2.7L V6 Engine: Other Dodge Intrepid II

CAMSHAFT TIMING VERIFICATION

1. Remove electrical and vacuum harness retaining clips from valve cover studs. Remove ignition coils. Remove valve covers. Rotate engine until number one cylinder is at TDC of exhaust stroke. Ensure intake camshaft sprocket timing mark is at 90 degrees from valve cover mating surface on both cylinder heads. (Scheme 24)
2. Count chain pins from mark on intake camshaft, toward exhaust camshaft. If 12 chain pins exist between timing marks on intake camshaft and exhaust camshaft, camshafts are timed correctly. (Scheme 24) If marks are not positioned as previously stated, ensure timing chain is not stretched. If timing chain is okay, remove and reinstall camshafts, timing chains or sprockets as necessary.

Scheme 24

FUEL PRESSURE RELEASE

Releasing Fuel Pressure

1. Remove fuel pump relay from underhood power distribution center. Start and run engine until it stalls. Attempt to restart engine. If engine will not start, turn ignition off.
2. Unplug connector from any fuel injector. Connect a fused jumper wire (with 18 gauge or smaller alligator clips) between either fuel injector terminal and positive battery terminal. Connect one end of a second fused jumper wire to remaining fuel injector terminal.
3. Momentarily touch other end of second jumper wire to negative battery terminal. DO NOT hold jumper wire to negative battery terminal for more than a few seconds. Disconnect quick-connect fitting at fuel line. See «FUEL LINE QUICK-CONNECT FITTING»(ref-9330-S10399366452000101800000) . After servicing vehicle, reconnect fuel line and replace fuel pump relay.

Repressurizing Fuel System

1. Using scan tool, perform ASD fuel system test in order to pressurize fuel system. When using ASD fuel system test, auto shutdown relay remains energized (battery voltage is supplied to fuel injectors, ignition coils and heating element in oxygen sensor) for 7 minutes, until test is stopped, or ignition is turned off.
2. Check for and clear any Diagnostic Trouble Codes (DTCs) that may have been set due to fuel pump relay removal. See procedures in appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.

COOLING SYSTEM BLEEDING

1. Close radiator drain hand tight only. Ensure block drain plugs are in place. Attach one end of a 1/4" I.D. clear, 48" long hose, to air bleed valve located on water outlet connector at front of engine. (Scheme 25) Routing hose away from drive belt, drive pulleys and fan motors, place open end of hose into a clean container.
2. Install Filling Aid Funnel (8195). Using a clip, pinch off overflow hose that connects 2 chambers of coolant bottle. Open bleed valve. Fill cooling system using a 50/50 mix of MOPAR® Extended Life Coolant (or equivalent) and distilled water. Slowly fill coolant pressure bottle until a steady stream of coolant flows from hose attached to bleed valve. Gently squeeze upper radiator hose until all air is removed from system.
3. Close bleed valve and continue filling to top of filling aid funnel. Remove clip from overflow hose. Allow coolant in filling aid funnel to drain into overflow chamber of pressure bottle. Install cap on coolant pressure bottle. Remove hose from bleed valve.
4. Drive vehicle for one hour. After one hour of normal driving, a drop of coolant level in pressure bottle may occur. Top off coolant as necessary. If engine cooling system overheats and pushes coolant into overflow side of bottle, coolant will be sucked back into cooling system only if pressure cap is left on bottle. If pressure cap is removed, vacuum path between 2 bottle chambers will be broken, preventing return of coolant to cooling system.
5. Outboard chamber of coolant bottle is only used to recover coolant in event of an overheat and should normally be empty. If there is coolant in overflow side of coolant bottle, disconnect end of overflow hose at fill neck and lower it into a clean container. Allow coolant to drain into container until overflow side of bottle is empty.

Scheme 25

PRIMARY TIMING CHAIN & SPROCKETS

Note. Before removing primary timing chain, check timing drive system wear limits. See INSPECTION .

Scheme 26

Scheme 27

1. Remove upper radiator crossmember. Disconnect fan assembly connector. Remove fan assembly. Remove drive belts. Using Crankshaft Pulley Holder (8191), hold crankshaft pulley and remove center bolt. Using a 3-jaw puller, remove crankshaft pulley.
2. Remove upper intake manifold. See «INTAKE MANIFOLD»(ref-9330-S42245533222000101800000). Remove electrical and vacuum harness retaining clips from valve cover studs. Remove ignition coils. Remove valve covers. Remove power steering pump, and set aside. Remove drive belt tensioner pulley and bracket. Remove timing chain cover. CAUTION: DO NOT turn camshaft. Rotate engine by turning crankshaft.
3. Align crankshaft sprocket timing mark to mark on oil pump housing. Mark on oil pump housing is 60 degrees ATDC of number one cylinder. (Scheme 26) CAUTION: When timing chain is removed and cylinder heads are installed, DO NOT rotate camshafts or crankshaft without first locating proper crankshaft position.
4. Remove primary timing chain tensioner from right cylinder head. Remove camshaft position sensor from left cylinder head. Remove chain guide access plug from left cylinder head. (Scheme 27)
5. Remove right camshaft sprocket bolts and sprocket. When camshaft sprocket bolts are removed, camshaft will rotate clockwise. Remove left camshaft sprocket attaching bolts and sprocket. Remove lower chain guide and tensioner arm. Remove primary timing chain. CAUTION: DO NOT turn crankshaft while removing crankshaft sprocket.
6. Remove crankshaft sprocket by installing crankshaft pulley bolt. Using a 3-arm puller, remove crankshaft sprocket. DO NOT rotate crankshaft.

ROCKER ARM & VALVE LASH ADJUSTER

CAMSHAFTS

WATER PUMP

Note. Water pump bolts directly to engine block and uses an "O" ring at pump-to-block mating surfaces. DO NOT allow oil or grease to contact "O" ring. Pump cannot be rebuilt and is serviced as a unit.

OIL PAN

Cylinder Head

Inspect cylinder head for damage, cracks and warpage. Repair or replace cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. DO NOT grind more than .008" (.20 mm) combined total from surfaces of cylinder head and cylinder block deck.

Valve Springs

1. Inspect valve spring pressure and free length. If valves and/or seats have been ground, measure valve height. (Scheme 28) If valve height is greater than 1.8737" (47.592 mm) on intake or 1.9347" (49.141 mm) on exhaust, grind valve tip until valve height is within specification. See «VALVES & VALVE SPRINGS»(ref-9330-S40584935902000101800000) table under ENGINE SPECIFICATIONS.
2. If valves and/or seats have been ground, measure valve spring installed height from top of spring seat to bottom of spring retainer. (Scheme 28) If spacers are installed, measure from top of spacer. If height exceeds 1.5256" (38.75 mm), install a 0.030" (.762 mm) thick spacer in cylinder head counterbore to obtain correct installed height. See «VALVES & VALVE SPRINGS»(ref-9330-S40584935902000101800000) table under ENGINE SPECIFICATIONS.

Valve Guides

1. Install valve into cylinder head so that valve head is slightly off of valve seat. Install a small piece of hose onto valve stem to hold valve in place. Using a dial indicator touching outside diameter of valve head, rock valve back and forth and measure valve stem-to-guide oil clearance (wobble). See «CYLINDER HEAD»(ref-9330-S34800433082000101800000) table under ENGINE SPECIFICATIONS.
2. Ensure valve guide is not loose in cylinder head. Ensure valve stem diameter is within specification. See «CYLINDER HEAD»(ref-9330-S34800433082000101800000) table under ENGINE SPECIFICATIONS. Replace cylinder head if stem-to-guide oil clearance exceeds specification, or if guide is loose in cylinder head.

Note. DO NOT ream valve guides from standard to maximum oversize in one step. Ream guides to oversize in gradual steps so guides are reamed true in relation to valve seat.

Valve Seat

Worn or burned valve seats can be reworked, provided proper angles and seat width are obtained. Lower valve seat using a 15-degree stone. Raise valve seat using a 65-degree stone. Inspect valve and spring installed height after refacing valve and seat. Cylinder head must be replaced if valve seat cannot be corrected.

Valves

Valve stems are chrome plated and should not be polished.

Scheme 28

Fitting Pistons

Note. Piston diameter should be measured at normal room temperature of 70°F (21°C).

To determine if piston-to-cylinder clearance is within specification, piston skirt diameter should be measured 39" (10 mm) from bottom of piston at 90-degree angle to piston pin. Piston diameter must be within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Cylinder bore measurements should be taken at approximately middle of bore and transverse to engine crankshaft center line.

Piston Rings

1. Check ring end gap and side clearances. Measure ring end gap.472" (12.0 mm) from bottom of cylinder bore. See «PISTONS, PINS & RINGS»(ref-9330-S01570577312000101800000) table under ENGINE SPECIFICATIONS. Install piston ring in following sequence. Install oil ring expander, upper oil ring side rail and lower oil ring side rail.
2. Install No. 2 compression ring and No. 1 compression ring. Ensure No. 2 ring is installed with dot (manufacturer's identification mark) facing up. (Scheme 30) DO NOT use a piston ring expander to install oil ring side rails or expander. Position ring gaps in proper locations before piston installation. (Scheme 31)

Rod Bearings

1. Upper and lower bearing halves are not interchangeable. Install bearings in pairs. DO NOT file rods or bearing caps. Before installing rod bearings, hold a straightedge across threads of connecting rod bolts.
2. Ensure connecting rod bolt threads contact straightedge in all areas. If threads fail to contact straightedge, bolts are stretched and must be replaced. Ensure rod bearing cap face surfaces are not damaged. If fractured rod and joint face are damaged, engine damage may occur.
3. Bearing shells must be installed with tangs inserted into machined grooves in rods and bearing caps. Ensure hole in upper bearing half aligns with oil hole in connecting rod. Connecting rod bearings are available in .001" (.025 mm) and .010" (.250 mm) undersize.
4. Using a dial indicator, test connecting rod cap side play. Rest indicator tip against connecting rod cap being tested. Move connecting rod to rear of its travel. Zero dial indicator. Move connecting rod forward of its travel and read dial indicator. See «CONNECTING RODS»(ref-9330-S09367755452000101800000) table under ENGINE SPECIFICATIONS. Apply light coat of engine oil to connecting rod threads before tightening nut to specification. See «TORQUE SPECIFICATIONS»(ref-9330-S05092372272000101800000) .

Scheme 29

Scheme 30

Crankshaft & Main Bearings

1. Before installing main bearings, hold a straightedge across threads of main bearing cap bolts. Ensure main bearing cap bolt threads contact straightedge in all areas. If threads fail to contact straightedge, bolts are stretched and must be replaced.
2. Apply light coat of engine oil to threads before tightening bolts to specification. Tighten inner main bearing cap bolts. Tighten windage and main cap tie (horizontal) bolts.
3. Crankshaft main bearing bore grade markings are located on pan rail, just below left engine mount bracket. (Scheme 32) These markings are read left to right, corresponding with bore number 1, 2, 3 and 4.
4. Crankshaft main bearing journal grade markings are located on crankshaft rear counter weight. (Scheme 33) These markings are read left to right, corresponding with journal number 1, 2, 3 and 4.
5. Using main bearing selection chart, select main bearing. (Scheme 34) For an example, if crankshaft main bearing bore grade number is 3, and crankshaft main journal grade number is 2, install bearing (2) size +.0002" (.005 mm). Bearing number is marked in ink on bearing inner surface. (Scheme 35)
6. No. 3 main bearing serves as trust washer location. To check crankshaft end play, install a dial indicator. Move crankshaft completely to rear of its travel and zero dial indicator, then move crankshaft completely to front of its travel and read dial indictor.

Cylinder Block

Note. Cylinder bore should be measured at normal room temperature of 70°F (21°C).

Check cylinder bore, out-of-round and taper. Measurements should be taken at approximately .0196" (.050 mm) below top surface of cylinder bore, middle of bore and approximately .0020" (.051 mm) from bottom of cylinder bore.

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Oil Pressure

Oil pressure is 5 psi (.35 kg/cm 2 ) at idle, and 25-80 psi (1.8-5.6 kg/cm 2 ) at 3000 RPM. Rocker arm shafts are hollow and are used as lubrication oil ducts. (Scheme 36)or (Scheme 37).

Scheme 36

Scheme 37