3.7L Engine - Service Information: Removal & Installation Dodge Dakota III рестайлинг

REMOVAL

The valve stem seal is integral with the valve spring seat, for removal. See Engine/Cylinder Head/SPRING(S), Valve - Removal .

INSTALLATION

The valve stem seal is integral with the valve spring seat. For installation, see Engine/Cylinder Head/SPRING(S), Valve - Installation .

1. Remove the cylinder head cover. See «Engine/Cylinder Head/COVER(S), Cylinder Head - Removal»(ref-352641-S36660118732010010600000) .
2. Use the Valve Spring Compressor 8426 to remove the rocker arms and the hydraulic lash adjusters.
3. Remove the spark plug for the cylinder the valve spring and seal are to be removed from.
4. Apply shop air to the cylinder to hold the valves in place when the spring is removed. NOTE: All six valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.
5. Using Valve Spring Compressor 8426, compress the valve spring. NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
6. Remove the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
7. Remove the valve spring compressor. NOTE: The valve springs are NOT common between intake and exhaust.
8. Remove the spring retainer, and the spring.
9. Remove the valve stem seal. NOTE: The valve stem seals are common between intake and exhaust.

Note. All six valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.

1. Apply shop air to the cylinder to hold the valves in place while the spring is installed. NOTE: The valve stem seals are common between intake and exhaust.
2. Install the valve stem seal. NOTE: The valve springs are NOT common between intake and exhaust.
3. Install the spring retainer, and the spring.
4. Using the Valve Spring Compressor 8426, compress the valve spring.
5. Install the two spring retainer lock halves. NOTE: The valve spring is under tension use care when releasing the valve spring compressor.
6. Remove the valve spring compressor.
7. Disconnect the shop air to the cylinder.
8. Install the spark plug for the cylinder the valve spring and seal was installed on.
9. Using the Valve Spring Compressor 8426, install the rocker arms and the hydraulic lash adjusters.
10. Install the cylinder head cover. See «Engine/Cylinder Head/COVER(S), Cylinder Head - Installation»(ref-352641-S28358361472010010600000) .

1. Position the flexplate onto the crankshaft and install the bolts hand tight.
2. Tighten the flexplate retaining bolts to 95 N.m (70 ft. lbs.) in the sequence shown in illustration.
3. Install the transmission. Refer to «Transmission and Transfer Case/Automatic - 42RLE - Installation»(ref-352659-S38174032602010010600000) or refer to «Transmission and Transfer Case/Automatic - 45RFE/545RFE - Installation»(ref-352643-S38957606722010010600000) .

Scheme 81

Scheme 82

1. Remove the primary and secondary timing chains. See «Engine/Valve Timing/CHAIN and SPROCKETS, Timing - Removal»(ref-352641-S24750492852010010600000) . NOTE: The balance shaft and gear are serviced as an assembly. Do not attempt to remove the gear from the balance shaft. Remove the retaining bolt (4) from the balance shaft thrust plate (2). 1 - BALANCE SHAFT REMOVAL AND INSTALLATION TOOL 2 - BALANCE SHAFT THRUST PLATE
2. Using Balance Shaft Remover/Installer 8641 (1), remove the balance shaft from the engine.

Note. The balance shaft and gear are serviced as an assembly. Do not attempt to remove the gear from the balance shaft.

1. Coat balance shaft bearing journals with clean engine oil. NOTE: The balance shaft is heavy, and care should be used when installing shaft, so bearings are not damaged.
2. Using Balance Shaft Remover/Installer 864, carefully install balance shaft into engine.
3. Install balance shaft thrust plate retaining bolt finger tight. Do not tighten bolt at this time.
4. Position the right side of the thrust plate with the right chain guide bolt, install bolt finger tight.
5. Torque the thrust plate retaining bolt to 28 N.m (250 in. lbs.).
6. Remove the chain guide bolt so that guide can be installed.

Scheme 83

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

Scheme 84

Scheme 85

Scheme 86

Scheme 87

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 in.) 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. NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs. PISTON RING SIDE CLEARANCE PISTON RING SPECIFICATION CHARTS Ring Position Groove Clearance Maximum Clearance Upper Ring 0.051-0.094 mm (0.0020-.0037 in.) 0.11 mm (0.004 in.) Intermediate Ring 0.04-0.08 mm (0.0016-0.0031 in.) 0.10 mm (0.004 in.) Oil Control Ring (Steel Rails) 0.019-0.229 mm (.0007-.0090 in.) 0.25 mm (0.010 in.) Ring Position Ring Gap Wear Limit Upper Ring 0.20-0.36 mm (0.0079-0.0142 in.) 0.43 mm (0.0017 in.) Intermediate Ring 0.37-0.63 mm (0.0146-0.0249 in.) 0.74 mm (0.029 in.) Oil Control Ring (Steel Rail) 0.025-0.76 mm (0.0099- 0.03 in.) 1.55 mm (0.061 in.)
5. Measure the ring side clearance as shown in illustration. Make 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 the upper side rail by placing one end between the piston ring groove and the expander ring. Hold the 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 88

The pistons (2) are made of a high strength aluminum alloy. The connecting rods are made of forged powdered metal, with a "fractured cap" design (1). A full floating piston pin (3) is used to attach the piston to the connecting rod.

Scheme 89

Inspect the connecting rod bearings for scoring (1) and (3). Check the bearings for normal wear patterns, scoring, grooving, fatigue and pitting. Replace any bearing that shows abnormal wear.

Inspect the connecting rod journals for signs of scoring, nicks and burrs.

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. Replace misaligned, bent or twisted connecting rods.

Scheme 90

Scheme 91

Scheme 92

Scheme 93

1. Wipe the oil from the connecting rod journal.
2. Lubricate the upper bearing insert (2) and position in connecting rod (1). Center bearing insert in connecting rod
3. Measure at point A and point B. Measurement should be less then 0.50 mm (0.0196 in.).
4. Use piston ring compressor (3) and Guide Pins Special Tool 8507 (4) to install the rod and piston assemblies. The oil slinger slots in the rods must face front of the engine. The "F"s (1) near the piston wrist pin bore should point to the front of the engine.
5. Install the lower bearing insert in the bearing cap. Center bearing insert in connecting rod. The lower insert must be dry. Place strip of Plastigage (1) across full width of the lower insert at the center of bearing cap. Plastigage must not crumble in use. If brittle, obtain fresh stock.
6. Install bearing cap and connecting rod on the journal and tighten bolts to 27 N.m (20 ft. lbs.) plus a 90° turn. DO NOT rotate crankshaft. Plastigage will smear, resulting in inaccurate indication.
7. Remove the bearing cap and determine amount of bearing-to-journal clearance by measuring the width of compressed Plastigage (2). Refer to «SPECIFICATIONS»(ref-352641-S10056889932010010600000) for the proper clearance. Plastigage should indicate the same clearance across the entire width of the insert. If the clearance varies, it may be caused by either a tapered journal, bent connecting rod or foreign material trapped between the insert and cap or rod.
8. If the correct clearance is indicated, replacement of the bearing inserts is not necessary. Remove the Plastigage from crankshaft journal and bearing insert. Proceed with installation.
9. If bearing-to-journal clearance exceeds the specification, determine which services bearing set to use the bearing sizes are as follows: Bearing Mark SIZE USED WITH JOURNAL SIZE 0.025 US 0.025 mm (0.001 in.) 57.883-57.867 mm (2.2788-2.2783 in.) Std. STANDARD 57.908-57.892 mm (2.2798-2.2792 in.) 0.250 US 0.250 mm (0.010 in.) 57.658-57.646 mm (2.2700-2.2695 in.)
10. Repeat the Plastigage measurement to verify your bearing selection prior to final assembly.
11. Once you have selected the proper insert, install the insert and cap. Tighten the connecting rod bolts to 27 N.m (20 ft. lbs.) plus a 90° turn.

Slide snug-fitting feeler gauge between the connecting rod and crankshaft journal flange. Refer to SPECIFICATIONS for the proper clearance. Replace the connecting rod if the side clearance is not within specification.

Scheme 94

Scheme 95

1. To correctly select the proper size piston, a cylinder bore gauge (2), capable of reading in 0.003 mm (.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer.
2. Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below top of bore (4). Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B.
3. The coated pistons will be serviced with the piston pin and connecting rod pre-assembled.
4. 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 . To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (.0001 in.) increments is required.
5. 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.

1. Disconnect the negative cable from battery.
2. Remove the following components: Oil pan and gasket/windage tray. See «Engine/Lubrication/PAN, Oil - Removal»(ref-352641-S08758547192010010600000) . Cylinder head(s). See «Engine/Cylinder Head - Removal»(ref-352641-S19671748002010010600000) .
3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
5. Remove connecting rod cap. Install Connecting Rod Guides l 8507 onto the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur
6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.

Note. Threadlocking compound must be applied to the bolts before installation.

1. Install the two bolts that attach the transmission mount to the transmission bracket.
2. Torque the bolts to 61 N.m (45 ft. lbs.) torque.
3. Lower the transmission so the transmission mount rests on the crossmember, and the studs of the transmission mount are aligned in the slots in the crossmember.
4. Install the nuts onto the transmission mount studs through the crossmember access slot.
5. Torque the nuts to 54 N.m (40 ft. lbs.).

1. Remove the oil pan and pick-up tube. See «Engine/Lubrication/PAN, Oil - Removal»(ref-352641-S08758547192010010600000) .
2. Remove the timing chain cover. See «Engine/Valve Timing/COVER(S), Engine Timing - Removal»(ref-352641-S21086580242010010600000) .
3. Remove the timing chains and tensioners. See «Engine/Valve Timing/CHAIN and SPROCKETS, Timing - Removal»(ref-352641-S24750492852010010600000) .
4. Remove the four bolts, primary timing chain tensioner and the oil pump.

1. Install the oil pressure switch.
2. Connect oil pressure switch connector.
3. Install front splash shield.
4. Lower vehicle.
5. Connect the negative battery cable.
6. Start the engine and ensure there are no oil leaks from the oil pressure switch.

Scheme 96

The exhaust manifolds (1 and 2) are log style with a patented flow enhancing design to maximize performance. The exhaust manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is used to improve sealing to the cylinder head.

Scheme 97

The exhaust manifolds are covered by a three layer laminated heat shield (1 and 3) for thermal protection and noise reduction. The heat shields (1 and 3) are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold.

Scheme 98

1. Disconnect the negative cable from the battery.
2. Raise and support the vehicle.
3. Remove the bolts and nuts attaching the exhaust pipe to the engine exhaust manifold.
4. Lower the vehicle.
5. Remove the exhaust heat shield (1).
6. Remove bolts, nuts (2) and washers attaching manifold to cylinder head.
7. Remove manifold and gasket from the cylinder head.

Scheme 99

1. Disconnect the negative cable from the battery.
2. Raise and support the vehicle.
3. Remove the bolts and nuts attaching the exhaust pipe to the engine exhaust manifold.
4. Lower the vehicle.
5. Remove the exhaust heat shields (1).
6. Remove bolts, nuts (2) and washers attaching manifold to cylinder head.
7. Remove manifold and gasket from the cylinder head.

1. Remove the primary and secondary timing chains and sprockets. Refer to «CHAIN and SPROCKETS, Timing»(ref-352641-S13735196762010010600000) . NOTE: To remove the idler shaft, it is necessary to tap threads into the shaft, to install the removal tool.
2. Using a 12 mm X 1.75 tap, cut threads in the idler shaft center bore.
3. Cover the radiator core with a suitable cover. CAUTION: Use care when removing the idler shaft, Do not strike the radiator cooling fins with the slide hammer.
4. Using Slide Hammer 8517, remove the idler shaft.

1. Thoroughly clean the idler shaft bore.
2. Position the idler shaft in the bore. NOTE: The two lubrication holes in the idler shaft do not require any special alignment. NOTE: Before using the retaining bolt to install the idler shaft, coat the threads and the pilot on the idler shaft, with clean engine oil.
3. Using the primary idler sprocket retaining bolt and washer, carefully draw the idler shaft into the bore until fully seated.
4. Coat the idler shaft with clean engine oil.
5. Install the timing chains and sprockets. Refer to «CHAIN and SPROCKETS, Timing»(ref-352641-S13735196762010010600000) .