Overhaul - 3.5L Engine: Other Chrysler Pacifica CS

STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND 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-in-place 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. Mopar® Engine RTV GEN II, Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties and can not be used in place of the other.

MOPAR® 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.

MOPAR® 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.

MOPAR® 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.

MOPAR® BED PLATE SEALANT is a unique (green-in-color) 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.

MOPAR® 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. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.

STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.

Never use the following to clean gasket surfaces

1. Metal scraper
2. Abrasive pad or paper to clean cylinder block and head
3. High speed power tool with an abrasive pad or a wire brush. (Scheme 142)

Note. Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Only use the following for cleaning gasket surfaces

1. Solvent or a commercially available gasket remover
2. Plastic or wood scraper. (Scheme 142)
3. Drill motor with 3M Roloc™ Bristle Disc (white or yellow). (Scheme 142)

Scheme 142

STANDARD PROCEDURE - 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.

Heli-Coil tools and inserts are readily available from automotive parts jobbers.

STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE

When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used.

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.
8. Install new spark plugs.
9. Drain engine oil and remove oil filter.
10. Install a new oil filter.
11. Fill engine with specified amount of approved oil.
12. Connect negative battery cable.
13. Start engine and check for any leaks.

STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS

Using a blunt tool such as a drift and a hammer, strike the bottom edge of the cup plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug. (Scheme 143)

Scheme 143

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 Mopar® Stud and Bearing Mount. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 in.) inside the lead-in chamfer.

It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately.

ENGINE CYLINDER HEAD SPECIFCATIONS

CYLINDER HEAD

COOLING SYSTEM TESTER METHOD

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.

LEFT CYLINDER HEAD

1. Perform the fuel relief procedure.
2. Disconnect the negative battery cable.
3. Drain cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).
4. Remove engine cover.
5. Remove air cleaner element housing (Refer to «HOUSING-AIR CLEANER»(ref-245454-S16653029582006110200000) ).
6. Remove radiator close out panel.
7. Remove radiator core support.
8. Remove radiator fan assembly «(Refer to COOLING/ENGINE/RADIATOR FAN - REMOVAL)»(ref-245448-S13296076712006110200000).
9. Disconnect the fuel line at the fuel rail.
10. Remove the lower intake manifold (Refer to «REMOVAL - LOWER INTAKE MANIFOLD»(ref-245454-S06513259672006110200000) ).
11. Remove the left exhaust manifold (Refer to «EXHAUST MANIFOLD - LEFT»(ref-245454-S02326411142006110200000) ).
12. Remove the outer timing belt cover (Refer to «TIMING BELT AND SPROCKETS»(ref-245454-S01103536842006110200000) ).
13. Rotate the engine to TDC and align the timing marks. see scheme 44
14. Remove the timing belt tensioner, timing belt, then reset tensioner. see scheme 44
15. Remove the left cylinder head cover to cylinder head ground strap.
16. Remove the left cylinder head cover.
17. Remove the left rocker arm assembly.
18. Remove the left camshaft thrust plate.
19. Counterhold the left cam gear and remove the cam gear retaining bolt. see scheme 44
20. Push the camshaft out of the back of the cylinder head approximately 3.5 inches and remove the cam gear.
21. Remove the front timing belt housing to cylinder head bolts. see scheme 44
22. Remove the cylinder head bolts in REVERSE of tightening sequence.
23. Remove the cylinder head.
24. Clean and inspect all mating surfaces.

CLEANING

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.

Note. Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Remove all gasket material from cylinder head and block (Refer to STANDARD PROCEDURE ). Be careful not to gouge or scratch the aluminum head sealing surface.

Clean all engine oil passages.

Scheme 144

1. Before cleaning, check for leaks, damage and cracks.
2. Clean cylinder head and oil passages.
3. Check cylinder head for flatness. (Scheme 145)
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.

RIGHT CYLINDER HEAD

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 must be replaced. (Scheme 146).

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 must be replaced. (Scheme 146)

Scheme 145

Scheme 146

1. Clean sealing surfaces of cylinder head and block.
2. Install head gasket over locating dowels. Ensure the gasket is installed on the correct side of engine.
3. Insert the front four cylinder head bolts into the cylinder head. Pull the bolts up to the top of their travel and retain with rubber bands.
4. Install the cylinder head over locating dowels and finger tighten the head bolts.
5. Tighten the cylinder head bolts in the sequence see scheme 50 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.
7. Install the inner timing cover to cylinder head bolts. Tighten bolts to 54 N.m (40 lbs.ft.).
8. Install camshaft sprocket. Counterhold the camshaft sprocket gear and tighten the camshaft sprocket bolt to 102 N.m plus a 1/4 turn (75 lbs. ft. plus a 1/4 turn). (Refer to «TIMING BELT AND SPROCKETS»(ref-245454-S01103536842006110200000) ).
9. Install the rear camshaft thrust plate.
10. Rotate the camshaft gear to it's alignment mark and check the left camshaft gear and crankshaft gear timing alignment marks.
11. Install the timing belt and tensioner. (Refer to «TIMING BELT AND SPROCKETS»(ref-245454-S01103536842006110200000) ).
12. Install the timing belt outer cover (Refer to «TIMING BELT AND SPROCKETS»(ref-245454-S01103536842006110200000) ).
13. Install the power steering reservoir.
14. Install the vibration damper (Refer to «VIBRATION DAMPER»(ref-245454-S23796174082006110200000) ).
15. Install the upper engine mount «(Refer to ENGINE/ENGINE MOUNTING/FRONT MOUNT - INSTALLATION)»(ref-245454-S05029375042006110200000).
16. Install the accessory drive belt tensioner.
17. Install the accessory drive belt idler pulley.
18. Install the right exhaust manifold (Refer to «EXHAUST MANIFOLD - RIGHT»(ref-245454-S00595405622006110200000) ).
19. Install the exhaust cross over pipe (Refer to «CROSSOVER PIPE - EXHAUST MANIFOLD»(ref-245454-S23822266912006110200000) ).
20. Install the catalytic converter and exhaust system.
21. Connect both oxygen sensors.
22. Lower the vehicle.
23. Install the right rocker arm assembly.
24. Install the right cylinder head cover and ground strap.
25. Install lower intake manifold (Refer to «INSTALLATION - LOWER INTAKE MANIFOLD»(ref-245454-S40680044462006110200000) ).
26. Install the fuel rail.
27. Install the upper intake manifold (Refer to «INSTALLATION - UPPER INTAKE MANIFOLD»(ref-245454-S28311178522006110200000) ).
28. Install the air cleaner element housing (Refer to «HOUSING-AIR CLEANER»(ref-245454-S16653029582006110200000) ).
29. Install the engine cover.
30. Fill the coolant system.
31. Connect the negative battery cable.

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 must be replaced. (Scheme 146).

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 must be replaced. see scheme 51

1. Clean sealing surfaces of cylinder head and block.
2. Install head gasket over locating dowels. Ensure the gasket is installed on the correct side of engine.
3. Install the cylinder head over locating dowels, insert and finger tighten the head bolts.
4. Tighten the cylinder head bolts in the sequence (Scheme 147) 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.
5. Bolt torque after 90° turn should be over 122 N.m (90 ft. lbs.) in the tightening direction. If not, replace the bolt.
6. Install the inner timing cover to cylinder head bolts. Tighten bolts to 54 N.m (40 lbs.ft.).
7. Install camshaft sprocket. Counterhold the camshaft sprocket gear and tighten the camshaft sprocket bolt to 115 N.m plus a 1/4 turn (85 lbs. ft. plus a 1/4 turn). (Refer to «TIMING BELT AND SPROCKETS»(ref-245454-S01103536842006110200000) ).
8. Install the rear camshaft thrust plate.
9. Rotate the camshaft gear to it's alignment mark and check the right camshaft gear and crankshaft gear timing alignment marks.
10. Install the timing belt and tensioner (Refer to «TIMING BELT AND SPROCKETS»(ref-245454-S01103536842006110200000) ).
11. Install the timing belt front cover (Refer to «FRONT TIMING BELT COVER»(ref-245454-S03005879422006110200000) ).
12. Install the vibration damper (Refer to «VIBRATION DAMPER»(ref-245454-S23796174082006110200000) ).
13. Install the upper engine mount «(Refer to ENGINE/ENGINE MOUNTING/FRONT MOUNT - INSTALLATION)»(ref-245454-S05029375042006110200000).
14. Install the accessory drive belt tensioner.
15. Install the accessory drive belt idler pulley.
16. Install the left exhaust manifold (Refer to «EXHAUST MANIFOLD - LEFT»(ref-245454-S02326411142006110200000) ).
17. Install the exhaust cross over pipe (Refer to «CROSSOVER PIPE - EXHAUST MANIFOLD»(ref-245454-S23822266912006110200000) ).
18. Install the left rocker arm assembly.
19. Install the left cylinder head cover and ground strap.
20. Install lower intake manifold (Refer to «INSTALLATION - LOWER INTAKE MANIFOLD»(ref-245454-S40680044462006110200000) ).
21. Install the fuel rail.
22. Install the upper intake manifold (Refer to «INSTALLATION - UPPER INTAKE MANIFOLD»(ref-245454-S28311178522006110200000) ).
23. Install the radiator cooling fan assembly «(Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION)»(ref-245448-S13225941362006110200000).
24. Install the radiator core support.
25. Install the radiator close out panel.
26. Install the air cleaner element housing (Refer to «HOUSING-AIR CLEANER»(ref-245454-S16653029582006110200000) ).
27. Install the engine cover.
28. Fill the coolant system.
29. Connect the negative battery cable.

1. Disconnect the negative battery cable.
2. Remove front timing cover and align the camshaft gear and crankshaft gear timing marks to TDC (Refer to «FRONT TIMING BELT COVER»(ref-245454-S03005879422006110200000) ).
3. Remove timing belt and right camshaft sprocket (Refer to «TIMING BELT AND SPROCKETS»(ref-245454-S01103536842006110200000) ).
4. Remove the camshaft thrust plate from the rear of the cylinder head.
5. Remove the cylinder head cover (Refer to «COVER CYLINDER HEAD - RIGHT»(ref-245454-S39824532402006110200000) ).
6. Remove the rocker arm assembly «(Refer to ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - REMOVAL)»(ref-245454-S34084756062006110200000).
7. Maneuver the camshaft rearward and out of the cylinder head approximately 3.5 inches. (Scheme 148)
8. Using an appropriate driver carefully remove camshaft oil seal. (Scheme 148)

Scheme 147

1. Disconnect the negative battery cable.
2. Drain cooling system.
3. Remove front timing cover and align the camshaft gear and crankshaft gear timing marks to TDC (Refer to «FRONT TIMING BELT COVER»(ref-245454-S03005879422006110200000) ).
4. Remove the rear timing cover. (Refer to «REAR TIMING BELT COVER»(ref-245454-S17876594162006110200000) ).
5. Remove the cylinder head cover (Refer to «CYLINDER HEAD COVER - LEFT»(ref-245454-S39502002092006110200000) ).
6. Remove the rocker arm assembly «(Refer to ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - REMOVAL)»(ref-245454-S34084756062006110200000).
7. Remove the camshaft thrust plate from the rear of the cylinder head.
8. Maneuver the camshaft rearward and out of the cylinder head approximately 3.5 inches. (Scheme 149)
9. Using an appropriate driver carefully remove camshaft oil seal. (Scheme 149)

Scheme 148

Scheme 149

Scheme 150

1. Position the camshaft seal into the cylinder head. (Scheme 150) 1 - REAR TIMING COVER 2 - SPECIAL TOOL 6788
2. Using special tool MD-998306 tap the seal into place. (Scheme 150)
3. Apply light coat of clean engine oil to the camshaft oil seal lip and Special Tool 6788 Seal Protector Sleeve.
4. Install oil seal Special Tool 6788 Seal Protector Sleeve onto the camshaft. (Scheme 151) 1 - REAR TIMING COVER 2 - SPECIAL TOOL 6788 3 - CAMSHAFT
5. Slide the camshaft forward, inserting the seal protector through the camshaft seal until the camshaft seats. (Scheme 151)
6. Remove Special Tool 6788 from the camshaft.
7. Install the camshaft thrust plate to the rear of the cylinder head.
8. Install camshaft sprocket and timing belt (Refer to «TIMING BELT AND SPROCKETS»(ref-245454-S01103536842006110200000) ).

Scheme 151

Scheme 152

1. Position the camshaft seal into the cylinder head
2. Using special tool MD-998306 tap the seal into place. (Scheme 152) 1 - MALLET 2 - SPECIAL TOOL MD-998306 3 - CYLINDER HEAD
3. Apply light coat of engine oil to the camshaft oil seal lip and Special Tool 6788 Seal Protector Sleeve.
4. Install oil seal Special Tool 6788 Seal Protector Sleeve onto the camshaft. see scheme 58
5. Slide the camshaft forward, inserting the seal protector through the camshaft seal until the camshaft seats. see scheme 58 1 - CAMSHAFT 2 - SPECIAL TOOL6788 3 - CAMSHAFT SEAL 4 - CYLINDER HEAD
6. Remove Special Tool 6788 from the camshaft.
7. Install the camshaft thrust plate to the rear of the cylinder head.
8. Install rear timing belt cover. (Refer to «REAR TIMING BELT COVER»(ref-245454-S17876594162006110200000) ).
9. Install the camshaft gear and align the timing marks.
10. Install the timing belt. (Refer to «TIMING BELT AND SPROCKETS»(ref-245454-S01103536842006110200000) ).
11. Install the rocker arm assembly.
12. Install the cylinder head cover.
13. Install the front timing belt cover (Refer to «FRONT TIMING BELT COVER»(ref-245454-S03005879422006110200000) ).
14. Install the vibration damper. (Refer to «VIBRATION DAMPER»(ref-245454-S23796174082006110200000) ).
15. Fill cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).
16. Connect the negative battery cable.

STANDARD PROCEDURE - VALVE AND VALVE SEAT REFACING

The valve face and valve seat angles are (Scheme 154)

Scheme 153

VALVES

1. Inspect the remaining margin after the valves are refaced (Refer to «SPECIFICATIONS - 3.5L ENGINE»(ref-245454-S36075951002006110200000) ).

Scheme 154

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.
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.). (Scheme 155) 1 - SEAT WIDTH 2 - FACE ANGLE 3 - SEAT ANGLE 4 - SEAT CONTACT AREA

Scheme 155

Scheme 156

Scheme 157

1. Coat valve stems with clean engine oil and insert them in cylinder head.
2. If valves or seats have been refaced, check valve tip height (A). (Scheme 156) 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. 1 - SPRING RETAINER 2 - GARTER SPRING 3 - VALVE SPRING SEAT TOP 4 - CYLINDER HEAD SURFACE
3. Install valve seal/spring seat assembly over valve guides on all valve stems. see scheme 73 Ensure that the garter spring is intact around the top of the rubber seal.
4. Place valve spring (color-coded end facing up ). (Scheme 157)and valve retainer into position on spring seat. (Scheme 156) 1 - YELLOW OR WHITE DYE 2 - ORANGE DYE 1 - VALVE 2 - VALVE RETAINING LOCKS 3 - VALVE SPRING RETAINER 4 - VALVE SPRING 5 - VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY
5. Compress valve springs with valve spring compressor C-3422-D and adapter 6526 (Refer to «SPECIAL TOOLS»(ref-245454-S36357384272006110200000) ), install locks and release tool.
6. If valves and/or seats are refaced, measure the installed height of springs. (Scheme 156) 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.

1. Clean all valves thoroughly and discard burned, warped and cracked valves.

STANDARD PROCEDURE - HYDRAULIC 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. (Scheme 159) Rotate engine as necessary.
4. For intake rocker arm positions: 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. see scheme 80 CAUTION: If probe tip breaks off within the lash adjuster, replace the affected rocker arm. Gently unseat lash adjuster's internal check ball. 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. Slowly release the rocker arm, thereby allowing the lash adjuster to extend, which in turn refills the high pressure chamber with non-aerated oil. Remove probe to allow check ball to seat. Recheck for sponginess. If the lash adjuster sponginess is not completely or nearly eliminated, then repeat procedure. If the spongy condition cannot be removed, replace effected rocker arm(s).
5. For exhaust rocker arm positions: Adjust Special Tool 8351 Release Probe 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. see scheme 80 CAUTION: If probe tip breaks off within the lash adjuster, replace the affected rocker arm. Gently unseat BOTH lash adjuster's internal check ball at the same time. 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. Slowly release the rocker arm, thereby allowing the lash adjuster to extend, which in turn refills the high pressure chamber with non-aerated oil. Remove probes to allow check balls to seat. Recheck for sponginess. If the lash adjuster sponginess is not completely or nearly eliminated, then repeat procedure. If the spongy condition cannot be removed, replace effected rocker arm(s).
6. Install cylinder head cover(s).

Scheme 158

Scheme 159

Clean cylinder block thoroughly using a suitable cleaning solvent.

ENGINE BLOCK

1. Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking.
2. If new core plugs are to be installed, (Refer to «STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS»(ref-245454-S03573051272006110200000) ).
3. Examine block and cylinder bores for cracks or fractures.
4. Check block deck surfaces for flatness. Deck surface must be within service limit of 0.1 mm (0.004 in.).

CYLINDER BORE

Note. The cylinder bores should be measured at normal room temperature, 21°C (70°F).

The cylinder walls should be checked for out-of-round and taper with Tool C119 or equivalent. (Scheme 161)(Refer to SPECIFICATIONS ). If the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted.

Measure the cylinder bore at three levels in directions A and B. (Scheme 161) Top measurement should be 10 mm (3/8 in.) down and bottom measurement should be 10 mm (3/8 in.) up from bottom of bore. (Refer to SPECIFICATIONS ).

Scheme 160

CONNECTING ROD BEARINGS

The bearing caps are not interchangeable and should be marked at removal to insure correct assembly.

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.

Fit all rods on one bank until complete.

Limits of taper or out-of-round on any crankshaft journals should be held to 0.005 mm (0.0001 in.). Bearings are available in standard, 0.025 mm (0.001 in.), and 0.254 mm (0.010 in.) undersizes. 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. For measuring main bearing clearance and connecting rod bearing clearance use plastigage. (Scheme 162) For more information on using plastigage (Refer to «STANDARD PROCEDURE»(ref-245454-S02562514762006110200000) ). Refer to «SPECIFICATIONS»(ref-245454-S19893092512006110200000) for bearing clearance specifications (Refer to «SPECIFICATIONS»(ref-245454-S19893092512006110200000) ).

Note. The rod bearing bolts should be examined before reuse. If the threads are necked down the bolts must be replaced. (Scheme 163)

Scheme 161

Scheme 162

1. Examine connecting rod bolts for stretching. Stretching can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt must be replaced. 1 - STRETCHED BOLT 2 - THREADS ARE NOT STRAIGHT ON LINE 3 - THREADS ARE STRAIGHT ON LINE 4 - UNSTRETCHED BOLT
2. Before installing the bolts the threads should be cleaned and inspected.
3. Install clean bolts finger tight. Then alternately torque each bolt to assemble the cap properly.
4. Tighten the connecting rod cap bolts to specification. (Refer to «SPECIFICATIONS»(ref-245454-S19893092512006110200000) ).

CONNECTING ROD SIDE CLEARANCE

1. 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. see scheme 102 Compare measurement to specification listed in engine specifications (Refer to «SPECIFICATIONS»(ref-245454-S19893092512006110200000) ). Repeat procedure for each connecting rod. Turn crankshaft for connecting rod accessibility.

Scheme 163

STANDARD PROCEDURE - 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. (Scheme 165) 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 (Scheme 166) The crankshaft journal grade marks (A, B, or C) are read left to right, corresponding with journal number 1, 2, 3, 4.

Refer to 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.).

Note. Service main bearings have a number from (1-5) marked in ink on the bearing surface. see scheme 112 For verification, refer to 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.

Scheme 164

Scheme 165

Scheme 166

MAIN BEARING SELECTION CHART

STANDARD PROCEDURE - FITTING PISTONS

The 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.

Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin at size location see scheme 125 Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line (Refer to OIL PAN ). Pistons and cylinder bores should be measured at normal room temperature, 70°F (21°C).

Scheme 167

STANDARD PROCEDURE - ENGINE OIL LEVEL CHECK

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. Add only when the level is at or below the ADD mark.

STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE

Change engine oil at mileage and time intervals described in the Maintenance Schedule. (Refer to MAINTENANCE SCHEDULES )

Scheme 168

Scheme 169

1. Run engine until achieving normal operating temperature.
2. Position the vehicle on a level surface and turn engine off.
3. Open hood, remove engine oil fill cap. see scheme 151 1 - ENGINE OIL FILL CAP 2 - TRANSMISSION FLUID LEVEL INDICATOR 3 - ENGINE OIL LEVEL INDICATOR
4. Raise vehicle on hoist.
5. Place a suitable drain pan under crankcase drain.
6. Remove oil pan 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.
7. Remove oil filter. see scheme 152
8. Install drain plug in crankcase. Torque oil pan drain plug to 27 N.m (20 ft. lbs.).
9. Install new oil filter. see scheme 152 1 - EXHAUST MANIFOLD 2 - ENGINE OIL COOLER 3 - ENGINE OIL FILTER 4 - AIR CONDITIONING COMPRESSOR 5 - OIL PRESSURE SENDING UNIT
10. Lower vehicle.
11. Fill crankcase with specified type and amount of engine oil. see scheme 151 «(Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION - ENGINE OIL)»(ref-245418-S21694775542006110200000) (Refer to «LUBRICATION & MAINTENANCE»(ref-245418) ).
12. Install oil fill cap. see scheme 151
13. Start engine and inspect for leaks.
14. Stop engine and inspect oil level.

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING above.

1. Clean all parts thoroughly in a suitable solvent.

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

1. Disassemble oil pump. (Refer to «DISASSEMBLY»(ref-245454-S11804438922006110200000) ).
2. Clean all parts thoroughly. Mating surface of the oil pump housing should be smooth. Replace pump cover if scratched or grooved.
3. Lay a straightedge across the pump cover surface. (Scheme 173) If a 0.025 mm (0.001 in.) feeler gauge can be inserted between cover and straight edge, cover should be replaced. 1 - STRAIGHT EDGE 2 - FEELER GAUGE 3 - OIL PUMP COVER
4. Measure thickness and diameter of outer rotor. If outer rotor thickness measures 14.299 mm (0.563 in.) or less. (Scheme 174), or if the diameter is 79.78 mm (3.141 inches.) or less, replace outer rotor.
5. If inner rotor measures 14.299 mm (0.563 in.) or less replace inner rotor. (Scheme 175)
6. Slide outer rotor into body, press to one side with fingers and measure clearance between rotor and body. (Scheme 176) If measurement is 0.39 mm (0.015 inch.) or more, replace body only if outer rotor is in specifications. 1 - FEELER GAUGE 2 - OUTER ROTOR
7. Install inner rotor into body. If clearance between inner and outer rotors. see scheme 174is 0.20 mm (0.008 inch.) or more, replace both rotors. 1 - FEELER GAUGE 2 - OUTER ROTOR 3 - INNER ROTOR
8. 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. see scheme 175ONLY if rotors are in specs. 1 - STRAIGHT EDGE 2 - FEELER GAUGES
9. 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.
10. The relief valve spring. see scheme 176has a free length of approximately 49.5 mm (1.95 in.) it should test between 101-110 N (23-25 lbs.) when compressed to 34 mm (1-11/32 in.). Replace spring that fails to meet specifications. 1 - RELIEF VALVE 2 - SPRING 3 - RETAINER CAP 4 - COTTER PIN
11. Assemble oil pump. (Refer to «ASSEMBLY»(ref-245454-S05902617452006110200000) ).

TIMING VERIFICATION

Remove the outer timing covers. Rotate the crankshaft until the pointer on the crankshaft sprocket aligns the TDC mark on the oil pump. Check to determine if the camshaft sprocket timing marks are aligned with the marks on the inner timing cover. It may take an additional full revolution of the crankshaft before the camshaft sprocket marks are aligned. see scheme 194

1. Perform fuel pressure release procedure. «(Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE)»(ref-245444-S24174060702006110200000).
2. Disconnect negative battery cable.
3. Remove both cylinder head covers and loosen the rocker arm assemblies.
4. Remove the front timing belt cover (Refer to «FRONT TIMING BELT COVER»(ref-245454-S03005879422006110200000) ).
5. Mark belt running direction, if timing belt is to be reused.
6. Rotate engine clockwise until crankshaft mark aligns with the TDC mark on oil pump housing and the camshaft sprocket timing marks are aligned with the marks on the rear cover. see scheme 1941 - RIGHT CAMSHAFT GEAR ALIGNMENT MARK 7 - LEFT CAMSHAFT GEAR 2 - RIGHT CAMSHAFT GEAR 8 - LEFT CAMSHAFT GEAR ALIGNMENT MARK 3 - CYLINDER HEAD TO INNER TIMING BELT COVER BOLTS - RIGHT 9 - CRANKSHAFT GEAR ALIGNMENT MARK 4 - TIMING BELT 10 - CRANKSHAFT GEAR 5 - WATER PUMP PULLEY 11 - TIMING BELT TENSIONER PULLEY 6 - CYLINDER HEAD TO INNER TIMING BELT COVER BOLTS - LEFT 12 - TIMING BELT TENSIONER
7. Remove the timing belt tensioner. see scheme 194and remove timing belt.
8. Inspect the tensioner for fluid leakage.
9. Inspect the pivot and bolt for free movement, bearing grease leakage, and smooth rotation. If not rotating freely, replace the arm and pulley assembly.
10. When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body. CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This ensures proper pin orientation when tensioner is installed on the engine. Place the tensioner into a vise and SLOWLY compress the plunger. see scheme 195 Total bleed down of tensioner should take about 5 minutes. 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.

Scheme 177

Remove the outer timing covers. Rotate the crankshaft until the pointer on the crankshaft sprocket (10). see scheme 200aligns the TDC mark on the oil pump (9). Check to determine if the camshaft sprocket (2, 7) timing marks (1, 8) are aligned with the marks on the inner timing cover. It may take an additional full revolution of the crankshaft before the camshaft sprocket marks are aligned.

TIMING BELT

1. Align the crankshaft sprocket (10). see scheme 204with the TDC mark (9) on oil pump cover.
2. Align the camshaft sprockets (2, 7) timing reference marks (1, 8) with the marks on the rear cover.
3. Install the timing belt starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley (11). NOTE: If the camshaft gears have been removed it is only necessary to have the camshaft gear retaining bolts installed to a snug torque at this time.
4. Holding the tensioner pulley (11) against the belt, install the tensioner into the housing and tighten to 28 N.m (250 in. lbs.). Each camshaft sprocket mark should remain aligned 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. If marks do not line up, repeat procedure. NOTE: If camshaft gears have been removed and timing is correct, counterhold and tighten the camshaft gears to final torque specification (Refer to «TIMING BELT AND SPROCKETS»(ref-245454-S01103536842006110200000) ).
7. Install the front timing belt cover (Refer to «FRONT TIMING BELT COVER»(ref-245454-S03005879422006110200000) ).
8. Tighten the rocker arm assemblies and install the cylinder head covers «(Refer to ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - INSTALLATION)»(ref-245454-S13812557382006110200000).
9. Connect negative battery cable.

TENSIONER

1. For timing belt tensioner removal procedure (Refer to «TIMING BELT AND SPROCKETS»(ref-245454-S01103536842006110200000) ).

1. For timing belt tensioner installation procedure (Refer to «TIMING BELT AND SPROCKETS»(ref-245454-S01103536842006110200000) ).