Special Tool(s)
SPECIAL TOOL SPECIFICATION 12 Volt Master UV Diagnostic Inspection Kit 164-R0756 or equivalent (Leak Detector) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Engine EAR 107-R2103 or equivalent Engine EAR/Chassis EAR 107-R2102 or equivalent Oil Pressure Gauge 303-088 (T73L-6600-A) Vacuum/Pressure Tester 164-R0253 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool
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SPECIAL TOOL SPECIFICATION Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent
Note. Refer to the appropriate ENGINE - 3.7L for the specification.
- Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play.
- Position the camshaft to the rear of the cylinder head.
- Zero the Dial Indicator Gauge.
- Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. If camshaft end play exceeds specifications, install a new camshaft and recheck end play. If camshaft end play exceeds specification after camshaft installation, install a new cylinder head.
Scheme 1429
SPECIAL TOOL SPECIFICATION Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent
Note. Refer to the appropriate ENGINE - 3.7L for the specification.
- Use the Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift. Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial Indicator Gauge reading to figure the camshaft lobe lift.
Scheme 1430
SPECIAL TOOL SPECIFICATION Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent
Note. Refer to the appropriate ENGINE - 3.7L for the specification.
- NOTE: Camshaft journals must be within specifications before checking runout.
Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout.
- Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial Indicator Gauge reading.
Scheme 1431
SPECIAL TOOL SPECIFICATION Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent
Note. Refer to the appropriate ENGINE - 3.7L for the specification.
- Install the Dial Indicator Gauge with Holding Fixture.
- Position the crankshaft to the rear of the cylinder block.
- Zero the Dial Indicator Gauge.
- Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
Scheme 1432
SPECIAL TOOL SPECIFICATION Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent
Scheme 1433
Note. Refer to the appropriate ENGINE - 3.7L for the specification.
- Using the Feeler Gauge Set, measure the clearance between the connecting rod and the piston. Verify the measurement is within specification.
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SPECIAL TOOL SPECIFICATION Scraper, Piston Ring Groove 303-D033 (D81L-6002-D) or equivalent
Scheme 1435
Note. Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can occur.
Scheme 1436
- Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses and the (4) tops of the pistons. If wear marks, scores or glazing is found on the piston skirt, check for a bent or twisted connecting rod.
- Use the Piston Ring Groove Scraper to clean the piston ring grooves. Make sure the oil ring holes are clean.
Scheme 1437
SPECIAL TOOL SPECIFICATION Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent
Note. Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore.
Note. Piston rings should not be transferred from one piston to another.
Note. Refer to the appropriate for the specification.
Note. The cylinder bore must be within specification for taper and out-of-round.
Scheme 1438
- Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel.
- Use the Feeler Gauge Set to measure the top piston ring end gap and the second piston ring end gap.
Scheme 1439
SPECIAL TOOL SPECIFICATION Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent
Note. Refer to the appropriate ENGINE - 3.7L for the specification.
Scheme 1440
- Inspect the piston for ring land damage or accelerated wear.
- Using the Feeler Gauge Set, measure the piston ring-to-groove clearance.
Scheme 1441
SPECIAL TOOL SPECIFICATION Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent
Note. Refer to the appropriate ENGINE - 3.7L for the specification.
- Using the Feeler Gauge Set, measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification.
Scheme 1442
SPECIAL TOOL SPECIFICATION Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent
Note. Refer to the appropriate ENGINE - 3.7L for the specification.
- Using the Feeler Gauge Set, measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification.
Scheme 1443
SPECIAL TOOL SPECIFICATION Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent
Note. Refer to the appropriate ENGINE - 3.7L for the specification.
- Using the Feeler Gauge Set, measure the clearance between the connecting rod and the crankshaft. Verify the measurement is within specification.
Scheme 1444
SPECIAL TOOL SPECIFICATION Clearance Gauge, Valve Guide 303-004 (TOOL-6505-E) or equivalent Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent
Note. Refer to the appropriate ENGINE - 3.7L for the specification.
Note. The valve stem diameter must be within specifications before checking valve stem-to-valve guide clearance.
Scheme 1445
- NOTE: If necessary, use a magnetic base. Install a Valve Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve guide.
- Move the Valve Guide Clearance Gauge toward the Dial Indicator Gauge with Holding Fixture and zero the Dial Indicator Gauge. Move the Valve Guide Clearance Gauge away from the Dial Indicator Gauge with Holding Fixture and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance.
SPECIAL TOOL SPECIFICATION Pressure Gauge, Valve/Clutch Spring 303-006 (TOOL-6513-DD) or equivalent
Scheme 1446
Note. Refer to the appropriate ENGINE - 3.7L for the specification.
- Use the Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length.
Scheme 1447
SPECIAL TOOL SPECIFICATION Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent
Note. Refer to the appropriate ENGINE - 3.7L for the specification.
- NOTE: Make sure all cylinder head surfaces are clear of any gasket material, silicone sealant, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.
Note. Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.
Using a Straightedge and a Feeler Gauge Set, inspect the cylinder head for flatness in the sequence shown.
Scheme 1448
SPECIAL TOOL SPECIFICATION Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent
Note. Refer to the appropriate ENGINE - 3.7L for the specification.
- NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.
Use a Straightedge and a Feeler Gauge Set to inspect the cylinder block for flatness.
Scheme 1449
SPECIAL TOOL SPECIFICATION Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent
- Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing surfaces.
- NOTE: New exhaust manifold gaskets, studs, nuts and/or bolts must be installed when an exhaust manifold is serviced.
Note. Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.
Using the Straightedge and a Feeler Gauge Set, check the exhaust manifold sealing surface for warpage. If the warpage is greater than 0.76 mm (0.0299 in), install a new exhaust manifold.
Scheme 1450
SPECIAL TOOL SPECIFICATION Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent
- Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing surfaces.
- NOTE: New exhaust manifold gaskets, studs, nuts and/or bolts must be installed when an exhaust manifold is serviced.
Note. Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.
Using the Straightedge and a Feeler Gauge Set, check the exhaust manifold sealing surface for warpage. If the warpage is greater than 0.76 mm (0.0299 in), install a new exhaust manifold.
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- Inspect the spark plug for a bridged gap. Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. Install a new spark plug.
- Check for oil fouling. Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. Correct the oil leak concern. Install a new spark plug.
- Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. Install new spark plugs.
- Inspect for normal burning. Check for light tan or gray deposits on the firing tip.
- Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. Install a new spark plug.
- Inspect for overheating, identified by white or light gray spots and a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. Install a new spark plug.
- Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. Install new spark plugs.
