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STANDARD PROCEDURE - ENGINE OIL
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 71
DIAGNOSIS AND TESTING - INTAKEMANIFOLD LEAKS . . . . . . . . . . . . . . . . . . . . . 71
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 72EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 73
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 74VALVE TIMING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 75
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
STANDARD PROCEDUREMEASURING TIMING CHAIN WEAR . . . . . . . 76
SERVICE PROCEDURE - TIMINGVERIFICATION. . . . . . . . . . . . . . . . . . . . . . . . 76
BALANCE SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79DR
IDLER SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80TIMING BELT / CHAIN COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
ENGINE - 3.7L DESCRIPTION
The 3.7 liter (226 CID) six-cylinder engine is an 90° single overhead camshaft engine (Fig. 1). The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bed- plate that comprises the lower portion of the cylinder
ENGINE - 3.7L
9 - 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 81
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84block and houses the lower half of the crankshaft main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3, and 5 and the right bank being numbered 2,4, and 6. The firing order is 1–6–5–4–3–2. The engine serial number is located at the right front side of the engine block
Fig.13.7LENGINE
ENGINE - 3.7L
9 - 4
ENGINE - 3.7L (Continued) DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - 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 per- formance (e.g., engine idles rough and stalls) or mechanical (e.g., a strange noise).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST- ING)—PERFORMANCE and (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)—MECHANICAL for possible causes and corrections of malfunctions. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING) and (Refer to 14 - FUEL SYSTEM/FUEL INJECTION - DIAGNOSIS AND TESTING) for the fuel system diagnosis.
DR
ENGINE - DIAGNOSIS AND TESTING).
Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts. Information concerning additional tests and diagno- sis is provided within the following diagnosis: † Cylinder Compression Pressure Test (Refer to 9 - † Cylinder Combustion Pressure Leakage Test (Refer to 9 - ENGINE - DIAGNOSIS AND TEST- ING).† Engine Cylinder Head Gasket Failure Diagnosis (Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNO- SIS AND TESTING). † Intake Manifold Leakage Diagnosis (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE DIAGNOSIS AND TESTING).
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION
POSSIBLE CAUSE
CORRECTION
ENGINE WILL NOT START
1. Weak battery
1. Charge or replace as necessary.
2. Corroded or loose battery connections.
3. Faulty starter.
4. Faulty coil or control unit.
5. Incorrect spark plug gap.
6. Incorrect right bank cam timing.
7. Dirt or water in fuel system.
8.Faulty fuel pump, relay or wiring. 9. Faulty cam or crank sensor
ENGINE STALLS OR ROUGH IDLE 1. Vacuum leak.
2. Faulty crank position sensor 3. Faulty coil.
2. Clean and tighten battery connections. Apply a coat of light mineral grease to the terminals. 3. (Refer to 8 - ELECTRICAL/ STARTING - DIAGNOSIS AND TESTING). 4. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL). 5. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 6. Refer to engine timing in this section. 7. Clean system and replace fuel filter. 8.Repair or replace as necessary. 9. Refer to Ignition system.
1. Inspect intake manifold and vacuum hoses, repair or replace as necessary. 2. Replace crank position sensor. 3. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL).
DR ENGINE - 3.7L (Continued)
ENGINE - 3.7L
9 - 5
CONDITION
POSSIBLE CAUSE
CORRECTION
4. Incorrect cam timing.
1. ENGINE LOSS OF POWER
1. Dirty or incorrectly gapped spark plugs.
2. Dirt or water in fuel system.
3. Faulty fuel pump.
4. Blown cylinder head gasket. 5. Low compression.
6. Burned, warped or pitted valves. 7. Plugged or restricted exhaust system. 8. Faulty coil.
9. Incorrect cam timing.
1. ENGINE MISSES ON ACCELERATION
1. Spark plugs dirty or incorrectly gapped.
2. Dirt in fuel system. 3. Burned, warped or pitted valves. 4. Faulty coil.
1. ENGINE MISSES AT HIGH SPEED
1. Spark plugs dirty or incorrectly gapped.
2. Faulty coil.
3. Dirt or water in fuel system.
4. (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE).
1. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 2. Clean system and replace fuel filter. 3. (Refer to 14 - FUEL SYSTEM/ FUEL DELIVERY/FUEL PUMP - DIAGNOSIS AND TESTING). 4. Replace cylinder head gasket. 5. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING), repair as necessary. 6. Replace as necessary. 7. Inspect and replace as necessary. 8. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL). 9. Refer to Engine TIming in this section.
1. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 2. Clean fuel system. 3. Replcae as necessary. 4. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL).
1. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 2. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL). 3. Clean system and replace fuel filter.
ENGINE - 3.7L
9 - 6
ENGINE - 3.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICALDR
CONDITION
POSSIBLE CAUSES
CORRECTIONS
NOISY VALVES
1. High or low oil level in crankcase.
2. Thin or diluted oil. 3. Low oil pressure.
4. Dirt in lash adjusters. 5. Worn rocker arms. 6. Worn lash adjusters 7. Worn valve guides.
8. Excessive runout of valve seats on valve faces.
CONNECTING ROD NOISE
1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil. 4. Excessive bearing clearance. 5. Connecting rod journal out-of-round. 6. Misaligned connecting rods.
MAIN BEARING NOISE
1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil. 4. Excessive bearing clearance. 5. Excessive end play. 6. Crankshaft journal out-of round. 7. Loose flywheel or torque converter.
1. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS)
2. Change oil and filter. 3. Check oil pump, if Ok, check rod and main bearings for excessive wear. 4. Replace as necessary. 5. Replace as necessary. 6. Replace as necessary. 7. (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE) 8. (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE)
1. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS)
2. Check oil pump, if Ok, check rod and main bearings for excessive wear. 3. Change oil and filter. 4. Replace as necessary. 5. Service or replace crankshaft.
6. Replace bent connecting rods.
1. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS) 2. Check oil pump, if Ok, check rod and main bearings for excessive wear. 3. Change oil and filter. 4. Replace as necessary. 5. Check thrust washers for wear. 6. Service or replace crankshaft. 7. Tighten to correct torque
DR ENGINE - 3.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION
ENGINE - 3.7L
9 - 7
CONDITION
OIL LEAKS
POSSIBLE CAUSES
CORRECTION
1. Gaskets and O-Rings.
1.
(a) Misaligned or damaged. (b) Loose fasteners, broken or porous metal parts. 2. Crankshaft rear seal
3. Crankshaft seal flange. Scratched, nicked or grooved. 4. Oil pan flange cracked.
5. Timing chain cover seal, damaged or misaligned.
OIL PRESSURE DROP
6. Scratched or damaged vibration damper hub.
1. Low oil level. 2. Faulty oil pressure sending unit.
3. Low oil pressure.
4. Clogged oil filter.
5. Worn oil pump.
6. Thin or diluted oil. 7. Excessive bearing clearance. 8. Oil pump relief valve stuck.
9. Oil pick up tube loose, damaged or clogged.
(a) Replace as necessary. (b) Tighten fasteners, Repair or replace metal parts. 2. Replace as necessary (Refer to 9
- ENGINE/ENGINE BLOCK/ CRANKSHAFT OIL SEAL - REAR - REMOVAL). 3. Polish or replace crankshaft.4. Replace oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). 5. Replace seal (Refer to 9 - ENGINE/ENGINE BLOCK/ CRANKSHAFT OIL SEAL - FRONT - REMOVAL). 6. Polish or replace damper.
1. Check and correct oil level. 2. Replace sending unit (Refer to 9
- ENGINE/LUBRICATION/OIL PRESSURE SENSOR/SWITCH - REMOVAL). 3. Check oil pump and bearing clearance. 4. Replace oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - REMOVAL). 5. Replace oil pump (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - REMOVAL). 6. Change oil and filter. 7. Replace as necessary. 8. Replace oil pump (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - REMOVAL). 9. Replace as necessary.ENGINE - 3.7L
9 - 8
ENGINE - 3.7L (Continued)DR
CONDITION
POSSIBLE CAUSES
CORRECTION
OIL PUMPING AT RINGS; SPARK
1. Worn or damaged rings.
PLUGS FOULING
2. Carbon in oil ring slots.
3. Incorrect ring size installed.
4. Worn valve guides.
5. Leaking valve guide seals.
1. Hone cylinder bores and replace rings. 2. Replace rings (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS - STANDARD PROCEDURE). 3. Replace rings (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS - STANDARD PROCEDURE). 4. Ream guides and replace valves (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE). 5. Replace valve guide seals.
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE
The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc- tions.
Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs. (3) Secure the throttle in the wide-open position. (4) Disable the fuel system (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DESCRIPTION).
(5) Remove the ASD relay (Refer to 8 - ELECTRI- CAL/IGNITION CONTROL/AUTO SHUT DOWN RELAY - REMOVAL).
(6) Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
(7) Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylin- ders.
(8) (Refer to 9 - ENGINE - SPECIFICATIONS) for
the correct engine compression pressures.
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition. Combustion pressure leakage testing will detect:
† Exhaust and intake valve leaks (improper seat- ing).† Leaks between adjacent cylinders or into water jacket.† Any causes for combustion/compression pressure loss. (1) Check the coolant level and fill as required. DO
NOT install the radiator cap.
(2) Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.
(3) Remove the spark plugs. (4) Remove the oil filler cap. (5) Remove the air cleaner hose. (6) Calibrate the tester according to the manufac- turer’s instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom- mended.(7) Perform the test procedures on each cylinder according to the tester manufacturer’s instructions. Set piston of cylinder to be tested at TDC compres- sion,While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE: At 552 kPa (80 psi) input pres- sure, a minimum of 414 kPa (60 psi) should be main- tained in the cylinder.
Refer to CYLINDER COMBUSTION PRESSURE
LEAKAGE DIAGNOSIS CHART.
DR ENGINE - 3.7L (Continued)
ENGINE - 3.7L
9 - 9
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION
AIR ESCAPES THROUGH THROTTLE BODY
POSSIBLE CAUSE
Intake valve bent, burnt, or not seated properly
AIR ESCAPES THROUGH TAILPIPE
Exhaust valve bent, burnt, or not seated properly
AIR ESCAPES THROUGH RADIATOR MORE THAN 50% LEAKAGE FROM ADJACENT CYLINDERS
MORE THAN 25% LEAKAGE AND AIR ESCAPES THROUGH OIL FILLER CAP OPENING ONLY
Head gasket leaking or cracked cylinder head or block Head gasket leaking or crack in cylinder head or block between adjacent cylinders Stuck or broken piston rings; cracked piston; worn rings and/or cylinder wall
CORRECTION
Inspect valve and valve seat. Reface or replace, as necessary. Inspect valve springs. Replace as necessary. Inspect valve and valve seat. Reface or replace, as necessary. Inspect valve springs. Replace as necessary. Remove cylinder head and inspect. Replace defective part Remove cylinder head and inspect. Replace gasket, head, or block as necessary Inspect for broken rings or piston. Measure ring gap and cylinder diameter, taper and out-of-round. Replace defective part as necessary
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain the original center line.
tially, this repair consists of:
Damaged or worn threads can be repaired. Essen- † Drilling out worn or damaged threads. † Tapping the hole with a special Heli-Coil Tap, or † Installing an insert into the tapped hole to bring
equivalent.
the hole back to its original thread size.
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in- place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket materials that are used in the engine area. Mopart Engine RTV GEN II, Mopart ATF-RTV, and Mopart
Gasket Maker gasket materials, each have different properties and can not be used in place of the other.
MOPARt ENGINE RTV GEN II Mopart Engine RTV GEN II is used to seal com- ponents exposed to engine oil. This material is a spe- cially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
MOPARt ATF RTV Mopart ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and seal- ing properties to seal components exposed to auto- matic coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
transmission fluid,
engine
MOPARt GASKET MAKER Mopart Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.
MOPARt GASKET SEALANT Mopart Gasket Sealant is a slow drying, perma- nently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage
ENGINE - 3.7L
9 - 10
ENGINE - 3.7L (Continued)of oil and coolant. Can be used on threaded and machined parts under all temperatures. This mate- rial is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will pre- vent corrosion. Mopart Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER APPLICATION
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gas- kets.
Mopart Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material sur- rounds each mounting hole. Excess material can eas- ily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smear- ing material off the location.
Mopart Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location.
Mopart Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION
To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.
Never use the following to clean gasket surfaces: † Metal scraper † Abrasive pad or paper to clean cylinder block † High speed power tool with an abrasive pad or a
and head
wire brush (Fig. 2)
NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
DR
remover
† Solvent or a commercially available gasket † Plastic or wood scraper (Fig. 2) † Drill motor with 3M Roloc™ Bristle Disc (white
or yellow) (Fig. 2)
CAUTION: Excessive pressure or high RPM (beyond the recommended speed), can damage the sealing surfaces. The mild (white, 120 grit) bristle disc is recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces with care.Fig.2ProperToolUsageForSurfacePreparation 1 - ABRASIVE PAD 2 - 3M ROLOC™ BRISTLE DISC 3 - PLASTIC/WOOD SCRAPER
REMOVAL
(1) Disconnect the battery negative cable. (2) Remove hood. Mark hood hinge location for
reinstallation.
(3) Remove air cleaner assembly. (4) Remove radiator core support bracket. (5) Remove fan shroud with viscous fan assembly. (6) Remove drive belt. (7) Remove A/C compressor and secure away from
(8) Remove generator and secure away from
engine.
engine.
NOTE: Do NOT remove the phenolic pulley from the P/S pump. It is not required for P/S pump removal.
(9) Remove power
steering pump with lines
attached and secure away from engine.
(10) Drain cooling system. (11) Disconnect the heater hoses from the engine.
DR ENGINE - 3.7L (Continued)
ENGINE - 3.7L
9 - 11
(12) Disconnect heater hoses from heater core and
remove hose assembly.
(13) Disconnect throttle and speed control cables. (14) Remove upper radiator hose from engine. (15) Remove lower radiator hose from engine. (16) Remove radiator/cooling module assembly. (17) Disconnect the engine to body ground straps
at the left side of cowl.
(18) Disconnect the engine wiring harness at the following points: † Intake air temperature (IAT) sensor † Fuel Injectors † Throttle Position (TPS) Switch † Idle Air Control (IAC) Motor † Engine Oil Pressure Switch † Engine Coolant Temperature (ECT) Sensor † Manifold Absolute Pressure MAP) Sensor † Camshaft Position (CMP) Sensor † Coil Over Plugs † Crankshaft Position Sensor (19) Remove coil over plugs. (20) Release fuel rail pressure. (21) Remove fuel
rail and secure away from
engine.
NOTE: It is not necessary to release the quick con- nect fitting from the fuel supply line for engine removal.
(22) Remove the PCV hose. (23) Remove the breather hoses. (24) Remove the vacuum hose for the power brake
booster.
(25) Disconnect knock sensors. (26) Remove engine oil dipstick tube. (27) Remove intake manifold. (28) Install engine lifting fixture,special tool#8247, using original fasteners from the removed intake manifold, and fuel rail. Torque to factory specifica- tions.
(35) Remove the starter. (36) Remove the ground straps from the left and
right side of the block.
(37) Disconnect the right and left exhaust pipes at the manifolds and from the crossover, and remove from the vehicle.
NOTE: The exhaust clamps at the manifolds cannot be reused. New clamps must be used or leaks may occur.
(38) Remove the structural cover. (39) Remove torque convertor bolts, and mark
location for reassembly.
(40) Remove transmission bellhousing to engine
bolts.
bolts.
(41) Remove left and right engine mount thru
(42) Lower the vehicle. (43) Support the transmission with a suitable jack. (44) Connect a suitable engine hoist to the engine
lift plate.
(45) Remove engine from vehicle.
INSTALLATION
onto engine.
(1) Position the engine in the vehicle. (2) Install both left and right side engine mounts
(3) Raise the vehicle. (4) Install the transmission bellhousing to engine mounting bolts. Tighten the bolts to 41 N·m (30ft. lbs.).
(5) Tighten the engine mount thru bolts. (6) Install the torque convertor bolts. (7) Connect the ground straps on the left and right
side of the engine.
(8) Install the starter. (9) Connect the crankshaft position sensor. (10) Install the engine block heater power cable, if
equipped.
NOTE: Recheck bolt before removing engine.
torque for engine lift plate
(29) Secure the left and right engine wiring har-
nesses away from engine.
(30) Raise vehicle. (31) Disconnect oxygen sensor wiring. (32) Disconnect crankshaft postion sensor. (33) Disconnect cable, if equipped.
the engine block heater power
(34) Disconnect the front propshaft at the front
differential and secure out of way.
NOTE: It is necessary to disconnect the front prop- shaft for access to the starter and left side exhaust flange.
CAUTION: The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover.
(11) Install the structural cover.
NOTE: New clamps must be used on exhaust man- ifold flanges. Failure to use new clamps may result in exhaust leaks.
(12) Install the left and right exhaust pipes. (13) Connect the left and right oxygen sensors. (14) Lower vehicle. (15) Remove the engine lift plate. (16) Connect the knock sensors.
ENGINE - 3.7L
9 - 12
ENGINE - 3.7L (Continued)DR
(17) Connect the engine to body ground straps at
the left side of the cowl.
(18) Install the intake manifold. (19) Install the engine oil dipstick tube. (20) Install the power brake booster vacuum hose. (21) Install the breather hoses. (22) Install the PCV hose. (23) Install the fuel rail. (24) Install the coil over plugs. (25) Connect the engine wiring harness at the fol- lowing points: † Intake air temperature (IAT) sensor † Fuel Injectors † Throttle Position (TPS) Switch † Idle Air Control (IAC) Motor † Engine Oil Pressure Switch † Engine Coolant Temperature (ECT) Sensor † Manifold Absolute Pressure MAP) Sensor † Camshaft Position (CMP) Sensor † Coil Over Plugs † Crankshaft Position Sensor (26) Reinstall the radiator/cooling module assem-
bly.
(27) Connect lower radiator hose. (28) Connect upper radiator hose. (29) Connect throttle and speed control cables. (30) Install the heater hose assembly. (31) Install coolant recovery bottle. (32) Install the power steering pump. (33) Install the generator. (34) Install the A/C compressor. (35) Install the drive belt. (36) Install the fan shroud with the viscous fan
assembly.
(37) Install the radiator core support bracket. (38) Install the air cleaner assembly. (39) Refill the engine cooling system. (40) Recharge the air conditioning. (41) Install the hood. (42) Check and fill engine oil. (43) Connect the battery negative cable. (44) Start the engine and check for leaks.
SPECIFICATIONS
SPECIFICATIONS – 3.7L ENGINE
DESCRIPTION
Engine Type Displacement
Bore Stroke
SPECIFICATION
90° SOHC V-6 12-Valve
3.7 Liters / 3700 cc 226 ( Cubic Inches) 93.0 mm (3.66 in.) 90.8 mm (3.40 in.)
Compression Ratio
9.1:1
Horsepower
Torque
Lead Cylinder Firing Order
210 BHP @ 5200 RPM 225 LB-FT @ 4200 RPM
#1 Left Bank 1-6-5-4-3-2
CYLINDER BLOCK
Cylinder Block Bore Diameter
Out of Round (MAX)
Taper (MAX)
Cast Iron
93.0 ± .0075 mm
(3.6619 ± 0.0003 in.) 0.076 mm (0.003 in.) 0.051 mm (0.002 in.)
PISTONS
Material Diameter Weight
Aluminum Alloy
92.975 mm (3.6605 in.) 367.5 grams (12.96 oz)
Ring Groove Diameter
No. 1
No. 2
No. 3
83.73 - 83.13 mm (3.296 - 3.273 in.) 82.833 - 83.033 mm (3.261 - 3.310 in.) 83.88 - 84.08 mm (3.302 - 3.310 in.)
PISTON PINS
Type
Floating
Clearance In Piston
0.006 - 0.015 mm
Diameter
(0.0002 - 0.0005 in.) 24.017 - 24.020 mm (0.9455 - 0.9456 in.)
PISTON RINGS
Ring Gap
Top Compression Ring
0.20 - 0.36 mm
(0.0079 - 0.0142 in.)
DR ENGINE - 3.7L (Continued)
DESCRIPTION Second Compression Ring
SPECIFICATION 0.37 - 0.63 mm
DESCRIPTION
End Play
(0.0146 - 0.0249 in.)
Oil Control (Steel Rails)
0.25 - 0.76 mm
(0.0099 - 0.30 in.)
End Play (MAX)
Connecting Rod Journal
ENGINE - 3.7L
9 - 13
SPECIFICATION 0.052 - 0.282 mm (0.0021 - 0.0112 in.) 0.282 mm (0.0112 in)
Side Clearance
Top Compression Ring
.051 - .094 mm
Second Compression Ring
(0.0020 - 0.0037 in.)
0.040 - 0.080 mm
(0.0016 - 0.0031 in.)
Diameter
57.908 - 57.892 mm
Bearing Clearance
0.015 - 0.055 mm
Out of Round (MAX)
Taper (MAX)
0.005 mm (0.0002 in.) 0.006 mm (0.0002 in.)
Oil Ring (Steel Ring)
.019 - .229 mm
CAMSHAFT
(.0007 - .0091 in.)
Bore Diameter
Ring Width
Top Compression Ring
Second Compression Ring
Oil Ring (Steel Rails)
1.472 - 1.490 mm (0.057 - 0.058 in.) 1.472 - 1.490 mm
(0.057 - 0.058 in.) 0.445 - 0.470 mm (0.017 - 0.018 in.)
CONNECTING RODS
Bearing Journal Diameter
Bearing Clearance
26.02 - 26.04 mm
(1.0245 - 1.0252 in.) 25.975 - 25.995 mm (1.0227 - 1.0235 in.)
0.025 - 0.065 mm (0.001 - 0.0026 in.)
Bearing Clearance (MAX)
0.065 mm (0.0026 in.)
End Play
End Play (MAX)
.075 - .200 mm
(0.003 - 0.0079 in.) .200 mm (0.0079 in.)
Bearing Clearance
0.015 - 0.055 mm
VALVE TIMING
Side Clearance
0.10 - 0.35 mm
(0.0006 - 0.0022 in.)
Intake
Piston Pin Clearance
(0.004 - 0.0138 in.)
.015 - .028 mm
(0.0006 - 0.0011 in.)
Exhaust
Bearing Bore Out of
0.004 mm
Round (MAX)
(0.0002 in.)
Total Weight (Less
612 grams (21.588
Bearing)
ounces)
CRANKSHAFT
Main Bearing Journal
Diameter
63.488 - 63.512 mm (2.4996 - 2.5005 in.)
Bearing Clearance
0.002 - 0.034 mm
Out of Round (MAX)
Taper (MAX)
0.005 mm (0.0002 in.) 0.006 mm (0.0004 in.)
Opens (ATDC) Closes (ATDC) Duration
Opens (BTDC) Closes (ATDC) Duration Valve Overlap
0.0° 236° 236°
233° 17° 250° 17°
VALVES
Face Angle
45° - 45.5°
Head Diameter
Intake
48.52 - 48.78 mm
Exhaust
(1.9103 - 1.9205 in.)
36.87 - 37.13 mm 1.4516 - 1.4618 in.)
Exhaust
6.902 - 6.928 mm
Number of Coils
(0.2717 - 0.2728 in.)
ENGINE - 3.7L
9 - 14
ENGINE - 3.7L (Continued)DESCRIPTION
SPECIFICATION
Length (Overall)
Intake
113.45 - 114.21 mm
Exhaust
(4.4666 - 4.4965)
114.92 - 115.68 mm (4.5244 - 4.5543 in.)
Intake
6.931 - 6.957 mm
(0.2729 - 0.2739 in.)
Stem Diameter
Stem - to - Guide Clearance
Intake
0.018 - 0.069 mm
(0.0008 - 0.0028 in.)
Exhaust
0.047 - 0.098 mm
(0.0019 - 0.0039 in.)
Max. Allowable Stem - to - Guide Clearance (Rocking
Method)
Intake Exhaust
0.069 mm (0.0028 in.) 0.098 mm (0.0039 in.)
Valve Lift (Zero Lash)
Intake Exhaust VALVE SPRING
12.00 mm (0.472 in.) 10.90 mm (0.4292 in.)
Free Length (Approx)
Intake Exhaust
48.92 mm (1.9260 in.) 49.81 mm (1.9610 in.)
Spring Force (Valve Closed)
Intake
Exhaust
361.0 - 390.0 N @ 40.12
mm (81.15 - 87.67 lbs. @ 1.5795 in.) 390.0 - 430.0 N @ 40.12
mm (87.67 - 96.66 lbs. @ 1.5795 in.)DR
DESCRIPTION Spring Force (Valve Open)
SPECIFICATION
Intake
Exhaust
984.0 - 1040.0 N @ 28.12 mm 221.2 - 233.8 lbs. @ 1.107 in.) 965.0 - 1055.0 N @ 28.12 mm 216.9 - 237.1 lbs. @ 1.107 in.)
Intake Exhaust
7.30
7.45Wire Diameter
Intake and Exhaust
4.77 × 3.80mm
(0.1878 - 0.1496 in.)
Installed Height (Spring Seat to Bottom of Retainer)
Nominal
Intake Exhaust CYLINDER HEAD
40.12 mm (1.579 in.) 40.12 mm (1.579 in.)
Gasket Thickness
(Compressed)
Valve Seat Angle
Valve Seat Runout (MAX) Valve Seat Width
0.7 mm (0.0276 in.)
44.5° - 45.0°
0.051 mm (0.002 in.)
Intake
1.75 - 2.36 mm
(0.0698 - 0.0928 in.)
Exhaust
1.71 - 2.32 mm
(0.0673 - 0.0911 in.)
Guide Bore Diameter
6.975 - 7.00 mm
(Std.)
(0.2747 - 0.2756 in.)
Cylinder Head Warpage
(Flatness)
0.0508 mm (0.002 in.)
OIL PUMP
Clearance Over
Rotors/End Face (MAX)
0.095 mm
(0.0038 in.)
DR ENGINE - 3.7L (Continued)
ENGINE - 3.7L
9 - 15
DESCRIPTION
SPECIFICATION
DESCRIPTION
Cover Out - of -Flat
0.025 mm (0.001 in.)
(MAX)
Inner and Outer Rotor
Thickness
Outer Rotor to pocket (Diametral) clearance
(MAX)
12.02 mm (0.4731 in.) .235 mm (.0093 in.)
Outer Rotor Diameter
85.925 mm (0.400 in.)
(MIN)
Tip Clearance Between
Rotors (MAX)
0.150 mm (0.006 in.)
OIL PRESSURE
At Curb Idle Speed
25 kPa (4 psi)
(MIN)*
@ 3000 rpm
170 - 758 kPa (25 - 110
psi)
* CAUTION: If pressure is zero at curb idle, DO NOT run engine at 3000 rpm.
TORQUE
DESCRIPTION
N·m
Ft.
In.
Camshaft
Non - Oiled Sprocket Bolt Bearing Cap Bolts shaft retaining bolt
Counterbalance
Timing Chain Cover—Bolts Connecting Rod Cap—Bolts
122
11
2858
27Lbs.
Lbs.
90
— —43
20— 100
250— —
Bed Plate—Bolts Crankshaft Damper—Bolt Cylinder Head—Bolts
PLUS 90° TURN Refer to Procedure 175
—130
Flexplate—Bolts Engine Mount Bracket to Block—Bolts Rear Mount to Transmission—Bolts Generator Mounting—Bolts
M10 Bolts M8 Bolts
Intake Manifold—Bolts
Oil Pan—Bolts Oil Pan—Drain Plug Oil Pump—Bolts Oil Pump Cover—Bolts Oil Pickup Tube—Bolt and Nut Oil Dipstick Tube to Engine Block—Bolt Oil Fill Tube—Bolts Timing Chain Guide—Bolts Timing Chain Tensioner Arm Hydraulic Tensioner—Bolts Timing Chain Primary Tensioner—Bolts Timing Drive Idler Sprocket— Bolt Thermostat Housing—Bolts Water Pump—Bolts
N·m
95
6146
Ft.
Lbs. 70
45In.
Lbs. — —
34
—
40
— —54
— 28
250
12
105
Refer to Procedurefor
Tightening Sequence 130
15
— 34
28
250
105
12
28
250— 25
— — —15
12
28
28
28
2834
12
58— — — — — —
25
— 43
130
105
250
250
250
250—
105
—Cylinder Head Cover—Bolts Exhaust Manifold—Bolts Exhaust Manifold Heat Shield—Nuts
M11 Bolts Refer M8 Bolts
ToProcedure — 18
—105
— 7212
25Then loosen 45°
ENGINE - 3.7L
9 - 16
ENGINE - 3.7L (Continued) SPECIAL TOOLSDR
SpannerWrench6958
HandleC-4171
AdapterPins8346
RearCrankshaftSealInstaller8349
FrontCrankshaftSealRemover8511
RearCrankshaftSealRemover8506
FrontCrankshaftSealInstaller8348
ConnectingRodGuides8507
DR ENGINE - 3.7L (Continued)
ENGINE - 3.7L
9 - 17
CrankshaftDamperInstaller8512
ChainTensionerPins8514
Puller1026
VALVESPRINGCOMPRESSOR8426
CrankshaftDamperRemovalInsert8513
ChainTensionerWedge8379
ENGINELIFTINGFIXTURE8427
CAMSHAFTHOLDER8428
ENGINE - 3.7L
9 - 18
ENGINE - 3.7L (Continued)DR
HOLDERSECONDARYCAMSHAFTCHAIN8429
INSTALLER-REMOVER-COUNTERBALANCE
SHAFT8641
Remover,RockerArm8516
ValveSpringTesterC-647
DialIndicatorC-3339
ValveSpringCompressorC-3422-B
IdlerShaftRemover8517
ValveSpringCompressorAdapters8519
DR ENGINE - 3.7L (Continued)
ENGINE - 3.7L
9 - 19
BoreSizeIndicatorC-119
PressureTesterKit7700
Bloc–Chek–KitC-3685–A
OilPressureGaugeC-3292
PistonRingCompressorC-385
ENGINESUPPORTFIXTURE8534
9 - 20
ENGINE - 3.7L
DR
AIR CLEANER ELEMENT REMOVAL
Filter Element Only
Housing removal is not necessary for element (fil-
ter) replacement.
at air cleaner cover.
(1) Loosen clamp (Fig. 3) and disconnect air duct
(2) Pry over 4 spring clips (Fig. 3) from housing
cover (spring clips retain cover to housing).
(3) Release housing cover from locating tabs on
housing (Fig. 3) and remove cover.
(4) Remove air cleaner element (filter) from hous-
(5) Clean inside of housing before replacing ele-
ing.
ment.
Fig.4AIRCLEANERHOUSING
1 - AIR CLEANER HOUSING ASSEMBLY 2 - LOCATING PINS (4)
(3) Pry up 4 spring clips (Fig. 3) and lock cover to
housing.
(4) Install air duct to air cleaner cover and tighten
hose clamp to 3 N·m (30 in. lbs.) torque.
(5) If any other hose clamps were removed from air intake system, tighten them to 3.4 N·m (30 in. lbs.) torque.
(6) If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 N·m (40 in. lbs.) torque.
CYLINDER HEAD - LEFT DIAGNOSIS AND TESTING - CYLINDER HEAD GASKET
A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket.
leaking between adjacent cylinders are:
Possible indications of the cylinder head gasket † Loss of engine power † Engine misfiring † Poor fuel economy Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
† Engine overheating † Loss of coolant
Fig.3AIRCLEANERHOUSINGCOVER
1 - CLAMP 2 - AIR DUCT 3 - AIR CLEANER COVER 4 - LOCATING TABS 5 - CLIPS (4)
Housing Assembly
(1) Loosen clamp (Fig. 3) and disconnect air duct
at air cleaner cover.
pins (Fig. 4).
(2) Lift entire housing assembly from 4 locating
INSTALLATION
(1) Install filter element into housing. (2) Position housing cover into housing locating
tabs (Fig. 3).
DR CYLINDER HEAD - LEFT (Continued) † Excessive steam (white smoke) emitting from exhaust † Coolant foaming CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the proce- dures in Cylinder Compression Pressure Test (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING). An engine cylinder head gasket leaking between adja- cent cylinders will result in approximately a 50–70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRES- SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCES- SIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRES- SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester’s pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent. Perform test following the procedures supplied with the tool kit.
REMOVAL
(1) Disconnect the negative cable from the battery. (2) Raise the vehicle on a hoist. (3) Disconnect the exhaust pipe at the left side
exhaust manifold.
(4) Drain the engine coolant(Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(5) Lower the vehicle.
ENGINE - 3.7L
9 - 21
(6) Remove the intake manifold(Refer
ENGINE/MANIFOLDS/INTAKE REMOVAL).
MANIFOLD
to 9 -
(7) Remove the master cylinder and booster assem- bly(Refer to 5 - BRAKES/HYDRAULIC/MECHANI- CAL/POWER BRAKE BOOSTER - REMOVAL).
(8) Remove the cylinder head cover(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(9) Remove the fan shroud and fan blade assem- bly(Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(10) Remove accessory drive belt(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(11) Remove the power steering pump and set
aside.
(12) Rotate the crankshaft until the damper tim- ing mark is aligned with TDC indicator mark (Fig. 5).
Fig.5EngineTopDeadCenter
1 - TIMING CHAIN COVER 2 - CRANKSHAFT TIMING MARKS
(13) Verify the V6 mark on the camshaft sprocket is at the 12 o’clock position (Fig. 6). Rotate the crank- shaft one turn if necessary.
(14) Remove the crankshaft damper(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(15) Remove the timing chain cover(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
ENGINE - 3.7L
9 - 22
CYLINDER HEAD - LEFT (Continued)DR
Fig.6CAMSHAFTSPROCKETV6MARKS(#1TDC,Exhauststroke)
1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD
(16) Lock the secondary timing chains to the idler
NOTE: Mark the secondary timing chain prior to removal to aid in installation.
(17) Mark the secondary timing chain, one link on each side of the V6 mark on the camshaft drive gear. (18) Remove the left side secondary chain ten-
sioner. Refer to Timing Chain and Sprockets.
(19) Remove the cylinder head access plug (Fig. 8).
Fig.7UsingSpecialTool8429
Fig.8CylinderHeadAccessPlugs
1 - SPECIAL TOOL 8429
2 - CAMSHAFT CHAIN 3 - CRANKSHAFT TIMING GEAR
sprocket using Special Tool 8429 Timing Chain Hold- ing Fixture (Fig. 7).
1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
(20) Remove
chain guide(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).
secondary
side
left
the
DR CYLINDER HEAD - LEFT (Continued)
ENGINE - 3.7L
9 - 23
(21) Remove the retaining bolt and the camshaft
drive gear.
(1) Clean the cylinder head and cylinder block
mating surfaces (Fig. 10).
CAUTION: Do not allow the engine to rotate. Severe damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at the front of the cylinder head. Do not attempt to remove the cylinder head without removing these four bolts.
NOTE: The cylinder head is attached to the cylinder block with twelve bolts.
(22) Remove the cylinder head retaining bolts. (23) Remove the cylinder head and gasket. Discard
the gasket.
CAUTION: Do not lay the cylinder head on its gas- ket sealing surface, due to the design of the cylin- der head gasket any distortion to the cylinder head sealing surface may prevent the gasket from prop- erly sealing resulting in leaks.
INSTALLATION
NOTE: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced.
Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced (Fig. 9).
Fig.10ProperToolUsageForSurfacePreparation 1 - PLASTIC/WOOD SCRAPER
(2) Position the new cylinder head gasket on the
locating dowels.
CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm.
(3) Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.
NOTE: The four smaller cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.
(4) Lubricate the cylinder head bolt threads with
clean engine oil and install the eight M11 bolts.
(5) Coat the four M8 cylinder head bolts with Mopart Lock and Seal Adhesive then install the bolts.
Fig.9CheckingCylinderHeadBoltsforStretching
(Necking)
1 - STRETCHED BOLT 2 - THREADS ARE NOT STRAIGHT ON LINE 3 - THREADS ARE STRAIGHT ON LINE 4 - UNSTRETCHED BOLT
CAUTION: When cleaning cylinder head and cylin- der block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use only a wooden or plastic scraper.
NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.
ing steps and torque values:
(6) Tighten the bolts in sequence using the follow- † Step 1: Tighten bolts 1–8, 27 N·m (20 ft. lbs.). † Step 2: Verify that bolts 1–8, all reached 27 N·m (20 ft. lbs.), by repeating step-1 without loosening the bolts. Tighten bolts 9 thru 12 to 14 N·m (10 ft. lbs.). † Step 3: Tighten bolts 1–8, 90 degrees (Fig. 11).
ENGINE - 3.7L
9 - 24
CYLINDER HEAD - LEFT (Continued) † Step 4: Tighten bolts 1–8, 90 degrees, again. Tighten bolts 9–12, 26 N·m (19 ft. lbs.)Fig.11CylinderheadTighteningSequence
* - INDICATES SEALANT ON THREADS
(7) Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V6 mark on the gear then using Special Tool 8428 Camshaft Wrench, position the gear onto the camshaft.
CAUTION: Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt. Fail- ure to do so may cause over-torqueing of bolt resulting in bolt failure.
(8) Install the camshaft drive gear retaining bolt. (9) Install the left side secondary chain guide(Re- fer to 9 - ENGINE/VALVE TIMING/TIMING BELT/ CHAIN AND SPROCKETS - INSTALLATION).
(10) Install the cylinder head access plug. (11) Re-set and Install
the left side secondary chain tensioner(Refer to 9 - ENGINE/VALVE TIM- ING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).
(12) Remove Special Tool 8429. (13) Install the timing chain cover(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(14) Install the crankshaft damper(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION). Tighten damper bolt 175 N·m (130
Ft. Lbs.).(15) Install the power steering pump.
DR
(16) Install the fan blade assembly and fan shrou- d(Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
(17) Install the cylinder head cover(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(18) Reinstall
the master cylinder and booster assembly(Refer to 5 - BRAKES/HYDRAULIC/ME- CHANICAL/POWER BRAKE BOOSTER - INSTAL- LATION).
(19) Install
the intake manifold(Refer
MANIFOLD
to 9 -
ENGINE/MANIFOLDS/INTAKE INSTALLATION).
(20) Refill the cooling system(Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(21) Raise the vehicle. (22) Install the exhaust pipe onto the left exhaust
manifold.
(23) Lower the vehicle. (24) Connect the negative cable to the battery. (25) Start the engine and check for leaks.
CAMSHAFT(S) DESCRIPTION
The camshafts consist of powdered metal steel lobes which are sinter-bonded to a steel tube. Four bearing journals are machined into the camshaft. Camshaft end play is controlled by two thrust walls that border the nose piece journal. Engine oil enters the hollow camshafts at the third journal and lubri- cates every intake lobe rocker through a drilled pas- sage in the intake lobe.
REMOVAL
CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT force- fully rotate the camshafts or crankshaft indepen- dently of each other. Severe valve and/or piston damage can occur.
CAUTION: When removing the cam sprocket, timing chains or camshaft, Failure to use Special Tool 8379 will result in hydraulic tensioner ratchet over extension, requiring timing chain cover removal to reset the tensioner ratchet.
(1) Remove cylinder head cover(Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(2) Set engine to TDC cylinder #1,
camshaft
sprocket V6 marks at the 12 o’clock position.
DR CAMSHAFT(S) (Continued)
(3) Mark one link on the secondary timing chain on both sides of the V6 mark on the camshaft sprocket to aid in installation.
CAUTION: Do not hold or pry on the camshaft tar- get wheel (Located on the right side camshaft sprocket) for any reason, Severe damage will occur to the target wheel resulting in a vehicle no start condition.
(4) Loosen but DO NOT remove the camshaft
