 Using a vise lightly compress the secondary chain tensioner piston until the piston step is flush with the tensioner body Using a pin or suitable tool release ratchet pawl by pulling pawl back against spring force through access hole on side of tensioner While continuing to hold pawl back Push ratchet device to approximately 2 mm from the tensioner body Install Special Tool 8514 lock pin into hole on front of tensioner Fig 107 Slowly open vise to transfer piston spring force to lock pin YD ras 1 w zz T Ui a Loy 80677052 Fig 107 Resetting Secondary Chain Tensioners VISE INSERT LOCK PIN RATCHET PAWL RATCHET PISTON TARO NP 2 Position primary chain tensioner over oil pump and insert bolts into lower two holes on tensioner bracket Tighten bolts to 28 N m 250 in Ibs 3 Install right side chain tensioner arm Apply Mopar Lock N Seal to torx bolt tighten bolt to 28 N m 250 in lbs CAUTION The silver bolts retain the guides to the cylin
113. nd play be checked Fig 112 The end play must be within 0 10 0 25 mm 0 004 0 010 in If not within specification the idler gear must be replaced 21 Install timing chain cover and crankshaft damper Refer to procedures 22 Install cylinder head covers Refer to proce dures NOTE Before installing threaded plug in right cylin der head the plug must be coated with sealant to prevent leaks 80b897e1 Fig 112 Measuring Idler Gear End Play 1 IDLER SPROCKET ASSEMBLY 2 DIAL INDICATOR 23 Coat the large threaded access plug with Mopar Thread Sealant with Teflon then install into the right cylinder head and tighten to 81 Nm 60 ft Ibs 24 Install the oil fill housing 25 Install access plug in left cylinder head 26 Install power steering pump 27 Fill cooling system 28 Connect negative cable to battery
114. ng sur faces Inspect and replace gasket as necessary 2 Tighten cylinder head cover bolts and double ended studs to 12 N m 105 in lbs 3 Install right rear breather tube and filter assembly 4 Connect injector ignition coil electrical connec tors and harness retaining clips 5 Install the oil fill tube 6 Install PCV hose 7 Install heater hoses 8 Install air conditioning compressor retaining bolts 9 Install accessory drive belt 10 Fill Cooling system 11 Install air cleaner assembly resonator assem bly and air inlet hose 12 Connect battery negative cable INTAKE EXHAUST VALVES amp SEATS STANDARD PROCEDURE REFACING NOTE Valve seats that are worn or burned can be reworked provided that correct angle and seat width are maintained Otherwise the cylinder head must be replaced K ENGINE 3 7L 9 35 INTAKE EXHAUST VALVES amp SEATS Continued NOTE When refacing valves and valve seats it is important that the correct size valve guide pilot be used for reseating stones A true and complete sur face must be obtained 1 Using a suitable dial indicator measure the center of the valve seat Total run out must not exceed 0 051 mm 0 002 in 2 Apply a small amount of Prussian blue to the valve seat insert the valve into the cylinder head while applying light pressure on the valve rotate the valve Remove the valve and examine the valve face If the blue is transferred below t
115. nt into housing 2 Position housing cover into housing locating tabs 3 Pry up spring dips and lock cover to housing If any air filter air resonator air intake tubes or air filter housing clamps had been loosened or removed tighten them to 5 N m 40 in lbs torque ENGINE 3 7L 9 19 CYLINDER HEAD LEFT DESCRIPTION VALVE GUIDES The valve guides are made of powered metal and are pressed into the cylinder head The guides are not replaceable or serviceable and valve guide ream ing is not recommended If the guides are worn beyond acceptable limits replace the cylinder heads DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING HYDRAULIC LASH ADJUSTER A tappet like noise may be produced from several items Check the following items 1 Engine oil level too high or too low This may cause aerated oil to enter the adjusters and cause them to be spongy 2 Insufficient running time after rebuilding cylin der head Low speed running up to 1 hour may be required 3 Turn engine off and let set for a few minutes before restarting Repeat this several times after engine has reached normal operating temperature 4 Low oil pressure 5 Theoil restrictor in cylinder head gasket or the oil passage to the cylinder head is plugged with debris 6 Air ingested into oil due to broken or cracked oil pump pick up 7 Worn valve guides 8 Rocker arm ears contacting valve spring retainer 9 Rocker arm loose adjust
116. o reset the tensioner ratchet 1 Remove cylinder head cover Refer to CYLIN DER HEAD COVER in this section 2 Set engine to TDC cylinder 1 camshaft sprocket V6 marks at the 12 o clock position 3 Mark one link on the secondary timing chain on both sides of the V6 mark on the camshaft sprocket to aid in installation CAUTION Do not hold or pry on the camshatt tar get wheel Located on the right side camshaft sprocket for any reason Severe damage will occur to the target wheel resulting in a vehicle no start condition 4 Loosen but DO NOT remove the camshaft sprocket retaining bolt Leave the bolt snug against the sprocket NOTE The timing chain tensioners must be secured prior to removing the camshaft sprockets Failure to secure tensioners will allow the tension ers to extend requiring timing chain cover removal in order to reset tensioners CAUTION Do not force wedge past the narrowest point between the chain strands Damage to the tensioners may occur 5 Position Special Tool 8379 timing chain wedge between the timing chain strands tap the tool to securely wedge the timing chain against the ten sioner arm and guide Fig 12 6 Hold the camshaft with Special Tool 8428 Cam shaft Wrench while removing the camshaft sprocket bolt and sprocket Fig 13 7 Using Special Tool 8428 Camshaft Wrench gently allow the camshaft to rotate 5 clockwise until the camshaft is in the neutral position no valve
117. on 9 54 ENGINE 3 7L PISTON RINGS Continued 5 RRO9B48 80268450 Fig 59 Side Rail Installation Fig 61 Piston Ring End Gap Position 1 SIDE RAIL END SIDE RAIL UPPER NO 1 RING GAP PISTON PIN SIDE RAIL LOWER NO 2 RING GAP AND SPACER EXPANDER GAP cO WD Fig 60 Upper and Intermediate Rings Installation VIBRATION DAMPER REMOVAL 1 Disconnect negative cable from battery 2 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 80b6b292 NOTE Transmission cooler line snaps into shroud Fig 62 Crankshaft Damper Removal lower right hand corner 1 SPECIAL TOOL 8513 INSERT 2 SPECIAL TOOL 1026 3 Remove crankshaft damper bolt 4 Remove damper using Special Tools 8513 Insert and 1026 Three J aw Puller Fig 62 K VIBRATION DAMPER Continued INSTALLATION CAUTION To prevent severe damage to the Crank shaft Damper or Special Tool 8512 thoroughly clean the damper bore and the crankshaft nose before installing Damper 1 Align crankshaft damper slot with key in crankshaft Slide damper onto crankshaft slightly CAUTION Special Tool 8512A is assembled in a specific sequence Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft 2 Assemble Special Tool 8512 A as follows The nut is threaded onto the shaft first Then the roller bearin
118. ondition exist replace the cylin der head INSTALLATION NOTE The cylinder head bolts are tightened using a torque plus angle procedure The bolts must be examined BEFORE reuse If the threads are necked down the bolts should be replaced Necking can be checked by holding a straight edge against the threads If all the threads do not contact the scale the bolt should be replaced CAUTION When cleaning cylinder head and cylin der block surfaces DO NOT use a metal scraper because the surfaces could be cut or ground Use only a wooden or plastic scraper 1 Clean the cylinder head and cylinder block mating surfaces 2 Position the new cylinder head gasket on the locating dowels K CAUTION When installing cylinder head use care not damage the tensioner arm or the guide arm 3 Position the cylinder head onto the cylinder block Make sure the cylinder head seats fully over the locating dowels NOTE The four M8 cylinder head mounting bolts require sealant to be added to them before install ing Failure to do so may cause leaks Do not reuse the old M8 bolts use new M8 bolts 4 Lubricate the cylinder head bolt threads with clean engine oil and install the eight M10 bolts 5 Coat the four M8 cylinder head bolts with Mopar Lock and Seal Adhesive then install the bolts The cylinder head bolts are tightened using an angle torque procedure however the bolts are not a torque to yield design 6 Tighten the
119. ontinued 19 Install oil fill housing onto cylinder head 20 Refill the cooling system 21 Raise the vehicle 22 Install the exhaust pipe onto the right exhaust manifold 23 Lower the vehicle 24 Reconnect battery negitive cable 25 Start the engine and check for leaks CAMSHAFT S DESCRIPTION The camshafts consist of powdered metal steel lobes which are sinter bonded to a steel tube Four bearing journals are machined into the camshaft Camshaft end play is controlled by two thrust walls that border the nose piece journal Engine oil enters the hollow camshafts at the third journal and lubri cates every intake lobe rocker through a drilled pas sage in the intake lobe REMOVAL CAUTION When the timing chain is removed and the cylinder heads are still installed DO NOT force fully rotate the camshafts or crankshaft indepen dently of each other Severe valve and or piston damage can occur CAUTION When removing the cam sprocket timing chains or camshaft Failure to use special tool 8379 will result in hydraulic tensioner ratchet over exten sion Requiring timing chain cover removal to re set the tensioner ratchet 1 Remove the cylinder head cover Refer to CYL INDER HEAD COVER in this section 2 Set engine to TDC cylinder 1 camshaft sprocket V6 marks at the 12 o clock position 3 Mark one link on the secondary timing chain on both sides of the V6 mark on the camshaft sprocket to aid in install
120. ournal is on the center of cylinder bore Insert rod and pis 9 52 ENGINE 3 7L PISTON amp CONNECTING ROD Continued A i z ZSR SUB gt s Re 80677088 Fig 55 Piston and Connecting Rod Installation Typical 1 F TOWARD FRONT OF ENGINE 2 OIL SLINGER SLOT 3 RING COMPRESSOR 4 SPECIAL TOOL 8507 ton into cylinder bore and carefully position connect ing rod guides over crankshaft journal 9 Tap piston down in cylinder bore using a ham mer handle While at the same time guide connect ing rod into position on rod journal CAUTION Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused Always replace the Rod Bolts whenever they are loosened or removed 10 Lubricate rod bolts and bearing surfaces with engine oil Install connecting rod cap and bearing Tighten bolts to 27 N m 20 ft Ibs plus 90 11 Install the following components e Cylinder head s Refer to 9 ENGINE CYLIN DER HEAD INSTALLATION e Timing chain and cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION KJ RIGHT FRONT VIEW LEFT SIDE OF OF ENGINE SIDE OF ENGINE ENGINE 808a1f06 Fig 56 Piston and Connecting Rod Orientation 1 MAJOR THRUST SIDE OF PISTON 2 OIL SLINGER SLOT e Cylinder head covers Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION e Oil pan and gasket windage tr
121. r shaft coat the threads and the pilot on the idler shaft with clean engine oil 3 Using the primary idler sprocket retaining bolt and washer carefully draw the idler shaft into the bore until fully seated 4 Coat the idler shaft with clean engine oil 5 Install the timing chains and sprockets Refer to procedure in this section ENGINE 3 7L 9 77 TIMING BELT CHAIN AND SPROCKET S REMOVAL 1 Disconnect negative cable from battery 2 Drain cooling system Refer to COOLING SYS TEM for procedures 3 Remove right and left cylinder head covers Refer to CYLINDER HEAD COVER 4 Remove radiator fan shroud Refer to COOL ING SYSTEM for procedure 5 Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover Fig 103 1 cylinder exhaust stroke and the cam shaft sprocket V6 marks are at the 12 o clock posi tion Fig 102 CAUTION The nut on the right side camshaft sprocket should not be removed for any reason as the sprocket and camshaft sensor target wheel is serviced as an assembly If the nut was removed retorque nut to 5 N m 44 in Ibs 6 Remove power steering pump Refer to STEER ING for procedure 7 Remove access plug from left and right cylinder heads for access to chain guide fasteners Fig 104 8 Remove the oil fill housing to gain access to the right side tensioner arm fastener 9 Remove crankshaft damper and timing chain cover Refer to
122. ring NOTE It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed 4 Remove the two spring retainer lock halves NOTE the valve spring is under tension use care when releasing the valve spring compressor 5 Remove the valve spring compressor 6 Remove the spring retainer and the spring 9 36 ENGINE 3 7L K INTAKE EXHAUST VALVES amp SEATS Continued NOTE Check for sharp edges on the keeper grooves Remove any burrs from the valve stem before removing the valve from the cylinder head 7 Remove the valve from the cylinder head NOTE The valve stem seals are common between intake and exhaust 8 Remove the valve stem seal Mark the valve for proper installation TESTING VALVE SPRINGS NOTE Whenever the valves are removed from the cylinder head it is recommended that the valve springs be inspected and tested for reuse Inspect the valve springs for physical signs of wear or damage Turn table of tool C 647 until surface is in line with the 40 69 mm 1 602 in mark on the threaded stud and the zero mark on the front Place spring over the stud on the table and lift compress ing lever to set tone device Pull on torque wrench until Ping is heard Take reading on torque wrench at this instant Multiply this reading by two This will give the spring load at test length Fractional measurements are indicated on the table for finer adjustments Ref
123. ry chain guide Refer to Timing Chain and Sprockets 20 Remove the retaining bolt and the camshaft drive gear CAUTION Do not allow the engine to rotate Severe damage to the valve train can occur CAUTION Do not overlook the four smaller bolts at the front of the cylinder head Do not attempt to remove the cylinder head without removing these four bolts NOTE The cylinder head is attached to the cylinder block with twelve bolts Zr LIH LIT 80c4f3e7 Fig 6 Using Special Tool 8429 1 SPECIAL TOOL 8429 2 CAMSHAFT CHAIN 3 CRANKSHAFT TIMING GEAR 9 22 ENGINE 3 7L CYLINDER HEAD LEFT Continued 2 80b897e2 Fig 7 Cylinder Head Access Plugs 1 RIGHT CYLINDER HEAD ACCESS PLUG 2 LEFT CYLINDER HEAD ACCESS PLUG 21 Remove the cylinder head retaining bolts 22 Remove the cylinder head and gasket Discard the gasket CAUTION Do not lay the cylinder head on its gas ket sealing surface due to the design of the cylin der head gasket any distortion to the cylinder head sealing surface may prevent the gasket from prop erly sealing resulting in leaks CLEANING To ensure engine gasket sealing proper surface preparation must be performed especially with the use of aluminum engine components Fig 8 Refer to 9 ENGINE STANDARD PROCEDURE INSTALLATION NOTE The cylinder head bolts are tightened using a torque plus angle procedure The bo
124. ssion AUTOMATIC TRANSMISSION e Remove the support cushion bolts and remove the cushion and the support bracket from the trans mission 4WD or from the adaptor bracket 2WD e On 2WD vehicles remove the bolts holding the transmission support adaptor bracket to the trans mission Remove the adaptor bracket INSTALLATION MANUAL TRANSMISSION 1 Install the transmission support bracket to the transmission Install the bolts and tighten to 46 Nm 34 ft Ibs torque 2 Install the support cushion to the support bracket Install the nuts and tighten to 75 N m 55 ft lbs torque 3 Position the crossmember onto the support cushion studs Install the stud nuts and tighten to 22 N m 192 in lbs torque 4 Install crossmember to sill bolts and tighten to 41 N m 30 ft Ibs torque 5 Remove the transmission support 6 Lower the vehicle 7 Connect negative cable to battery AUTOMATIC TRANSMISSION 1 On 2WD vehicles position the transmission support adaptor bracket to the transmission Install the bolts and tighten to 75 N m 55 ft Ibs torque 2 Position the transmission support bracket and support cushion to the adaptor bracket 2WD or the transmission 4WD Install the bolts and tighten to 75 N m 55 ft Ibs torque 3 Position the crossmember onto the support cushion studs Install the stud nuts and tighten to 22 N m 192 in lbs torque 4 Install crossmember to sill bolts and tighten to 41
125. the same or opposite directions the primary chain or both secondary chains are at fault Refer to Timing Chain and Sprockets procedure in this section 5 If only one of the camshaft drive gears is off and the other is correct the problem is confined to one secondary chain Refer to Single camshaft tim ing in this procedure K 2 Fig 91 Engine Top Dead Center TDC Indicator Mark 1 TIMING CHAIN COVER 2 CRANKSHAFT TIMING MARKS 80b76f65 6 If both camshaft drive gear V6 marks are at the twelve o clock or the six o dock position the engine base timing is correct Reinstall the cylinder head covers COUNTER BALANCE SHAFT TIMING 1 Ensure that the engine is at TDC with both camshaft sprocket marks are in the 12 o clock posi tion Fig 94 2 Look down the left cylinder gear chain cavity The timing dot on the counter balance shaft drive gear should be in the 6 o dock position Fig 92 TIMING SINGLE CAMSHAFT NOTE to adjust the timing on one camshaft pre form the following procedure 1 Using Chain Tensioner Wedge Special Tool 8379 stabilize the secondary chain drive For refer ence purposes mark the chain to sprocket position Fig 93 2 Remove the camshaft drive gear retaining bolt 3 Carefully remove the camshaft drive gear from the camshaft 4 Reindex the camshaft drive gear in the chain until the V6 mark is at the same position as the V6 mark on the opposite camshaft drive ge
126. ttom of Retainer Nominal Intake Exhaust 361 0 399 0 N 40 12 mm 81 15 89 70 Ibs 1 5795 in 984 0 1076 0 N O 28 12 mm 221 2 241 9 lbs O 1 107 in 4 77 x 3 80mm 0 1878 0 1496 in 41 11 mm 1 619 in 41 13 mm 1 619 in Gasket Thickness Clearance 0 018 0 069 mm 0 0008 0 0028 in 0 047 0 098 mm Intake Exhaust Max Allowable Stem to Guide Clearance Rocking Method Intake Exhaust 0 0019 0 0039 in 0 069 mm 0 0028 in 0 098 mm 0 0039 in Valve Seat Width Intake Exhaust Guide Bore Diameter Std 1 75 2 36 mm 0 0698 0 0928 in 1 71 232 mm 0 0673 0 0911 in 6 975 7 00 mm 0 2747 0 2756 in kj ENGINE 3 71 9 15 ENGINE 3 7L Continued Cylinder Head Warpage M Flatness 0 0508 mm 0 002 in OIL PUMP Clearance Over 0 035 0 095 mm lt gt Rotors End Face MAX O 0 0014 0 0038 in Cover Out of Flat 0 025 mm 0 001 in MAX Inner and Outer Rotor Thickness Adapter Pins 8346 MAX Outer Rotor Diameter MIN Tip Clearance Between Rotors MAX 0 150 mm 0 006 in OIL PRESSURE A ra 23 kPa psi Front Crankshaft Seal Remover 8511 3000 rpm 170 758 kPa 25 110 psi CAUTION If pressure is zero at curb idle DO NOT run engine at 3000 rpm SPECIAL TOOLS 3 7L ENGINE Front Crankshaft Seal Installer 8348 Spanner Wrench 6958 Handle C 4171 9 16 ENGINE 3 7L
127. un clip the injector harness 4 Route injector harness in front of cylinder head cover 5 Disconnect the left side breather tube and remove the breather tube 6 Remove the cylinder head cover mounting bolts Fig 16 7 Remove cylinder head cover and gasket NOTE The gasket may be used again providing no cuts tears or deformation has occurred 9 26 ENGINE 3 7L CYLINDER HEAD COVER S Continued 3NION3 30 LNOHJ 80ca556d Fig 15 CYLINDER HEAD COVERS 1 LEFT SIDE CYLINDER HEAD COVER 2 RIGHT SIDE CYLINDER HEAD COVER INSTALLATION CAUTION Do not use harsh cleaners to clean the cylinder head covers Severe damage to covers may occur NOTE The gasket may be used again provided no cuts tears or deformation has occurred 1 Clean cylinder head cover and both sealing sur faces Inspect and replace gasket as necessary 2 Tighten cylinder head cover bolts and double ended studs to 12 N m 105 in Ibs 3 Install left side breather and connect breather tube 4 Connect injector electrical connectors and injec tor harness retaining clips 5 Install the resonator and air inlet hose 6 Connect negative cable to battery KJ M 80cb41a5 Fig 16 CYLINDER HEAD COVER TYPICAL 1 SCREWS 2 CYLINDER HEAD COVER INTAKE EXHAUST VALVES amp SEATS DESCRIPT
128. urement near the middle of the bore then repeat the measurement near the bottom of the bore 4 Determine taper by subtracting the smaller diameter from the larger diameter 5 Rotate measuring device 90 and repeat steps above KJ 6 Determine out of roundness by comparing the difference between each measurement 7 If cylinder bore taper does not exceed 0 025 mm 0 001 inch and out of roundness does not exceed 0 025 mm 0 001 inch the cylinder bore can be honed If the cylinder bore taper or out of round condition exceeds these maximum limits the cylinder block must be replaced A slight amount of taper always exists in the cylinder bore after the engine has been in use for a period of time CONNECTING ROD BEARINGS STANDARD PROCEDURE CONNECTING ROD BEARING FITTING Inspect the connecting rod bearings for scoring and bent alignment tabs Fig 34 Fig 35 Check the bearings for normal wear patterns scoring grooving fatigue and pitting Fig 36 Replace any bearing that shows abnormal wear Inspect the connecting rod journals for signs of scoring nicks and burrs HEAVIER WEAR PATTERN ON LOWER INSERT 8086fd05 Fig 34 Connecting Rod Bearing Inspection 1 UPPER BEARING HALF 2 MATING EDGES 3 GROOVES CAUSED BY ROD BOLTS SCRATCHING JOURNAL DURING INSTALLATION 4 WEAR PATTERN ALWAYS GREATER ON UPPER BEARING 5 LOWER BEARING HALF K CONNECTING ROD BEARINGS Continued D J890
129. ve the intake manifold Refer to proce dure in this section 7 Remove the cylinder head cover Refer to proce dure in this section 8 Remove the fan shroud and fan blade assembly Refer to COOLING SYSTEM 9 Remove accessory drive belt Refer to COOL ING SYSTEM 10 Remove the power steering pump and set aside 11 Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark Fig 4 2 Fig 4 Engine Top Dead Center 1 TIMING CHAIN COVER 2 CRANKSHAFT TIMING MARKS 80b76f65 12 Verify the V6 mark on the camshaft sprocket is at the 12 o dock position Fig 5 Rotate the crank shaft one turn if necessary 13 Remove the crankshaft damper Refer to Pro cedure 14 Remove the timing chain cover Refer to pro cedure K CYLINDER HEAD LEFT Continued ENGINE 3 7L 9 21 80ca8813 Fig 5 Camshaft Sprocket V6 Marks 1 LEFT CYLINDER HEAD 2 RIGHT CYLINDER HEAD 15 Lock the secondary timing chains to the idler sprocket using Special Tool 8429 Timing Chain Hold ing Fixture Fig 6 NOTE Mark the secondary timing chain prior to removal to aid in installation 16 Mark the secondary timing chain one link on each side of the V6 mark on the camshaft drive gear 17 Remove the left side secondary chain ten sioner Refer to Timing Chain and Sprockets 18 Remove the cylinder head access plug Fig 7 19 Remove the left side seconda

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