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sprocket retaining bolt. Leave the bolt snug against the sprocket.
NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tension- ers to extend, requiring timing chain cover removal in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur.
(5) Position Special Tool 8379 timing chain wedge between the timing chain strands, tap the tool to securely wedge the timing chain against the ten- sioner arm and guide (Fig. 12).
Fig.12SECURINGTIMINGCHAINTENSIONERS
USINGTIMINGCHAINWEDGE—Typical
1 - SPECIAL TOOL 8379
2 - CAMSHAFT SPROCKET 3 - CAMSHAFT SPROCKET BOLT 4 - CYLINDER HEAD(6) Hold the camshaft with Special Tool 8428 Cam- shaft Wrench, while removing the camshaft sprocket bolt and sprocket (Fig. 13).
ENGINE - 3.7L
9 - 25
Fig.13SpecialTool8428
1 - Camshaft hole 2 - Special Tool 8428
(7) Using Special Tool 8428 Camshaft Wrench, gently allow the camshaft to rotate 5° clockwise until the camshaft is in the neutral position (no valve load).
(8) Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM- SHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
(9) Remove the camshaft bearing caps and the
camshaft.
INSTALLATION
(1) Lubricate camshaft journals with clean engine
oil.
NOTE: Position the left side camshaft so that the camshaft sprocket dowel is near the 1 o’clock posi- tion, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
(2) Position the camshaft into the cylinder head.
ENGINE - 3.7L
9 - 26
CAMSHAFT(S) (Continued)(3) Install the camshaft bearing caps, hand tighten
the retaining bolts.
NOTE: Caps should be installed so that the stamped numbers on the caps are in numerical order, ( 1 thru 4 ) from the front to the rear of the engine. All caps should be installed so that the stamped arrows on the caps point toward the front of the engine.
(4) Working in 1⁄2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward (Fig. 14).
DR
(10) Using Special Tool 6958 spanner wrench with adapter pins 8346, torque the camshaft sprocket retaining bolt to 122 N·m (90 ft. lbs.).
(11) Install the cylinder head cover(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
CYLINDER HEAD COVER(S) DESCRIPTION
The cylinder head covers are made of single layer stamped steel, and are not interchangable from side- to-side (Fig. 15).
Fig.14CAMSHAFTBEARINGCAPSTIGHTENING (5) Torque the camshaft bearing cap retaining
bolts to 11 N·m (100 in. lbs.).
(6) Position the camshaft drive gear into the tim- ing chain aligning the V6 mark between the two marked chain links (Two links marked during remov- al).
(7) Using Special Tool 8428 Camshaft Wrench, the camshaft sprocket in the camshaft
rotate the camshaft until dowel sprocket. Install the sprocket onto the camshaft.
is aligned with the slot
CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over- torque resulting in bolt failure.
(8) Remove excess oil from bolt, then install the
camshaft sprocket retaining bolt and hand tighten.
(9) Remove Special Tool 8379 timing chain wedge.
Fig.15CYLINDERHEADCOVERS
1 - LEFT SIDE CYLINDER HEAD COVER 2 - RIGHT SIDE CYLINDER HEAD COVER
REMOVAL
(1) Disconnect negative cable from battery. (2) Remove the resonator assemble and air inlet
hose.
cover.
injector harness.
(3) Disconnect injector connectors and un-clip the
(4) Route injector harness in front of cylinder head
(5) Disconnect
the left side breather tube and
remove the breather tube.
DR CYLINDER HEAD COVER(S) (Continued)
ENGINE - 3.7L
9 - 27
(6) Remove the cylinder head cover mounting bolts
(Fig. 16).
(7) Remove cylinder head cover and gasket.
NOTE: The gasket may be used again, providing no cuts, tears, or deformation has occurred.
Fig.16CYLINDERHEADCOVER-TYPICAL
1 - SCREWS 2 - CYLINDER HEAD COVER
INSTALLATION
CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur.
NOTE: The gasket may be used again, provided no cuts, tears, or deformation has occurred.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2) Tighten cylinder head cover bolts and double
ended studs to 12 N·m (105 in. lbs.).
(3) Install left side breather and connect breather
tube.
(4) Connect injector electrical connectors and injec-
tor harness retaining clips.
(5) Install the resonator and air inlet hose. (6) Connect negative cable to battery.
INTAKE/EXHAUST VALVES & SEATS DESCRIPTION
The valves are made of heat resistant steel and have chrome plated stems to prevent scuffing. Each valve is actuated by a roller rocker arm which pivots on a stationary lash adjuster. All valves use three bead lock keepers to retain the springs and promote valve rotation.
STANDARD PROCEDURE - REFACING
NOTE: Valve seats that are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced.
NOTE: When refacing valves and valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete sur- face must be obtained.
(1) Using a suitable dial
indicator measure the center of the valve seat Total run out must not exceed 0.051 mm (0.002 in).
(2) Apply a small amount of Prussian blue to the valve seat, insert the valve into the cylinder head, while applying light pressure on the valve rotate the valve. Remove the valve and examine the valve face. If the blue is transferred below the top edge of the valve face, lower the valve seat using a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, raise the valve seat using a 65 degree stone.
(3) When the seat is properly positioned the width of the intake seat must be 1.75 – 2.36 mm (0.0689 – 0.0928 in.) and the exhaust seat must be 1.71 – 2.32
mm (0.0673 – 0.0911 in.).(4) Check the valve spring installed height after refacing the valve and seat. The installed height for both intake and exhaust valve springs must not exceed 40.74 mm (1.6039 in.).
ENGINE - 3.7L
9 - 28
INTAKE/EXHAUST VALVES & SEATS (Continued)(5) The valve seat and valve face must maintain a
face angle of 44.5 – 45 degrees angle (Fig. 17).
DR
Fig.17ValveAssemblyConfiguration
1 - CAMSHAFT 2 - SPECIAL TOOL 8516
Fig.18RockerArmRemoval
1 - VALVE LOCKS (3–BEAD) 2 - RETAINER 3 - VALVE STEM OIL SEAL 4 - INTAKE VALVE 5 - EXHAUST VALVE 6 - VALVE SPRING
REMOVAL
NOTE: The cylinder heads must be removed in order to perform this procedure.
(1) Remove rocker arms and lash adjusters(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - REMOVAL). (Fig. 18).
(2) Remove the camshaft bearing caps and the
camshaft.
NOTE: All six valve springs and valves are removed in the same manner; this procedure only covers one valve and valve spring.
(3) Using Special Tool C-3422–B or C-3422–C tool 8519
Valve Spring Compressor and Special Adapter, compress the valve spring.
NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
(4) Remove the two spring retainer lock halves.
NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
(5) Remove the valve spring compressor. (6) Remove the spring retainer, and the spring.
NOTE: Check for sharp edges on the keeper grooves. Remove any burrs from the valve stem before removing the valve from the cylinder head.
(7) Remove the valve from the cylinder head.
NOTE: The valve stem seals are common between intake and exhaust.
(8) Remove the valve stem seal. Mark the valve for
proper installation.
TESTING VALVE SPRINGS
NOTE: Whenever the valves are removed from the cylinder head it the valve springs be inspected and tested for reuse.
is recommended that
Inspect the valve springs for physical signs of wear or damage. Turn table of tool C-647 until surface is in line with the 40.12 mm (1.579 in.) mark on the threaded stud and the zero mark on the front. Place spring over the stud on the table and lift compress- ing lever to set tone device. Pull on torque wrench until Ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer
DR INTAKE/EXHAUST VALVES & SEATS (Continued)
adjustments. Refer to Specifications Section to obtain specified height and allowable tensions. Replace any springs that do not meet specifications (Fig. 19).
ENGINE - 3.7L
9 - 29
Fig.19TestingValveSprings
1 - SPECIAL TOOL C-647
INSTALLATION
(1) coat the valve stem with clean engine oil and
insert it into the cylinder head.
(2) Install the valve stem seal. make sure the seal is fully seated and that the garter spring at the top of the seal is intact.
(3) Install the spring and the spring retainer (Fig.
20).
(4) Using the valve spring compressor, compress the spring and install the two valve spring retainer halves.
(5) Release the valve spring compressor and make sure the two spring retainer halves and the spring retainer are fully seated.
(6) lubricate the camshaft
then Position the camshaft
journal with clean engine oil (with the sprocket dowel on the left camshaft at 11 o’clock and the right camshaft at 12 o’clock), then position the camshaft bearing caps.
(7) Install
the camshaft bearing cap retaining bolts. Tighten the bolts 9–13 N·m (100 in. lbs.) in 1⁄2
turn increments in the sequence shown (Fig. 21).(8) Position the hydraulic
lash adjusters and rocker arms(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - INSTAL- LATION).
Fig.20ValveAssemblyConfiguration
1 - VALVE LOCKS (3–BEAD) 2 - RETAINER 3 - VALVE STEM OIL SEAL 4 - INTAKE VALVE 5 - EXHAUST VALVE 6 - VALVE SPRING
Fig.21CamshaftBearingCapsTightening
Sequence
DR
9 - 30
ENGINE - 3.7L
ROCKER ARM DESCRIPTION
The rocker arms are steel stampings with an inte- gral roller bearing. The rocker arms incorporate a 2.8
mm (0.11 inch) oil hole in the lash adjuster socket for roller and camshaft lubrication.REMOVAL
NOTE: Disconnect the battery negative cable to pre- vent accidental starter engagement.
(1) Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(2) For rocker arm removal on cylinder #4, Rotate the crankshaft until cylinder #1 is at BDC intake stroke.
(3) For rocker arm removal on cylinder #1, Rotate the crankshaft until cylinder #1 is at BDC combus- tion stroke.
(4) For rocker arm removal on cylinders #3 and #5, Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke.
(5) For rocker arm removal on cylinders #2 and #6, Rotate the crankshaft until cylinder #1 is at TDC ignition stroke.
(6) Using special tool 8516 Rocker Arm Remover, press downward on the valve spring, remove rocker arm (Fig. 22).
INSTALLATION
CAUTION: Make sure the rocker arms are installed with the concave pocket over the lash adjusters. Failure to do so may cause severe damage to the rocker arms and/or lash adjusters.
NOTE: Coat the rocker arms with clean engine oil prior to installation.
(1) For rocker arm installation on cylinders #4, Rotate the crankshaft until cylinder #1 is at BDC intake stroke.
(2) For rocker arm installation on cylinder #1, Rotate the crankshaft until cylinder #1 is at BDC combustion stroke.
(3) For rocker arm installation on cylinders #3 and #5, Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke.
(4) For rocker arm installation on cylinders #2 and #6, Rotate the crankshaft until cylinder #1 is at TDC ignition stroke.
(5) Using special tool 8516 press downward on the
valve spring, install rocker arm (Fig. 23).
Fig.22RockerArm-Removal
1 - CAMSHAFT 2 - SPECIAL TOOL 8516
Fig.23RockerArm-Installation
1 - CAMSHAFT 2 - SPECIAL TOOL 8516
(6) Install the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
DR
ENGINE - 3.7L
9 - 31
VALVE GUIDE SEALS DESCRIPTION
The valve guide seals are made of rubber and incorporate an integral steel valve spring seat. The integral garter spring maintains consistent lubrica- tion control to the valve stems.
VALVE SPRINGS DESCRIPTION
The valve springs are made from high strength chrome silicon steel. The springs are NOT common for intake and exhaust applications. The valve spring seat is integral with the valve stem seal, which is a positive type seal to control lubrication.
REMOVAL
(1) Remove the cylinder head cover(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(2) Using Special Tool 8516 Valve Spring Compres- sor, remove the rocker arms and the hydraulic lash adjusters.
(3) Remove the spark plug for the cylinder the
valve spring and seal are to be removed from.
(4) Apply shop air to the cylinder to hold the
valves in place when the spring is removed.
NOTE: All six valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.
(5) Using Special Tool 8387 Valve Spring Compres-
sor, compress the valve spring.
NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
(6) Remove the two spring retainer lock halves.
NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
(7) Remove the valve spring compressor.
NOTE: The valve springs are NOT common between intake and exhaust.
(8) Remove the spring retainer, and the spring. (9) Remove the valve stem seal.
NOTE: The valve stem seals are common between intake and exhaust.
INSTALLATION
NOTE: All six valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.
(1) Apply shop air to the cylinder to hold the
valves in place while the spring is installed.
NOTE: The valve stem seals are common between intake and exhaust.
(2) Install the valve stem seal.
NOTE: The valve springs are NOT common between intake and exhaust.
(3) Install the spring retainer, and the spring. (4) Using Special Tool 8387 Valve Spring Compres-
sor, compress the valve spring.
(5) Install the two spring retainer lock halves.
NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
(6) Remove the valve spring compressor. (7) Disconnect the shop air to the cylinder. (8) Install the spark plug for the cylinder the valve
spring and seal was installed on.
(9) Using Special Tool 8516 Valve Spring Compres- sor, install the rocker arms and the hydraulic lash adjusters.
(10) Install the cylinder head cover(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
CYLINDER HEAD - RIGHT DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy.
(2) Insufficient running time after rebuilding cylin- der head. Low speed running up to 1 hour may be required.
(3) Turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature.
(4) Low oil pressure. (5) The oil restrictor in cylinder head gasket or the oil passage to the cylinder head is plugged with debris.
ENGINE - 3.7L
9 - 32
CYLINDER HEAD - RIGHT (Continued)DR
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides. (8) Rocker arm ears
retainer.
contacting valve
spring
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Oil leak or excessive cam bore wear in cylin-
der head.
(11) Faulty lash adjuster. a. Check lash adjusters
sponginess while installed in cylinder head and cam on camshaft at base circle. Depress part of rocker arm over adjuster. Normal adjusters should feel very firm. Spongy adjusters can be bottomed out easily.
for
b. Remove suspected lash adjusters, and replace. c. Before installation, make sure adjusters are at least partially full of oil. This can be verified by little or no plunger travel when lash adjuster is depressed.
REMOVAL
(1) Disconnect battery negative cable. (2) Raise the vehicle on a hoist. (3) Disconnect the exhaust pipe at the right side
exhaust manifold.
(4) Drain the engine coolant(Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(5) Lower the vehicle. (6) Remove the intake manifold(Refer
ENGINE/MANIFOLDS/INTAKE REMOVAL).
MANIFOLD
to 9 -
(7) Remove the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(8) Remove the fan shroud(Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL).
(9) Remove oil fill housing from cylinder head. (10) Remove accessory drive belt(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(11) Rotate the crankshaft until the damper timing
mark is aligned with TDC indicator mark.
(12) Verify the V6 mark on the camshaft sprocket is at the 12 o’clock position. Rotate the crankshaft one turn if necessary.
(13) Remove the crankshaft damper(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(14) Remove the timing chain cover(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(15) Lock the secondary timing chains to the idler sprocket using Special Tool 8429 Timing Chain Hold- ing Fixture.
NOTE: Mark the secondary timing chain prior to removal to aid in installation.
(16) Mark the secondary timing chain, one link on each side of the V6 mark on the camshaft drive gear. (17) Remove the right side secondary chain ten- sioner(Refer to 9 - ENGINE/VALVE TIMING/TIM- ING BELT/CHAIN AND SPROCKETS - REMOVAL).
(18) Remove the cylinder head access plug. (19) Remove secondary
chain guide(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).
right
side
the
CAUTION: The nut on the right side camshaft sprocket should not be removed for any reason, as the sprocket and camshaft sensor target wheel is serviced as an assembly. If the nut was removed retorque nut to 5 N·m (44 in. lbs.).
(20) Remove the retaining bolt and the camshaft
drive gear.
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.
CAUTION: Do not hold or pry on the camshaft tar- get wheel for any reason. A damaged target wheel can result in a vehicle no start condition.
NOTE: The cylinder head is attached to the cylinder block with twelve bolts.
(21) Remove the cylinder head retaining bolts. (22) Remove the cylinder head and gasket. Discard
the gasket.
CAUTION: Do not lay the cylinder head on its gas- ket sealing surface, do to the design of the cylinder 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 (Fig. 24). If all the threads do not contact the scale, the bolt should be replaced.
DR CYLINDER HEAD - RIGHT (Continued)
ENGINE - 3.7L
9 - 33
(3) Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.
NOTE: The four M8 cylinder head mounting bolts require sealant to be added to them before install- ing. Failure to do so may cause leaks.
Fig.24CheckingCylinderHeadBoltsforStretching
(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.
(1) Clean the cylinder head and cylinder block
mating surfaces (Fig. 25).
(4) Lubricate the cylinder head bolt threads with
clean engine oil and install the eight M10 bolts.
(5) Coat the four M8 cylinder head bolts with Mopar Lock and Seal Adhesive then install the bolts.
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. 26). † Step 4: Tighten bolts 1–8, 90 degrees, again.
Tighten bolts 9–12, 26 N·m (19 ft. lbs.)
Fig.25ProperToolUsageForSurfacePreparation 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.
Fig.26CylinderHeadTighteningSequence
* - INDICATES SEALANT ON THREADS
CAUTION: The nut on the right side camshaft sprocket should not be removed for any reason, as the sprocket and camshaft sensor target wheel is serviced as an assembly. If the nut was removed retorque nut to 5 ft. lbs.( 60 in. lbs.).
ENGINE - 3.7L
9 - 34
CYLINDER HEAD - RIGHT (Continued)(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-torquing of bolt result- ing in bolt failure.
(8) Install the camshaft drive gear retaining bolt. (9) Install the right 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 right 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) - REMOVAL).
(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 accessory drive belt(Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- LATION).
(16) Install the fan shroud(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) Install
the intake manifold(Refer
MANIFOLD
to 9 -
ENGINE/MANIFOLDS/INTAKE INSTALLATION).
(19) Install oil fill housing onto cylinder head. (20) Refill the cooling system(Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(21) Raise the vehicle. (22) Install
exhaust manifold.
the exhaust pipe onto the right
(23) Lower the vehicle. (24) Reconnect battery negative cable. (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
DR
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 exten- sion, Requiring timing chain cover removal to re-set the tensioner ratchet.(1) Remove the 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.
(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 for any reason, Severe damage will occur to the target wheel. A damaged target wheel could cause a vehicle no start condition.
(4) Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave bolt snug against sprocket.
NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tension- ers to extend, requiring timing chain cover removal in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur.
(5) Position Special Tool 8379 timing chain wedge between the timing chain strands. Tap the tool to securely wedge the timing chain against the ten- sioner arm and guide.
(6) Remove the camshaft position sensor. (7) Hold the camshaft with Special Tool 8428 Cam- shaft Wrench, while removing the camshaft sprocket bolt and sprocket.
DR CAMSHAFT(S) (Continued)
(8) Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM- SHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
(9) Remove the camshaft bearing caps and the
camshaft.
INSTALLATION
(1) Lubricate camshaft journals with clean engine
oil.
NOTE: Position the right side camshaft so that the camshaft sprocket dowel is near the 10 o’clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
(2) Position the camshaft into the cylinder head. (3) Install the camshaft bearing caps, hand tighten
the retaining bolts.
NOTE: Caps should be installed so that the stamped numbers on the caps are in numerical order, ( 1 thru 4 ) from the front to the rear of the engine. All caps should be installed so that the stamped arrows on the caps point toward the front of the engine.
(4) Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward (Fig. 27).
(5) Torque the camshaft bearing cap retaining
bolts to 11 N·m (100 in. lbs.).
(6) Position the camshaft drive gear into the tim- ing chain aligning the V6 mark between the two marked chain links (Two links marked during remov- al).
(7) Using Special Tool 8428 Camshaft Wrench, the camshaft sprocket in the camshaft
rotate the camshaft until dowel sprocket. Install the sprocket onto the camshaft.
is aligned with the slot
CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over- torque resulting in bolt failure.
(8) Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and hand tighten.
ENGINE - 3.7L
9 - 35
Fig.27CAMSHAFTBEARINGCAPSTIGHTENING (9) Remove timing chain wedge special tool 8379. (10) Using Special Tool 6958 spanner wrench with adapter pins 8346, torque the camshaft sprocket retaining bolt to 122 N·m (90 ft. lbs.).
(11) Install the camshaft position sensor. (12) Install the cylinder head cover(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
CYLINDER HEAD COVER(S) REMOVAL
(1) Disconnect battery negative cable. (2) Remove air cleaner assembly, resonator assem-
bly and air inlet hose.
(3) Drain cooling system, below the level of the heater hoses(Refer to 7 - COOLING - STANDARD PROCEDURE).
(4) Remove accessory drive belt(Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV- AL).
(5) Remove air conditioning compressor retaining
bolts and move compressor to the left.
(6) Remove heater hoses. (7) Disconnect injector and ignition coil connectors. (8) Disconnect and remove positive crankcase ven-
tilation (PCV) hose.
(9) Remove oil fill tube. (10) Un-clip injector and ignition coil harness and
move away from cylinder head cover.
(11) Remove right rear breather tube and filter
assembly.
ENGINE - 3.7L
9 - 36
CYLINDER HEAD COVER(S) (Continued)(12) Remove cylinder head cover retaining bolts. (13) Remove cylinder head cover.
INSTALLATION
CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur.
NOTE: The gasket may be used again, provided no cuts, tears, or deformation has occurred.
DR
(3) For rocker arm removal on cylinder #1, Rotate the crankshaft until cylinder #1 is at BDC combus- tion stroke.
(4) For rocker arm removal on cylinders #3 and #5, Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke.
(5) For rocker arm removal on cylinders #2 and #6, Rotate the crankshaft until cylinder #1 is at TDC ignition stroke.
(6) Using special tool 8516 Rocker Arm Remover, press downward on the valve spring, remove rocker arm (Fig. 28).
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2) Tighten cylinder head cover bolts and double
ended studs to 12 N·m (105 in. lbs).
(3) Install right rear breather tube and filter
assembly.
(4) Connect injector, ignition coil electrical connec-
tors and harness retaining clips.
(5) Install the oil fill tube. (6) Install PCV hose. (7) Install heater hoses. (8) Install air conditioning compressor retaining
bolts.
(9) Install accessory drive belt(Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- LATION).
(10) Fill Cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(11) Install air cleaner assembly, resonator assem-
bly and air inlet hose.
(12) Connect battery negative cable.
ROCKER ARM DESCRIPTION
The rocker arms are steel stampings with an inte- gral roller bearing. The rocker arms incorporate a 2.8
mm (0.11 inch) oil hole in the lash adjuster socket for roller and camshaft lubrication.REMOVAL
NOTE: Disconnect the battery negative cable to pre- vent accidental starter engagement.
(1) Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(2) For rocker arm removal on cylinder #4, Rotate the crankshaft until cylinder #1 is at BDC intake stroke.
Fig.28RockerArm-Removal
1 - CAMSHAFT 2 - SPECIAL TOOL 8516
VALVE GUIDE SEALS DESCRIPTION
The valve guide seals are made of rubber and incorporate an integral steel valve spring seat. The integral garter spring maintains consistent lubrica- tion control to the valve stems.
VALVE SPRINGS DESCRIPTION
The valve springs are made from high strength chrome silicon steel. There are different springs for intake and exhaust applications. The valve spring seat is integral with the valve stem seal, which is a positive type seal to control lubrication.
DR VALVE SPRINGS (Continued) REMOVAL
(1) Remove the cylinder head cover(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(2) Using Special Tool 8516 Valve Spring Compres- sor, remove the rocker arms and the hydraulic lash adjusters.
(3) Remove the spark plug for the cylinder the
valve spring and seal are to be removed from.
(4) Apply shop air to the cylinder to hold the
valves in place when the spring is removed.
NOTE: All six valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.
(5) Using Special Tool 8387 Valve Spring Compres-
sor, compress the valve spring.
NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
(6) Remove the two spring retainer lock halves.
NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
(7) Remove the valve spring compressor.
NOTE: The valve springs are NOT common between intake and exhaust.
(8) Remove the spring retainer, and the spring. (9) Remove the valve stem seal.
NOTE: The valve stem seals are common between intake and exhaust.
INSTALLATION
NOTE: All six valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.
(1) Apply shop air to the cylinder to hold the
valves in place while the spring is installed.
NOTE: The valve stem seals are common between intake and exhaust.
(2) Install the valve stem seal.
ENGINE - 3.7L
9 - 37
NOTE: The valve springs are NOT common between intake and exhaust.
(3) Install the spring retainer, and the spring. (4) Using Special Tool 8387 Valve Spring Compres-
sor, compress the valve spring.
(5) Install the two spring retainer lock halves.
NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
(6) Remove the valve spring compressor. (7) Disconnect the shop air to the cylinder. (8) Install the spark plug for the cylinder the valve
spring and seal was installed on.
(9) Using Special Tool 8516 Valve Spring Compres- sor, install the rocker arms and the hydraulic lash adjusters.
(10) Install the cylinder head cover(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
ENGINE BLOCK DESCRIPTION
The cylinder block is made of cast iron. The block is a closed deck design with the left bank forward. To provide high rigidity and improved NVH an enhanced compacted graphite bedplate is bolted to the block. The block design allows coolant flow between the cylinders bores, and an internal coolant bypass to a single poppet inlet thermostat is included in the cast aluminum front cover.
STANDARD PROCEDURE—CYLINDER BORE HONING
Before honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area.
(1) Used carefully, the Cylinder Bore Sizing Hone C-823, equipped with 220 grit stones, is the best tool for this job. In addition to deglazing, it will reduce taper and out-of-round, as well as removing light scuffing, scoring and scratches. Usually, a few strokes will clean up a bore and maintain the required lim- its.
CAUTION: DO NOT use rigid type hones to remove cylinder wall glaze.
ENGINE - 3.7L
9 - 38
ENGINE BLOCK (Continued)(2) Deglazing of the cylinder walls may be done if the cylinder bore is straight and round. Use a cylin- der surfacing hone, Honing Tool C-3501, equipped with 280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be suf- ficient to provide a satisfactory surface. Using honing oil C-3501-3880, or a light honing oil, available from major oil distributors.CAUTION: DO NOT use engine or transmission oil, mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up and down fast enough to get a crosshatch pattern. The hone marks should INTERSECT at 50° to 60° for proper seating of rings (Fig. 29).
DR
CLEANING
Thoroughly clean the oil pan and engine block gas-
ket surfaces.
Use compressed air to clean out: † The galley at the oil filter adaptor hole. † The front and rear oil galley holes. † The feed holes for the crankshaft main bearings. Once the block has been completely cleaned, apply Loctite PST pipe sealant with Teflon 592 to the threads of the front and rear oil galley plugs. Tighten the 1/4 inch NPT plugs to 20 N·m (177 in. lbs.) torque. Tighten the 3/8 inch NPT plugs to 27 N·m (240 in. lbs.) torque.
INSPECTION
(1) It is mandatory to use a dial bore gauge to measure each cylinder bore diameter. To correctly select the proper size piston, a cylinder bore gauge, capable of reading in 0.003 mm (.0001 in.) INCRE- MENTS is required. If a bore gauge is not available, do not use an inside micrometer (Fig. 30).
Fig.29CYLINDERBORECROSSHATCHPATTERN 1 - CROSSHATCH PATTERN 2 - INTERSECT ANGLE
(4) A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper cross- hatch angle. The number of up and down strokes per minute can be regulated to get the desired 50° to 60° angle. Faster up and down strokes increase the cross- hatch angle.
(5) After honing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash parts with a solution of hot water and deter- gent. Dry parts thoroughly. Use a clean, white, lint- free cloth to check that the bore is clean. Oil the bores after cleaning to prevent rusting.
Fig.30BOREGAUGE-TYPICAL
1 - FRONT 2 - BORE GAUGE 3 - CYLINDER BORE 4 - 38 MM (1.5 in)
(2) Measure the inside diameter of the cylinder bore at three levels below top of bore. Start perpen- dicular (across or at 90 degrees) to the axis of the crankshaft and then take two additional reading.
(3) Measure the cylinder bore diameter crosswise to the cylinder block near the top of the bore. Repeat the measurement near the middle of the bore, then repeat the measurement near the bottom of the bore.
DR ENGINE BLOCK (Continued)
ENGINE - 3.7L
9 - 39
(4) Determine taper by subtracting the smaller
diameter from the larger diameter.
(5) Rotate measuring device 90° and repeat steps
above.
(6) Determine out-of-roundness by comparing the
difference between each measurement.
(7) If cylinder bore taper does not exceed 0.025
mm (0.001 inch) and out-of-roundness does not exceed 0.025 mm (0.001 inch), the cylinder bore can be honed. If the cylinder bore taper or out- of-round condition exceeds these maximum limits, the cylinder block must be replaced. A slight amount of taper always exists in the cylinder bore after the engine has been in use for a period of time.CRANKSHAFT DESCRIPTION
The crankshaft is constructed of nodular cast iron. The crankshaft is a three throw split pin design with six counterweights for balancing purposes. The crankshaft is supported by four select fit main bear- ings with the number two serving as the thrust washer location. The main journals of the crankshaft are cross drilled to improve rod bearing lubrication. The number six counterweight has provisions for crankshaft position sensor target wheel mounting. The select fit main bearing markings are located on the rear side of the target wheel (Fig. 31). The crank- shaft oil seals are one piece design. The front oil seal is retained in the timing chain cover, and the rear seal is pressed in to a bore formed by the cylinder block and the bedplate assembly.
REMOVAL
NOTE: To remove the crankshaft from the engine, the engine must be removed from the vehicle.
(1) Remove the engine(Refer to 9 - ENGINE -
REMOVAL).
(2) Remove the engine oil pump(Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - REMOVAL).
CAUTION: DO NOT pry on the oil pan gasket when removing the oil pan, The oil pan gasket is mounted to the cylinder block in three locations and will remain attached to block when removing oil pan. Gasket can not be removed with oil pan.
(3) Remove the bedplate mounting bolts. Note the
location of the two stud bolts for installation.
(4) Remove the connecting rods from the crank-
shaft.
Fig.31CRANKSHAFTANDTARGETRING
1 - CRANKSHAFT 2 - CRANKSHAFT POSITION SENSOR TARGET RING
CAUTION: The bedplate to cylinder block mating surface is a critical sealing surface. Do not pry on or damage this surface in anyway.
NOTE: The bedplate contains the lower main bear- ing halves. Use care when handling bedplate as not to drop or damage bearing halves. Installing main bearing halves in the wrong position will cause severe damage to the crankshaft.
NOTE: The bedplate has pry points cast into it. Use these points only. The pry points are shown below.
(5) Carefully pry on the pry points (Fig. 32) to
loosen the bedplate then remove the bedplate.
CAUTION: When removing the crankshaft, use care not to damage bearing surfaces on the crankshaft.
(6) Remove the crankshaft. (7) Remove the crankshaft tone wheel.
ENGINE - 3.7L
9 - 40
CRANKSHAFT (Continued)DR
Fig.32BEDPLATEPRYPOINTLOCATION
INSPECTION
NOTE: Thoroughly inspect the connecting rod bear- ing bores and main bearing bores for scoring, blue- ing or severe scratches. Further disassembly may be required.
If connecting rod bearing bores show damage, the cylinder heads must be removed to service the piston and rod assemblies. If the bedplate or the cylinder block main bearing bores show damage the engine must be replaced.
(1) If required, remove the main bearing halves
from the cylinder block and bedplate.
(2) Thoroughly clean the bedplate to cylinder block sealing surfaces and main bearing bores. Remove all oil and sealant residue.
(3) Inspect the bedplate main bearing bores for cracks, scoring or severe blueing. If either condition exists the engine must be replaced.
(4) Inspect the crankshaft thrust washers for scor- ing, scratches, wear or blueing. If either condition exist replace the thrust washers.
(5) Inspect the oil pan gasket/windage tray for splits, tears or cracks in the gasket sealing surfaces. Replace gasket as necessary.
DR CRANKSHAFT (Continued) INSTALLATION
CAUTION: Main bearings are select fit. Refer to Crankshaft Main Bearings in this section for proper bearing selections.
CAUTION: When installing crankshaft, use care not to damage bearing surfaces on the crankshaft.
NOTE: Apply sealant to the tone wheel retaining screws prior to installation.
ENGINE - 3.7L
9 - 41
NOTE: Make sure that the bedplate and cylinder block sealing surfaces are clean and free of oil or other contaminants. Contaminants on the sealing surfaces may cause main bearing distortion and/or oil leaks.
(5) Apply a 2.5mm (0.100 inch) bead of Mopart Engine RTV sealant to the cylinder block-to-bedplate mating surface as shown (Fig. 34).
(1) Lubricate upper main bearing halves with
clean engine oil.
(2) Install the crankshaft tone wheel. Torque the
mounting screws to 15 N·m (11 ft. lbs.).
(3) Position crankshaft in cylinder block. (4) Install the thrust washers (Fig. 33).
Fig.34BEDPLATESEALANT
1 - CYLINDER BLOCK 2 - SEALENT 3 - SEALANT
(6) Coat
the crankshaft main bearing journals with clean engine oil and position the bedplate onto the cylinder block.
NOTE: Lubricate the bedplate retaining bolts with clean engine oil prior to installation.
Fig.33CrankshaftThrustWasherInstallation
1 - CRANKSHAFT THRUST WASHER
CAUTION: The bedplate to cylinder block mating surface must be coated with MoparT Engine RTV sealant prior to installation. Failure to do so will cause severe oil leaks.
ENGINE - 3.7L
9 - 42
CRANKSHAFT (Continued)DR
Fig.35BEDPLATETIGHTENINGSEQUENCE
plate contacts the block.
(7) Install the bedplate retaining bolts, making sure to place the stud bolts in the correct location, Torque the bolts in the sequence shown (Fig. 35). † Hand tighten bolts 1D,1G and 1F until the bed- † Tighten bolts 1A–1J to 54 N·m (40 ft. lbs.) † Tighten bolts 1–8 to 7 N·m (5 ft. lbs.) † Turn bolts 1–8 an additional 90°. † Tighten bolts A–E 27 N·m ( 20 ft. lbs.). (8) Measure crankshaft end play.
(9) Install the connecting rods and measure side clearance(Refer to 9 - ENGINE/ENGINE BLOCK/ PISTON & CONNECTING ROD - STANDARD PRO- CEDURE).
(10) Install oil pump(Refer to 9 - ENGINE/LUBRI-
CATION/OIL PUMP - INSTALLATION).
(11) Install the engine(Refer to 9 - ENGINE -
INSTALLATION).
DR
ENGINE - 3.7L
9 - 43
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE
MAIN BEARING FITTING
SELECT FIT IDENTIFICATION
The main bearings are “select fit” to achieve proper oil clearances. For main bearing selection, the crank- shaft position sensor target wheel has grade identifi- cation marks stamped into it (Fig. 36). These marks are read from left to right, corresponding with jour- nal number 1, 2, 3, 4. The crankshaft position sensor target wheel is mounted to the number 6 counter weight on the crankshaft.
Fig.36MARKINGSONTARGETWHEEL
1 - REARMOST CRANKSHAFT COUNTER WEIGHT 2 - TARGET WHEEL 3 - MAIN BEARING SELECT FIT MARKINGS
INSPECTION
Wipe the inserts clean and inspect for abnormal wear patterns and for metal or other foreign material imbedded in the lining. Normal main bearing insert wear patterns are illustrated.
Inspect the back of the inserts for fractures, scrap-
ings or irregular wear patterns.
Inspect the upper insert locking tabs for damage. Replace all damaged or worn bearing inserts.
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)
Remove the crankshaft from the cylinder block(Re- fer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT - REMOVAL).
Clean the oil off the main bearing journal. Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal.
The maximum allowable taper is 0.008mm (0.0004
inch.) and maximum out of round is 0.005mm (0.002
inch). Compare the measured diameter with the jour- nal diameter specification (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance.Install the crankshaft into the cylinder block(Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT - INSPECTION).
Check crankshaft end play.
CRANKSHAFT MAIN BEARING SELECTION
(1) Service main bearings are available in four grades. The chart below identifies the four service grades available.
JOURNAL SIZE SIZE mm (in.)
63.488 - 63.496 mm (2.4995 - 2.4998 in.) 63.496 - 63.500 mm (2.4998 - 2.4999
in.) 63.500 - 63.504 mm (2.4999 - 2.501
in.) 63.504 - 63.512 mm (2.5001 - 2.5004
in.)Bearing size
Size
Application
Crankshaft
MARKING 9R9 Size
9S9 Size
9T9 Size
9U9 Size
Bearing Code
Upper Bearing
.2.443 - 2.447
Use with crankshaft
mm
size 9R9
(.0961 - .0963
in.)
2.439 - 2.443
Use with crankshaft
mm
(0.960 -.o961
in.) 2.435 - 2.439mm
9S, T9
Use with crankshaft
9U9
ENGINE - 3.7L
9 - 44
CRANKSHAFT MAIN BEARINGS (Continued)DR
Crankshaft
MARKING
JOURNAL SIZE SIZE mm (in.)
(.0958 - .0960
in.)
Lower Bearing Main 919 and 949
919
2.441 - 2.447
Use with crankshaft
mm
(.0961 -.0963
in.)
9R, S9
929
2.435 - 2.441
Use with crankshaft
mm
(.0958 - .0962
in.)
9T, U9
Lower Main Bearing 929 and 939
939
2.429 - 2.435
Use with crankshaft
mm
(.0956 - .0958
in.)
9R, S9
949
2.423 - 2.429
Use with crankshaft
mm
(.0953 - .0956
in.)
9T, U9
Bearing Clearances Main 91, 49
Crankshaft 9R9
Crankshaft 9S9
Crankshaft 9T9
Crankshaft 9U9
Main 92, 39
Crankshaft 9R9
Crankshaft 9S9
Crankshaft 9T9
Crankshaft 9U9.004 - .034 mm ( .00015 - .0013 in.)
.004 - .030 mm ( .00015 - .0011 in.)
.006 - .032 mm (.0002 - .0012 in.)
.002 - .032 mm (.00007 -. 0012 in.)
.016 - .046 mm (.0006 - .0018 in.)
.016 - .042 mm (.00062 - .016 in.)
.018 - .044 mm (.0007 - .0017 in.)
.014 - .044 mm (.0005 - .0017 in.)
CRANKSHAFT OIL SEAL - FRONT REMOVAL
(1) Disconnect negative cable from battery. (2) Remove accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(3) Remove A/C compressor mouning fasteners and
set aside.
(4) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(5) Remove upper radiator hose. (6) Disconnect electrical connector for fan mounted
inside radiator shroud.
(7) Remove radiator shroud attaching fasteners.
NOTE: Transmission cooler line snaps into shroud lower right hand corner.
(8) Remove radiator cooling fan and shroud (Refer - COOLING/ENGINE/RADIATOR FAN -
to REMOVAL).
(9) Remove crankshaft damper bolt. (10) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 37).
Fig.37CrankshaftDamperRemoval
1 - SPECIAL TOOL 8513 INSERT 2 - SPECIAL TOOL 1026
DR CRANKSHAFT OIL SEAL - FRONT (Continued)
(11) Using Special Tool 8511, remove crankshaft
front seal (Fig. 38).
ENGINE - 3.7L
9 - 45
Fig.39CrankshaftFrontSealInstallation
Fig.38CrankshaftFrontSealRemoval
1 - TIMING CHAIN COVER 2 - SPECIAL TOOL 8348
3 - SPECIAL TOOL 85121 - SPECIAL TOOL 8511
INSTALLATION
CAUTION: To prevent severe damage to the Crank- shaft, Damper or Special Tool 8512, thoroughly clean the damper bore and the crankshaft nose before installing Damper.
CRANKSHAFT OIL SEAL - REAR REMOVAL
NOTE: This procedure can be performed in vehicle.
(1) Using Special Tool 8348 and 8512,
install
crankshaft front seal (Fig. 39).
(2) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTAL- LATION).
(3) Install radiator cooling fan and shroud (Refer - COOLING/ENGINE/RADIATOR FAN -
to INSTALLATION).
(4) Install upper radiator hose. (5) Install A/C compressor and tighten fasteners to
54 N·m (40 ft. lbs.).
(6) Install accessory drive belt refer (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(7) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(8) Connect negative cable to battery.
(1) If being preformed in vehicle, remove the
transmission.
(2) Remove the flexplate (Refer to 9 - ENGINE/
ENGINE BLOCK/FLEX PLATE - REMOVAL).
NOTE: The crankshaft oil seal CAN NOT be reused after removal.
NOTE: The crankshaft rear oil seal remover Special Tool 8506 must be installed deeply into the seal. Continue to tighten the removal tool into the seal until the tool can not be turned farther. Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine.
ENGINE - 3.7L
9 - 46
CRANKSHAFT OIL SEAL - REAR (Continued)(3) Using Special Tool 8506 (Fig. 40), remove the
crankshaft rear oil seal.
DR
(3) Using Special Tools 8349 Crankshaft Rear Oil Seal Installer and C-4171 Driver Handle (Fig. 42), with a hammer, tap the seal into place. Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore.
Fig.40CrankshaftRearOilSealRemoval
1 - REAR CRANKSHAFT SEAL 2 - SPECIAL TOOL 8506
INSTALLATION
(1) Lubricate the crankshaft flange with engine oil. (2) Position the magnetic seal guide Special Tool 8349–2 (Fig. 41) onto the crankshaft rear face. Then position the crankshaft rear oil seal onto the guide.
Fig.42CrankshaftRearOilSealInstallation
1 - REAR CRANKSHAFT SEAL 2 - SPECIAL TOOL 8349–1 INSTALLER 3 - SPECIAL TOOL C-4171 HANDLE
(4) Install the flexplate. (5) Install the transmission.
Fig.41CrankshaftRearOilSealGuideSpecialTool
8349–2andOil
1 - REAR CRANKSHAFT SEAL 2 - SPECIAL TOOL 8349–2 GUIDE
DR
ENGINE - 3.7L
9 - 47
FLEX PLATE REMOVAL
(1) Remove the transmission. (2) Remove the bolts and flexplate.
INSTALLATION
(1) Position the flexplate onto the crankshaft and
install the bolts hand tight.
(2) Tighten the flexplate retaining bolts to 95 N·m
(70 ft. lbs.) in the sequence shown (Fig. 43).
(3) Install the transmission.
PISTON & CONNECTING ROD DESCRIPTION
CAUTION: Do not use a metal stamp to mark con- necting rods as damage may result, instead use ink or a scratch awl.
The pistons are made of a high strength aluminum alloy. The connecting rods are made of forged pow- dered metal, with a “fractured cap” design. A full floating piston pin is used to attach the piston to the connecting rod (Fig. 44).
Fig.43FlexplateTighteningSequence
1 - FLEXPLATE
Fig.44PISTONANDRODASSEMBLY
1 - CONNECTING ROD 2 - PISTON 3 - PISTON PIN 4 - OIL SLINGER SLOT
ENGINE - 3.7L
9 - 48
PISTON & CONNECTING ROD (Continued) STANDARD PROCEDURECONNECTING ROD BEARING FITTING
DR
Inspect the connecting rod bearings for scoring. Check the bearings for normal wear patterns, scor- ing, grooving, fatigue and pitting (Fig. 45). Replace any bearing that shows abnormal wear.
Inspect the connecting rod journals for signs of
scoring, nicks and burrs (Fig. 46).
Fig.46ScoringCausedbyInsufficientLubrication
orDamagedCrankshaftJournal
Fig.47BearingInsertLocation
1 - Connecting Rod 2 - Bearing Insert - A, B less then .50 mm (.0196 in.)
The lower insert must be dry. Place strip of Plasti- gage across full width of the lower insert at the cen- ter of bearing cap. Plastigage must not crumble in use. If brittle, obtain fresh stock.
Fig.45ConnectingRodBearingInspection
1 - UPPER BEARING HALF 2 - MATING EDGES 3 - GROOVES CAUSED BY ROD BOLTS SCRATCHING JOURNAL DURING INSTALLATION 4 - WEAR PATTERN - ALWAYS GREATER ON UPPER BEARING
Misaligned or bent connecting rods can cause abnormal wear on pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft con- necting rod journals. If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod, inspect it for correct rod alignment. Replace misaligned, bent or twisted con- necting rods.
(1) Wipe the oil from the connecting rod journal. (2) Lubricate the upper bearing insert and position in connecting rod. Center bearing insert in connect- ing rod (Fig. 47)
(3) Use piston ring compressor and Guide Pins Special Tool 8507 (Fig. 48) to install the rod and pis- ton assemblies. The oil slinger slots in the rods must face front of the engine. The “F”’s near the piston wrist pin bore should point to the front of the engine. (4) Install the lower bearing insert in the bearing cap. Center bearing insert in connecting rod (Fig. 47).
DR PISTON & CONNECTING ROD (Continued)
ENGINE - 3.7L
9 - 49
Fig.49MeasuringBearingClearancewith
Plastigage
1 - PLASTIGAGE SCALE 2 - COMPRESSED PLASTIGAGE
Bearing
Mark
.025 US
SIZE
USED WITH
JOURNAL SIZE
.025 mm (.001 in.)
57.883-57.867 mm (2.2788-2.2783 in.)
Std.
STANDARD
57.908-57.892 mm (2.2798-2.2792 in.)
.250 US
.250 mm (.010 in.)
57.658-57.646 mm (2.2700-2.2695 in.)
CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed.
(9) Repeat the Plastigage measurement to verify
your bearing selection prior to final assembly.
(10) Once you have selected the proper insert, install the insert and cap. Tighten the connecting rod bolts to 27 N·m (20 ft. lbs.) plus a 90° turn.
Fig.48PistonandConnectingRod-Installation-
Typical 1 - “F” TOWARD FRONT OF ENGINE 2 - OIL SLINGER SLOT 3 - RING COMPRESSOR 4 - SPECIAL TOOL 8507
(5) Install bearing cap and connecting rod on the journal and tighten bolts to 27 N·m (20 ft. lbs.) plus a 90° turn. DO NOT rotate crankshaft. Plastigage will smear, resulting in inaccurate indication.
(6) Remove the bearing cap and determine amount of bearing-to-journal clearance by measuring the width of compressed Plastigage (Fig. 49). Refer to Engine Specifications for the proper clearance. Plas- tigage should indicate the same clearance across the entire width of the insert. If the clearance varies, it may be caused by either a tapered journal, bent connecting rod or foreign material trapped between the insert and cap or rod.
(7) If the correct clearance is indicated, replace- ment of the bearing inserts is not necessary. Remove the Plastigage from crankshaft journal and bearing insert. Proceed with installation.
(8) If bearing-to-journal
the specification, determin which services bearing set to use the bearing sizes are as follows:
clearance exceeds
ENGINE - 3.7L
9 - 50
PISTON & CONNECTING ROD (Continued)Slide snug-fitting feeler gauge between the con- necting rod and crankshaft journal flange (Fig. 50). Refer to Engine Specifications for the proper clear- ance. Replace the connecting rod if the side clearance is not within specification.
DR
Fig.51DONOTMEASUREMOLYCOATEDPISTON 1 - MOLY COATED 2 - MOLY COATED
Fig.50CheckingConnectingRodSideClearance-
Typical
STANDARD PROCEDURE—PISTON FITTING
(1) To correctly select the proper size piston, a cyl- inder bore gauge, capable of reading in 0.003 mm ( .0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer.
(2) Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B (Fig. 52).
(3) The coated pistons will be serviced with the
piston pin and connecting rod pre-assembled.
(4) The coating material is applied to the piston after the final piston machining process. Measuring the out- side diameter of a coated piston will not provide accu- rate results (Fig. 51). Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY. To correctly select the proper size pis- ton, a cylinder bore gauge capable of reading in 0.003
mm (.0001 in.) increments is required.(5) Piston installation into
cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.
the
REMOVAL
(1) Disconnect negative cable from battery. (2) Remove the following components: † Oil pan and gasket/windage tray (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - REMOVAL).
Fig.52BOREGAUGE-TYPICAL
1 - FRONT 2 - BORE GAUGE 3 - CYLINDER BORE 4 - 38 MM (1.5 in)
† Cylinder head covers (Refer to 9 - ENGINE/ CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) and (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL). † Timing chain cover (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). † Cylinder head(s) (Refer to 9 - ENGINE/CYLIN- DER HEAD - REMOVAL) and (Refer to 9 - ENGINE/ CYLINDER HEAD - REMOVAL).
ENGINE - 3.7L
9 - 51
GINE BLOCK/CONNECTING ROD BEARINGS - STANDARD PROCEDURE).
Check the connecting rod for signs of twist or bending. Check the piston for taper and elliptical shape before it is fitted into the cylinder bore (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECT- ING ROD - STANDARD PROCEDURE).
Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks
