3.6L Engine - Service Information: Diagnosis Dodge Avenger II facelift

ENGINE PERFORMANCE DIAGNOSTIC TABLE

ENGINE MECHANICAL DIAGNOSTIC TABLE

DIAGNOSTIC PROCEDURES

The following diagnostic procedures are used to determine the source of excessive internal oil Consumption, these procedures and tests apply to vehicles with 50, 000 miles or less.

Note. Engine oil consumption may be greater than normal during engine break-in. Repairs should be delayed until vehicle has been driven at least 7, 500 miles.

Severe service (high ambient temperature, short trips, heavy loading, trailer towing, taxi, off-road, or law enforcement use) may result in greater oil consumption than normal.

Sustained high speed driving and high engine RPM operation may result in increased oil consumption.

Failure to comply with the recommended oil type and viscosity rating, as outlined in the owner's manual, may impact oil economy as well as fuel economy.

Oil consumption may increase with vehicle age and mileage due to normal engine wear.

Note. Because a few drops of external oil leakage per mile can quickly account for the loss of one quart of oil in a few hundred miles, ensure no external engine oil leaks are present.

1. Oil leakage is not the same as oil consumption and all external leakage must be eliminated before any action can be taken to verify and/or correct oil consumption complaints.
2. Verify that the engine has the correct oil level dipstick and dipstick tube installed.
3. Verify that the engine is not being run in an overfilled condition. Check the oil level 15 minutes after a hot shutdown with the vehicle parked on a level surface. In no case should the level be above MAX or the FULL mark on the dipstick.

OIL CONSUMPTION TEST

1. Check the oil level at least 15 minutes after a hot shutdown.
2. If the oil level is low, top off with the proper viscosity and API service level engine oil. Add one bottle of MOPAR® 4-In-1 Leak Detection Dye into the engine oil.
3. Tamper proof the oil pan drain plug, oil filter, dipstick and oil fill cap.
4. Record the vehicle mileage.
5. Instruct the customer to drive the vehicle as usual.
6. Ask the customer to return to the servicing dealer after accumulating 500 miles, Check the oil level at least 15 minutes after a hot shutdown. If the oil level is half way between the "FULL" and "ADD" mark continue with the next step.
7. Using a black light, re-check for any external engine oil leaks, repair as necessary, if no external engine oil leaks are present, continue with oil consumption diagnosis.

OIL CONSUMPTION DIAGNOSIS

1. Check the positive crankcase ventilation (PCV) system. Make sure the system is not restricted and the PCV valve has the correct part number and correct vacuum source (18-20 in. Hg at idle below 3000 ft. above sea level is considered normal).
2. Perform a «CYLINDER COMPRESSION PRESSURE LEAKAGE»(ref-485476-S18661667702012071300000) test and «CYLINDER-TO-CYLINDER LEAKAGE TEST»(ref-485476-S22170412752012071300000) using the standard leak down gauge following manufacturers suggested best practices. NOTE: Verify the spark plugs are not oil saturated. If the spark plugs are oil saturated and compression is good it can be assumed the valve seals or valve guides are at fault.
3. If one or more cylinders have more than 15% leak down further engine tear down and inspection will be required.

ENGINE LUBRICATION DIAGNOSTIC TABLE

Scheme 391

Due to the high amounts of failures cased by dust, dirt, moisture and other foreign debris being introduced to the engine during service. Covers or caps are needed to reduce the possible damage that can be caused or created.

Scheme 392

Covers over openings will reduce any possibilities for foreign materials to enter the engine systems. Using miller tool (special tool #10368, Set, Universal Protective Cap), Select the appropriated cover needed to the procedure.

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. Refer to CYLINDER COMPRESSION PRESSURE LEAKAGE . 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

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.

Scheme 393

Install Cooling System Tester (special tool #7700-A, Tester, Cooling System) 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.

Scheme 394

Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit (special tool #C-3685-A, Bloc-Chek Kit) or equivalent. Perform test following the procedures supplied with the tool kit.

DIAGNOSIS AND TESTING - HYDRAULIC LIFTER(S) NOISE DIAGNOSIS

Proper noise diagnosis is essential in locating the source of an 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 for possible causes and correction of a lash adjuster (tappet) type noise.

LASH ADJUSTER (TAPPET) NOISE CHART

Scheme 395

Note. The LH cylinder head hydraulic lifters are shown in illustration, the RH cylinder head hydraulic lifters are similar.

1. Disconnect and isolate the negative battery cable.
2. Remove the camshaft(s). Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-485476-S02001420762012071300000) . NOTE: If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.
3. Remove the rocker arm(s). Refer to «ROCKER ARM, VALVE, REMOVAL»(ref-485476-S18060150142012071300000) . NOTE: If the hydraulic lifters are to be reused, identify their positions so that they can be reassembled into their original locations.
4. Remove the hydraulic lifter(s) (1).

INSPECTION

1. Wipe the inserts (1) clean.
2. Inspect the inserts for abnormal wear patterns, scoring, grooving, fatigue, pitting and for metal or other foreign material imbedded in the lining.
3. Inspect the back of the inserts for fractures, scrapes, or irregular wear patterns.
4. Inspect the insert locking tabs for damage.
5. Replace any bearing that shows abnormal wear. Refer to «Engine/Engine Block/BEARING(S), Connecting Rod - Standard Procedure»(ref-485476-S08098216892012071300000) .
6. Inspect the connecting rod bearing bores for signs of scoring, nicks and burrs. NOTE: Misaligned or bent connecting rods can cause abnormal wear on pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft connecting rod journals. If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod, inspect it for correct rod alignment.
7. Replace misaligned, bent or twisted connecting rods. NOTE: Connecting rods are serviced with the piston pre-assembled. The pistons are "select fit" to achieve proper oil clearance. Refer to «Engine/Engine Block/ROD, Piston and Connecting - Standard Procedure»(ref-485476-S29806254732012071300000) . NOTE: Typical coated piston shown in illustration.
8. Inspect the piston for scoring or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration.
9. Check the piston for taper and out of round shape. NOTE: The coating material (1 and 2) is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston will not provide accurate results. Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY . Refer to «Engine/Engine Block - Inspection»(ref-485476-S28540286292012071300000) .
10. Compare the measured cylinder bore diameter to the engine block cylinder bore grade marking chart Select the piston size that corresponds to the engine block markings for each cylinder to provide the proper oil clearance. Refer to «Engine/Engine Block/ROD, Piston and Connecting - Standard Procedure»(ref-485476-S29806254732012071300000) .

Note. Piston installation into the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.

Note. The coated pistons will be serviced with the piston pin and connecting rod pre-assembled.

Scheme 396

1. If required, select and fit new piston and connecting rod assemblies to the engine block. Refer to «Engine/Engine Block/ROD, Piston and Connecting - Standard Procedure»(ref-485476-S29806254732012071300000) .
2. If required, select and fit new bearings to the connecting rod. Refer to «Engine/Engine Block/BEARING(S), Connecting Rod - Standard Procedure»(ref-485476-S08098216892012071300000) .
3. If required, hone the cylinder bores. Refer to «Engine/Engine Block - Standard Procedure»(ref-485476-S03755150802012071300000) .
4. If removed, install the piston rings. Refer to «RING(S), PISTON, INSTALLATION»(ref-485476-S20462209052012071300000) .
5. Position the piston ring end gaps as follows: Oil ring expander gap (5) Oil ring lower side rail end gap (4) Oil ring upper side rail end gap (1) No. 2 (intermediate) ring end gap (5) No. 1 (upper) ring end gap (2) NOTE: Typical V6 engine configuration shown in illustration. NOTE: Ensure the position of the ring end gaps does not change when installing the ring compressor.
6. Lubricate the piston rings with clean engine oil. Position Piston Compressor (special tool #C-385, Compressor, Piston) (2) over the piston and rings. Tighten the compressor (2). NOTE: Install the rod bearings in pairs. Do not mix sizes or use a new bearing half with an old bearing half.
7. Install the bearing shell (8) on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
8. Remove the plastic guide plates (3) from the Guide Pins (special tool #8189, Guide Pins) (7) and install the Guide Pins to the connecting rod being installed. NOTE: Right cylinder bank shown in illustration, left cylinder bank similar.
9. The pistons crowns are stamped with a mark (1) indicating installation position. This mark must be positioned toward the front of engine on both cylinder banks.
10. Wipe the cylinder bore clean and lubricate with clean engine oil.
11. Rotate the crankshaft until the connecting rod journal is on the center of cylinder bore. CAUTION: Avoid contact with the piston oil cooler jet(s). Positioning of the oil cooler jet(s) is critical for proper engine operation.
12. Insert the piston and connecting rod into the cylinder bore and carefully position the guide pins over the crankshaft journal.
13. Tap the piston down in the cylinder bore using a hammer handle while guiding the connecting rod into position over the rod journal. NOTE: Typical V6 engine configuration shown in illustration. CAUTION: The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.
14. Install the bearing shell (6) on the connecting rod cap (4) with the tang inserted into the machined groove in the cap. Lubricate the bearing surface with clean engine oil. NOTE: Do not lubricate the threads of the connecting rod cap bolts (5).
15. Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten the NEW connecting rod cap bolts (5) to 20 N.m (15 ft. lbs.) plus 90°.
16. If required, check the connecting rod side clearance. Refer to «Engine/Engine Block/ROD, Piston and Connecting - Standard Procedure»(ref-485476-S29806254732012071300000) .
17. Repeat the previous steps for each piston being installed. CAUTION: The main bearing cap 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.
18. Check the main bearing cap bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
19. Install the windage tray with eight main bearing cap bolts. Tighten the bolts in the sequence shown in illustration to 21 N.m (16 ft. lbs.) plus 90°.
20. Install the engine oil pump and oil pump pick-up. Refer to «PUMP, ENGINE OIL, INSTALLATION»(ref-485476-S18747126302012071300000) .
21. Install the cylinder heads, engine timing cover and oil pans. Refer to «CYLINDER HEAD, INSTALLATION»(ref-485476-S00213433672012071300000) .
22. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .
23. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
24. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
25. Operate the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

Scheme 397

Scheme 398

Scheme 399

1. Remove the accessory drive belt and the crankshaft vibration damper. Refer to «DAMPER, VIBRATION, REMOVAL»(ref-485476-S14126021502012071300000) .
2. Install the sleeve (2) from Seal Remover (special tool #8511, Remover, Seal) around the flywheel key (1) and onto the nose of the crankshaft.
3. Screw Seal Remover (special tool #8511, Remover, Seal) (1) into the front crankshaft oil seal (2).
4. Install the extractor screw (2) into the Seal Remover (special tool #8511, Remover, Seal) (1). Hold the seal remover stationary and tighten the extractor screw against the sleeve until the front crankshaft oil seal (3) is removed from the engine timing cover.

Scheme 400

1. Position the front crankshaft oil seal (3) into place on the engine timing cover.
2. Align the Front Crankshaft Seal Installer (special tool #10199, Installer, Crankshaft Front Oil Seal) (1) to the flywheel key on the crankshaft and against the front crankshaft oil seal (3). CAUTION: Only tighten the crankshaft vibration damper bolt until the oil seal is seated in the cover. Overtightening of the bolt can crack the front timing cover.
3. Install and tighten the crankshaft vibration damper bolt (2) until the Crankshaft oil seal is seated in the engine timing cover.
4. Install the crankshaft vibration damper and accessory drive belt. Refer to «DAMPER, VIBRATION, INSTALLATION»(ref-485476-S32510645082012071300000) .

Scheme 401

1. Remove the upper and lower oil pans. Refer to «PAN, OIL, REMOVAL»(ref-485476-S01269687182012071300000) . CAUTION: Do not attempt to support the weight of the engine on the windage tray. The windage tray is a thin cast aluminum construction and can be easily damaged.
2. Support the rear of the engine with a screw-jack when removing the transmission. Position the support on the engine oil pan flange and not the windage tray.
3. Remove the transmission. Refer to «REMOVAL»(ref-485526-S38232624722012071300000) .
4. Remove the flexplate (3). Refer to «FLEXPLATE, REMOVAL»(ref-485476-S18805842032012071300000) . NOTE: The rear crankshaft oil seal is incorporated into the seal retainer (2) and can not be removed from the retainer. The rear crankshaft oil seal and seal retainer (2) are serviced as an assembly.
5. Remove the eight seal retainer attaching screws (1).
6. Remove and discard the seal retainer (2).

Scheme 402

Scheme 403

Scheme 404

Scheme 405

1. Inspect the crankshaft to make sure there are no nicks or burrs on the seal surface.
2. Clean the engine block sealing surfaces thoroughly. NOTE: It is not necessary to lubricate the seal or the crankshaft when installing the seal retainer. Residual oil following installation can be mistaken for seal leakage.
3. Carefully position the oil seal retainer assembly (2), and seal protector (1) on the crankshaft and push firmly into place on the engine block (during this step, the seal protector will be pushed from the rear oil seal assembly as a result of installing the rear oil seal).
4. Verify that the seal lip (2) on the retainer is uniformly curled inward toward the engine on the crankshaft (1). NOTE: Make sure that the seal retainer flange is flush with the engine block oil pan sealing surface.
5. Install the eight seal retainer bolts (1) and tighten to 12 N.m (106 in. lbs.).
6. Install the flexplate. Refer to «FLEXPLATE, INSTALLATION»(ref-485476-S22222826772012071300000) .
7. Install the transmission. Refer to «INSTALLATION»(ref-485526-S07738426872012071300000) .
8. Install the upper and lower oil pans. Refer to «PAN, OIL, INSTALLATION»(ref-485476-S34328764342012071300000) .
9. Fill the engine crankcase with the proper oil to the correct level. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .

Scheme 406

Scheme 407

1. Disconnect and isolate the negative battery cable.
2. Remove the air cleaner body. Refer to «BODY, AIR CLEANER, REMOVAL»(ref-485476-S11662508332012071300000) .
3. Remove the front fore and aft crossmember. Refer to «CROSSMEMBER, FRONT FORE AND AFT, REMOVAL»(ref-485477-S17979691932012071300000) , «CROSSMEMBER, FRONT SUSPENSION, REMOVAL»(ref-485477-S35953511442012071300000) and «CROSSMEMBER, REAR SUSPENSION, REMOVAL»(ref-485477-S22760813262012071300000) .
4. Lower the vehicle.
5. Carefully position a floor jack under transmission to support the transmission.
6. Remove the two transmission mount to transmission bolts (1).
7. Remove the PCM. Refer to «REMOVAL»(ref-485476-S01887388302012071300000) .
8. Raise the vehicle up enough to gain access to the two lower transmission isolator bolts (3).
9. Remove the two upper bolts (1) and one lower bolt (3) from the left transmission mount isolator (2).

AIR LEAK DETECTION TEST METHOD

1. Disconnect the make-up air hose from the cylinder head cover. Cap or plug the make-up air hose nipple.
2. Remove the PCV hose from the PCV valve. Cap or plug the PCV valve nipple.
3. Attach an air hose with a pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.
4. Gradually increase air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected leak source. Adjust the regulator to a suitable test pressure within this range that provides the best bubble generation which will pinpoint the leak source. If the oil leak is detected and identified, repair per service information procedures.
5. If the leakage occurs at the rear oil seal area, follow the procedures for rear seal area leaks. Refer to «DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS»(ref-485476-S01556369042012071300000) .
6. If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve and make-up air hoses.
7. Clean the oil off of 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.

Scheme 408

Scheme 409

1. Disconnect and isolate the negative battery cable.
2. Remove the oil pressure sensor (2) from the oil filter housing (3). Refer to «SENSOR, OIL PRESSURE, REMOVAL»(ref-485476-S28596924282012071300000) .
3. Install Pressure Gauge (special tool #C-3292A, Gauge, Pressure) (1) to the oil pressure port. Tighten to 20 N.m (177 in. lbs.).
4. Install the upper and lower intake manifolds and air inlet hose. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
5. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
6. Start and idle the engine. If oil pressure is 0 at idle, shut off the engine and consult the Engine Lubrication and Diagnostic Table. Refer to «ENGINE LUBRICATION DIAGNOSTIC TABLE»(ref-485476-S35025108622012071300000) .
7. Run the engine until it reaches normal operating temperature.
8. Verify that the engine has acceptable oil pressure. Refer to «Engine - Specifications»(ref-485476-S24399402942012071300000) .

DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS

Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.

If the leakage occurs at the crankshaft rear oil seal area

1. Disconnect and isolate the negative battery cable.
2. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
3. Remove the torque converter dust shield (1).
4. Remove two rubber plugs (2) covering the rear oil seal retainer flange bolts.
5. Inspect the flexplate and rear of the block for evidence of oil. Use a black light to check for the oil leak: Circular spray pattern generally indicates seal leakage or crankshaft damage. Where leakage tends to run straight down, possible causes are a porous block, rear oil seal retainer, oil galley pipe plug and rear seal retainer to oil pan mating surfaces.
6. If no leaks are detected, use the Air Leak Detection Method as outlined in Engine Oil Leak. Refer to «AIR LEAK DETECTION TEST METHOD»(ref-485476-S18219216302012071300000) . CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.
7. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks or scratches. The crankshaft seal flange is specially machined to complement the function of the rear oil seal.
8. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. Refer to «SEAL, CRANKSHAFT OIL, REAR, REMOVAL»(ref-485476-S09556213482012071300000) .

Scheme 410

The oil cooler is attached to the top of the oil filter housing which is located in the V of the cylinder block. The oil cooler is a plate style coolant-to-oil heat exchanger.

Scheme 411

Oil flows from the engine oil pump to the oil filter housing inlet (1) and to the oil filter element located within the oil filter housing. After the oil is filtered it travels internally through the engine oil cooler and then to the main oil gallery (5).

Coolant flows from the right cylinder block water jacket (3) and from the left cylinder block water jacket (4) into the housing. The coolant flows through the oil cooler and exits the housing from the rear hose nipple (6) where it is returned to the water pump. A coolant by-pass in the housing is designed to direct excessive coolant flow around the oil cooler for continuous circulation.

Scheme 412

Note. The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, replace the oil cooler.

Scheme 413

1. Perform the fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-485510-S12963059542012071300000) .
2. Disconnect and isolate the negative battery cable.
3. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
4. Remove the air cleaner housing assembly, upper and lower intake manifolds. Refer to «MANIFOLD, INTAKE, REMOVAL»(ref-485476-S08989499162012071300000) .
5. Remove four bolts (2) and two screws (1) and (3).
6. Remove the oil cooler (4).
7. Remove and discard the oil cooler seals (1).

DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS

An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.

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.

Scheme 414

Scheme 415

Scheme 416

Scheme 417

1. Disconnect and isolate the negative battery cable.
2. Remove the engine cover (1).
3. Remove the resonator (1). Refer to «RESONATOR, AIR CLEANER, REMOVAL»(ref-485476-S12665908032012071300000) .
4. Disconnect the electrical connectors from the Manifold Absolute Pressure (MAP) sensor (1) and the Electronic Throttle Control (ETC) (7).
5. Disengage the ETC harness from the clip (8) on the throttle body. Disengage the wire harness retainers (4 and 5) from the upper intake manifold near the MAP sensor and reposition the wire harness.
6. Disconnect the following hoses from the upper intake manifold: Positive Crankcase Ventilation (PCV) (3) vapor purge (6) brake booster (2)
7. Disengage the wire harness retainer (4) from the upper intake manifold support bracket (5).
8. Disengage the wire harness retainer (3) from the studbolt (2).
9. Remove two nuts (1), loosen the studbolt (2) and reposition the upper intake manifold support bracket (5).
10. Remove the nut (2) from the support bracket of the heater core return tube (1).
11. Remove two nuts (1), loosen two studbolts (3) and reposition the two upper intake manifold support brackets (2). NOTE: The upper intake manifold attaching bolts are captured in the upper intake manifold. Once loosened, the bolts will have to be lifted out of the lower intake manifold and held while removing the upper intake manifold. NOTE: Exercise care not to inadvertently loosen the two fuel rail attachment bolts that are in close proximity of the upper intake manifold attaching bolts.
12. Remove seven manifold attaching bolts (1) and remove the upper intake manifold (2).
13. Remove and discard the six upper to lower intake manifold seals (1).
14. Cover the open intake ports to prevent debris from entering the engine.
15. If required, remove the insulator (2) from the LH cylinder head cover.

Prior to disassembly of the timing chains and sprockets, measure the timing chain wear (1). Refer to Engine/Valve Timing - Standard Procedure .

Inspect the following valve timing components

1. Sprockets for excessive tooth wear. Some tooth markings are normal and not a cause for sprocket replacement.
2. Idler sprocket assembly bushing and shaft for excessive wear.
3. Chain guides and tensioner arms. Replace these parts if grooving in plastic face is more than 1 mm (0.039 in.) deep.
4. Secondary chain tensioner piston and ratcheting device. Inspect for evidence of heavy contact between tensioner piston and tensioner arm. If this condition exist the tensioner arm and chain should be replaced.
5. Primary chain tensioner plastic faces. Replace as required.