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

Scheme 378

Note. RWD engine configuration shown in illustration, FWD similar.

The 3.6 liter (219.7 CID) flexible fuel V-6 engine features Variable Valve Timing (VVT), Dual Overhead Camshafts (DOHC) and a high-pressure die-cast aluminum cylinder block with steel liners in a 60° configuration. The 3.6 liter engine has a chain driven variable discharge oil pump with a two-stage pressure regulator for improved fuel economy. The exhaust manifolds are integrated into the cylinder heads for reduced weight. The cylinders are numbered from front to rear. The right bank is numbered 1, 3, 5 and the left bank is numbered 2, 4, 6. The firing order is 1-2-3-4-5-6. The engine serial number is located on the left side of the cylinder block at the transmission flange.

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 performance (e.g., engine idles rough and stalls) or mechanical (e.g., a strange noise).

Refer to ENGINE PERFORMANCE DIAGNOSTIC TABLE and ENGINE MECHANICAL DIAGNOSTIC TABLE for possible causes and corrections of malfunctions.

Refer to FUEL SYSTEM article, for the fuel system diagnosis.

Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the following diagnosis

1. Cylinder Compression Pressure Test. Refer to «CYLINDER COMPRESSION PRESSURE LEAKAGE»(ref-485476-S18661667702012071300000) .
2. Cylinder Combustion Pressure Leakage Test. Refer to «CYLINDER COMBUSTION PRESSURE LEAKAGE»(ref-485476-S02894849892012071300000) .
3. Engine Cylinder Head Gasket Failure Diagnosis. Refer to «DIAGNOSIS AND TESTING»(ref-485476-S13199300522012071300000) .
4. Intake Manifold Leakage Diagnosis. Refer to «DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS»(ref-485476-S36395108972012071300000) .

DESCRIPTION

The lubrication system is a full flow filtration, pressure feed type lubrication system. The oil pump is mounted to the bottom of the cylinder block and chain driven by the crankshaft sprocket. The oil pump pick-up tube is attached to the oil pump and supported at the windage tray. There are three oil gallery plugs installed in the engine block. A system oil pressure sensor allows oil pressure to be monitored with a diagnostic scan tool. The oil pressure and oil temperature sensors are located on the oil filter housing assembly which is mounted to the top of the engine block between the cylinder heads. The oil cooler is mounted to the oil filter housing. There is a pressure relief valve in the oil pump that is only activated on a cold start or for emergency relief since the oil pump output is self-regulating. There are three piston oil cooler jets mounted to the engine block. Each jet cools two pistons.

Scheme 379

The oil from the oil pan is pumped by a vane type oil pump mounted to the bottom of the cylinder block that is chain driven by the crankshaft sprocket. The oil from the pump travels to the oil filter element and then to the oil cooler assembly. After the oil has been filtered and cooled, the oil enters the main oil gallery. The pressurized oil travels through the main gallery to the four main journals to lubricate the crankshaft main bearings. The pressurized oil travels through the crankshaft main journals to cross-drilling supplying oil to the connecting rod journals. From the number one main bearing gallery, oil travels to the right secondary chain tensioner and to the primary chain idler shaft. The main oil gallery also supplies oil to three sets of piston oil cooling jets. From the cylinder block the oil flows through drillings into the left and right cylinder heads. Left cylinder head oil is supplied to the left secondary timing chain tensioner, camshaft journals and hydraulic lash adjusters. Right cylinder hear oil is supplied to the right camshaft journals and hydraulic lash adjusters. The camshaft valve lobes and rocker arms are lubricated through a small hole in the rocker arm; oil flows through the lash adjuster then through the rocker arm and onto the camshaft lobe. Oil also flows through each of the four forward camshaft bearings into the camshafts and phasers.

ENGINE LUBRICATION FLOW CHART

The oil filter housing is located in the V of the cylinder block. The oil filter element is located within the housing and the engine oil cooler is attached to the top of the housing. Both the oil pressure and oil temperature sensors are located at the rear of the housing.

OPERATION

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 and then cooled it travels to the main oil gallery (5). An oil filter by-pass is built into the housing and is not serviceable. Removing the oil filter cap from the housing allows oil to drain from the oil filter cavity into to the crankcase (2).

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 380

Scheme 381

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. Disconnect the oil temperature sensor electrical connector (5).
6. Disconnect the oil pressure sensor electrical connector (4).
7. Remove five bolts (2) and remove the oil filter housing (1).
8. Lift the oil filter housing (1) and remove the heater hose (3).
9. Remove and discard the oil filter housing seals (2). The O-ring seal (1) can be reused.
10. If required, remove two screws (1) and (3) and remove the oil cooler (4) from the oil filter housing.
11. Remove and discard the oil cooler seals (1).
12. If required, remove the oil temperature sensor (1) from the oil filter housing (3).
13. If required, remove the oil pressure sensor (2) from the oil filter housing (3).

Scheme 382

1. If removed, install the oil pressure sensor (2) and tighten to 20 N.m (177 in. lbs.).
2. If removed, install the oil temperature sensor (1) and tighten to 20 N.m (177 in. lbs.). NOTE: Always use new dry seals (1) when installing the oil cooler. Do not lubricate the seals.
3. If removed, install the new oil cooler seals (1) onto the oil filter housing (2).
4. If removed, position the oil cooler (4) on the oil filter housing and install two screws (1) and (3). Tighten the screws to 4 N.m (35 in. lbs.). NOTE: Always use new dry seals (2) when installing the oil filter housing. Do not lubricate the seals. The O-ring seal (1) can be reused. Lubricate the O-ring seal with clean engine oil prior to installation.
5. Install new oil filter housing seals (2) onto the oil filter housing.
6. Install the heater hose (2) to the oil filter housing (1).
7. Position the oil filter housing (1) on the engine block.
8. Install five bolts and tighten in the sequence shown in illustration to 12 N.m (106 in. lbs.).
9. Connect the oil pressure sensor electrical connector (3).
10. Connect the oil temperature sensor electrical connector (4).
11. Install the upper and lower intake manifolds and air cleaner housing assembly. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
12. 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) .
13. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
14. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
15. Operate the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

Scheme 383

The 3.6 liter engine has three engine blocked-mounted oil jets (1) installed to cool the underside of each piston. The oil jets are fed by the main oil gallery, and spray upward on the bottom of the pistons and cylinder walls. Each set of jets has a check valve which closes below 2.5 bar (35 psi) to maintain ample oil pressure at idle. All three sets of oil jets are identical and seal to the engine block using an o-ring and fastener.

Scheme 384

Note. Piston oil cooler jet for cylinders one/two shown in illustration. Piston oil cooler jets for cylinders three/four and five/six are similar.

Scheme 385

1. Remove the crankshaft. Refer to «CRANKSHAFT, REMOVAL»(ref-485476-S06866850082012071300000) .
2. Remove the bolt (1) and the piston oil cooler jet(s) (2) from the engine block.
3. Remove and discard the O-ring seal (1) from the piston oil cooler jet(s).

The oil pressure sensor (2) is located on the oil filter housing (3). The oil pressure sensor is a three wire sensor with a tapered threaded sensor port. The sensor port is mounted to the oil filter housing through an access hole. A thread lock patch seals the oil pressure sensor to the oil filter housing.

Scheme 386

The oil pressure sensor is a silicon based sensing unit that measures the pressure of the engine oil. The Powertrain Control Module (PCM) supplies a 5 volt reference and a ground to the sensor. The input to the PCM occurs on the signal return circuit. The oil pressure sensor is a linear sensor; as pressure changes, voltage changes proportionately and returns a voltage signal to the PCM that reflects oil pressure. The zero pressure reading is 0.5 volt and full scale is 4.5 volt.

Scheme 387

1. Release fuel system pressure. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-485510-S12963059542012071300000) .
2. Disconnect and isolate the negative battery cable.
3. Remove the air inlet hose, upper intake manifold and lower intake manifold with the fuel injectors and fuel rail (2). Refer to «MANIFOLD, INTAKE, REMOVAL»(ref-485476-S08989499162012071300000) .
4. Disconnect the oil pressure sensor electrical connector (4).
5. Remove the oil pressure sensor (2) from the oil filter housing (3).

The oil temperature sensor (1) is located on the oil filter housing (3). The oil temperature sensor is a two wire sensor with a tapered threaded sensor probe. The sensor probe is mounted to the oil filter housing through an access hole. A thread lock patch seals the oil temperature sensor to the oil filter housing.

Scheme 388

The oil temperature sensor is a variable resistor that measures the temperature of the engine oil. The Powertrain Control Module (PCM) supplies a 5 volt reference and a ground to the sensors low reference signal circuit. When the oil temperature is low, the sensor resistance is high. When the oil temperature is high, the sensor resistance is low.

The 3.6L aluminum cylinder heads are a unique design with left and right castings. The exhaust manifolds are integrated into the cylinder heads. If any damaged is found to the exhaust manifold portion, the cylinder head must be removed for repair or replacement. Refer to CYLINDER HEAD, REMOVAL .

Scheme 389

The upper intake manifold is an injection molded nylon composite design. The upper intake manifold is sealed to the lower intake manifold using six individual press-in-place port silicone gaskets. Replace the gaskets whenever the upper intake manifold is removed from the engine. There is a silencer pad positioned between the upper and lower intake manifolds for improved noise, vibration and harshness (NVH). The left cylinder head cover has two alignment posts to aid proper installation of the silencer pad. The seven upper intake manifold fasteners thread directly into the composite lower intake manifold and are a self-taping design. If the upper intake manifold is damaged or cracked, it must be replaced.

The Electronic Throttle Control (ETC) and Manifold Air Pressure (MAP) sensor are attached directly to the upper intake manifold. The upper intake manifold also provides vacuum ports for brake booster, positive crankcase ventilation (PCV) and emissions control.

Scheme 390

The lower intake manifold is an injection molded nylon composite design. The lower intake manifold is sealed to the cylinder heads using six individual press-in-place port silicone gaskets. Replace the gaskets whenever the lower intake manifold is removed from the engine. The seven upper intake manifold fasteners thread directly into the composite lower intake manifold and are a self-taping design.

The fuel injection fuel rail is also a composite design. The four fuel rail fasteners thread directly into the composite lower intake manifold and are a self-taping design. The lower intake manifold can be serviced without removing the fuel injector rail. The fuel rail and fuel injectors must be installed into the lower intake manifold as an assembly. Do not attempt to install the fuel rail when the injectors are in the manifold. Always install new O-rings on the fuel injectors.

If the lower intake manifold is damaged or cracked, it must be replaced.