3.7L Engine - Service Information: Other Dodge Durango II

CYLINDER COMPRESSION PRESSURE

The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.

Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.

1. Clean the spark plug recesses with compressed air.
2. Remove the spark plugs.
3. Secure the throttle in the wide-open position.
4. Disable the fuel system. Refer to «FUEL DELIVERY»(ref-564649) .
5. Remove the Automatic Shutdown (ASD) relay (Refer to «RELAY-AUTO SHUT DOWN»(ref-238310-S01616294542006072400000) ).
6. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
7. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders.
8. Refer (Refer to «SPECIFICATIONS»(ref-212814-S38214486652005122700000) ) for the correct engine compression pressures.

CYLINDER COMBUSTION PRESSURE LEAKAGE

The combustion pressure leakage test provides an accurate means for determining engine condition.

Combustion pressure leakage testing will detect

1. Exhaust and intake valve leaks (improper seating).
2. Leaks between adjacent cylinders or into water jacket.
3. Any causes for combustion/compression pressure loss.

1. Check the coolant level and fill as required. DO NOT install the radiator cap.
2. Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.
3. Remove the spark plugs.
4. Remove the oil filler cap.
5. Remove the air cleaner hose.
6. Calibrate the tester according to the manufacturer's instructions. The shop air source for testing should maintain-483 kPa (70 psi) minimum, 1,379 kPa (200 psi) maximum and 552 kPa (80 psi) recommended.
7. Perform the test procedures on each cylinder according to the tester manufacturer's instructions. Set piston of cylinder to be tested at TDC compression. While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the radiator coolant.

All gauge pressure indications should be equal, with no more than 25% leakage.

FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the cylinder.

Refer to CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART

REPAIR DAMAGED OR WORN THREADS

Damaged or worn threads can be repaired. Essentially, this repair consists of

1. Drilling out worn or damaged threads.
2. Tapping the hole with a special Heli-Coil Tap, or equivalent.
3. Installing an insert into the tapped hole to bring the hole back to its original thread size.

FORM-IN-PLACE GASKETS AND SEALERS

There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in-place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket.

There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Engine RTV GEN II, Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties and can not be used in place of the other.

MOPAR® ENGINE RTV GEN II

Mopar® Engine RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® ATF RTV

Mopar® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® GASKET MAKER

Mopar® Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.

MOPAR® GASKET SEALANT

Mopar® Gasket Sealant is a slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This material is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 4 oz./16 oz. can w/applicator

ENGINE GASKET SURFACE PREPARATION

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.

Never use the following to clean gasket surfaces

1. Metal scraper.
2. Abrasive pad or paper to clean cylinder block and head.
3. High speed power tool with an abrasive pad or a wire brush (1).

Note. Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Only use the following for cleaning gasket surfaces

Scheme 105

1. Solvent or a commercially available gasket remover
2. Plastic or wood scraper (3).
3. Drill motor with 3M Roloc&381 tread; Bristle Disc (white or yellow) (2).

CYLINDER BLOCK

CYLINDER BLOCK SPECIFICATION

PISTON

PISTON SPECIFICATION

PISTON PINS

PISTON PINS SPECIFICATION

PISTON RINGS

PISTON RINGS SPECIFICATION

CONNECTING RODS

CONNECTING RODS SPECIFICATION

CRANKSHAFT

CRANKSHAFT SPECIFICATION

CAMSHAFT

CAMSHAFT SPECIFICATION

VALVE TIMING

VALVE TIMING SPECIFICATION

VALVE

VALVE SPECIFICATION

VALVE SPRING

VALVE SPRING SPECIFICATION

CYLINDER HEAD

CYLINDER HEAD SPECIFICATION

OIL PUMP

OIL PUMP SPECIFICATION

OIL PRESSURE

OIL PRESSURE SPECIFICATION

Filter Element Only

Housing removal is not necessary for element (filter) replacement.

Scheme 106

1. Loosen clamp (1) and disconnect air duct at air cleaner cover (3).
2. Pry over 4 spring clips (5) from housing cover (spring clips retain cover to housing).
3. Release housing cover (3) from locating tabs on housing and remove cover (3).
4. Remove air cleaner element (filter) from housing.
5. Clean inside of housing before replacing element.

Scheme 107

1. Loosen clamp and disconnect air duct at air cleaner cover.
2. Lift entire housing assembly (1) from 4 locating pins (2).

Scheme 108

1. Install filter element into housing (1).
2. Position housing cover into housing locating tabs.
3. Pry up 4 spring clips and lock cover to housing.
4. Install air duct to air cleaner cover and tighten hose clamp to 3 N.m (30 in. lbs.) torque.
5. If any other hose clamps were removed from air intake system, tighten them to 3.4 N.m (30 in. lbs.) torque.
6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 N.m (40 in. lbs.) torque.

The cylinder heads are made of an aluminum alloy. The cylinder head features two valves per cylinder with pressed in powdered metal valve guides. The cylinder heads also provide enclosures for the timing chain drain, necessitating unique left and right cylinder heads.

VALVE GUIDE SEALS

The valve guide seals are made of rubber and incorporate an integral steel valve spring seat. The integral garter spring maintains consistent lubrication control to the valve stems.

CYLINDER HEAD GASKET

A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket.

Possible indications of the cylinder head gasket leaking between adjacent cylinders are

1. Loss of engine power
2. Engine misfiring
3. Poor fuel economy

Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are

1. Engine overheating
2. Loss of coolant
3. Excessive steam (white smoke) emitting from exhaust
4. Coolant foaming

COOLING SYSTEM TESTER METHOD

Install Cooling System Tester 7700 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.

CYLINDER HEAD - RIGHT

1. Disconnect battery negative cable.
2. Raise the vehicle on a hoist.
3. Disconnect the exhaust pipe at the right side exhaust manifold.
4. Drain the engine coolant (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) )
5. Lower the vehicle.
6. Remove the intake manifold (Refer to «MANIFOLD-INTAKE»(ref-212814-S37585498582005122700000) ).
7. Remove the cylinder head cover (Refer to «REMOVAL»(ref-212814-S22748134532005122700000) ).
8. Remove the radiator fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
9. Remove oil fill housing from cylinder head.
10. Remove accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
11. Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark.
12. Verify the V6 mark on the camshaft sprocket is at the 12 o'clock position. Rotate the crankshaft one turn if necessary.
13. Remove the crankshaft damper (Refer to «REMOVAL»(ref-212814-S15075701832005122700000) ).
14. Remove the timing chain cover (Refer to «REMOVAL»(ref-212814-S24469805602005122700000) ).
15. Lock the secondary timing chains to the idler sprocket using Special Tool 8429 Timing Chain Holding Fixture. NOTE: Mark the secondary timing chain prior to removal to aid in installation.
16. Mark the secondary timing chain, one link on each side of the V6 mark on the camshaft drive gear.
17. Remove the right side secondary chain tensioner (Refer to «REMOVAL»(ref-212814-S14303263392005122700000) ).
18. Remove the cylinder head access plug.
19. Remove the right side secondary chain guide (Refer to «REMOVAL»(ref-212814-S14303263392005122700000) ). 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 (44 in. lbs.).
20. 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. CAUTION: Do not hold or pry on the camshaft target wheel for any reason. A damaged target wheel can result in a vehicle no start condition. NOTE: The cylinder head is attached to the cylinder block with twelve bolts.
21. Remove the cylinder head retaining bolts.
22. Remove the cylinder head and gasket. Discard the gasket. CAUTION: Do not lay the cylinder head on its gasket sealing surface, do to the design of the cylinder head gasket any distortion to the cylinder head sealing surface may prevent the gasket from properly sealing resulting in leaks.

CYLINDER HEAD - LEFT

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 109

Scheme 110

Scheme 111

1. Clean the cylinder head and cylinder block mating surfaces.
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 with an *.
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® 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-torqueing of bolt resulting in bolt failure.
8. Install the camshaft drive gear retaining bolt.
9. Install the left side secondary chain guide (Refer to «INSTALLATION»(ref-212814-S03069402672005122700000) ).
10. Install the cylinder head access plug.
11. Re-set and install the left side secondary chain tensioner (Refer to «INSTALLATION»(ref-212814-S03069402672005122700000) )
12. Remove Special Tool 8429.
13. Install the timing chain cover (Refer to «INSTALLATION»(ref-212814-S33417072122005122700000) )
14. Install the crankshaft damper (Refer to «INSTALLATION»(ref-212814-S06377403922005122700000) ). 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 «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
17. Install the cylinder head cover (Refer to «INSTALLATION»(ref-212814-S39327807952005122700000) ).
18. Install the master cylinder and booster assembly (Refer to «POWER BRAKE BOOSTER»(ref-163273-S21590373612004062400000) ).
19. Install the intake manifold (Refer to «INSTALLATION»(ref-212814-S39327807952005122700000) ).
20. Refill the cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
21. Raise the vehicle.
22. Install the exhaust pipe onto the left exhaust manifold (Refer to «EXHAUST SYSTEM»(ref-212817) ).
23. Lower the vehicle.
24. Connect the negative cable to the battery.
25. Start the engine and check for leaks.

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 112

Scheme 113

Scheme 114

Scheme 115

1. Clean the cylinder head and cylinder block mating surfaces.
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 °. Step 4: Tighten bolts 1-8, 90 °, 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 «INSTALLATION»(ref-212814-S03069402672005122700000) ).
10. Install the cylinder head access plug.
11. Re-set and install the right side secondary chain tensioner (Refer to «INSTALLATION»(ref-212814-S03069402672005122700000) ).
12. Remove Special Tool 8429.
13. Install the timing chain cover (Refer to «INSTALLATION»(ref-212814-S33417072122005122700000) ).
14. Install the crankshaft damper (Refer to «INSTALLATION»(ref-212814-S06377403922005122700000) ). Tighten damper bolt 175 N.m (130 Ft. Lbs.).
15. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
16. Install the radiator fan and shroud (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
17. Install the cylinder head cover (Refer to «INSTALLATION»(ref-212814-S39327807952005122700000) ).
18. Install the intake manifold (Refer to «INSTALLATION»(ref-212814-S39327807952005122700000) ).
19. Install oil fill housing onto cylinder head.
20. Refill the cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
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.

CAMSHAFT-LEFT

1. Remove cylinder head cover (Refer to «REMOVAL»(ref-212814-S22748134532005122700000) ).
2. Set engine to TDC cylinder No. 1, camshaft sprocket V6 marks (1) at the 12 o'clock position.
3. Mark one link on the secondary timing chain on both sides of the V6 mark on the camshaft sprocket to aid in installation. CAUTION: Do not hold or pry on the camshaft target wheel (Located on the right side camshaft sprocket) for any reason, Severe damage will occur to the target wheel resulting in a vehicle no start condition.
4. Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave the bolt snug against the sprocket. NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners. CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur.
5. Position Special Tool 8379 timing chain wedge (1) between the timing chain strands, tap the tool to securely wedge the timing chain against the tensioner arm and guide.
6. Hold the camshaft with Special Tool 8428 Camshaft Wrench (2), while removing the camshaft sprocket bolt and sprocket.
7. Using Special Tool 8428 Camshaft Wrench (2), gently allow the camshaft to rotate 5° clockwise until the camshaft is in the neutral position (no valve load).
8. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps. CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS. NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
9. Remove the camshaft bearing caps and the camshaft.

CAMSHAFT-RIGHT

Scheme 116

1. Remove the cylinder head cover (Refer to «REMOVAL»(ref-212814-S22748134532005122700000) ).
2. Set engine to TDC cylinder No. 1, camshaft sprocket V6 marks at the 12 o'clock position.
3. Mark one link on the secondary timing chain on both sides of the V6 mark on the camshaft sprocket to aid in installation. CAUTION: Do not hold or pry on the camshaft target wheel for any reason, Severe damage will occur to the target wheel. A damaged target wheel could cause a vehicle no start condition.
4. Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave bolt snug against sprocket. NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners. CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur.
5. Position Tool 8379 timing chain wedge between the timing chain strands. Tap the tool to securely wedge the timing chain against the tensioner arm and guide.
6. Remove the camshaft position sensor.
7. Hold the camshaft with Tool 8428 Camshaft Wrench, while removing the camshaft sprocket bolt and sprocket.
8. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps. CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS. NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
9. Remove the camshaft bearing caps and the camshaft.

1. Lubricate camshaft journals with clean engine oil. NOTE: Position the left side camshaft so that the camshaft sprocket dowel is near the 1 o'clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
2. Position the camshaft into the cylinder head.
3. Install the camshaft bearing caps, hand tighten the retaining bolts. NOTE: Caps should be installed so that the stamped numbers on the caps are in numerical order, ( 1 thru 4 ) from the front to the rear of the engine. All caps should be installed so that the stamped arrows on the caps point toward the front of the engine.
4. Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward.
5. Torque the camshaft bearing cap retaining bolts to 11 N.m (100 in. lbs.).
6. Position the camshaft drive gear into the timing chain aligning the V6 mark between the two marked chain links (Two links marked during removal).
7. Using Tool 8428 Camshaft Wrench, rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft. CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over-torque resulting in bolt failure.
8. Remove excess oil from bolt, then install the camshaft sprocket retaining bolt and hand tighten.
9. Remove Special Tool 8379 timing chain wedge.
10. Using Special Tool 6958 spanner wrench with adapter pins 8346, torque the camshaft sprocket retaining bolt to 122 N.m (90 ft. lbs.).
11. Install the cylinder head cover (Refer to «INSTALLATION»(ref-212814-S39327807952005122700000) ).

1. Lubricate camshaft journals with clean engine oil. NOTE: Position the right side camshaft so that the camshaft sprocket dowel is near the 10 o'clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
2. Position the camshaft into the cylinder head.
3. Install the camshaft bearing caps, hand tighten the retaining bolts. NOTE: Caps should be installed so that the stamped numbers on the caps are in numerical order, (1 thru 4) from the front to the rear of the engine. All caps should be installed so that the stamped arrows on the caps point toward the front of the engine.
4. Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward as shown.
5. Torque the camshaft bearing cap retaining bolts to 11 N.m (100 in. lbs.).
6. Position the camshaft drive gear into the timing chain aligning the V6 mark between the two marked chain links (Two links marked during removal).
7. Using Special Tool 8428 Camshaft Wrench, rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft. CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over-torque resulting in bolt failure.
8. Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and hand tighten.
9. Remove timing chain wedge Tool 8379.
10. Using Tool 6958 spanner wrench with adapter pins 8346, torque the camshaft sprocket retaining bolt to 122 N.m (90 ft. lbs.).
11. Install the camshaft position sensor.
12. Install the cylinder head cover (Refer to «INSTALLATION»(ref-212814-S39327807952005122700000) ).

REFACING

Note. Valve seats that are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced.

Note. When refacing valves and valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained.

1. Using a suitable dial indicator measure the center of the valve seat Total run out must not exceed 0.051 mm (0.002 in).
2. Apply a small amount of Prussian blue to the valve seat, insert the valve (4) or (5) into the cylinder head, while applying light pressure on the valve rotate the valve. Remove the valve and examine the valve face. If the blue is transferred below the top edge of the valve face, lower the valve seat using a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, raise the valve seat using a 65 degree stone.
3. When the seat is properly positioned the width of the intake seat must be 1.75 - 2.36 mm (0.0689 - 0.0928 in.) and the exhaust seat must be 1.71 - 2.32 mm (0.0673 - 0.0911 in.).
4. Check the valve spring installed height after refacing the valve (4) and (5) and seat. The installed height for both intake and exhaust valve springs must not exceed 40.74 mm (1.6039 in.).
5. The valve seat and valve face must maintain a face angle of 44.5 - 45 ° angle.

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 very firm. Spongy adjusters can be bottomed out easily. Remove suspected lash adjusters, and replace. Before installation, make sure adjusters are at least partially full of oil. This can be verified by little or no plunger travel when lash adjuster is depressed.

STANDARD PROCEDURE - CYLINDER BORE HONING

Before honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area.

Scheme 117

1. Used carefully, the Cylinder Bore Sizing Hone C-823, equipped with 220 grit stones, is the best tool for this job. In addition to deglazing, it will reduce taper and out-of-round, as well as removing light scuffing, scoring and scratches. Usually, a few strokes will clean up a bore and maintain the required limits. CAUTION: DO NOT use rigid type hones to remove cylinder wall glaze.
2. Deglazing of the cylinder walls may be done if the cylinder bore is straight and round. Use a cylinder surfacing hone, Honing Tool C-3501, equipped with 280 grit stones (C-3501-3810). about 20-60 strokes, depending on the bore condition, will be sufficient to provide a satisfactory surface. Using honing oil C-3501-3880, or a light honing oil, available from major oil distributors. CAUTION: DO NOT use engine or transmission oil, mineral spirits, or kerosene.
3. Honing should be done by moving the hone up and down fast enough to get a Crosshatch pattern. The hone marks should INTERSECT at 50° to 60° for proper seating of rings.
4. A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper Crosshatch angle (1). The number of up and down strokes per minute can be regulated to get the desired 50° to 60° angle (2). Faster up and down strokes increase the Crosshatch angle.
5. After honing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash parts with a solution of hot water and detergent. Dry parts thoroughly. Use a clean, white, lint-free cloth to check that the bore is clean. Oil the bores after cleaning to prevent rusting.

CLEANING

Thoroughly clean the oil pan and engine block gasket surfaces.

Use compressed air to clean out

1. The galley at the oil filter adaptor hole.
2. The front and rear oil galley holes.
3. The feed holes for the crankshaft main bearings.

Once the block has been completely cleaned, apply Loctite PST pipe sealant with Teflon 592 to the threads of the front and rear oil galley plugs. Tighten the 1/4 inch NPT plugs to 20 N.m (177 in. lbs.) torque. Tighten the 3/8 inch NPT plugs to 27 N.m (240 in. lbs.) torque.

MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)

Remove the crankshaft from the cylinder block (Refer to REMOVAL ). Clean the oil off the main bearing journal.

Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal.

The maximum allowable taper is 0.008mm (0.0004 inch.) and maximum out of round is 0.005mm (0.002 inch). Compare the measured diameter with the journal diameter specification (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance.

Install the crankshaft into the cylinder block (Refer to INSTALLATION ).

Check crankshaft end play.

CRANKSHAFT MAIN BEARING SELECTION

1. Service main bearings are available in four grades. The chart below identifies the four service grades available. CRANKSHAFT MARKING AND JOURNAL SIZE Crankshaft Marking JOURNAL SIZE SIZE mm (in.) "R" Size 63.488 - 63.496 mm (2.4995 - 2.4998 in.) "S" Size 63.496 - 63.500 mm (2.4998 - 2.4999 in.) "T" Size 63.500 - 63.504 mm (2.4999 - 2.501 in.) "U" Size 63.504 - 63.512 mm (2.5001 - 2.5004 in.) Bearing size Bearing Code Size Application Upper Bearing A .2.443 - 2.447 mm (.0961 - .0963 in.) Use with crankshaft size "R" B 2.439 - 2.443 mm (0.960 - .0961 in.) Use with crankshaft "S, T" C 2.435 - 2.439 mm (.0958 - .0960 in.) Use with crankshaft "U" Lower Bearing Main "1" and "4" "1" 2.441 - 2.447 mm (.0961 -.0963 in.) Use with crankshaft "R, S" "2" 2.435 - 2.441 mm (.0958 - .0962 in.) Use with crankshaft "T, U" Lower Main Bearing "2" and "3" "3" 2.429 - 2.435 mm (.0956 - .0958 in.) Use with crankshaft "R, S" "4" 2.423 - 2.429 mm (.0953 - .0956 in.) Use with crankshaft "T, U" Bearing Clearances Main "1,4" Crankshaft "R" .004 - .034 mm (.00015 - .0013 in.) Crankshaft "S" .004 - .030 mm (.00015 - .0011 in.) Crankshaft "T" .006 - .032 mm (.0002 - .0012 in.) Crankshaft "U" .002 - .032 mm (.00007 -. 0012 in.) Main "2, 3" Crankshaft "R" .016 - .046 mm (.0006 - .0018 in.) Crankshaft "S" .016 - .042 mm (.00062 - .016 in.) Crankshaft "T" .018 - .044 mm (.0007 - .0017 in.) Crankshaft "U" .014 - .044 mm (.0005 - .0017 in.)

Scheme 118

Scheme 119

1. Disconnect negative cable from battery.
2. Remove accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
3. Remove A/C compressor mounting fasteners and set aside.
4. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
5. Remove upper radiator hose.
6. Disconnect electrical connector for fan mounted inside radiator shroud.
7. Remove radiator cooling fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
8. Remove crankshaft damper bolt.
9. Remove damper using Special Tools 8513 Insert (1) and Tool 1026 Three Jaw Puller (2).
10. Using Special Tool 8511 (1), remove crankshaft front seal.

CONNECTING ROD BEARING FITTING

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 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

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 .50mm (.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-212814-S38214486652005122700000) 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 AND SIZE Bearing Mark SIZE USED WITH JOURNAL SIZE .025 US .025 mm (.001 in.) 57.883-57.867 mm (2.2788-2.2783 in.) Std. STANDARD 57.908-57.892 mm (2.2798-2.2792 in.) .250 US .250 mm (.010 in.) 57.658-57.646 mm (2.2700-2.2695 in.) 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.
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»(ref-212814-S38214486652005122700000) for the proper clearance. Replace the connecting rod if the side clearance is not within specification.

Scheme 125

Scheme 126

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. Using a suitable cleaning solvent clean the pistons in warm water and towel dry.
2. Use a wood or plastic scraper to clean the ring land grooves.

PISTON RING FITTING

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

Scheme 127

Scheme 128

Scheme 129

Scheme 130

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 12mm (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 PISTON RING SPECIFICATIONS Ring Position Groove Clearance Maximum Clearance Upper Ring .051-.094 mm (0.0020-.0037 in.) 0.11 mm (0.004 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) .019-.229 mm (.0007-.0090 in.) .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 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 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. 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 131

1. Disconnect negative cable from battery.
2. Remove radiator fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
3. Remove accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
4. Remove crankshaft damper bolt.
5. Remove damper using Special Tools 8513 Insert (1) and 1026 Three Jaw Puller (2).

2WD

1. Disconnect the negative cable from the battery. CAUTION: Remove the viscous fan before raising engine. Failure to do so may cause damage to the fan blade, fan clutch and fan shroud.
2. Remove the viscous fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
3. Raise the vehicle.
4. Remove the engine oil filter.
5. Remove the oil drain trough.
6. Support the engine with a suitable jack and a block of wood across the full width of the engine oil pan.
7. Support the front axle with a suitable jack.
8. Remove the (4) bolts that attach the engine mounts to the front axle.
9. Remove the (3) bolts that attach the front axle to the left engine bracket.
10. Lower the front axle.
11. Remove the through bolts
12. Raise the engine far enough to be able to remove the left and right engine mounts.
13. Remove the (8) mount to engine attaching bolts
14. Remove the engine mounts.

Scheme 132

Scheme 133

1. Disconnect the negative cable from the battery. CAUTION: Remove the viscous fan before raising engine. Failure to do so may cause damage to the fan blade, fan clutch and fan shroud.
2. Remove the viscous fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
3. Raise the vehicle.
4. Remove the skid plate.
5. Remove the front crossmember.
6. Remove the engine oil filter.
7. Remove the oil drain trough.
8. Support the engine with a suitable jack and a block of wood across the full width of the engine oil pan.
9. Support the front axle with a suitable jack.
10. Remove the (4) bolts that attach the engine mounts to the front axle.
11. Remove the (3) bolts that attach the front axle to the left engine bracket.
12. Lower the front axle.
13. Remove the (6) through bolts
14. Raise the engine far enough to be able to remove the left and right engine mounts.
15. Remove the engine mounts.

Note. For mount to engine block and left engine bracket to front axle bolts, apply Mopar® Lock and Seal Adhesive, Medium Strength Threadlocker.

Scheme 134

1. Install the right and left side engine mounts to the engine block with (8) bolts. Torque bolts to 54 N.m (40 ft. lbs.).
2. Insert the (2) through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts.
3. Lower the engine until the through bolts rest onto the slots in the frame brackets.
4. Tighten the through bolt nuts to 94 N.m (70 ft. lbs.).
5. Install the oil drain trough.
6. Install the engine oil filter.
7. Lower the vehicle.
8. Install the viscous fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
9. Reconnect the negative battery cable.

4WD

Note. For mount to engine block and left engine bracket to front axle bolts, apply Mopar® Lock and Seal Adhesive, Medium Strength Threadlocker.

Scheme 135

1. Install the right and left side engine mounts to the front axle. Torque nuts to 94 N.m (70 ft. lbs.).
2. Raise the front axle into the frame and install the left and right side through bolts. Torque nuts to 94 N.m (70 ft. lbs.).
3. Insert the two upper through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts.
4. Lower the engine until the left and right side engine brackets rest on the through bolts, and the lower engine bracket through holes align with the engine mounts, and the left engine bracket holes align with the front axle slots.
5. Loose assemble the (3) bolts that attach the front axle to the left engine bracket.
6. Loose assemble the lower through bolts.
7. Torque the nuts for the (4) through bolts to 101 N.m (75 ft. lbs.).
8. Torque the (3) bolts that attach the front axle to the left engine bracket to 101 N.m (75 ft. lbs.).
9. Install the oil drain trough.
10. Install the engine oil filter.
11. Install the front crossmember.
12. Install the skid plate.
13. Lower the vehicle.
14. Install the viscous fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
15. Reconnect the negative battery cable.

Scheme 136

1. Raise the vehicle on a hoist.
2. Using a suitable jack, support transmission.
3. Remove the nuts from the transmission mount.
4. Remove the two bolts that attach the transmission mount to the engine bracket.
5. Raise the transmission enough to remove the mount from the crossmember.
6. Remove the mount.

ENGINE OIL LEAK

Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed

1. Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak.
2. Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light.
3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair per service manual instructions.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspection. If the oil leak source is not positively identified at this time, proceed with «Air Leak Detection Test Method»(ref-212814-S17159692692005122700000) .

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, camshaft bore cup plugs, oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. See appropriate section 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-212814-S17159692692005122700000) 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 «DIAGNOSIS AND TESTING»(ref-212814-S07951376272005122700000) ), for components inspections and possible causes and corrections.
7. After the oil leak root cause and appropriate corrective action have been identified, (Refer to «REMOVAL»(ref-212814-S06252210452005122700000) ).

1. Clean oil pan in solvent and wipe dry with a clean cloth.
2. Clean the oil pan gasket surface. DO NOT use a grinder wheel or other abrasive tool to clean sealing surface.
3. Clean oil screen and tube thoroughly in clean solvent.

ENGINE OIL SERVICE

API SERVICE GRADE CERTIFIED

Use an engine oil that is API Service Grade Certified. MOPAR® provides engine oils that conform to this service grade.

SAE VISCOSITY

An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30 in the 3.7L engines. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation.

Scheme 137

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.

Scheme 138

OIL LEVEL INDICATOR (DIPSTICK)

The engine oil level indicator (2) is located at the right rear of the engine on the 3.7L engines.

Scheme 139

ENGINE OIL CHANGE

Change engine oil at mileage and time intervals described in Maintenance Schedules.

Run engine until achieving normal operating temperature.

1. Position the vehicle on a level surface and turn engine off.
2. Hoist and support vehicle on safety stands.
3. Remove oil fill cap.
4. Place a suitable drain pan under crankcase drain.
5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged.
6. Install drain plug in crankcase.
7. Lower vehicle and fill crankcase with specified type and amount of engine oil described in this section.
8. Install oil fill cap.
9. Start engine and inspect for leaks.
10. Stop engine and inspect oil level.

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the ENGINE OIL SERVICE WARNING at beginning of this section.

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.

RIGHT EXHAUST MANIFOLD

1. Position the engine exhaust manifold and gasket on the two studs located on the cylinder head. Install conical washers and nuts on these studs.
2. Install remaining conical washers. Starting at the center arm and working outward, tighten the bolts and nuts to 25 N.m (18 ft. lbs.) torque.
3. Install the exhaust heat shields.
4. Raise and support the vehicle. CAUTION: Over tightening heat shield fasteners, may cause shield to distort and/or crack.
5. Assemble exhaust pipe to manifold and secure with bolts, nuts and retainers. Tighten the bolts and nuts to 34 N.m (25 ft. lbs.) torque.

LEFT EXHAUST MANIFOLD

1. Position the engine exhaust manifold and gasket on the two studs located on the cylinder head. Install conical washers and nuts on these studs.
2. Install remaining conical washers. Starting at the center arm and working outward, tighten the bolts and nuts to 25 N.m (18 ft. lbs.) torque.
3. Install the exhaust heat shields.
4. Raise and support the vehicle. CAUTION: Over tightening heat shield fasteners, may cause shield to distort and/or crack.
5. Assemble exhaust pipe to manifold and secure with bolts, nuts and retainers. Tighten the bolts and nuts to 34 N.m (25 ft. lbs.) torque.

Scheme 140

The timing drive system has been designed to provide quiet performance and reliability to support a non-free wheeling engine. Specifically the intake valves are non-free wheeling and can be easily damaged with forceful engine rotation if camshaft-to-crankshaft timing is incorrect. The timing drive system consists of a primary chain, two secondary timing chain drives and a counterbalance shaft drive.

MEASURING TIMING CHAIN WEAR

Note. This procedure must be performed with the timing chain cover removed.

1. Remove the timing chain cover (Refer to «REMOVAL»(ref-212814-S14303263392005122700000) ).
2. To determine if the secondary timing chains are worn, rotate the engine clockwise until maximum tensioner piston extension is obtained. Measure the distance between the secondary timing chain tensioner housing and the step ledge on the piston. The measurement at point (A) must be less than 15mm (.5906 inches).
3. If the measurement exceeds the specification the secondary timing chains are worn and require replacement (Refer to «REMOVAL»(ref-212814-S14303263392005122700000) ).

SERVICE PROCEDURE - TIMING VERIFICATION

Note. Components referred to as left hand or right hand are as viewed from the drivers position inside the vehicle.

Note. The blue link plates on the chains and the dots on the camshaft drive sprockets may not line up during the timing verification procedure. The blue link plates are lined up with the sprocket dots only when re-timing the complete timing drive. Once the timing drive is rotated blue link-to-dot alignment is no longer valid.

Engine base timing can be verified by the following procedure

Scheme 141

Scheme 142

1. Remove the cylinder head covers. Refer to «COVER(S)-CYLINDER HEAD»(ref-212814-S10822392052005122700000) .
2. Using a mirror, locate the TDC arrow (2) on the front cover (1). Rotate the crankshaft until the mark on the crankshaft damper is aligned with the TDC arrow on the front cover. The engine is now at TDC.
3. Note the location of the V6 mark (1) stamped into the camshaft drive gears. If the V6 mark on each camshaft drive gear is at the twelve o'clock position, the engine is at TDC on the exhaust stroke. If the V6 mark on each gear is at the six o'clock position, the engine is at TDC on the compression stroke.
4. If both of the camshaft drive gears are off in the same or opposite directions, the primary chain or both secondary chains are at fault. Refer to «BELT/CHAIN-TIMING AND SPROCKETS»(ref-212814-S33582905642005122700000) .
5. If only one of the camshaft drive gears is off and the other is correct, the problem is confined to one secondary chain. Refer to «TIMING - SINGLE CAMSHAFT»(ref-212814-S00130243242005122700000) .
6. If both camshaft drive gear V6 marks are at the twelve o'clock or the six o'clock position the engine base timing is correct. Reinstall the cylinder head covers.

Scheme 143

Scheme 144

1. Ensure that the engine is at TDC with both camshaft sprocket V6 marks (1) in the 12 o'clock position.
2. Look down the left cylinder head chain cavity. The, timing dot on the counter balance shaft drive gear should be in the 6 o'clock position (2).

TIMING - SINGLE CAMSHAFT

Note. to adjust the timing on one camshaft, preform the following procedure.

Scheme 145

Scheme 146

Scheme 147

Scheme 148

1. Using Chain Tensioner Wedge, Special Tool 8379 (2), stabilize the secondary chain drive (3). For reference purposes, mark the chain-to-sprocket position.
2. Remove the camshaft drive gear retaining bolt.
3. Carefully remove the camshaft drive gear (2) from the camshaft.
4. Re-index the camshaft drive gear in the chain until the V6 mark is at the same position as the V6 mark on the opposite camshaft drive gear.
5. Using Special Tool 8428 Camshaft Wrench (2), rotate the camshaft until the alignment dowel on the camshaft is aligned with the slot in the cam shaft drive gear. CAUTION: Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt. Failure to do so may cause over-torqueing of bolt resulting in bolt failure.
6. Position the camshaft drive gear onto the camshaft, remove oil from bolt then install the retaining bolt. Using Special Tools, Spanner Wrench 6958 with Adapter Pins 8346 (4) and a suitable torque wrench (1), tighten retaining bolt to 122 N.m (90 ft. Lbs.).
7. Remove Special Tool 8379.
8. Rotate the crankshaft two full revolutions, then verify that the camshaft drive gear V6 marks are in fact aligned.
9. Install the cylinder head covers (Refer to «INSTALLATION»(ref-212814-S41942186802005122700000) ).

Scheme 149

Scheme 150

1. Remove the primary and secondary timing chains. (Refer to «REMOVAL»(ref-212814-S14303263392005122700000) ). 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 counterbalance shaft thrust plate (2).
2. Using Special Tool 8641 Counterbalance shaft remover/installer tool (1), remove the counterbalance shaft from the engine.