2.7L DOHC Engine - Service Information: Overview Dodge Charger V

Scheme 36

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. The engine does not have provisions for a free wheeling valve train.

Scheme 37

The cylinders are numbered from front to rear, with the right bank odd numbered, and the left bank even numbered. The firing order is 1-2-3-4-5-6.

Scheme 38

The engine identification number is located on the rear of the cylinder block just below the left cylinder head

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 (egg, engine idles rough and stalls).

Refer to ENGINE DIAGNOSIS - MECHANICAL and ENGINE DIAGNOSIS - PERFORMANCE , 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

1. Cylinder Compression Pressure Test
2. Cylinder Combustion Pressure Leakage Test
3. Cylinder Head Gasket Failure Diagnosis
4. Intake Manifold Leakage Diagnosis
5. Lash Adjuster (Tappet) Noise Diagnosis
6. Engine Oil Leak Inspection

DESCRIPTION

The assembled fabricated camshafts are composed of five bearing journals machined onto a hollow steel tube. The camshafts are secured in the cylinder head (6) by the camshaft bearing caps (1)&(2). 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 (7) and by a thrust flange on the exhaust camshafts (3). The intake camshafts are driven by the primary chain. The exhaust camshafts (3) are driven by the intake camshafts (10) through a secondary chain (11). The secondary chain tensioner (7) keeps tension on the secondary chain (11).

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.

Scheme 39

1. Remove the primary timing chain «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)»(ref-255938-S02301169722007060500000).
2. Remove secondary chain tensioner (6) 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 the order see scheme 97
4. Remove camshaft bearing caps (1).
5. Remove intake camshaft (7), exhaust camshaft (2), secondary timing chain (8), and secondary timing chain tensioner (6) together as an assembly.
6. Remove secondary timing chain tensioner (6) and secondary timing chain (8) from camshafts (2)&(7).
7. Inspect camshafts «(Refer to ENGINE/CYLINDER HEAD/CAMSHAFT(S) - INSPECTION»(ref-255938-S31789461202007060500000) ).

Scheme 40

1. Inspect camshaft bearing journals (2) for damage and binding. 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 (5) surfaces for abnormal wear and damage. Replace camshaft if defective. Measure the actual wear and replace, if out of limits-standard value is 0.0254 mm (0.001 in.); wear limit is 0.254 mm (0.010 in.).

Scheme 41

Scheme 42

Scheme 43

1. Assemble camshaft chain on the cams. Verify that plated links (1) are facing toward the front. Align the plated links (1) to the dots (4) on the camshaft sprockets.
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: Place tensioner (1) into a soft jaw vise. SLOWLY compress tensioner until fabricated lock pin (2) or the equivalent can be inserted into the locking holes. Remove compressed and locked tensioner from the vise.
4. Insert the compressed and locked camshaft chain tensioner (2) in between the camshafts and chain.
5. Rotate the cams so that the plated links (1) and dots (4) are facing the 12:00 o'clock position.
6. Install cams to cylinder head. Verify that rocker arms are correctly seated and in proper positions.
7. Install camshaft bearing caps. Verify that bearing caps are installed in same position as removed.
8. Tighten cam bearing cap bolts gradually in sequence (Scheme 43)to 12 N.m (105 in. lbs.).
9. Install secondary chain tensioner (2) bolts and tighten to 12 N.m (105 in. lbs.).
10. Remove locking pin (3) from secondary tensioners (2).
11. Measure camshafts end play (Refer to «STANDARD PROCEDURE - Cylinder Head Oil Gallery Cup Plug Service»(ref-255938-S40367779332007060500000) ).
12. Install the primary timing chain «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(ref-255938-S05586880332007060500000).

Scheme 44

Scheme 45

Scheme 46

1. Disconnect negative battery (1) cable located in trunk.
2. Remove upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(ref-255938-S39869547212007060500000) .
3. Disconnect electrical connectors from ignition coils (1).
4. Remove ground strap from cylinder head cover stud (1) and disconnect capacitor connector (2). Reposition electrical harness.
5. Disconnect electrical harness retaining clips from cylinder head cover studs. Reposition electrical harness.
6. Remove make up air hose.
7. Remove fastener attaching ignition coil capacitor.
8. Remove ignition coils (1).
9. Loosen all cylinder head cover fasteners (1)&(2). NOTE: Cylinder head cover attaching bolts are captured to the cover. CAUTION: Make certain the double ended studs (1) in the center of the cylinder head cover are loose before attempting to remove cover.
10. Remove cylinder head cover.

Scheme 47

Scheme 48

Scheme 49

1. Disconnect negative battery (1) cable.
2. Remove upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(ref-255938-S39869547212007060500000) .
3. Disconnect electrical connectors from ignition coils (1).
4. Disconnect capacitor electrical connector (2).
5. Remove PCV hose from cylinder head cover grommet.
6. Remove ground strap from cylinder head cover stud (1).
7. Disconnect electrical harness retaining clips from cylinder head cover studs. Reposition electrical harness.
8. Remove fastener attaching ignition coil capacitor.
9. Remove ignition coils.
10. Remove foam insulator (1).
11. Loosen all cylinder head cover fasteners. NOTE: Cylinder head cover attaching bolts are captured to the cover. CAUTION: Make certain the double ended studs in the center of the cylinder head cover are loose before attempting to remove cover.
12. Remove cylinder head cover.

Scheme 50

1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gaskets (1)&(2) as necessary.
2. Install cylinder head cover and hand start all fasteners. Verify that all double-ended studs are in the correct locations.
3. Tighten cylinder head cover attaching bolts and double-ended studs to 12 N.m (105 in. lbs.).
4. Install ignition coils (1).
5. Install ignition coil capacitor (2) and fastener.
6. Install ground strap (1) to cylinder head cover stud.
7. Connect all electrical connectors and harness clips.
8. Connect make up air hose.
9. Install upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION)»(ref-255938-S11951671622007060500000) .
10. Connect negative battery (1) cable.

The valves (5)&(6) are made of heat resistant steel, and have chrome plated stems to prevent scuffing. The four valves per cylinder (two intake (6) and two exhaust (5)) are actuated by roller rocker arms, which pivot on stationary lash adjusters. All valves use three bead lock keepers (1) to retain springs (3) and to promote valve rotation.

Scheme 51

The intake and exhaust valves have a 44.5 to 45 degree face angle (1). The valve seats (2) have a 45 to 45.5 degree face angle.

Scheme 52

Inspect the remaining margin (5) after the valves are refaced (Refer to ENGINE - SPECIFICATIONS) .

The valve springs (3) are made from high strength, chrome-silicon steel. The springs are common for intake and exhaust applications. The valve spring seat is integral with the valve stem seal (4), which incorporates a garter spring to maintain consistent lubrication control to the valve stem.

The crankshaft (7) 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. 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 is part of a housing that attaches to the cylinder block.

Scheme 53

1. Mount a dial indicator to a stationary point at front of engine. Locate the probe perpendicular against nose of crankshaft. (Scheme 53)
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. For crankshaft end play clearances «(Refer to ENGINE - SPECIFICATIONS)»(ref-255938-S07703709042007060500000).

Scheme 54

Scheme 55

1. Drain engine oil (5) and remove oil filter (3).
2. Remove engine from vehicle «(Refer to ENGINE - REMOVAL)»(ref-255938-S32767279582007060500000)
3. Mount engine on an engine stand.
4. Remove oil pan and oil pick-up tube «(Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)»(ref-255938-S29606497662007060500000) .
5. Remove idler pulley bracket for accessory drive belt.
6. Remove upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(ref-255938-S39869547212007060500000) .
7. Remove cylinder head covers «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL»(ref-255938-S28577895762007060500000) ).
8. Remove timing chain cover «(Refer to ENGINE/VALVE TIMING/TIMING CHAIN COVER - REMOVAL)»(ref-255938-S34893933152007060500000) .
9. Remove primary timing chain «(Refer to ENGINE/VALVE TIMING/TIMING CHAIN AND SPROCKETS - REMOVAL)»(ref-255938-S02301169722007060500000) .
10. Remove crankshaft sprocket «(Refer to ENGINE/VALVE TIMING/TIMING CHAIN AND SPROCKETS - REMOVAL)»(ref-255938-S02301169722007060500000) .
11. Remove oil pump «(Refer to ENGINE/LUBRICATION/OIL PUMP - REMOVAL)»(ref-255938-S23306156732007060500000) .
12. Remove crankshaft rear oil seal retainer «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT REAR OIL SEAL RETAINER - REMOVAL)»(ref-255938-S09282953602007060500000) .
13. Remove windage tray (1) «(Refer to ENGINE/ENGINE BLOCK/WINDAGE TRAY / STRUCT SUPPORT - REMOVAL)»(ref-255938-S41616818002007060500000) .
14. Turn crankshaft until connecting rod cap to be removed is accessible. 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 (1)&(2).
18. Remove main bearing caps (2). CAUTION: When removing crankshaft, use care not to damage bearing surfaces on the crankshaft.
19. Remove crankshaft (7) from cylinder block (6).

Scheme 56

Note. Upper and lower bearing halves are NOT interchangeable.

Scheme 57

Scheme 58

1. Install the main bearing in the block and main caps making sure the tangs engage the slots in the block and main caps.
2. Lubricate upper main bearing halves with engine oil. CAUTION: When installing crankshaft, use care not to damage bearing surfaces on the crankshaft.
3. Install crankshaft. NOTE: Make sure that the coated and oil groove side of crankshaft thrust washer faces the crankshaft thrust surface.
4. Push crankshaft forward. Lubricate and install the front thrust washer (1) by rolling the thrust washer onto the machined shelf between the No. 3 upper main bulk head and crankshaft thrust surface.
5. 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.
6. Lubricate lower main bearings with engine oil.
7. Install main bearings caps. NOTE: Lubricate main bearing cap bolts with engine oil before installation. NOTE: 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.
8. Install the inner main bearing cap bolts and tighten to 20 N.m + 1/4 Turn (15 ft. lbs. + 1/4 Turn).
9. Measure crankshaft end play «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT - STANDARD PROCEDURE)»(ref-255938-S15923509702007060500000) .
10. Install connecting rods and measure side clearance «(Refer to ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD - INSTALLATION)»(ref-255938-S23318310952007060500000) «(Refer to ENGINE/ENGINE BLOCK/CONNECTING ROD BEARINGS - STANDARD PROCEDURE)»(ref-255938-S06290113382007060500000) .
11. Install windage tray (1) with the slots to right side of engine. Lubricate bolts (3) with engine oil and tighten to 27 N.m + 1/4 Turn (20 ft. lbs. + 1/4 turn).
12. Install the main cap tie (horizontal) bolts (1&2) and tighten to 28 N.m (250 in. lbs.).
13. Install rear crankshaft oil seal retainer and oil seal assembly «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT REAR OIL SEAL RETAINER - INSTALLATION)»(ref-255938-S20592330082007060500000) .
14. Install oil pump assembly (5) «(Refer to ENGINE/LUBRICATION/OIL PUMP - INSTALLATION)»(ref-255938-S40811614462007060500000) .
15. Install oil pick-up tube (3) and O-ring (2). Tighten bolts (4) to 28 N.m (250 in.lbs.).
16. Install oil pan gasket, oil pan, and oil filter «(Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)»(ref-255938-S37307360612007060500000) .
17. Install crankshaft sprocket «(Refer to ENGINE/VALVE TIMING/TIMING CHAIN AND SPROCKETS - INSTALLATION)»(ref-255938-S05586880332007060500000) .
18. Install timing chain «(Refer to ENGINE/VALVE TIMING/TIMING CHAIN AND SPROCKETS - INSTALLATION)»(ref-255938-S05586880332007060500000) .
19. Install timing chain cover «(Refer to ENGINE/VALVE TIMING/TIMING CHAIN COVER - INSTALLATION)»(ref-255938-S08541723342007060500000) .
20. Install cylinder head covers «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION»(ref-255938-S38867256082007060500000) ).
21. Install oil dipstick tube.
22. Install engine assembly «(Refer to ENGINE - INSTALLATION)»(ref-255938-S02141865692007060500000) .
23. Fill engine crankcase with proper oil to correct level «(Refer to ENGINE/LUBRICATION/OIL - STANDARD PROCEDURE)»(ref-255938-S14831506762007060500000) .
24. Fill with coolant «(Refer to COOLING - STANDARD PROCEDURE)»(ref-255951-S06865140152007060500000) .
25. Start engine and check for leaks.

Scheme 59

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. These marks are read left to right, corresponding to main bore 1, 2, 3, 4.

Scheme 60

The grade marks for the crankshaft are located on the rearmost crankshaft counter weight (Scheme 60) The crankshaft journal grade marks are read left to right, corresponding with journal number 1, 2, 3, 4.

MAIN BEARING SELECTION CHART - 2.7L

Refer to MAIN BEARING SELECTION CHART - 2.7L 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.). Each bearing grade increment of 0.003 mm is for wall thickness so diametrical clearances are adjusted 0.006 m per select fit class.

Scheme 61

Note. Service main bearings have a number from 1-5 marked in ink on the bearing surface. For verification, use MAIN BEARING SELECTION CHART - 2.7L for number to size identification.

The upper main bearing (2) has a oil feed hole and a center groove (3) 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.

Scheme 62

1. Remove crankshaft vibration damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL)»(ref-255938-S04822974262007060500000) .
2. Install Special Tool 8194 (1), Insert into crankshaft nose. Remove seal using Special Tool 6771, Remover.

Scheme 63

1. Install new seal (4) using Special Tools 6780-2 Sleeve (1), 6780-1 Installer (3), and 8179 Stud (2).
2. Install crankshaft vibration damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION)»(ref-255938-S39330170832007060500000) .

Scheme 64

The crankshaft rear oil seal is incorporated in the seal adapter (2) and can not be removed from the adapter. The crankshaft rear oil seal/seal adapter (2) are serviced as an assembly.

Scheme 65

1. Disconnect negative battery (1) cable.
2. Raise vehicle.
3. Remove splash shield retaining bolts (1) and splash shield (2).
4. Remove the structural collar «(Refer to ENGINE/ENGINE BLOCK/STRUCTURAL COVER - REMOVAL)»(ref-255938-S19427294102007060500000) .
5. Remove transmission (Refer to «REMOVAL»(ref-256190-S24802159432007061100000) ).
6. Remove flex plate attaching bolts (2), backing plate (3), and flex plate (1).
7. Remove oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)»(ref-255938-S29606497662007060500000) . NOTE: The integrated stamped steel rear crankshaft seal is not interchangable with the cast aluminum rear seal adapter and seal assembly.
8. Remove seal retainer attaching screws.
9. Remove crankshaft rear oil seal/adapter (2).

Scheme 66

Note. The integrated rear crankshaft seal (2) is not interchangeable with the cast aluminum rear seal adapter and seal assembly.

Note. Inspect the crankshaft to make sure no nicks or burrs are on the seal surface.

Scheme 67

Scheme 68

Scheme 69

1. Clean sealing surfaces thoroughly.
2. Apply engine oil to the seal lip inside diameter. NOTE: The seal lip (2) on the retainer must always uniformly curl inward toward the engine on the crankshaft (1).
3. Position the special tool 6926 (1) onto the crankshaft and gently slide the seal (2) over the crankshaft.
4. Install seal retaining bolts finger tight. NOTE: The following steps must be performed to prevent oil leaks at sealing joints.
5. Attach Special Tools 8225 (1) 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). NOTE: Make sure that the seal flange is flush with the block oil pan sealing surface.
6. While applying firm pressure to the seal assembly (2) against Special Tools 8225 (1), tighten seal assembly screws to 12 N.m (105 in. lbs.).
7. Remove special tool 8225.
8. Install oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)»(ref-255938-S37307360612007060500000) .
9. Install flex plate (1), backing plate (3), and attaching bolts (2) «(Refer to ENGINE/ENGINE BLOCK/FLEX PLATE - INSTALLATION)»(ref-255938-S38687360342007060500000) .
10. Install transmission (Refer to «INSTALLATION»(ref-256190-S17300908442007061100000) ).
11. Install lower splash shield retaining bolts (1) and splash shield (2).
12. Lower vehicle.
13. Fill with oil (5).
14. Connect negative battery (1) cable.
15. Start engine and check for leaks.

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 windage tray is used to increase power by minimizing oil windage at high engine RPM. An engine oil cooler is used on some models.

Scheme 70

Oil from the oil pan is pumped by a gerotor type oil pump (3) directly coupled to the crankshaft. Oil pressure is controlled by a relief valve mounted inside the oil pump housing. (Scheme 70), (Scheme 71) or (Scheme 72) for engine oil lubrication circuits.

Scheme 71

Scheme 72

For engine oil type and capacity (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION - ENGINE OIL)

Engine oil travels from the oil cooler (4) and into the oil filter (3). Engine oil then exits the filter into the main gallery. Engine coolant flows from the upper radiator hose to and from the cooler through hoses (2) and back to the upper radiator hose.

The engine oil pressure switch (1) is located on the right side of the engine block. The switch screws into the engine main oil gallery. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster.