3.5L Engine - Service Information: Overview Dodge Journey I

Scheme 347

The 3.5 Liter 60 degree V-6 engine is a single overhead camshaft design with hydraulic lifters and four valves per cylinder. The engine does not have provisions for a free wheeling valve train.

Scheme 348

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 349

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

OPERATION

The rocker arm is the pivot point between the camshaft lobe and the valve.

The valve spring returns the valve against its seat for a positive seal of the combustion chamber.

DESCRIPTION

Valves are made of highly heat-resistant steel and are chrome plated to prevent stem scuffing. The intake valve is a one-piece forging, while the exhaust valve has a forged head with a welded stem for lock groove durability. The four valves (two intake and two exhaust) employ a three-groove lock design to help facilitate valve rotation.

The intake valve allows the air/fuel mixture to enter the combustion chamber. The exhaust valve allows the burned air/fuel mixture to exit the combustion chamber. Also, the intake and exhaust valves seal the combustion chamber during the compression and power strokes.

The crankshaft is constructed of a forged micro alloy steel. A six throw, nine counterweight crankshaft is supported by four select fit main bearings with number two serving as the thrust washer location. The six separate connecting rod throws are an even-firing design which reduces torque fluctuations while a torsional vibration damper is used to control torsion caused vibration of the crankshaft. Rubber lipped seals are used at front and rear. The front seal is retained in the oil pump case and the rear seal is retained in a block-mounted housing.

The crankshaft transfers force generated by combustion within the cylinder to the flywheel or flexplate.

Scheme 350

1. Mount a dial indicator to front of engine with the locating probe on 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. Crankshaft end play must be within specification. See «Engine - Specifications»(ref-353585-S22148766082010011200000) .

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1. Remove engine from vehicle. See «Engine - Removal»(ref-353585-S20179926982010011200000) .
2. Remove oil pan. See «Engine/Lubrication/PAN, Oil - Removal»(ref-353585-S23700294392010011200000) .
3. Remove oil pickup tube (1) and windage tray (3).
4. Remove front timing belt cover. See «Engine/Valve Timing/COVER(S), Engine Timing - Removal»(ref-353585-S15810965992010011200000) .
5. Remove timing belt and tensioner. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) .
6. Remove crankshaft sprocket. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) .
7. Tap dowel pin out of crankshaft.
8. Remove oil pump assembly. See «Engine/Lubrication/PUMP, Engine Oil - Removal»(ref-353585-S04532376412010011200000) . 1 - REAR OIL SEAL AND RETAINER ASSEMBLY 2 - BOLT 3 - ALIGNMENT DOWEL
9. Remove crankshaft rear oil seal retainer (1). NOTE: Do not use a metal stamp to mark the bearing caps. Do use a scribe or paint mark.
10. Identify rod bearing caps before removal. Also scribe a location reference mark from the #2 main bearing cap to the engine block to use as a guide during reassembly.
11. Remove connecting rod bearing caps. Connecting rod bearing caps are not interchangeable and should be paint marked or scribed before removal to insure correct assembly.
12. Remove main bearing caps (1). Main bearing caps are not interchangeable and are marked to insure correct assembly and location.
13. Remove crankshaft (4) from cylinder block (7). NOTE: Before installing crankshaft, refer to fitting of main bearings and installation of connecting rod bearings. See «Engine/Engine Block/BEARING(S), Crankshaft - Standard Procedure»(ref-353585-S31839982652010011200000) and «Engine/Engine Block/BEARING(S), Connecting Rod - Standard Procedure»(ref-353585-S06877968392010011200000) .

The pistons are made of a high strength aluminum alloy. Top land height has been decreased to reduce emissions. Piston skirts are coated with a solid lubricant for scuff resistance. Connecting rod is forged steel with a fractured connecting rod cap design. The connecting rod is also equipped with a squirt hole and attaches to the piston with a full floating pin retained by lock rings.

Scheme 355

The pistons are machined to two different weight specifications and matched to rods based on weight. All piston and rod assemblies weigh the same to maintain engine balance.

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

Scheme 356

1. Remove the cylinder heads. See «Engine/Cylinder Head - Removal»(ref-353585-S12478010902010011200000)
2. Remove the oil pan. See «Engine/Lubrication/PAN, Oil - Removal»(ref-353585-S23700294392010011200000)
3. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore.
4. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them with a paint mark or scribe (1).
5. Remove connecting rod cap. Install protectors on connecting rod. Push each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals.
6. After removal, install bearing cap on the mating rod.

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1. Install the piston rings. See «Engine/Engine Block/RING(S), Piston - Installation»(ref-353585-S05605175612010011200000) NOTE: The connecting rod bearing cap bolts must be examined before reuse. If the threads are necked down (1 and 2), the bolts must be replaced.
2. Check connecting rod bolts for necking by holding a scale or straight edge against the threads. If all threads do not contact the scale, the bolt must be replaced. 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
3. Before installing pistons and connecting rod assemblies into the bore, ensure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. 1 - "F" TOWARD FRONT OF ENGINE 2 - RING COMPRESSOR 3 - SPECIAL TOOL 8189 4 - OIL SQUIRT HOLE
4. Immerse the piston head and rings in clean engine oil, slide the ring compressor over the piston and tighten with the special wrench. Ensure position of rings does not change during this operation.
5. Install connecting rod bolt protectors on rod bolts.
6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. CAUTION: Do Not interchange piston assemblies cylinder-to-cylinder or bank-to-bank.
7. The arrow (1) on top of piston must be pointing toward front of engine and oil squirt hole on connecting rod faces the major thrust (right) side of the cylinder bore.
8. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.
9. Install rod caps. Install cleaned and inspected connecting rod bolts and tighten to 27 N.m (20 ft. lbs.) Plus 1/4 turn.
10. Install the cylinder head(s). See «Engine/Cylinder Head - Installation»(ref-353585-S38825678362010011200000)
11. Install the oil pan. See «Engine/Lubrication/PAN, Oil - Installation»(ref-353585-S21699418692010011200000)

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1. Remove the crankshaft sprocket. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) .
2. Tap the dowel pin (2) out of the crankshaft.
3. Remove crankshaft seal using Special Tool 6341A (1). CAUTION: Do not nick shaft seal surface or seal bore.
4. Shaft seal lip surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary.

Scheme 364

1. Install crankshaft seal using Special Tool 6342 (1).
2. Install the dowel pin into the crankshaft to 1.2 mm (0.047 in.) protrusion.
3. Install the crankshaft sprocket. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-353585-S01282825562010011200000) .

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1. Disconnect and isolate the negative battery cable.
2. Remove air cleaner housing assembly (4). See «Engine/Air Intake System/BODY, Air Cleaner - Removal»(ref-353585-S33364826632010011200000) .
3. Remove the belly pan (2).
4. Support transmission with floor jack and wooden block.
5. Remove the vertical bolts (1) from the left engine mount (2) to transmission bracket.
6. Slightly lower transmission with floor jack to gain access to mount to frame rail fastener (2).
7. Remove mount isolator (3).

Engine oil stored in the oil pan is drawn in and discharged by a gerotor type oil pump. The oil pump is directly coupled to the crankshaft. Oil pressure is regulated by a relief valve. The oil is fed through an oil filter and to the crankshaft journals from the oil gallery in the cylinder block. This gallery also feeds oil under pressure to the cylinder heads. Oil flows through each cylinder heads oil passage to the rocker shafts. Oil then feeds the camshaft journals, rocker arms, and hydraulic lash adjusters.

Scheme 367

Check oil pressure using a gauge at oil pressure switch location (7).

1. Remove the oil pressure switch (7). See «Engine/Lubrication/SWITCH, Oil Pressure - Removal»(ref-353585-S02181508462010011200000) .
2. Install oil pressure test gauge, Special Tool C-3292A with Adapter 8406. For Special Tool identification. See «Engine - Special Tools»(ref-353585-S16939443142010011200000) . CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM.
3. Warm engine to normal operating temperature.
4. Monitor gauge readings at idle and 3000 RPM. For specifications. See «Engine - Specifications»(ref-353585-S22148766082010011200000) .

Scheme 368

Note. When servicing the oil filter, avoid deforming the filter can. Install the remove/install tool band strap against the base lock seam. The lock seam joining the can to the base is reinforced by the base plate.

1. Using a suitable oil filter wrench, unscrew filter (2) from base and discard.

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

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Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick (1), and observe oil level. Add oil only when the level is at or below the SAFE mark. If the oil level is in the safe (2) range, do not add oil.