3.7L Engine - Service Information: Removal & Installation Dodge Durango II

REMOVAL

Note. This procedure applies to both the 4X2 and 4X4 vehicles, steps that apply to the 4X4 vehicle only, are identified.

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

1. Discharge A/C system (Refer to «STANDARD PROCEDURE»(ref-212855-S20896637952005122700000) ).
2. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) .
3. Release fuel rail pressure. Refer to «FUEL DELIVERY»(ref-564649) .
4. Remove air cleaner assembly.
5. Disconnect battery.
6. Remove accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
7. Remove viscous fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
8. Remove A/C compressor (Refer to «COMPRESSOR-A/C»(ref-212855-S21919888982005122700000) ).
9. Remove generator and secure away from engine. NOTE: Do NOT remove the phenolic pulley from the P/S pump. It is not required for P/S pump removal.
10. Remove power steering pump with lines attached and secure away from engine.
11. Disconnect the heater hoses from the engine.
12. Disconnect heater hoses from heater core and remove hose assembly.
13. Remove upper radiator hose from engine.
14. Remove lower radiator hose from engine.
15. Disconnect transmission oil cooler lines at the radiator.
16. Disconnect the power steering cooler lines.
17. Remove radiator assembly (Refer to «RADIATOR»(ref-212747-S10591844532006072400000) .
18. Disconnect throttle and speed control cables.
19. Disconnect the engine to body ground straps at the left side of cowl.
20. Disconnect the engine wiring harness at the following points: Intake air temperature (IAT) sensor Fuel Injectors Throttle Position (TPS) Switch Idle Air Control (IAC) Motor Engine Oil Pressure Switch Engine Coolant Temperature (ECT) Sensor Manifold Absolute Pressure MAP) Sensor Camshaft Position (CMP) Sensor Coil Over Plugs Crankshaft Position Sensor
21. Remove coil over plugs.
22. Remove fuel rail and secure away from engine. NOTE: It is not necessary to release the quick connect fitting from the fuel supply line for engine removal.
23. Remove the PCV hose.
24. Remove the breather hoses.
25. Remove the vacuum hose for the power brake booster.
26. Disconnect knock sensors.
27. Remove engine oil dipstick tube.
28. Remove intake manifold.
29. Install engine lifting fixture, Tool 8247, using original fasteners from the removed intake manifold, and fuel rail. Torque to factory specifications.
30. Raise vehicle on hoist.
31. Disconnect exhaust pipes from exhaust manifolds (Refer to «EXHAUST SYSTEM»(ref-212817) ).
32. 4X4 vehicles Disconnect axle vent tube from left side engine mount.
33. Remove the through bolt retaining nut (1) and bolt (3) from both the left and right side engine mounts (2).
34. 4X4 vehicles Remove locknut (1) from left and right side engine mount brackets (4).
35. Disconnect two ground straps (1) from the lower left hand side and one ground strap (5) from the lower right hand side of the engine.
36. Disconnect crankshaft position sensor (1). NOTE: The following step applies to 4X4 vehicles equipped with automatic transmission only.
37. 4X4 vehicles Remove the axle isolator bracket (2) from the engine, transmission and the axle
38. Remove structural cover (Refer to «REMOVAL»(ref-212814-S08282494032005122700000) ).
39. Remove starter.
40. Remove torque converter bolts (Automatic Transmission Only).
41. Remove transmission to engine mounting bolts.
42. Disconnect the engine block heater power cable from the block heater, if equipped.
43. Lower vehicle.
44. Remove throttle body resonator assembly and air inlet hose.
45. Disconnect throttle and speed control cables.
46. Disconnect tube from both the left and right side crankcase breathers (1). Remove breathers
47. Remove generator.
48. Disconnect the two heater hoses (1) from the timing chain cover and heater core.
49. Unclip and remove heater hoses and tubes (1) and (2). from the intake manifold.
50. Disconnect engine harness at the following points Intake air temperature (IAT) sensor (4) Fuel Injectors Throttle Position (TPS) Switch (2) Idle Air Control (IAC) Motor (3) Engine Oil Pressure Switch Engine Coolant Temperature (ECT) Sensor Manifold absolute pressure (MAP) Sensor Camshaft Position (CMP) Sensor Coil Over Plugs
51. Disconnect the vacuum lines at the throttle body and intake manifold.
52. Remove power steering pump and position out of the way.
53. Disconnect body ground strap at the right side cowl (3).
54. Disconnect body ground strap at the left side cowl (2). NOTE: It will be necessary to support the transmission in order to remove the engine.
55. Position a suitable jack under the transmission.
56. Remove engine from the vehicle.

Scheme 80

Scheme 81

1. Position engine in the vehicle.
2. Position both the left and right side engine mount brackets and install the through bolts (3) and nuts (1). Tighten nuts (1) to 4X2 vehicles 95 N.m (70 ft. lbs.). 4X4 vehicles 102 N.m (75 ft. lbs.).
3. 4X4 vehicles lnstall locknuts onto the engine mount brackets. Tighten locknuts to 41 N.m (30 ft. lbs.).
4. Remove jack from under the transmission.
5. Remove Engine Lifting Fixture Special Tool 8347.
6. Remove Special Tools 8400 Lifting Studs.
7. Position generator wiring behind the oil dipstick tube, then install the oil dipstick tube upper mounting bolt.
8. Connect both left and right side body ground straps.
9. Install power steering pump.
10. Connect fuel supply line quick connect fitting.
11. Connect the vacuum lines at the throttle body and intake manifold.
12. Connect engine harness at the following points: Intake Air Temperature (IAT) Sensor Idle Air Control (IAC) Motor Fuel Injectors Throttle Position (TPS) Switch Engine Oil Pressure Switch Engine Coolant Temperature (ECT) Sensor Manifold Absolute Pressure (MAP) Sensor Camshaft Position (CMP) Sensor Coil Over Plugs
13. Position and install heater hoses and tubes (1) onto intake manifold.
14. Install the heater hoses onto the heater core and the engine front cover.
15. Install generator Refer to «GENERATORS & REGULATORS»(ref-166557)
16. Install radiator assembly (Refer to «RADIATOR»(ref-212747-S10591844532006072400000) ).
17. Connect radiator upper and lower hoses.
18. Connect power steering cooler lines.
19. Connect the transmission oil cooler lines to the radiator.
20. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ) and (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
21. Install A/C compressor (Refer to «COMPRESSOR-A/C»(ref-212855-S21919888982005122700000) ).
22. Install both breathers. Connect tube to both crank-case breathers.
23. Connect throttle and speed control cables.
24. Install throttle body resonator assembly and air inlet hose. Tighten clamps 4 N.m (35 in. lbs.).
25. Raise vehicle.
26. Install transmission to engine mounting bolts. Tighten the bolts to 41 N.m (30 ft. lbs.).
27. Install torque converter bolts (Automatic Transmission Only).
28. Connect crankshaft position sensor.
29. 4X4 vehicles Position and install the axle isolator bracket onto the axle, transmission and engine block. Tighten bolts to specification (Refer to «SPECIFICATIONS»(ref-212814-S38214486652005122700000) ).
30. Install starter. CAUTION: The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover.
31. Install structural cover (Refer to «INSTALLATION»(ref-212814-S25848232402005122700000) ).
32. Install exhaust crossover pipe.
33. Install engine block heater power cable, If equipped.
34. 4X4 vehicles Connect axle vent tube to left side engine mount.
35. Lower vehicle.
36. Check and fill engine oil.
37. Recharge the A/C system (Refer to «STANDARD PROCEDURE»(ref-212855-S20896637952005122700000) ).
38. Refill the engine cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
39. Install the battery tray and battery.
40. Connect the battery positive and negative cables.
41. Start the engine and check for leaks.

INSTALLATION

Note. The gasket may be used again, provided no cuts, tears, or deformation has occurred.

1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary.
2. Tighten cylinder head cover bolts and double ended studs to 12 N.m (105 in. lbs.).
3. Install left side breather and connect breather tube.
4. Connect injector electrical connectors and injector harness retaining clips.
5. Install the resonator and air inlet hose.
6. Connect negative cable to battery.

Note. The cylinder heads must be removed in order to perform this procedure.

1. Remove rocker arms and lash adjusters (Refer to «ARM-ROCKER»(ref-212814-S40746025872005122700000) ).
2. Remove the camshaft bearing caps and the camshaft. NOTE: All six valve springs and valves are removed in the same manner; this procedure only covers one valve and valve spring.
3. Using Tool C-3422-B or C-3422-C Valve Spring Compressor and Tool 8519 Adapter (2), 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.
4. Remove the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
5. Remove the valve spring compressor (2).
6. Remove the spring retainer, and the spring. NOTE: Check for sharp edges on the keeper grooves. Remove any burrs from the valve stem before removing the valve from the cylinder head.
7. Remove the valve from the cylinder head. NOTE: The valve stem seals are common between intake and exhaust.
8. Remove the valve stem seal. Mark the valve for proper installation.

Note. Disconnect the battery negative cable to prevent accidental starter engagement.

Scheme 82

1. Remove the cylinder head cover (Refer to «REMOVAL»(ref-212814-S22748134532005122700000) ).
2. For rocker arm removal on cylinder No. 4, Rotate the crankshaft until cylinder No. 1 is at BDC intake stroke.
3. For rocker arm removal on cylinder No. 1, Rotate the crankshaft until cylinder No. 1 is at BDC combustion stroke.
4. For rocker arm removal on cylinders No. 3 and No. 5, Rotate the crankshaft until cylinder No. 1 is at TDC exhaust stroke.
5. For rocker arm removal on cylinders No. 2 and No. 6, Rotate the crankshaft until cylinder No. 1 is at TDC ignition stroke.
6. Using special Tool 8516 Rocker Arm Remover (2), press downward on the valve spring, remove rocker arm.

Scheme 83

1. Using Tool 8516 (2) press downward on the valve spring, install rocker arm. CAUTION: Make sure the rocker arms are installed with the concave pocket over the lash adjusters. Failure to do so may cause severe damage to the rocker arms and/or lash adjusters. NOTE: Coat the rocker arms with clean engine oil prior to installation.
2. For rocker arm installation on cylinders No. 4, Rotate the crankshaft until cylinder No. 1 is at BDC intake stroke.
3. For rocker arm installation on cylinder No. 1, Rotate the crankshaft until cylinder No. 1 is at BDC combustion stroke.
4. For rocker arm installation on cylinders No. 3 and No. 5, Rotate the crankshaft until cylinder No. 1 is at TDC exhaust stroke.
5. For rocker arm installation on cylinders No. 2 and No. 6, Rotate the crankshaft until cylinder No. 1 is at TDC ignition stroke.
6. Install the cylinder head cover (Refer to «INSTALLATION»(ref-212814-S39327807952005122700000) ).

1. Remove the cylinder head cover (Refer to «REMOVAL»(ref-212814-S22748134532005122700000) ).
2. Using Special Tool 8516 Valve Spring Compressor, 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 Special Tool 8387 Valve Spring Compressor, 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 Special Tool 8387 Valve Spring Compressor, 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 Special Tool 8516 Valve Spring Compressor, install the rocker arms and the hydraulic lash adjusters.
10. Install the cylinder head cover (Refer to «INSTALLATION»(ref-212814-S39327807952005122700000) ).

Note. To remove the crankshaft from the engine, the engine must be removed from the vehicle.

Scheme 84

1. Remove the engine (Refer to «REMOVAL»(ref-212814-S11652062142005122700000) ).
2. Remove the engine oil pump (Refer to «REMOVAL»(ref-212814-S34133887422005122700000) ). CAUTION: DO NOT pry on the oil pan gasket when removing the oil pan, The oil pan gasket is mounted to the cylinder block in three locations and will remain attached to block when removing oil pan. Gasket can not be removed with oil pan.
3. Remove the bedplate mounting bolts. Note the location of the two stud bolts for installation.
4. Remove the connecting rods from the crankshaft. CAUTION: The bedplate to cylinder block mating surface is a critical sealing surface. Do not pry on or damage this surface in anyway. NOTE: The bedplate contains the lower main bearing halves. Use care when handling bedplate as not to drop or damage bearing halves. Installing main bearing halves in the wrong position will cause severe damage to the crankshaft. NOTE: The bedplate has pry points (1) cast into it. Use these points only.
5. Carefully pry on the pry points (1) to loosen the bedplate then remove the bedplate. CAUTION: When removing the crankshaft, use care not to damage bearing surfaces on the crankshaft.
6. Remove the crankshaft.
7. Remove the crankshaft tone wheel.

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

Scheme 85

Scheme 86

Scheme 87

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). CAUTION: The bedplate to cylinder block mating surface must be coated with Mopar® 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 2.5mm (0.100 inch) bead of Mopar® 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. 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 «STANDARD PROCEDURE»(ref-212814-S18190421062005122700000) ).
10. Install oil pump (Refer to «INSTALLATION»(ref-212814-S30821640192005122700000) ).
11. Install the engine (Refer to «INSTALLATION»(ref-212814-S41942186802005122700000) ).

1. Using Special Tool 8348 (2) and 8512 (3), install crankshaft front seal.
2. Install vibration damper (Refer to «INSTALLATION»(ref-212814-S06377403922005122700000) ).
3. Install radiator cooling fan and shroud (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
4. Install upper radiator hose.
5. Install A/C compressor and tighten fasteners to 54 N.m (40 ft. lbs.).
6. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
7. Refill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
8. Connect negative cable to battery.

Note. This procedure can be performed in vehicle.

Scheme 88

1. If being performed in vehicle, remove the transmission.
2. Remove the flexplate (Refer to «REMOVAL»(ref-212814-S37487061682005122700000) ). 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 89

Scheme 90

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 «INSTALLATION»(ref-212814-S12194371632005122700000) ).
5. Install the transmission.

1. Remove the transmission.
2. Remove the bolts and flexplate.

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.
3. Install the transmission.

1. Disconnect negative cable from battery.
2. Remove the following components: Oil pan and gasket/windage tray (Refer to «REMOVAL»(ref-212814-S32885733702005122700000) ). Cylinder head(s) (Refer to «REMOVAL»(ref-212814-S22748134532005122700000) ) and (Refer to «REMOVAL»(ref-212814-S22748134532005122700000) ).
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 Special Tool 8507 Connecting Rod Guides into 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.

Scheme 91

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® 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 «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
6. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) )
7. Connect negative cable to battery.

Scheme 92

1. Position the structural cover in the vehicle.
2. Install all bolts (1,2,3) retaining the cover-to-engine. DO NOT tighten the bolts at this time.
3. Install the four cover-to-transmission bolts. Do NOT tighten at this time. CAUTION: The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence. Failure to do so may cause damage to the cover.
4. Starting with the two rear cover-to-engine bolts, tighten bolts (1) to 54 N.m (40 ft. lbs.), then tighten bolts (2) and (3) to 54 N.m ( 40 ft. lbs.) in the sequence shown.
5. Install the exhaust pipe on left hand exhaust manifold.
6. Tighten exhaust manifold-to-exhaust pipe retaining bolts to 20 - 26 N.m (15-20 ft. lbs.).

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. Clean the oil pan gasket mating surface of the bedplate and oil pan.
2. Inspect integrated oil pan gasket, and replace as necessary.
3. Position the integrated oil pan gasket/windage tray assembly.
4. Install the oil pickup tube
5. If removed, install stud at position No. 9.
6. Install the mounting bolt and nuts. Tighten nuts to 28 N.m (20 ft. lbs.).
7. Position the oil pan and install the mounting bolts. Tighten the mounting bolts to 15 N.m (11 ft. lbs.) in the sequence shown.
8. Install structural dust cover, if equipped.
9. Lower the engine into mounts using Special Tool 8534.
10. Install both the left and right side engine mount through bolts. Tighten the nuts to 68 N.m (50 ft. lbs.).
11. Remove Special Tool 8534.
12. Install the intake manifold (Refer to «MANIFOLD-INTAKE»(ref-212814-S37585498582005122700000) ).
13. Fill engine oil.
14. Reconnect the negative battery cable.
15. Start engine and check for leaks.

1. Install oil pressure sender.
2. Connect oil pressure sender wire.
3. Install front splash shield.
4. Lower vehicle.
5. Connect the negative battery cable.

1. Remove the oil pan and pick-up tube (Refer to «REMOVAL»(ref-212814-S32885733702005122700000) ).
2. Remove the timing chain cover (Refer to «REMOVAL»(ref-212814-S24469805602005122700000) ).
3. Remove the timing chains and tensioners (Refer to «REMOVAL»(ref-212814-S14303263392005122700000) ).
4. Remove the four bolts, primary timing chain tensioner and the oil pump.

All engines are equipped with a high quality full-flow, disposable type oil filter (1). DaimlerChrysler Corporation recommends a Mopar® or equivalent oil filter be used.

Scheme 93

1. Position a drain pan under the oil filter.
2. Using a suitable oil filter wrench loosen filter.
3. Rotate the oil filter (1) counterclockwise to remove it from the cylinder block oil filter boss.
4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter.
5. With a wiping cloth, clean the gasket sealing surface of oil and grime.

Scheme 94

1. Lightly lubricate oil filter gasket (2) with engine oil.
2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface (1), hand tighten filter (2) one full turn, do not over tighten.
3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks.

1. Disconnect negative cable from battery.
2. Remove resonator assembly and air inlet hose.
3. Disconnect throttle and speed control cables.
4. Disconnect electrical connectors for the following components: Refer to «FUEL INJECTION»(ref-212820) for component locations. Manifold Absolute Pressure (MAP) Sensor Intake Air Temperature (IAT) Sensor Throttle Position (TPS) Sensor Coolant Temperature (CTS) Sensor Idle Air Control (IAC) Motor
5. Disconnect vapor purge hose, brake booster hose, speed control servo hose, positive crankcase ventilation (PCV) hose.
6. Disconnect generator electrical connections.
7. Disconnect air conditioning compressor electrical connections.
8. Disconnect left and right radio suppressor straps.
9. Disconnect and remove ignition coil towers.
10. Remove top oil dipstick tube retaining bolt and ground strap.
11. Bleed fuel system. Refer to «FUEL DELIVERY»(ref-564649) .
12. Remove fuel rail.
13. Remove throttle body assembly and mounting bracket.
14. Drain cooling system below coolant temperature level (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
15. Remove the heater hoses from the engine front cover and the heater core.
16. Unclip and remove heater hoses and tubes from intake manifold.
17. Remove coolant temperature sensor (Refer to «SENSOR-ENGINE COOLANT TEMPERATURE»(ref-212747-S16545540332006072400000) ).
18. Remove intake manifold retaining fasteners in reverse order of tightening sequence.
19. Remove intake manifold.

1. Install intake manifold gaskets.
2. Install intake manifold.
3. Install intake manifold retaining bolts and tighten in sequence shown in to 12 N.m (105 in. lbs.).
4. Install left and right radio suppressor straps.
5. Install throttle body assembly.
6. Connect throttle cable and speed control cable to throttle body.
7. Install fuel rail.
8. Install ignition coil towers.
9. Position and install heater hoses and tubes onto intake manifold.
10. Install the heater hoses to the heater core and engine front cover.
11. Connect electrical connectors for the following components: Manifold Absolute Pressure (MAP) Sensor Intake Air Temperature (IAT) Sensor Throttle Position (TPS) Sensor Coolant Temperature (CTS) Sensor Idle Air Control (IAC) Motor Ignition coil towers Fuel injectors
12. Install top oil dipstick tube retaining bolt and ground strap.
13. Connect generator electrical connections.
14. Connect Vapor purge hose, Brake booster hose; Speed control servo hose, Positive crankcase ventilation (PCV) hose.
15. Fill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
16. Install resonator assembly and air inlet hose.
17. Connect negative cable to battery.

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

1. Coat counterbalance 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 Special Tool 8641 Counterbalance shaft remover/installer tool, carefully install counterbalance shaft into engine.
3. Install Counterbalance 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.

1. Remove the primary and secondary timing chains and sprockets. Refer to «BELT/CHAIN-TIMING AND SPROCKETS»(ref-212814-S33582905642005122700000) . 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 Special Tool 8517 Slide Hammer, 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 «BELT/CHAIN-TIMING AND SPROCKETS»(ref-212814-S33582905642005122700000) .

Scheme 95

Scheme 96

1. Disconnect the battery negative cable.
2. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
3. Remove electric cooling fan and fan shroud assembly.
4. Remove radiator fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
5. Disconnect both heater hoses at timing cover.
6. Disconnect lower radiator hose at engine.
7. Remove accessory drive belt tensioner assembly (1).
8. Remove crankshaft damper (Refer to «REMOVAL»(ref-212814-S15075701832005122700000) ).
9. Remove the generator (Refer to «GENERATORS & REGULATORS»(ref-166557) ).
10. Remove A/C compressor (Refer to «COMPRESSOR-A/C»(ref-212855-S21919888982005122700000) ). CAUTION: The 3.7L engine uses an anerobic sealer instead of a gasket to seal the front cover to the engine block, from the factory. For service, Mopar® Engine RTV sealant must be substituted. NOTE: It is not necessary to remove the water pump for timing cover removal.
11. Remove the bolts holding the timing cover to engine block.
12. Remove the timing cover.

Scheme 97

Scheme 98

1. Clean timing chain cover and block surface using rubbing alcohol. CAUTION: The 3.7L uses a special anerobic sealer instead of a gasket to seal the timing cover to the engine block, from the factory. For service repairs, Mopar® Engine RTV must be used as a substitute.
2. Inspect the water passage o-rings (2) for any damage, and replace as necessary.
3. Apply Mopar® Engine RTV sealer to front cover as shown (3) using a 3 to 4mm thick bead.
4. Install cover. Tighten fasteners in sequence as . shown in to 58 N.m (43 ft. lbs.).
5. Install crankshaft damper (Refer to «INSTALLATION»(ref-212814-S06377403922005122700000) ).
6. Install the A/C compressor (Refer to «COMPRESSOR-A/C»(ref-212855-S21919888982005122700000) ).
7. Install the generator (Refer to «GENERATORS & REGULATORS»(ref-166557) ).
8. Install accessory drive belt tensioner (Refer to «ACCESSORY DRIVE»(ref-212748) ).
9. Install radiator upper and lower hoses.
10. Install both heater hoses.
11. Install radiator fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
12. Fill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
13. Connect the battery negative cable.

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

1. Disconnect negative cable from battery.
2. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
3. Remove right and left cylinder head covers (Refer to «REMOVAL»(ref-212814-S22748134532005122700000) ).
4. Remove radiator fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
5. Rotate engine until tinning mark (2) on crankshaft damper aligns with TDC mark on timing chain cover (1).
6. Make sure the camshaft sprocket "V6" marks (1) are at the 12 o'clock position (No. 1 TDC exhaust stroke).
7. Remove power steering pump (Refer to «PUMP»(ref-212826) ).
8. Remove access plugs (1 and 2) from left and right cylinder heads for access to chain guide fasteners.
9. Remove the oil fill housing to gain access to the right side tensioner arm fastener.
10. Remove crankshaft damper (Refer to «REMOVAL»(ref-212814-S15075701832005122700000) ) and timing chain cover (Refer to «REMOVAL»(ref-212814-S24469805602005122700000) ).
11. Collapse and pin primary chain tensioner. CAUTION: Plate behind left secondary chain tensioner could fall into oil pan. Therefore, cover pan opening.
12. Remove secondary chain tensioners.
13. Remove camshaft position sensor (2). CAUTION: Care should be taken not to damage camshaft target wheel. Do not hold target wheel while loosening or tightening camshaft sprocket. Do not place the target wheel near a magnetic source of any kind. A damaged or magnetized tar-Jet wheel could cause a vehicle no start condition. CAUTION: Do not forcefully rotate the camshafts or crankshaft independently of each other. Damaging intake valve to piston contact will occur. Ensure negative battery cable is disconnected to guard against accidental starter engagement.
14. Remove left and right camshaft sprocket bolts.
15. While holding the left camshaft steel tube with Special Tool 8428 Camshaft Wrench (2), remove the left camshaft sprocket. Slowly rotate the camshaft approximately 5 degrees clockwise to a neutral position.
16. While holding the right camshaft steel tube with Special Tool 8428 Camshaft Wrench (2), remove the right camshaft sprocket.
17. Remove idler sprocket assembly bolt.
18. Slide the idler sprocket assembly and crank sprocket forward simultaneously to remove the primary and secondary chains.
19. Remove both pivoting tensioner arms and chain guides.
20. Remove primary chain tensioner.