2.7L V6 Engine: Diagnosis Dodge Intrepid II

TROUBLE SHOOTING

Note. To trouble shoot mechanical engine components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION.

Inspection

Before cleaning, check for leaks, damage and cracks. Using a gasket removing compound, soften old gasket material. Clean cylinder head and engine block. Clean oil passages. see scheme 34 Check cylinder head for warpage. Ensure cylinder head is not warped beyond.008" (0.2 mm). DO NOT grind more than.008" (.20 mm) combined total from surfaces of cylinder head and cylinder block deck.

Note. Cylinder head bolts are tightened using a torque-to-yield procedure. Examine bolts before reuse. If threads are necked down or stretched, replace bolts. Necking can be checked by holding a straightedge against threads. If all threads do not contact straightedge, replace bolt.

Remove right valve cover. Looking through cylinder head timing drive cavity, inspect primary chain tensioner plunger. Rotate engine clockwise to remove any chain slack and to achieve maximum tensioner extension. If maximum wear indicator groove (machined groove) on plunger is visible, timing chain and/or related components are worn or stretched to service limits. (Scheme 1) Inspect all sprockets, tensioners and chain guides. Replace as necessary.

Scheme 1

Scheme 2

Scheme 3

1. Using sprocket installer, install crankshaft sprocket until sprocket bottoms against crankshaft step flange. (Scheme 2) DO NOT rotate crankshaft.
2. Measure crankshaft sprocket installed depth from sprocket outer face to end of crankshaft. (Scheme 3) Sprocket should be 1.535-1.539" (38.99-39.09 mm) below end of crankshaft.
3. Align crankshaft sprocket timing mark to mark on oil pump housing. Lubricate primary timing chain and guides with engine oil. Place left primary timing chain sprocket onto chain so that timing mark on sprocket is located between 2 plated links on chain. see scheme 9
4. Lower primary timing chain, with left sprocket, through left cylinder head opening. Loosely position left camshaft sprocket over camshaft hub. Allow camshaft sprockets to float on camshaft hub. Align plated link to crankshaft sprocket timing mark.
5. Position chain onto water pump drive sprocket. Align right camshaft sprocket timing mark to plated link on timing chain and loosely position over camshaft hub. see scheme 9 Ensure all plated links are properly aligned to timing marks on all sprockets. Install left lower chain guide and tensioner arm and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-9330-S05092372272000101800000).
6. Inspect "O" ring on chain guide access plug before installing. Replace "O" ring if necessary. Install chain guide access plug and tighten to specification.
7. Remove primary timing chain tensioner from tensioner housing. (Scheme 4) Place check ball end of tensioner into shallow end of Timing Chain Tensioner Resetting Gauge (8186). (Scheme 1) Using hand pressure, slowly depress tensioner until check ball unseats and oil is purged from cylinder.
8. Reinstall tensioner into tensioner housing. Position cylinder plunger into deeper end of timing chain tensioner purging and resetting tool. Using hand pressure, slowly depress tensioner until tensioner body bottoms against top edge of timing chain tensioner purging and resetting tool. NOTE: Ensure tensioner is properly reset. Failure to properly reset tensioner will cause tensioner jamming.
9. Install chain tensioner into right cylinder head. Using a 3/8" drive shaft and breaker bar, rotate right camshaft until camshaft hub aligns to camshaft sprocket. Install right camshaft sprocket and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-9330-S05092372272000101800000).
10. Rotate left camshaft. Install left camshaft sprocket and tighten bolts to specification. Slightly rotate engine clockwise to remove timing chain slack, if necessary. Using a flat-blade screwdriver, gently pry tensioner arm toward tensioner slightly to release tensioner arm. (Scheme 5) Ensure tensioner extends. To complete installation, reverse removal procedure.

Scheme 4

Scheme 5

Check rocker arm roller and rocker arm bore for scuffing or wear. Inspect rocker arm for fatigue or cracking. With a small wire, check oil holes for clogging. Replace any rocker arm showing wear or fatigue.

1. Inspect camshaft bearing journals for damage and binding. If journals are binding, also check cylinder head for damage. Check cylinder head oil passages for clogging. see scheme 34
2. Check cam lobes for abnormal wear and damage. Replace if damaged. Measure lobe height and replace if out of tolerance. See «CAMSHAFT»(ref-9330-S09925929222000101800000) table under ENGINE SPECIFICATIONS. (Scheme 7) Check cam follower assembly for wear or damage. Replace as necessary.

Note. Two styles of secondary camshaft chain tensioners are used. Early build tensioners can be disassembled into subcomponents, but later build tensioners cannot. Different repair procedures are used on early and late build camshaft chain tensioners.

Scheme 6

Scheme 7

1. Ensure mating surface of oil pump housing is smooth. If oil pump housing cover is scratched or grooved, replace oil pump cover. Using a straightedge and a feeler gauge, check flatness of oil pump cover. Replace cover if it is equal to or exceeds specification. See «OIL PUMP SPECIFICATIONS»(ref-9330-S33429638052000101800000) table.
2. Measure thickness of both rotors. Replace rotors if not within specification. See «OIL PUMP SPECIFICATIONS»(ref-9330-S33429638052000101800000) table.
3. Install outer rotor into oil pump housing. Measure clearance between outer rotor and oil pump housing. If clearance is equal to or exceeds specification but outer rotor O.D. is within specification, replace timing belt cover.
4. Install inner rotor, and measure clearance between inner and outer rotors. Replace pump assembly if clearance is equal to or exceeds specification. See «OIL PUMP SPECIFICATIONS»(ref-9330-S33429638052000101800000) table.
5. Place a straightedge across oil pump housing, between bolt holes. Using a feeler gauge, check clearance between straightedge and oil pump rotors. If clearance is equal to or exceeds specification and rotors are at correct thickness, replace oil pump assembly.
6. Ensure pressure relief valve slides freely in bore and is free from scoring. If small marks are present, they may be removed using 400-grit dry sandpaper. Check free length and pressure of pressure relief valve spring. Replace spring if it is not within specification. See «OIL PUMP SPECIFICATIONS»(ref-9330-S33429638052000101800000) table.