3.2L Engine & 3.5L V6 Engine: Other Dodge Intrepid II

CAMSHAFT SPROCKET TIMING PROCEDURE

Note. If camshaft sprocket bolts have been loosened or removed, check camshafts timing, and discard camshaft sprocket bolts.

1. Lift left side of engine slightly. This will supply left side camshaft sprocket bolt clearance. Left camshaft sprocket bolt is 1.65" (42 mm) longer than right side bolt. Remove and discard camshaft sprockets bolts. Remove sprockets.
2. Position crankshaft sprocket to TDC mark located on oil pump housing. (Scheme 58) Place tip of a dial indicator on top of number one cylinder piston. (Scheme 59) Check TDC of piston by rotating crankshaft until number one piston is at exactly TDC. Install Camshaft Aligner (6642) onto rear of each cylinder head. (Scheme 60)
3. Place timing belt tensioner in a soft-jaw vise. (Scheme 61) Ensure timing belt tensioner is placed in vise in same position as it is installed in engine. Slowly compress timing belt tensioner plunger. Timing belt tensioner bleed down will take about 5 minutes. Insert locking pin through timing belt tensioner body and plunger. (Scheme 61)
4. Ensure pin head is facing outside of engine when tensioner is reinstalled. Once a pin is installed, tensioner must be stored with plunger facing up until tensioner is ready to be reinstalled.
5. Using NEW bolts, install camshaft sprockets finger tight. Ensure camshaft sprocket with DIS pickup slots is installed on left camshaft. (Scheme 62) DO NOT tighten bolts.
6. Position both camshaft sprocket marks between marks on cover. (Scheme 58) Install timing belt by starting at crankshaft sprocket and working in a counterclockwise direction. Maintain tension on belt as it is positioned around tensioner pulley. Ensure camshaft sprocket marks are still positioned between marks on covers.
7. Push tensioner pulley against timing belt. Install tensioner into housing, and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-9332-S11039190512000101800000). When tensioner is in place, pull locking pin to allow tensioner to extend to pulley bracket. With number one piston at TDC and all timing marks aligned, tighten camshaft bolts to specification.
8. Reassemble all remaining parts. Start engine, and allow to idle for about one minute. Increase engine speed to 1200-1500 RPM and allow it to run for about 5 minutes. This will help to bleed any air remaining in timing belt tensioner.

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

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-9332-S09838558542000101800000) . 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 switch 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 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 63) 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 drawn 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 emptied.

Scheme 63

TIMING BELT & SPROCKETS

Note. If camshaft sprocket bolts have been loosened or removed, check camshafts timing, and discard camshaft sprocket bolts. See CAMSHAFT SPROCKET TIMING PROCEDURE under ADJUSTMENTS.

ROCKER ARM & VALVE LASH ADJUSTER

Note. To prevent air ingestion into lash adjusters, avoid turning rocker arm assembly upside down

CAMSHAFTS

WATER PUMP

Note. Water pump bolts directly to engine block and uses an "O" ring for pump-to-block mating surfaces. DO NOT allow oil or grease to contact "O" ring. Manufacture recommends pump to be serviced as a unit.

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 64) If valve height is greater than 1.8102" (45.980 mm) on intake or 1.7185" (43.650 mm) on exhaust, grind valve tip until valve height is within specification. See «VALVES & VALVE SPRINGS»(ref-9332-S05452557422000101800000) 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 64) 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-9332-S05452557422000101800000) table.
3. Intake and exhaust springs are of 2 different lengths, are wound in different directions, and are color coded. Intake spring (Orange) is wound in right direction. Exhaust spring (Yellow) is wound in left direction.

Valve Guides

1. Install valve into cylinder head so that valve face is as specified. See «CYLINDER HEAD»(ref-9332-S14226533912000101800000) table under ENGINE SPECIFICATIONS. Install a small piece of hose onto valve stem to hold valve .59" (15 mm) off valve seat. Using a dial indicator touching outer diameter of valve head, rock valve back and forth and measure valve stem-to-guide oil clearance (wobble).
2. Ensure valve guide is not loose in cylinder head. Ensure valve stem diameter is within specification. See «CYLINDER HEAD»(ref-9332-S14226533912000101800000) 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 64

Fitting Pistons

To determine if piston-to-cylinder clearance is within specification, measure piston skirt diameter .50" (12 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. Install pistons with arrow on top of piston pointing toward front of engine.

Piston Rings

1. Check ring end gap and side clearances. Measure ring end gap.50" (12.7 mm) from bottom of cylinder bore. See «PISTONS, PINS & RINGS»(ref-9332-S23241958582000101800000) 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 65) 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 66)

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.
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. Rod bearings are available in 3 oversizes; .001" (.03 mm), .003" (.08 mm) and .010" (.25 mm).
4. Using a dial indicator, test connecting rod cap side play. Rest tip of dial indicator 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-9332-S03026923272000101800000) table under ENGINE SPECIFICATIONS. Apply light coat of engine oil to connecting rod bolt threads before tightening nut to specification. See «TORQUE SPECIFICATIONS»(ref-9332-S11039190512000101800000) .

Crankshaft & Main Bearings

1. If reusing main bearings, mark both upper and lower bearing halves for proper installation. Upper and lower bearing halves are not interchangeable with each other or with any other main bearing sets. All upper bearing halves are interchangeable with each other. All lower bearing halves are interchangeable with each other. Check journals for excessive wear, taper, out-of-round and scoring.
2. DO NOT grind journal.012" (.30 mm) under standard journal diameter. DO NOT grind thrust faces of number 2 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes. Clean out all oil passages.
3. Ensure that after grinding, final paper or cloth polish in same direction as normal engine rotation. Remove bearing caps one at a time. Insert Upper Main Bearing Puller (C-3059) into oil hole of crankshaft. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell. (Scheme 67)
4. Selectively fit only one main bearing at a time, while all other main bearing caps are tightened to specification. When installing a new upper bearing shell, slightly chamfer sharp edges from plain side.
5. Lubricate main bearing with clean engine oil. Start bearing in position and insert upper main bearing puller into oil hole of crankshaft. Slowly rotate crankshaft counterclockwise sliding bearing into position.
6. 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. Main bearings are available in.001" (.03 mm) and.010" (.25 mm) undersize.
7. Apply light coat of engine oil to threads before tightening bolts to specification. Tighten using following procedure: tighten inner main bearing cap bolts, tighten windage and tighten main cap tie (horizontal) bolts.
8. Crankshaft main bearing bore grade markings are located on left side of pan rail, just rear of left engine mount bracket. (Scheme 68) These markings are read left to right, corresponding with bore number 1, 2, 3, 4.
9. Crankshaft main bearing journal grade markings are located on crankshaft rear counter weight. (Scheme 69) These markings are read left to right, corresponding with journal number 1, 2, 3, 4.
10. Using main bearing selection chart, select main bearing. (Scheme 70) For 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 71)
11. To check crankshaft end play, install a dial indicator. Move crankshaft completely to rear of its travel and zero dial indicator, then move it completely to front of its travel and read dial indictor.

Cylinder Block

Check cylinder bore, out-of-round and taper. Measurements should be taken at approximately .0019" (.050 mm) below top surface of cylinder bore, middle of bore and approximately .0020" (.050 mm) from bottom of cylinder bore.

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

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

Oil Pressure

Oil pressure is 5 psi (0.35 kg/cm 2 ) at idle, and 45-105 psi (3.1-7.3 kg/cm 2 ) at 3000 RPM. Rocker arm shafts are hollow and are used as lubrication oil ducts. (Scheme 72)

Scheme 72