2.7L DOHC Engine - Service Information: Overview Dodge Journey I

Scheme 585

The 2.7 Liter (167 Cubic Inches) 60 degree V6 engine is a double overhead camshaft design with hydraulic lifters and four valves per cylinder. The engine does not have provisions for a free wheeling valve train.

Scheme 586

The cylinders are numbered from front to rear, with the right bank odd numbered, and the left bank even numbered. The firing order is 1-2-3-4-5-6.

Scheme 587

The engine identification number is located on the rear of the cylinder block just below the left cylinder head.

ENGINE DIAGNOSIS - INTRODUCTION

Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance.

These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls).

See ENGINE DIAGNOSIS - PERFORMANCE and ENGINE DIAGNOSIS - MECHANICAL for possible causes and corrections of malfunctions.

Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that cannot be isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the following

1. Cylinder Compression Pressure Test: Refer to «CYLINDER COMPRESSION PRESSURE TEST»(ref-353618-S33564518072010011200000) .
2. Cylinder Combustion Pressure Leakage Test: Refer to «CYLINDER COMBUSTION PRESSURE LEAKAGE TEST»(ref-353618-S28644978322010011200000) .
3. Cylinder Head Gasket Failure Diagnosis: Refer to «CYLINDER HEAD GASKET»(ref-353618-S22183022182010011200000) .
4. Intake Manifold Leakage Diagnosis: Refer to . «INTAKE MANIFOLD LEAKS»(ref-353618-S14002361402010011200000)
5. Lash Adjuster (Tappet) Noise Diagnosis: Refer to «DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS»(ref-353618-S04150003542010011200000) .
6. Engine Oil Leak Inspection: Refer to «ENGINE OIL LEAK INSPECTION»(ref-353618-S33728751312010011200000) .

DESCRIPTION

The assembled fabricated camshafts (3,10) are composed of five bearing journals machined into a hollow steel tube. Six steel lobes, a secondary timing drive sprocket, and a primary sprocket/thrust flange are pressed onto the camshaft tube using a unique assembly process. Camshaft end play is controlled by the primary camshaft sprocket attachment flange on the intake camshafts (10) and by a thrust flange on the exhaust camshafts.

OPERATION

The camshaft has precisely machined (egg shaped) lobes to provide accurate valve timing and duration. The camshaft is driven by the crankshaft via drive sprockets and chains.

The valve springs are made from high strength, chrome-silicon steel. The springs are common for intake and exhaust applications. The valve spring seat is integral with the valve stem seal, which incorporates a garter spring to maintain consistent lubrication control to the valve stem.

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1. Perform fuel system pressure release procedure before attempting any repairs. Refer to «Fuel System/Fuel Delivery - Standard Procedure»(ref-353596-S39204571612010011200000) .
2. Disconnect negative cable from remote jumper terminal.
3. Remove air cleaner housing and inlet hose (1). 1 - DOUBLE ENDED STUDS 2 - BOLTS
4. Remove upper intake manifold. See «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353618-S26296796972010011200000) .
5. Remove cylinder head covers. See «Engine/Cylinder Head/COVER(S), Cylinder Head - Removal»(ref-353618-S35378812432010011200000) .
6. Remove crankshaft vibration damper. See «Engine/Engine Block/DAMPER, Vibration - Removal»(ref-353618-S27047139172010011200000) . 1 - VALVE SEAL TOOL 2 - VALVE STEM
7. Remove camshafts and rocker arms. See «Engine/Cylinder Head/CAMSHAFT, Engine - Removal»(ref-353618-S20661924232010011200000) .
8. With air hose attached to spark plug adapter installed in the cylinder being serviced, apply 620.5-689 kPa (90-100 psi) air pressure. This is to hold valves in place while servicing components.
9. Using Special Tool MD 998772A with adapter 6779, compress valve spring and remove valve locks, retainer, and valve spring.
10. Remove valve stem seal. See «Engine/Cylinder Head/SEAL(S), Valve Guide - Removal»(ref-353618-S04568718262010011200000) .

The valves are made of heat resistant steel, and have chrome plated stems to prevent scuffing. The four valves per cylinder (two intake and two exhaust) are actuated by roller rocker arms, which pivot on stationary lash adjusters. All valves use three bead lock keepers to retain springs and to promote valve rotation.

Scheme 590

The intake and exhaust valves have a 44.5 to 45 degree face angle (2). The valve seats have a 45 to 45.5 degree face angle (3).

The crankshaft is constructed of a forged micro alloy steel. The six throw, nine counterweight crankshaft is supported by four select fit main bearings with the number three serving as the thrust washer location. The select fit identification markings will be on the rear side of the number nine (rearmost) counterweight. The six separate connecting rod throws are an even-firing design which reduces torque fluctuations while a vibration damper is used to control torsional vibration.

The crankshaft oil seals are a one piece design. The front seal is retained by the timing chain cover, and the rear seal in a housing that attaches to the cylinder block.

Scheme 591

1. Mount a dial indicator to a stationary point at front of engine. Locate the probe perpendicular against nose of crankshaft.
2. Move crankshaft all the way to the rear of its travel.
3. Zero the dial indicator.
4. Move crankshaft all the way to the front and read the dial indicator. For crankshaft end play clearances, see «Engine - Specifications»(ref-353618-S39691483892010011200000) .

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1. Drain engine oil and remove oil filter. See «Engine/Lubrication/OIL - Standard Procedure»(ref-353618-S27731926192010011200000)
2. Remove engine from vehicle. See «Engine - Removal»(ref-353618-S30990594722010011200000) .
3. Mount engine on an engine stand.
4. Remove oil pan and oil pick-up tube. See «Engine/Lubrication/PAN, Oil - Removal»(ref-353618-S41779359542010011200000) .
5. Remove idler pulley bracket for accessory drive belt.
6. Remove upper intake manifold. See «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353618-S26296796972010011200000) .
7. Remove cylinder head covers. See «Engine/Cylinder Head/COVER(S), Cylinder Head - Removal»(ref-353618-S35378812432010011200000) .
8. Remove timing chain cover. See «Engine/Valve Timing/COVER(S), Engine Timing - Removal»(ref-353618-S33729398542010011200000) .
9. Remove primary timing chain. See «Engine/Valve Timing/CHAIN and SPROCKETS, Timing - Removal»(ref-353618-S07109882762010011200000) .
10. Remove crankshaft sprocket. See «Engine/Valve Timing/CHAIN and SPROCKETS, Timing - Removal»(ref-353618-S07109882762010011200000) .
11. Remove oil pump. See «Engine/Lubrication/PUMP, Engine Oil - Removal»(ref-353618-S28925654422010011200000) .
12. Remove crankshaft rear oil seal retainer (2). See «Engine/Engine Block/SEAL, Crankshaft Oil - Removal»(ref-353618-S12901343662010011200000) .
13. Remove windage tray (1).
14. Turn crankshaft until connecting rod cap to be removed is accessible. NOTE: Connecting rod bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.
15. Mark connecting rod bearing cap positions using a permanent ink marker or scribe tool. Also scribe a location reference mark from the #3 main bearing cap to the engine block to use as a guide during reassembly.
16. Remove connecting rod bearing caps. Use care to prevent damage to the crankshaft bearing surfaces. CAUTION: Care should be taken not to damage the fractured rod and cap joint face surfaces or damage to the engine may occur.
17. Remove main bearing tie bolts (1) and (2).
18. Remove main bearing cap bolts (1) and main bearing caps (2). CAUTION: When removing crankshaft, use care not to damage bearing surfaces on the crankshaft.
19. Remove crankshaft (7) from cylinder block (6).

Scheme 597

Note. Upper and lower bearing halves are NOT interchangeable.

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1. Install crankshaft upper main bearings in cylinder block. Ensure the tangs engage the slots in the block and oil holes in bearings line up with oil holes in cylinder block. See «Engine/Engine Block/BEARING(S), Crankshaft - Standard Procedure»(ref-353618-S36710664642010011200000) .
2. Lubricate upper main bearing halves with engine oil. CAUTION: When installing crankshaft, use care not to damage bearing surfaces on the crankshaft.
3. Install crankshaft. NOTE: Make sure that the coated and oil groove side of crankshaft thrust washer faces the crankshaft thrust surface.
4. Push crankshaft forward. Lubricate and install the front thrust washer (1) by rolling the thrust washer onto the machined shelf between the No. 3 upper main bulk head and crankshaft thrust surface.
5. Move crankshaft rearward. Lubricate and install the rear thrust washer by rolling the thrust washer onto the machined shelf between the No. 3 upper main bulk head and crankshaft thrust surface.
6. Install lower main bearings (3) into main bearing caps (2).
7. Lubricate lower main bearings (3) with clean engine oil. NOTE: Lubricate main bearing cap bolts with engine oil before installation.
8. Install each main cap (2) and tighten inner bolts (1) finger tight. Align the location reference mark scribed on the #3 main bearing cap during disassembly. CAUTION: The #3 main bearing cap must be centered over the inner bolt holes located on the block. Failure to center the bearing cap can result in contact with the crankshaft counterweights and thrust bearing failure.
9. Verify that the #3 main bearing cap is properly centered over the inner bolt holes located in the block: Tighten main bearing cap inner bolts to 20 N.m (15 ft. lbs.). Move crankshaft (1) forward to limit of travel so that crankshaft thrust face (2) is tight against thrust bearing. Verify that a 0.25 mm (0.010 inch) shim or feeler gage will fit between the #3 main cap (rear face) and the crankshaft thrust face. Slide the gage side-to-side all of the way across the cap making sure that the clearance at all areas exceeds 0.25 mm (0.010 inch). The feeler gage should slide all the way down to the #3 main journal. Move crankshaft (1) rearward to limit of travel so that crankshaft thrust face (2) is tight against thrust bearing. Verify that a 0.25 mm (0.010 inch) shim or feeler gage will fit between the #3 main cap (front face) and the crankshaft thrust face. Slide the gage side-to-side all of the way across the cap making sure that the clearance at all areas exceeds 0.25 mm (0.010 inch). The feeler gage should slide all the way down to the #3 main journal. A properly centered #3 main bearing cap has a minimum of 0.25 mm (0.010 inch) clearance in both the forward and rearward crankshaft positions. If measured clearance is less than 0.25 mm (0.010 inch), loosen and reposition #3 main bearing cap until this minimum clearance can be verified by repeating this procedure.
10. Following verification of proper #3 bearing cap centering, finish tightening the main bearing cap inner bolts an additional 90° turn.
11. Measure crankshaft end play. See «Engine/Engine Block/CRANKSHAFT - Standard Procedure»(ref-353618-S35077266922010011200000) .
12. Install connecting rods and measure side clearance. See «Engine/Engine Block/BEARING(S), Connecting Rod - Standard Procedure»(ref-353618-S40245559692010011200000) . NOTE: The main bearing cap bolts must be tightened in the proper sequence. First the inner main cap bolts, secondly the windage tray bolts, and lastly the main cap tie (horizontal) bolts.
13. Install windage tray (1) with the slots to right side of engine. Lubricate bolts (3) with engine oil and tighten to 27 N.m + 90° Turn (20 ft. lbs. + 90° turn).
14. Install the main cap tie (horizontal) bolts (1) and (2) and tighten to 28 N.m (250 in. lbs.).
15. Install rear crankshaft oil seal retainer and oil seal assembly. Refer to «Engine/Engine Block/RETAINER, Crankshaft Rear Oil Seal - Installation»(ref-353585-S40550648402010011200000) .
16. Install oil pump assembly (5). See «Engine/Lubrication/PUMP, Engine Oil - Installation»(ref-353618-S34253044832010011200000) .
17. Install oil pick-up tube (3) and O-ring (2). Tighten bolts (4) to 28 N.m (250 in. lbs.).
18. Install oil pan gasket, oil pan, and oil filter. See «Engine/Lubrication/PAN, Oil - Installation»(ref-353618-S40433574152010011200000) .
19. Install crankshaft sprocket. See «Engine/Valve Timing/CHAIN and SPROCKETS, Timing - Installation»(ref-353618-S25049796892010011200000) .
20. Install timing chain. See «Engine/Valve Timing/CHAIN and SPROCKETS, Timing - Installation»(ref-353618-S25049796892010011200000) .
21. Install timing chain cover. See «Engine/Valve Timing/COVER(S), Engine Timing - Installation»(ref-353618-S03533396422010011200000) .
22. Install cylinder head covers. See «Engine/Cylinder Head/COVER(S), Cylinder Head - Installation»(ref-353618-S21770656922010011200000) .
23. Install oil dipstick tube.
24. Install engine assembly. See «Engine - Installation»(ref-353618-S38522580052010011200000) .
25. Fill engine crankcase with proper oil to correct level. See «Engine/Lubrication/OIL - Standard Procedure»(ref-353618-S27731926192010011200000) .
26. Fill with coolant. Refer to «Cooling - Standard Procedure»(ref-353584-S11330501202010011200000) .
27. Start engine and check for leaks.

Scheme 605

1. Disconnect negative battery cable.
2. Remove right front wheel and belt splash shield.
3. Remove accessory drive belts. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353584-S03638748182010011200000) .
4. Remove damper bolt.
5. Remove damper by using Special Tools 8194 Insert and 8454 Puller (1).

Scheme 606

1. Install damper using Special Tools 8179 (3) Screw, with Nut and Thrust Bearing from 6792, and 6792-1 Installer (2).
2. Install damper center bolt. Tighten center bolt to 170 N.m (125 ft. lbs.).
3. Install accessory drive belts. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-353584-S15414070972010011200000) .
4. Install belt splash shield and right front wheel.
5. Lower vehicle.
6. Connect negative battery cable.

Scheme 607

1. Remove transmission.
2. Remove flex plate attaching bolts (2).
3. Remove backing plate (3) and flex plate (1).

Scheme 608

1. Position the flex plate (1) with backing plate (3) on the crankshaft.
2. Apply Mopar® Lock AND Seal Adhesive to the eight flex plate bolts (2).
3. Install the flex plate bolts (2). Tighten the bolts to 95 N.m (70 ft. lbs.).
4. Install the transaxle. Refer to «Transmission and Transfer Case/Automatic - 62TE - Installation»(ref-353619-S09372831292010011200000) . NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to «DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure»(ref-353603-S03528494482010011200000) .

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1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 inch.) from bottom of cylinder bore. Check gap with feeler gauge (1). Refer to «Engine - Specifications»(ref-353618-S39691483892010011200000) for clearance measurements. 1 - FEELER GAUGE
2. Check piston ring to groove clearance (1). For clearance specifications, see «Engine - Specifications»(ref-353618-S39691483892010011200000) .

Scheme 611

1. Remove piston and connecting rod. See «Engine/Engine Block/ROD, Piston and Connecting - Removal»(ref-353618-S31110249522010011200000) .
2. Remove No. 1 and No. 2 piston rings from piston using a ring expander tool.
3. Remove upper oil ring side rail.
4. Remove lower oil ring side rail.
5. Remove oil ring expander.

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1. Measure clearance of piston rings to the cylinder bore and piston. See «Engine/Engine Block/RING(S), Piston - Standard Procedure»(ref-353618-S06536224132010011200000) . CAUTION: Install piston rings in the following order: Oil ring expander. Upper oil ring side rail. Lower oil ring side rail. No. 2 Intermediate piston ring. No. 1 Upper piston ring.
2. Install oil ring expander.
3. Install upper side rail first and then the lower side rail. NOTE: 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.
4. Install No. 2 piston ring and then No. 1 piston ring. 1 - SIDE RAIL UPPER 2 - NO. 1 RING GAP 3 - PISTON PIN 4 - SIDE RAIL LOWER 5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
5. Position piston ring end gaps as shown in illustration.
6. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control.

Scheme 615

The pistons (1) are made of a high strength aluminum alloy with an anodized top ring groove. Piston skirts are coated with a solid lubricant for scuff resistance. The connecting rods are made of powdered metal with a "fractured cap" design. The connecting rod attaches to the piston with a full floating pin retained by lock rings. The piston and connecting rod are serviced as an assembly.

Scheme 616

The pistons have been cast and machined to one size and weight. The piston and rod assemblies are matched to weigh the same for engine balance.

Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin. Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line. Refer to Engine - Specifications . Pistons and cylinder bores should be measured at normal room temperature, 70°F (21°C).

The lubrication system is a full-flow filtration, pressure feed type. The oil pump body is mounted to the engine block. The pump inner rotor is driven by the crankshaft. A structural windage tray is used to increase power by minimizing oil windage at high engine RPM. An engine oil cooler is used on some models.

Oil from the oil pan is pumped by a gerotor type oil pump (3) directly coupled to the crankshaft. Oil pressure is controlled by a relief valve mounted inside the oil pump housing.

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For engine oil type and capacity, refer to Vehicle Quick Reference/Capacities and Recommended Fluids - Description .

The engine oil pressure switch is located on the right side of the engine block. The switch screws into the engine main oil gallery. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster.