Service Information - 3.7L Engine: Diagnosis Dodge Dakota III

ENGINE DIAGNOSIS - PERFORMANCE

ENGINE DIAGNOSIS - MECHANICAL

ENGINE DIAGNOSIS - LUBRICATION

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 . 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.

CHEMICAL TEST METHOD

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

DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER

A tappet-like noise may be produced from several items. Check the following items.

1. Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy.
2. Insufficient running time after rebuilding cylinder head. Low speed running up to 1 hour may be required.
3. Turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature.
4. Low oil pressure.
5. The oil restrictor in cylinder head gasket or the oil passage to the cylinder head is plugged with debris.
6. Air ingested into oil due to broken or cracked oil pump pick up.
7. Worn valve guides.
8. Rocker arm ears contacting valve spring retainer.
9. Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system.
10. Oil leak or excessive cam bore wear in cylinder head.
11. Faulty lash adjuster. Check lash adjusters for sponginess while installed in cylinder head and cam on camshaft at base circle. Depress part of rocker arm over adjuster. Normal adjusters should feel firm when pressed quickly. When pressed very slowly, lash adjusters should collapse. Remove suspected lash adjusters, and replace. Before installation, make sure adjusters are full of oil. This can be verified by little plunger travel when lash adjuster is depressed quickly.

Scheme 47

Scheme 48

Scheme 49

Scheme 50

1. Disconnect the negative cable from the battery.
2. Raise the vehicle on a hoist.
3. Disconnect the exhaust pipe at the left side exhaust manifold.
4. Drain the engine coolant «(Refer to COOLING - STANDARD PROCEDURE)»(ref-247624-S05505992522007020100000) .
5. Lower the vehicle.
6. Remove the intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(ref-247616-S36741527942007020100000) .
7. Remove the master cylinder and booster assembly «(Refer to BRAKES/HYDRAULIC/MECHANICAL/POWER BRAKE BOOSTER - REMOVAL)»(ref-247605-S25060782312007020100000) .
8. Remove the cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL)»(ref-247616-S02086164582007020100000) .
9. Remove the fan shroud and fan blade assembly «(Refer to COOLING/ENGINE/RADIATOR FAN - REMOVAL)»(ref-247624-S28211438172007020100000) .
10. Remove accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)»(ref-247624-S17004004882007020100000) .
11. Remove the power steering pump and set aside.
12. Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark (2).
13. Verify the V6 mark (1) on the camshaft sprocket is at the 12 o'clock position, with the No. 1 cylinder at TDC on the exhaust stroke. Rotate the crankshaft one turn if necessary.
14. Remove the crankshaft damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL)»(ref-247616-S25337929552007020100000) .
15. Remove the timing chain cover «(Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL)»(ref-247616-S29943246272007020100000) .
16. Lock the secondary timing chains (2) to the idler sprocket using Special Tool 8429 Timing Chain Holding Fixture (1). NOTE: Mark the secondary timing chain prior to removal to aid in installation.
17. Mark the secondary timing chain (2), one link on each side of the V6 mark on the camshaft drive gear.
18. Remove the left side secondary chain tensioner «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)»(ref-247616-S34754275192007020100000) .
19. Remove the cylinder head access plug (1) and (2).
20. Remove the left side secondary chain guide «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)»(ref-247616-S34754275192007020100000) .
21. Remove the retaining bolt and the camshaft drive gear. CAUTION: Do not allow the engine to rotate. Severe damage to the valve train can occur. CAUTION: Do not overlook the four smaller bolts at the front of the cylinder head. Do not attempt to remove the cylinder head without removing these four bolts. NOTE: The cylinder head is attached to the cylinder block with twelve bolts.
22. Remove the cylinder head retaining bolts.
23. Remove the cylinder head and gasket. Discard the gasket.

INSPECTION

1. Inspect the cylinder head for out-of-flatness, using a straightedge and a feeler gauge. If tolerances exceed 0.0508 mm (0.002 in.) replace the cylinder head.
2. Inspect the valve seats for damage. Service the valve seats as necessary.
3. Inspect the valve guides for wear, cracks or looseness. If either condition exist, replace the cylinder head.

Scheme 51

Note. The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced.

Necking can be checked by holding a straight edge against the threads (2). If all the threads do not contact the scale, the bolt should be replaced.

Scheme 52

Scheme 53

1. Clean the cylinder head and cylinder block mating surfaces. * - INDICATES SEALANT ON THREADS
2. Position the new cylinder head gasket on the locating dowels. CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm.
3. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels. NOTE: The four smaller cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks. The locations are identified wit *.
4. Lubricate the cylinder head bolt threads with clean engine oil and install the eight M11 bolts.
5. Coat the four M8 cylinder head bolts with Mopar(R) Lock and Seal Adhesive then install the bolts. NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.
6. Tighten the bolts in sequence using the following steps and torque values: Step 1: Tighten bolts 1-8, 27 N.m (20 ft. lbs.). Step 2: Verify that bolts 1-8, all reached 27 N.m (20 ft. lbs.), by repeating step 1 without loosening the bolts. Tighten bolts 9 thru 12 to 14 N.m (10 ft. lbs.). Step 3: Tighten bolts 1-8, 90 degrees. Step 4: Tighten bolts 1-8, 90 degrees, again. Tighten bolts 9-12, 26 N.m (19 ft. lbs.)
7. Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V6 mark on the gear then using Special Tool 8428 Camshaft Wrench, position the gear onto the camshaft. CAUTION: Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt. Failure to do so may cause over-torquing of bolt resulting in bolt failure.
8. Install the camshaft drive gear retaining bolt.
9. Install the left side secondary chain guide «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(ref-247616-S02926903782007020100000) .
10. Install the cylinder head access plug.
11. Reset and install the left side secondary chain tensioner «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(ref-247616-S02926903782007020100000) .
12. Remove Special Tool 8429.
13. Install the timing chain cover «(Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION)»(ref-247616-S34702611892007020100000) .
14. Install the crankshaft damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION)»(ref-247616-S34369034152007020100000) . Tighten damper bolt 175 N.m (130 Ft. Lbs.).
15. Install the power steering pump.
16. Install the fan blade assembly and fan shroud «(Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION)»(ref-247624-S29957863532007020100000) .
17. Install the cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION)»(ref-247616-S39926205412007020100000) .
18. Install the master cylinder and booster assembly «(Refer to BRAKES/HYDRAULIC/MECHANICAL/POWER BRAKE BOOSTER - INSTALLATION)»(ref-247605-S21517018852007020100000) .
19. Install the intake manifold. Refer to «INSTALLATION»(ref-247616-S36556345412007020100000) .
20. Refill the cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-247624-S05505992522007020100000) .
21. Raise the vehicle.
22. Install the exhaust pipe onto the left exhaust manifold. Refer to «EXHAUST SYSTEM»(ref-247646) .
23. Lower the vehicle.
24. Connect the negative cable to the battery.
25. Start the engine and check for leaks.

Scheme 54

Note. The cylinder head bolts (4) are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced.

Necking can be checked by holding a straight edge against the threads (2). If all the threads do not contact the scale, the bolt should be replaced.

Scheme 55

Scheme 56

1. Clean the cylinder head and cylinder block mating surfaces. * - INDICATES SEALANT ON THREADS
2. Position the new cylinder head gasket on the locating dowels. CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm.
3. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels. NOTE: The four M8 cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.
4. Lubricate the cylinder head bolt threads with clean engine oil and install the eight M10 bolts.
5. Coat the four M8 cylinder head bolts with Mopar Lock and Seal Adhesive then install the bolts. NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.
6. Tighten the bolts in sequence using the following steps and torque values: Step 1: Tighten bolts 1-8, 27 N.m (20 ft. lbs.). Step 2: Verify that bolts 1-8, all reached 27 N.m (20 ft. lbs.), by repeating step 1 without loosening the bolts. Tighten bolts 9 thru 12 to 14 N.m (10 ft. lbs.). Step 3: Tighten bolts 1-8, 90 degrees. Step 4: Tighten bolts 1-8, 90 degrees, again. Tighten bolts 9-12, 26 N.m (19 ft. lbs.) CAUTION: The nut on the right side camshaft sprocket should not be removed for any reason, as the sprocket and camshaft sensor target wheel is serviced as an assembly. If the nut was removed retorque nut to 5 N.m ( 60 in. lbs.).
7. Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V6 mark on the gear then using Tool 8428 Camshaft Wrench, position the gear onto the camshaft. CAUTION: Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt. Failure to do so may cause over-torquing of bolt resulting in bolt failure.
8. Install the camshaft drive gear retaining bolt.
9. Install the right side secondary chain guide «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(ref-247616-S02926903782007020100000) .
10. Install the cylinder head access plug.
11. Reset and install the right side secondary chain tensioner «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(ref-247616-S02926903782007020100000) .
12. Remove Special Tool 8429.
13. Install the timing chain cover «(Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION)»(ref-247616-S34702611892007020100000) .
14. Install the crankshaft damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION)»(ref-247616-S34369034152007020100000) . Tighten damper bolt 175 N.m (130 Ft. Lbs.).
15. Install accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)»(ref-247624-S16163766032007020100000) .
16. Install the radiator fan and shroud «(Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION)»(ref-247624-S29957863532007020100000) .
17. Install the cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION)»(ref-247616-S39926205412007020100000) .
18. Install the intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION)»(ref-247616-S36556345412007020100000) .
19. Install oil fill housing onto cylinder head.
20. Refill the cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-247624-S05505992522007020100000) .
21. Raise the vehicle.
22. Install the exhaust pipe onto the right exhaust manifold.
23. Lower the vehicle.
24. Reconnect battery negative cable.
25. Start the engine and check for leaks.

Note. Thoroughly inspect the connecting rod bearing bores and main bearing bores for scoring, blueing or severe scratches. Further disassembly may be required.

If connecting rod bearing bores show damage, the cylinder heads must be removed to service the piston and rod assemblies. If the bedplate or the cylinder block main bearing bores show damage the engine must be replaced.

1. If required, remove the main bearing halves from the cylinder block and bedplate.
2. Thoroughly clean the bedplate to cylinder block sealing surfaces and main bearing bores. Remove all oil and sealant residue.
3. Inspect the bedplate main bearing bores for cracks, scoring or severe blueing. If either condition exists the engine must be replaced.
4. Inspect the crankshaft thrust washers for scoring, scratches, wear or blueing. If either condition exist replace the thrust washers.
5. Inspect the oil pan gasket/windage tray for splits, tears or cracks in the gasket sealing surfaces. Replace gasket as necessary.

Scheme 57

Note. Apply sealant to the tone wheel retaining screws prior to installation.

Scheme 58

Scheme 59

1. Lubricate upper main bearing halves with clean engine oil.
2. Install the crankshaft tone wheel. Torque the mounting screws to 15 N.m (11 ft. lbs.).
3. Position crankshaft in cylinder block.
4. Install the thrust washers (1). 1 - CYLINDER BLOCK 2 - SEALANT 3 - SEALANT CAUTION: The bedplate to cylinder block mating surface must be coated with Mopar(R) Engine RTV sealant prior to installation. Failure to do so will cause severe oil leaks. NOTE: Make sure that the bedplate and cylinder block sealing surfaces are clean and free of oil or other contaminants. Contaminants on the sealing surfaces may cause main bearing distortion and/or oil leaks.
5. Apply a 2.5 mm (0.100 inch) bead of Mopar(R) Engine RTV sealant to the cylinder block-to-bedplate mating surface (1) and (2).
6. Coat the crankshaft main bearing journals with clean engine oil and position the bedplate onto the cylinder block. NOTE: Lubricate the bedplate retaining bolts with clean engine oil prior to installation.
7. Install the bedplate retaining bolts, making sure to place the stud bolts in the correct location, Torque the bolts in the sequence shown in illustration. Hand tighten bolts 1D, 1G and 1F until the bedplate contacts the block. Tighten bolts 1A - 1J to 54 N.m (40 ft. lbs.) Tighten bolts 1 - 8 to 7 N.m (5 ft. lbs.) Turn bolts 1 - 8 an additional 90°. Tighten bolts A - E 27 N.m ( 20 ft. lbs.).
8. Measure crankshaft end play.
9. Install the connecting rods and measure side clearance «(Refer to ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD - STANDARD PROCEDURE)»(ref-247616-S06066846262007020100000) .
10. Install oil pump «(Refer to ENGINE/LUBRICATION/OIL PUMP - INSTALLATION)»(ref-247616-S00797099582007020100000) .
11. Install the engine «(Refer to ENGINE - INSTALLATION)»(ref-247616-S26272560242007020100000) .

Scheme 60

The main bearings are "select fit" to achieve proper oil clearances. For main bearing selection, the crankshaft position sensor target wheel (2) has grade identification marks (3) stamped into it. These marks are read from left to right, corresponding with journal number 1, 2, 3, 4. The crankshaft position sensor target wheel (2) is mounted to the number 6 counter weight (1) on the crankshaft.

Wipe the inserts clean and inspect for abnormal wear patterns and for metal or other foreign material imbedded in the lining. Normal main bearing insert wear patterns are illustrated.

Inspect the back of the inserts for fractures, scrapings or irregular wear patterns.

Inspect the upper insert locking tabs for damage.

Replace all damaged or worn bearing inserts.

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 the battery.
2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak: Circular spray pattern generally indicates seal leakage or crankshaft damage. Where leakage tends to run straight down, possible causes are a porous block, distributor seal, camshaft bore cup plugs, oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. See Engine, for proper repair procedures of these items.
4. If no leaks are detected, pressurized the crankcase as outlined in «AIR LEAK DETECTION TEST METHOD»(ref-247616-S28855385912007020100000) . CAUTION: Do not exceed 20.6 kPa (3 psi).
5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks or scratches. The crankshaft seal flange is specially machined to complement the function of the rear oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. «(Refer to ENGINE - DIAGNOSIS AND TESTING)»(ref-247616-S40205957772007020100000) , under the Oil Leak row, for components inspections on possible causes and corrections.
7. After the oil leak root cause and appropriate corrective action have been identified, «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - REMOVAL)»(ref-247616-S21401309902007020100000) .

Scheme 61

Note. This procedure can be performed in vehicle.

1. If being preformed in vehicle, remove the transmission.
2. Remove the flexplate «(Refer to ENGINE/ENGINE BLOCK/FLEX PLATE - REMOVAL)»(ref-247616-S23633382812007020100000) . NOTE: The crankshaft oil seal (1) CAN NOT be reused after removal. NOTE: The crankshaft rear oil seal remover Special Tool 8506 (2) must be installed deeply into the seal. Continue to tighten the removal tool into the seal until the tool can not be turned farther. Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine.
3. Using Special Tool 8506 (2) , remove the crankshaft rear oil seal (1).

Scheme 62

Scheme 63

1. Lubricate the crankshaft flange with engine oil.
2. Position the magnetic seal guide Special Tool 8349-2 (2) onto the crankshaft rear face. Then position the crankshaft rear oil seal (1) onto the guide.
3. Using Special Tools 8349 Crankshaft Rear Oil Seal Installer (2) and C-4171 Driver Handle (3), with a hammer, tap the seal (1) into place. Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore.
4. Install the flexplate «(Refer to ENGINE/ENGINE BLOCK/FLEX PLATE - INSTALLATION)»(ref-247616-S32891533922007020100000) .
5. Install the transmission.

Scheme 64

1. Remove the transmission. «(Refer to TRANSMISSION/TRANSAXLE/AUTOMATIC - 42RLE - REMOVAL)»(ref-247625-S26650588632007020100000) .
2. Remove the bolts using the sequence provided.
3. Remove the flexplate.

Check the connecting rod journal for excessive wear, taper and scoring (Refer to ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD - STANDARD PROCEDURE) .

Check the connecting rod for signs of twist or bending.

Check the piston for taper and elliptical shape before it is fitted into the cylinder bore (Refer to ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD - STANDARD PROCEDURE) .

Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration.

Scheme 65

Scheme 66

1. Before installing piston and connecting rod assemblies into the bore, install the piston rings.
2. Immerse the piston head and rings in clean engine oil. Position a ring compressor (3) over the piston and rings. Tighten ring compressor (3). Ensure position of rings do not change during this operation.
3. Position bearing onto connecting rod. Ensure that hole in bearing shell aligns with hole in connecting rod. Lubricate bearing surface with clean engine oil.
4. Install Special Tool 8507 Connecting Rod Guides (4) into connecting rod bolt threads.
5. The pistons are marked on the piston pin bore surface with an raised "F" (1) indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks. The connecting rod oil slinger slot faces the front of the engine.
6. Wipe cylinder bore clean and lubricate with engine oil.
7. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal.
8. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal. CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed.
9. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 27 N.m (20 ft. lbs.) plus 90°.
10. Install the following components: Cylinder head(s) «(Refer to ENGINE/CYLINDER HEAD - INSTALLATION)»(ref-247616-S11410195822007020100000) . Timing chain and cover «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(ref-247616-S02926903782007020100000) . Cylinder head covers «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION)»(ref-247616-S39926205412007020100000) . Oil pan and gasket/windage tray. «(Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)»(ref-247616-S41581751952007020100000) .
11. Fill crankcase with proper engine oil to correct level.
12. Connect negative cable to battery.

Scheme 67

Before reinstalling used rings or installing new rings, the ring clearances must be checked.

Scheme 68

Scheme 69

Scheme 70

Scheme 71

1. Wipe the cylinder bore clean.
2. Insert the ring in the cylinder bore. NOTE: The ring gap measurement must be made with the ring positioned at least 12 mm (0.50 inch.) from bottom of cylinder bore.
3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder.
4. Using a feeler gauge (1), check the ring end gap. Replace any rings not within specification. PISTON RING SIDE CLEARANCE NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs. PISTON RING SPECIFICATION CHART Ring Position Groove Clearance Maximum Clearance Upper Ring .051-.094 mm 0.11 mm (0.0020-.0037 in.) (0.004 in.) Intermediate Ring 0.04-0.08 mm 0.10 mm (0.0016-0.0031 in.) (0.004 in.) Oil Control Ring .019-.229 mm .25 mm (Steel Rails) (.0007-.0090 in.) (0.010 in.) Ring Position Ring Gap Wear Limit Upper Ring 0.20-0.36 mm 0.43 mm - (0.0079-0.0142 in.) (0.0017 in.) Intermediate Ring 0.37-0.63 mm 0.74 mm - (0.0146-0.0249 in.) (0.029 in.) Oil Control Ring 0.025-0.76 mm 1.55 mm (Steel Rail) (0.0099- 0.03 in.) (0.061 in.)
5. Measure the ring side clearance as shown in illustration, making sure the feeler gauge (1) fits snugly between the ring land and the ring. Replace any ring not within specification.
6. Rotate the ring around the piston, the ring must rotate in the groove with out binding.
7. The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston. NOTE: Piston rings are installed in the following order: Oil ring expander. Upper oil ring side rail (1). Lower oil ring side rail. No. 2 Intermediate piston ring. No. 1 Upper piston ring.
8. Install the oil ring expander.
9. Install upper side rail by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail.
10. Install No. 2 intermediate piston ring using a piston ring installer.
11. Install No. 1 upper piston ring using a piston ring installer.
12. Position piston ring end gaps as shown in illustration. It is important that expander ring gap is at least 45° from the side rail gaps, but not on the piston pin center or on the thrust direction.

Scheme 72

1. Disconnect negative cable from battery.
2. Remove radiator fan «(Refer to COOLING/ENGINE/RADIATOR FAN - REMOVAL)»(ref-247624-S28211438172007020100000) .
3. Remove accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)»(ref-247624-S17004004882007020100000) .
4. Remove crankshaft damper bolt.
5. Remove damper using Special Tools 8513 Insert (1) and 1026 Three Jaw Puller (2).

Scheme 73

Scheme 74

1. Align crankshaft damper slot with key in crankshaft. Slide damper onto crankshaft slightly. CAUTION: Special Tool 8512-A, is assembled in a specific sequence. Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft.
2. Assemble Special Tool 8512-A as follows, The nut (2) is threaded onto the threaded rod (3) first. Then the roller bearing (1) is placed onto the threaded rod (The hardened bearing surface of the bearing MUST face the nut (4) ). Then the hardened washer (5) slides onto the threaded rod. Once assembled coat the threaded rod's threads with Mopar(R) Nickel Anti-Seize or equivalent.
3. Using Special Tool 8512-A, press damper onto crankshaft.
4. Install then tighten crankshaft damper bolt to 175 N.m (130 ft. lbs.).
5. Install radiator fan «(Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION)»(ref-247624-S29957863532007020100000) .
6. Install accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)»(ref-247624-S16163766032007020100000)
7. Connect negative cable to battery.

Air Leak Detection Test Method

1. Disconnect the breather cap to air cleaner hose at the breather cap end. Cap or plug breather cap nipple.
2. Remove the PCV valve from the cylinder head cover. Cap or plug the PCV valve grommet.
3. Attach an air hose with pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.
4. Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable test pressure that provide the best bubbles 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, refer to «INSPECTION FOR REAR SEAL AREA LEAKS»(ref-247616-S39420510792007020100000) .
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 breather cap hose.
7. Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.

INSPECTION FOR REAR SEAL AREA LEAKS

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

If the leakage occurs at the crankshaft rear oil seal area

1. Disconnect the battery.
2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak: Circular spray pattern generally indicates seal leakage or crankshaft damage. Where leakage tends to run straight down, possible causes are a porous block, distributor seal, camshaft bore cup plugs oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces.
4. If no leaks are detected, pressurize the crankcase as outlined in the «AIR LEAK DETECTION TEST METHOD»(ref-247616-S28855385912007020100000) . CAUTION: Do not exceed 20.6 kPa (3 psi).
5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled.

Scheme 75

1. Remove oil pressure sending unit (2) and install gauge assembly C-3292.
2. Run engine until thermostat opens.
3. Oil Pressure: Curb Idle - 25 kPa (4 psi) minimum 3000 RPM - 170 - 758 kPa (25 - 110 psi)
4. If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck open.

1. Inspect oil drain plug and plug hole for stripped or damaged threads. Repair as necessary.
2. Inspect the oil pan mounting flange for bends or distortion. Straighten flange, if necessary.

Scheme 76

Scheme 77

Scheme 78

1. Clean the oil pan gasket mating surface of the bedplate and oil pan.
2. Position the oil pan gasket and pickup tube with new O-ring. Install the mounting bolt and nuts. Tighten bolt and nuts to 28 N.m (20 ft. lbs.).
3. Position the oil pan and install the mounting bolts. Tighten the mounting bolts to 15 N.m (11 ft. lbs.) in the sequence shown in illustration.
4. Lower the engine into mounts using special tool (1) # 8534.
5. Install both the left and right side engine mount through bolts. Tighten the bolts to 68 N.m (50 ft. lbs.).
6. Remove special tool # 8534.
7. Install structural dust cover. NOTE: On 4WD vehicles, the front axle must be lowered, to provide clearance for oil pan removal. It is not necessary to remove the front axle from the vehicle, or remove the axle shafts.
8. For 4WD Vehicles Raise axle using suitable jack.
9. For 4WD Vehicles Install the front axle mounting bolts.
10. For 4WD Vehicles Install the pinion bracket.
11. For 4WD Vehicles Install the front driveshaft to the front axle.
12. Fill engine oil.
13. Reconnect the negative battery cable.
14. Start engine and check for leaks.

CRANKCASE OIL LEVEL INSPECTION

Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about five minutes before checking oil level. Checking engine oil level on a cold engine is not accurate.

To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick.

1. Position vehicle on level surface.
2. With engine OFF, allow approximately ten minutes for oil to settle to bottom of crankcase, remove engine oil dipstick.
3. Wipe dipstick clean.
4. Install dipstick and verify it is seated in the tube.
5. Remove dipstick, with handle held above the tip, take oil level reading.
6. Add oil only if level is below the ADD mark on dipstick.

Inspect the following 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. Idler sprocket assembly spline joint. The joint should be tight with no backlash or axial movement.
4. Chain guides and tensioner arms. Replace these parts if grooving in plastic face is more than 1 mm (0.039 in.) deep. If plastic face is severely grooved or melted, the tensioner lube jet may be clogged. The tensioner should be replaced.
5. 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.
6. Primary chain tensioner plastic faces. Replace as required.

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

1. Using a vise, lightly compress the secondary chain tensioner piston until the piston step (5) is flush with the tensioner body. Using a pin or suitable tool, release ratchet pawl (4) by pulling pawl back against spring force through access hole on side of tensioner. While continuing to hold pawl back, Push ratchet device to approximately 2 mm from the tensioner body. Install Special Tool 8514 lock pin (2) into hole on front of tensioner. Slowly open vise to transfer piston spring force to lock pin.
2. Position primary chain tensioner over oil pump and insert bolts into lower two holes on tensioner bracket. Tighten bolts to 28 N.m (250 in. lbs.).
3. Install right side chain tensioner arm. Install Torx(R) bolt. Tighten Torx(R) bolt to 28 N.m (250 in. lbs.). CAUTION: The silver bolts retain the guides to the cylinder heads and the black bolts retain the guides to the engine block.
4. Install the left side chain guide. Tighten the bolts to 28 N.m (250 in. lbs.).
5. Install left side chain tensioner arm, and Torx(R) bolt. Tighten Torx(R) bolt to 28 N.m (250 in. lbs.).
6. Install the right side chain guide. Tighten the bolts to 28 N.m (250 in. lbs.). 1 - SPECIAL TOOL 8429 2 - PRIMARY CHAIN IDLER SPROCKET 3 - CRANKSHAFT SPROCKET
7. Install both secondary chains onto the idler sprocket (2). Align two plated links on the secondary chains to be visible through the two lower openings on the idler sprocket (4 o'clock and 8 o'clock). Once the secondary timing chains are installed, position special tool 8429 ( 1) to hold chains in place for installation.
8. Align primary chain double plated links with the timing mark at 12 o'clock on the idler sprocket. Align the primary chain single plated link with the timing mark at 6 o'clock on the crankshaft sprocket.
9. Lubricate idler shaft and bushings with clean engine oil. NOTE: The idler sprocket must be timed to the counterbalance shaft drive gear before the idler sprocket is fully seated. 1 - COUNTERBALANCE SHAFT GEAR 2 - TIMING MARK 3 - IDLER SPROCKET GEAR
10. Install all chains, crankshaft sprocket, and idler sprocket as an assembly. (Scheme 80) After guiding both secondary chains through the block and cylinder head openings, affix chains with a elastic strap or equivalent. This will maintain tension on chains to aid in installation. Align the timing mark (2) on the idler sprocket gear (3) to the timing mark on the counterbalance shaft drive gear (1), then seat idler sprocket fully. (Scheme 81) Before installing idler sprocket bolt, lubricate washer with oil, and tighten idler sprocket assembly retaining bolt to 34 N.m (25 ft. lbs.). NOTE: It will be necessary to slightly rotate camshafts for sprocket installation.
11. Align left camshaft sprocket "L" dot to plated link on chain.
12. Align right camshaft sprocket "R" dot to plated link on chain. CAUTION: Remove excess oil from the camshaft sprocket bolt. Failure to do so can result in over-torque of bolt resulting in bolt failure.
13. Remove Special Tool 8429, then attach both sprockets to camshafts. Remove excess oil from bolts, then Install sprocket bolts, but do not tighten at this time.
14. Verify that all plated links are aligned with the marks on all sprockets and the "V6" marks on camshaft sprockets are at the 12 o'clock position. CAUTION: Ensure the plate between the left secondary chain tensioner and block is correctly installed.
15. Install both secondary chain tensioners. Tighten bolts to 28 N.m (250 in. lbs.). NOTE: Left and right secondary chain tensioners are not common.
16. Remove all locking pins (3) from tensioners. CAUTION: After pulling locking pins out of each tensioner, DO NOT manually extend the tensioner(s) ratchet. Doing so will over tension the chains, resulting in noise and/or high timing chain loads. 1 - TORQUE WRENCH 2 - CAMSHAFT SPROCKET 3 - LEFT CYLINDER HEAD 4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
17. Using Special Tool 6958, Spanner with Adaptor Pins 8346 (4), tighten left. camshaft sprocket bolts to 122 N.m (90 ft. lbs.). 1 - TORQUE WRENCH 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346 3 - LEFT CAMSHAFT SPROCKET 4 - RIGHT CAMSHAFT SPROCKET
18. Using Special Tool 6958, Spanner with Adaptor Pins 8346 (2), tighten right camshaft sprocket bolts to 122 N.m (90 ft. lbs.).
19. Rotate engine two full revolutions. Verify timing marks are at the follow locations: primary chain idler sprocket dot is at 12 o'clock primary chain crankshaft sprocket dot is at 6 o'clock secondary chain camshaft sprockets "V6" marks are at 12 o'clock counterbalancer shaft drive gear dot is aligned to the idler sprocket gear dot
20. Lubricate all three chains with engine oil. 1 - IDLER SPROCKET ASSEMBLY 2 - DIAL INDICATOR
21. After installing all chains, it is recommended that the idler gear end play be checked. The end play must be within 0.10 -0.25 mm (0.004 - 0.010 in.). If not within specification, the idler gear ( 1) must be replaced.
22. Install timing chain cover and crankshaft damper «(Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION)»(ref-247616-S34702611892007020100000) and «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION)»(ref-247616-S34369034152007020100000).
23. Install cylinder head covers «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION)»(ref-247616-S39926205412007020100000). 1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG NOTE: Before installing threaded plug in right cylinder head, the plug must be coated with sealant to prevent leaks.
24. Coat the large threaded access plug (2) with Mopar(R) Thread Sealant with Teflon, then install into the right cylinder head and tighten to 81 N.m (60 ft. lbs.).
25. Install the oil fill housing.
26. Install access plug (1) in left cylinder head.
27. Install power steering pump «(Refer to STEERING/PUMP - INSTALLATION)»(ref-247608-S03312465172007020100000).
28. Fill cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-247624-S05505992522007020100000).
29. Connect negative cable to battery.