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Position the assembly upside down to access the elec- trical connectors located on the bottom of the unit.
(6) Disconnect the electrical connectors by depress- ing the locking tab and rotating the connector arm outboard, until the connector is free from the module assembly. Be certain to pull the connectors straight off.
(7) Position the integrated power module on a bench and remove the four front control module retaining screws.
(8) Disconnect the front control module by pulling
it straight off the integrated power module.
INSTALLATION
(1) Connect the front control module by pushing it straight on the integrated power module electrical receptacle.
(2) Install the four front control module retaining
screws. Torque to 30 in. lbs. +/-5.
NOTE: Integrated power module electrical connec- tors are color coded to ease location reference (Fig. 4).
(3) Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the module assembly.
Fig.4INTEGRATEDPOWERMODULEELECTRICAL
CONNECTIONS
1 - RETAINING LATCH 2 - GRAY CONNECTOR 3 - GREEN CONNECTOR 4 - GREEN CONNECTOR 5 - BLUE CONNECTOR 6 - WHITE CONNECTOR 7 - BLACK CONNECTOR 8 - BLACK CONNECTOR
(4) Grasp the integrated power module with two hands and install the assembly on the battery tray (Fig. 5).
(5) Install the integrated power module retaining
bolt and screw.
(6) Connect the gray connector on the integrated
power module housing.
(7) Install the B+ terminal cable and nut on the integrated power module B+ terminal. Snap the cover in place. (8) Connect
the negative and positive battery
cables.
FRONT CONTROL MODULE DESCRIPTION
The Front Control Module (FCM) is a micro con- troller based module located in the left front corner of the engine compartment. On this model the inte- grated power module must be positioned aside in order to access the front control module. The front control module mates to the power distribution cen- ter to form the Integrated Power Module (IPM). The integrated power module connects directly to the bat-
DR FRONT CONTROL MODULE (Continued)
8W-97 POWER DISTRIBUTION
8W - 97 - 5
† Power Ground † Ambient Temperature Sensing † Ignition Switch Run † Washer Fluid Level Switch † Windshield Wiper Park Switch † PCI Bus Circuit
DIAGNOSIS AND TESTING - FRONT CONTROL MODULE
The front control module is a printed circuit board based module with a on-board micro-processor. The front control module interfaces with other electronic modules in the vehicle via the Programmable Com- munications Interface (PCI) data bus (J1850). In order to obtain conclusive testing the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to, or receive outputs from the front control module must be checked. All PCI (J1850) communication faults must be resolved prior to further diagnosing any front control module related issues.
The front control module was designed to be diag- nosed with an appropriate diagnostic scan tool, such as the DRB IIIt. The most reliable, efficient, and accurate means to diagnose the front control module requires the use of a DRB IIIt scan tool and the proper Body Diagnostic Procedures manual.
Before any testing of the front control module is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle.
REMOVAL
(1) Disconnect the positive and negative battery
cables from the battery.
(2) Partially remove the integrated power module from the engine compartment (Refer to 8 - ELECTRI- CAL/POWER DISTRIBUTION/INTEGRATED POWER MODULE - REMOVAL).
(3) Remove
the
front
control module
retaining
screws.
(4) Using both hands, pull the front control module straight from the integrated power module assembly to disconnect the 49-way electrical connector and remove the front control module from the vehicle.
INSTALLATION
(1) Install the front control module on the inte- grated power module assembly by pushing the 49-way electrical connector straight in.
(2) Install
the front
control module retaining
screws. Torque the screws to 7 in. lbs.
(3) Install the integrated power module (Refer to 8
ELECTRICAL/POWER DISTRIBUTION/INTE-GRATED POWER MODULE - INSTALLATION).
(4) Connect the positive and negative battery cables.
Fig.5INTEGRATEDPOWERMODULEMOUNTING
TABS
1 - INTEGRATED POWER MODULE MOUNTING HOLES 2 - BATTERY TRAY ASSEMBLY 3 - FRONT CONTROL MODULE
tery and provides the primary means of circuit pro- tection and power distribution for all vehicle electrical systems. The front control module controls power to some of these vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit (J1850).
For information on the Integrated Power Mod- ule Refer to the Power Distribution Section of the service manual.
OPERATION
As messages are sent over the PCI bus circuit, the front control module reads these messages and con- trols power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the Front Control Module:
† Headlamp Power with Voltage Regulation † Windshield Wiper “ON/OFF” Relay Actuation † Windshield Wiper “HI/LO” Relay Actuation † Windshield Washer Pump Motor † Fog Lamp Relay Actuation † Park Lamp Relay Actuation † Horn Relay Actuation The following inputs are Received/Monitored by † B+ Connection Detection
the Front Control Module:
8W - 97 - 6
8W-97 POWER DISTRIBUTION
DR
IOD FUSE DESCRIPTION
Fig.6IODFUSELOCATION
1 - IOD FUSE
All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Inte- grated Power Module when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the Integrated Power Module as part of the preparation procedures performed just prior to new vehicle delivery.
A laser printed fuse layout map is integral to the Integrated Power Module cover to ensure proper fuse identification. The IOD fuse is a 20 ampere mini blade-type fuse, located in fuse cavity # 51 (Fig. 6). The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its Integrated Power Module cavity, and as a fuse holder that conveniently stores the fuse in the same Inte- grated Power Module cavity after it has been discon- nected.
CIRCUITS INCLUDED WITH IOD FUSE
† Cluster (CCN) † Diagnostic Connector † Map Lamps † Glove Box Lamp † Courtesy Lamps † Radio † Underhood Lamp
OPERATION
The term ignition-off draw identifies a normal con- dition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery cur- rent when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical sys- tem during new vehicle transportation and pre-deliv- ery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehi- cle transportation company and dealer personnel.
The IOD fuse is disconnected from Integrated Power Module fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is pre- pared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse.
thirty days. However,
The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be discon- nected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the bat- tery from becoming discharged or damaged.
REMOVAL
The Ignition-Off Draw (IOD) fuse is disconnected from Integrated Power Module fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation.
(1) Turn the ignition switch to the Off position. (2) Remove the Integrated Power Module cover. (3) Grasp the outer tabs of the IOD fuse holder unit in fuse cavity # 51 between the thumb and fore- finger and pull the unit firmly upward.
(4) Install the Integrated Power Module cover.
8W-97 POWER DISTRIBUTION
8W - 97 - 7
DR IOD FUSE (Continued) INSTALLATION
(1) Turn the ignition switch to the Off position. (2) Remove the Integrated Power Module cover. (3) To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity # 51 firmly into the Integrated Power Module.
(4) Install the Integrated Power Module cover.
POWER OUTLET DESCRIPTION
Two power outlets are utilized on this model. One in the instrument panel center lower bezel and the other in the center console. The power outlet bases are secured by a snap fit within the instrument panel or trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power out- let is in use.
The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced.
OPERATION
The power outlet base or receptacle shell is con- nected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the integrated power module at all times.
While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the recepta- cle shell that are used to secure the cigar lighter heating element to the insulated contact.
DIAGNOSIS AND TESTING - POWER OUTLET
For complete circuit diagrams, refer to Wiring
Diagrams.
(1) Check the fused B(+) fuse in the integrated power module. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse in the integrated power module. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the battery as required.
(3) Remove the plastic protective cap from the power outlet receptacle. Check for continuity between the inside circumference of the power outlet recepta- cle and a good ground. There should be continuity. If OK, go to Step 4. If not OK, go to Step 5.
(4) Check for battery voltage at the insulated con- tact located at the back of the power outlet recepta- cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative cable. Remove the power outlet receptacle from the instrument panel. Disconnect the wire harness con- nector from the power outlet receptacle. Check for continuity between the ground circuit cavity of the power outlet wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required.
(6) Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power outlet wire harness connector. If OK, replace the faulty power outlet receptacle. If not OK, repair the open fused B(+) circuit to the integrated power module fuse as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the pro- tective cap from the power outlet receptacle base.
(3) Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangu- lar retaining bosses of the mount that secures the receptacle base to the panel (Fig. 7).
(4) Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount.
(5) Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount.
(6) Pull the receptacle base away from the instru- far enough to access the instrument
ment panel panel wire harness connector.
(7) Disconnect the instrument panel wire harness connector from the cigar lighter or power outlet receptacle base connector receptacle.
(8) Remove the cigar lighter or power outlet mount
from the instrument panel.
INSTALLATION
(1) Reconnect the instrument panel wire harness connector to the cigar lighter or power outlet recep- tacle base connector receptacle.
(2) Install the cigar lighter or power outlet mount
into the instrument panel.
(3) Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount.
8W - 97 - 8
POWER OUTLET (Continued)8W-97 POWER DISTRIBUTION
DR
Fig.8ISORelay
Fig.7CigarLighterandPowerOutletRemove/
Install
1 - KNOB AND ELEMENT 2 - RETAINING BOSSES-ENGAGE PLIERS HERE 3 - BASE 4 - PARTIALLY REMOVED 5 - EXTERNAL SNAP-RING PLIERS 6 - MOUNT 7 - BASE
(4) Press firmly on the cigar lighter or power out- let receptacle base until the retaining bosses of the mount are fully engaged in their receptacles.
(5) Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base.
(6) Reconnect the battery negative cable.
RELAY DESCRIPTION
A relay (Fig. 8) is an electromechanical device that switches fused battery current to a electrical compo- nent when the ignition switch is turned to the Acces- sory or Run positions, or when controlled by a electronic module. The relays are located in the inte- grated power module.
The relay is a International Standards Organiza- tion (ISO) relay. Relays conforming to the ISO speci- fications have common physical dimensions, current capacities, terminal patterns, and terminal functions. if
A relay cannot be repaired or adjusted and,
faulty or damaged, it must be replaced.
30
85
86
87
87AOPERATION
COMMON FEED COIL GROUND COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
is held against one of
The ISO relay consists of an electromagnetic coil, a resistor and three (two fixed and one movable) elec- trical contacts. The movable (common feed) relay con- tact the fixed contacts (normally closed) by spring pressure. When the elec- tromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact.
When the electromagnetic coil
is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are pro- duced when the coil is de-energized.
DIAGNOSIS AND TESTING - RELAY
The relays are located in the integrated power module. For complete circuit diagrams, refer to Wir- ing Diagrams.
(1) Remove the relay from its mounting location. (2) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec- tromagnet) should be 60.7 - 80.3 ohms. If OK, go to Step 4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay.
8W-97 POWER DISTRIBUTION
8W - 97 - 9
DR RELAY (Continued) DIAGNOSIS & TESTING - RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) of the integrated power module is connected to battery voltage and should be hot at all times. Check for bat- tery voltage at the fused B(+) circuit cavity in the integrated power module receptacle for the relay. If OK, go to Step 2. If not OK, repair the fused B(+) cir- cuit to the integrated power module fuse as required. is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3.
(2) The relay normally closed terminal
(87A)
(3) The relay normally open terminal (87) is con- nected to the common feed terminal (30) in the ener- gized position. This terminal supplies battery voltage to the fused B(+) fuse in the integrated power module that feeds the accessory when the relay is energized by the ignition switch. There should be continuity between the integrated power module cavity for relay terminal 87 and the fused B(+) fuse in the integrated power module at all times. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit to the inte- grated power module fuse as required.
(4) The coil ground terminal (85) is connected to the electromagnet in the relay. It receives battery feed to energize the relay when the ignition switch is in the Accessory or Run positions. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (acc/run) circuit cavity for relay terminal 85 in the integrated power module receptacle for the relay. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (acc/run) circuit to the ignition switch as required.
(5) The coil battery terminal (86) is connected to the electromagnet in the relay. The integrated power module cavity for this terminal should have continu- ity to ground at all times. If not OK, repair the open ground circuit to ground as required.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the relay by grasping it firmly and pulling it straight out from its receptacle. A slight back and fourth rocking motion may help the removal process.
INSTALLATION
(1) Position the relay to the proper receptacle. (2) Align the relay terminals with the terminal
cavities in the receptacle.
(3) Push firmly and evenly on the top of the relay until the terminals are fully seated in the terminal cavities in the receptacle.
(4) Connect the negative battery cable.
MICRO RELAY DESCRIPTION
Fig.9DRISOMicroRelay
30 - COMMON FEED 85 - COIL GROUND 86 - COIL BATTERY 87 - NORMALLY OPEN 87A - NORMALLY CLOSED
A micro-relay is a conventional International Stan- dards Organization (ISO) micro relay (Fig. 9). Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal pat- terns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base.
Relays cannot be adjusted or repaired and, if faulty
or damaged, the unit must be replaced.
OPERATION
A micro-relay is an electromechanical switch that uses a low current input from one source to control a high current output to another device. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electro- magnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses.
DIAGNOSIS AND TESTING - MICRO-RELAY
(1) Remove the relay from its mounting location. (2) A relay in the de-energized position should have continuity between terminals 87A and 30, and
8W - 97 - 10
MICRO RELAY (Continued)8W-97 POWER DISTRIBUTION
DR
no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec- tromagnet) should be 67.5 - 82.5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, reinstall the relay and use a DRB IIIt scan tool to perform further testing. Refer to the appropriate diagnostic information.
Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds.
REMOVAL
cable.
(1) Disconnect and isolate the negative battery
(2) Remove the relay by grasping it firmly and pulling it straight out from its receptacle. A slight back and fourth rocking motion may help the removal process.
INSTALLATION
(1) Align the micro-relay terminals with the termi-
nal cavities in the receptacle.
(2) Push firmly and evenly on the top of the relay until the terminals are fully seated in the terminal cavities in the receptacle.
(3) Connect the battery negative cable.
DR
ENGINE
9 - 1
ENGINE
TABLE OF CONTENTS
ENGINE - 3.7L . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE - 4.7L . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ENGINE - 5.7L . . . . . . . . . . . . . . . . . . . . . . . . . . 176ENGINE - 5.9L . . . . . . . . . . . . . . . . . . . . . . . . . . 223
ENGINE 5.9L DIESEL . . . . . . . . . . . . . . . . . . . . . 280
ENGINE 8.0L. . . . . . . . . . . . . . . . . . . . . . . . . . . . 351page
page
ENGINE - 3.7L
TABLE OF CONTENTS
page
page
ENGINE - 3.7L
CAMSHAFT(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - ENGINE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25DIAGNOSIS - INTRODUCTION . . . . . . . . . . . . 4
CYLINDER HEAD COVER(S)
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - ENGINE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . . 6
INTAKE/EXHAUST VALVES & SEATS
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - LUBRICATION . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE . . . . . . . 8
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
STANDARD PROCEDURE - REFACING . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29ROCKER ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30DAMAGED OR WORN THREADS . . . . . . . . . . 9
VALVE GUIDE SEALS
STANDARD PROCEDURE - FORM-IN-
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
PLACE GASKETS AND SEALERS . . . . . . . . . . 9
VALVE SPRINGS
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONSSPECIFICATIONS – 3.7L ENGINE . . . . . . . . . 12
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . 16SPECIAL TOOLS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31CYLINDER HEAD - RIGHT
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER
. . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32AIR CLEANER ELEMENT
CAMSHAFT(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20CYLINDER HEAD - LEFT
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35CYLINDER HEAD COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 369 - 2
ENGINE - 3.7L
DR
ROCKER ARM
REAR MOUNT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60VALVE GUIDE SEALS
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37ENGINE BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
STANDARD PROCEDURE—CYLINDER BOREHONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CRANKSHAFTDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE
MAIN BEARING FITTING . . . . . . . . . . . . . . . . 43
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46FLEX PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 47
STANDARD PROCEDURECONNECTING ROD BEARING FITTING . . . . 48
STANDARD PROCEDURE—PISTONFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55STRUCTURAL COVER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 56
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56FRONT MOUNT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 60
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING—ENGINE OIL
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . 64
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . 64
OIL PAN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 65
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66OIL PRESSURE SENSOR/SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 66
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 67
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70OIL
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
