ENGINE 3.7L - Service Information

Overview📷 1

Description

3.7L ENGINE DESCRIPTION

The 3.7 liter (226 CID) six-cylinder engine is an 90° single overhead camshaft engine. 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 bedplate that comprises the lower portion of the cylinder block 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. See Fig. 1.

CONDITION POSSIBLE CAUSE CORRECTION

AIR ESCAPES THROUGH	Intake valve bent, burnt, or not	Inspect valve and valve seat.
THROTTLE BODY	seated properly	Reface or replace, as necessary.

Inspect valve springs. Replace as necessary.

AIR ESCAPES THROUGH   Exhaust valve bent, burnt, or not Inspect valve and valve seat.
TAILPIPE              seated properly                   Reface or replace, as necessary.

Inspect valve springs. Replace as necessary.

AIR ESCAPES THROUGH	Head gasket leaking or cracked	Remove cylinder head and
RADIATOR	cylinder head or block	inspect. Replace defective part
MORE THAN 50% LEAKAGE Head gasket leaking or crack in	Remove cylinder head and
FROM ADJACENT	cylinder head or block between	inspect. Replace gasket, head, or
CYLINDERS	adjacent cylinders	block as necessary
MORE THAN 25% LEAKAGE Stuck or broken piston rings;	Inspect for broken rings or piston.
AND AIR ESCAPES THROUGH cracked piston; worn rings and/or	Measure ring gap and cylinder
OIL FILLER CAP OPENING	cylinder wall	diameter, taper and out-of-round.
ONLY	Replace defective part as

necessary

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 performance (e.g, engine idles rough and stalls) or mechanical (e.g, a strange noise).

See ENGINE PERFORMANCE DIAGNOSTIC TABLE and ENGINE MECHANICAL DIAGNOSTIC

TABLE. For possible causes and corrections of malfunctions, refer to 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 diagnosis is provided within the following diagnosis:

Cylinder Compression Pressure Test. See CYLINDER COMPRESSION PRESSURE. Cylinder Combustion Pressure Leakage Test. See CYLINDER COMBUSTION PRESSURE

LEAKAGE.

Engine Cylinder Head Gasket Failure Diagnosis. See CYLINDER HEAD GASKET. Intake Manifold Leakage Diagnosis. See INTAKE MANIFOLD LEAKS.

CONDITION POSSIBLE CAUSES CORRECTION

OIL LEAKS           1. Gaskets and O-Rings.            -
                            (a) Misaligned or damaged.         (a) Replace as necessary.
                            (b) Loose fasteners, broken or     (b) Tighten fasteners, Repair or
                            porous metal parts.                replace metal parts.
                            2. Crankshaft rear seal            2. Replace as necessary. See

Removal

Crankshaft seal flange. 3. Polish or replace crankshaft.

Scratched, nicked or grooved.

Oil pan flange cracked. 4. Replace oil pan. See

Removal

Timing chain cover seal 5. Reseal timing cover.

damaged.

Scratched or damaged vibration 6. Polish or replace damper.

damper hub. OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.

Faulty oil pressure sending unit. 2. Replace sending unit. See

Removal

Low oil pressure. 3. Check oil pump and bearing

clearance.

Clogged oil filter. 4. Replace oil filter. See

Removal

Worn oil pump. 5. Replace oil pump. See

Removal

Thin or diluted oil. 6. Change oil and filter.

Excessive bearing clearance. 7. Replace as necessary.

Oil pump relief valve stuck. 8. Replace oil pump. See

Removal

Oil pick up tube loose, damaged 9. Replace as necessary.

or clogged. OIL PUMPING AT RINGS; 1. Worn or damaged rings. 1. Hone cylinder bores and replace SPARK PLUGS FOULING rings.

Carbon in oil ring slots. 2. Replace rings. See

Standard procedure

Incorrect ring size installed. 3. Replace rings. See

Standard procedure

Worn valve guides. 4. Ream guides and replace

valves. See STANDARD

PROCEDURE.

5. Leaking valve guide seals. 5. Replace valve guide seals.

CONDITION POSSIBLE CAUSES CORRECTIONS

NOISY VALVES 1. High or low oil level in 1. Refer to SPECIFICATIONS . crankcase.

                           2. Thin or diluted oil.          2. Change oil and filter.
                           3. Low oil pressure.             3. Check oil pump, if OK, check rod

and main bearings for excessive wear.

                           4. Dirt in lash adjusters.       4. Clean or replace as necessary.
                           5. Worn rocker arms.             5. Replace as necessary.
                           6. Worn valve guides.            6. See STANDARD

PROCEDURE.

7. Excessive runout of valve          7. Service valves and valve seats.
                      seats.                                See STANDARD PROCEDURE.
   ENGINE VIBRATION      1. Counter Balance Shaft not       1. Refer to VALVE TIMING

timed properly

 CONNECTING ROD NOISE 1. Insufficient oil supply.            1. Refer to SPECIFICATIONS .
                      2. Low oil pressure.                   2. Check oil pump, if OK, check rod

and main bearings for excessive wear. 3. Thin or diluted oil. 3. Change oil and filter. 4. Excessive bearing clearance. 4. Replace as necessary. 5. Connecting rod journal out-of- 5. Service or replace crankshaft. round. 6. Misaligned connecting rods. 6. Replace bent connecting rods.

  MAIN BEARING NOISE       1. Insufficient oil supply.       1. Refer to SPECIFICATIONS .
                           2. Low oil pressure.              2. Check oil pump, if OK, check rod

and main bearings for excessive wear. 3. Thin or diluted oil. 3. Change oil and filter. 4. Excessive bearing clearance. 4. Replace as necessary.

                           5. Excessive end play.            5. Check thrust washers for wear.
                           6. Crankshaft journal out-of      6. Service or replace crankshaft.

round. 7. Loose flywheel or torque 7. Tighten to correct torque converter.

CAUSE

ENGINE WILL      1. Weak battery  1. Charge or replace
   NOT START                        as necessary.

2. Corroded or loose 2. Clean and tighten battery connections. battery connections. Apply a coat of light mineral grease to the terminals. 3. Faulty starter. 3. Refer to

TESTING .

4. Faulty coil or    4. Refer to
               control unit.        REMOVAL .

5. Incorrect spark 5. (Refer to SPARK

               plug gap.            PLUG .
               6. Incorrect right   6. Refer to VALVE

bank cam timing. TIMING. 7. Dirt or water in 7. Clean system and fuel system. replace fuel filter. 8. Faulty fuel pump, 8. Repair or replace

               relay or wiring.     as necessary.
               9. Faulty cam or     9. Refer to
               crank sensor         IGNITION

INFORMATION .

ENGINE STALLS 1. Vacuum leak.       1. Inspect intake
OR ROUGH IDLE                       manifold and
                                    vacuum hoses,        -

repair or replace as necessary.

               2. Faulty crank      2. Replace crank
               position sensor      position sensor.
               3. Faulty coil.      3. Refer to

Removal

Incorrect cam 4. See STANDARD

timing. PROCEDURE. ENGINE LOSS OF 1. Dirty or 1. Refer to SPARK POWER incorrectly gapped PLUG . spark plugs.

Dirt or water in 2. Clean system and

fuel system. replace fuel filter.

Faulty fuel pump. 3. Refer to PUMP-

FUEL .

4. Blown cylinder 4. Replace cylinder

               head gasket.         head gasket.
               5. Low               5. See

compression. DIAGNOSIS AND TESTING, repair as necessary. 6. Burned, warped 6. Replace as

                    or pitted valves.    necessary.
                    7. Plugged or        7. Inspect and

restricted exhaust replace as

                    system.              necessary.
                    8. Faulty coil.      8. Refer to

Removal

Incorrect cam 9. Refer to VALVE

timing. TIMING. ENGINE MISSES 1. Spark plugs dirty 1. Refer to SPARK ON or incorrectly PLUG . ACCELERATION gapped.

Dirt in fuel 2. Clean fuel

system. system.

Burned, warped 3. Replace as

or pitted valves. necessary.

Faulty coil. 4. Refer to

Removal

ENGINE MISSES 1. Spark plugs dirty 1. Refer to SPARK AT HIGH SPEED or incorrectly PLUG . gapped.

Faulty coil. 2. Refer to

Removal

Dirt or water in 3. Clean system and

fuel system. replace fuel filter.

BOOSTER📷 5

NOTE: It is not necessary to release the quick connect 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.   Disconnect the engine to body ground straps (2) at the cowl.

27. Remove intake manifold. 28. Remove engine oil dipstick tube. 29. Install Engine Lifting Fixture 8427.

NOTE: Recheck bolt torque for engine lift plate before removing engine.

30. Secure the left and right engine wiring harnesses away from engine. 31. Raise vehicle.

32. Disconnect oxygen sensor wiring. 33. Disconnect the engine block heater power cable, if equipped. 34. Disconnect the front propshaft at the front differential and secure out of way.

NOTE: It is necessary to disconnect the front propshaft for access to the starter and left side exhaust flange.

35. Remove the ground straps from the left and right side of the block. 36. 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.

NOTE: For manual transmission vehicles, the transmission must be removed from the vehicle, before the engine can be removed. The manual transmission will contact the floorpan before the engine clears the motor mounts, so it must be removed.

37. Remove the starter. Refer to REMOVAL .

1 - BOLT 2 - BOLT 3 - BOLT

38.   Remove the structural cover retaining bolts (1), and cover. See REMOVAL.
39.   Remove torque convertor bolts, and mark location for reassembly.
40.   Remove transmission bellhousing to engine bolts.
41.   Loosen left and right engine mount thru bolts.

NOTE: It is not necessary to completely remove engine mount thru bolts, for engine removal.

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

Position the engine in the vehicle.

Install both left and right side engine mounts onto engine.

Raise the vehicle.

Install the transmission bellhousing to engine mounting bolts. Tighten the bolts to 41 N.m (30 ft. lbs.).

Tighten the engine mount thru bolts.

Install the torque convertor bolts.

Connect the ground straps on the left and right side of the engine.

Install the starter (2). Refer to INSTALLATION .

1 - BOLT 2 - BOLT 3 - BOLT

Install the engine block heater power cable, if equipped.

CAUTION

The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover.

Install the structural cover, and torque bolts (1). See INSTALLATION.

NOTE

New clamps must be used on exhaust manifold flanges. Failure to use new clamps may result in exhaust leaks.

Install the left and right exhaust pipes.

Connect the left and right oxygen sensors.

Lower vehicle.

1 - NUT 2- STRAP 3-

BOOSTER📷 2

14. Connect the engine to body ground straps at the cowl. 15. Remove the engine lift plate. 16. Connect the knock sensors.

17.   Install the intake manifold. See INSTALLATION.
18.   Install the engine oil dipstick tube.
19.   Install the power brake booster vacuum hose.
20.   Install the breather hoses.
21.   Install the PCV hose.
22.   Install the fuel rail.
23.   Install the coil over plugs.

SENSOR 2 - CYLINDER

HEAD COVER 3-

SENSOR 4 - RIGHT

DESCRIPTION SPECIFICATION📷 1

Type                                                      90° SOHC V6 12 Valve
Number of Cylinders                                                  6
Firing Order                                                   1-6-5-4-3-2
Lead Cylinder                                                 No. 1 Left Bank
Compression Ratio                                                  9.6:1
Max. Variation Between Cylinders                                   25%
                                                Metric                Standard
Displacement                                   3.7 Liters                     226 Cubic Inches
Bore                                           93.0 mm                            3.66 in.

Stroke	90.8 mm	3.40 in.
Horsepower	211 @ 5200 RPM
Torque	236 ft. lbs. @ 4000 RPM
Compression Pressure	1172-1551 kPa	170-225 psi

DESCRIPTION SPECIFICATION

Metric	Standard
Bore Diameter	93.013 ± 0.0075 mm	3.6619 ± 0.0003 in.
Out of Round (MAX)	0.076 mm	0.003 in.
Taper (MAX)	0.051 mm	0.002 in.

DESCRIPTION SPECIFICATION

Metric	Standard
Diameter	92.975 mm	3.6605 in.
Weight	365.0 grams	12.87 oz

Ring Groove Diameter

No. 1	85.37 - 83.13 mm	3.282 - 3.273 in
No. 2	82.833 - 83.033 mm	3.261 - 3.310 in.
No. 3	83.88 - 84.08 mm	3.302 - 3.310 in.

DESCRIPTION SPECIFICATION

Metric	Standard
Clearance In Piston	0.006 - 0.015 mm	0.0002 - 0.0005 in.
Diameter	24.017 - 24.020 mm	0.9455 - 0.9456 in.

DESCRIPTION SPECIFICATION

Metric Standard Ring Gap

Top Compression Ring	0.20 - 0.36 mm	0.0079 - 0.0142 in.
Second Compression Ring	0.37 - 0.63 mm	0.0146 - 0.0249 in.
Oil Control (Steel Rails)	0.25 - 0.76 mm	0.0099 - 0.30 in.
Side Clearance	-
Top Compression Ring	0.051 - 0.094 mm	0.0020 - 0.0037 in.
Second Compression Ring	0.040 - 0.080 mm	0.0016 - 0.0031 in.
Oil Ring (Steel Ring)	0.019 - 0.229 mm	0.0007 - 0.0091 in.

Ring Width

Top Compression Ring	1.472 - 1.490 mm	0.057 - 0.058 in.
Second Compression Ring	1.472 - 1.490 mm	0.057 - 0.058 in.

Oil Ring (Steel Rails) 0.445 - 0.470 mm 0.017 - 0.018 in.

DESCRIPTION SPECIFICATION

Metric	Standard
Bearing Clearance	0.006 - 0.044 mm	0.0002 - 0.0017 in.
Side Clearance	0.10 - 0.35 mm	0.004 - 0.0138 in.
Piston Pin Clearance	0.015 - 0.028 mm	0.0006 - 0.0011 in.
Bearing Bore Out of Round	0.004 mm	0.0002 in.

(MAX)

Total Weight (Less Bearing) 612 grams 21.588 ounces

DESCRIPTION SPECIFICATION

Metric	Standard
Main Bearing Journal Diameter	63.488 - 63.512 mm	2.4996 - 2.5005 in.
Bearing Clearance	0.002 - 0.046 mm	0.00008 - 0.0018 in.
Out of Round (MAX)	0.005 mm	0.0002 in.
Taper (MAX)	0.006 mm	0.0004 in.
End Play	0.052 - 0.282 mm	0.0021 - 0.0112 in.
End Play (MAX)	0.282 mm	0.0112 in.
Connecting Rod Journal Diameter	57.908 - 57.892 mm	2.2798 - 2.2792 in.
Bearing Clearance	0.006 - 0.044	0.0002 - 0.0011 in.
Out of Round (MAX)	0.005 mm	0.0002 in.
Taper (MAX)	0.006 mm	0.0002 in.

DESCRIPTION SPECIFICATION

Metric	Standard
Bore Diameter	26.02 - 26.04 mm	1.0245 - 1.0252 in.
Bearing Journal Diameter	25.975 - 25.995 mm	1.0227 - 1.0235 in.
Bearing Clearance	0.025 - 0.065 mm	0.001 - 0.0026 in.
Bearing Clearance (MAX)	0.065 mm	0.0026 in.
End Play	0.075 -0.200 mm	0.003 - 0.0079 in.
End Play (MAX)	0.200 mm	0.0079 in.

DESCRIPTION SPECIFICATION

Intake

                                    Opens (BTDC)                    5.6°
                                    Closes (ATDC)                  240.1°
                                          Duration                 245.7°

Exhaust

                                    Opens (BTDC)                            241.5°
                                    Closes (ATDC)                            20.1°
                                          Duration                          261.6°
                   Valve Overlap                                             25.7°

DESCRIPTION SPECIFICATION

Metric                                Standard
Face Angle                                                    45° - 45.5°

Head Diameter

Intake	48.52 - 48.78 mm	1.9103 - 1.9205 in.
Exhaust	36.87 - 37.13 mm	1.4516 - 1.4618 in.

Length (Overall)

Intake	113.45 - 114.21 mm	4.4666 - 4.4965 in.
Exhaust	114.92 - 115.68 mm	4.5244 - 4.5543 in.

Stem Diameter

Intake	6.931 - 6.957 mm	0.2729 - 0.2739 in.
Exhaust	6.902 - 6.928 mm	0.2717 - 0.2728 in.

Stem-to-Guide Clearance

Intake	0.018 - 0.069 mm	0.0008 - 0.0028 in.
Exhaust	0.047 - 0.098 mm	0.0019 - 0.0039 in.

Max. Allowable Stem-to-Guide Clearance (Rocking Method)

Intake	0.069 mm	0.0028 in.
Exhaust	0.098 mm	0.0039 in.

Valve Lift (Zero Lash)

Intake	12.00 mm	0.472 in.
Exhaust	12.00 mm	0.472 in.

DESCRIPTION SPECIFICATION

Metric Standard Free Length (Approx)

Intake	48.18 mm	1.896 in.
Exhaust - w/damper	49.2 mm	1.973 in.

Spring Force (Valve Closed)

                           Intake 332.0 - 368.0 N @ 40.12 mm           74.63 - 82.72 lbs. @ 1.5795 in.
      Exhaust - (without damper) 356 - 394 N @ 39.12 mm                80.031 - 88.57 lbs. @ 1.54 in.

Spring Force (Valve Open)

                           Intake 948.0 - 1038.0 N @ 28.12 mm          213.2 - 233.8 lbs. @ 1.107 in.
        Exhaust - without damper 874 - 956 N @ 27.12 mm                196.5 - 214.9 lbs. @ 1.067 in.
Number of Coils                   -                                -

Intake	7.30
Exhaust	7.15
Wire Diameter	-	-
Intake	4.77 x 3.80 mm	0.1878 x 0.1496 in.
Exhaust	4.66 x 3.72 mm	0.1843 x.1464 in.

Installed Height (Spring Seat to Bottom of Retainer) Nominal

Intake	40.12 mm	1.579 in.
Exhaust - w/damper	40.12 mm	1.579 in.

DESCRIPTION SPECIFICATION

Metric	Standard
Gasket Thickness (Compressed)	0.7 mm	(0.0276 in.)
Valve Seat Angle	44.5° - 45.0°
Valve Seat Runout (MAX)	0.051 mm	0.002 in.

Valve Seat Width

Intake	1.75 - 2.36 mm	0.0698 - 0.0928 in.
Exhaust	1.71 - 2.32 mm	0.0673 - 0.0911 in.
Guide Bore Diameter (Std.)	6.975 - 7.00 mm	0.2747 - 0.2756 in.
Cylinder Head Warpage (Flatness)	0.0508 mm	0.002 in.

DESCRIPTION SPECIFICATION

Metric                            Standard
Clearance Over Rotors/End Face             0.095 mm                           0.0038 in.

(MAX)

Cover Out - of -Flat (MAX)	0.025 mm	0.001 in.
Inner and Outer Rotor Thickness	12.02 mm	0.4731 in.
Outer Rotor to pocket (Diametral)	.235 mm	0.0093 in.

clearance (MAX)

Outer Rotor Diameter (MIN)	85.925 mm	0.400 in.
Tip Clearance Between Rotors	0.150 mm	0.006 in.

SPECIFICATION SPECIFICATION

Metric	Standard
At Curb Idle Speed (MIN)*	25 kPa	4 psi
@ 3000 RPM	170 - 758 kPa	25 - 110 psi

* CAUTION: If pressure is zero at curb idle, DO NOT run engine at 3000 RPM.

Torque specifications

DESCRIPTION	N.m	Ft.	In.
-	Lbs.	Lbs.
Camshaft	-	-	-
Non - Oiled Sprocket Bolt	122	90	-
Bearing Cap Bolts	11	-	100
Counterbalance shaft retaining bolt	28	-	250
Timing Chain Cover Bolts	58	43	-
Connecting Rod Cap Bolts	27	20	-

PLUS 90° TURN📷 28

Bed Plate-Bolts                                                    Refer to Procedure
Crankshaft Damper Bolt                                      175            130           -

Cylinder Head Bolts

M11 Bolts	Refer To Procedure
M8 Bolts	Refer To Procedure
Cylinder Head Cover Bolts	12	-	105
Exhaust Manifold Bolts	25	18	-
Exhaust Manifold Heat Shield Nuts	8	-	72

Then loosen 45°

Flexplate Bolts	95	70	-
Engine Mount Bracket to Block Bolts	61	45	-
Rear Mount to Transmission Bolts	46	34	-

Generator Mounting Bolts

M10 Bolts	54	40	-
M8 Bolts	28	-	250
Intake Manifold Bolts	12	-	105

Refer to Procedure Tightening Sequence

Oil Pan Bolts	15	-	130
Oil Pan-Drain Plug	34	25	-
Oil Pump Bolts	28	-	250
Oil Pump Cover Bolts	12	-	105
Oil Pickup Tube Bolt and Nut	28	-	250
Oil Dipstick Tube to Engine	-	-	-
Block Bolt	15	-	130
Oil Fill Tube Bolts	12	-	105
Timing Chain Guide Bolts	28	-	250
Timing Chain Tensioner Arm Bolt	28	-	250
Hydraulic Tensioner Bolts	28	-	250
Timing Chain Primary Tensioner Bolts	28	-	250
Timing Drive Idler Sprocket Bolt	34	25	-

Thermostat Housing Bolts	12	-	105
Water Pump Bolts	58	43	-

Special tools

3.7L ENGINE

+18 more figures in this topic

OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT.

NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).

Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester's pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.

* - INDICATES SEALANT ON THREADS📷 1

NOTE: The four smaller cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.

4. Lubricate the cylinder head bolt threads with clean engine oil and install the eight M11 bolts. 5. Coat the four M8 cylinder head bolts with 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.

6. Tighten the bolts in sequence using the following steps and torque values: 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 through 12 to 14 N.m (10 ft. lbs.). Step 3: Tighten bolts 1-8, 90 degrees. See Fig. 55. Step 4: Tighten bolts 1-8, 90 degrees, again. Tighten bolts 9-12, 26 N.m (19 ft. lbs.) 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 Camshaft Holder 8428, position the gear onto the camshaft.

CAUTION: Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt. Failure to do so may cause over-torqueing of bolt resulting in bolt failure.

  8.   Install the camshaft drive gear retaining bolt.
  9.   Install the left side secondary chain guide.
 10.   Install the cylinder head access plug.
 11.   Reset and Install the left side secondary chain tensioner.
 12.   Remove Secondary Camshaft Chain Holder 8429.
 13.   Install the timing chain cover.
 14.   Install the crankshaft damper. Tighten damper bolt 175 N.m (130 Ft. Lbs.)
 15.   Install the power steering pump.
 16.   Install the fan blade assembly and fan shroud.
 17.   Install the cylinder head cover.
 18.   Install the intake manifold.
 19.   Refill the cooling system
 20.   Raise the vehicle.
 21.   Install the exhaust pipe onto the left exhaust manifold.
 22.   Lower the vehicle.
 23.   Connect the negative cable to the battery.
 24.   Start the engine and check for leaks.

CAMSHAFT

OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT.

NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).

* - INDICATES SEALANT ON THREADS📷 1

NOTE: The cylinder head is attached to the cylinder block with twelve bolts.

21. Remove the cylinder head retaining bolts. See Fig. 72.

22. Remove the cylinder head and gasket. Discard the gasket.

CAUTION: Do not lay the cylinder head on its gasket sealing surface, do to the design of the cylinder head gasket any distortion to the cylinder head sealing surface may prevent the gasket from properly sealing resulting in leaks.

* - INDICATES SEALANT ON THREADS📷 5

2. Position the new cylinder head gasket on the locating dowels.

CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm.

3. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.

NOTE: The four M8 cylinder head mounting bolts (1) require sealant to be added to them before installing. Failure to do so may cause leaks.

4. Lubricate the cylinder head bolt threads with clean engine oil and install the eight 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.

6. Tighten the bolts in sequence using the following steps and torque values. See Fig. 76: 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 °. Step 4: Tighten bolts 1-8, 90 °, again. Tighten bolts 9-12, 26 N.m (19 ft. lbs.)

1 - SPECIAL TOOL 8429 2 - CAMSHAFT CHAIN 3 - CRANKSHAFT TIMING GEAR

7. Position the secondary chain (2) onto the camshaft drive gear, making sure one marked chain link is on either side of the V6 mark (1) on the gear, then using the Camshaft Holder 8428, position the gear onto the camshaft. See Fig. 77 and Fig. 78.

CAUTION: Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt. Failure to do so may cause over-torquing of bolt resulting in bolt failure.

8. Install the camshaft drive gear retaining bolt. 9. Install the right side secondary chain guide. See INSTALLATION.

1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG

10. Install the cylinder head access plug (1,2). See Fig. 79. 11. Reset and install the right side secondary chain tensioner. See INSTALLATION.

1 - SPECIAL TOOL 8429 2 - CAMSHAFT CHAIN 3 - CRANKSHAFT TIMING GEAR

12.   Remove the Camshaft Holder 8429 (1). See Fig. 80.
13.   Install the timing chain cover. See REMOVAL.
14.   Install the crankshaft damper. See INSTALLATION. Tighten damper bolt 175 N.m (130 ft. lbs.).
15.   Install accessory drive belt. Refer to INSTALLATION .
16.   Install the fan shroud. Refer to INSTALLATION .

 17.   Install the cylinder head cover. See INSTALLATION.
 18.   Install the intake manifold. See INSTALLATION.
 19.   Install oil fill housing onto cylinder head.
 20.   Refill the cooling system. Refer to STANDARD PROCEDURE .
 21.   Raise the vehicle.
 22.   Install the exhaust pipe onto the right exhaust manifold.
 23.   Lower the vehicle.
 24.   Reconnect battery negative cable.
 25.   Start the engine and check for leaks.

CAMSHAFT

FLEXPLATE📷 1

1. Remove the transmission. 2. Remove the bolts and flexplate.

FLEXPLATE📷 1

1 - FLEXPLATE

1. Position the flexplate (1) 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 in illustration. See Fig. 111. 3. Install the transmission.

ROD-PISTON AND CONNECTING

STRUCTURAL DUST COVER

The structural dust cover is made of die cast aluminum and joins the lower half of the transmission bell housing to the engine bedplate.

STRUCTURAL DUST COVER

The structural cover provides additional powertrain stiffness and reduces noise and vibration.

STRUCTURAL COVER

1 - BOLT 2 - BOLT 3 - BOLT

1. Raise vehicle on hoist. 2. Remove the bolts (1) retaining structural cover. See Fig. 130. 3. Remove the structural cover.

STRUCTURAL COVER📷 2

1 - BOLT 2 - BOLT 3 - BOLT

CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will cause severe damage to the cover.

1. Position the structural cover in the vehicle. 2. Install all bolts (1) retaining the cover-to-engine. DO NOT tighten the bolts at this time. 3. Install the cover-to-transmission bolts. Do NOT tighten at this time.

CAUTION: The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence. Failure to do so may cause damage to the cover.

4. Starting with the two rear cover-to-engine bolts, tighten bolts (1) to 54 N.m (40 ft. lbs.), then tighten bolts (2) and (3) to 54 N.m (40 ft. lbs.) in the sequence shown in illustration. See Fig. 131.

MOUNT - ENGINE FRONT

FROM TO

Oil Pickup Tube                                        Oil Pump
Oil Pump                                               Oil Filter
Oil Filter                                             Block Main Oil Gallery
Block Main Oil Gallery                                 1. Crankshaft Main Journal
-                                                      2. Left Cylinder Head*
-                                                      3. Right Cylinder Head*
-                                                      4. Counterbalance Shaft Rear Journal
Crankshaft Main Journals                               Crankshaft Rod Journals
Crankshaft Number One Main Journal                     1. Front Timing Chain Idler Shaft
-                                                      2. Counterbalance Shaft - Front Journal
-                                                      3. Both Secondary Chain Tensioners
Left Cylinder Head                                     Refer to ENGINE LUBRICATION FLOW CHART

- CYLINDER HEADS: TABLE 2

Right Cylinder Head Refer to ENGINE LUBRICATION FLOW CHART

- CYLINDER HEADS: TABLE 2

* The cylinder head gaskets have an oil restricter to control oil flow to the cylinder heads

FROM TO📷 1

Cylinder Head Oil Port (in bolt hole) Diagonal Cross Drilling to Main Oil Gallery Main Oil Gallery (drilled through head from rear to 1. Base of Camshaft Towers front)

-                                                      2. Lash Adjuster Towers
Base of Camshaft Towers                                Vertical Drilling Through Tower to Camshaft

Bearings** Lash Adjuster Towers Diagonal Drillings to Hydraulic Lash Adjuster Pockets ** The number three camshaft bearing journal feeds oil into the hollow camshaft tubes. Oil is routed to the intake lobes, which have oil passages drilled into them to lubricate the rocker arms.

1 - OIL FLOW TO RIGHT CYLINDER HEAD 2 - CYLINDER BLOCK MAIN OIL GALLERY 3 - LEFT CYLINDER HEAD OIL GALLERY 4 - OIL FLOW TO BOTH SECONDARY TENSIONERS 5 - OIL FLOW TO LEFT CYLINDER HEAD 6 - OIL PRESSURE SENSOR LOCATION 7 - OIL FLOW TO COUNTER BALANCE SHAFT 8 - OIL PUMP OUTLET TO CYLINDER BLOCK 9 - OIL PUMP

10 - OIL FLOW TO CRANKSHAFT MAIN JOURNALS 11 - CRANKSHAFT MAIN BEARING JOURNALS 12 - RIGHT CYLINDER HEAD OIL GALLERY

Oil from the oil pan is pumped by a gerotor type oil pump (9) directly mounted to the crankshaft nose. Oil pressure is controlled by a relief valve mounted inside the oil pump housing.

The camshaft exhaust valve lobes and rocker arms are lubricated through a small hole in the rocker arm; oil flows through the lash adjuster then through the rocker arm and onto the camshaft lobe. Due to the orientation of the rocker arm, the camshaft intake lobes are not lubed in the same manner as the exhaust lobes. The intake lobes are lubed through internal passages in the camshaft. Oil flows through a bore in the No. 3 camshaft bearing bore, and as the camshaft turns, a hole in the camshaft aligns with the hole in the camshaft bore allowing engine oil to enter the camshaft tube. See Fig. 138. The oil then exits through 1.6 mm (0.063 in.) holes drilled into the intake lobes, lubricating the lobes and the rocker arms.

PINS 8346📷 4

1 - TORQUE WRENCH 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346 3 - LEFT CAMSHAFT SPROCKET 4 - RIGHT CAMSHAFT SPROCKET

CAUTION: Ensure the plate between the left secondary chain tensioner and block is correctly installed.

15. Install both secondary chain tensioners. Tighten bolts to 28 N.m (250 in. lbs.).

NOTE: Left and right secondary chain tensioners are not common.

16. Remove all 3 locking pins from tensioners.

CAUTION: After pulling locking pins out of each tensioner, DO NOT manually extend the tensioner(s) ratchet. Doing so will over tension the chains, resulting in noise and/or high timing chain loads.

17. Using Spanner Wrench 6958 with Adapter Pins 8346, (4) tighten left and right camshaft sprocket bolts to 122 N.m (90 ft. lbs.). See Fig. 194 and Fig. 195. 18. Rotate engine two full revolutions. Verify timing marks are at the follow locations: primary chain idler sprocket dot is at 12 o'clock primary chain crankshaft sprocket dot is at 6 o'clock secondary chain camshaft sprockets "V6" marks are at 12 o'clock counterbalancer shaft drive gear dot is aligned to the idler sprocket gear dot 19. Lubricate all three chains with engine oil.

1 - IDLER SPROCKET ASSEMBLY 2 - DIAL INDICATOR

20. After installing all chains, it is recommended that the idler gear end play be checked. The end play must be within 0.10 - 0.25 mm (0.004 - 0.010 in.). If not within specification, the idler gear must be replaced. See Fig. 196. 21. Install timing chain cover and crankshaft damper. 22. Install cylinder head covers. See INSTALLATION.

1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG

NOTE: Before installing threaded plug in right cylinder head, the plug must be coated with sealant to prevent leaks.

23. Coat the large threaded access plug with Mopar® Thread Sealant with Teflon , then install into the right cylinder head (1) and tighten to 81 N.m (60 ft. lbs.). See Fig. 197. 24. Install the oil fill housing. 25. Install access plug in left cylinder head (2). 26. Install power steering pump. Refer to INSTALLATION . 27. Fill cooling system. Refer to STANDARD PROCEDURE . 28. Connect negative cable to battery.