3.5L Engine - Service Information: Overhaul Dodge Journey I

DISASSEMBLY

Scheme 484

Scheme 485

1. Using a permanent ink or paint marker, identify the location and position on each rocker arm and remove the rocker arm and shaft assembly. See «Engine/Cylinder Head/ROCKER ARM, Valve - Removal»(ref-353585-S29730719562010011200000) 1 - 4 mm SCREW AND NUT 2 - 4 mm SCREW AND NUT 3 - WASHER 4 - SPACER 5 - DOWEL 6 - DOWEL 7 - SPACER 8 - WASHER
2. Remove the dowel pins using a 4 mm screw, nut, spacer, and washer installed into the pin. Thread the screw into the pin, then loosen the nut on the screw. This will pull the dowel out of the shaft support. Do not reuse the dowel pins. NOTE: The identification marks (notches) (1) face toward the front of the engine for the left head and toward the rear of the engine for the right head.
3. Remove the rocker arms and pedestals in order.
4. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if damaged or heavily worn.
5. Check the shaft oil holes for clogging with a small wire, clean as required.

Scheme 486

The rocker arm shafts are hollow and are used as lubrication oil ducts. The rocker arm and shaft assembly on the right side of the engine has an oil passage hole from the cylinder head located at the third rocker shaft support pedestal. The rocker arm and shaft assembly on the left side of the engine has an oil passage hole from the cylinder head located at the second rocker shaft support pedestal.

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

The intake and exhaust rocker arms are different. They should be identified before disassembling the assembly.

Scheme 487

Check rocker arms for wear or damage

1. Roller scuffing or wear
2. Shaft bore scuffing or wear
3. Swivel pad on lash adjuster missing or broken
4. Rocker arm showing signs of fatigue or cracking
5. Roller axle protruding from arm

Replace assembly as necessary if any rocker arms shows signs of wear.

ASSEMBLY

Note. A new fully assembled rocker arm and shaft assembly can be installed on either the right or left side of the engine. The identification marks (notches) (1) face toward the front of the engine for the left head and toward the rear of the engine for the right head.

Scheme 488

1. Position the shafts with the notches (1) facing up. Install the rocker arms and pedestals onto the shafts. 1 - HYDRAULIC LASH ADJUSTERS 2 - DOWEL PIN 3 - PEDESTAL 4 - ROLLER CAUTION: New dowel pins must be installed when reassembling.
2. Install the dowel pins (2). The dowel pins (2) pass through the pedestal (3) into the exhaust rocker shafts. Dowel pins (2) should be pressed in until they bottom-out against the rocker shaft in the pedestal (3).
3. Install the rocker arm and shafts assembly. See «Engine/Cylinder Head/ROCKER ARM, Valve - Installation»(ref-353585-S37836136412010011200000)

Scheme 489

Note. The rocker arm and shaft assembly can be installed either prior to or after (preferred) cylinder head installation.

1. Rotate camshaft gears clockwise to where the number one cylinder intake valves would just start to open. The camshaft lobes are now in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it. NOTE: A new fully assembled rocker arm and shaft assembly can be installed on either the right or left side of the engine. The identification marks (notches) (1) face toward the front of the engine for the left head and toward the rear of the engine for the right head.
2. Install the rocker arm and shaft assembly making sure that the identification marks (1) face toward the front of engine for left head and toward the rear of the engine for right head.
3. Tighten the rocker arm/shaft assembly bolts in the sequence shown in illustration to 31 N.m (275 in. lbs.).
4. Install the cylinder head covers. See «Engine/Cylinder Head/COVER(S), Cylinder Head - Installation»(ref-353585-S25597530122010011200000) .

TENSIONER PULLEY ASSEMBLY

Note. The tensioner pulley, bracket, and pivot bolt is serviced as an assembly.

1. Inspect pulley for free movement. Replace if pulley is loose, seized, or rough turning.
2. Inspect pulley bearing and seal. Replace if damaged.
3. Inspect pivot bolt for free movement in assembly housing. Replace assembly if seized or excessive looseness.

1. Install the timing belt tensioner pulley (1) assembly. Tighten the pivot bolt (2) to 61 N.m (45 ft. lbs.).
2. Install the timing belt. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-353585-S01282825562010011200000) .