engine - DodgeIntrepid.Net
ENGINE
LH
9-1
ENGINE
TABLE OF CONTENTS
page
page
2.7L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.2/3.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.7L ENGINE
TABLE OF CONTENTS
page
DESCRIPTION AND OPERATION
2.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . 3
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PISTONS AND CONNECTING RODS . . . . . . . . . . . 5
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . 5
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TIMING DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . 6
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 9
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 9
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS—INTRODUCTION. . . . . . . . 13
ENGINE DIAGNOSIS—PERFORMANCE . . . . . . . 13
ENGINE DIAGNOSIS—MECHANICAL . . . . . . . . . 15
CHECKING ENGINE OIL PRESSURE. . . . . . . . . . 16
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 16
CYLINDER COMPRESSION PRESSURE TEST . . 17
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 17
CYLINDER HEAD GASKET FAILURE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LASH ADJUSTER (TAPPET) NOISE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . . 19
SERVICE PROCEDURES
ENGINE OIL LEVEL—CHECKING . . . . . . . . . . . . 20
ENGINE OIL SERVICE . . . . . . . . . . . . . . . . . . . . . 20
FORM-IN-PLACE GASKETS & SEALERS . . . . . . . 21
ENGINE GASKET SURFACE PREPARATION . . . . 22
REPAIR OF DAMAGED OR WORN THREADS . . . 22
CYLINDER BORE—HONING . . . . . . . . . . . . . . . . 23
HYDROSTATIC LOCKED ENGINE . . . . . . . . . . . . 23
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
page
PISTON RING—FITTING . . . . . . . . . . . . . . . . . .
CONNECTING ROD BEARING—
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT MAIN BEARING—FITTING . . . . .
CRANKSHAFT END PLAY—CHECKING . . . . . . .
VALVE AND VALVE SEAT—REFACING . . . . . . .
ENGINE TIMING—VERIFICATION . . . . . . . . . . .
INTAKE MANIFOLD VACUUM PORT REPAIR—
2.7L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
ENGINE MOUNTS—LEFT AND RIGHT. . . . . . . .
ENGINE MOUNT—REAR . . . . . . . . . . . . . . . . . .
STRUCTURAL COLLAR . . . . . . . . . . . . . . . . . . .
ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT DAMPER . . . . . . . . . . . . . . . . . .
INTAKE MANIFOLD—UPPER . . . . . . . . . . . . . . .
INTAKE MANIFOLD—LOWER . . . . . . . . . . . . . .
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVERS . . . . . . . . . . . . . . . .
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC LASH ADJUSTER . . . . . . . . . . . . .
VALVE STEM SEALS OR VALVE SPRINGS—IN
VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . .
VALVE AND VALVE SPRINGS . . . . . . . . . . . . . .
TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . .
TIMING CHAIN AND SPROCKETS . . . . . . . . . . .
CRANKSHAFT SPROCKET . . . . . . . . . . . . . . . .
CRANKSHAFT OIL SEAL—FRONT. . . . . . . . . . .
CRANKSHAFT OIL SEAL—REAR. . . . . . . . . . . .
CRANKSHAFT OIL SEAL RETAINER—REAR . . .
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON AND CONNECTING ROD . . . . . . . . . . .
. 24
. 25
. 26
. 27
. 27
. 29
. 30
. 31
. 31
. 32
. 32
. 35
. 36
. 37
. 38
. 39
. 40
. 41
. 42
. 42
. 43
. 44
. 45
. 46
. 51
. 52
. 52
. 53
. 54
. 55
. 57
. 57
. 58
9-2
2.7L ENGINE
ENGINE CORE AND OIL PLUGS
DISASSEMBLY AND ASSEMBLY
OIL PUMP . . . . . . . . . . . . . . . . .
CLEANING AND INSPECTION
INTAKE MANIFOLD . . . . . . . . . .
EXHAUST MANIFOLD . . . . . . . .
CAMSHAFT . . . . . . . . . . . . . . . .
CYLINDER HEAD. . . . . . . . . . . .
CAMSHAFT FOLLOWER . . . . . .
VALVE INSPECTION . . . . . . . . .
LH
. . . . . . . . . . . . . 61
. . . . . . . . . . . . . 62
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. 63
. 63
. 63
. 63
. 63
. 63
OIL PUMP . . . . . . . . . . . . . . . . . . . . .
CYLINDER BLOCK AND BORE . . . . .
ENGINE HYDRO-MOUNT ISOLATOR .
TIMING DRIVE SYSTEM . . . . . . . . . .
SPECIFICATIONS
2.7L ENGINE . . . . . . . . . . . . . . . . . . .
TORQUE . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS
2.7L ENGINE . . . . . . . . . . . . . . . . . . .
DESCRIPTION AND OPERATION
2.7L ENGINE
Fig. 1 2.7 Liter Engine
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. 64
. 66
. 66
. 66
. . . . . . . . . 67
. . . . . . . . . 69
. . . . . . . . . 70
2.7L ENGINE
LH
9-3
DESCRIPTION AND OPERATION (Continued)
DESCRIPTION
The 2.7 Liter (167 Cubic Inches) 60 degree V-6
engine is a double overhead camshaft design with
hydraulic lifters and four valves per cylinder (Fig. 1).
The engine does not have provisions for a free wheeling valve train.
The cylinders are numbered from front to rear, with
the right bank odd numbered, and the left bank even
numbered (Fig. 2). The firing order is 1–2–3–4–5–6.
The engine identification number is located on the
rear of the cylinder block just below the left cylinder
head (Fig. 3).
X
X
MODEL MANUFACTURING
YEAR
PLANT
LAST
DIGIT
OF
MODEL
YEAR
KENOSHA 9
XXXXX
XXXX
COMPONENT MONTH/
CODE/
DAY
USAGE
XXXXX
SERIAL
CODE
ENGINE 2.7L
USAGE
PASS CAR
PC
Fig. 3 Engine Identification
Fig. 2 Cylinder Numbering and Firing Order
CYLINDER BLOCK
DESCRIPTION
The cylinder block is made of heat treated aluminum with cast-in-place iron liners (Fig. 4). The block
is a closed deck design with the right bank forward.
To provide high rigidity and improved NVH, the
block has cast-in contours and ribs, along with powdered metal 6 bolt main caps (4 vertical, 2 horizontal), with a die cast aluminum structural beam
windage tray mounted to the main caps.
The block design allows coolant flow between the
cylinder bores and an internal coolant by-pass to the
thermostat.
9-4
2.7L ENGINE
LH
DESCRIPTION AND OPERATION (Continued)
Fig. 4 Cylinder Block and Crankshaft
1
2
3
4
–
–
–
–
MAIN
MAIN
MAIN
MAIN
CAP BOLT—VERTICAL
CAP
BEARING—LOWER
BEARING—UPPER
5 – MAIN CAP BOLT—HORIZONTAL
6 – CYLINDER BLOCK
7 – CRANKSHAFT
2.7L ENGINE
LH
9-5
DESCRIPTION AND OPERATION (Continued)
CRANKSHAFT
DESCRIPTION
The crankshaft is constructed of a forged micro
alloy steel. The six throw, nine counterweight crankshaft is supported by four select fit main bearings
with the number three serving as the thrust washer
location (Fig. 4). The select fit identification markings will be on the rear side of the number nine
(rearmost) counterweight. The six separate connecting rod throws are an even-firing design which
reduces torque fluctuations while a vibration damper
is used to control torsional vibration.
The crankshaft oil seals are a one piece design.
The front seal is retained by the timing chain cover,
and the rear seal in a housing that attaches to the
cylinder block.
OPERATION
The crankshaft transfers force generated by combustion within the cylinder to the flywheel or flexplate.
PISTONS AND CONNECTING RODS
DESCRIPTION
The pistons are made of a high strength aluminum
alloy with an anodized top ring groove and crown.
Piston skirts are coated with a solid lubricant for
scuff resistance. The connecting rods are made of
powdered metal with a “fractured cap” design. The
connecting rod attaches to the piston with a full
floating pin retained by lock rings. The piston and
connecting rod are serviced as an assembly (Fig. 5).
Fig. 5 Piston and Connecting Rod
1
2
3
4
–
–
–
–
“F” TOWARD FRONT OF ENGINE
RING COMPRESSOR
SPECIAL TOOL 8189
OIL SQUIRT HOLE
OPERATION
The piston and connecting rod is the link between
the combustion force to the crankshaft.
CYLINDER HEAD
DESCRIPTION
The cylinder heads are made of an aluminum alloy
(Fig. 6). The cylinder head features four valves per
cylinder with pressed in powdered metal valve
guides. The cylinder heads provide enclosures for the
timing chain drive, necessitating a unique right and
left cylinder head.
VALVES
DESCRIPTION
The valves are made of heat resistant steel, and
have chrome plated stems to prevent scuffing (Fig.
6). The four valves per cylinder (two intake and two
exhaust) are actuated by roller rocker arms, which
pivot on stationary lash adjusters. All valves use
three bead lock keepers to retain springs and to promote valve rotation.
OPERATION
The intake valve allows the air/fuel mixture to
enter the combustion chamber. The exhaust valve
allows the burned air/fuel mixture to exit the combustion chamber. Also, the intake and exhaust valves
seal the combustion chamber during the compression
and power strokes.
9-6
2.7L ENGINE
LH
DESCRIPTION AND OPERATION (Continued)
Fig. 6 Cylinder Head, Valves, and Springs
1
2
3
4
5
6
–
–
–
–
–
–
VALVE KEEPER
SPRING RETAINER
VALVE KEEPER
VALVE SPRING-EXHAUST
SPRING RETAINER
VALVE STEM SEAL
VALVE SPRINGS
DESCRIPTION
The valve springs are made from high strength,
chrome-silicon steel (Fig. 6). The springs are common
for intake and exhaust applications. The valve spring
seat is integral with the valve stem seal, which incorporates a garter spring to maintain consistent lubrication control to the valve stem.
OPERATION
The valve spring returns the valve against its seat
for a positive seal of the combustion chamber.
TIMING DRIVE SYSTEM
DESCRIPTION
The timing drive system has been designed to provide quiet performance and reliability to support a
NON free-wheeling engine. The system consists of a
primary and secondary chain drive.
7 – VALVE-EXHAUST
8 – VALVE-INTAKE
9 – CYLINDER HEAD
10 – VALVE STEM SEAL
11 – VALVE SPRING-INTAKE
The primary timing chain drive (Fig. 7) uses a
single, double-flexure, inverted tooth type chain. The
primary chain drives both of the intake camshafts
directly from a sprocket mounted on the crankshaft.
In addition, the water pump is driven by the “back
side” of the primary chain, necessitating the doubleflexure type chain.
The chain is controlled by three fixed chain guides
and a pivoting tensioner arm (Fig. 7). These guides
utilize low-friction and long wearing nylon plastic
wear faces. To tension the primary chain, a fully
automatic spring-loaded, engine oil-fed, hydraulic
tensioner is used. The tensioner is mounted in the
right cylinder head with the plunger contacting the
pivoting tensioner arm. A mechanical ratchet mechanism inside the tensioner prevents excessive chain
slack upon engine start-up as the chain wears. The
tensioner is designed with an internal oil reservoir to
assure noise-free performance, even during engine
start-up before oil pressure reaches the tensioner.
2.7L ENGINE
LH
9-7
DESCRIPTION AND OPERATION (Continued)
To reduce engine NVH and timing chain loads a
camshaft damper is used. This damper mounts to the
right intake camshaft sprocket. The damper utilizes
a synthetic rubber elastomer to provide damping,
similar to a crankshaft damper.
For lubrication the primary chain utilizes oil leakage from the front of the oil pump. This oil spills on
the crankshaft sprocket, which is then carried by the
chain throughout the primary drive.
The secondary timing chain drive system uses
two conventional roller-type chains, one at each cylinder bank (Fig. 8). The purpose of the secondary
chain is to provide a mechanical driven connection
between the intake and exhaust camshafts. The
intake camshafts drive the exhaust camshafts. The
sprockets for both intake and exhaust camshafts are
a press-fit and are only serviced as an assembly with
the camshafts.
To tension the secondary chain a spring-loaded,
hydraulic tensioner is used at each bank and
attaches to each cylinder head between the intake
and exhaust camshafts (Fig. 8). The tensioner incorporates upper and lower chain guide faces. The lower
guide face is attached directly to the tensioner’s
hydraulic plunger. Also, the tensioner uses an internal oil reservoir design to prevent engine start-up
noise. The secondary chains are lubricated via an oil
passage through the upper guide face on each tensioner.
CAMSHAFT
DESCRIPTION
The assembled fabricated camshafts are composed
of five bearing journals machined into a hollow steel
tube (Fig. 8). Six steel lobes, a secondary timing
drive sprocket, and a primary sprocket/thrust flange
are pressed onto the camshaft tube using a unique
assembly process. Camshaft end play is controlled by
the primary camshaft sprocket attachment flange on
the intake camshafts and by a thrust flange on the
exhaust camshafts.
Fig. 7 Timing Drive System
1
2
3
4
5
6
–
–
–
–
–
–
CAMSHAFT DAMPER
CHAIN GUIDE
ACCESS PLUG
CAMSHAFT POSITION SENSOR
PRIMARY TIMING CHAIN
CRANKSHAFT SPROCKET
7 – CHAIN GUIDE
8 – CHAIN TENSIONER ARM
9 – CHAIN TENSIONER
10 – CAMSHAFT SPROCKETS
11 – CHAIN GUIDE
9-8
2.7L ENGINE
LH
DESCRIPTION AND OPERATION (Continued)
Fig. 8 Valvetrain Components
1
2
3
4
5
6
–
–
–
–
–
–
CAMSHAFT BEARING CAP-INTAKE
CAMSHAFT BEARING CAP-EXHAUST
CAMSHAFT-EXHAUST
ROCKER ARM
HYDRAULIC LIFTER
CYLINDER HEAD
7 – CAMSHAFT (SECONDARY) CHAIN TENSIONER
8 – CYLINDER BLOCK
9 – CYLINDER HEAD
10 – CAMSHAFT-INTAKE
11 – CAMSHAFT (SECONDARY) TIMING CHAIN
OPERATION
The camshaft has precisely machined (egg shaped)
lobes to provide accurate valve timing and duration.
The camshaft is driven by the crankshaft via drive
sprockets and chains.
ROCKER ARMS
DESCRIPTION
The rocker arms are composed of steel stampings
with an integral roller bearing (Fig. 9). The rocker
arms incorporate a 0.5 mm (0.0197 in.) oil hole in the
lash adjuster socket for roller/camshaft lobe lubrication (Fig. 9).
OPERATION
The rocker arm is the pivot point between the camshaft lobe and the valve.
Fig. 9 Rocker Arm
1 – LASH ADJUSTER POCKET
2 – OIL SQUIRT HOLE
3 – ROLLER
2.7L ENGINE
LH
9-9
DESCRIPTION AND OPERATION (Continued)
INTAKE MANIFOLD
DESCRIPTION
The two piece intake manifold is made of a composite material. The intake manifold features a compact, low rumble design that maximizes engine
performance while minimizing induction noise. A
manifold tuning valve (MTV) is used on some models.
OPERATION
The intake air plenum chambers absorb air pulsations created during each cylinder’s intake stroke.
The manifold tuning valve (if equipped) connects
both sides of the intake manifold plenums at specific
engine speeds to maximize low RPM torque, without
reducing high RPM power.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds are a log style design and
made of cast nodular iron (Fig. 10). The outlets are
designed for V-band clamp attachment of close coupled catalytic converters.
ENGINE LUBRICATION
DESCRIPTION
The lubrication system is a full-flow filtration,
pressure feed type. The oil pump body is mounted to
the engine block. The pump inner rotor is driven by
the crankshaft. A structural windage tray is used to
increase power by minimizing oil windage at high
engine RPM. An engine oil cooler is used on some
models.
Fig. 10 Exhaust Manifold
1
2
3
4
5
6
–
–
–
–
–
–
HEAT SHIELD
BOLT
GASKET
BOLT
EXHAUST MANIFOLD
HEAT SHIELD
OPERATION
Oil from the oil pan is pumped by an geroter type
oil pump directly coupled to the crankshaft (Fig. 11).
Oil pressure is controlled by a relief valve mounted
inside the oil pump housing. See (Fig. 11), (Fig. 12),
and (Fig. 13) for engine oil lubrication circuits.
9 - 10
2.7L ENGINE
LH
DESCRIPTION AND OPERATION (Continued)
Fig. 11 Cylinder Block Oil Lubrication System
1
2
3
4
–
–
–
–
5 – OIL FILTER
6 – TO CRANKSHAFT MAIN JOURNALS
7 – MAIN OIL GALLERY
TO RIGHT CYLINDER HEAD
TO LEFT CYLINDER HEAD
OIL PUMP
OIL PICKUP TUBE
FROM:
TO:
FROM:
Main Oil Gallery – Center
of Block
TO:
Oil Pump
Oil Filter Mounting (inlet)
1. Crankshaft Main
Bearings
Oil Filter Mounting (inlet)
Oil Filter
2. Left Cylinder Head*
Oil Filter
Oil Filter Mounting (outlet)
3. Right Cylinder Head*
Oil Filter Mounting (outlet)
Oil Gallery – Right side of
Block
Crankshaft Main Bearings
Connecting Rod Bearings
Oil Gallery – Right side of
Block
Oil Gallery – Rear of
Block and to Oil Cooler
(some models)
Left Cylinder Head
Refer to (Fig. 12)
Oil Gallery – Rear of
Block
Main Oil Gallery – Center
of Block
Right Cylinder Head
Refer to (Fig. 13)
* The cylinder head gaskets have an oil restrictor to control oil flow to the cylinder heads.
2.7L ENGINE
LH
9 - 11
DESCRIPTION AND OPERATION (Continued)
Fig. 12 Cylinder Head Oil Lubrication System—Left Side
1 – CAM JOURNALS
2 – OIL FEED TO CAMSHAFT (SECONDARY) CHAIN
TENSIONER
3 – LASH ADJUSTER BORES
FROM:
4 – OIL FEED FROM BLOCK
5 – VENT HOLE
6 – ACCUMULATOR
TO:
Left Cylinder Head Oil Inlet Gallery (intake side of
head)
Oil Gallery and Accumulator – Rear of Head*
Oil Gallery and Accumulator – Rear of Head*
1. Exhaust Camshaft Oil Passage
2. Intake Camshaft Oil Passage
Left Exhaust Camshaft Oil Passage
1. Left Exhaust Camshaft Journals
2. Hydraulic Valve Lash Adjusters and Rocker Arms
3. Left Camshaft (Secondary) Chain Tensioner**
Left Intake Camshaft Oil Passage
1. Left Intake Camshaft Journals
2. Hydraulic Valve Lash Adjusters and Rocker Arms
* When oil reaches the back of the cylinder head, the oil gallery feeds oil into an accumulator chamber that is
located towards center of the head. The accumulator chamber is closed off with a pressed in core plug that has a
small orifice to act as a vent. Oil then travels down at a 45 degree angle from the accumulator into two passages,
one for the intake and one for the exhaust side of the cylinder head.
** The secondary camshaft chain tensioner is the last component to receive oil on the left cylinder head.
9 - 12
2.7L ENGINE
LH
DESCRIPTION AND OPERATION (Continued)
Fig. 13 Cylinder Head Oil Lubrication System—Right Side
1 – OIL FEED TO CAMSHAFT (SECONDARY) CHAIN
TENSIONER
2 – OIL FEED TO TIMING CHAIN (PRIMARY) TENSIONER
3 – CAM JOURNALS
4 – ACCUMULATOR
FROM:
5 – VENT HOLE
6 – OIL FEED FROM BLOCK
7 – LASH ADJUSTOR BORES
TO:
Right Cylinder Head Oil Inlet Gallery (intake side of
head)
Oil Gallery and Accumulator – Rear of Head*
Oil Gallery and Accumulator – Rear of Head*
1. Exhaust Camshaft Oil Passage
2. Intake Camshaft Oil Passage
Right Exhaust Camshaft Oil Passage
1. Right Exhaust Camshaft Journals
2. Hydraulic Valve Lash Adjusters and Rocker Arms
3. Right Camshaft (Secondary) Chain Tensioner
4. Primary Timing Chain Tensioner - Right Head**
Right Intake Camshaft Oil Passage
1. Right Intake Camshaft Journals
2. Hydraulic Valve Lash Adjusters and Rocker Arms
* When oil reaches the back of the cylinder head, the oil gallery feeds oil into an accumulator chamber that is
located towards center of the head. The accumulator chamber is closed off with a pressed in core plug that has a
small orifice to act as a vent. Oil then travels down at a 45 degree angle from the accumulator into two passages,
one for the intake and one for the exhaust side of the cylinder head.
** The timing (primary) chain tensioner is the last component to receive oil on the right cylinder head.
2.7L ENGINE
LH
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
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Service Diagnosis—Mechanical Chart
and the Service Diagnosis—Performance Chart, for
possible causes and corrections of malfunctions. Refer
to FUEL SYSTEM for the fuel system diagnosis.
9 - 13
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that cannot be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagnosis is provided within the following:
• Cylinder Compression Pressure Test
• Cylinder Combustion Pressure Leakage Test
• Cylinder Head Gasket Failure Diagnosis
• Intake Manifold Leakage Diagnosis
• Lash Adjuster (Tappet) Noise Diagnosis
• Engine Oil Leak Inspection
ENGINE DIAGNOSIS—PERFORMANCE
CONDITION
ENGINE WILL NOT START
ENGINE STALLS OR
IDLES ROUGH
POSSIBLE CAUSE
CORRECTION
1. Weak battery.
1. Test battery. Charge or replace as
necessary. Refer to BATTERY.
2. Corroded or loose battery
connections.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter.
3. Test starting system. Refer to
STARTING.
4. Faulty coil(s) or control unit.
4. Test and replace as needed. Refer to
IGNITION SYSTEM.
5. Incorrect spark plug gap.
5. Set gap. Refer to IGNITION
SYSTEM.
6. Contamination in fuel system.
6. Clean system and replace fuel filter.
7. Faulty fuel pump.
7. Test fuel pump and replace as
needed. Refer to FUEL SYSTEM.
8. Incorrect engine timing.
8. Check for a skipped timing belt/chain
or a loose camshaft sprocket (3.2/3.5L).
1. Idle speed too low.
1. Test minimum air flow. Refer to FUEL
SYSTEM.
2. Incorrect fuel mixture.
2. Refer to FUEL SYSTEM.
3. Intake manifold leakage.
3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty coil(s).
4. Test and replace as necessary. Refer
to IGNITION SYSTEM.
9 - 14
2.7L ENGINE
LH
DIAGNOSIS AND TESTING (Continued)
CONDITION
ENGINE LOSS OF
POWER
ENGINE MISSES ON
ACCELERATION
ENGINE MISSES AT HIGH
SPEED
POSSIBLE CAUSE
CORRECTION
1. Dirty or incorrectly gapped plugs.
1. Clean plugs and set gap. Refer to
IGNITION SYSTEM.
2. Contamination in fuel system.
2. Clean system and replace fuel filter.
3. Faulty fuel pump.
3. Test and replace as necessary. Refer
to FUEL SYSTEM.
4. Incorrect valve timing.
4. Correct valve timing.
5. Leaking cylinder head gasket.
5. Replace cylinder head gasket.
6. Low compression.
6. Test compression of each cylinder.
7. Burned, warped, or pitted valves.
7. Replace valves.
8. Plugged or restricted exhaust system.
8. Install new parts, as necessary.
9. Faulty coil(s).
9. Test and replace as necessary. Refer
to IGNITION SYSTEM.
1. Dirty or incorrectly gapped spark
plugs.
1. Clean spark plugs and set gap. Refer
to IGNITION SYSTEM.
2. Contamination in Fuel System.
2. Clean fuel system and replace fuel
filter.
3. Burned, warped, or pitted valves.
3. Replace valves.
4. Faulty coil(s).
4. Test and replace as necessary. Refer
to IGNITION SYSTEM.
1. Dirty or incorrect spark plug gap.
1. Clean spark plugs and set gap. Refer
to IGNITION SYSTEM.
2. Faulty coil(s).
2. Test and replace as necessary. Refer
to IGNITION SYSTEM.
3. Dirty fuel injector(s).
Test and replace as necessary. Refer to
FUEL SYSTEM.
4. Contamination in fuel system.
4. Clean system and replace fuel filter.
2.7L ENGINE
LH
9 - 15
DIAGNOSIS AND TESTING (Continued)
ENGINE DIAGNOSIS—MECHANICAL
CONDITION
NOISY VALVES
CONNECTING ROD
NOISE
MAIN BEARING NOISE
POSSIBLE CAUSES
CORRECTION
1. High or low oil level in crankcase.
1. Check and correct engine oil level.
2. Thin or diluted oil.
2. Change oil to correct viscosity.
3. Low oil pressure.
3. Check and correct engine oil level.
4. Dirt in tappets/lash adjusters.
4. Replace rocker arm/hydraulic lash
adjuster assembly.
5. Worn rocker arms.
5. Inspect oil supply to rocker arms.
6. Worn tappets/lash adjusters.
6. Install new rocker arm/hydraulic lash
adjuster assembly.
7. Worn valve guides.
7. Ream guides and install new valves
with oversize stems.
8. Excessive runout of valve seats on
valve faces.
8. Grind valve seats and valves.
9. Missing adjuster pivot.
9. Replace rocker arm/hydraulic lash
adjuster assembly.
1. Insufficient oil supply.
1. Check engine oil level.
2. Low oil pressure.
2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil.
3. Change oil to correct viscosity.
4. Excessive bearing clearance.
4. Measure bearings for correct
clearance. Repair as necessary.
5. Connecting rod journal out-of-round.
5. Replace crankshaft or grind surface.
6. Misaligned connecting rods.
6. Replace bent connecting rods.
1. Insufficient oil supply.
1. Check engine oil level.
2. Low oil pressure.
2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil.
3. Change oil to correct viscosity.
4. Excessive bearing clearance.
4. Measure bearings for correct
clearance. Repair as necessary.
5. Excessive end play.
5. Check thrust bearing for wear on
flanges.
6. Crankshaft journal out-of-round or
worn.
6. Replace crankshaft or grind journals.
7. Loose flywheel or torque converter.
7. Tighten to correct torque.
9 - 16
2.7L ENGINE
LH
DIAGNOSIS AND TESTING (Continued)
CONDITION
OIL PRESSURE DROP
OIL LEAKS
OIL CONSUMPTION OR
SPARK PLUGS FOULED
POSSIBLE CAUSES
CORRECTION
1. Low oil level.
1. Check engine oil level.
2. Faulty oil pressure sending unit.
2. Install new sending unit.
3. Low oil pressure.
3. Check sending unit and main bearing
oil clearance.
4. Clogged oil filter.
4. Install new oil filter.
5. Worn parts in oil pump.
5. Replace worn parts or pump.
6. Thin or diluted oil.
6. Change oil to correct viscosity.
7. Oil pump relief valve stuck.
7. Remove valve and inspect, clean, or
replace.
8. Oil pump suction tube loose.
8. Remove oil pan and install new tube
or clean, if necessary.
9. Oil pump cover warped or cracked.
9. Install new oil pump.
10. Excessive bearing clearance.
10. Measure bearings for correct
clearance.
1. Misaligned or deteriorated gaskets.
1. Replace gasket(s).
2. Loose fastener, broken or porous
metal part.
2. Tighten, repair or replace the part.
3. Misaligned or deteriorated cup or
threaded plug.
3. Replace as necessary.
1. PCV system malfunction.
1. Check system and repair as
necessary. Refer to EMISSION
CONTROL SYSTEMS.
2. Worn, scuffed or broken rings.
2. Hone cylinder bores. Install new rings.
3. Carbon in oil ring slots.
3. Install new rings.
4. Rings fitted too tightly in grooves.
4. Remove rings and check grooves. If
groove is not proper width, replace
piston.
5. Worn valve guide(s).
5. Ream guide(s) and replace valve(s)
with oversize valve(s) and seal(s).
6. Valve stem seal(s) worn or damaged.
6. Replace seal(s).
CHECKING ENGINE OIL PRESSURE
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
(1) Remove oil pressure sending unit and install
an oil pressure test gauge assembly.
(2) Run engine until thermostat opens.
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
CAUTION: If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM
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.
(3) Oil Pressure: Curb Idle 25 kPa (4 psi) minimum 3000 RPM 170/724 kPa (25/105 psi).
(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open or a
clogged oil pickup screen.
(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 suspected leak has been found.
(4) Repair as required.
LH
2.7L ENGINE
9 - 17
DIAGNOSIS AND TESTING (Continued)
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunctions.
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) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference.
(4) Disconnect coil wire from distributor and
secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct
Ignition System DIS disconnect the coil connector.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gage adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0–500 psi (Blue) pressure
transducer with cable adaptors to the DRBIIIt.
(7) Crank engine until maximum pressure is
reached on gage. Record this pressure as #1 cylinder
pressure.
(8) Repeat the previous step for all remaining cylinders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cylinder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended compression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunction is present.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
• Exhaust and intake valve leaks (improper seating).
• Leaks between adjacent cylinders or into water
jacket.
• Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains normal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufacturer’s instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) recommended.
Perform the test procedures on each cylinder
according to the tester manufacturer’s instructions.
While testing, listen for pressurized air escaping
through 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 per cylinder.
FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the cylinder.
CYLINDER HEAD GASKET FAILURE DIAGNOSIS
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:
• Loss of engine power
• Engine misfiring
• Poor fuel economy
• Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
• Engine overheating
• Loss of coolant
• Excessive steam (white smoke) emitting from
exhaust
• Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the procedures in Cylinder Compression Pressure Test in this
9 - 18
2.7L ENGINE
LH
DIAGNOSIS AND TESTING (Continued)
section. An engine cylinder head gasket leaking
between adjacent 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 PRESSURE 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
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRESSURE 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.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
Proper noise diagnosis is essential in locating the
source of a NVH complaint. Locating a lash adjuster
(tappet) type noise can sometimes be difficult. As a
result, an initial misdiagnosis may occur.
Refer to the following chart indicating possible lash
adjuster (tappet) noise sources and possible sources
that could lead to a misdiagnosis.
Refer to Lash Adjuster (Tappet) Noise Chart for
Possible Causes and Correction of a lash adjuster
(tappet) type noise.
LASH ADJUSTER (TAPPET) NOISE CHART
POSSIBLE CAUSES
CORRECTION
1. Engine oil level—too high or too low. This may cause
aerated oil to enter the adjusters and cause them to be
spongy.
1. Check and correct engine oil level.
2. Insufficient running time after rebuilding cylinder
head.
2. Low speed running of up to 1 hour may be required
to fully evacuate trapped air from the valve train
system. During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
3. Air trapped in lash adjuster (after 1 hour run time).
3. See below:
(a) Check lash adjusters for sponginess while installed
in cylinder head. Depress part of rocker arm over
adjuster. Normal adjusters should feel very firm. Very
spongy adjusters can be bottomed out easily.
(b) If lash adjuster(s) are still spongy, replace with new
adjuster/rocker arm assembly.
4. Low oil pressure
4. See below:
(a) Check and correct engine oil level.
(b) Check engine oil pressure.
(c) Check for excessive bearing clearance and correct.
(d) Check for worn oil pump.
2.7L ENGINE
LH
9 - 19
DIAGNOSIS AND TESTING (Continued)
POSSIBLE CAUSES
CORRECTION
5. Oil passage to cylinder head(s) plugged with debris.
5. Check cylinder head oil passages and cylinder head
gasket restrictor for blockage. Clean or replace as
necessary.
6. Worn valve guide(s).
6. Ream guide(s) and replace valve(s) with oversize
valves and seal(s).
7. Air injested into oil due to broken or cracked oil
pump pickup tube.
7. Inspect pickup tube and replace as necessary.
8. Collapsed lash adjuster due to debris injestion.
8. Clean debris from engine and replace lash
adjuster(s).
ENGINE OIL LEAK INSPECTION
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 various speeds for approximately 24 km (15 miles), and
repeat inspection.
(5) If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
• Disconnect the fresh air hose (make-up air) at
the cylinder head cover and plug or cap the nipple on
the cover.
• Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
• 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.
• Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
• If the leakage occurs at the crankshaft 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.
Remove the air hose, all plugs, and caps. Install the
PCV valve and fresh air hose (make-up air). Proceed
to next step.
(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.
NOTE: If oil leakage is observed at the dipstick
tube to block location; remove the tube, clean and
reseal using MoparT Stud & Bearing Mount (press
fit tube applications only), and for O-ring style
tubes, remove tube and replace the O-ring seal.
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 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. If a leak is
present in this area, remove transmission for further
inspection.
(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, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crankcase as previously described.
9 - 20
2.7L ENGINE
LH
DIAGNOSIS AND TESTING (Continued)
CAUTION: Do not exceed 20.6 kPa (3 psi).
ENGINE OIL SERVICE
(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.
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
PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
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 disassembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified, refer to Crankshaft Oil Seal—Rear for proper replacement procedures.
SERVICE PROCEDURES
ENGINE OIL LEVEL—CHECKING
The best time to check engine oil level is after it
has sat overnight, or if the engine has been running,
allow the engine to be shut off for at least 5 minutes
before checking oil level.
Checking the oil while the vehicle is on level
ground will improve the accuracy of the oil level
reading (Fig. 14). Add only when the level is at or
below the ADD mark.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certified. MOPARt provides engine oils that conform to
this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. The
preferred viscosity oil for the 2.7L engine is 5W-30.
These oils are specified with a dual SAE viscosity
grade which indicates the cold-to-hot temperature
viscosity range. Select an engine oil that is best
suited to your particular temperature range and variation (Fig. 15).
Fig. 15 Temperature/Engine Oil Viscosity—2.7L
Engine
Fig. 14 Engine Oil Fill and Dipstick Locations—2.7L
1 – ENGINE OIL DIPSTICK
2 – ENGINE OIL FILL
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.
LH
2.7L ENGINE
9 - 21
SERVICE PROCEDURES (Continued)
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. 16).
Fig. 16 Engine Oil Container Standard Notations
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating temperature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(3) Remove oil fill cap, (Fig. 14).
(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 and
gasket if damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil, (Fig. 14). Refer to
LUBRICATION AND MAINTENANCE.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
ENGINE OIL FILTER CHANGE
FILTER SPECIFICATION
All engines are equipped with a high quality fullflow, disposable type oil filter. When replacing oil filter, use a Mopart filter or equivalent.
OIL FILTER REMOVAL
Refer to procedure in this section.
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 listed above.
FORM-IN-PLACE GASKETS & SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results. Do not use form-inplace gasket material unless specified. Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, Mopart ATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARt ENGINE RTV GEN II
Mopart Engine RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARt ATF RTV
Mopart ATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARt GASKET MAKER
Mopart Gasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARt BED PLATE SEALANT
Mopart Bed Plate Sealant is a unique (green-incolor) anaerobic type gasket material that is specially
made to seal the area between the bedplate and cylinder block without disturbing the bearing clearance
or alignment of these components. The material
cures slowly in the absence of air when torqued
9 - 22
2.7L ENGINE
LH
SERVICE PROCEDURES (Continued)
between two metallic surfaces, and will rapidly cure
when heat is applied.
MOPARt GASKET SEALANT
Mopart Gasket Sealant is a slow drying, permanently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This material is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will prevent corrosion. Mopart Gasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it’s easier then using precut gaskets.
Mopart Gasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smearing material off the location.
Mopart Engine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
Mopart Gasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
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 the following to clean gasket surfaces:
• Metal scraper
• Abrasive pad or paper to clean cylinder block
and head
• High speed power tool with an abrasive pad or a
wire brush (Fig. 17)
NOTE: Multi-Layer Steel (MLS) head
require a scratch free sealing surface.
gaskets
Only use the following for cleaning gasket surfaces:
• Solvent or a commercially available gasket
remover
• Plastic or wood scraper (Fig. 17)
• Drill motor with 3M Rolocy Bristle Disc (white
or yellow) (Fig. 17)
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.
Fig. 17 Proper Tool Usage For Surface Preparation
1 – ABRASIVE PAD
2 – 3M ROLOCY BRISTLE DISC
3 – PLASTIC/WOOD SCRAPER
REPAIR OF DAMAGED OR WORN THREADS
Damaged or worn threads (excluding spark plug
and camshaft bearing cap attaching threads) can be
repaired. Essentially, this repair consists of drilling
out worn or damaged threads, tapping the hole with
a special Heli-Coil Tap, (or equivalent) and installing
an insert into the tapped hole. This brings the hole
back to its original thread size.
CAUTION: Be sure that the tapped holes maintain
the original centerline.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
2.7L ENGINE
LH
9 - 23
SERVICE PROCEDURES (Continued)
CYLINDER BORE—HONING
(1) Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped
with 220 grit stones, is the best tool for this honing
procedure. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required limits.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20–60
strokes depending on the bore condition, will be sufficient to provide a satisfactory surface. Inspect cylinder walls after each 20 strokes, using a light
honing oil. 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 cross-hatch pattern.
When hone marks intersect at 50-60 degrees, the
cross hatch angle is most satisfactory for proper seating of rings (Fig. 18).
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.).
(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Fill engine with specified amount of approved
oil and install new oil filter.
(11) Connect negative battery cable.
(12) Start engine and check for any leaks.
Fig. 18 Cylinder Bore Cross-Hatch Pattern
1 – CROSS-HATCH PATTERN
(4) A controlled hone motor speed between
200–300 RPM is necessary to obtain the proper crosshatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50–60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
PISTONS
The pistons have been cast and machined to one
size and weight. The piston and rod assemblies are
matched to weigh the same for engine balance.
FITTING PISTONS
Piston and cylinder wall must be clean and dry.
Piston diameter should be measured 90 degrees to
piston pin at size location shown in (Fig. 19). Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft
center line. Refer to Engine Specifications. Pistons
and cylinder bores should be measured at normal room temperature, 70°F (21°C).
9 - 24
2.7L ENGINE
LH
SERVICE PROCEDURES (Continued)
Fig. 19 Piston Measurements
PISTON PINS
The piston pin is full floating and is held in place
by lock rings. Pistons and rods are weight matched
for balance. Do Not switch pistons with other
rods. Piston and Rods are serviced as an assembly
for balance.
PISTON RING—FITTING
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 inch.) from bottom
of cylinder bore. Check gap with feeler gauge (Fig.
20). Refer to Engine Specifications.
Fig. 21 Measuring Piston Ring Side Clearance
1 – FEELER GAUGE
CAUTION: Install piston rings in the following
order:
(2) Oil ring expander.
(3) Upper oil ring side rail.
(4) Lower oil ring side rail.
(5) No. 2 Intermediate piston ring.
(6) No. 1 Upper piston ring.
(7) Install the side rail by placing one end between
the piston ring groove and the expander. Hold end
firmly and press down the portion to be installed
until side rail is in position. Do not use a piston
ring expander during this step (Fig. 23).
Fig. 20 Check Gap on Piston Rings
1 – FEELER GAUGE
(2) Check piston ring to groove clearance: (Fig. 21).
Refer to Engine Specifications.
PISTON RINGS—INSTALLATION
(1) The No. 1 and No. 2 piston rings have a different cross section. Insure that No. 2 ring is installed
with the manufacturers I.D. mark (dot) facing up,
towards top of the piston (Fig. 22).
Fig. 22 Piston Ring—Installation
1 – SPACER EXPANDER
2 – SIDE RAIL
2.7L ENGINE
LH
9 - 25
SERVICE PROCEDURES (Continued)
Fig. 25 Piston Ring End Gap Position
Fig. 23 Side Rail—Installation
1 – SIDE RAIL END
1
2
3
4
5
–
–
–
–
–
SIDE RAIL UPPER
NO. 1 RING GAP
PISTON PIN
SIDE RAIL LOWER
NO. 2 RING GAP AND SPACER EXPANDER GAP
The bearing shells must be installed with the
tangs inserted into the machined grooves in the rods
and caps. Also, assure that the hole in upper bearing
half aligns with oil squirt hole in rod. Install cap
with the tangs on the same side as the rod.
CAUTION: Assure that hole in upper bearing half
aligns with hole in connecting rod as engine damage may occur.
Fig. 24 Upper and Intermediate Rings—Installation
(8) Install upper side rail first and then the lower
side rail.
(9) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 24).
(10) Position piston ring end gaps as shown in
(Fig. 25).
(11) Position oil ring expander gap at least 45°
from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is
important for oil control.
CONNECTING ROD BEARING—INSTALLATION
Fit all rods on one bank until complete.
The bearing caps are not interchangeable and
should be marked at removal to insure correct
assembly.
CAUTION: Care must be taken not to damage the
fractured rod and cap joint face surfaces as engine
damage may occur.
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.015 mm (0.0006 in.).
Bearings are available 0.025 mm (0.001 in.) and
0.250 mm (0.010 in.) undersize. Install the bearings in pairs. Do not use a new bearing half
with an old bearing half. Do not file the rods or
bearing caps.
(1) Follow procedure specified in the Standard Service Procedure Section for Selecting and Measuring
Main Bearing Clearance and Connecting Rod Bearing Clearance (Fig. 26). Refer to Engine Specifications.
NOTE: The connecting rod bearing cap bolts must
be examined before reuse. If the threads are necked
down the bolts should be replaced (Fig. 27).
NOTE: Connecting rod bolts are retained in the rod
cap with a light press fit. If bolts are to be removed,
use a hammer and punch to drive bolts from connecting rod cap using care not to damage fractured
cap surface.
9 - 26
2.7L ENGINE
LH
SERVICE PROCEDURES (Continued)
Refer to Engine Specifications. Repeat procedure for
each connecting rod. Turn crankshaft for connecting
rod accessibility.
Fig. 28 Connecting Rod Side Clearance Measuring
CRANKSHAFT MAIN BEARING—FITTING
Fig. 26 Checking Connecting Rod Bearing
Clearance—Typical
Fig. 27 Check for Stretched Bolts
1
2
3
4
–
–
–
–
STRETCHED BOLT
THREADS ARE NOT STRAIGHT ON LINE
THREADS ARE STRAIGHT ON LINE
UNSTRETCHED BOLT
(2) Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
(3) Before installing the bolts, lubricate the
threads with engine oil.
(4) Install bolts finger tight then alternately
torque each nut to assemble the cap properly.
(5) Tighten the nuts to 27 N·m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn).
(6) Mount a dial indicator to a stationary point on
engine. Locate probe perpendicular to and resting
against the connecting rod cap being checked. Move
connecting rod all the way to rear of its travel. Zero
the dial indicator. Move connecting rod forward to
limit of travel and read the dial indicator (Fig. 28).
The main bearings are “select fit” to achieve proper
oil clearances. For main bearing selection, the block
and crankshaft have grade identification marks.
The grade marks for the cylinder block main bearing bore grade is located on the pan rail just below
the left side engine mount bracket (Fig. 30). These
marks are read left to right, corresponding to main
bore 1, 2, 3, 4.
The grade marks for the crankshaft are located on
the rearmost crankshaft counter weight as shown in
(Fig. 29). The crankshaft journal grade marks are
read left to right, corresponding with journal number
1, 2, 3, 4.
Use the Main Bearing Selection Chart to properly
select the main bearings. For an example, if the main
bore grade is 3 and the journal grade is 2, the proper
select fit bearing would be (2) +0.003 mm (+0.0002
in.).
NOTE: Service main bearings have a number from
1 – 5 marked in ink on the bearing surface (Fig. 31).
For verification, use the Main Bearing Selection
Chart for number to size identification.
The upper main bearing has a oil feed hole and a
center groove to allow lubrication of the main journal
and must be properly positioned in the block.
NOTE: Although cylinder bores are graded for size,
there is only one piston size.
2.7L ENGINE
LH
9 - 27
SERVICE PROCEDURES (Continued)
Fig. 29 Crankshaft Main Journal Grade Marking
Location
Fig. 31 Main Bearing Grade Marks
1
2
3
4
–
–
–
–
LOWER MAIN BEARING
UPPER MAIN BEARING
OIL FEED HOLE AND GROOVE
GRADE SELECTION INK MARKS
MAIN BEARING SELECTION CHART—2.7L
Main Bearing Bore Grade Mark
Fig. 30 Cylinder Block Main Bore Grade Marking
Location
CRANKSHAFT END PLAY—CHECKING
(1) Mount a dial indicator to a stationary point at
front of engine. Locate the probe perpendicular
against nose of crankshaft (Fig. 32).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Engine Specifications.
Crankshaft
Main
Journal
Grade Mark
1
2
3
1
(3)
standard
(2)
+0.003
mm
(+0.0002
in.)
(1)
+0.006
mm
(+0.0003
in.)
2
(4)
-0.003
mm
(-0.0002)
(3)
standard
(2)
+0.003
mm
(+0.0002
in.)
3
(5)
-0.006
mm
(-0.0003
in.)
(4)
-0.003
mm
(-0.0002
in.)
(3)
standard
VALVE AND VALVE SEAT—REFACING
The intake and exhaust valves have a 44.5 to 45
degree face angle. The valve seats have a 45 to 45.5
degree face angle. The valve face and valve seat
angles are shown in (Fig. 33).
9 - 28
2.7L ENGINE
LH
SERVICE PROCEDURES (Continued)
(3) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, then lower valve seat
with a 15 degree stone. If the blue is transferred to
the bottom edge of valve face, then raise valve seat
with a 65 degree stone.
NOTE: Valve seats which are worn or burned can
be reworked, provided that correct angle and seat
width are maintained. Otherwise cylinder head must
be replaced.
Fig. 32 Checking Crankshaft End Play
VALVES
Inspect the remaining margin after the valves are
refaced. Refer to Engine Specifications.
VALVE SEATS
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseating stones. A true and complete surface must be
obtained.
(2) Measure the concentricity of valve seat using
dial indicator. Total runout should not exceed 0.051
mm (0.002 inch.) total indicator reading.
Fig. 33 Valve Seats
ITEM
DESCRIPTION
A
Seat Width
SPECIFICATION
Intake:
1.00 –
1.50 mm
(0.39 –
0.059 in.)
Exhaust:
1.25 – 1.75
mm (0.049
– 0.069 in.)
B
Face Angle
Intake & Exhaust: 44.5 –
45°
C
Seat Angle
Intake & Exhaust: 45 –
45.5°
D
Seat Contact
Area
Valve to seat contact
must be at center of
valve face.
(4) When seat is properly positioned the width of
the intake 1.00 to 1.50 mm (0.0394 to 0.0591 in.) and
exhaust seats should be 1.25 to 1.75 mm (0.049 to
0.069 in.) (Fig. 33).
(5) Check the valve spring installed height after
refacing the valve and seat (Fig. 35).
VALVE SPRINGS
The valve springs are common for intake and
exhaust valves. Refer to Engine Specifications.
TESTING VALVE SPRINGS
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested (Fig. 34). As an example; the compression
length of the spring to be tested is 38.00 mm (1.496
in.). Turn table of Tool C-647 until surface is in line
with the 38.00 mm (1.496 in.) mark on the threaded
stud and the zero mark on the front. Place spring
over stud on the table and lift compressing 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.
VALVE INSTALLATION
(1) Coat valve stems with clean engine oil and
insert them in cylinder head.
(2) If valves or seats have been reground, check
valve tip height (A) (Fig. 35). If valve tip height for
intake valve is greater than 47.59 (1.8737 in.) or
49.14 (1.9347 in.) for exhaust valve, grind valve tip
until within specifications. Make sure measurement
is taken from cylinder head surface to the top of
valve stem.
(3) Install valve seal/spring seat assembly over
valve guides on all valve stems (Fig. 36). Ensure that
2.7L ENGINE
LH
9 - 29
SERVICE PROCEDURES (Continued)
Fig. 34 Testing Valve Spring with Tool C-647
1 – SPECIAL TOOL C-647
Fig. 36 Valve Seal and Spring
1
2
3
4
5
–
–
–
–
–
VALVE
VALVE
VALVE
VALVE
VALVE
RETAINING LOCKS
SPRING RETAINER
SPRING
SEAL AND VALVE SPRING SEAT ASSEMBLY
ENGINE TIMING—VERIFICATION
Fig. 35 Checking Valve Tip Height and Valve Spring
Installed Height
1
2
3
4
–
–
–
–
SPRING RETAINER
GARTER SPRING
VALVE SPRING SEAT TOP
CYLINDER HEAD SURFACE
the garter spring is intact around the top of the rubber seal. Install valve springs, valve retainers.
(4) Compress valve springs with a valve spring
compressor install locks and release tool. If valves
and/or seats are reground, measure the
installed height of springs (B) (Fig. 35), make
sure measurements are taken from top of
spring seat to the bottom surface of spring
retainer. If height is greater than 38.75 mm (1.5256
in.), install a 0.762 mm (0.030 in.) spacer in head
counterbore under the valve spring seat to bring
spring height back within specification.
Correct timing is critical for the NON free-wheeling designed, 2.7L engine. Engine timing can be verified by using the following procedures:
(1) Remove cylinder head covers. Refer to procedure in this section.
(2) Rotate engine until number one cylinder is at
TDC on the EXHAUST stroke.
(3) View the intake camshaft sprocket timing
mark. The mark should be 90° from the cylinder
head cover sealing surface (Fig. 37) on both right and
left cylinder banks.
(4) Count chain pins from the mark on the intake
camshaft towards the exhaust camshaft. Engine is
timed correctly when there are 12 chain pins
between the timing marks on the intake camshaft
and exhaust camshaft (Fig. 37).
(5) If marks are not correctly aligned, proceed to
Camshafts, Timing Chain and Sprockets, Removal
and Installation procedures.
9 - 30
2.7L ENGINE
LH
SERVICE PROCEDURES (Continued)
Fig. 37 Engine Timing
1 – 12 PINS
2 – CAMSHAFT TIMING MARKS
3 – 12 PINS
INTAKE MANIFOLD VACUUM PORT REPAIR—
2.7L
The composite intake manifold vacuum ports can
be repaired. Although, if the manifold plenum chamber is damaged or cracked, the manifold must be
replaced.
To repair a broken or damaged vacuum nipple
(port) on the composite intake manifold, perform the
following procedure:
PARTS REQUIRED
TOOLS REQUIRED
Brass Nipple – 3/8” O.D.
x 1/4” pipe thread (Speed
Control Port)
Pipe Tap – 1/4” - 18 NPT
Brass Nibble – 1/2” O.D.
x 1/4” pipe thread (Brake
Booster Port)
Drill Bit – 7/16”
(4) Apply Mopart Thread Sealant to threads of
repair nipple(s).
(5) Install repair nipple(s). Do not over torque
repair nipple(s).
File/Sand Paper
NOTE: While performing this procedure, avoid getting the manifold material residue into the plenum
chamber.
(1) File or sand the remaining port back until a
flat surface is obtained (plane normal to nipple (port)
axis).
(2) Drill out the nipple (port) base using a 7/16”
drill bit (Fig. 38).
(3) Using a 1/4”–18 NPT pipe tap, cut internal
threads (Fig. 38). Use caution to start tap in a axis
same as original nipple.
Fig. 38 Manifold Port (Nipple) Repair
1 – 1/4” — 18NPT PIPE TAP
2 – NIPPLE (PORT)
2.7L ENGINE
LH
9 - 31
SERVICE PROCEDURES (Continued)
Fig. 39 Engine Mounting—Right, Left, and Rear
1
2
3
4
5
–
–
–
–
–
NUT
REAR ISOLATOR
BOLT
NUT
ISOLATOR
6
7
8
9
–
–
–
–
HEAT SHIELD
BOLT
ENGINE MOUNT BRACKET
NUT
ENGINE MOUNTS—LEFT AND RIGHT
(5) Install the upper attaching nuts to mount and
tighten to 61 N·m (45 ft. lbs.) (Fig. 39).
(6) Lower vehicle.
REMOVAL
ENGINE HYDRO-MOUNT ISOLATORS
REMOVAL AND INSTALLATION
(1) Raise vehicle on hoist.
(2) Remove the isolator attaching nuts from top of
the mounting bracket (Fig. 39).
(3) Support the engine with a jack and a block of
wood across the full width of the oil pan.
(4) Remove the lower attaching nuts from the bottom of the isolator to the frame (Fig. 39).
(5) Raise engine carefully with jack enough to
remove the isolator with heat shield from its mount.
INSTALLATION
(1) Install isolator mount with heat shield onto the
frame.
(2) Lower the engine onto the isolator mount.
(3) Remove jack from vehicle.
(4) Tighten the isolator to frame nuts to 61 N·m
(45 ft. lbs.) (Fig. 39).
Engine hydro-mounts may show surface cracks,
this will not effect performance and hydro-mount
should not be replaced. Only replace the engine
hydro-mounts when leaking fluid:
• Driveshaft Diagnosis. Refer to DIFFERENTIAL
AND DRIVELINE.
• Any front end structural damage (after repair).
• Isolator replacement.
ENGINE MOUNT—REAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Support transaxle with a jack.
(3) Remove isolator nuts from the mount to transaxle mount bracket (Fig. 39).
(4) Remove rear mount isolator bolts to crossmember and remove mount (Fig. 39).
9 - 32
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Position isolator onto crossmember.
(2) Install bolts attaching isolator to crossmember
and tighten to 33 N·m (250 in. lbs.) (Fig. 39).
(3) Lower transaxle onto isolator.
(4) Install isolator nuts and tighten to 61 N·m (45
ft. lbs.) (Fig. 39).
(5) Lower vehicle.
STRUCTURAL COLLAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove bolts attaching structural collar to oil
pan and transmission housing (Fig. 40).
(3) Remove collar (Fig. 40).
ENGINE ASSEMBLY
REMOVAL
(1) Release fuel pressure. Refer to FUEL SYSTEM
for procedure.
(2) Disconnect negative cable at remote jumper
terminal located at right strut tower (Fig. 41).
(3) Mark hood position at hinges and remove hood.
(4) Drain cooling system. Refer to COOLING SYSTEM for procedure.
(5) Remove both wiper arms.
(6) Remove right and left cowl covers (Fig. 42).
(7) Remove cowl support (Fig. 43).
(8) Remove air cleaner assembly and air inlet hose
(Fig. 44).
(9) Remove upper radiator crossmember. Refer to
BODY for procedure.
Fig. 40 Structural Collar
1 – BOLT-HORIZONTAL
2 – BOLT-VERTICAL
3 – STRUCTURAL COLLAR
INSTALLATION
CAUTION: The collar must be tighten using this
service procedure, as damage to collar and/or oil
pan may occur.
(1) Install structural collar (Fig. 40) using the following tightening sequence:
a. Install the vertical collar to oil pan bolts.
Torque bolts initially to 1.1 N·m (10 in. lbs.).
b. Install the horizontal collar to transmission
bolts and torque to 55 N·m (40 ft. lbs.).
c. Starting with the center vertical bolts and working outward, final torque bolts to 55 N·m (40 ft. lbs.).
(2) Lower vehicle.
Fig. 41 Negative Cable Remote Terminal
1 – RIGHT STRUT TOWER
2 – BATTERY NEGATIVE CABLE
2.7L ENGINE
LH
9 - 33
REMOVAL AND INSTALLATION (Continued)
Fig. 42 Cowl Covers
1 – WINDSHIELD
2 – LEFT COWL COVER
3 – RIGHT COWL COVER
Fig. 44 Air Cleaner and Inlet Hose
1 – AIR CLEANER ASSEMBLY WITH AIR INLET HOSE
2 – THROTTLE BODY
(20) Remove accessory drive belts. Refer to COOLING SYSTEM.
(21) Remove power steering pump mounting bolts
and set pump aside. Refer to STEERING for procedure.
NOTE: Generator can be removed with engine
assembly.
Fig. 43 Cowl Support
1 – COWL SUPPORT
2 – WINDSHIELD
3 – SUPPORT FASTENERS
(11) Disconnect hood release cable from hood latch.
(12) Remove cooling fan module. Refer to COOLING SYSTEM.
(13) Disconnect upper radiator hose at engine.
(14) Disconnect lower radiator hose at radiator.
(15) Disconnect engine oil cooler lines at radiator
(if equpped).
(16) Disconnect transmission oil cooler lines at
radiator.
(17) Remove fasteners attaching A/C condenser to
radiator.
(18) Remove transaxle cooler lines support bracket
and attaching screw at left side of radiator.
(19) Remove radiator.
(22) Disconnect A/C compressor electrical connector.
(23) Remove A/C compressor mounting bolts and
set compressor aside.
(24) Loosen and remove V-Band clamps at exhaust
manifolds.
(25) Disconnect throttle and speed control cables.
(26) Disconnect coolant hoses at coolant pressure
bottle.
(27) Disconnect heater hoses.
(28) Perform fuel pressure release procedure and
disconnect fuel line.
(29) Disconnect all vacuum lines and electrical
connectors.
(30) Disconnect all ground straps attaching to
engine.
(31) Hoist vehicle and drain engine oil.
(32) Remove fasteners supporting catalytic converter down pipes at front and rear mounts.
(33) Remove structural collar bolts from oil pan
and transaxle. Remove structural collar.
9 - 34
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(34) Mark flex plate to torque converter position.
Remove torque converter bolts.
(35) Disconnect both transaxle cooler line brackets
from engine.
(36) Remove starter. Refer to STARTING for procedure.
(37) Remove crankshaft position sensor.
(38) Remove the two lower transaxle to block bolts.
(39) Lower vehicle.
(40) Remove EGR valve assembly. Refer to EMISSION CONTROL SYSTEMS for procedure.
(41) Remove screws attaching fuel line and electrical harness to the throttle body bracket.
(42) Remove the fasteners attaching the following
brackets to the transaxle to block double-ended bolts:
• Electrical harness attaching bracket.
• Transaxle shift cable attaching bracket.
• Throttle body support bracket.
(43) Remove the upper transaxle to block bolts.
(44) Remove right and left engine mount isolator
to engine mount bracket fasteners.
(10) Install the transaxle oil cooler lines bracket to
engine
(11) Install structural collar to oil pan and transaxle. Refer to procedure in this section.
(12) Lower vehicle.
(13) Install rear throttle body support bracket.
(14) Install electrical harness and fuel line support
brackets to the throttle body support bracket.
(15) Install fastener attaching electrical harness
bracket to the transaxle to block bolt.
(16) Install EGR valve assembly. Refer to EMISSION CONTROL SYSTEMS for procedure.
(17) Connect heater hoses.
(18) Connect all ground straps to engine.
(19) Connect all vacuum hoses and electrical connectors.
(20) Connect both hoses at coolant pressure bottle.
(21) Connect throttle and speed control cables.
(22) Connect fuel line.
CAUTION: Intake manifolds and cylinder head covers are a composite design. Therefore, care should
be taken when lifting the engine from engine compartment.
(23) Install new V-Band clamps at exhaust manifolds and tighten to 11 N·m (100 in. lbs.).
(24) Install catalytic converter down pipe front and
rear supports.
(25) Install air conditioning compressor and
tighten fasteners to 28 N·m (250 in. lbs.)
(26) Install power steering pump and tighten fasteners to 28 N·m (250 in. lbs.).
(27) Install radiator.
(28) Connect engine oil cooler lines to radiator (if
equipped).
(29) Connect transmission oil cooler lines to radiator.
(30) Attach A/C condenser to radiator.
(31) Install lower radiator hose.
(32) Install upper radiator hose.
(33) Install accessory drive belts and cooling fan
module. Refer to COOLING SYSTEM for procedures.
(34) Refill cooling system. Refer to COOLING SYSTEM for procedure.
(35) Fill engine with proper amount of oil.
(36) Connect hood release cable to hood latch and
install upper radiator crossmember.
(37) Install air cleaner and air inlet hose.
(38) Install cowl support.
(39) Install right and left cowl covers.
(40) Install both wiper arms.
(41) Install hood.
(42) Connect negative cable to remote jumper terminal at right strut tower.
(45) Attach Special Tool 8342, Engine Lifting Fixture to engine at the locations shown in (Fig. 45).
(46) Support transaxle with a floor jack.
(47) Hoist engine from engine compartment.
INSTALLATION
(1) Attach Special Tool 8342, Engine Lifting Fixture to engine (Fig. 45). Lower engine into engine
compartment.
CAUTION: Do not tighten the transaxle case to
engine block bolts until all bolts have been hand
started, and the two mating surfaces are completely
joined together, as damage to cylinder block or
transaxle could occur.
(2) Align engine mounts and install fasteners but
do not tighten until all mounting bolts have been
installed.
(3) Install transaxle case to engine block bolts and
tighten to 102 N·m (75 ft. lbs.).
(4) Remove Engine Lifting Fixture.
(5) Tighten left and right engine mount isolator to
engine mount bracket fasteners to 61 N·m (45 ft.
lbs.).
(6) Raise vehicle.
(7) Align flex plate to torque converter and install
mounting bolts tighten to 75 N·m (55 ft. lbs.).
(8) Install crankshaft position sensor.
(9) Install starter.
NOTE: Do not reuse V-Band clamps.
2.7L ENGINE
LH
9 - 35
REMOVAL AND INSTALLATION (Continued)
Fig. 45 Engine Lifting Fixture
1 – SPECIAL TOOL 8342 ENGINE LIFTING FIXTURE
2 – ATTACHING LOCATION
CRANKSHAFT DAMPER
REMOVAL
(1) Remove upper radiator crossmember. Refer to
BODY for procedure.
(2) Remove fan module and accessory drive belts.
Refer to COOLING SYSTEM for procedures.
3 – ATTACHING LOCATION
(3) Remove damper center bolt while holding the
damper with Special Tool 8191 (Fig. 46).
CAUTION: Before removing damper, verify that A/C
belt tensioner is not contacting the damper, as
damage could occur to tensioner, timing chain
cover, and/or damper.
9 - 36
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(4) Remove damper by using Special Tools 8194
Insert and 1023 Three Jaw Puller (Fig. 47).
Fig. 48 Crankshaft Damper—Installation
1 – SPECIAL TOOL 6792–1
2 – SPECIAL TOOL 8179
Fig. 46 Crankshaft Damper Center Bolt—Removal
and Installation
1 – SPECIAL TOOL 8191
(2) Install damper center bolt. Tighten center bolt
while holding the damper with Special Tool 8191 to
170 N·m (125 ft. lbs.) (Fig. 46).
(3) Install accessory drive belts and cooling fan
module. Refer to COOLING SYSTEM for procedures.
(4) Install upper radiator crossmember. Refer to
BODY for procedure.
INTAKE MANIFOLD—UPPER
REMOVAL
Fig. 47 Crankshaft Damper—Removal
1 – SPECIAL TOOL 1023
2 – SPECIAL TOOL 8194 INSERT
INSTALLATION
(1) Install damper using Special Tools 8179 Screw,
with Nut and Thrust Bearing from 6792, and 6792-1
Installer (Fig. 48).
(1) Disconnect negative cable from battery remote
jumper terminal.
(2) Remove air inlet resonator and inlet tube.
(3) Remove throttle cable and speed control cable
from throttle arm and bracket.
(4) Remove throttle cable bracket.
(5) Disconnect electrical connectors from the following components (Refer to FUEL SYSTEM for component locations):
• Manifold Absolute Pressure (MAP) Sensor
• Intake Air Temperature (IAT) Sensor
• Throttle Position Sensor (TPS) Sensor
• Idle Air Control (IAC) Motor
• Manifold Tuning Valve (MTV)—(if equipped)
(6) Disconnect Vapor Purge hose, Brake Booster
hose, Speed Control Servo, Positive Crankcase Ventilation (PCV) hose.
(7) Remove EGR tube. Refer to EMISSION CONTROL SYSTEMS for procedure.
(8) Loosen upper fastener at throttle body support
bracket.
2.7L ENGINE
LH
9 - 37
REMOVAL AND INSTALLATION (Continued)
(9) Remove engine name cover from manifold by
applying upward pressure to release retaining clip.
(10) Remove manifold attaching bolts.
(11) Remove upper manifold.
(9) Install throttle cable bracket.
(10) Install throttle and speed control cables to
bracket and throttle arm.
(11) Connect negative cable to battery remote
jumper terminal.
INTAKE MANIFOLD—LOWER
REMOVAL
(1) Release fuel system pressure. Refer to FUEL
SYSTEM for procedure.
(2) Remove upper intake manifold. Refer to procedure in this section.
(3) Disconnect electrical connectors from the fuel
injectors.
(4) Remove fuel supply hose from fuel rail.
(5) Remove screw attaching fuel rail support
bracket to the throttle body support bracket.
(6) Remove bolts attaching fuel rail.
(7) Remove fuel rail and injectors as an assembly.
(8) Remove manifold attaching bolts.
(9) Remove lower manifold.
Fig. 49 Upper Intake Manifold Tightening Sequence
INSTALLATION
(1) Clean and inspect sealing surfaces. Gaskets
can be reused, if free of cuts or tears.
NOTE: Make sure fuel injectors and wiring harnesses are in correct position to not interfere with
upper manifold installation.
(2) Position upper manifold onto lower manifold.
(3) Install manifold attaching bolts and tighten in
sequence shown in (Fig. 49) to 12 N·m (105 in. lbs.).
(4) Install engine name cover to manifold.
(5) Tighten upper fastener at throttle body support
bracket.
(6) Install EGR tube to manifold. Refer to EMISSION CONTROL SYSTEMS for procedure.
(7) Connect speed control servo hose, PCV hose,
and vapor purge hoses.
(8) Connect electrical connectors to the following
components:
• Manifold Absolute Pressure (MAP) Sensor
• Intake Air Temperature (IAT) Sensor
• Throttle Position Sensor (TPS) Sensor
• Idle Air Control (IAC) Motor
• Manifold Tuning Valve (MTV)—(if equipped)
Fig. 50 Lower Intake Manifold Tightening Sequence
INSTALLATION
(1) Clean and inspect sealing surfaces of cylinder
head and manifold. Gaskets can be reused provided
they are free of cuts or tears.
9 - 38
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(2) Position manifold on cylinder head surfaces.
NOTE: For ease of installing upper intake manifold,
install a bolt 2 – 3 turns to the rearmost attaching
hole of intake. This will properly position lower
manifold.
(3) Install fuel rail with injectors.
(4) Install manifold attaching bolts and tighten in
sequence shown in (Fig. 50) to 12 N·m (105 in. lbs.).
Remove bolt used for aligning manifold.
(5) Connect the fuel injector electrical connectors.
NOTE: Make sure fuel injectors are located in the
correct position, as upper intake manifold interference could occur.
(6) Install screw attaching fuel rail support
bracket to the throttle body support bracket.
(7) Connect fuel supply hose to fuel rail.
(8) Install upper intake manifold. Refer to procedure in this section.
(9) With the DRB scan tool use ASD Fuel System
Test to pressurize system to check for leaks.
INSTALLATION
(1) Install exhaust manifold and gasket. Tighten
bolts working from center outwards to 23 N·m (200
in. lbs.) (Fig. 51).
(2) Install heat shields. Tighten attaching screws
to 12 N·m (105 in. lbs.) (Fig. 51).
(3) Install a new V-Band clamp and tighten 10
N·m (100 in. lbs.).
(4) Install oxygen sensor and connect electrical
connector.
(5) Install EGR tube using new gaskets. Tighten
screws to 11 N·m (95 in. lbs.).
(6) Install bolt attaching battery cable housing
tube to transmission housing. Tighten bolt to 101
N·m (75 ft. lbs.).
(7) Install air intake plenum and air filter housing.
(8) Connect negative cable.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD relay will remain energized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
EXHAUST MANIFOLD
RIGHT EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Remove air intake plenum and air filter housing.
(3) Remove bolt attaching battery cable housing
tube to transmission housing.
(4) Remove bolts attaching EGR tube from exhaust
manifold and EGR valve. Discard gaskets.
(5) Disconnect electrical connector and remove
exhaust manifold mounted oxygen sensor.
(6) Loosen and remove the manifold to catalytic
converter V-Band clamp.
NOTE: Do not reuse V-Band clamp.
(7) Remove heat shield attaching screws and
remove heat shields (Fig. 51).
(8) Remove exhaust manifold attaching bolts and
remove manifold (Fig. 51).
Fig. 51 Exhaust Manifold—2.7L Engine
1
2
3
4
5
6
–
–
–
–
–
–
HEAT SHIELD
BOLT
GASKET
BOLT
EXHAUST MANIFOLD
HEAT SHIELD
LEFT EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Raise vehicle on hoist.
(3) Remove exhaust system. Refer to EXHAUST
SYSTEM for procedure.
2.7L ENGINE
LH
9 - 39
REMOVAL AND INSTALLATION (Continued)
(4) Remove left catalytic converter.
EXHAUST SYSTEM for procedure.
Refer
to
NOTE: Do not reuse V-Band clamp.
NOTE: Cylinder head cover attaching bolts are captured to the cover.
(7) Remove cylinder head covers.
(5) Remove bolt attaching transmission dipstick
tube and rotate housing away from engine.
(6) Lower vehicle.
(7) Remove screws attaching the two electrical connectors and harness to support bracket.
(8) Remove engine wiring harness support bracket
from cylinder head.
(9) Disconnect exhaust manifold mounted oxygen
sensor connector and remove sensor from manifold.
(10) Remove engine oil dipstick tube.
(11) Remove heat shield attaching screws and
remove heat shields (Fig. 51).
(12) Remove exhaust manifold attaching bolts and
remove manifold (Fig. 51).
INSTALLATION
(1) Install exhaust manifold and gasket. Tighten
bolts starting at the center working outward to 23
N·m (200 in. lbs.) (Fig. 51).
(2) Install heat shields. Tighten screws to 12 N·m
(105 in. lbs.) (Fig. 51).
(3) Install oxygen sensor and connect electrical
connector.
(4) Raise vehicle on hoist.
(5) Install bolt attaching transmission dipstick
tube.
(6) Replace the O-ring on engine oil dipstick tube
and install tube.
(7) Install catalytic converter. Refer to EXHAUST
SYSTEM for procedures.
(8) Install a new V-Band clamp and tighten to 10
N·m (100 in. lbs.).
(9) Install engine wiring harness support bracket
to cylinder head and attach connectors to bracket.
(10) Install exhaust system. Refer to EXHAUST
SYSTEM for procedure.
(11) Connect negative cable.
CYLINDER HEAD COVERS
REMOVAL
(1) Remove upper intake manifold. Refer to procedure in this section.
(2) Remove electrical connectors from ignition
coils.
(3) Remove ground strap from right cylinder head.
(4) Disconnect electrical and vacuum harness
retaining clips from cylinder head cover studs.
(5) Remove fasteners attaching ignition coil capacitors.
(6) Loosen all cylinder head cover attaching bolts
(Fig. 52).
Fig. 52 Cylinder Head Covers
Fig. 53 Cylinder Head Cover Gasket and Spark Plug
Seals
1 – ONE PIECE GASKET
2 – SPARK PLUG WELL SEALS
INSTALLATION
(1) Clean cylinder head cover and both sealing surfaces. Inspect and replace gaskets as necessary (Fig.
53).
(2) Install cylinder head covers and hand start all
fasteners. Verify that all double-ended studs are in
the correct locations as shown in (Fig. 52).
9 - 40
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(3) Tighten cylinder head cover attaching bolts and
double-ended studs to 12 N·m (105 in. lbs.).
(4) Connect all electrical connectors and harness
clips.
(5) Install ignition coil capacitors and fasteners.
(6) Install upper intake manifold. Refer to procedure in this section.
CAMSHAFT
REMOVAL
(2) If camshaft chain tensioner is already in the
compressed and locked position, proceed to step (4).
(3) When the camshaft chain tensioner is removed,
it is necessary to compress and lock the tensioner
using the following procedures:
(a) Place tensioner into a soft jaw vise (Fig. 55).
(b) SLOWLY compress tensioner until fabricated
lock pin or the equivalent can be inserted into the
locking holes.
(c) Remove compressed and locked tensioner
from the vise.
(1) Remove the primary timing chain. Refer to procedure in this section.
(2) Remove secondary chain tensioner mounting
bolts.
NOTE: Camshaft bearing caps have been marked
during engine manufacturing. For example, number
one exhaust camshaft bearing is marked “1E>”
(3) Slowly loosen camshaft bearing cap bolts in
reverse order of installation (Fig. 54).
(4) Remove camshaft bearing caps.
(5) Remove camshafts, secondary chain, and tensioner together as an assembly.
(6) Remove tensioner and camshaft chain from
camshafts.
(7) Inspect camshafts. Refer to Cleaning and
Inspection in the Section.
Fig. 55 Locking Camshaft (Secondary) Chain
Tensioner
1 – VISE
2 – LOCK PIN
Fig. 54 Camshaft Bearing Cap Tightening Sequence
INSTALLATION
CAUTION: When the timing chain is removed and
the cylinder heads are installed, DO NOT rotate the
camshafts or crankshaft without first locating the
proper crankshaft position. Failure to do so will
result in valve and/or piston damage.
(1) Assemble camshaft chain on the cams. Ensure
that plated links are facing toward the front. Align
the plated links to the dot on the camshaft sprockets
(Fig. 56).
(4) Insert the compressed and locked camshaft
chain tensioner in-between the camshafts and chain.
(5) Rotate the cams so that the plated links and
dots are facing the 12:00 O’clock position (Fig. 56).
(6) Install cams to cylinder head. Ensure that
rocker arms are correctly seated and in proper positions.
(7) Install camshaft bearing caps. Ensure that
bearing caps are installed in same position as
removed.
(8) Tighten cam bearing cap bolts gradually in
sequence shown in (Fig. 54) to 12 N·m (105 in. lbs.).
(9) Install secondary chain tensioner bolts and
tighten to 12 N·m (105 in. lbs.).
(10) Remove locking pin from secondary tensioners.
(11) Measure camshafts end play by mounting a
dial indicator to a stationary point on cylinder head.
Locate the probe perpendicular against the end of
camshaft being checked. Move camshaft all the way
to the rear of its travel. Zero the dial indicator. Move
camshaft forward to limits of travel and read the dial
indicator (Fig. 57).
2.7L ENGINE
LH
9 - 41
REMOVAL AND INSTALLATION (Continued)
(12) Install primary timing chain. Refer to procedure in this section.
CAUTION: Always rotate engine by turning the
crankshaft. Failure to do so will result in valve
and/or piston damage.
(2) Rotate engine until the cam lobe is on its base
circle (heel), on the rocker arm being removed.
CAUTION: Depress valve spring only enough to
remove rocker arm.
(3) Using Special Tools 8215 and 8216 Adaptor,
depress valve spring only enough to release tension
on rocker arm (Fig. 58).
(4) Remove rocker arm from cylinder head.
CAUTION: If rocker arms are to be reused, identify
position of rocker arms for reassembly in their original positions.
(5) Repeat procedure for each rocker arm being
removed.
Fig. 56 Camshaft Chain Timing
1 – PLATED CHAIN LINKS
2 – CAMSHAFT TIMING MARKS
Fig. 58 Rocker Arm—Removal/Installation
1 – SPECIAL TOOL 8215
2 – ADAPTOR 8216
INSPECTION
Inspect the rocker arm for wear or damage (Fig.
59). Replace as necessary.
INSTALLATION
Fig. 57 Camshaft End Play Measuring
1 – DIAL INDICATOR
ROCKER ARMS
REMOVAL
(1) Remove cylinder head cover(s). Refer to procedure in this section.
(1) Lubricate rocker arms with clean engine oil
before installation.
(2) Rotate engine until cam lobe is on its base circle (heel) of rocker arm being installed.
(3) Using Special Tools 8215 and 8216 Adaptor,
depress valve spring only enough to install rocker
arm (Fig. 58).
(4) Install rocker arm in original position (if
reused) over valve and lash adjuster. Release tension
on valve spring.
9 - 42
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
Fig. 59 Rocker Arm
1 – TIP
2 – LASH ADJUSTER POCKET
3 – ROLLER
NOTE: Inspect rocker arm for proper engagement
into lash adjuster and valve tip.
(3) Remove air cleaner housing cover and inlet
hose.
(4) Remove upper intake manifold. Refer to procedure in this section.
(5) Remove cylinder head cover(s). Refer to procedure in this section.
(6) Remove crankshaft damper, timing chain cover,
and timing chain. Refer to procedures in this section.
(7) Remove camshafts. Refer to procedure in this
section.
(8) With air hose attached to spark plug adapter
installed in the cylinder being serviced, apply 620.5 –
689 kPa (90 – 100 psi) air pressure. This is to hold
valves in place while servicing components.
(9) Using Special Tool MD 998772A with adapter
6779, compress valve spring and remove valve locks,
retainer, and valve spring.
(10) Remove valve stem seals by using a valve seal
tool (Fig. 60).
(5) Repeat procedure for each rocker arm being
installed.
(6) Install cylinder head cover(s). Refer to procedure in this section.
HYDRAULIC LASH ADJUSTER
REMOVAL
(1) Remove cylinder head cover(s). Refer to procedure in this section.
(2) Remove rocker arm(s). Refer to procedure in
this section.
CAUTION: If lash adjusters and rocker arms are to
be reused, always mark position for reassembly in
their original positions.
(3) Remove lash adjuster(s).
INSTALLATION
(1) Install hydraulic lash adjuster making sure
adjusters are at least partially full of oil. This can be
verified by little or no plunger travel when lash
adjuster is depressed.
(2) Install rocker arm(s) and cylinder head covers.
Refer to procedure in this section.
VALVE STEM SEALS OR VALVE SPRINGS—IN
VEHICLE
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs. Refer to FUEL
SYSTEM for procedure.
(2) Disconnect negative cable from remote jumper
terminal.
Fig. 60 Valve Stem Seal—Removal
1 – VALVE SEAL TOOL
2 – VALVE STEM
INSTALLATION
(1) The valve stem seal/valve spring seat should be
pushed firmly and squarely over the valve guide
using the valve stem as guide. Do Not Force seal
against top of guide. When installing the valve
retainer locks, compress the spring only enough to
install locks
(2) Follow the same procedure on the remaining 5
cylinders using the firing sequence 1-2-3-4-5-6. Make
sure piston is at TDC on the cylinder that the
valve spring is to be removed.
(3) Remove spark plug adapter tool and Special
Tool MD 998772A.
(4) Install rocker arm(s). Refer to procedure in this
section.
(5) Install camshafts, timing chain, and timing
chain cover.
(6) Install cylinder head covers.
(7) Install upper intake manifold.
2.7L ENGINE
LH
9 - 43
REMOVAL AND INSTALLATION (Continued)
(8) Connect negative cable.
(12) Remove V-Band clamp(s) at exhaust manifold
to catalytic converter pipe.
CYLINDER HEAD
NOTE: Do not reuse V-Band clamp.
REMOVAL
(1) Perform fuel pressure release procedure before
attempting any repairs. Refer to FUEL SYSTEM
for procedure.
(2) Disconnect negative cable from remote jumper
terminal.
(3) Drain cooling system and remove accessory
drive belts. Refer to COOLING SYSTEM for procedures.
(4) Remove crankshaft damper.
(5) Remove upper and lower intake manifolds.
Refer to procedures in this section.
(6) Remove cylinder head cover and timing chain
cover. Refer to procedure in this section.
(7) Remove water outlet connector (Fig. 61). Refer
to COOLING SYSTEM for procedure.
CAUTION: Ensure cylinder head bolts 11–9 (Fig. 63)
are removed before attempting the removal of cylinder head, as damage to cylinder head and/or block
may occur.
(13) Remove cylinder head bolts in reverse
sequence of installation (Fig. 63) starting with bolts
11–9, then bolts 8–1.
(14) Remove cylinder head(s).
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 (Fig. 62).
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. 62).
Fig. 62 Checking Cylinder Head Bolts for Stretching
(Necking)
1
2
3
4
–
–
–
–
STRETCHED BOLT
THREADS ARE NOT STRAIGHT ON LINE
THREADS ARE STRAIGHT ON LINE
UNSTRETCHED BOLT
Fig. 61 Water Outlet Connector
1 – BOLT (2)
2 – BOLT (2)
3 – WATER OUTLET CONNECTOR
(8) Rotate crankshaft until crankshaft sprocket
timing mark aligns with timing mark on oil pump
housing.
(9) Remove primary timing chain. Refer to procedure in this section.
(10) Remove camshaft bearing caps gradually in
reverse sequence of installation (Fig. 64).
(11) Remove camshafts from cylinder head.
CAUTION: When cleaning cylinder head and cylinder 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 sealing surfaces of cylinder head and
block.
(2) Install new head gasket over locating dowels.
(3) Install cylinder head to block, assuring head is
properly positioned over locating dowels.
(4) Lubricate bolt threads with clean engine oil
and install bolts.
9 - 44
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(5) Tighten bolts in sequence shown in (Fig. 63),
using the following steps and torque values:
• Step 1: Bolts 1–8 to 48 N·m (35 ft. lbs.)
• Step 2: Bolts 1–8 to 75 N·m (55 ft. lbs.)
• Step 3: Bolts 1–8 to 75 N·m (55 ft. lbs.)
• Step 4: Bolts 1–8 to +90° Turn Do not use a
torque wrench for this step.
• Step 5: Bolts 9–11 to 28 N·m (250 in. lbs.)
(12) Install lower and upper intake manifolds.
Refer to procedures in this section.
(13) Install accessory drive belts. Refer to COOLING SYSTEM for procedure.
(14) Fill cooling system. Refer to COOLING SYSTEM for procedure.
(15) Connect negative cable to remote jumper terminal.
VALVE AND VALVE SPRINGS
REMOVAL
(1) With cylinder head removed, compress valve
springs using a Special Tool C-3422-B, Valve Spring
Compressor.
(2) Remove valve retaining locks, valve spring
retainers, valve springs and valve spring seat/stem
seal assembly.
(3) Before removing valves, remove any burrs
from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure
installation in original location.
INSTALLATION
Fig. 63 Cylinder Head Tightening Sequence
(6) Connect catalytic converter to exhaust manifold
with a new V-Band clamp. Tighten V-Band clamp to
10 N·m (100 in. lbs.).
(7) Install camshafts. Refer to procedure in the
section.
(1) Coat valve stems with clean engine oil and
insert them in cylinder head.
(2) If valves or seats have been reground, check
valve tip height (A) (Fig. 65). If valve tip height for
intake valve is greater than 47.59 mm (1.8737 in.) or
49.14 mm (1.9347 in.) for exhaust valve, grind valve
tip until within specifications. Make sure measurement is taken from cylinder head surface to the top
of valve stem.
Fig. 64 Camshaft Bearing Cap Tightening Sequence
(8) Install timing chain and sprockets. Refer to
procedure in this section.
(9) Install water outlet connector (Fig. 61). Refer
to COOLING SYSTEM for procedure.
(10) Install cylinder head covers. Refer to procedure in this section.
(11) Install timing chain cover and crankshaft
damper. Refer to procedures in this section.
Fig. 65 Valve Tip Height and Valve Spring Installed
Height Checking
1
2
3
4
–
–
–
–
SPRING RETAINER
GARTER SPRING
VALVE SPRING SEAT TOP
CYLINDER HEAD SURFACE
2.7L ENGINE
LH
9 - 45
REMOVAL AND INSTALLATION (Continued)
(3) Install valve seal/spring seat assembly over
valve guides on all valve stems (Fig. 66). Ensure that
the garter spring is intact around the top of the rubber seal. Install valve springs, valve retainers.
(4) Compress valve springs with a valve spring
compressor install locks and release tool. If valves
and/or seats are reground, measure the
installed height of springs (B) (Fig. 65), make
sure measurements are taken from top of
spring seat to the bottom surface of spring
retainer. If height is greater than 38.75 mm (1.5256
inches), install a 0.762 mm (0.030 inch.) spacer in
head counterbore under the valve spring seat to
bring spring height back within specification.
(7) Remove timing chain cover attaching bolts and
remove cover (Fig. 67).
Fig. 67 Timing Chain Cover
1
2
3
4
–
–
–
–
GASKET
TIMING CHAIN COVER
BOLT-M6
BOLT-M10
Fig. 66 Valve, Spring, and Valve Stem Seal
1
2
3
4
5
–
–
–
–
–
VALVE
VALVE
VALVE
VALVE
VALVE
RETAINING LOCKS
SPRING RETAINER
SPRING
SEAL AND VALVE SPRING SEAT ASSEMBLY
TIMING CHAIN COVER
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Remove upper radiator support crossmember.
Refer to BODY for procedure.
(3) Remove fan module and accessory drive belts.
Refer to COOLING SYSTEM for procedure.
(4) Remove crankshaft damper. Refer to procedure
in this section.
(5) Remove power steering pump from mounting
bracket.
(6) Remove accessory drive belt tensioner pulley
and bracket.
Fig. 68 Timing Chain Cover Sealing
1 – PLACE A 1/8 INCH BEAD OF SEALER AT PARTING LINE
INSTALLATION
(1) Inspect and clean sealing surfaces. Inspect and
replace gasket and seal as necessary.
9 - 46
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(2) If front crankshaft seal was bench installed,
place Special Tool 6780-2, Sleeve over crankshaft
nose to guide and protect seal lip.
(3) Before installing timing cover gasket apply a
1/8 inch bead of Mopart Engine RTV GEN II to the
parting lines between the oil pan and cylinder block
(Fig. 68).
(4) Install timing cover and gasket. Tighten M10
cover bolts to 54 N·m (40 ft. lbs.) and M6 bolts to 12
N·m (105 in. lbs.) (Fig. 67).
(5) If not previously performed, install crankshaft
oil seal using Special Tool 6780-2 sleeve and 6780-2
installer.
(6) Install crankshaft damper and tighten center
bolt to 170 N·m (125 ft. lbs.).
(7) Attach power steering pump to bracket.
(8) Install A/C belt tensioner assembly to timing
cover.
(9) Install generator/power steering drive belt tensioner pulley and bracket.
(10) Install fan module and accessory drive belts.
Refer to COOLING SYSTEM for procedure.
(11) Install upper radiator crossmember. Refer to
BODY for procedure.
(12) Connect negative cable.
TIMING CHAIN AND SPROCKETS
REMOVAL
(1) Remove upper intake manifold. Refer to procedure in this section.
(2) Remove cylinder head covers, crankshaft
damper, and timing chain cover. Refer to procedures
in this section.
CAUTION: When aligning timing marks, always
rotate engine by turning the crankshaft. Failure to
do so will result in valve and/or piston damage.
Fig. 69 Primary Timing Drive System
1
2
3
4
5
6
–
–
–
–
–
–
CAMSHAFT DAMPER
CHAIN GUIDE
ACCESS PLUG
CAMSHAFT POSITION SENSOR
PRIMARY TIMING CHAIN
CRANKSHAFT SPROCKET
7 – CHAIN GUIDE
8 – CHAIN TENSIONER ARM
9 – CHAIN TENSIONER
10 – CAMSHAFT SPROCKETS
11 – CHAIN GUIDE
2.7L ENGINE
LH
9 - 47
REMOVAL AND INSTALLATION (Continued)
(3) Align crankshaft sprocket timing mark to mark
on oil pump housing (Fig. 70). The mark on oil pump
housing is 60° ATDC of #1 cylinder.
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT rotate
the camshafts or crankshaft without first locating
the proper crankshaft position. Failure to do so will
result in valve and/or piston damage.
(2) If removed, install right and left side short
chain guides (Fig. 69). Tighten attaching bolts to 28
N·m (250 in. lbs.).
(3) Align crankshaft sprocket timing mark to the
mark on oil pump housing (Fig. 71).
NOTE: Lubricate timing chain and guides with
engine oil before installation.
(4) Place left side primary chain sprocket onto the
chain so that the timing mark is located in-between
the two (plated) timing links (Fig. 71).
(5) Lower the primary chain with left side sprocket
through the left cylinder head opening.
NOTE: The camshaft sprockets can be allowed to
float on the camshaft hub during installation.
Fig. 70 Timing Mark Alignment
1 – CAMSHAFT TIMING MARKS
2 – CRANKSHAFT TIMING MARKS
(4) Remove primary timing chain tensioner from
right cylinder head (Fig. 74).
(5) Remove camshaft position sensor from left cylinder head (Fig. 69).
(6) Remove chain guide access plug from left cylinder head (Fig. 69).
NOTE: When camshaft sprocket bolts are removed,
the camshafts will rotate in a clockwise direction.
(7) Starting with the right camshaft sprocket,
remove the sprocket attaching bolts. Remove camshaft damper and sprocket (Fig. 69).
(8) Remove left side camshaft sprocket attaching
bolts and remove sprocket (Fig. 69).
(9) Remove lower chain guide and tensioner arm
(Fig. 69).
(10) Remove the primary timing chain.
INSTALLATION
(1) Inspect all sprockets and chain guides. Replace
if worn. Refer to crankshaft sprocket, for removal
and installation procedures in this section.
(6) Loosely position left side camshaft sprocket
over camshaft hub.
(7) Align timing (plated) link to the crankshaft
sprocket timing mark (Fig. 71).
(8) Position primary chain onto water pump drive
sprocket.
(9) Align right camshaft sprocket timing mark to
the timing (plated) link on the timing chain (Fig. 71)
and loosely position over camshaft hub.
(10) Verify that all chain timing (plated) links are
properly aligned to the timing marks on all sprockets
(Fig. 71).
(11) Install left side lower chain guide and tensioner arm (Fig. 69). Tighten attaching bolts to 28
N·m (250 in. lbs.).
NOTE: Inspect oil ring on chain guide access plug
before installing. Replace O-ring as necessary.
(12) Install chain guide access plug to left side cylinder head (Fig. 69). Tighten plug to 20 N·m (15 ft.
lbs.).
NOTE: To reset the primary timing chain tensioner,
engine oil will first need to be purged from the tensioner (Fig. 72).
(13) Purge oil from timing chain tensioner using
the following procedure:
(a) Place the check ball end of tensioner into the
shallow end of Special Tool 8186 (Fig. 72).
(b) Using hand pressure, slowly depress tensioner until oil is purged from tensioner (Fig. 72).
(14) Reset timing chain tensioner using the following procedure:
(a) Position cylinder plunger into the deeper end
of Special Tool 8186 (Fig. 73).
(b) Apply a downward force until tensioner is
reset (Fig. 73).
9 - 48
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
Fig. 71 Primary Timing Chain Marks
1
2
3
4
5
–
–
–
–
–
CAMSHAFT TIMING MARKS
CHAIN GUIDE
CRANKSHAFT TIMING MARKS
CRANKSHAFT SPROCKET
CHAIN TENSIONER ARM
6 – CHAIN TENSIONER
7 – CAMSHAFT TIMING MARK
8 – INTAKE CAMSHAFT SPROCKETS
9 – CHAIN GUIDES
10 – WATER PUMP SPROCKET
2.7L ENGINE
LH
9 - 49
REMOVAL AND INSTALLATION (Continued)
Fig. 72 Timing Chain Tensioner—Oil Purging
1 – TENSIONER
2 – CHECK BALL
NOTE: If oil was not first purged from the tensioner, use slight finger pressure to assist the center arm pin of Special Tool 8186 to unseat the
tensioner’s check ball.
3 – SPECIAL TOOL 8186
4 – PIN
CAUTION: Ensure the tensioner is properly reset.
The tensioner body must bottom against the top
edge of Special Tool 8186. Failure to properly perform the resetting procedure may cause tensioner
jamming.
9 - 50
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
Fig. 73 Timing Chain Tensioner—Resetting
1 – TENSIONER
2 – SPECIAL TOOL 8186
(15) Install the reset chain tensioner into the right
cylinder head (Fig. 74).
(16) Position tensioner retaining plate and tighten
bolts to 12 N·m (105 in. lbs.) (Fig. 74).
(17) Starting at the right cylinder bank, insert a
3/8” square drive extension with a breaker bar into
intake camshaft drive hub. Rotate camshaft until the
camshaft hub aligns to the camshaft sprocket and
damper attaching holes. Install the sprocket attaching bolts and tighten to 28 N·m (250 in. lbs.) (Fig.
71).
(18) Turn the left side camshaft by inserting a 3/8”
square drive extension with a breaker bar into intake
camshaft drive hub and rotate camshaft until the
sprocket attaching bolts can be installed. Tighten
sprocket bolts to 28 N·m (250 in. lbs.) (Fig. 71).
(19) Rotate engine slightly clockwise to remove
timing chain slack, if necessary.
(20) To arm the timing chain tensioner: Use a flat
bladed pry tool to gently pry tensioner arm towards
the tensioner slightly (Fig. 75). Then, release the tensioner arm. Verify the tensioner is armed (extends).
(21) Install the timing chain cover, crankshaft
damper, and cylinder head covers.
(22) Install camshaft position sensor and connect
electrical connector.
(23) Install upper intake manifold. Refer procedure
in this section.
NOTE: After installation of a reset tensioner, engine
noise will occur after initial start-up. This noise will
normally disappear within 5–10 seconds.
2.7L ENGINE
LH
9 - 51
REMOVAL AND INSTALLATION (Continued)
(2) Remove crankshaft sprocket by first installing
the crankshaft damper bolt. Apply grease or equivalent to damper bolt head and position Special Tools
5048-1, 5048-6, and 8539 on sprocket and crankshaft
nose (Fig. 76). Remove sprocket using care not to
rotate the crankshaft.
Fig. 74 Primary Timing Chain Tensioner
1 – TENSIONER
2 – RETAINER CAP
3 – BOLT
Fig. 76 Crankshaft Sprocket—Removal
1 – SPECIAL TOOL 8539
2 – SPECIAL TOOL 5048-6
3 – SPECIAL TOOL 5048-1
Fig. 75 Timing Chain Tensioner Arming
CRANKSHAFT SPROCKET
REMOVAL
(1) Remove primary timing chain. Refer to procedure in this section.
CAUTION: Use care not to turn crankshaft while
removing crankshaft sprocket, as damage to valves
and or pistons could occur.
Fig. 77 Crankshaft Sprocket—Installation
1 – SPECIAL TOOL 6780–1
2 – SPECIAL TOOL 8179
INSTALLATION
(1) Install crankshaft sprocket using Special Tools
6780-1 and 8179 (Fig. 77) until sprocket bottoms
9 - 52
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
against crankshaft step flange. Use care not to rotate
crankshaft.
(2) Verify that crankshaft sprocket is installed to
proper depth by measuring from sprocket outer face
to end of crankshaft (Fig. 78). Measurement should
read: 39.05 60.50 mm (1.5374 60.020 in.).
(3) Install primary timing chain. Refer to procedure in this section.
INSTALLATION
(1) Install new seal using Special Tools 6780-2
Sleeve, 6780-1 Installer, and 8179 Stud (Fig. 80).
(2) Install crankshaft damper.
Fig. 78 Crankshaft Sprocket Depth Measurement
CRANKSHAFT OIL SEAL—FRONT
REMOVAL
(1) Remove crankshaft damper. Refer to procedure
in this section.
(2) Install Special Tool 8194, Insert into crankshaft
nose. Remove seal using Special Tool 6771, Remover
(Fig. 79).
Fig. 80 Crankshaft Front Oil Seal—Installation
1
2
3
4
–
–
–
–
SPECIAL TOOL 6780–2
SPECIAL TOOL 8179
SPECIAL TOOL 6780–1
SEAL
CRANKSHAFT OIL SEAL—REAR
REMOVAL
(1) Remove transaxle from vehicle. Refer to TRANSAXLE for procedure.
(2) Remove drive plate.
(3) Insert a 3/16” wide flat bladed screwdriver
between the dust lip and the metal case of the crankshaft seal. Angle the screwdriver (Fig. 81) through
the dust lip against the metal case of the seal. Pry
out seal.
Fig. 79 Crankshaft Front Oil Seal—Removal
1 – SPECIAL TOOL 6771
CAUTION: Do not allow the screwdriver blade to
contact the crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (chamfer) is permitted.
2.7L ENGINE
LH
9 - 53
REMOVAL AND INSTALLATION (Continued)
Fig. 81 Rear Crankshaft Oil Seal Removal—Typical
1
2
3
4
5
6
7
8
9
–
–
–
–
–
–
–
–
–
REAR CRANKSHAFT SEAL
ENGINE BLOCK
ENGINE BLOCK
REAR CRANKSHAFT SEAL METAL CASE
PRY IN THIS DIRECTION
CRANKSHAFT
SCREWDRIVER
REAR CRANKSHAFT SEAL DUST LIP
SCREWDRIVER
INSTALLATION
Fig. 82 Crankshaft Rear Seal—Installation
1
2
3
4
–
–
–
–
C-4171 HANDLE
6926–2 INSTALLER
6926–1 GUIDE
SEAL
(2) Remove seal retainer attaching screws (Fig.
83).
(3) Remove retainer and gasket (Fig. 83).
CAUTION: If a burr or scratch is present on the
crankshaft edge (chamfer), clean surface using 400
grit sand paper to prevent seal damage during
installation.
(1) Place Special Tool 6926-1 Guide on crankshaft
(Fig. 82). This is a pilot tool with a magnetic base.
(2) Position seal over pilot tool. Assure that lip of
seal is facing towards the crankshaft during installation. The pilot tool remains on crankshaft during seal
installation.
(3) Using Special Tool 6926-2 Installer, and C-4171
Handle (Fig. 82), drive seal into the retainer housing
until seal is flush with housing surface.
(4) Install drive plate and transaxle. Refer to
TRANSAXLE for procedures.
CRANKSHAFT OIL SEAL RETAINER—REAR
REMOVAL
(1) Remove crankshaft rear oil seal and oil pan.
Refer to procedures in this section.
Fig. 83 Oil Seal Retainer
1 – SCREWS (7)
2 – SEAL RETAINER
9 - 54
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Clean sealing surfaces and replace gasket as
needed.
(2) Install gasket and loose assemble seal retainer
to block.
NOTE: The following steps must be performed to
prevent oil leaks at sealing joints.
(7) Disconnect engine oil cooler line from pan (if
equipped).
CAUTION: Assure removal of the two bolts attaching the timing cover to the oil pan, as damage to
the timing cover and/or oil pan may occur.
(8) Remove oil pan attaching fasteners. Remove oil
pan and gasket (Fig. 86).
(3) Attach Special Tools 8225 to pan rail using the
oil pan fasteners.
NOTE: Make sure that the “2.7L” stamped on the
special tool is facing the cylinder block (flat side of
tools against pan rail).
(4) While applying firm pressure to the seal
retainer against Special Tools 8225 (Fig. 84), tighten
seal retainer screws to 12 N·m (105 in. lbs.).
Fig. 85 Structural Collar
1 – BOLT-HORIZONTAL
2 – BOLT-VERTICAL
3 – STRUCTURAL COLLAR
INSTALLATION
Fig. 84 Rear Crankshaft Seal Retainer Alignment
1 – SPECIAL TOOLS 8225
2 – SEAL RETAINER
(5) Install oil pan and crankshaft rear oil seal.
Refer to procedures in this section.
OIL PAN
REMOVAL
(1) Remove dipstick and tube.
(2) Raise vehicle on hoist.
(3) Drain engine oil and remove oil filter.
(4) Disconnect suspension stabilizer bar and reposition for oil pan clearance. Refer to SUSPENSION
for procedure.
(5) Remove structural collar from oil pan to transmission housing (Fig. 85).
(6) Remove lower bolt attaching the A/C compressor to oil pan.
(1) Clean oil pan and sealing surfaces. Inspect oil
pan and timing chain cover gaskets. Replace as necessary.
(2) Apply a 1/8 inch bead of Mopart Engine RTV
GEN II to the front T-joints (oil pan gasket to timing
cover gasket interface) (Fig. 86).
(3) Install oil pan gasket to block.
NOTE: To prevent oil leaks at oil pan to timing
chain cover, the following tightening sequence procedure must be performed.
(4) Install oil pan and fasteners (Fig. 86) using the
following tightening sequence:
(a) Install oil pan bolts and nuts finger tight
only—just tight enough to compress the gasket’s rubber seal.
(b) Install timing chain cover to pan bolts and
tighten to 12 N·m (105 in. lbs.).
(c) Tighten oil pan bolts to 28 N·m (250 in. lbs.).
(d) Tighten oil pan nuts to 12 N·m (105 in. lbs.).
(5) Install lower bolt attaching the A/C compressor
to oil pan. Tighten bolt to 28 N·m (21 ft. lbs.).
(6) Connect engine oil cooler line to oil pan (if
equipped).
2.7L ENGINE
LH
9 - 55
REMOVAL AND INSTALLATION (Continued)
CRANKSHAFT
REMOVAL
(1) Remove engine from vehicle. Refer to procedure
in this section.
(2) Mount engine on an engine stand.
(3) Drain engine oil and remove oil filter.
(4) Remove oil pan and oil pick-up tube.
(5) Remove idler pulley bracket for accessory drive
belt.
(6) Remove upper intake manifold. Refer to procedure in this section.
(7) Remove cylinder head covers.
(8) Remove timing chain cover.
(9) Remove primary timing chain.
(10) Remove crankshaft sprocket.
(11) Remove oil pump.
(12) Remove crankshaft rear oil seal retainer.
(13) Remove structural windage tray (Fig. 91).
(14) Turn crankshaft until connecting rod cap to be
removed is accessible.
Fig. 86 Oil Pan
1
2
3
4
5
6
7
–
–
–
–
–
–
–
SEALER LOCATION
BOLT-M6
GASKET
NUT-M6
OIL PAN
BOLT-M8
NUT-M6
CAUTION: The collar must be tighten using the following procedure, as damage to the collar or oil
pan may occur.
(7) Install structural collar (Fig. 85) using the following tightening sequence:
(a) Install the vertical collar to oil pan bolts.
Torque bolts initially to 1.1 N·m (10 in. lbs.).
(b) Install the horizontal collar to transmission
bolts and torque to 55 N·m (40 ft. lbs.).
(c) Starting with the center vertical bolts and
working outward, final torque bolts to 55 N·m (40
ft. lbs.).
(8) Install oil filter and drain plug.
(9) Connect suspension stabilizer bar. Refer to
SUSPENSION for procedure.
(10) Lower vehicle and install oil dipstick and
tube.
(11) Fill engine crankcase with proper oil to correct level.
NOTE: Connecting rod bearing caps are not interchangeable and should be marked before removing
to ensure correct reassembly.
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.
(15) Mark connecting rod bearing cap positions
using a permanent ink marker or scribe tool.
(16) Remove connecting rod bearing caps. Use care
to prevent damage to the crankshaft bearing surfaces.
CAUTION: Care should be taken not to damage the
fractured rod and cap joint face surfaces or damage
to the engine may occur.
(17) Remove main bearing cap bolts and tie bolts
(Fig. 87).
(18) Remove main bearing caps (Fig. 87).
CAUTION: When removing crankshaft, use care not
to damage bearing surfaces on the crankshaft.
(19) Remove crankshaft from cylinder block.
INSTALLATION
NOTE: Upper and lower bearing halves are NOT
interchangeable.
9 - 56
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(3) Push crankshaft forward. Lubricate and install
the front thrust washer by rolling the thrust washer
onto the machined shelf between the No. 3 upper
main bulk head and crankshaft thrust surface (Fig.
89).
(4) Move crankshaft rearward. Lubricate and
install the rear thrust washer by rolling the thrust
washer onto the machined shelf between the No. 3
upper main bulk head and crankshaft thrust surface.
Fig. 87 Main Bearing Cap Identification
1 – TIE BOLTS
2 – TIE BOLTS
CAUTION: Main bearings are select fit. Refer to
Crankshaft Main Bearing Fitting in this section for
proper bearing selections.
(1) Lubricate upper main bearing halves with
engine oil (Fig. 88).
CAUTION: When installing crankshaft, use care not
to damage bearing surfaces on the crankshaft.
Fig. 89 Thrust Washer—Installation
1 – FRONT THRUST WASHER
(5) Lubricate lower main bearings with engine oil.
(6) Install main bearings and caps.
NOTE: Lubricate main bearing cap bolts with
engine oil before installation.
Fig. 88 Main Bearing Identification
(2) Install crankshaft.
NOTE: Make sure that the coated and oil groove
side of crankshaft thrust washer faces the crankshaft thrust surface.
The main bearing cap bolts must be tightened in
the proper sequence. First the inner main cap bolts,
secondly the windage tray bolts, and lastly the main
cap tie (horizontal) bolts.
(7) Install the inside main bearing cap bolts and
tighten to 20 N·m + 1/4 Turn (15 ft. lbs. + 1/4 Turn)
(Fig. 90).
(8) Measure crankshaft end play. Refer to Service
Procedures—Crankshaft Bearing Installation for procedure.
(9) Install connecting rods and measure side clearance. Refer to Service Procedures—Connecting Rod
Bearing Installation for procedures.
(10) Install windage tray (Fig. 91). Lubricate bolts
with engine oil and tighten to 27 N·m + 1/4 Turn (20
ft. lbs. + 1/4 turn).
(11) Install the main cap tie (horizontal) bolts and
tighten to 28 N·m (250 in. lbs.) (Fig. 90).
(12) Install rear crankshaft oil seal retainer and
oil seal. Refer to procedures in this section.
(13) Install oil pump assembly. Refer to procedure
in this section.
2.7L ENGINE
LH
9 - 57
REMOVAL AND INSTALLATION (Continued)
OIL FILTER
(1) Remove oil filter using suitable oil filter
wrench (Fig. 92). Dispose of oil filter following enviromental guidelines.
Fig. 90 Main Bearing Cap Identification
1 – TIE BOLTS
2 – TIE BOLTS
Fig. 92 Engine Oil Filter
1 – OIL FILTER
Fig. 91 Windage Tray
1 – STRUCTURAL WINDAGE TRAY
(14) Install crankshaft sprocket. Refer to procedure in this section.
(15) Install timing chain. Refer to procedure in
this section.
(16) Install timing chain cover.
(17) Install cylinder head covers.
(18) Install idler pulley bracket for accessory drive
belt.
(19) Install oil pick-up tube and O-ring.
(20) Install oil pan and oil filter.
(21) Install oil dipstick tube.
(22) Install engine assembly.
(23) Fill engine crankcase with proper oil to correct level.
(2) Wipe filter base clean, then inspect gasket sealing surface.
(3) Lubricate gasket of new filter with clean
engine oil.
(4) Install oil filter and tighten to 20 N·m (15 ft.
lbs.) of torque after gasket contacts base. Use filter
wrench if necessary.
(5) Fill crankcase with proper engine oil to correct
level if drained. Start engine and check for leaks.
OIL PUMP
REMOVAL
The oil pump pressure relief valve can be serviced
by removing the oil pan.
(1) Refer to procedures in this section for removing
the following components:
• Crankshaft Damper
• Timing Chain Cover
• Timing Chain
• Crankshaft Sprocket
• Oil Pan
(2) Remove oil pick-up tube and O-ring (Fig. 94).
(3) Ensure that crankshaft position is at 60° ATDC
of No.1 cylinder, or crankshaft sprocket mark aligns
9 - 58
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
with mark on oil pump (Fig. 93). This position will
properly locate oil pump upon installation.
(4) Remove oil pump attaching bolts (Fig. 94).
(5) Remove oil pump.
Fig. 93 Crankshaft Positioned At 60° ATDC No.1
Cylinder
1 – CRANKSHAFT POSITION = 60° ATDC NO. 1 CYLINDER
INSTALLATION
CAUTION: Crankshaft position must be at 60° ATDC
of No.1 cylinder before installing oil pump (Fig. 93).
This position will properly locate oil pump. If not
properly located, severe damage to oil pump can
occur.
(1) Prime oil pump before installation by filling
rotor cavity with engine oil.
(2) If crankshaft has been rotated, it must be repositioned to 60° ATDC of No.1 cylinder prior to oil
pump installation (Fig. 93).
(3) Install oil pump carefully over crankshaft and
into position.
(4) Install oil pump attaching bolts. Tighten bolts
to 28 N·m (250 in. lbs.) (Fig. 94).
(5) Install oil pick-up tube with new O-ring. Lubricate O-ring before installation. Tighten attaching
bolts to 28 N·m (250 in. lbs.) (Fig. 94).
(6) Install the following remaining components following procedures in this section:
• Oil Pan
• Crankshaft Sprocket
• Timing Chain
• Timing Chain Cover
• Crankshaft Damper
(7) Fill Crankcase with proper engine oil to correct
level.
PISTON AND CONNECTING ROD
REMOVAL
(1) Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons
covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and
connecting rod assemblies from the engine,
rotate crankshaft so that each connecting rod
is centered in cylinder bore.
NOTE: Connecting rod bearing caps are not interchangeable and should be marked before removing
to ensure correct reassembly.
Fig. 94 Oil Pump and Pick-up Tube
1
2
3
4
5
–
–
–
–
–
BOLTS
O-RING
PICK-UP TUBE
BOLT
OIL PUMP
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.
(2) Mark connecting rod and bearing cap positions
using a permanent ink marker or scribe tool (Fig.
95).
2.7L ENGINE
LH
9 - 59
REMOVAL AND INSTALLATION (Continued)
CAUTION: Install piston rings in the following
order:
Fig. 95 Identify Connecting Rod to Cylinder—
Typical
(2) Oil ring expander.
(3) Upper oil ring side rail.
(4) Lower oil ring side rail.
(5) No. 2 Intermediate piston ring.
(6) No. 1 Upper piston ring.
(7) Install the side rail by placing one end between
the piston ring groove and the expander. Hold end
firmly and press down the portion to be installed
until side rail is in position. Do not use a piston
ring expander during this step (Fig. 98).
Fig. 97 Piston Ring—Installation
1 – SPACER EXPANDER
2 – SIDE RAIL
Fig. 96 Connecting Rod Guides
1 – SPECIAL TOOL 8189 CONNECTING ROD GUIDES
CAUTION: Care must be taken not to damage the
fractured rod and cap joint face surfaces, as engine
damage may occur.
(3) Remove connecting rod cap. Install Special Tool
8189 Connecting Rod Guides into the connecting rod
being removed (Fig. 96). Remove each piston and rod
assembly out of cylinder bore.
NOTE: Be careful not to nick crankshaft journals.
(4) After removal, install bearing cap on the mating rod to prevent damage to the fractured cap to rod
surfaces.
PISTON RINGS—INSTALLATION
(1) The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with
manufacturers I.D. mark (dot) facing up, towards top
of the piston (Fig. 97).
Fig. 98 Side Rail—Installation
1 – SIDE RAIL END
(8) Install upper side rail first and then the lower
side rail.
(9) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 99).
9 - 60
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
and tighten with the special wrench. Ensure position of rings does not change during this operation.
Fig. 99 Upper and Intermediate Rings—Installation
(10) Position piston ring end gaps as shown in
(Fig. 100).
(11) Position oil ring expander gap at least 45°
from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is
important for oil control.
Fig. 101 Piston and Connecting Rod—Installation
1
2
3
4
–
–
–
–
“F” TOWARD FRONT OF ENGINE
RING COMPRESSOR
SPECIAL TOOL 8189
OIL SQUIRT HOLE
Fig. 100 Piston Ring End Gap Position
1
2
3
4
5
–
–
–
–
–
SIDE RAIL UPPER
NO. 1 RING GAP
PISTON PIN
SIDE RAIL LOWER
NO. 2 RING GAP AND SPACER EXPANDER GAP
PISTON AND CONNECTING ROD—INSTALLATION
(1) Before installing piston and connecting rod
assemblies into the bore, ensure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 100).
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor over the piston
CAUTION: Ensure the hole in bearing half aligns
with hole in connecting rod, as damage to engine
may occur.
(4) Position bearing onto connecting rod. Ensure
that hole in bearing half is aligned to hole in connecting rod. Lubricate bearing surface with clean
engine oil.
(5) Install Special Tools 8189 Connecting Rod
Guides into connecting rod (Fig. 96).
(6) The pistons are marked on top with an arrow
and with an “F” (Front) above the pin boss. These
marks must be pointing toward the front of engine
on both cylinder banks. The connecting rod oil squirt
hole faces the major thrust (right) side of the block
(Fig. 102).
2.7L ENGINE
LH
9 - 61
REMOVAL AND INSTALLATION (Continued)
Fig. 102 Piston and Connecting Rod Positioning
1 – MAJOR THRUST SIDE OF PISTON
2 – OIL SQUIRT HOLE
(7) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod over
the crankshaft journal (Fig. 101).
CAUTION: Do Not interchange piston assemblies
bank to bank, as engine damage may occur.
(8) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(9) Lubricate rod bolts and bearing surface with
engine oil. Install connecting rod cap and bearing.
Tighten bolts to 27 N·m (20 ft. lbs.) Plus 1/4 turn.
ENGINE CORE AND OIL PLUGS
REMOVAL
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 suitable tool and remove plug (Fig. 103).
CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopart
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.
9 - 62
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
Fig. 103 Core Hole Plug Removal
1
2
3
4
5
–
–
–
–
–
CYLINDER BLOCK
REMOVE PLUG WITH PLIERS
STRIKE HERE WITH HAMMER
DRIFT PUNCH
CUP PLUG
DISASSEMBLY AND ASSEMBLY
Fig. 104 Oil Pressure Relief Valve
OIL PUMP
(1) Remove the pressure relief valve by remove the
threaded retaining cap from the oil pump housing.
1 – RELIEF VALVE
2 – SPRING
3 – RETAINER CAP
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 104) or engine damage
may occur.
(2) Remove spring and relief valve.
(3) Remove oil pump cover screws and lift off cover
plate (Fig. 105).
(4) Remove pump rotors.
(5) Wash all parts in a suitable solvent. Inspect
components carefully for damage or wear. Refer to
Cleaning and Inspection, Oil Pump in this section for
procedures.
(6) Tighten cover screws to 12 N·m (105 in. lbs.)
(Fig. 105). Tighten oil pressure relief valve retaining
cap to 12 N·m (105 in. lbs.) (Fig. 104).
Fig. 105 Oil Pump
1
2
3
4
5
–
–
–
–
–
OIL PUMP COVER
SCREWS (8)
OIL PUMP INNER ROTOR
OIL PUMP HOUSING
OIL PUMP OUTER ROTOR
2.7L ENGINE
LH
9 - 63
CLEANING AND INSPECTION
CYLINDER HEAD
INTAKE MANIFOLD
CLEANING
Check for:
• Damage and cracks of each section.
• Clogged water passages in end cross over and
clogged gas passages.
(1) Use a gasket removal compound to soften the
old gasket material.
EXHAUST MANIFOLD
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface with a straightedge and thickness gauge.
CAMSHAFT
CAUTION: When cleaning the cylinder head and
block mating surfaces, do not use a metal scraper
because the sealing surfaces could be cut or
ground. Instead, use a wooden or plastic scraper.
(2) Make sure the gasket and/or foreign material
does not enter the oil feed hole or the oil return
holes.
INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 107).
(4) Cylinder head must be flat within:
• Standard dimension = less than 0.05 mm (0.002
inch.)
• Service Limit = 0.2 mm (0.008 inch.)
• Grinding Limit = Maximum of 0.2 mm (0.008
inch.) is permitted.
CAUTION: 0.20 mm (0.008 in.) MAX is a combined
total dimension of the stock removal limit from cylinder head and block top surface (Deck) together.
Fig. 106 Camshaft Inspection
1
2
3
4
5
–
–
–
–
–
ACTUAL WEAR
BEARING JOURNAL
EXHAUST CAMSHAFT
INTAKE CAMSHAFT
LOBE
(1) Inspect camshaft bearing journals for damage
and binding (Fig. 106). If journals are binding, check
the cylinder head for damage. Also check cylinder
head oil holes for clogging.
(2) Inspect camshaft sprockets for excessive wear.
Replace camshafts if necessary.
(3) Check the cam lobe surfaces for abnormal wear
and damage. Replace camshaft if defective. Measure
the actual wear (Fig. 106) and replace, if out of limits—standard value is 0.0254 mm (0.001 in.); wear
limit is 0.254 mm (0.010 in.).
Fig. 107 Checking Cylinder Head Flatness—Typical
CAMSHAFT FOLLOWER
Inspect the cam follower assembly for wear or
damage (Fig. 108). Replace as necessary.
VALVE INSPECTION
(1) Clean valves thoroughly and replace burned,
warped and cracked valves.
(2) Measure valve stems for wear (Fig. 109). Refer
to Engine Specifications.
9 - 64
2.7L ENGINE
LH
CLEANING AND INSPECTION (Continued)
Fig. 108 Cam Follower Assembly
1 – LASH ADJUSTER POCKET
2 – OIL SQUIRT HOLE
3 – ROLLER
Fig. 110 Measuring Valve Guide Wear—Typical
NOTE: Valve stems are chrome plated and should
not be polished (Fig. 109).
VALVE GUIDES
NOTE: Replace cylinder head if stem-to-guide
clearance exceeds specifications, or if guide is
loose in cylinder head.
OIL PUMP
INSPECTION AND REPAIR
(1) Clean all parts thoroughly. Mating surface of
the oil pump housing should be smooth. Replace
pump cover if scratched or grooved.
(2) Lay a straightedge across the pump cover surface (Fig. 111). If a 0.025 mm (0.001 inch.) feeler
gauge can be inserted between cover and straight
edge, cover should be replaced.
Fig. 109 Intake and Exhaust Valves
1
2
3
4
–
–
–
–
MARGIN
FACE
STEM
VALVE SPRING RETAINER LOCK GROOVES
(3) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
CHECKING VALVE GUIDES
(1) Measure valve stem-to-guide clearance as follows:
(2) Install valve into cylinder head so it is 15 mm
(0.590 inch.) off the valve seat. A small piece of hose
may be used to hold valve in place.
(3) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 110).
(4) Move valve to and from the indicator. Refer to
Engine Specifications.
Fig. 111 Checking Oil Pump Cover Flatness—
Typical
1 – STRAIGHT EDGE
2 – FEELER GAUGE
3 – OIL PUMP COVER
2.7L ENGINE
LH
9 - 65
CLEANING AND INSPECTION (Continued)
(3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 9.474 mm (0.373
in.) or less (Fig. 112), or if the diameter is 89.174 mm
(3.5108 inches.) or less, replace outer rotor.
Fig. 114 Measuring Outer Rotor Clearance in
Housing
Fig. 112 Measuring Outer Rotor Thickness
1 – FEELER GAUGE
2 – OUTER ROTOR
Fig. 113 Measuring Inner Rotor Thickness
(4) If inner rotor measures 9.474 mm (0.373 inch.)
or less replace inner rotor (Fig. 113).
(5) Slide outer rotor into body, press to one side
with fingers and measure clearance between rotor
and body (Fig. 114). If measurement is 0.39 mm
(0.015 inch.) or more, replace body only if outer rotor
is in specifications.
(6) Install inner rotor into body. If clearance
between inner and outer rotors (Fig. 115) is 0.20 mm
(0.008 inch.) or more, replace both rotors.
(7) Place a straightedge across the face of the body,
between bolt holes. If a feeler gauge of 0.077 mm
(0.003 inch.) or more can be inserted between rotors
and the straightedge, replace pump assembly (Fig.
116) ONLY if rotors are in specs.
(8) Inspect oil pressure relief valve plunger for
scoring and free operation in its bore. Small marks
may be removed with 400-grit wet or dry sandpaper.
Fig. 115 Measuring Clearance Between Rotors
1 – OUTER ROTOR
2 – FEELER GAUGE
3 – INNER ROTOR
(9) The relief valve spring has a free length of
approximately 49.5 mm (1.95 inches) it should test
between 23 – 25 pounds when compressed to 34 mm
(1.34 in.). Replace spring that fails to meet specifications.
9 - 66
2.7L ENGINE
LH
CLEANING AND INSPECTION (Continued)
CYLINDER BORE INSPECTION
The cylinder walls should be checked for out-ofround and taper with Tool C-119 as shown in (Fig.
117).
Measure the cylinder bore at three levels in directions A and B (Fig. 117). Top measurement should be
12 mm (0.50 inch.) down and bottom measurement
should be 12 mm (0.50 inch.) up from bottom of bore.
Refer to Engine Specifications.
NOTE: There are no service procedures to bore the
cylinder bores for installation of oversized pistons.
Fig. 116 Measuring Clearance Over Rotors
1 – STRAIGHT EDGE
2 – FEELER GAUGE
OIL PUMP ASSEMBLY
(1) Assemble pump, using new parts as required.
(2) Tighten cover screws to 12 N·m (105 in. lbs.).
(3) Prime oil pump before installation by filling
rotor cavity with engine oil.
(4) If oil pressure is low and pump is within specifications, inspect for worn engine bearings or other
reasons for oil pressure loss.
CYLINDER BLOCK AND BORE
CLEANING AND INSPECTION
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are installed, refer to Service
Procedures, Engine Core Plugs.
(3) Examine block for cracks or fractures.
(4) Inspect for damaged bolt threads. Repair
threads as needed. Refer to Service Procedures,
Repair of Damaged or Worn Threads.
NOTE: Refer to Honing Cylinder Bores in the Standard Service Procedures for specification and procedures.
(5) After a cylinder honing or deglazing procedure:
(a) Clean bores with soap and water solution.
(b) Thoroughly rinse cylinder bores with clean
water to remove soap/water solution and wipe
bores dry with a clean lint-free cloth.
(c) Oil the bores after cleaning to prevent rusting.
Fig. 117 Cylinder Bore Size Checking
ENGINE HYDRO-MOUNT ISOLATOR
Engine hydro-mounts may show surface cracks.
This will not effect performance and mount should
not be replaced. Only replace the engine hydromounts when leaking fluid:
• Driveshaft diagnosis. Refer to DIFFERENTIAL
AND DRIVELINE.
• Any front end structural damage (after repair).
• Isolator replacement.
TIMING DRIVE SYSTEM
INSPECTION
For checking timing drive system wear limits, use
the following procedure.
(1) Remove right cylinder head cover.
(2) Viewing through the cylinder head timing drive
cavity, inspect the primary chain tensioner plunger.
Rotate the engine clockwise to remove any chain
slack and to achieve the maximum tensioner exten-
2.7L ENGINE
LH
9 - 67
CLEANING AND INSPECTION (Continued)
sion. If a machined groove on the plunger is visible
(Fig. 118), the timing chain and/or related components are worn or stretched to service limits.
(3) Inspect all chain guides, sprockets and tensioners for wear. Replace as necessary following the procedures this section.
DESCRIPTION
SPECIFICATION
Clearance at Size
Location
– 0.0016 to +0.0396 mm
(– 0.0001 to +0.0016 in.)
Piston Weight
316–326 grams
(11.1466–11.4994 oz.)
Piston Ring Groove
Diameter—No. 1
77.65–77.85 mm
(3.0571–3.065 in.)
Piston Ring Groove
Diameter—No. 2
75.72–75.92 mm
(2.9811–2.989 in.)
Piston Ring Groove
Diameter—No. 3
77.42–77.62 mm
(3.0481–3.0559 in.)
Piston Pins
Type
Full Floating
Pin Diameter
21.997–22.000 mm
(0.8661–0.8662 in.)
Fig. 118 Primary Timing Chain Tensioner
1 – MAXIMUM WEAR INDICATOR GROOVE
Clearance in Piston
0.002–0.010 mm
(0.0001–0.0004 in.)
Clearance in Rod
SPECIFICATIONS
0.007–0.018 mm
(0.0003–0.0008 in.)
2.7L ENGINE
Piston Rings
DESCRIPTION
SPECIFICATION
General Specifications
Type
60° DOHC V-6 24-Valve
Displacement
2.7 Liters (167 Cubic
Inches)
86.0 x 78.5 mm
Bore & Stroke
(3.386 in. x 3.091 in.)
Compression Ratio
9.67:1
Lead Cylinder
#1 Right Bank
Firing Order
Ring Gap—Top
Compression Ring
Ring Gap—2nd
Compression Ring
Ring Gap—Oil Control
(Steel Rails)
Compression Rings—Top
and Second
Oil Ring (Steel Rails)
(3.3859 in.)
0.076 mm
Compresion Rings—Top
and Second
Oil Ring (Steel Rails)
(0.003 in.)
(0.010–0.030 in.)
0.040–0.080 mm
(0.0016–0.0031 in.)
0.061–0.207 mm
1.47–1.49 mm
(0.0579–0.0587 in.)
0.445–0.470 mm
Connecting Rods
Bearing Clearance
Pistons
Piston Diameter
0.25–0.76 mm
(0.0176–0.0186 in.)
0.051 mm
(0.002 in.)
Material
(0.0146–0.0249 in.)
Piston Ring Width
86.0 mm
Taper (Max.)
0.37–0.63 mm
(0.0025–0.0082 in.)
Cylinder Block
Out of Round (Max.)
(0.008–0.014 in.)
Piston Ring Side Clearance
1-2-3-4-5-6
Cylinder Bore Diameter
0.20–0.36 mm
0.024–0.064 mm
(0.001–0.0026 in.)
Aluminum Alloy
85.981 mm 60.013
(3.3851 in. 60.0006)
Side Clearance
0.13–0.38 mm
(0.0052–0.015 in.)
9 - 68
2.7L ENGINE
LH
SPECIFICATIONS (Continued)
DESCRIPTION
SPECIFICATION
Side Clearance (Max.)
0.4318 mm
DESCRIPTION
SPECIFICATION
End Play
0.13 mm
(0.017 in.)
Piston Pin Bore Diameter
(0.0051–0.0110 in.)
22.007–22.015 mm
Valve Timing—Intake Valve
(0.8665–0.8668 in.)
Opens (ATDC)
2°
0.004 mm
Closes (ABDC)
44°
Duration
222°
Bearing Bore Out of
Round (Max.)
(0.0002 in.)
529.9 67 grams
Total Weight (Less
Bearing)
(18.6917 60.247 oz.)
Crankshaft Main Bearing Journals
Diameter
63.49–63.51 mm
(2.4997–2.5004 in.)
Bearing Clearance
Valve Timing—Exhaust Valve
Opens (BBDC)
36°
Closes (ATDC)
4°
Duration
Valve Overlap
0.035–0.053 mm
(0.0014–0.0021 in.)
Bearing Clearance (Max.)
Out of Round (Max.)
220°
2°
Cylinder Head
1.50 mm 60.05
0.087 mm
Gasket Thickness
(Compressed)
(0.0591 in. 60.002 in.)
(0.0034 in.)
Valve Seat Angle
44.5°–45°
0.015 mm
Valve Seat Runout (Max.)
(0.0006 in.))
Taper (Max.)
0.015 mm
Intake Valve Seat Width
(0.0006 in.)
End Play
0.0475–0.2725 mm
(0.0019–0.0108 in.)
End Play (Max.)
0.43 mm
(0.017 in.)
Connecting Rod Journals
Diameter
53.51–53.49 mm
Bearing Clearance
(0.0394–0.0591 in.)
Exhaust Valve Seat
Width
1.25–1.75 mm
(0.0492–0.0689 in.)
Guide Bore Diameter
(Std.)
5.975–6.00 mm
(0.2353–0.2363 in.)
Valve Guide Height*—
Intake & Exhaust
13.25–13.75 mm
(0.5217–0.5414 in.)
*Measured from cylinder head surface to top of guide
0.024–0.064 mm
Valves
0.015 mm
Face Angle
45–45.5 mm
Head Diameter—Intake
33.67–33.93
(0.0006 in.)
Taper (Max.)
0.015 mm
(1.3256–1.3358 in.)
Head Diameter—Exhaust
(0.0006 in.)
Camshaft
Bore Diameter
Length—Intake (Overall)
24.000–23.981
(0.9449–0.9441 in.)
Bearing Clearance
Bearing Clearance (Max.)
0.13 mm
(0.0051 in.)
107.89–108.39 mm
(4.2476–4.2673 in.)
Length—Exhaust
(Overall)
Stem Diameter—Intake
0.05–0.09 mm
(0.0020–0.0035 in.)
27.67–27.93 mm
(1.0894–1.1000 in.)
24.050–24.071 mm
(0.9469–0.09476 in.)
Bearing Journal Diameter
1.00–1.5 mm
(2.1067–2.106 in.)
(0.001–0.0026 in.)
Out of Round (Max.)
0.05 mm
(0.002 in.)
105.88–106.38 mm
(4.1685–4.1882 in.)
5.934–5.952 mm
(0.2337–0.2344 in.)
Stem Diameter—Exhaust
5.906–5.924 mm
(0.2326–0.2333 in.)
2.7L ENGINE
LH
9 - 69
SPECIFICATIONS (Continued)
DESCRIPTION
SPECIFICATION
Stem-to-Guide
Clearance—Intake (New)
0.023–0.066 mm
(0.0009–0.0026 in.)
Stem-to-Guide
Clearance—Exhaust
(New)
0.051–0.094 mm
(0.002–0.0037 in.)
Stem-to-Guide
Clearance—Intake (Max.,
Rocking Method)
0.29 mm
(0.0114 in.)
Stem-to-Guide
Clearance—Exhaust
(Max., Rocking Method)
0.370 mm
9.0 mm
(0.3543 in.)
Valve Lift—Exhaust (Zero
Lash)
8.0 mm
(0.3150 in.)
47.120 60.467 mm
(1.8551 60.00184 in.)
48.672 60.467 mm
Valve Stem Tip
Height—Exhaust
SPECIFICATION
Inner & Outer Rotor
Thickness
9.475–9.500 mm
(0.3731–0.3741 in.)
Outer Rotor Clearance
(Max.)
0.39 mm
(0.015 in.)
Outer Rotor Diameter
(Min.)
89.175 mm
(3.5109 in.)
Tip Clearance Between
Rotors (Max.)
0.20 mm
(0.008 in.)
Oil Pressure
(0.0146 in.)
Valve Lift—Intake (Zero
Lash)
Valve Stem Tip
Height—Intake
DESCRIPTION
Pressure @ Curb Idle
Speed*
34.7 kPa
Pressure @ 3000 rpm
170–724 kPa
(5 psi)
(25–105 psi)
*CAUTION: If oil pressure is zero at idle, DO NOT run
engine at 3000 rpm.
TORQUE
(1.9162 60.00184 in.)
Valve Spring
Free Length—Intake &
Exhaust (Approx.)
Spring Force—Intake &
Exhaust (Valve Closed)
DESCRIPTION
45.63 mm
(1.7965 in.)
249–284 N @ 38.0 mm
(56.0–64.0 lbs. @ 1.4961
in.)
Spring Force—Intake
(Valve Open)
658–721 N @ 29.0 mm
Spring Force—Exhaust
(Valve Open)
614–671 N @ 30.0 mm
(147.9–162.1 lbs. @
1.1417 in.)
7.35
Wire Diameter—Intake &
Exhaust
3.861 mm
Installed Height—Intake
& Exhaust (Spring seat to
bottom of retainer)
(0.1520 in.)
28
21
—
Camshaft Sprocket—Bolts
28
—
250
Camshaft Chain Tensioner
(Secondary)—Bolts
12
—
105
Camshaft Bearing Cap—Bolts
12
—
105
Connecting Rod Cap—Bolts
27
20
+ 1 ⁄4
+ 1 ⁄4
Turn Turn
—Tie Bolts
28
Cover—Out-of-Flat
(Max.)
—
250
—Inner Cap Bolts
20
15
+ 1 ⁄4
+ 1 ⁄4
Turn Turn
—
—Outer Cap Bolts
27
20
+1⁄4
+ 1 ⁄4
Turn Turn
—
170
—
Crankshaft Damper—Bolt
Cylinder Head—Bolts
125
Refer to
Procedure
Oil Pump
Clearance Over Rotors
(Max.)
—
Crankshaft Main Bearing Cap
38.0 mm
(1.4961 in.)
Ft.
In.
Lbs. Lbs.
A/C Compressor to Engine—Bolts
(138.0–150.8 lbs. @
1.1811 in.)
Number of Coils—Intake
& Exhaust
N·m
0.077 mm
Cylinder Head Cover—Bolts
12
—
105
(0.003 in.)
Exhaust Manifold—Bolts
23
—
200
0.025 mm
Exhaust Manifold Heat Shield—
Bolts
12
—
105
Exhaust Manifold to Catalytic
Converter V-Band Clamp
11
—
100
(0.001 in.)
9 - 70
2.7L ENGINE
LH
SPECIFICATIONS (Continued)
DESCRIPTION
N·m
Ft.
In.
Lbs. Lbs.
Engine Mount Bracket to Block—
Bolts
61
45
—
Engine Mount Isolator—Nuts
61
45
—
Intake Manifold (Upper and
Lower)—Bolts
12
—
105
Generator Bracket—Bolts
41
30
—
—Bolts
28
—
250
—Nuts
SPECIAL TOOLS
2.7L ENGINE
Oil Pan
12
—
105
Oil Pan Drain—Plug
28
—
250
Oil Filter
20
15
—
Oil Pump to Block—Bolts
28
—
250
Oil Pump Cover—Bolts
12
—
105
Oil Pump Pick Up Tube—Bolt
28
—
250
PCV Valve
7
—
60
Crankshaft Rear Seal Retainer—
Bolts
12
—
105
Spark Plugs
20
15
—
Starter Mounting—Bolts
41
30
—
Structural Collar
Refer to
Procedure
Engine Lifting Fixture 8342
Puller 1023
Thermostat Housing/Water Inlet
Connector—Bolts
12
—
105
Throttle Body—Bolts
12
—
105
—M6 Bolts
12
—
105
—M10 Bolts
54
40
—
Timing Chain Tensioner (Primary)
54
40
—
Timing Chain Guide Access Plug
20
15
—
Water Pump—Bolts
12
—
105
Cooling System Bleed Screw
12
—
110
Water Outlet Housing—Bolts
12
—
105
Timing Chain Cover
Crankshaft Damper Remover Insert 8194
Crankshaft Damper Installer Screw 8179
2.7L ENGINE
LH
9 - 71
SPECIAL TOOLS (Continued)
Crankshaft Damper Installer 6792-1
Puller 5048
Crankshaft Damper Holder 8191
Puller Adaptor 8539
Crankshaft Seal Remover 6771
Crankshaft Rear Seal Guide 6926-1 & Installer
6926-2
Crankshaft Seal & Sprocket Installer 6780-1
Crankshaft Real Seal Retainer Alignment Fixture
8225
Crankshaft Seal Protector 6780-2
Timing Chain Tensioner Resetting Gauge 8186
9 - 72
2.7L ENGINE
LH
SPECIAL TOOLS (Continued)
Dial Indicator C-3339
Valve Spring Tester C-647
Valve Spring Compressor 8215
Valve Spring Compressor MD-998772-A
Adapter 8216
Valve Spring Adapter 6527
Valve Spring Compressor C-3422-B
Indicator Bore Size C-119
Valve Spring Adapter 6526
Connecting Rod Installation Guides 8189
2.7L ENGINE
LH
SPECIAL TOOLS (Continued)
Main Bearing Remover/Installer C-3059
Cooling System Tester 7700
Combustion Leak Tester C-3685-A
Adaptor 8116
9 - 73
9 - 74
3.2/3.5L ENGINE
LH
3.2/3.5L ENGINE
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
3.2/3.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 75
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 76
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
PISTONS AND CONNECTING RODS . . . . . . . . . . 78
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 78
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 78
TIMING DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . 78
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
ROCKER ARM SHAFTS . . . . . . . . . . . . . . . . . . . . 79
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 80
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . 81
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . 81
DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS—INTRODUCTION. . . . . . . . 82
ENGINE DIAGNOSIS—PERFORMANCE . . . . . . . 83
ENGINE DIAGNOSIS—MECHANICAL . . . . . . . . . 84
CHECKING ENGINE OIL PRESSURE. . . . . . . . . . 86
VALVE SPRING TESTING . . . . . . . . . . . . . . . . . . 86
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 86
CYLINDER COMPRESSION PRESSURE TEST . . 86
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 87
CYLINDER HEAD GASKET FAILURE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
LASH ADJUSTER (TAPPET) NOISE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . . 89
SERVICE PROCEDURES
ENGINE OIL LEVEL—CHECKING . . . . . . . . . . . . 90
ENGINE OIL SERVICE . . . . . . . . . . . . . . . . . . . . . 91
FORM-IN-PLACE GASKETS & SEALERS . . . . . . . 92
ENGINE GASKET SURFACE PREPARATION . . . . 93
REPAIR OF DAMAGED OR WORN THREADS . . . 93
CYLINDER BORE—HONING . . . . . . . . . . . . . . . . 93
HYDROSTATIC LOCKED ENGINE . . . . . . . . . . . . 94
LASH ADJUSTER—BLEEDING. . . . . . . . . . . . . . . 94
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
PISTON RING—FITTING . . . . . . . . . . . . . . . . . . . 96
CONNECTING ROD BEARING—INSTALLATION . . . 97
CRANKSHAFT MAIN BEARING—FITTING . . . . . . 98
CRANKSHAFT END PLAY—CHECKING . . . . . . . . 99
VALVE AND VALVE SEAT—REFACING . . . . . . . . 99
REMOVAL AND INSTALLATION
ENGINE MOUNTS—LEFT AND RIGHT . . . . . . . . 101
ENGINE MOUNT—REAR . . . . . . . . . . . . . . . . . . 101
STRUCTURAL COLLAR . . . . . . . . . . . . . . . . . . . 101
ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . 103
CRANKSHAFT DAMPER . . . . . . . . . . . . . . . . . . 105
INTAKE MANIFOLD—UPPER . . . . . . . . . . . . . . . 106
INTAKE MANIFOLD—LOWER . . . . . . . . . . . . . . 107
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 110
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 111
SPARK PLUG TUBES . . . . . . . . . . . . . . . . . . . . . 112
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 112
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
CAMSHAFT SPROCKETS AND TIMING
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 117
ROCKER ARMS AND SHAFT ASSEMBLY . . . . . . 119
VALVE STEM SEALS OR VALVE SPRINGS—IN
VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
VALVE AND VALVE SPRINGS . . . . . . . . . . . . . . 121
TIMING BELT COVERS . . . . . . . . . . . . . . . . . . . 122
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
CAMSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . . . 127
CRANKSHAFT OIL SEAL—FRONT. . . . . . . . . . . 128
CRANKSHAFT OIL SEAL—REAR . . . . . . . . . . . . 129
CRANKSHAFT OIL SEAL RETAINER—REAR . . . 129
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . 130
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
PISTON AND CONNECTING ROD . . . . . . . . . . . 133
ENGINE CORE AND OIL PLUGS . . . . . . . . . . . . 136
DISASSEMBLY AND ASSEMBLY
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
ROCKER ARMS AND SHAFT ASSEMBLY. . . . . . 137
CLEANING AND INSPECTION
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 138
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 138
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 138
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . 139
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . 139
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
CYLINDER BLOCK AND BORE . . . . . . . . . . . . . 142
ENGINE HYDRO-MOUNT INSULATORS. . . . . . . 142
TIMING BELT INSPECTION—IN VEHICLE . . . . . 142
SPECIFICATIONS
3.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
SPECIAL TOOLS
3.2/3.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 149
3.2/3.5L ENGINE
LH
DESCRIPTION AND OPERATION
3.2/3.5L ENGINE
Fig. 1 3.2/3.5L Engine
9 - 75
9 - 76
3.2/3.5L ENGINE
LH
DESCRIPTION AND OPERATION (Continued)
DESCRIPTION
The 3.2 Liter (167 Cubic Inches) and 3.5 Liter (214
Cubic Inches) 60 degree V-6 engines are a single
overhead camshaft design with hydraulic lifters and
four valves per cylinder (Fig. 1). The engines do not
have provisions for a free wheeling valve train.
The cylinders are numbered from front to rear, with
the right bank odd numbered, and the left bank even
numbered (Fig. 2). The firing order is 1–2–3–4–5–6.
The engine identification number is located on the
rear of engine block just below the cylinder head
(Fig. 3).
X
X
XXXXX
XXXX
XXXXX
Model
Year
Manufacturing
Plant
Component
Code/Usage
Month/
Day
Serial
Code
Last
digit of
model
year
Trenton T
Engine
3.2L
3.5L
Usage
Pass Car PC
Fig. 3 Engine Identification
CYLINDER BLOCK
Fig. 2 Cylinder Numbering & Firing Order—3.2/3.5L
DESCRIPTION
The cylinder block (Fig. 4) is made of heat treated
aluminum with cast-in-place iron liners. The block is
a closed deck design with the right bank forward. To
provide high rigidity and improved NVH, the block
has cast-in contours and ribs, along with powdered
metal 6 bolt main caps (4 vertical, 2 horizontal), with
a die cast aluminum structural beam windage tray
mounted to the main caps.
3.2/3.5L ENGINE
LH
9 - 77
DESCRIPTION AND OPERATION (Continued)
Fig. 4 Cylinder Block and Crankshaft
1
2
3
4
–
–
–
–
MAIN
MAIN
MAIN
MAIN
CAP BOLT - VERTICAL
CAP
BEARING - LOWER
BEARING - UPPER
CRANKSHAFT
DESCRIPTION
The crankshaft (Fig. 4) is constructed of a forged
micro alloy steel. A six throw, nine counterweight
crankshaft is supported by four select fit main bearings with number two serving as the thrust washer
location. The six separate connecting rod throws are
an even-firing design which reduces torque fluctuations while a torsional vibration damper is used to
5
6
7
8
–
–
–
–
CYLINDER BLOCK
MAIN CAP BOLT - HORIZONTAL
CRANKSHAFT THRUST WASHER
CRANKSHAFT
control torsion caused vibration of the crankshaft.
Rubber lipped seals are used at front and rear. The
front seal is retained in the oil pump case and the
rear seal is retained in a block-mounted housing.
OPERATION
The crankshaft transfers force generated by combustion within the cylinder to the flywheel or flexplate.
9 - 78
3.2/3.5L ENGINE
LH
DESCRIPTION AND OPERATION (Continued)
PISTONS AND CONNECTING RODS
DESCRIPTION
The pistons are made of a high strength aluminum
alloy. Top land height has been decreased to reduce
emissions. Piston skirts are coated with a solid lubricant for scuff resistance. Connecting rod is forged
steel with a squirt hole and attaches to the piston
with a full floating pin retained by lock rings.
CYLINDER HEAD
DESCRIPTION
The aluminum alloy cylinder heads feature crossflow type intake and exhaust ports. Valve guides and
seat inserts are powdered metal. Valves are arranged
in a “V”, with each camshaft on center. To improve
combustion speed the chambers are a compact spherical design with a squish area of approximately 30
percent of the piston top area. The cylinder heads are
common to either cylinder bank by reversing the
direction of installation.
OPERATION
The intake valve allows the air/fuel mixture to
enter the combustion chamber. The exhaust valve
allows the burned air/fuel mixture to exit the combustion chamber. Also, the intake and exhaust valves
seal the combustion chamber during the compression
and power strokes.
VALVE SPRINGS
DESCRIPTION
Valve springs are unique for intake versus exhaust.
Both are made from chrome silicon alloy wire and
incorporate a “bee-hive” design. Valve spring retainers and locks are common from valve-to-valve. The
valve spring seat is integral with the valve stem oil
seal, which incorporates a garter spring to maintain
consistent lubrication control to the valve stem.
OPERATION
The valve spring returns the valve against its seat
for a positive seal of the combustion chamber.
VALVES
TIMING DRIVE SYSTEM
DESCRIPTION
DESCRIPTION
Valves are made of highly heat-resistant steel and
are chrome plated to prevent stem scuffing. The
intake valve is a one-piece forging, while the exhaust
valve has a forged head with a welded stem for lock
groove hardenability. The four valves (two intake and
two exhaust) employ a three-groove lock design to
help facilitate valve rotation.
The timing drive system (Fig. 5) has been designed
to provide quiet performance and reliability to support a NON free-wheeling engine.
The timing drive components include a crankshaft
sprocket, camshaft sprockets, tensioner pulley,
hydraulic tensioner and a timing belt. The water
pump is driven by the back side of the timing belt.
The right and left camshaft sprockets are not interchangeable because of the cam sensor pick-up wheel
on the left sprocket.
3.2/3.5L ENGINE
LH
9 - 79
DESCRIPTION AND OPERATION (Continued)
Fig. 5 Timing Drive System
1
2
3
4
5
6
7
–
–
–
–
–
–
–
TIMING BELT COVER - RIGHT REAR
TENSIONER-TIMING BELT
CAMSHAFT SPROCKET
BOLT-CAMSHAFT SPROCKET
TIMING BELT
CRANKSHAFT SPROCKET
CRANKSHAFT DAMPER
8 – BOLT-CRANKSHAFT DAMPER
9 – TIMING BELT COVER-LOWER
10 – TIMING BELT COVER-RIGHT
11 – TIMING BELT COVER-LEFT
12 – TENSIONER PULLEY
13 – BOLT-CAMSHAFT SPROCKET
14 – CAMSHAFT SPROCKET
CAMSHAFT
ROCKER ARM SHAFTS
DESCRIPTION
DESCRIPTION
A single overhead camshaft per cylinder head provides valve actuation. The left camshaft accommodates a cam sensor pick-up wheel and is therefore
longer. Each camshaft is supported by four bearing
journals. Thrust for each camshaft is taken at a
thrust plate attached to the rear of each cylinder
head. Right and left camshaft driving sprockets are
not interchangeable because of the cam sensor
pick-up wheel on the left sprocket. Camshaft bearing
lubrication is provided via oil feed passage through
each rocker shaft pedestal dowel.
The rocker arm shafts (Fig. 6) are tubular steel
and are supported by several forged aluminum alloy
pedestals, which are fastened to the cylinder head.
Four shafts are used, one for each intake and
exhaust rocker arm bank on each cylinder head. The
shafts are hollow to provide a duct for lubricating oil
flow from the cylinder head to the valve mechanisms.
One hollow dowel per pedestal is used to locate the
pedestal to the cylinder head, orient the exhaust
rocker shaft, and serve as a cam bearing oil feed passage.
9 - 80
3.2/3.5L ENGINE
LH
DESCRIPTION AND OPERATION (Continued)
INTAKE MANIFOLD
DESCRIPTION
Fig. 6 Rocker Arms and Shafts
ROCKER ARMS
The composite upper intake manifold is a crossflow type with long runners to improve air charge
inertia (Fig. 8). An active Short Runner Valve (SRV)
opens during certain operating conditions to improve
top end performance. A Manifold Tuning Valve (MTV)
connects the plenums at specific engine speeds to
maximize low RPM torque without reducing high
RPM power.
The aluminum lower intake manifold attaches to
each cylinder head and uses a gasket for sealing (Fig.
9). The manifold coolant passage allows coolant to
flow between cylinder heads. An attached steel tube,
allows coolant flow to the heater.
DESCRIPTION
Rocker arms are made of light weight permanent
mold aluminum alloy with a roller type follower operating against the camshaft (Fig. 7). The valve actuating end of the rocker arms are machined to retain
hydraulic lash adjusters, eliminating the need for
manual valve lash adjustment.
OPERATION
The rocker arm is the pivot point between the camshaft lobe and the valve.
Fig. 8 Upper Intake Manifold
1 – INTAKE MANIFOLD-UPPER
2 – BOLT
Fig. 7 Rocker Arm Assembly
1 – RETAINER
2 – SWIVEL PAD
3 – ROLLER
3.2/3.5L ENGINE
LH
9 - 81
DESCRIPTION AND OPERATION (Continued)
Fig. 9 Lower Intake Manifold
1
2
3
4
5
–
–
–
–
–
BOLT
HEATER SUPPLY TUBE
BOLT
BOLT
KNOCK SENSOR
EXHAUST MANIFOLD
DESCRIPTION
Both manifolds are a log style made of ductile cast
iron (Fig. 10). The outlets are designed for V-Band
clamp attachment of close coupled catalytic converters.
ENGINE LUBRICATION SYSTEM
DESCRIPTION
System is a full-flow filtration, pressure feed type.
The oil pump body is mounted to the engine block.
The pump inner rotor is driven by the crankshaft. A
windage tray, increases power by minimizing oil
windage at high engine RPM. For increased oil cooling, an oil-to-coolant oil cooler is used. This cooler is
mounted inside the radiator tank.
6
7
8
9
–
–
–
–
GASKET
BOLT
O-RING
INTAKE MANIFOLD-LOWER
OPERATION
Engine oil stored in the oil pan is drawn in and
discharged by a gerotor type oil pump. The oil pump
is directly coupled to the crankshaft. Oil pressure is
regulated by a relief valve. The oil is fed through an
oil filter and to the crankshaft journals from the oil
gallery in the cylinder block. This gallery also feeds
oil under pressure to the cylinder heads. Oil flows
through each cylinder heads oil passage to the rocker
shafts. Oil then feeds the camshaft journals, rocker
arms, and hydraulic lash adjusters (Fig. 11).
9 - 82
3.2/3.5L ENGINE
LH
DESCRIPTION AND OPERATION (Continued)
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
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Service Diagnosis—Mechanical Chart
and the Service Diagnosis—Performance Chart, for
possible causes and corrections of malfunctions. Refer
to FUEL SYSTEM for the fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that cannot be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagnosis is provided within the following:
• Cylinder Compression Pressure Test
• Cylinder Combustion Pressure Leakage Test
• Cylinder Head Gasket Failure Diagnosis
• Intake Manifold Leakage Diagnosis
Fig. 10 Exhaust Manifold
1
2
3
4
5
–
–
–
–
–
BOLT
HEAT SHIELD
EXHAUST MANIFOLD
BOLT
HEAT SHIELD
1
2
3
4
5
6
7
8
–
–
–
–
–
–
–
–
CRANKSHAFT
OUTER ROTOR
INNER ROTOR
RELIEF VALVE
OIL PAN
OIL SCREEN
OIL PUMP CASE
OIL FLOWS TO ONLY ONE PEDESTAL AN EACH HEAD.
SECOND FROM REAR ON RIGHT HEAD AND SECOND
FROM FRONT ON LEFT HEAD.
Fig. 11 Oil Lubrication System
9 – PEDESTAL DRILLED PASSAGE
10 – EXHAUST ROCKER SHAFT
11 – SHAFT/PEDESTAL DOWEL PASSAGE
12 – CAMSHAFT BEARING BORE
13 – CYLINDER BLOCK OIL GALLERY
14 – CYLINDER HEAD GASKET
15 – HEAD BOLT HOLE
16 – INTAKE ROCKER SHAFT
3.2/3.5L ENGINE
LH
9 - 83
DIAGNOSIS AND TESTING (Continued)
• Lash Adjuster (Tappet) Noise Diagnosis
• Engine Oil Leak Inspection
ENGINE DIAGNOSIS—PERFORMANCE
CONDITION
ENGINE WILL NOT START
ENGINE STALLS OR
IDLES ROUGH
ENGINE LOSS OF
POWER
POSSIBLE CAUSE
CORRECTION
1. Weak battery.
1. Test battery. Charge or replace as
necessary. Refer to BATTERY.
2. Corroded or loose battery
connections.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter.
3. Test starting system. Refer to
STARTING.
4. Faulty coil(s) or control unit.
4. Test and replace as needed. Refer to
IGNITION SYSTEM.
5. Incorrect spark plug gap.
5. Set gap. Refer to IGNITION
SYSTEM.
6. Contamination in fuel system.
6. Clean system and replace fuel filter.
7. Faulty fuel pump.
7. Test fuel pump and replace as
needed. Refer to FUEL SYSTEM.
8. Incorrect engine timing.
8. Check for a skipped timing belt/chain
or a loose camshaft sprocket (3.2/3.5L).
1. Idle speed too low.
1. Test minimum air flow. Refer to FUEL
SYSTEM.
2. Incorrect fuel mixture.
2. Refer to FUEL SYSTEM.
3. Intake manifold leakage.
3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty coil(s).
4. Test and replace as necessary. Refer
to IGNITION SYSTEM.
1. Dirty or incorrectly gapped plugs.
1. Clean plugs and set gap. Refer to
IGNITION SYSTEM.
2. Contamination in fuel system.
2. Clean system and replace fuel filter.
3. Faulty fuel pump.
3. Test and replace as necessary. Refer
to FUEL SYSTEM.
4. Incorrect valve timing.
4. Correct valve timing.
5. Leaking cylinder head gasket.
5. Replace cylinder head gasket.
6. Low compression.
6. Test compression of each cylinder.
7. Burned, warped, or pitted valves.
7. Replace valves.
8. Plugged or restricted exhaust system.
8. Install new parts, as necessary.
9. Faulty coil(s).
9. Test and replace as necessary. Refer
to IGNITION SYSTEM.
9 - 84
3.2/3.5L ENGINE
LH
DIAGNOSIS AND TESTING (Continued)
CONDITION
ENGINE MISSES ON
ACCELERATION
ENGINE MISSES AT HIGH
SPEED
POSSIBLE CAUSE
CORRECTION
1. Dirty or incorrectly gapped spark
plugs.
1. Clean spark plugs and set gap. Refer
to IGNITION SYSTEM.
2. Contamination in Fuel System.
2. Clean fuel system and replace fuel
filter.
3. Burned, warped, or pitted valves.
3. Replace valves.
4. Faulty coil(s).
4. Test and replace as necessary. Refer
to IGNITION SYSTEM.
1. Dirty or incorrect spark plug gap.
1. Clean spark plugs and set gap. Refer
to IGNITION SYSTEM.
2. Faulty coil(s).
2. Test and replace as necessary. Refer
to IGNITION SYSTEM.
3. Dirty fuel injector(s).
Test and replace as necessary. Refer to
FUEL SYSTEM.
4. Contamination in fuel system.
4. Clean system and replace fuel filter.
ENGINE DIAGNOSIS—MECHANICAL
CONDITION
NOISY VALVES
CONNECTING ROD
NOISE
POSSIBLE CAUSES
CORRECTION
1. High or low oil level in crankcase.
1. Check and correct engine oil level.
2. Thin or diluted oil.
2. Change oil to correct viscosity.
3. Low oil pressure.
3. Check and correct engine oil level.
4. Dirt in tappets/lash adjusters.
4. Replace rocker arm/hydraulic lash
adjuster assembly.
5. Worn rocker arms.
5. Inspect oil supply to rocker arms.
6. Worn tappets/lash adjusters.
6. Install new rocker arm/hydraulic lash
adjuster assembly.
7. Worn valve guides.
7. Ream guides and install new valves
with oversize stems.
8. Excessive runout of valve seats on
valve faces.
8. Grind valve seats and valves.
9. Missing adjuster pivot.
9. Replace rocker arm/hydraulic lash
adjuster assembly.
1. Insufficient oil supply.
1. Check engine oil level.
2. Low oil pressure.
2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil.
3. Change oil to correct viscosity.
4. Excessive bearing clearance.
4. Measure bearings for correct
clearance. Repair as necessary.
5. Connecting rod journal out-of-round.
5. Replace crankshaft or grind surface.
6. Misaligned connecting rods.
6. Replace bent connecting rods.
3.2/3.5L ENGINE
LH
9 - 85
DIAGNOSIS AND TESTING (Continued)
CONDITION
MAIN BEARING NOISE
OIL PRESSURE DROP
OIL LEAKS
OIL CONSUMPTION OR
SPARK PLUGS FOULED
POSSIBLE CAUSES
CORRECTION
1. Insufficient oil supply.
1. Check engine oil level.
2. Low oil pressure.
2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil.
3. Change oil to correct viscosity.
4. Excessive bearing clearance.
4. Measure bearings for correct
clearance. Repair as necessary.
5. Excessive end play.
5. Check thrust bearing for wear on
flanges.
6. Crankshaft journal out-of-round or
worn.
6. Replace crankshaft or grind journals.
7. Loose flywheel or torque converter.
7. Tighten to correct torque.
1. Low oil level.
1. Check engine oil level.
2. Faulty oil pressure sending unit.
2. Install new sending unit.
3. Low oil pressure.
3. Check sending unit and main bearing
oil clearance.
4. Clogged oil filter.
4. Install new oil filter.
5. Worn parts in oil pump.
5. Replace worn parts or pump.
6. Thin or diluted oil.
6. Change oil to correct viscosity.
7. Oil pump relief valve stuck.
7. Remove valve and inspect, clean, or
replace.
8. Oil pump suction tube loose.
8. Remove oil pan and install new tube
or clean, if necessary.
9. Oil pump cover warped or cracked.
9. Install new oil pump.
10. Excessive bearing clearance.
10. Measure bearings for correct
clearance.
1. Misaligned or deteriorated gaskets.
1. Replace gasket(s).
2. Loose fastener, broken or porous
metal part.
2. Tighten, repair or replace the part.
3. Misaligned or deteriorated cup or
threaded plug.
3. Replace as necessary.
1. PCV system malfunction.
1. Check system and repair as
necessary. Refer to EMISSION
CONTROL SYSTEMS.
2. Worn, scuffed or broken rings.
2. Hone cylinder bores. Install new rings.
3. Carbon in oil ring slots.
3. Install new rings.
4. Rings fitted too tightly in grooves.
4. Remove rings and check grooves. If
groove is not proper width, replace
piston.
5. Worn valve guide(s).
5. Ream guide(s) and replace valve(s)
with oversize valve(s) and seal(s).
6. Valve stem seal(s) worn or damaged.
6. Replace seal(s).
9 - 86
3.2/3.5L ENGINE
LH
DIAGNOSIS AND TESTING (Continued)
CHECKING ENGINE OIL PRESSURE
Check oil pressure using gauge at oil pressure
switch location. Oil pressure should be 34 kPa (5 psi)
at idle or 205 to 724 kPa (30 to 105 psi.) at 3000
RPM.
(1) Remove pressure sending unit. The pressure
sending unit is located on the left front of engine
near the oil filter.
(2) Install oil pressure gauge.
specified height and allowable tensions. Replace
springs that do not meet specifications.
CAUTION: If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM.
(3) Warm engine to normal operating temperature.
VALVE SPRING TESTING
VALVE SPRING IDENTIFICATION
The valve springs are of two different lengths and
are wound in different directions. The valve springs
are color coded: the intake spring has a right hand
coil direction with orange dye on the top coils and the
exhaust spring has a left hand coil direction with yellow dye on the top coils (Fig. 12).
Fig. 13 Testing Valve Spring with Tool C-647
1 – SPECIAL TOOL C-647
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
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.
Fig. 12 Valve Spring Identification
1 – YELLOW DYE
2 – ORANGE DYE
TESTING VALVE SPRINGS
When valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested (Fig. 13). As an example; the compression
length of the spring to be tested is 38.00 mm (1.496
in.). Turn table of Tool C-647 until surface is in line
with the 38.00 mm (1.496 inches.) mark on the
threaded stud and the zero mark on the front. Place
spring over stud on the table and lift compressing
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
(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 suspected leak has been found.
(4) Repair as required.
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunctions.
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) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
LH
3.2/3.5L ENGINE
9 - 87
DIAGNOSIS AND TESTING (Continued)
mal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference.
(4) Disconnect coil wire from distributor and
secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct
Ignition System DIS disconnect the coil connector.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gage adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0–500 psi (Blue) pressure
transducer with cable adaptors to the DRBIIIt.
(7) Crank engine until maximum pressure is
reached on gage. Record this pressure as #1 cylinder
pressure.
(8) Repeat the previous step for all remaining cylinders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cylinder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended compression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunction is present.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
• Exhaust and intake valve leaks (improper seating).
• Leaks between adjacent cylinders or into water
jacket.
• Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains normal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufacturer’s instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) recommended.
Perform the test procedures on each cylinder
according to the tester manufacturer’s instructions.
While testing, listen for pressurized air escaping
through 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 per cylinder.
FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the cylinder.
CYLINDER HEAD GASKET FAILURE DIAGNOSIS
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:
• Loss of engine power
• Engine misfiring
• Poor fuel economy
• Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
• Engine overheating
• Loss of coolant
• Excessive steam (white smoke) emitting from
exhaust
• Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the procedures in Cylinder Compression Pressure Test in this
section. An engine cylinder head gasket leaking
between adjacent 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 PRESSURE 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
exists, bubbles will be visible in the coolant.
9 - 88
3.2/3.5L ENGINE
LH
DIAGNOSIS AND TESTING (Continued)
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRESSURE 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.
POSSIBLE NOISE SOURCES
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.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
Proper noise diagnosis is essential in locating the
source of a NVH complaint. Locating a lash adjuster
(tappet) type noise can sometimes be difficult. As a
result, an initial misdiagnosis may occur.
Refer to the following chart indicating possible lash
adjuster (tappet) noise sources and possible sources
that could lead to a misdiagnosis.
Refer to Lash Adjuster (Tappet) Noise Chart for
Possible Causes and Correction of a lash adjuster
(tappet) type noise.
POSSIBLE NOISE MISDIAGNOSIS SOURCES
Spongy/soft/aerated lash adjusters.
SRV valve axle chatter.
Missing lash adjuster swivel contact pads.
Exhaust rocker arm-to-cylinder head cover contact.
Intake rocker-to-camshaft bearing journal contact.
Piston pin bore fit.
Rocker arm bind-up.
Timing drive hydraulic tensioner tick.
Intake rocker arm-to-spark plug tube contact.
Accessory drive belt deterioration.
Excessive cam end play.
Piston-to-bore clearance knock.
Broken valve spring.
Crankshaft bearing noise.
Broken/loose camshaft sprocket bolt.
Incomplete cam lobe machining.
Cracked lash adjuster cartridge body.
3.2/3.5L ENGINE
LH
9 - 89
DIAGNOSIS AND TESTING (Continued)
LASH ADJUSTER (TAPPET) NOISE CHART
POSSIBLE CAUSES
CORRECTION
1. Engine oil level—too high or too low. This may cause
aerated oil to enter the adjusters and cause them to be
spongy.
1. Check and correct engine oil level.
2. Insufficient running time after rebuilding cylinder
head.
2. Low speed running of up to 1 hour may be required
to fully evacuate trapped air from the valve train
system. During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
3. Air trapped in lash adjuster (after 1 hour run time).
3. See below:
(a) Check lash adjusters for sponginess while installed
in cylinder head. Depress part of rocker arm over
adjuster. Normal adjusters should feel very firm. Very
spongy adjusters can be bottomed out easily.
(b) Before proceeding, perform Lash Adjuster Bleeding
procedure.
(c) If lash adjuster(s) are still spongy, replace with new
adjuster/rocker arm assembly*.
4. Low oil pressure
4. See below:
(a) Check and correct engine oil level.
(b) Check engine oil pressure.
(c) Check for excessive bearing clearance and correct.
(d) Check for worn oil pump.
5. Oil passage to cylinder head(s) plugged with debris.
5. Check cylinder head oil passages and cylinder head
gasket restrictor for blockage. Clean or replace as
necessary.
6. Worn valve guide(s).
6. Ream guide(s) and replace valve(s) with oversize
valves and seal(s).
7. Air injested into oil due to broken or cracked oil
pump pickup tube.
7. Inspect pickup tube and replace as necessary.
8. Collapsed lash adjuster due to debris injestion.
8. Clean debris from engine and replace lash
adjuster/rocker assembly*.
9. Intake rocker arm roller clevis ear(s) contacting
camshaft bearing journal(s) on side.
9. Inspect camshaft end play and all valve train
components for wear. Replace as necessary.
*3.2/3.5L engine lash adjusters are serviced with the rocker arms—do not disassemble.
ENGINE OIL LEAK INSPECTION
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 various speeds for approximately 24 km (15 miles), and
repeat inspection.
9 - 90
3.2/3.5L ENGINE
LH
DIAGNOSIS AND TESTING (Continued)
(5) If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
• Disconnect the fresh air hose (make-up air) at
the cylinder head cover and plug or cap the nipple on
the cover.
• Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
• 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.
• Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
• If the leakage occurs at the crankshaft 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.
Remove the air hose, all plugs, and caps. Install the
PCV valve and fresh air hose (make-up air). Proceed
to next step.
(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.
NOTE: If oil leakage is observed at the dipstick
tube to block location; remove the tube, clean and
reseal using MoparT Stud & Bearing Mount (press
fit tube applications only), and for O-ring style
tubes, remove tube and replace the O-ring seal.
(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. If a leak is
present in this area, remove transmission for further
inspection.
(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, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crankcase as previously described.
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 disassembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified, refer to Crankshaft Oil Seal—Rear for proper replacement procedures.
SERVICE PROCEDURES
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 vehicle.
ENGINE OIL LEVEL—CHECKING
The best time to check engine oil level is after it
has sat overnight, or if the engine has been running,
allow the engine to be shut off for at least 5 minutes
before checking oil level.
Checking the oil while the vehicle is on level
ground will improve the accuracy of the oil level
reading (Fig. 14). Add only when the level is at or
below the ADD mark.
3.2/3.5L ENGINE
LH
9 - 91
SERVICE PROCEDURES (Continued)
Fig. 14 Engine Oil Fill and Dipstick Locations—3.2/
3.5L
1 – ENGINE OIL FILL
2 – ENGINE OIL DIPSTICK
ENGINE OIL SERVICE
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
PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certified. MOPARt provides engine oils that conform to
this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. The
preferred viscosity oil for the 3.2/3.5L engine is 10W30. These oils are specified with a dual SAE viscosity
grade which indicates the cold-to-hot temperature
viscosity range. Select an engine oil that is best
suited to your particular temperature range and variation (Fig. 15).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.
Fig. 15 Temperature/Engine Oil Viscosity—3.2/3.5L
Engines
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. 16).
Fig. 16 Engine Oil Container Standard Notations
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating temperature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(3) Remove oil fill cap (Fig. 14).
(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 and
gasket if damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil (Fig. 14). Refer to
Group 0, Lubrication and Maintenance.
(8) Install oil fill cap.
9 - 92
3.2/3.5L ENGINE
LH
SERVICE PROCEDURES (Continued)
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
ENGINE OIL FILTER CHANGE
FILTER SPECIFICATION
All engines are equipped with a high quality fullflow, disposable type oil filter. When replacing oil filter, use a Mopart filter or equivalent.
OIL FILTER REMOVAL
Refer to Removal and Installation Section in Group
9, Engine for procedure.
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 listed above.
FORM-IN-PLACE GASKETS & SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results. Do not use form-inplace gasket material unless specified. Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, Mopart ATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARt ENGINE RTV GEN II
Mopart Engine RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARt ATF RTV
Mopart ATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARt GASKET MAKER
Mopart Gasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARt BED PLATE SEALANT
Mopart Bed Plate Sealant is a unique (green-incolor) anaerobic type gasket material that is specially
made to seal the area between the bedplate and cylinder block without disturbing the bearing clearance
or alignment of these components. The material
cures slowly in the absence of air when torqued
between two metallic surfaces, and will rapidly cure
when heat is applied.
MOPARt GASKET SEALANT
Mopart Gasket Sealant is a slow drying, permanently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This material is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will prevent corrosion. Mopart Gasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it’s easier then using precut gaskets.
Mopart Gasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smearing material off the location.
Mopart Engine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
Mopart Gasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
3.2/3.5L ENGINE
LH
9 - 93
SERVICE PROCEDURES (Continued)
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
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 the following to clean gasket surfaces:
• Metal scraper
• Abrasive pad or paper to clean cylinder block
and head
• High speed power tool with an abrasive pad or a
wire brush (Fig. 17)
NOTE: Multi-Layer Steel (MLS) head
require a scratch free sealing surface.
gaskets
Only use the following for cleaning gasket surfaces:
• Solvent or a commercially available gasket
remover
• Plastic or wood scraper (Fig. 17)
• Drill motor with 3M Rolocy Bristle Disc (white
or yellow) (Fig. 17)
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.
Fig. 17 Proper Tool Usage For Surface Preparation
1 – ABRASIVE PAD
2 – 3M ROLOCY BRISTLE DISC
3 – PLASTIC/WOOD SCRAPER
REPAIR OF DAMAGED OR WORN THREADS
Damaged or worn threads (excluding spark plug
and camshaft bearing cap attaching threads) can be
repaired. Essentially, this repair consists of drilling
out worn or damaged threads, tapping the hole with
a special Heli-Coil Tap, (or equivalent) and installing
an insert into the tapped hole. This brings the hole
back to its original thread size.
CAUTION: Be sure that the tapped holes maintain
the original centerline.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
CYLINDER BORE—HONING
(1) Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped
with 220 grit stones, is the best tool for this honing
procedure. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required limits.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20–60
strokes depending on the bore condition, will be sufficient to provide a satisfactory surface. Inspect cylinder walls after each 20 strokes, using a light
honing oil. 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 cross-hatch pattern.
When hone marks intersect at 50-60 degrees, the
cross hatch angle is most satisfactory for proper seating of rings (Fig. 18).
(4) A controlled hone motor speed between
200–300 RPM is necessary to obtain the proper crosshatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50–60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
9 - 94
3.2/3.5L ENGINE
LH
SERVICE PROCEDURES (Continued)
LASH ADJUSTER—BLEEDING
Use this procedure to manually bleed aerated oil
from the lash adjuster and remove sponginess.
(1) Run the engine, bringing it to operating temperature in order to freshly pressurize and warm the
valvetrain system oil supply.
(2) Remove cylinder head cover(s).
(3) Ensure the rocker arm is positioned on the
base circle of the cam (Fig. 19). Rotate engine as necessary.
(4) For intake rocker arm positions:
(a) Adjust Special Tool 8351 Release Probe’s
gauge pin to extend approximately 20 mm (0.787
in.). Then, carefully insert the release probe gauge
pin into the lash adjuster service access hole (Fig.
20).
Fig. 18 Cylinder Bore Cross-Hatch Pattern
1 – CROSS-HATCH PATTERN
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.)
(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Fill engine with specified amount of approved
oil and install new oil filter.
(11) Connect negative battery cable.
(12) Start engine and check for any leaks.
CAUTION: If probe tip breaks off within the lash
adjuster, replace the affected rocker arm.
(b) Gently unseat lash adjuster’s internal check
ball.
(c) While the internal check ball is held
unseated, press the rocker arm into the valve tip,
allowing the lash adjuster to fully collapse. Hold
this fully collapsed position for about one second,
or longer.
(d) Slowly release the rocker arm, thereby
allowing the lash adjuster to extend, which in turn
refills the high pressure chamber with non-aerated
oil.
(e) Remove probe to allow check ball to seat.
(f) Recheck for sponginess. If the lash adjuster
sponginess is not completely or nearly eliminated,
then repeat procedure.
(g) If the spongy condition cannot be removed,
replace effected rocker arm(s).
(5) For exhaust rocker arm positions:
(a) Adjust Special Tool 8351 Release Probe’s
gauge pin to extend approximately 20 mm (0.787
in.). Then, using two release probes, carefully
insert gauge pins into the lash adjuster service
access holes (Fig. 20).
CAUTION: If probe tip breaks off within the lash
adjuster, replace the affected rocker arm.
(b) Gently unseat BOTH lash adjuster’s internal
check ball at the same time.
(c) While the internal check ball is held
unseated, press the rocker arm into the valve tip,
allowing the lash adjuster to fully collapse. Hold
this fully collapsed position for about one second,
or longer.
(d) Slowly release the rocker arm, thereby allowing the lash adjuster to extend, which in turn
3.2/3.5L ENGINE
LH
9 - 95
SERVICE PROCEDURES (Continued)
refills the high pressure chamber with non-aerated
oil.
(e) Remove probes to allow check balls to seat.
(f) Recheck for sponginess. If the lash adjuster
sponginess is not completely or nearly eliminated,
then repeat procedure.
(g) If the spongy condition cannot be removed,
replace effected rocker arm(s).
(6) Install cylinder head cover(s).
Fig. 20 Purging Air From Lash Adjuster
1
2
3
4
5
6
–
–
–
–
–
–
SPECIAL TOOL 8351
OIL AIR RELIEF SERVICE ACCESS HOLE
ROCKER ARM ASSY
INTERNAL CHECK BALL
VALVE TIP
HYDRAULIC LASH ADJUSTER WITHIN ROCKER ARM
Fig. 19 Rocker Arm Positioned On Base Circle Of
Camshaft
1 – CAMSHAFT BASE CIRCLE
2 – HIGH-PRESSURE CHAMBER
PISTONS
Pistons are machined to two different weight specifications and matched to rods based on weight. All
piston and rod assemblies weigh the same to maintain engine balance.
FITTING PISTONS
Piston and cylinder wall must be clean and dry.
Piston diameter should be measured 90 degrees to
piston pin at size location shown in (Fig. 21). Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft
center line. Refer to Engine Specifications. Pistons
and cylinder bores should be measured at normal room temperature, 70°F (21°C).
Fig. 21 Piston Measurements
PISTON PINS
The piston pin is full floating and is held in place
by lock rings. Pistons and rods are weight matched
for balance. Do Not switch pistons with other
rods. Piston and Rods are serviced as an assembly
for balance.
9 - 96
3.2/3.5L ENGINE
LH
SERVICE PROCEDURES (Continued)
PISTON RING—FITTING
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 inch.) from bottom
of cylinder bore. Check gap with feeler gauge (Fig.
22). Refer to Engine Specifications.
CAUTION: Install piston rings in the following
order:
(2) Oil ring expander.
(3) Upper oil ring side rail.
(4) Lower oil ring side rail.
(5) No. 2 Intermediate piston ring.
(6) No. 1 Upper piston ring.
(7) Install the side rail by placing one end between
the piston ring groove and the expander. Hold end
firmly and press down the portion to be installed
until side rail is in position. Do not use a piston
ring expander during this step (Fig. 25).
Fig. 22 Check Gap on Piston Rings
1 – FEELER GAUGE
Fig. 24 Piston Ring—Installation
1 – SIDE RAIL
2 – SPACER EXPANDER
Fig. 23 Measuring Piston Ring Side Clearance
1 – FEELER GAUGE
(2) Check piston ring to groove clearance: (Fig. 23).
Refer to Engine Specifications.
PISTON RINGS—INSTALLATION
(1) The No. 1 and No. 2 piston rings have a different cross section. Insure that the No. 2 ring is
installed with manufacturers I.D. mark (dot) facing
up, towards top of the piston (Fig. 24).
Fig. 25 Side Rail—Installation
1 – SIDE RAIL END
3.2/3.5L ENGINE
LH
9 - 97
SERVICE PROCEDURES (Continued)
The bearing shells must be installed with the
tangs inserted into the machined grooves in the rods
and caps. Install cap with the tangs on the same side
as the rod.
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.015 mm (0.0006 in.).
Bearings are available in 0.025 mm (0.001 in.) and
0.254 mm (0.010 in.) undersize. Install the bearings in pairs. Do not use a new bearing half
with an old bearing half. Do not file the rods or
bearing caps.
(1) Follow procedure specified in the Standard Service Procedure Section for Measuring Main Bearing
Clearance and Connecting Rod Bearing Clearance
(Fig. 28). Refer to Engine Specifications.
Fig. 26 Upper and Intermediate Rings—Installation
(8) Install upper side rail first and then the lower
side rail.
(9) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 26).
(10) Position piston ring end gaps as shown in
(Fig. 27).
(11) Position oil ring expander gap at least 45°
from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is
important for oil control.
NOTE: The rod bearing bolts should be examined
before reuse. If the threads are necked down the
bolts should be replaced (Fig. 29).
Fig. 28 Checking Connecting Rod Bearing
Clearance—Typical
Fig. 27 Piston Ring End Gap Position
1
2
3
4
5
–
–
–
–
–
SIDE RAIL UPPER
NO. 1 RING GAP
PISTON PIN
SIDE RAIL LOWER
NO. 2 RING GAP AND SPACER EXPANDER GAP
CONNECTING ROD BEARING—INSTALLATION
Fit all rods on one bank until complete.
The bearing caps are not interchangeable and
should be marked at removal to insure correct
assembly.
(2) Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
(3) Before installing the nuts the threads should
be oiled with engine oil.
(4) Install nuts on each bolt finger tight then alternately torque each nut to assemble the cap properly.
(5) Tighten the nuts to 54 N·m PLUS 1/4 turn (40
ft. lbs. PLUS 1/4 turn).
(6) Using a feeler gauge, check connecting rod side
clearance (Fig. 30). Refer to Engine Specifications.
9 - 98
3.2/3.5L ENGINE
LH
SERVICE PROCEDURES (Continued)
NOTE: Service main bearings have a number from
(1 – 5) marked in ink on the bearing surface (Fig.
33). For verification, use the Main Bearing Selection
Chart for number to size identification.
The upper main bearing has a oil feed hole and a
center groove to allow lubrication of the main journal
and must be properly positioned in the block.
Fig. 29 Check for Stretched Bolts
1
2
3
4
–
–
–
–
STRETCHED BOLT
THREADS ARE NOT STRAIGHT ON LINE
THREADS ARE STRAIGHT ON LINE
UNSTRETCHED BOLT
Fig. 31 Cylinder Block Main Bore Grade Marking
Location
Fig. 30 Connecting Rod Side Clearance Measuring
CRANKSHAFT MAIN BEARING—FITTING
The main bearings are a “select fit” to achieve
proper oil clearances. For main bearing selection, the
block and crankshaft have grade identification
marks.
The marks for the cylinder block main bore grade
are located on the left side pan rail, just rear of the
left engine mount bracket (Fig. 31). These grade
marks (1, 2, or 3) are read left to right, corresponding
to main bore 1, 2, 3, 4.
The grade marks for the crankshaft are located on
the rearmost crankshaft counter weight as shown in
(Fig. 32). The crankshaft journal grade marks (A, B,
or C) are read left to right, corresponding with journal number 1, 2, 3, 4.
Use the Main Bearing Selection Chart to properly
select the main bearings. For an example, if the main
bore grade is 3 and the journal grade is B, the proper
select fit bearing would be a (2) +0.003 mm (+0.0002
in.).
Fig. 32 Crankshaft Main Journal Grade Marking
Location—Rear Of Block (Inverted) View
3.2/3.5L ENGINE
LH
9 - 99
SERVICE PROCEDURES (Continued)
CRANKSHAFT END PLAY—CHECKING
(1) Using Dial Indicator C-3339 and Mounting
Post L-4438, attach to front of engine, locating probe
perpendicular on nose of crankshaft (Fig. 34).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Engine Specifications.
Fig. 33 Main Bearing Grade Marks
1
2
3
4
–
–
–
–
LOWER MAIN BEARING
UPPER MAIN BEARING
OIL FEED HOLE AND GROOVE
GRADE SELECTION INK MARKS
Fig. 34 Checking Crankshaft End Play
VALVE AND VALVE SEAT—REFACING
MAIN BEARING SELECTION CHART—3.2/3.5L
Main Bearing Bore Grade
Marks
Crankshaft
Main Journal
Grade Marks
1
2
3
A
(3)
standard
(2) +003
mm
(+0.0002
in.)
(1)
+0.006
mm
(+0.0003
in.)
B
(4)
-0.003
mm
(-0.0002
in.)
(3)
standard
(2) +003
mm
(+0.0002
in.)
C
(5)
-0.006
mm
(-0.0003
in.)
(4)
-0.003
mm
(-0.0002
in.)
(3)
standard
The intake and exhaust valves have a 44.5 to 45
degree face angle. The valve seats have a 45 to 45.5
degree face angle. The valve face and valve seat
angles are shown in (Fig. 36).
VALVES
Fig. 35 Intake and Exhaust Valves
1
2
3
4
–
–
–
–
MARGIN
FACE
STEM
VALVE SPRING RETAINER LOCK GROOVES
(1) Inspect the remaining margin after the valves
are refaced (Fig. 35). Refer to Engine Specifications.
9 - 100
3.2/3.5L ENGINE
LH
SERVICE PROCEDURES (Continued)
VALVE SEATS
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseating stones. A true and complete surface must be
obtained.
(2) Measure the concentricity of valve seat using
dial indicator. Total runout should not exceed 0.051
mm (0.002 inch.) total indicator reading.
(5) Check the valve spring installed height after
refacing the valve and seat (Fig. 38).
VALVE SPRING IDENTIFICATION
The valve springs are of two different lengths and
are wound in different directions. The valve springs
are color coded, intake spring is right hand coil direction with orange dye on the top coils and the exhaust
spring is left hand coil direction with a yellow dye on
the top coils (Fig. 37).
Fig. 36 Valve Seats
ITEM
A
DESCRIPTION
Seat Width
SPECIFICATION
Intake:
0.75 – 1.25
mm (0.030
– 0.049 in.)
Exhaust:
1.25 – 1.75
mm (0.049
– 0.069 in.)
B
Face Angle
Intake & Exhaust: 44.5 –
45°
C
Seat Angle
Intake & Exhaust: 45 –
45.5°
D
Seat Contact
Area
Valve to seat contact
must be at center of valve
face.
(3) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, then lower valve seat
with a 15 degree stone. If the blue is transferred to
the bottom edge of valve face, then raise valve seat
with a 65 degree stone.
NOTE: Valve seats which are worn or burned can
be reworked, provided that correct angle and seat
width are maintained. Otherwise cylinder head must
be replaced.
(4) When seat is properly positioned the width of
the intake seats should be 0.75 to 1.25 mm (0.0296 to
0.0493 in.) and exhaust seats should be 1.25 to 1.75
mm (0.049 to 0.069 in.) (Fig. 36).
Fig. 37 Valve Spring Identification
1 – YELLOW DYE
2 – ORANGE DYE
VALVE INSTALLATION
(1) Coat valve stems with clean engine oil and
insert them in cylinder head.
(2) If valves or seats have been reground, check
valve tip height (A) (Fig. 38). If valve tip height is
greater than 43.65 mm (1.7185 in.) intake or 45.98
mm (1.8102 in.) exhaust, grind valve tip until within
specifications. Make sure measurement is taken from
cylinder head surface to the top of valve stem.
(3) Install valve seal/spring seat assembly over
valve guides on all valve stems (Fig. 39). Ensure that
the garter spring is intact around the top of the rubber seal. Place valve springs (color-coded end facing
up) and valve retainers into position.
(4) Compress valve springs with a valve spring
compressor, install locks and release tool. If valves
and/or seats are reground, measure the
installed height of springs (B) (Fig. 38), make
sure measurements are taken from top of
spring seat to the bottom surface of spring
retainer. If height is greater than 38.75 mm (1.5256
in.), install a 0.762 mm (0.030 in.) spacer in head
counterbore under the valve spring seat to bring
spring height back within specification.
3.2/3.5L ENGINE
LH
9 - 101
SERVICE PROCEDURES (Continued)
(2) Remove the isolator attaching nuts from top of
the mounting bracket (Fig. 40).
(3) Support the engine with a jack and a block of
wood across the full width of the oil pan.
(4) Remove the lower attaching nuts from the bottom of the isolator to the frame (Fig. 40).
(5) Raise engine carefully with jack enough to
remove the isolator with heat shield from its mount.
INSTALLATION
Fig. 38 Checking Valve Tip Height and Valve Spring
Installed Height
1
2
3
4
–
–
–
–
SPRING RETAINER
GARTER SPRING
VALVE SPRING SEAT TOP
CYLINDER HEAD SURFACE
(1) Install isolator mount with heat shield onto the
frame.
(2) Lower the engine onto the isolator mount.
(3) Remove jack from vehicle.
(4) Tighten the isolator to frame nuts to 61 N·m
(45 ft. lbs.) (Fig. 40).
(5) Install the upper attaching nuts to mount and
tighten to 61 N·m (45 ft. lbs.) (Fig. 40).
(6) Lower vehicle.
ENGINE HYDRO-MOUNT ISOLATORS
Engine hydro-mounts may show surface cracks,
this will not effect performance and hydro-mount
should not be replaced. Only replace the engine
hydro-mounts when leaking fluid:
• Driveshaft Diagnosis. Refer to DIFFERENTIAL
AND DRIVELINE.
• Any front end structural damage (after repair).
• Isolator replacement.
ENGINE MOUNT—REAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Support transaxle with a jack.
(3) Remove isolator nuts from the mount to transaxle mount bracket (Fig. 40).
(4) Remove rear mount isolator bolts to crossmember and remove mount (Fig. 40).
INSTALLATION
Fig. 39 Valve Seal and Spring—Installation
1
2
3
4
5
–
–
–
–
–
VALVE
VALVE
VALVE
VALVE
VALVE
RETAINING LOCKS
SPRING RETAINER
SPRING
SEAL AND VALVE SPRING SEAT ASSEMBLY
REMOVAL AND INSTALLATION
ENGINE MOUNTS—LEFT AND RIGHT
REMOVAL
(1) Raise vehicle on hoist.
(1) Position isolator onto crossmember.
(2) Install bolts attaching isolator to crossmember
and tighten to 33 N·m (250 in. lbs.) (Fig. 40).
(3) Lower transaxle onto isolator.
(4) Install isolator nuts and tighten to 61 N·m (45
ft. lbs.) (Fig. 40).
(5) Lower vehicle.
STRUCTURAL COLLAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove bolts attaching structural collar to oil
pan and transmission housing (Fig. 41).
(3) Remove collar (Fig. 41).
9 - 102
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
Fig. 40 Engine Mounting—Right, Left, and Rear
1
2
3
4
5
–
–
–
–
–
NUT
REAR ISOLATOR
BOLT
NUT
ISOLATOR
6
7
8
9
–
–
–
–
HEAT SHIELD
BOLT
ENGINE MOUNT BRACKET
NUT
INSTALLATION
CAUTION: The collar must be tighten using this
service procedure, as damage to collar and/or oil
pan may occur.
(1) Install structural collar (Fig. 41) using the following tightening sequence:
a. Install the vertical collar to oil pan bolts.
Torque bolts initially to 1.1 N·m (10 in. lbs.).
b. Install the horizontal collar to transmission
bolts and torque to 55 N·m (40 ft. lbs.).
c. Starting with the center vertical bolts and working outward, final torque bolts to 55 N·m (40 ft. lbs.).
(2) Lower vehicle.
Fig. 41 Structural Collar
1 – BOLT-HORIZONTAL
2 – BOLT-VERTICAL
3 – STRUCTURAL COLLAR
3.2/3.5L ENGINE
LH
9 - 103
REMOVAL AND INSTALLATION (Continued)
ENGINE ASSEMBLY
REMOVAL
(1) Disconnect negative cable at right strut tower
(Fig. 42).
(2) Mark hood position at hinges and remove hood.
(3) Remove both wiper arms.
(4) Remove both cowl covers (Fig. 43).
(5) Remove cowl support (Fig. 44).
(6) Remove air cleaner assembly with air inlet
hose (Fig. 45).
(7) Remove upper radiator crossmember. Refer to
BODY for procedure.
Fig. 43 Cowl Covers
1 – WINDSHIELD
2 – LEFT COWL COVER
3 – RIGHT COWL COVER
Fig. 42 Negative Cable—Disconnect
1 – RIGHT STRUT TOWER
2 – BATTERY NEGATIVE CABLE
(8) Disconnect hood release cable from hood latch.
(9) Drain cooling system. Refer to COOLING SYSTEM for procedure.
(10) Remove cooling fan module and accessory
drive belts. Refer to COOLING SYSTEM for procedures.
(11) Disconnect upper radiator hose at engine.
(12) Disconnect lower radiator hose at radiator.
(13) Disconnect engine oil and transmission cooler
lines at radiator.
(14) Remove power steering line bracket at left
side of radiator.
(15) Remove fasteners attaching air conditioning
condenser to radiator.
(16) Remove radiator.
(17) Remove generator.
Fig. 44 Cowl Support
1 – COWL SUPPORT
2 – WINDSHIELD
3 – SUPPORT FASTENERS
(18) Remove power steering pump mounting bolts
and set pump aside.
(19) Remove air conditioning compressor mounting
bolts and set aside.
(20) Loosen and remove V-Band clamp at right
exhaust manifold.
(21) Remove front and rear support bracket fasteners attaching right side catalytic converter down
pipe.
(22) Release fuel pressure. Refer to FUEL SYSTEM for procedure.
(23) Disconnect fuel line.
(24) Disconnect throttle and speed control cables
from bracket.
9 - 104
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(40) For starter removal, loosen the left converter
exhaust pipe band clamp and exhaust pipe support
bracket at transaxle.
(41) Remove starter.
(42) Remove left engine mount bolts.
(43) Remove right engine mount bolts.
(44) Remove crankshaft position sensor.
(45) Remove two lower transmission to block bolts.
(46) Lower vehicle.
(47) Attach lifting device to engine.
(48) Insert floor jack with small block of wood
under transmission pan to support transmission.
(49) Hoist engine from engine compartment.
INSTALLATION
Fig. 45 Air Cleaner With Inlet Hose
1 – AIR CLEANER ASSEMBLY WITH AIR INLET HOSE
2 – THROTTLE BODY
(25) Disconnect both hoses at coolant bottle.
(26) Disconnect all vacuum hoses.
(27) Disconnect ground straps at both cylinder
heads.
CAUTION: Upper Intake manifold is a composite
design. Therefore, manifold should be removed
before lifting engine or damage to the manifold
could occur.
(28) Remove upper intake manifold. Cover intake
manifold openings with tape.
(29) Disconnect heater hoses.
(30) Remove rear throttle body support bracket.
(31) Remove fastener for water pipe at transmission to block bolt.
(32) Remove four upper transmission to block
bolts.
(33) Disconnect all electrical connections.
(34) Hoist vehicle.
(35) Drain engine oil.
(36) Remove structural collar and mark flex plate
to torque converter position.
(37) Remove bolts holding torque converter to flex
plate.
(38) Disconnect both transmission oil cooler line
brackets from engine.
(39) Loosen and remove left exhaust manifold
V-Band clamp.
(1) Attach lifting device and lower engine into
engine compartment.
(2) Align engine mounts and install fasteners but
do not tighten until all mounting bolts have been
installed.
(3) Install transmission case to engine block
tighten bolts to 102 N·m (75 ft. lbs.).
(4) Remove engine lifting device.
(5) Raise vehicle.
(6) Tighten engine mount fastener to 61 N·m (45
ft. lbs.).
(7) Align flex plate to torque converter and install
mounting bolts. Tighten bolts to 75 N·m (55 ft. lbs.).
(8) Install crankshaft position sensor.
(9) Install starter.
(10) Install new V-Band clamp at left side exhaust
manifold to catalytic converter. Tighten V-Band
clamp to 11 N·m (100 in. lbs.).
(11) Install left side catalytic converter down pipe
support fastener at transaxle. Tighten fastener to 47
N·m (35 ft. lbs.).
(12) Tighten the left converter down pipe band
clamp.
(13) Install the transmission oil cooler lines
bracket to engine.
(14) Install structural collar. Refer to procedure in
this section.
(15) Lower vehicle.
(16) Connect all electrical connections.
(17) Install four upper transmission to block bolts
tighten to 102 N·m (75 ft. lbs.).
(18) Install water pipe and retaining fasteners to
the transaxle/cylinder block double-ended bolts.
(19) Install rear throttle body support bracket.
(20) Connect heater hoses.
(21) Install upper intake manifold. Refer to procedure in this section.
(22) Connect ground straps at both cylinder heads.
(23) Connect all vacuum hoses.
(24) Connect both hoses at coolant bottle.
3.2/3.5L ENGINE
LH
9 - 105
REMOVAL AND INSTALLATION (Continued)
(25) Connect throttle and speed control cables to
bracket and throttle arm.
(26) Connect fuel line.
(27) Install new V-Band clamp at right exhaust
manifold. Tighten V-Band clamp to 11 N·m (100 in.
lbs.).
(28) Install and tighten right side catalytic converter down pipe support bracket fastener at transaxle mount.
(29) Install air conditioning compressor and
tighten fasteners to 28 N·m (250 in. lbs.).
(30) Install power steering pump and tighten fasteners to 28 N·m (250 in. lbs.).
(31) Install generator.
(32) Install radiator.
(33) Attach air conditioning condenser to radiator.
(34) Install power steering line bracket to radiator.
(35) Connect engine oil and transmission cooler
lines to radiator.
(36) Install lower radiator hose.
(37) Install upper radiator hose.
(38) Install accessory drive belts and cooling fan
module. Refer to COOLING SYSTEM for procedures.
(39) Fill cooling system. Refer to COOLING SYSTEM for procedure.
(40) Fill engine with proper amount of oil.
(41) Connect hood release cable to hood latch and
install upper radiator crossmember.
(42) Install air cleaner and air inlet hose.
(43) Install cowl support.
(44) Install both cowl covers.
(45) Install both wiper arms.
(46) Install hood.
(47) Connect negative cable.
Fig. 46 Crankshaft Damper Center Bolt—Removal
and Installation
1 – SPECIAL TOOL 8191
2 – CRANKSHAFT DAMPER
CRANKSHAFT DAMPER
REMOVAL
(1) Disconnect negative cable at right strut tower.
(2) Remove upper radiator crossmember. Refer to
BODY for procedure.
(3) Remove fan module. Refer to COOLING SYSTEM for procedure.
(4) Remove the accessory drive belts. Refer to
COOLING SYSTEM for procedure.
(5) Use Special Tool 8191 to hold crankshaft
damper while removing center bolt (Fig. 46).
(6) Use Special Tool 1023 puller, and insert
C-4685-C2, remove crankshaft damper (Fig. 47).
INSTALLATION
(1) Install crankshaft damper using Special Tools
C-4685-C1 (5.9 in.) Bolt, with Nut and Thrust Bearing from 6792, and 6792-1 Installer (Fig. 48). Install
center bolt and tighten to 115 N·m (85 ft. lbs.) (Fig.
46).
Fig. 47 Crankshaft Damper—Removal
1 – SPECIAL TOOL
1023
2 – SPECIAL TOOL
C-4685–C2
INSERT
(2) Install accessory drive belts. Refer to COOLING SYSTEM for procedure.
(3) Install fan module. Refer to COOLING SYSTEM for procedure.
(4) Install upper radiator crossmember. Refer to
BODY for procedure.
(5) Connect negative cable.
9 - 106
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
Fig. 49 Air Cleaner Housing and Inlet Hose
Fig. 48 Crankshaft Damper—Installation
1 – SPECIAL TOOL
6792–1
2 – SPECIAL TOOL
C-4685–C1
INTAKE MANIFOLD—UPPER
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Remove air cleaner housing and inlet hose (Fig.
49).
(3) Remove throttle and speed control cables from
throttle arm and bracket.
(4) Disconnect electrical connectors from the following sensors and actuators (Refer to FUEL SYSTEM for component locations):
• Secondary Runner Valve (SRV)
• Manifold Tuning Valve (MTV)
• Throttle Position Sensor (TPS)
• Idle Air Control (IAC)
• Intake Air Temperature/Manifold Absolute Pressure (TMAP)
• Vacuum Reservoir Solenoid
(5) Disconnect vacuum hoses from the following:
• Secondary Runner Valve (SRV) Reservoir
• Speed Control Reservoir
• Positive Crankcase Ventilation (PCV) Valve
• Proportional Purge Solenoid
• Power Brake Booster
1 – AIR CLEANER ASSEMBLY WITH AIR INLET HOSE
2 – THROTTLE BODY
(6) Remove right side (Fig. 50) and left side (Fig.
51) intake manifold supports.
(7) Remove support brackets at intake manifold
front corners and at MTV (Fig. 52).
(8) Loosen upper fastener attaching throttle body
to support bracket.
(9) Remove clips attaching EGR tubes to intake
manifold. Refer to EMISSION CONTROL SYSTEM
for procedure.
(10) Remove bolts attaching intake manifold and
remove manifold.
Fig. 50 Intake Manifold Support—Right Side
1 – SUPPORT BRACKET
3.2/3.5L ENGINE
LH
9 - 107
REMOVAL AND INSTALLATION (Continued)
Fig. 51 Intake Manifold Support—Left Side
1 – SUPPORT BRACKET
Fig. 53 Upper Intake Manifold Tightening Sequence
Fig. 52 Intake Manifold Supports—Front
1 – SUPPORT BRACKETS
INSTALLATION
(1) Clean and inspect gasket sealing surfaces.
NOTE: Intake gaskets can be reused, provided they
are free of cuts or tears.
(2) Inspect gasket for cuts or tears. Replace gaskets as necessary.
(3) Install intake manifold and hand start all
attaching bolts.
(4) Tighten bolts gradually in sequence shown in
(Fig. 53) until a torque of 12 N·m (105 in. lbs.) is
obtained.
(5) Install right side (Fig. 50) and left side (Fig.
51) intake manifold supports.
(6) Install manifold support brackets at front corners and at MTV (Fig. 52).
(7) Tighten fastener attaching throttle body to support bracket.
(8) Connect vacuum lines to the following:
• Secondary Runner Valve (SRV) Reservoir
• Speed Control Reservoir
• Positive Crankcase Ventilation (PCV) Valve
• Proportional Purge Solenoid
• Power Brake Booster
(9) Connect electrical connectors to the following:
• Secondary Runner Valve (SRV)
• Manifold Tuning Valve (MTV)
• Throttle Position Sensor (TPS)
• Idle Air Control (IAC)
• Intake Air Temperature/Manifold Absolute Pressure (TMAP)
• Vacuum Reservoir Solenoid
(10) Install EGR tubes to intake manifold. Refer to
EMISSION CONTROL SYSTEM for procedure.
(11) Install throttle and speed control cables to
bracket and throttle arm.
(12) Install air cleaner housing and inlet tube.
(13) Connect negative cable to remote jumper terminal.
INTAKE MANIFOLD—LOWER
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND
AVOID IGNITION SOURCES. NEVER SMOKE WHILE
SERVICING THE VEHICLE.
9 - 108
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Perform fuel pressure release. Refer to FUEL
SYSTEM for procedure.
(2) Drain cooling system. Refer to COOLING SYSTEM for procedure.
(3) Remove upper intake manifold. Refer to procedure in this section.
(4) Disconnect electrical connectors to fuel injectors and coolant temperature sensor.
(5) Disconnect heater and coolant bottle supply
hoses from coolant tube at rear of intake manifold
(Fig. 54).
Fig. 54 Heater Supply Hose Connections
1 – HEATER SUPPLY HOSE
2 – COOLANT BOTTLE SUPPLY HOSE
(6) Disconnect fuel supply hose from fuel rail.
(7) Remove screw attaching fuel rail support
bracket to the throttle body support bracket.
(8) Remove bolts attaching fuel rail.
(9) Remove fuel rail and injectors as an assembly.
(10) Remove bolts attaching lower intake and
remove intake manifold (Fig. 55).
INSTALLATION
(1) Clean all sealing surfaces.
NOTE: Gaskets can be reused provided they are
free of tears or cuts.
(2) Inspect gaskets for tears or cuts. Replace as
necessary.
(3) Position gaskets and intake manifold on cylinder head surfaces.
(4) Install fuel rail with injectors.
(5) Install intake manifold bolts and gradually
tighten in sequence shown in (Fig. 56) until a torque
of 28 N·m (250 in. lbs.) is obtained.
(6) Install screw attaching fuel rail support
bracket to the throttle body support bracket.
(7) Connect fuel supply hose to fuel rail.
(8) Connect heater and coolant bottle supply hoses
to coolant tube at rear of intake manifold (Fig. 54).
(9) Connect electrical connectors to fuel injectors
and coolant temperature sensor.
(10) Install upper intake manifold. Refer to procedure in this section.
(11) Fill cooling system. Refer to COOLING SYSTEM for procedure.
(12) With the DRBIIIt scan tool use ASD Fuel
System Test to pressurize fuel system to check for
leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
Fig. 55 Lower Intake Manifold
1
2
3
4
5
–
–
–
–
–
BOLT
HEATER SUPPLY TUBE
BOLT
BOLT
KNOCK SENSOR
6
7
8
9
–
–
–
–
GASKET
BOLT
O-RING
INTAKE MANIFOLD-LOWER
9 - 109
9 - 110
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(11) Remove air conditioning compressor bracket.
(12) Disconnect oxygen sensor electrical connector
and remove sensor.
(13) Remove heat shield attaching bolts and
remove heat shield (Fig. 57).
(14) Remove exhaust manifold attaching bolts (Fig.
57).
(15) Remove exhaust manifold (Fig. 57).
Fig. 56 Lower Intake Manifold Tightening Sequence
EXHAUST MANIFOLD
RIGHT EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Raise vehicle on hoist.
(3) Remove exhaust system. Refer to EXHAUST
SYSTEM for procedure.
(4) Loosen converter pipe support attaching bolt at
transaxle mount.
(5) Loosen A/C belt. Refer to COOLING SYSTEM
for procedure.
(6) Lower vehicle.
(7) Remove air cleaner housing and air inlet tube.
(8) Loosen and remove V-Band clamp at exhaust
manifold connector.
NOTE: Do not reuse V-Band clamp.
(9) Remove A/C compressor attaching bolts and set
compressor aside.
(10) Remove engine oil dipstick tube.
INSTALLATION
(1) Install exhaust manifold. Tighten bolts starting
at the center working outward to 23 N·m (200 in.
lbs.) (Fig. 57).
(2) Install heat shields and tighten attaching bolts
to 12 N·m (105 in. lbs.) (Fig. 57).
(3) Install oxygen sensor to manifold and connect
electrical connector.
(4) Install air conditioning compressor mounting
bracket.
(5) Install engine oil dipstick tube.
(6) Install air conditioning compressor and drive
belt. Refer to COOLING SYSTEM for belt installation procedure.
(7) Install a new V-Band clamp and tighten to 11
N·m (100 in. lbs.).
(8) Raise vehicle on hoist.
(9) Install exhaust system. Refer to EXHAUST
SYSTEM for procedure.
(10) Install and/or tighten nut attaching converter
pipe support to transaxle mount to 47 N·m (35 ft.
lbs.).
(11) Lower vehicle.
(12) Install air cleaner housing and air inlet tube.
(13) Connect negative cable.
LEFT EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Raise vehicle on hoist.
(3) Remove exhaust system. Refer to EXHAUST
SYSTEM for procedure.
(4) Loosen converter pipe support attaching bolt at
transaxle mount.
(5) Lower vehicle.
(6) Loosen and remove V-Band clamp at exhaust
manifold connector.
NOTE: Do not reuse V-Band clamp.
(7) Remove electrical connector harness bracket.
(8) Disconnect oxygen sensor electrical connector
and remove sensor from manifold.
(9) Remove heat shield attaching bolts and remove
heat shield (Fig. 57).
(10) Remove manifold attaching bolts (Fig. 57).
3.2/3.5L ENGINE
LH
9 - 111
REMOVAL AND INSTALLATION (Continued)
(1) Remove air cleaner assembly and upper intake
manifold. Refer to Intake Manifold in this section for
procedure.
(2) Cover lower intake manifold with a suitable
cover during service.
(3) Disconnect electrical connectors and remove
ignition coils (Fig. 59).
(4) Remove nuts attaching wire harness to cylinder head cover (Fig. 58). Move harness for cover
removal clearance.
Fig. 57 Exhaust Manifold—3.2/3.5L Engine
1
2
3
4
5
–
–
–
–
–
BOLT
HEAT SHIELD
EXHAUST MANIFOLD
BOLT
HEAT SHIELD
Fig. 58 Wire Harness Retaining Nuts
(11) Remove manifold (Fig. 57).
INSTALLATION
(1) Install exhaust manifold. Tighten bolts starting
at the center working outward to 23 N·m (200 in.
lbs.) (Fig. 57).
(2) Install heat shields and tighten bolts to 12 N·m
(105 in. lbs.) (Fig. 57).
(3) Install oxygen sensor to manifold and connect
electrical connector.
(4) Attach electrical connector bracket to brace.
(5) Install a new V-Band clamp and tighten to 11
N·m (100 In. lbs.).
(6) Raise vehicle on hoist.
(7) Install and/or tighten nut attaching converter
pipe support to transaxle mount to 47 N·m (35 ft.
lbs.).
(8) Install exhaust system. Refer to EXHAUST
SYSTEM for procedure.
(9) Lower vehicle and connect negative cable.
CYLINDER HEAD COVER
REMOVAL
WARNING: DO NOT START OR RUN ENGINE WITH
CYLINDER HEAD COVER REMOVED FROM THE
ENGINE. DAMAGE OR PERSONAL INJURY MAY
OCCUR.
1 – NUTS
2 – WIRE HARNESS
(5) For right cylinder head cover removal perform
the following:
(a) Remove A/C compressor belt. Refer to COOLING SYSTEM for procedure.
(b) Remove A/C compressor mounting bolts.
(c) Move compressor aside for cylinder head
cover clearance.
(6) Remove cylinder head cover bolts and remove
cover (Fig. 60).
INSTALLATION
(1) Clean cylinder head and cover mating surfaces.
Inspect and replace gasket and seals as necessary
(Fig. 61).
(2) To replace spark plug tube seals:
(a) Using a suitable pry tool, carefully remove
tube seals.
(b) Position new seal with the part number on
seal facing cylinder head cover.
(c) Install seals using Special Tool MD-998306
(Fig. 62).
(3) Install cylinder head cover bolts and tighten to
12 N·m (105 in. lbs.) (Fig. 60).
(4) For right cylinder head cover installation perform the following:
(a) Position A/C compressor on bracket and
install mounting bolts.
9 - 112
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
Fig. 61 Cylinder Head Cover Gasket and Spark Plug
Tube Seals
1 – CYLINDER HEAD COVER GASKET
2 – SPARK PLUG TUBE SEALS
Fig. 59 Ignition Coils
Fig. 62 Spark Plug Tube Seal Installation
1 – SPECIAL TOOL MD-998306
2 – SPARK PLUG TUBE SEAL
Fig. 60 Cylinder Head Covers
1 – CYLINDER HEAD COVER-LEFT SIDE
2 – BOLTS (8)
(b) Install A/C compressor belt. Refer to COOLING SYSTEM for procedure.
(5) Position wire harness on cylinder head cover
and install retaining nuts (Fig. 58).
(6) Install ignition coils and connect all electrical
connectors.
(7) Install upper intake manifold and air cleaner
assembly.
SPARK PLUG TUBES
REMOVAL
(1) Remove cylinder head cover(s). Refer to procedure in this section.
(2) Using locking pliers remove the tube from the
cylinder head (Fig. 63). Discard old tube.
(3) Clean area around spark plug with Mopart
Parts Cleaner or equivalent.
(4) Refer to Cylinder Head Covers for spark plug
tube seal replacement.
INSTALLATION
(1) Apply Mopart Stud and Bearing Mount to a
new tube approximately 1 mm (0.039 in.) from the
end of tube, in a 3 mm (0.118 in.) wide area.
(2) Install sealer end of tube into the cylinder
head. Then carefully install the tube using a hardwood block and mallet. Install the tube until it is
seated into the bottom of the bore.
(3) Install cylinder head cover(s). Refer to procedure in this section.
CYLINDER HEAD
REMOVAL
(1) Drain cooling system. Refer to COOLING SYSTEM for procedure.
3.2/3.5L ENGINE
LH
9 - 113
REMOVAL AND INSTALLATION (Continued)
NOTE: Do not reuse V-Band Clamp.
(7) Remove rear timing belt cover to cylinder head
fasteners (Fig. 64). Remove the rear covers.
(8) The right side rear timing belt cover has
O-rings to seal the water pump passages to cylinder
block (Fig. 65). Do not reuse O-rings.
Fig. 63 Servicing Spark Plug Tubes
1 – SPARK PLUG TUBE
2 – LOCKING PLIERS
(2) Remove crankshaft damper.
(3) Remove front timing belt covers.
(4) Remove camshaft sprockets. Refer to Camshaft
Sprocket and Engine Timing Procedure in this section.
(5) Remove upper and lower intake manifold.
Refer to procedures in this section.
Fig. 64 Rear Timing Belt Cover Attaching Bolts
1 – REAR COVER TO CYLINDER HEAD BOLTS
2 – APPLY SEALANT TO BOLT THREADS
3 – REAR COVER TO CYLINDER BLOCK BOLTS
Cylinder Head, Camshaft, and Rocker Arms
1
2
3
4
–
–
–
–
SPARK PLUG TUBE
ROCKER ARM ASSEMBLY
CAMSHAFT
SEAL
(6) Remove V-Band clamp(s) at exhaust manifold
to catalytic converter pipe connection.
Fig. 65 Right Side Timing Belt Cover Water Pump
O-Rings
1 – REAR TIMING BELT COVER TO ENGINE BLOCK O-RINGS
2 – WATER PUMP IMPELLER
(9) Remove cylinder head bolts and remove cylinder head(s).
9 - 114
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
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 (Fig.
66).
Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
Fig. 66 Checking Bolts for Stretching (Necking)
1
2
3
4
–
–
–
–
STRETCHED BOLT
THREADS ARE NOT STRAIGHT ON LINE
THREADS ARE STRAIGHT ON LINE
UNSTRETCHED BOLT
CAUTION: When cleaning cylinder head and cylinder 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 sealing surfaces of cylinder head and
block.
CAUTION: Ensure that the correct head gaskets are
used and are oriented correctly on cylinder block.
The 3.5L engine head gaskets have perfectly round
combustion sealing rings. The 3.2L engine does
NOT have perfectly round combustion sealing
rings.
(2) Install head gasket over locating dowels.
Ensure the gasket is installed on the correct side of
engine (Fig. 67).
(3) Install cylinder head over locating dowels.
(4) Before installing the bolts, lubricate the
threads with engine oil.
(5) Tighten the cylinder head bolts in the sequence
shown in (Fig. 68). Using the 4 step torque-turn
method, tighten according to the following torque values:
• Step 1: All to 61 N·m (45 ft. lbs.)
• Step 2: All to 88 N·m (65 ft. lbs.)
• Step 3: All (again) to 88 N·m (65 ft. lbs.)
• Step 4: + 90° Turn Do not use a torque
wrench for this step.
(6) Bolt torque after 90° turn should be over 122
N·m (90 ft. lbs.) in the tightening direction. If not,
replace the bolt.
Fig. 68 Cylinder Head Bolt Tightening Sequence
Fig. 67 Cylinder Head Gasket Identification
(7) Clean right rear timing belt cover O-ring sealing surfaces and grooves (Fig. 65). Lubricate new
O-rings with Mopart Dielectric Grease or equivalent
to facilitate assembly.
(8) Install rear timing belt covers (Fig. 64) and
(Fig. 65). Tighten bolts to specified torque:
• M10—54 N·m (40 ft. lbs.)
• M8—28 N·m (20 ft. lbs.)
• M6—12 N·m (105 in. lbs.)
3.2/3.5L ENGINE
LH
9 - 115
REMOVAL AND INSTALLATION (Continued)
(9) Install camshaft sprockets and timing belt.
Refer to procedure in this section.
(10) Install front timing belt covers. Refer to procedure in this section.
(11) Install crankshaft damper.
(12) Install upper and lower intake manifold. Refer
to procedures in this section.
(13) Connect catalytic converter to exhaust manifold with a new V-Band clamp(s). Tighten V-Band
clamp to 10 N·m (100 in. lbs.).
(14) Fill cooling system. Refer to COOLING SYSTEM for procedure.
CRANKSHAFT
Fig. 69 Connecting Rod to Cylinder Identification
1 – CYLINDER NUMBER
REMOVAL
(1) Remove engine from vehicle. Refer to Engine
Assembly Removal and Installation in this section.
(2) Remove oil pan.
(3) Remove oil pickup tube.
(4) Remove crankshaft damper. Refer to procedure
in this section.
(5) Remove idler pulley for accessory drive belt.
(6) Remove front lower timing belt cover.
(7) Remove front main timing belt cover.
(8) Remove front left side timing belt cover.
(9) Remove timing belt tensioner and timing belt.
(10) Remove crankshaft sprocket. Refer to Front
Crankshaft Oil Seal Removal and Installation for
procedure.
(11) Tap dowel pin out of crankshaft. Refer to
Front Crankshaft Oil Seal Removal and Installation
for procedure.
(12) Remove oil pump assembly.
(13) Remove rear crankshaft oil seal retainer.
(14) Remove connecting rod bearing caps. Connecting rod bearing caps are not interchangeable and
should be marked before removal to insure correct
assembly (Fig. 69).
(15) Remove main bearing caps. Main bearing caps
are not interchangeable and are marked to insure
correct assembly (Fig. 70).
(16) Remove Crankshaft.
Fig. 70 Main Bearing Cap Identification
NOTE: Before installing Crankshaft refer to Fitting
Main Bearings and Installation of Connecting Rod
Bearings in this section.
INSTALLATION
CAUTION: Main bearings are select fit. Refer to
Crankshaft Main Bearing Fitting in this section for
proper bearing selection.
(1) Install Crankshaft.
Fig. 71 Main Bearing Identification
(2) Move crankshaft forward to limit of travel.
Lubricate and install the front thrust washer by rolling the washer onto the machined shelf between the
9 - 116
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
No. 2 upper main bulk head and crankshaft thrust
surface (Fig. 72).
(3) Move crankshaft rearward to limit of travel.
Lubricate and install the rear thrust washer by rolling the washer onto the machined shelf between the
No. 2 upper main bulk head and crankshaft thrust
surface.
(14) Install crankshaft sprocket. Refer to Front
Crankshaft Oil Seal Removal and Installation for
procedure.
(15) Install Timing Belt. Refer to Camshaft
Sprockets and Timing Procedure in this section.
(16) Install (3) timing belt covers.
(17) Install crankshaft damper. Refer to procedure
in this section.
(18) Install idler pulley for accessory drive belt.
(19) Install oil pickup tube and tighten bolt to 28
N·m (250 in. lbs.).
(20) Install oil pan. Refer to procedure in this section.
(21) Install engine assembly.
(22) Fill engine crankcase with proper amount of
oil.
CAMSHAFT
REMOVAL
Fig. 72 Thrust Washer Installation
1 – FRONT THRUST WASHER
(4) Lubricate lower main bearings with clean
engine oil.
NOTE: Lubricate main bearing cap bolts with
engine oil before installation.
(5) Install each main cap and tighten bolts finger
tight.
The main bearing cap bolts must be tightened in
the proper sequence. First the inner main cap bolts,
secondly the windage tray bolts, lastly the main cap
tie (horizontal) bolts.
(6) Install the inside main bearing cap bolts and
tighten to 20 N·m + 1/4 turn (15 ft. lbs. + 1/4 turn).
(7) Measure crankshaft end play. Refer to Service
Procedures in this section.
(8) Install connecting rods and measure side clearance. Refer to Service Procedures in this section.
(9) Install windage tray. Lubricate bolts with
engine oil and tighten to 27 N·m + 1/4 turn (20 ft.
lbs. + 1/4 turn).
(10) Install the main cap tie (horizontal) bolts and
tighten to 28 N·m (250 in. lbs.).
(11) Install rear crankshaft oil seal retainer and oil
seal. Refer to procedure in this section.
(12) Install oil pump assembly. Refer to Oil Pump
Removal and Installation in this section.
(13) Install dowel pin in crankshaft. Refer to Front
Crankshaft Oil Seal Removal and Installation for
procedure.
Camshafts are serviced from the rear of the cylinder head. The cylinder head must be removed.
(1) Remove Camshaft Sprocket(s). Refer to procedure in this section.
(2) Remove cylinder head(s). Refer to procedure in
this section.
(3) Mark the rocker arm and shaft assembly before
removal. Remove the rocker arm and shaft assembly
from the head.
(4) Remove the rear camshaft cover and O-ring
from head.
CAUTION: Be careful not to Nick or Scratch the
journals when removing the camshaft.
(5) Carefully remove the camshaft from the rear of
the cylinder head.
INSTALLATION
(1) Lubricate camshaft journals and cam with
clean engine oil and install camshaft into cylinder
head.
(2) Install cylinder head(s). Refer to procedure in
this section.
(3) Install the rocker arm assembly. Refer to procedure in this section.
NOTE: Refer to Camshaft Sprocket and Timing Procedure to complete camshaft installation.
3.2/3.5L ENGINE
LH
9 - 117
REMOVAL AND INSTALLATION (Continued)
CAMSHAFT SPROCKETS AND TIMING
PROCEDURE
REMOVAL
CAUTION: The 3.2/3.5L engines are NOT a freewheeling design. Therefore, care should be taken
not to rotate the camshafts or crankshaft with the
timing belt removed.
(1) Drain cooling system. Refer to COOLING SYSTEM for procedure.
(2) Remove accessory drive belts. Refer to COOLING SYSTEM for procedure.
(3) Remove crankshaft damper.
(4) Remove timing belt covers and timing belt.
CAUTION: When camshaft sprocket bolts are loosened or removed, the camshafts must be re-timed
to the engine. Also, the camshaft sprocket bolts
must NOT be reused. Refer to camshaft timing and
timing belt installation procedure in this section.
Fig. 73 Camshaft Sprocket Identification
1 – DIS PICKUP SLOTS
(5) Hold camshaft sprocket with 36 mm (1 7/16 in.)
box wrench loosen and remove bolt and washer. To
remove the bolt with engine in the vehicle it may be
necessary to lift that side of the engine because the
right bolt is 213 mm (8 3/8 in.) long and the left bolt
is 255 mm (10.0 in.) long.
(6) Remove camshaft sprocket from camshaft.
Each sprocket has a D shaped hole that allows it to
rotate several degrees in each direction on its shaft.
This design must be timed with the engine to ensure
proper performance of the engine. Refer to camshaft
and timing belt installation in this section for procedures.
TIMING PROCEDURE—3.2/3.5L
CAUTION: The camshaft sprockets are not interchangeable from side to side (Fig. 73).
(1) Place crankshaft sprocket to the TDC mark on
the oil pump housing (Fig. 74).
(2) Install a dial indicator in number 1 cylinder to
check TDC of the piston (Fig. 79). Rotate the crankshaft until the piston is at exactly TDC.
(3) Install the camshaft alignment Special Tools
6642 to the rear of each cylinder head (Fig. 75).
CAUTION: Compress the tensioner slowly, as damage to the tensioner could result.
(4) Slowly pre-load the tensioner with a vise and
install locking pin (Fig. 76).
Fig. 74 Timing Belt System
1
2
3
4
5
–
–
–
–
–
REAR TIMING BELT COVERS
WATER PUMP
TDC INDICATOR
BELT TENSIONER
TENSIONER PULLEY
NOTE: Once pin is installed, the tensioner must be
stored with the plunger facing upward until it is
ready to be reinstalled.
(5) Install camshaft sprockets onto the camshafts.
Install NEW sprocket attaching bolts into place. The
255 mm (10 in.) bolt is to be installed in the left camshaft and the 213 mm (8 3/8 in.) bolt is to be
installed into the right camshaft. Do not tighten
the bolts. Camshaft sprocket mark should be posi-
9 - 118
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
Fig. 77 Camshaft Sprocket Timing Marks
1 – ALIGN CAMSHAFT SPROCKET TIMING MARK BETWEEN
MARKS ON REAR TIMING BELT COVER
2 – CRANKSHAFT AT TDC
Fig. 75 Camshaft Alignment Special Tools 6642
1 – LEFT CAMSHAFT PILOT HOLE
2 – RIGHT CAMSHAFT PILOT HOLE
3 – CAMSHAFT ALIGNMENT SPECIAL TOOLS 6642
Fig. 78 Timing Belt—Installation
Fig. 76 Compressing Timing Belt Tensioner
1 – VISE
2 – LOCKING PIN
tioned between the marks on the cover (Fig. 77) at
both sprocket.
(6) Install the timing belt starting at the crankshaft sprocket going in a counterclockwise direction
(Fig. 78). Install the belt around the last sprocket.
Maintain tension on the belt as it is positioned
around the tensioner pulley. Each camshaft sprockets
mark should still fall between the cover marks.
1 – ALIGN CAMSHAFTS WITH TIMING MARKS
2 – INSTALL TENSIONER LOOSE
3 – CRANKSHAFT AT TDC
(7) Holding the tensioner pulley against the belt,
install the tensioner into the housing and tighten to
28 N·m (250 in. lbs.).
(8) When tensioner is in place pull retaining pin to
allow the tensioner to extend to the pulley bracket.
(9) With number 1 piston at TDC (Fig. 79), hold
the camshaft sprocket hex with a 36 mm (1 7/16 in.)
wrench and tighten the camshaft bolts to 102 N·m
(75 ft. lbs.) plus a 90 degree turn for the Right side
and 115 N·m (85 ft. lbs.) plus a 90 degree turn for
the Left side.
3.2/3.5L ENGINE
LH
9 - 119
REMOVAL AND INSTALLATION (Continued)
arm shaft assembly on the LEFT side of the engine
has an oil passage hole from the cylinder head to
the second rocker shaft support.
REMOVAL
(1) Remove cylinder head covers. Refer to procedure in this section.
(2) Identify the rocker arm assembly and rocker
arms before disassembly (Fig. 80).
(3) Remove rocker arm assembly bolts.
(4) Remove rocker arm assembly.
NOTE: To prevent air ingestion into lash adjusters,
avoid turning rocker arm assembly upside down.
CAUTION: Do not allow rocker arm assembly to
rest on lash adjusters, as damage may occur to
lash adjusters and/or plastic retainers.
Fig. 79 Dial Indicator Locating Piston at TDC
(10) Remove dial indicator and install spark plug.
(11) Remove camshaft alignment Special Tools
6642 and install cam covers and O-rings. Tighten fasteners to 28 N·m (250 in. lbs.).
(12) Install timing belt covers. Refer to Timing
Belt Covers in this section.
(13) Install crankshaft damper.
(14) Install accessory drive belts. Refer to COOLING SYSTEM for procedure.
(15) Fill cooling system. Refer to COOLING SYSTEM for procedure.
(16) Start engine and allow to idle for approximately 1 minute. If a noticeable noise is present from
the timing belt/tensioner, air has possibly entered the
tensioner.
(a) To remove air from tensioner; using a DRB
IIIt, operate the engine at speed of 1600–2000
RPM for 10 minutes. This will purge air from tensioner and noise will be dissipated.
NOTE: If air is present, the tensioner will be soft
and may generate noise. This noise should disappear after no more than 15 minutes of engine running time.
Fig. 80 Rocker Arms and Shaft Identification—Left
Bank
DISASSEMBLY
(1) Remove dowel pin using a 4 mm screw, nut,
spacer, and washer installed into the pin (Fig. 81).
Tighten the screw into the pin, then loosen the nut
on the screw. This will pull the dowel out of the shaft
support. Do not reuse dowel pins. Remove the rocker
arms and pedestals in order.
(2) Check the rocker arm mounting portion of the
shafts for wear or damage. Replace if damaged or
heavily worn.
(3) Check shaft oil holes for clogging with small
wire, clean as required.
ASSEMBLY
ROCKER ARMS AND SHAFT ASSEMBLY
CAUTION: The rocker arm shafts are hollow and
are used as lubrication oil passages. The rocker
arm and shaft assembly on the RIGHT side of the
engine has an oil passage hole from the cylinder
head to the third rocker shaft support. The rocker
CAUTION: New dowel pins must be installed during
assembly.
(1) Install the rocker arms, and pedestals onto the
shaft.
9 - 120
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
NOTE: Rocker arm and shaft assembly can be
installed either prior to or after (preferred) cylinder
head installation.
Fig. 81 Rocker Arms and Shaft—Disassembly
1
2
3
4
5
6
7
8
–
–
–
–
–
–
–
–
4mm SCREW AND NUT
4mm SCREW AND NUT
WASHER
SPACER
DOWEL
DOWEL
SPACER
WASHER
(1) Rotate camshafts to the position shown in (Fig.
83). With the camshafts in these positions the lobes
are in a neutral position (no load to the valve). This
will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load
on it.
(2) Install the rocker arm and shaft assembly
making sure that the identification marks face
toward the front of engine for left head and toward
the rear of the engine for right head.
(3) Tighten rocker arm/shaft assembly bolts in
sequence to 31 N·m (275 in. lbs.) (Fig. 84).
NOTE: The notches on the rocker shafts face up
(Fig. 80). Notches on the right cylinder bank face
towards rear of engine. Notches on left cylinder
bank face toward front of engine.
(2) Install dowel pins (Fig. 82). Dowel pins pass
through the pedestal into the exhaust rocker shafts.
Dowel pins should be pressed in until they bottomout against the rocker shaft in the pedestal.
CAUTION: Inspect all lash adjuster plastic retaining
caps for proper retention before installation.
Fig. 82 Assemble Rocker Arms and Shaft
1
2
3
4
–
–
–
–
HYDRAULIC LASH ADJUSTERS
DOWEL PIN
PEDESTAL
ROLLER
Fig. 83 Camshaft Sprockets Neutral Position
Fig. 84 Rocker Arm and Shaft Assembly Tightening
Sequence
VALVE STEM SEALS OR VALVE SPRINGS—IN
VEHICLE
(1) Perform fuel system pressure release procedure
before attempting any repairs. Refer to FUEL
SYSTEM for procedure.
3.2/3.5L ENGINE
LH
9 - 121
REMOVAL AND INSTALLATION (Continued)
(2) Disconnect negative battery cable.
(3) Remove air cleaner housing and hose assembly.
(4) Remove upper intake manifold. Refer to procedure in this section.
(5) Remove cylinder head covers and spark plugs.
Refer to procedures in this section.
(6) Remove rocker arm and shaft assembly. Refer
to procedure in this section.
(7) Rotate the crankshaft clockwise, until the number 1 piston is at TDC (Top Dead Center) on the compression stroke.
(8) With air hose attached to spark plug adapter
installed in number 1 spark plug hole, apply 620.5 to
689 kPa (90 to 100 psi) air pressure. This is to hold
valves into place while servicing components.
(9) Using Tool MD 998772A with adapter 6527 or
equivalent, compress valve spring and remove valve
locks, retainer, and valve spring.
(10) Remove valve stem seals by using a valve
stem seal tool (Fig. 85).
Fig. 86 Valve Seal Garter Spring
1
2
3
4
–
–
–
–
SPRING RETAINER
GARTER SPRING
VALVE SPRING SEAT TOP
CYLINDER HEAD SURFACE
(15) Install cylinder head covers. Refer to procedure in this section.
(16) Install ignition coils and connect all electrical
connectors.
(17) Install upper intake manifold. Refer to procedure in this section.
(18) Connect negative cable.
VALVE AND VALVE SPRINGS
REMOVAL
Fig. 85 Valve Stem Seal Removal—Typical
1 – VALVE SEAL TOOL
2 – VALVE STEM
(11) The valve stem seal/valve spring seat should
be pushed firmly and squarely over the valve guide
using the valve stem as guide. Do Not Force seal
against top of guide. When installing the valve
retainer locks, compress the spring only enough to
install the locks.
CAUTION: Do not remove garter spring around the
seal at the top of the valve stem seal (Fig. 86).
(12) Follow the same procedure on the remaining 5
cylinders using the firing sequence 1-2-3-4-5-6. Make
sure piston in cylinder is at TDC on the valve
spring that is being covered.
(13) Remove spark plug adapter tool.
(14) Remove Special Tool MD 998772A and install
rocker arm and shaft assembly. Refer to procedure in
this section.
(1) With cylinder head removed, compress valve
springs using the Valve Spring Compressors shown
in (Fig. 87).
(2) Remove valve retaining locks, valve spring
retainers, valve springs and valve spring seat/stem
seal assembly.
(3) Before removing valves, remove any burrs
from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure
installation in original location.
INSTALLATION
(1) Coat valve stems with clean engine oil and
insert them in cylinder head.
(2) If valves or seats have been reground, check
valve tip height (A) (Fig. 88). If valve tip height is
greater than 43.65 mm (1.7185 in.) intake or 45.98
mm (1.8102 in.) exhaust, grind valve tip until within
specifications. Make sure measurement is taken from
cylinder head surface to the top of valve stem.
(3) Install valve seal/spring seat assembly over
valve guides on all valve stems (Fig. 89). Ensure that
the garter spring is intact around the top of the rub-
9 - 122
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
Fig. 87 Valve Spring Compressors
1 – ADAPTER 6537
2 – ADAPTER 6526
Fig. 89 Valve, Spring, and Valve Seal—Installation
1
2
3
4
5
–
–
–
–
–
VALVE
VALVE
VALVE
VALVE
VALVE
RETAINING LOCKS
SPRING RETAINER
SPRING
SEAL AND VALVE SPRING SEAT ASSEMBLY
TIMING BELT COVERS
REMOVAL
Fig. 88 Checking Valve Tip Height and Valve Spring
Installed Height
1
2
3
4
–
–
–
–
SPRING RETAINER
GARTER SPRING
VALVE SPRING SEAT TOP
CYLINDER HEAD SURFACE
ber seal. Place valve springs (color-coded end facing
up) and valve retainers into position.
(4) Compress valve springs with a valve spring
compressor install locks and release tool. If valves
and/or seats are reground, measure the
installed height of springs (B) (Fig. 88), make
sure measurements are taken from top of
spring seat to the bottom surface of spring
retainer. If height is greater than 38.75 mm (1.5256
inches), install a.762 mm (0.030 inch.) spacer in head
counterbore under the valve spring seat to bring
spring height back within specification.
(1) Disconnect negative cable from remote jumper
terminal.
(2) Remove upper radiator crossmember. Refer to
BODY for procedure.
(3) Remove the cooling fan module and accessory
drive belts. Refer to COOLING SYSTEM for procedures.
(4) Use Special Tool 8191 to hold crankshaft
damper while removing center bolt.
(5) Remove crankshaft damper using Special Tools
1023 and C-4685-C2 (Fig. 90).
(6) Remove the lower belt cover located behind the
crankshaft damper (Fig. 92).
(7) Remove the A/C belt guide/lift bracket (Fig. 91).
(8) Remove the stamped steel cover (Fig. 92). Do
not remove the sealer on the cover, it is reusable (Fig. 93). If some sealer is missing use Mopart
Engine RTV GEN II to replace the missing sealer.
(9) Remove the left cast cover (Fig. 92).
INSTALLATION
(1) Install the left cast cover (Fig. 92) and generator/power steering belt tensioner pulley and bracket.
(2) Install the right stamped steel cover (Fig. 92).
(3) Install A/C belt guide/lift bracket (Fig. 91).
(4) Install the lower cover (Fig. 92).
3.2/3.5L ENGINE
LH
9 - 123
REMOVAL AND INSTALLATION (Continued)
Fig. 90 Crankshaft Damper—Removal
1 – SPECIAL TOOL
1023
2 – SPECIAL TOOL
C-4685–C2
INSERT
Fig. 92 Timing Belt Covers
1 – RIGHT SIDE COVER (STAMPED)
2 – LEFT SIDE COVER (CAST)
3 – LOWER COVER
Fig. 91 A/C Belt Guide/Lift Bracket
1 – A/C BELT GUIDE/LIFT BRACKET
2 – NUT
Fig. 93 Sealer, Timing Belt Cover
1 – SEALER
(5) Install the crankshaft damper using Special
Tools C-4685-C1 Bolt (5.9 in.) and 6792-1. Install center bolt, and while holding damper with Special Tool
8191, tighten center bolt to 115 N·m (85 ft. lbs.).
(6) Install the cooling fan module, accessory drive
belts. Refer to COOLING SYSTEM for procedures.
(7) Install upper radiator crossmember. Refer to
BODY for procedure.
(8) Connect negative cable to remote jumper terminal.
TIMING BELT
REMOVAL
CAUTION: The following procedure can only be
used when the camshaft sprockets HAVE NOT
BEEN LOOSENED or removed from the camshafts.
Refer to Camshaft Sprocket and Engine Timing in
this Section, if sprocket(s) or camshaft(s) have
been loosened or removed.
9 - 124
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
CAUTION: The 3.2/3.5L are NOT freewheeling
engines. Therefore, care should be taken not to
rotate the camshafts or crankshaft with the timing
belt removed.
(1) Disconnect negative cable from remote jumper
terminal.
(2) Remove upper radiator crossmember. Refer to
BODY for procedure.
(3) Disconnect fan module electrical connector.
(4) Remove cooling fan module and accessory drive
belts. Refer to COOLING SYSTEM for procedures.
(5) Remove crankshaft damper and front timing
belt covers. Refer to procedures this section.
(6) Mark belt running direction, if timing belt is to
be reused.
NOTE: When timing belt tensioner is removed from
engine, always store in the vertical (plunger facing
upward) position.
(9) Remove the timing belt tensioner (Fig. 95) and
remove timing belt.
CAUTION: When aligning timing marks, always
rotate engine by turning the crankshaft. Failure to
do so will result in valve and/or piston damage.
(7) Rotate engine clockwise until crankshaft mark
aligns with the TDC mark on oil pump housing and
the camshaft sprocket timing marks are between the
marks on the rear covers (Fig. 94).
CAUTION: Align the camshaft sprockets between
the marks on rear belt covers before timing belt
removal or damage to valve and/or pistons could
occur.
(8) Using a ink or paint marker; mark the exact
position of the camshaft sprocket timing mark relative to the two timing marks on the rear timing
cover.
Fig. 95 Timing Belt System
1
2
3
4
5
–
–
–
–
–
REAR TIMING BELT COVERS
WATER PUMP
TDC INDICATOR
BELT TENSIONER
TENSIONER PULLEY
TIMING BELT TENSIONER
(10) When tensioner is removed from the engine it
is necessary to compress the plunger into the tensioner body.
CAUTION: Compress the tensioner slowly, as damage to tensioner could result.
(11) Place the tensioner into a vise and SLOWLY
compress the plunger (Fig. 96). Total bleed down of
tensioner should take about 5 minutes.
CAUTION: Index the tensioner in the vise the same
way it is installed on the engine. This is to ensure
proper pin orientation when tensioner is installed
on the engine.
Fig. 94 Engine Timing Mark Alignment
1 – ALIGN CAMSHAFT SPROCKET TIMING MARK BETWEEN
MARKS ON REAR TIMING BELT COVER
2 – CRANKSHAFT AT TDC
(12) When plunger is compressed into the tensioner body install a pin through the body and
plunger to retain plunger in place until tensioner is
installed.
3.2/3.5L ENGINE
LH
9 - 125
REMOVAL AND INSTALLATION (Continued)
NOTE: When timing belt tensioner is removed from
engine, always store in the vertical (plunger facing
upward) position.
Fig. 96 Compressing Timing Belt Tensioner
1 – VISE
2 – LOCKING PIN
INSTALLATION
CAUTION: This procedure can only be used when
the camshaft sprockets HAVE NOT BEEN LOOSENED or removed from the camshafts.
CAUTION: If camshafts have moved from the timing marks, always rotate camshaft towards the
direction nearest to the timing marks (DO NOT
TURN CAMSHAFTS A FULL REVOLUTION OR DAMAGE to valves and/or pistons could result).
(1) Align the crankshaft sprocket with the TDC
mark on oil pump cover (Fig. 97).
(2) Align the camshaft sprockets (to reference
mark made upon removal) between the marks on the
rear covers (Fig. 94).
(3) Install the timing belt starting at the crankshaft sprocket going in a counterclockwise direction
(Fig. 97). Install the belt around the last sprocket.
Maintain tension on the belt as it is positioned
around the tensioner pulley.
(4) Holding the tensioner pulley against the belt,
Install the tensioner into the housing and tighten to
28 N·m (250 in. lbs.). Each camshaft sprocket mark
should still fall between the cover marks.
(5) When tensioner is in place pull retaining pin to
allow the tensioner to extend to the pulley bracket.
(6) Rotate crankshaft sprocket 2 revolutions and
check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations (Fig. 97). If marks do not line up,
repeat procedure.
Fig. 97 Timing Belt Installation
1 – ALIGN CAMSHAFTS WITH TIMING MARKS
2 – INSTALL TENSIONER LOOSE
3 – CRANKSHAFT AT TDC
(7) Install timing belt covers and crankshaft
damper. Refer to procedure in this section.
(8) Install accessory drive belts and cooling fan
module. Refer to COOLING SYSTEM for procedures.
(9) Install upper radiator crossmember. Refer to
BODY for procedure.
(10) Connect negative cable to remote jumper terminal.
(11) Start engine and allow to idle for approximately 1 minute. If a noise is present from the timing belt/tensioner, air has possibly entered the
tensioner.
(a) To remove air from tensioner; using a DRB
IIIt, operate the engine at speed of 1600–2000
RPM for 10 minutes. This will purge air from tensioner.
NOTE: If air is present, the timing belt tensioner
will be soft and may generate noise. This noise
should disappear after no more than 15 minutes of
engine running time.
OIL PAN
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Remove dipstick and tube.
(3) Raise vehicle on hoist and drain engine oil.
(4) Remove structural collar from rear of oil pan
and transmission housing (Fig. 98).
(5) Disconnect engine oil cooler line from pan.
9 - 126
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(6)
(7)
(8)
(9)
Disconnect transmission oil cooler line clips.
Remove oil pan (Fig. 99).
Remove oil pan gasket.
Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Apply a 1/8 inch bead of Mopart Engine RTV
GEN II at the parting line of the oil pump housing
and the rear seal retainer (Fig. 100).
(2) Install oil pan gasket to the engine block.
(3) Install pan and attaching fasteners (Fig. 99).
(4) Install the structural collar (Fig. 98), using the
follow procedure:
(a) Install the vertical collar to oil pan bolts.
Pre-torque bolts to 1.1 N·m (10 in. lbs.).
(b) Install the horizontal collar to transmission
bolts and tighten to 55 N·m (40 ft. lbs.).
(c) Starting with center vertical bolts and working outward, final torque all bolts to 55 N·m (40 ft.
lbs.).
Fig. 98 Structural Collar
1 – BOLT-HORIZONTAL
2 – BOLT-VERTICAL
3 – STRUCTURAL COLLAR
Fig. 99 Oil Pan
1
2
3
4
–
–
–
–
GASKET
OIL PAN
BOLT-M6
NUT-M6
5 – BOLT-M8
6 – BOLT-M8
7 – BOLT-M6
3.2/3.5L ENGINE
LH
9 - 127
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Apply light coat of engine oil to the camshaft
oil seal lip.
(2) Install the oil seal using Special Tool 6788 Seal
Protector Sleeve (Fig. 102) and Seal Installer 6052
(Fig. 103).
(3) Install camshaft sprocket(s). Refer to procedure
in this section.
Fig. 100 Oil pan Sealing
(5) Lower vehicle and install dipstick and tube.
(6) Fill engine crankcase with proper oil to correct
level.
(7) Connect negative cable.
CAMSHAFT OIL SEAL
REMOVAL
(1) Remove camshaft sprocket(s). Refer to procedure in this section.
(2) Use Special Tool C-3981B to remove camshaft
oil seal (Fig. 101).
Fig. 102 Camshaft Oil Seal Protector Sleeve
1 – SPECIAL TOOL 6788
Fig. 103 Camshaft Oil Seal—Installation
1 – SPECIAL TOOL 6052
Fig. 101 Camshaft Oil Seal—Removal
1 – SPECIAL TOOL C-3981B
9 - 128
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
CRANKSHAFT OIL SEAL—FRONT
(5) Shaft seal lip surface must be free of varnish,
dirt or nicks. Polish with 400 grit paper if necessary.
REMOVAL
(1) Remove timing belt. Refer to procedure in this
section.
(2) Remove crankshaft sprocket using Special Tool
L-4407-A (Fig. 104).
Fig. 106 Crankshaft Oil Seal with Special Tool
6341A—Removal
1 – SPECIAL TOOL 6341A
Fig. 104 Crankshaft Sprocket—Removal
1 – SPECIAL TOOL L-4407–A
INSTALLATION
(1) Install crankshaft seal using Special Tool 6342
(Fig. 107).
(2) Install the dowel pin into the crankshaft to 1.2
mm (0.047 in.) protrusion (Fig. 105).
NOTE: To assure proper installation depth of crankshaft sprocket, Special Tool 6641 must be used.
(3) Install crankshaft sprocket using Special Tools
6641 and C-4685-C1 (Fig. 108).
(4) Install timing belt.
Fig. 105 Crankshaft Sprocket Dowel Pin—Removal/
Installation
1 – PIN PUNCH
2 – DOWEL
(3) Tap the dowel pin out of the crankshaft (Fig.
105).
(4) Remove crankshaft seal using Special Tool
6341A (Fig. 106).
CAUTION: Do not nick shaft seal surface or seal
bore.
Fig. 107 Crankshaft Oil Seal with Special Tool
6342—Installation
1 – SPECIAL TOOL 6342
3.2/3.5L ENGINE
LH
9 - 129
REMOVAL AND INSTALLATION (Continued)
Fig. 108 Crankshaft Sprocket—Installation
1 – INSTALL WITH SPECIAL TOOL 6641 WITH 12mm SCREW
C-4685–C1 AND THRUST BEARING AND WASHER
CRANKSHAFT OIL SEAL—REAR
REMOVAL
Fig. 109 Rear Crankshaft Oil Seal Removal—Typical
(1) Remove transaxle from vehicle. Refer to TRANSAXLE for procedure.
(2) Remove drive plate.
(3) Insert a 3/16” wide flat bladed screwdriver
between the dust lip and the metal case of the crankshaft seal. Angle the screwdriver (Fig. 109) through
the dust lip against the metal case of the seal. Pry
out seal.
1
2
3
4
5
6
7
8
9
CAUTION: Do not allow the screwdriver blade to
contact the crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (chamfer) is permitted.
INSTALLATION
CAUTION: If a burr or scratch is present on the
crankshaft edge (chamfer), clean surface using 400
grit sand paper to prevent seal damage during
installation.
(1) Place Special Tool 6926-1 Guide on crankshaft
(Fig. 110). This is a pilot tool with a magnetic base.
(2) Position seal over pilot tool. Assure that lip of
seal is facing towards the crankshaft during installation. The pilot tool remains on crankshaft during seal
installation.
(3) Using Special Tool 6926-2 Installer, and C-4171
Handle (Fig. 110), drive seal into the retainer housing until seal is flush with housing surface.
(4) Install drive plate and transaxle. Refer to
TRANSAXLE for procedures.
–
–
–
–
–
–
–
–
–
REAR CRANKSHAFT SEAL
ENGINE BLOCK
ENGINE BLOCK
REAR CRANKSHAFT SEAL METAL CASE
PRY IN THIS DIRECTION
CRANKSHAFT
SCREWDRIVER
REAR CRANKSHAFT SEAL DUST LIP
SCREWDRIVER
CRANKSHAFT OIL SEAL RETAINER—REAR
REMOVAL
(1) Remove crankshaft rear oil seal and oil pan.
Refer to procedure in this section.
(2) Remove seal retainer attaching screws.
(3) Remove seal retainer (Fig. 111).
NOTE: Seal retainer gasket is bonded to the
retainer and must be replaced as an assembly.
INSTALLATION
(1) Clean all sealing surfaces. Replace retainer
assembly if gasket is torn or damaged.
(2) Install seal retainer to block, but do not tighten
attaching screws at this time.
NOTE: The following steps must be performed to
prevent oil leaks at sealing joints.
(3) Attach Special Tools 8225 to pan rail using the
oil pan fasteners.
9 - 130
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(4) While applying firm pressure to the seal
retainer against Special Tools 8225 (Fig. 112), tighten
seal retainer screws to 12 N·m (105 in. lbs.).
Fig. 110 Crankshaft Rear Seal—Installation
1
2
3
4
–
–
–
–
C-4171 HANDLE
6926–2 INSTALLER
6926–1 GUIDE
SEAL
Fig. 112 Rear Crankshaft Seal Retainer Alignment
1 – SEAL RETAINER
2 – SPECIAL TOOLS 8225
(5) Install crankshaft rear oil seal and oil pan.
Refer to procedures in this section.
CRANKSHAFT MAIN BEARINGS
Bearing caps are not interchangeable and are
marked to insure correct assembly (Fig. 113). Upper
and lower bearing halves are NOT interchangeable.
Fig. 111 Oil Seal Retainer
1 – SCREWS (7)
2 – SEAL RETAINER
NOTE: Make sure the marking “3.2/3.5L” on Special
Tools 8225, is facing towards the cylinder block pan
rail surface (notch on tool is towards the seal
retainer).
CRANKSHAFT MAIN JOURNALS
The crankshaft journals should be checked for
excessive wear, taper and scoring. Limits of taper or
out-of-round on any crankshaft journals should be
held to 0.015 mm (0.0006 in.). Journal grinding
should not exceed 0.305 mm (0.012 inch.) under the
standard journal diameter. DO NOT grind thrust
faces of Number 2 main bearing. DO NOT nick crank
pin or bearing fillets. After grinding, remove rough
3.2/3.5L ENGINE
LH
9 - 131
REMOVAL AND INSTALLATION (Continued)
edges from crankshaft oil holes and clean out all passages.
CAUTION: With a forged steel crankshaft it is
important that the final paper or cloth polish after
any journal regrind be in the same direction as normal rotation in the engine.
REMOVAL
(1) Remove oil pan, pick-up tube, and windage
tray. Refer to procedures in this section. Identify
bearing caps before removal.
(2) Remove bearing caps one at a time. Remove
upper half of bearing by inserting Special Main Bearing Tool C-3059 (Fig. 115) into the oil hole of crankshaft.
(3) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
Fig. 113 Main Bearing Cap Identification
The crankshaft thrust is controlled with thrust
washers located at the upper No. 2 main bearing
bulk head (Fig. 114). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
before installation. Bearing shells are available in
standard and the following undersize: 0.025 mm
(0.001 in.) and 0.254 mm (0.010 in.). Never install an
undersize bearing that will reduce clearance below
specifications.
Fig. 115 Removing and Installing Upper Main
Bearing With Special Tool C- 3059
1
2
3
4
–
–
–
–
SPECIAL TOOL C-3059
BEARING
SPECIAL TOOL C-3059
BEARING
INSTALLATION
CAUTION: Main bearings are select fit. Refer to
Crankshaft Main Bearing Fitting in this section for
proper bearing selection.
NOTE: Only one main bearing should be selectively
fitted while all other main bearing caps are properly
tightened.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Lubricate main bearing with clean engine oil.
(2) Start bearing in place, and insert Main Bearing
Tool C-3059 into oil hole of crankshaft (Fig. 115).
(3) Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Special Main
Bearing Tool C-3059.
Fig. 114 Main Bearing Identification
NOTE: Lubricate main bearing cap bolts with
engine oil before installation.
9 - 132
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(4) Lubricate and install lower bearing half and
main cap Tighten bolts finger tight.
(5) For installing thrust washers at the No. 2 main
bearing location, use the following procedure:
(a) Move crankshaft forward to limit of travel.
Lubricate and install the front thrust washer by
rolling the washer onto the machined shelf
between the No. 2 upper main bulk head and
crankshaft thrust surface (Fig. 116).
(b) Move crankshaft rearward to limit of travel.
Lubricate and install the rear thrust washer by
rolling the washer onto the machined shelf
between the No. 2 upper main bulk head and
crankshaft thrust surface.
strap against the base lock seam. The lock seam
joining the can to the base is reinforced by the
base plate.
(1) Using a suitable oil filter wrench, unscrew filter from base and discard (Fig. 117).
Fig. 116 Thrust Washer Installation
1 – FRONT THRUST WASHER
The main bearing cap bolts must be tightened in
the proper sequence. First the inner main cap bolts,
secondly the windage tray bolts, lastly the main cap
tie (horizontal) bolts.
(6) Install each main bearing cap and tighten
inner bolts finger tight.
(7) Tighten inner main bearing cap bolts to 20 N·m
+ 1/4 turn (15 ft. lbs. + 1/4 turn).
(8) Measure crankshaft end play. Refer to Service
Procedures in this section.
(9) Install windage tray. Lubricate bolts with
engine oil and tighten to 27 N·m + 1/4 turn (20 ft.
lbs. + 1/4 turn).
(10) Install the main cap tie (horizontal) bolts and
tighten to 28 N·m (250 in. lbs.).
(11) Install oil pump pick-up tube and oil pan.
(12) Fill engine crankcase with proper oil to correct level.
OIL FILTER
NOTE: When servicing the oil filter, avoid deforming the filter can. Install the remove/install tool band
Fig. 117 Oil Filter
1 – OIL FILTER
(2) Wipe base clean, then inspect gasket contact
surface.
(3) Lubricate gasket of new filter with clean
engine oil.
(4) Install and tighten filter to 20 N·m (15 ft. lbs.)
of torque after gasket contacts base. Use filter
wrench if necessary.
(5) Start engine and check for leaks.
OIL PUMP
REMOVAL
It is necessary to remove the oil pan, oil pickup
and oil pump body to service the oil pump rotors. The
oil pump pressure relief valve can be serviced by
removing the oil pan.
(1) Drain cooling system and remove fan module.
Refer to COOLING SYSTEM for procedures.
(2) Remove the accessory drive belts. Refer to
COOLING SYSTEM for procedure.
(3) Remove the crankshaft damper and timing belt
covers. Refer to procedures in this section.
3.2/3.5L ENGINE
LH
9 - 133
REMOVAL AND INSTALLATION (Continued)
(4) Remove timing belt. Refer to procedure in this
section.
(5) Remove crankshaft sprocket. Refer to Crankshaft Oil Seal—Front procedure in this section.
(6) Remove oil pan. Refer to procedure in this section.
(7) Remove oil pickup tube.
(8) Remove oil pump fasteners. Remove pump and
gasket from engine (Fig. 118).
necting rods must be removed from top of cylinder block. When removing piston and
connecting rod assemblies from the engine,
rotate crankshaft so that each connecting rod
is centered in cylinder bore.
(3) Inspect connecting rods and connecting rod
caps for cylinder identification. Identify them if necessary (Fig. 119).
Fig. 119 Identify Connecting Rod to Cylinder
1 – CYLINDER NUMBER
Fig. 118 Oil Pump—Removal and Installation
1 – OIL PUMP
2 – GASKET
INSTALLATION
(1) Prime oil pump before installation by filling
rotor cavity with engine oil.
(2) Install oil pump and gasket carefully over the
crankshaft. Position pump onto block and tighten
bolts to 28 N·m (250 in. lbs.)
(3) Install new O-ring on oil pickup tube.
(4) Install oil pickup tube.
(5) Install oil pan. Refer to procedure in this section.
(6) Install crankshaft sprocket. Refer to Crankshaft Oil Seal—Front procedure in this section.
(7) Install timing belt. Refer to procedure in this
section.
(8) Install the timing belt covers and crankshaft
damper. Refer to procedures in this section.
(9) Install the accessory drive belts and fan module. Refer to COOLING SYSTEM for procedures.
(10) Fill cooling system. Refer to COOLING SYSTEM for procedure.
Fig. 120 Connecting Rod Guides and Crankshaft
Protectors
1 – COVER ROD BOLTS WITH A SUITABLE COVERING WHEN
REMOVING OR INSTALLING PISTON ASSEMBLY
(4) Remove connecting rod cap. Install protectors
on connecting rod bolts (Fig. 120). Push each piston
and rod assembly out of cylinder bore.
PISTON AND CONNECTING ROD
NOTE: Be careful not to nick crankshaft journals.
REMOVAL
(5) After removal, install bearing cap on the mating rod.
(1) Remove cylinder heads and oil pan. Refer to
procedures in this section.
(2) Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons
covered during this operation. Pistons and con-
PISTON RINGS—INSTALLATION
NOTE: Refer to FITTING PISTON RINGS in this section for piston ring specifications.
9 - 134
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(1) The No. 1 and No. 2 piston rings have a different cross section. Insure that the No. 2 ring is
installed with manufacturers I.D. mark (dot) facing
up, towards top of the piston (Fig. 121).
CAUTION: Install piston rings in the following
order:
(2) Oil ring expander.
(3) Upper oil ring side rail.
(4) Lower oil ring side rail.
(5) No. 2 Intermediate piston ring.
(6) No. 1 Upper piston ring.
(7) Install the side rail by placing one end between
the piston ring groove and the expander. Hold end
firmly and press down the portion to be installed
until side rail is in position. Do not use a piston
ring expander during this step (Fig. 122).
Fig. 122 Side Rail—Installation
1 – SIDE RAIL END
Fig. 123 Upper and Intermediate Rings—Installation
Fig. 121 Piston Ring—Installation
1 – SIDE RAIL
2 – SPACER EXPANDER
(8) Install upper side rail first and then the lower
side rail.
(9) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 123).
(10) Position piston ring end gaps as shown in
(Fig. 124).
(11) Position oil ring expander gap at least 45°
from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is
important for oil control.
PISTON—INSTALLATION
NOTE: The connecting rod bearing cap bolts must
be examined before reuse. If the threads are necked
down, the bolts should be replaced.
(1) Check connecting rod bolts for necking by holding a scale or straight edge against the threads. If all
threads do not contact the scale, the bolt should be
replaced (Fig. 125).
(2) Before installing pistons and connecting rod
assemblies into the bore, ensure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 124).
(3) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 126).
3.2/3.5L ENGINE
LH
9 - 135
REMOVAL AND INSTALLATION (Continued)
Fig. 126 Piston—Installation
Fig. 124 Piston Ring End Gap Position
1
2
3
4
5
–
–
–
–
–
SIDE RAIL UPPER
NO. 1 RING GAP
PISTON PIN
SIDE RAIL LOWER
NO. 2 RING GAP AND SPACER EXPANDER GAP
1
2
3
4
–
–
–
–
STRETCHED BOLT
THREADS ARE NOT STRAIGHT ON LINE
THREADS ARE STRAIGHT ON LINE
UNSTRETCHED BOLT
(7) The arrow on top of piston must be pointing
toward front of engine (Fig. 127) and oil squirt hole
on connecting rod faces the major thrust (right) side
of the cylinder bore (Fig. 128).
Fig. 125 Check for Stretched Bolts
(4) Immerse the piston head and rings in clean
engine oil, slide the ring compressor over the piston
and tighten with the special wrench. Ensure position of rings does not change during this operation.
(5) Install connecting rod bolt protectors on rod
bolts (Fig. 120).
(6) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod over
the crankshaft journal.
CAUTION: Do Not interchange piston assemblies
cylinder-to-cylinder or bank-to-bank.
Fig. 127 Piston Orientation
1 – ARROW FACES FRONT OF ENGINE
(8) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(9) Install rod caps. Install nuts on cleaned and
oiled rod bolts and tighten nuts to 54 N·m (40 ft. lbs.)
Plus 1/4 turn.
(10) Install cylinder heads and oil pan. Refer to
procedures in this section.
9 - 136
3.2/3.5L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
Fig. 128 Connecting Rod Positioning
1 – MAJOR THRUST SIDE OF PISTON
2 – OIL SQUIRT HOLE
ENGINE CORE AND OIL PLUGS
REMOVAL
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 suitable tool and remove plug (Fig. 129).
CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopart
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.
3.2/3.5L ENGINE
LH
9 - 137
REMOVAL AND INSTALLATION (Continued)
Fig. 130 Oil Pressure Relief Valve
Fig. 129 Core Hole Plug Removal
1
2
3
4
5
–
–
–
–
–
CYLINDER BLOCK
REMOVE PLUG WITH PLIERS
STRIKE HERE WITH HAMMER
DRIFT PUNCH
CUP PLUG
1
2
3
4
–
–
–
–
RELIEF VALVE
SPRING
RETAINER CAP
COTTER PIN
1
2
3
4
5
–
–
–
–
–
OIL PUMP
OIL PUMP
SCREWS
OIL PUMP
OIL PUMP
DISASSEMBLY AND ASSEMBLY
OIL PUMP
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
(2) Remove cotter pin. Drill a 3.175 mm (1/8 inch.)
hole into the relief valve retainer cap and insert a
self-threading sheet metal screw into cap.
(3) Clamp screw into a vise and while supporting
oil pump body, remove cap by tapping oil pump body
using a soft hammer. Discard retainer cap and
remove spring and relief valve (Fig. 130).
(4) Remove oil pump cover screws, and lift off
cover.
(5) Remove pump rotors.
(6) Wash all parts in a suitable solvent and inspect
carefully for damage or wear (Fig. 131).
Fig. 131 Oil Pump
BODY
OUTER ROTOR
COVER
INNER ROTOR
ROCKER ARMS AND SHAFT ASSEMBLY
DISASSEMBLY
(1) Remove dowel pin using a 4 mm screw, nut,
spacer, and washer installed into the pin (Fig. 132).
Thread the screw into the pin, then loosen the nut on
the screw. This will pull the dowel out of the shaft
support. Do not reuse dowel pins. Remove the rocker
arms and pedestals in order.
(2) Check the rocker arm mounting portion of the
shafts for wear or damage. Replace if damaged or
heavily worn.
(3) Check shaft oil holes for clogging with small
wire, clean as required.
ASSEMBLY
CAUTION: New dowel pins must be installed when
reassembling.
(1) Install the rocker arms, and pedestals onto the
shaft.
(2) Install dowel pins (Fig. 133). Dowel pins pass
through the pedestal into the exhaust rocker shafts.
9 - 138
3.2/3.5L ENGINE
LH
DISASSEMBLY AND ASSEMBLY (Continued)
CYLINDER HEAD
CLEANING
(1) Use a gasket removal compound to soften the
old gasket material.
CAUTION: When cleaning the cylinder head and
block mating surfaces, do not use a metal scraper
because the sealing surfaces could be cut or
ground. Instead, use a wooden or plastic scraper.
(2) Make sure the gasket and/or foreign material
does not enter the oil feed hole or the oil return
holes.
1
2
3
4
5
6
7
8
Fig. 132 Rocker Arms and Shaft—Disassembly
INSPECTION
–
–
–
–
–
–
–
–
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 134).
(4) Cylinder head must be flat within:
• Standard dimension = less than 0.05 mm (0.002
inch.)
• Service Limit = 0.2 mm (0.008 inch.)
• Grinding Limit = Maximum of 0.2 mm (0.008
inch.) is permitted.
4mm SCREW AND NUT
4mm SCREW AND NUT
WASHER
SPACER
DOWEL
DOWEL
SPACER
WASHER
Dowel pins should be pressed in until they bottomout against the rocker shaft in the pedestal.
CAUTION: 0.20 mm (0.008 in.) MAX is a combined
total dimension of the stock removal limit from cylinder head and block top surface (Deck) together.
Fig. 133 Assemble Rocker Arms and Shaft
1
2
3
4
–
–
–
–
HYDRAULIC LASH ADJUSTERS
DOWEL PIN
PEDESTAL
ROLLER
CLEANING AND INSPECTION
INTAKE MANIFOLD
Check for:
• Damage and cracks of each section.
• Clogged water passages in end cross over and
clogged gas passages.
EXHAUST MANIFOLD
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface with a straightedge and thickness gauge.
Fig. 134 Checking Cylinder Head Flatness
CAMSHAFT
(1) Inspect camshaft bearing journals for damage
and binding (Fig. 135). If journals are binding, check
the cylinder head for damage. Also check cylinder
head oil holes for clogging.
(2) Check the cam surface for abnormal wear and
damage and replace if defective. Measure the actual
wear (Fig. 135) and replace if out of limit, standard
3.2/3.5L ENGINE
LH
9 - 139
CLEANING AND INSPECTION (Continued)
The intake and exhaust rocker arms are different.
They should be identified before disassembling the
assembly (Fig. 136).
Check rocker arms for wear or damage (Fig. 137) :
• Roller scuffing or wear
• Shaft bore scuffing or wear
• Swivel pad on lash adjuster missing or broken
• Rocker arm showing signs of fatigue or cracking
• Roller axle protruding from arm
Replace assembly as necessary if any rocker arms
shows signs of wear.
CAUTION: Do Not remove lash adjuster from rocker
arm assembly. Damage to the adjuster and rocker
arm will result.
Fig. 135 Camshaft Inspection
1
2
3
4
5
–
–
–
–
–
ACTUAL WEAR
LEFT CAMSHAFT
RIGHT CAMSHAFT
BEARING JOURNAL
LOBE
value is 0.0254 mm (.001 in.), wear limit is 0.254
mm (0.010 in.).
ROCKER ARMS
The rocker arm shafts are hollow and are used as
lubrication oil ducts. The rocker arm and shaft
assembly on the right side of the engine has an oil
passage hole from the cylinder head located at the
third rocker shaft support pedestal. The rocker arm
and shaft assembly on the left side of the engine has
an oil passage hole from the cylinder head located at
the second rocker shaft support pedestal.
NOTE: To prevent air ingestion into lash adjusters,
avoid turning rocker arm assembly upside down.
Fig. 137 Rocker Arm/Lash Adjuster—Inspection
CAUTION: Do not allow rocker arm assembly to
rest on lash adjusters, as damage may occur to
lash adjuster and plastic retainer.
1 – RETAINER
2 – SWIVEL PAD
3 – ROLLER
VALVE INSPECTION
(1) Clean valves thoroughly and replace burned,
warped and cracked valves.
(2) Measure valve stems for wear (Fig. 138). Refer
to Engine Specifications.
NOTE: Valve stems are chrome plated and should
not be polished (Fig. 138).
(3) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
Fig. 136 Intake and Exhaust Rocker Arms—Left Side
9 - 140
3.2/3.5L ENGINE
LH
CLEANING AND INSPECTION (Continued)
OIL PUMP
INSPECTION AND REPAIR
(1) Clean all parts thoroughly. Mating surface of
the oil pump housing should be smooth. Replace
pump cover if scratched or grooved.
(2) Lay a straightedge across the pump cover surface (Fig. 140). If a 0.025 mm (0.001 in.) feeler gauge
can be inserted between cover and straight edge,
cover should be replaced.
Fig. 138 Intake and Exhaust Valves
1
2
3
4
–
–
–
–
MARGIN
FACE
STEM
VALVE SPRING RETAINER LOCK GROOVES
CHECKING VALVE GUIDES
(1) Measure valve stem-to-guide clearance as follows:
(2) Install valve into cylinder head so it is 15 mm
(0.590 inch.) off the valve seat. A small piece of hose
may be used to hold valve in place.
(3) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 139).
(4) Move valve to and from the indicator. Refer to
Engine Specifications.
Fig. 140 Checking Oil Pump Cover Flatness
1 – STRAIGHT EDGE
2 – FEELER GAUGE
3 – OIL PUMP COVER
(3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 14.299 mm (0.563
in.) or less (Fig. 141), or if the diameter is 79.78 mm
(3.141 inches.) or less, replace outer rotor.
Fig. 139 Measuring Valve Guide Wear
VALVE GUIDES
NOTE: Replace cylinder head if stem-to-guide
clearance exceeds specifications, or if guide is
loose in cylinder head.
Fig. 141 Measuring Outer Rotor Thickness
3.2/3.5L ENGINE
LH
9 - 141
CLEANING AND INSPECTION (Continued)
Fig. 142 Measuring Inner Rotor Thickness
Fig. 144 Measuring Clearance Between Rotors
1 – FEELER GAUGE
2 – OUTER ROTOR
3 – INNER ROTOR
Fig. 143 Measuring Outer Rotor Clearance in
Housing
1 – FEELER GAUGE
2 – OUTER ROTOR
Fig. 145 Measuring Clearance Over Rotors
(4) If inner rotor measures 14.299 mm (0.563 in.)
or less replace inner rotor (Fig. 142).
(5) Slide outer rotor into body, press to one side
with fingers and measure clearance between rotor
and body (Fig. 143). If measurement is 0.39 mm
(0.015 inch.) or more, replace body only if outer rotor
is in specifications.
(6) Install inner rotor into body. If clearance
between inner and outer rotors (Fig. 144) is 0.20 mm
(0.008 inch.) or more, replace both rotors.
(7) Place a straightedge across the face of the body,
between bolt holes. If a feeler gauge of 0.077 mm
(0.003 in.) or more can be inserted between rotors
and the straightedge, replace pump assembly (Fig.
145) ONLY if rotors are in specs.
(8) Inspect oil pressure relief valve plunger for
scoring and free operation in its bore. Small marks
may be removed with 400-grit wet or dry sandpaper.
1 – STRAIGHT EDGE
2 – FEELER GAUGES
(9) The relief valve spring has a free length of
approximately 49.5 mm (1.95 inches) it should test
between 23 – 25 pounds when compressed to 34 mm
(1 – 11/32 inches). Replace spring that fails to meet
specifications.
OIL PUMP ASSEMBLY
(1) Assemble pump, using new parts as required.
(2) Tighten cover screws to 12 N·m (105 in. lbs.).
(3) Prime oil pump before installation by filling
rotor cavity with engine oil.
(4) If oil pressure is low and pump is within specifications, inspect for worn engine bearings or other
reasons for oil pressure loss.
9 - 142
3.2/3.5L ENGINE
LH
CLEANING AND INSPECTION (Continued)
CYLINDER BLOCK AND BORE
CLEANING AND INSPECTION
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are installed, Refer to Engine
Core Plugs.
(3) Examine block for cracks or fractures.
(4) Inspect for damaged bolt threads. Repair
threads as needed. Refer to Service Procedures,
Repair of Damaged or Worn Threads.
NOTE: Refer to Honing Cylinder Bores outlined in
the Standard Service Procedures for specification
and procedures.
(5) After a cylinder bore honing or deglazing procedure:
(a) Clean bores with a soap and water solution.
(b) Thoroughly rinse cylinder bores with clean
water to remove soap/water solution and wipe
bores with a clean lint-free cloth.
(c) Oil the bores after cleaning to prevent rust.
CYLINDER BORE INSPECTION
The cylinder walls should be checked for out-ofround and taper with Tool C-119 (Fig. 146).
Measure the cylinder bore at three levels in directions A and B (Fig. 146). Top measurement should be
12 mm (0.50 inch.) down and bottom measurement
should be 12 mm (0.50 inch.) up from bottom of bore.
Refer to Engine Specifications.
NOTE: There are no service procedures to bore the
cylinder bores for installation of oversized pistons.
Fig. 146 Checking Cylinder Bore Size
ENGINE HYDRO-MOUNT INSULATORS
Engine hydro-mounts may show surface cracks this
will not effect performance and mount should not be
replaced. Only replace the engine hydro-mounts
when leaking fluid:
• Drive shaft distress: Refer to Driveshafts in Suspension, Group 2.
• Any front end structural damage (after repair).
• Insulator replacement.
TIMING BELT INSPECTION—IN VEHICLE
(1) Remove the accessory drive belts. Refer to
COOLING SYSTEM for procedure.
(2) Remove timing belt covers. Refer to procedure
in this section.
(3) Inspect both sides of the timing belt. Replace
belt if any of the following conditions exist (Fig. 147):
(a) Hardening of back rubber back side is glossy
without resilience and leaves no indent when
pressed with fingernail.
(b) Cracks on rubber back.
(c) Cracks or peeling of canvas.
(d) Cracks on rib root.
(e) Cracks on belt sides.
(f) Missing teeth.
(g) Abnormal wear of belt sides. The sides are
normal if they are sharp as if cut by a knife.
(h) Vehicle mileage at component maintenance
requirement. Refer to LUBRICATION AND MAINTENANCE.
(4) If none of the above conditions are seen on the
belt, the belt cover can be installed.
NOTE: If belt requires replacing, ensure the proper
length belt is used.
3.2/3.5L ENGINE
LH
9 - 143
CLEANING AND INSPECTION (Continued)
DESCRIPTION
SPECIFICATION
Taper (Max.)
0.051 mm
(0.002 in.)
Pistons
Type Material
Aluminum (Full Floating
Pins)
Clearance at Size
Location
–0.007 to +0.047 mm
(–0.0003 to +0.0018 in.)
Piston Weight
—A Size
409–414 grams
(14.4271–14.6035 oz.)
—B Size
404–409 grams
(14.2507–14.427 oz.)
Piston Ring Groove
Diameter
—No. 1
83.69–83.89 mm
(3.2949–3.3028 in.)
Fig. 147 Timing Belt Inspection
1
2
3
4
5
6
7
–
–
–
–
–
–
–
PEELING
TOOTH MISSING AND CANVAS FIBER EXPOSED
RUBBER EXPOSED
CRACKS
PEELING
ROUNDED EDGE
ABNORMAL WEAR (FLUFFY STRAND)
—No. 2
(3.1937–3.2016 in.)
—No. 3
82.3–82.5 mm
(3.2402–3.2481 in.)
Piston Pins
Type
Full Floating
Clearance in Piston
SPECIFICATIONS
81.12–81.32 mm
0.005–0.015 mm
(0.0002–0.0006 in.)
Clearance in Rod
3.2L ENGINE
0.007–0.018 mm
(0.0003–0.007 in.)
DESCRIPTION
Type
SPECIFICATION
Diameter
23.997–24.000 mm
(0.9448–0.9449 in.)
60° SOHC V-6 24-Valve
Displacement
Piston Rings
3.2 Liters
(195 Cubic Inches)
Bore and Stroke
92.0 x 81.0 mm
(3.622 x 3.189 in.)
Compression Ratio
9.5:1
Lead Cylinder
#1 Right Bank
Firing Order
1-2-3-4-5-6
92.0 mm 60.0076
(3.622 in. 60.0003 in.)
Out-of-Round (Max.)
Ring Gap—2nd
Compression Ring
Ring Gap—Oil Control
(Steel Rails)
0.20–0.36 mm
(0.008–0.014 in.)
0.22–0.49 mm
(0.0087–0.0193 in.)
0.25–0.76 mm
(0.010–0.030 in.)
Ring Side Clearance
Cylinder Block
Cylinder Bore Diameter
Ring Gap—Top
Compression Ring
0.076 mm
(0.003 in.)
Top and Second
Compression Ring
Oil Ring (Steel Rails)
0.040–0.080 mm
(0.0016–0.0031 in.)
0.038–0.184 mm
(0.0015–0.0073 in.)
9 - 144
3.2/3.5L ENGINE
LH
SPECIFICATIONS (Continued)
DESCRIPTION
SPECIFICATION
DESCRIPTION
Ring Width
Top Compression Ring
SPECIFICATION
Camshaft
1.17–1.19 mm
Bore Diameter
43.038–43.059 mm
(0.0461–0.0469 in.)
2nd Compression Ring
1.47–1.49 mm
(1.6944–1.6952 in.)
Bearing Journal Diameter
(0.0580–0.0587 in.)
Oil Ring (Steel Rings)
0.445–0.470 mm
(1.6905–1.6913 in.)
Diametrical Clearance
(0.0176–0.0186 in.)
—(Max.)
(0.0059 in.)
End Play
Total Weight (Less
Bearing)
(0.004–0.014 in.)
Valve Timing—Intake Valve
0.40 mm
Opens (ATDC)
1°
(0.0157 in.)
Closes (ABDC)
51°
647 grams
Duration
230°
Centerline
116°
(22.8223 oz.)
Crankshaft Main Bearing Journals
Diameter
Main Bearing Diametrical
Clearance
—(Max. Allowable)
0.11–0.35 mm
24.0076–24.0153 mm
(0.9452–0.9455 in.)
Side Clearance (Max.)
Valve Timing—Exhaust Valve
63.987–64.013 mm
Opens (BBDC)
(2.519–2.520 in.)
Closes (ATDC)
12°
0.011–0.077 mm
Duration
240°
Centerline
108°
(0.0007–0.0030 in.)
0.087 mm
Taper (Max.)
End Play
0.015 mm
11°
Cylinder Head
(0.0006 in.)
Gasket Thickness
(Compressed)
(0.070 in.)
0.015 mm
Valve Seat Angle
45–45.5°
(0.0006 in)
Valve Seat Runout (Max.)
0.051 mm
0.10–0.30 mm
(0.004–0.012 in.)
—(Max.)
Connecting Rod Journals
Diameter
57.979–58.005 mm
(2.283–2.284 in.)
Bearing Diametrical
Clearance
0.019–0.087 mm
(0.00075–0.0034 in.)
Out-of-Round (Max.)
0.015 mm
(0.0006 in.)
0.015 mm
(0.0006 in.)
1.78 mm
(0.002 in.)
Valve Seat Width—Intake
0.43 mm
(0.017 in.)
Taper (Max.)
48°
Valve Overlap
(0.0034 in.)
Out-of-Round (Max.)
0.15 mm
0.019–0.087 mm
(0.0007–0.0034 in.)
Piston Pin Bore Diameter
0.078–0.12 mm
(0.003–0.0047 in.)
Connecting Rods
Bearing Clearance
42.939–42.960 mm
0.75–1.25 mm
(0.0295–0.0492 in.)
Valve Seat Width—
Exhaust
1.25–1.75 mm
(0.0492–0.0689 in.)
Guide Bore Diameter
(Std.)
6.975–7.00 mm
(0.2746–0.2756 in.)
Valve Guide Height*
9.5–10.5 mm
(0.3740–0.4134 in.)
*Measured from cylinder head surface
3.2/3.5L ENGINE
LH
9 - 145
SPECIFICATIONS (Continued)
DESCRIPTION
SPECIFICATION
Valves
Face Angle
44.5–45°
Head Diameter—Intake
28.87–29.13 mm
(1.1366–1.1469 in.)
Length—Intake (Overall)
114.41–114.99 mm
(4.5043–4.5272 in.)
Length—Exhaust
(Overall)
125.67–126.25 mm
(4.9476–4.9705 in.)
Stem Diameter—Intake
6.935–6.953 mm
(0.2730–0.2737 in.)
Stem Diameter—Exhaust
6.906–6.924 mm
(0.2719–0.2726 in.)
Stem-to-Guide
Clearance—Intake
0.022–0.065 mm
(0.0009–0.0026 in.)
—(Max.) Rocking Method
0.29 mm
(0.0114 in.)
Stem-to-Guide
Clearance—Exhaust
SPECIFICATION
Spring Force—Intake
(Valve Open)
36.37–36.63 mm
(1.4319–1.4421 in.)
Head Diameter—Exhaust
DESCRIPTION
0.051–0.094 mm
(0.002–0.0037 in.)
—(Max.) Rocking Method
0.370 mm
Spring Force—Exhaust
(Valve Open)
8.55 mm
6.53 mm
(1.6680–1.7187 in.)
44.705–45.986 mm
(1.760–1.8105 in.)
Valve Springs
Free Length—Intake
(Approx.)
Free Length—Exhaust
(Approx.)
Spring Force—Intake
(Valve Closed)
Spring Force—Exhaust
(Valve Closed)
(130–144 lbs. @ 1.239
in.)
6.86
Number of Coils—
Exhaust
7.66
Color of Spring (Top of
Coils)
—Intake (Right Hand Coil
Direction)
Orange
—Exhaust (Left Hand
Coil Direction)
Yellow
Wire Diameter—Intake
4.29–4.35 mm
(0.1689–0.1712 in.)
Wire Diameter—Exhaust
4.09–4.15 mm
(0.1608–0.1632 in.)
Spring Installed Height
(Spring Seat to Bottom of
Retainer)—Intake &
Exhaust
43.675 mm
(1.7195 in.)
44.319 mm
Clearance Over Rotors
(69.5–80.5 lbs. @ 1.4961
in.)
314–354 N @ 38.0 mm
(71–79 lbs. @ 1.4961 in.)
(1.4961 in.)
0.077 mm
(0.003 in.)
Cover Out-of-Flat (Max.)
0.025 mm
(0.001 in.)
Inner & Outer Rotor
Thickness (MIn.)
Outer Rotor Thickness
(Max.)
Outer Rotor Diameter
(Min.)
Tip Clearance Between
Rotors (Max.)
14.299 mm
(0.563 in.)
0.39 mm
(0.015 in.)
79.997 mm
(3.149 in.)
0.20 mm
(0.008 in.)
Oil Pressure
(1.7448 in.)
309–358 N @ 38.0 mm
38.0 mm
Oil Pump
(0.2571 in.)
42.366–43.655 mm
Valve Stem Tip
Height—Exhaust
579–640 N @ 31.47 mm
(0.3367 in.)
Valve Lift—Exhaust (Zero
Lash)
Valve Stem Tip
Height—Intake
(188–204 lbs. @ 1.1594
in.)
Number of Coils—Intake
(0.0146 in.)
Valve Lift—Intake (Zero
Lash)
836–907 N @ 29.85 mm
@ Curb Idle Speed*
34.47 kPa
(5 psi)
@ 3000 rpm
170–724 kPa
(25–105 psi)
*CAUTION: If pressure is zero at curb idle, DO NOT
run engine at 3000 rpm.
9 - 146
3.2/3.5L ENGINE
LH
SPECIFICATIONS (Continued)
3.5L ENGINE
DESCRIPTION
SPECIFICATION
Diameter
DESCRIPTION
23.997–24.000 mm
SPECIFICATION
Type
(0.9448–0.9449 in.)
60° SOHC V-6 24-Valve
Displacement
3.5 Liters
(214 Cubic Inches)
Bore and Stroke
96.0 x 81.0 mm
(3.780 x 3.189 in.)
Compression Ratio
9.9:1
Lead Cylinder
#1 Right Bank
Firing Order
Piston Rings
Ring Gap—Top
Compression Ring
96.0 mm 60.0076
Cylinder Bore Diameter
(3.780 in. 60.0003 in.)
Out-of-Round (Max.)
(0.008–0.014 in.)
Ring Gap—2nd
Compression Ring
0.23–0.50 mm
(0.0091–0.0197 in.)
Ring Gap—Oil Control
(Steel Rails)
1-2-3-4-5-6
Cylinder Block
0.20–0.36 mm
Ring Groove Clearance
Top and Second
Compression Ring
0.035–0.085 mm
(0.0014–0.0034 in.)
Oil Ring (Steel Rails)
0.038–0.184 mm
0.076 mm
(0.0015–0.0073 in.)
(0.003 in.)
Taper (Max.)
0.051 mm
(0.002 in.)
Pistons
Type Material
Ring Width
Top Compression Ring
2nd Compression Ring
–0.007 to +0.047 mm
1.17–1.19 mm
(0.0461–0.0469 in.)
Aluminum (Full Floating
Pins)
Clearance at Size
Location
0.25–0.76 mm
(0.010–0.030 in.)
1.47–1.49 mm
(0.058–0.059 in.)
Oil Ring (Steel Rings)
0.445–0.470 mm
(0.0176–0.0186 in.)
(–0.0003 to +0.0018 in.)
Connecting Rods
Piston Weight
—A Size
438–443 grams
Bearing Clearance
(0.0007–0.0034 in.)
(15.45–15.62 oz.)
—B Size
433–438 grams
(15.27–15.45 oz.)
Piston Ring Groove
Diameter
Piston Pin Bore Diameter
(0.9452–0.9455 in.)
Side Clearance (Max.)
87.4–87.6 mm
Total Weight (Less
Bearing)
(3.441–3.449 in.)
—No. 2
86.3–86.5 mm
(3.397–3.4055 in.)
—No. 3
85.8–86.0 mm
(3.378–3.385 in.)
Piston Pins
Clearance in Piston
Full Floating
0.005–0.015 mm
(0.0002–0.0006 in.)
Clearance in Rod
24.0076–24.0153 mm
0.40 mm
(0.0157 in.)
—No. 1
Type
0.019–0.087 mm
0.007–0.018 mm
(0.0003–0.007 in.)
647 grams
(22.8223 oz.)
Crankshaft Main Bearing Journals
Diameter
63.987–64.013 mm
(2.519–2.520 in.)
Main Bearing Diametrical
Clearance
—(Max. Allowable)
0.011–0.077 mm
(0.0007–0.0030 in.)
0.087 mm
(0.0034 in.)
Out-of-Round (Max.)
0.015 mm
(0.0006 in.)
Taper (Max.)
0.015 mm
(0.0006 in)
3.2/3.5L ENGINE
LH
9 - 147
SPECIFICATIONS (Continued)
DESCRIPTION
SPECIFICATION
End Play
0.10–0.30 mm
(0.004–0.012 in.)
—(Max.)
0.43 mm
(0.017 in.)
Connecting Rod Journals
Diameter
DESCRIPTION
SPECIFICATION
Valve Seat Width—
Exhaust
1.25–1.75 mm
(0.0492–0.0689 in.)
Guide Bore Diameter
(Std.)
6.975–7.00 mm
(0.2746–0.2756 in.)
Valve Guide Height*
9.5–10.5 mm
(0.3740–0.4134 in.)
57.979–58.005 mm
(2.283–2.284 in.)
Bearing Diametrical
Clearance
(0.00075–0.0034 in.)
Out-of-Round (Max.)
0.015 mm
*Measured from cylinder head surface
Valves
0.019–0.087 mm
Face Angle
44.5–45°
Head Diameter—Intake
(1.4319–1.4421 in.)
(0.0006 in.)
Taper (Max.)
0.015 mm
Head Diameter—Exhaust
Bore Diameter
Length—Intake (Overall)
Bearing Journal Diameter
42.939–42.960 mm
(1.6905–1.6913 in.)
Diametrical Clearance
—(Max.)
0.15 mm
(0.0059 in.)
End Play
Length—Exhaust
(Overall)
125.67–126.25 mm
(4.9476–4.9705 in.)
Stem Diameter—Intake
Stem Diameter—Exhaust
Valve Timing—Intake Valve
Opens (ATDC)
3°
Closes (ABDC)
61°
Duration
238°
Valve Timing—Exhaust Valve
Opens (BBDC)
56°
Closes (ATDC)
16°
Duration
252°
Valve Overlap
13°
Cylinder Head
Gasket Thickness
(Compressed)
1.78 mm
(0.070 in.)
Valve Seat Angle
45–45.5°
Valve Seat Runout (Max.)
0.051 mm
(0.002 in.)
Valve Seat Width—Intake
0.75–1.25 mm
(0.0295–0.0492 in.)
6.906–6.924 mm
(0.2719–0.2726 in.)
Stem-to-Guide
Clearance—Intake
0.022–0.065 mm
(0.0009–0.0026 in.)
0.11–0.35 mm
(0.004–0.014 in.)
6.935–6.953 mm
(0.2730–0.2737 in.)
0.078–0.12 mm
(0.003–0.0047 in.)
114.41–114.99 mm
(4.5043–4.5272 in.)
43.038–43.059 mm
(1.6944–1.6952 in.)
28.87–29.13 mm
(1.1366–1.1469 in.)
(0.0006 in.)
Camshaft
36.37–36.63 mm
—(Max.) Rocking Method
0.29 mm
(0.0114 in.)
Stem-to-Guide
Clearance—Exhaust
0.051–0.094 mm
(0.002–0.0037 in.)
—(Max.) Rocking Method
0.370 mm
(0.0146 in.)
Valve Lift—Intake (Zero
Lash)
8.55 mm
(0.3367 in.)
Valve Lift—Exhaust (Zero
Lash)
Valve Stem Tip
Height—Intake
6.53 mm
(0.2571 in.)
42.366–43.655 mm
(1.6680–1.7187 in.)
Valve Stem Tip
Height—Exhaust
44.705–45.986 mm
(1.760–1.8105 in.)
Valve Springs
Free Length—Intake
(Approx.)
Free Length—Exhaust
(Approx.)
43.675 mm
(1.7195 in.)
44.319 mm
(1.7448 in.)
9 - 148
3.2/3.5L ENGINE
LH
SPECIFICATIONS (Continued)
DESCRIPTION
SPECIFICATION
Spring Force—Intake
(Valve Closed)
309–358 N @ 38.0 mm
(69.5–80.5 lbs. @ 1.4961
in.)
Spring Force—Exhaust
(Valve Closed)
Spring Force—Intake
(Valve Open)
Spring Force—Exhaust
(Valve Open)
314–354 N @ 38.0 mm
(71–79 lbs. @ 1.4961 in.)
836–907 N @ 29.85 mm
DESCRIPTION
SPECIFICATION
@ 3000 rpm
170–724 kPa
(25–105 psi)
*CAUTION: If pressure is zero at curb idle, DO NOT
run engine at 3000 rpm.
TORQUE
(188–204 lbs. @ 1.1594
in.)
N·m
DESCRIPTION
579–640 N @ 31.47 mm
(130–144 lbs. @ 1.239
in.)
Number of Coils—Intake
6.86
Number of Coils—
Exhaust
7.66
A/C Compressor Bracket to
Engine—Bolts
A/C Compressor to Bracket
Orange
—Exhaust (Left Hand
Coil Direction)
Yellow
Wire Diameter—Intake
—
Camshaft Sprocket Bolt—Left Side
115
85
—
—
—Inner Main Cap Bolts
20 15
+1⁄4 +1⁄4
Turn Turn
—
—Outer Main Cap Bolts
27 20
+1⁄4 +1⁄4
Turn Turn
—
(0.1638–0.1661 in.)
38.0 mm
28
— 250
95
70
—
—Step 1
61
45
—
0.077 mm
—Step 2
88
65
—
(0.003 in.)
—Step 3
88
65
—
0.025 mm
—Step 4
+1⁄4 +1⁄4
Turn Turn
—
(1.4961 in.)
(0.001 in.)
Inner & Outer Rotor
Thickness (MIn.)
Outer Rotor Thickness
(Max.)
Outer Rotor Diameter
(Min.)
Tip Clearance Between
Rotors (Max.)
14.299 mm
(0.563 in.)
0.39 mm
(0.015 in.)
79.997 mm
(3.149 in.)
0.20 mm
(0.008 in.)
Crankshaft Damper—Bolt
*Refer to procedure for tightening sequence
Cylinder Head Cover—Bolts
12
— 105
Exhaust Manifold to Cylinder
Head—Bolts
23
— 200
Exhaust Manifold Heat Shield—Bolts
12
— 105
Engine Mount Bracket to Block—
Bolts
61
45
—
Engine Mount Isolator—Nuts
61
45
—
Generator Bracket—Bolts
54
40
—
Intake Manifold
Oil Pressure
@ Curb Idle Speed*
—Tie Bolts (Horizontal)
Cylinder Head Bolts*
Oil Pump
Cover Out-of-Flat (Max.)
— 250
Crankshaft Main Bearing Cap
4.16–4.22 mm
Clearance Over Rotors
28
54 40
+1⁄4 +1⁄4
Turn Turn
4.29–4.34 mm
Spring Installed Height
(Spring Seat to Bottom of
Retainer)—Intake &
Exhaust
— 250
75
(0.1689–0.1709 in.)
Wire Diameter—Exhaust
—
102
Connecting Rod Cap—Nuts
—Intake (Right Hand Coil
Direction)
28
40
Camshaft Sprocket Bolt—Right Side
Camshaft Thrust Plate—Bolts
Color of Spring (Top of
Coils)
54
Ft. In.
Lbs. Lbs.
34.47 kPa
—M6 Bolts
12
— 105
(5 psi)
—M8 Bolts
28
— 250
3.2/3.5L ENGINE
LH
9 - 149
SPECIFICATIONS (Continued)
N·m
Ft. In.
Lbs. Lbs.
—M6 Bolts
12
— 105
—M8 Bolts
28
— 250
Oil Pan Drain Plug
35
25
—
Oil Filter
20
15
—
Oil Pump to Block—Bolts
28
— 250
DESCRIPTION
Oil Pan
Oil Pump Cover—Bolts
12
— 105
Oil Pump Pick Up Tube—Bolt
28
— 250
PCV Valve
7
—
Crankshaft Rear Seal Retainer
12
— 105
Rocker Shaft Pedestal Retaining—
Bolts
31
— 275
Spark Plugs
28
20
Structural Collar
Crankshaft Damper Remover Insert C-4685-C2
60
—
Refer to
Procedure
Thermostat Housing/Water Inlet
Connector—Bolts
12
— 105
Throttle Body—Bolts
12
— 105
Timing Belt Tensioner—Bolts
28
— 250
Timing Belt Tensioner Pulley
Assembly—Bolt
61
45
—M6 Bolts
12
— 105
—M8 Bolts
28
— 250
—M10 Bolts
54
40
Water Pump—Bolts
12
— 105
Water Outlet Bleed—Screw
8
—
Crankshaft Damper Installer Bolt C-4685-C1
—
Timing Belt Cover
Crankshaft Damper Installer 6792-1
—
70
SPECIAL TOOLS
3.2/3.5L ENGINE
Puller Damper 1023
Crankshaft Damper Holder 8191
Crankshaft Sprocket Puller L-4407A
9 - 150
3.2/3.5L ENGINE
LH
SPECIAL TOOLS (Continued)
Crankshaft Seal Remover 6341A
Camshaft Seal Remover C-3981B
Crankshaft Seal Installer 6342
Camshaft Seal Installer 6052
Crankshaft Sprocket Installer 6641
Dial Indicator C-3339
Camshaft Alignment 6642
Valve Spring Compressor 7068
Camshaft Seal Protector 6788
Valve Spring Compressor C-3422-B
3.2/3.5L ENGINE
LH
9 - 151
SPECIAL TOOLS (Continued)
Main Bearing Remover/Installer C-3059
Valve Spring Adapter 6526
Crankshaft Rear Seal Guide 6926-1 & Installer
6926-2
Valve Spring Tester C-647
Crankshaft Rear Seal Retainer Alignment Fixture
8225
Valve Spring Compressor MD-998772-A
Valve Spring Adapter 6527
Indicator Bore Size C-119
Release Probe 8351
9 - 152
3.2/3.5L ENGINE
LH
SPECIAL TOOLS (Continued)
Cooling System Tester 7700
Adaptor 8116
Combustion Leak Tester C-3685-A
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising