2004 Chrysler Town & Country

2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

2004 ENGINE

Overhaul - Caravan & Town & Country - 3.3L/3.8L

ENGINE 3.3/3.8L
DESCRIPTION

The 3.3 Liter (201 cu. in.) and 3.8 Liter (231 cu. in.) engines are 60° V-6 engines with cast iron cylinder blocks
and aluminum cylinder heads (Fig. 1). The engine uses a single, block mounted camshaft with pushrods to
actuate the valves. These engines do not have provisions for a free wheeling valve train.

Fig. 1: Identifying 3.3/3.8L V-6 Engines

Courtesy of DAIMLERCHRYSLER CORP.

The firing order is 1-2-3-4-5-6. The cylinders are numbered from the front of the engine to the rear. The front
cylinder bank is numbered 2, 4, and 6. The rear cylinder bank is numbered 1, 3, and 5.

The engine identification number is located on the rear of the cylinder block just below the cylinder head (Fig.
2).

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Fig. 2: Locating Engine Identification Labels

Courtesy of DAIMLERCHRYSLER CORP.

DIAGNOSIS AND TESTING

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

Refer to the Engine Mechanical and the Engine Performance diagnostic charts, for possible causes and
corrections of malfunctions (Refer to DIAGNOSIS AND TESTING - ENGINE MECHANICAL) (Refer to
DIAGNOSIS AND TESTING - ENGINE PERFORMANCE).

For fuel system diagnosis, (Refer to DIAGNOSIS AND TESTING - FUEL DELIVERY SYSTEM ).

Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that cannot be
isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided
within the following:

Cylinder Compression Pressure Test

Cylinder Combustion Pressure Leakage Test
Engine Cylinder Head Gasket Failure Diagnosis
Intake Manifold Leakage Diagnosis
Hydraulic Lash Adjuster Noise Diagnosis
Engine Oil Leak Inspection

DIAGNOSIS AND TESTING - ENGINE PERFORMANCE

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Fig. 3: Engine Performance Diagnosis (1 Of 2)

Courtesy of DAIMLERCHRYSLER CORP.

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Fig. 4: Engine Performance Diagnosis (2 Of 2)

Courtesy of DAIMLERCHRYSLER CORP.

DIAGNOSIS AND TESTING - ENGINE MECHANICAL

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Fig. 5: Engine Mechanical Diagnosis (1 Of 3)

Courtesy of DAIMLERCHRYSLER CORP.

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Fig. 6: Engine Mechanical Diagnosis (2 Of 3)

Courtesy of DAIMLERCHRYSLER CORP.

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Fig. 7: Engine Mechanical Diagnosis (3 Of 3)

Courtesy of DAIMLERCHRYSLER CORP.

DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION

Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil
leak source is not readily identifiable, the following steps should be followed:

1. Do not clean or degrease the engine at this time because some solvents may cause rubber to swell,
temporarily stopping the leak.
2. Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil
leak. If the oil leak is found and identified, repair as necessary.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat
inspection.
5. If the oil leak source is not positively identified at this time, proceed with the air leak detection test
method as follows:
Disconnect the fresh air hose (make-up air) at the cylinder head cover and plug or cap the nipple on
the cover.
Remove the PCV valve hose from the cylinder head cover. Cap or plug the PCV valve nipple on
the cover.
Attach an air hose with pressure gauge and regulator to the dipstick tube.

CAUTION: Do not subject the engine assembly to more than 20.6 kpa (3
PSI) of test pressure.

Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the

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suspected source. Adjust the regulator to the suitable test pressure that provides the best bubbles
which will pinpoint the leak source. If the oil leak is detected and identified, repair per service
procedures.
If the leakage occurs at the crankshaft rear oil seal area, refer to INSPECTION FOR REAR
SEAL AREA LEAKS.
6. If no leaks are detected, turn off the air supply. Remove the air hose, all plugs, and caps. Install the PCV
valve and fresh air hose (make-up air). Proceed to next step.
7. Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds
approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.

NOTE: If oil leakage is observed at the dipstick tube to block location; remove the tube,
clean and reseal using Mopar® Stud & Bearing Mount (press fit tube
applications only), and for O-ring style tubes, remove tube and replace the O-
ring seal.

INSPECTION FOR REAR SEAL AREA LEAKS

Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more
involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.

If the leakage occurs at the crankshaft rear oil seal area:

1. Disconnect the battery.

2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a
black light to check for the oil leak. If a leak is present in this area, remove transmission for further
inspection.
a. Circular spray pattern generally indicates seal leakage or crankshaft damage.
b. Where leakage tends to run straight down, possible causes are a porous block, oil gallery cup plug,
bedplate to cylinder block mating surfaces and seal bore. See proper repair procedures for these
items.

CAUTION: Do not exceed 20.6 kPa (3 psi).

4. If no leaks are detected, pressurize the crankcase as previously described.

CAUTION: Use extreme caution when crankshaft polishing is necessary to

remove minor nicks and scratches. The crankshaft seal flange is
especially machined to complement the function of the rear oil seal.

5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected
between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal
surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be

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polished out with emery cloth.

6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled.
7. After the oil leak root cause and appropriate corrective action have been identified, replace component(s)
as necessary.

DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST

The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.

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. Check engine oil level and add oil if necessary.

2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and
other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly.
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal
firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference.
4. Remove the Auto Shutdown (ASD) relay from the PDC.
5. Be sure throttle blade is fully open during the compression check.
6. Insert compression gauge adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0-500 psi (Blue) pressure transducer (Special Tool CH7059) with cable
adaptors to the DRBIII®. For Special Tool identification, (Refer to SPECIAL TOOLS).
7. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure.
8. Repeat the previous step for all remaining cylinders.
9. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder
to cylinder.
10. If one or more cylinders have abnormally low compression pressures, repeat the compression test.
11. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it
could indicate the existence of a problem in the cylinder in question. The recommended compression
pressures are to be used only as a guide to diagnosing engine problems. An engine should not be
disassembled to determine the cause of low compression unless some malfunction is present.

DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST

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 seating).

Leaks between adjacent cylinders or into water jacket.
Any causes for combustion/compression pressure loss.

WARNING: DO NOT REMOVE THE PRESSURE CAP WITH THE SYSTEM HOT AND
UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.

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Check the coolant level and fill as required. DO NOT install the pressure cap.

Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.

Clean spark plug recesses with compressed air.

Remove the spark plugs.

Remove the oil filler cap.

Remove the air cleaner.

Calibrate the tester according to the manufacturer's instructions. The shop air source for testing should maintain
483 kPa (70 psi) minimum, 1,379 kPa (200 psi) maximum, with 552 kPa (80 psi) recommended.

Perform the test procedures on each cylinder according to the tester manufacturer's instructions. While testing,
listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for
bubbles in the coolant.

All gauge pressure indications should be equal, with no more than 25% leakage per cylinder.

FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in
the cylinder.

STANDARD PROCEDURE

STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE

Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the
recommended procedure for the use of Plastigage:

1. Remove oil film from surface to be checked. Plastigage is soluble in oil.

2. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6.35 mm
(1/4 in.) off center and away from the oil holes (Fig. 8). (In addition, suspected areas can be checked by
placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to
the proper specifications.

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Fig. 8: Placing Plastigage In Lower Shell - Typical

Courtesy of DAIMLERCHRYSLER CORP.

NOTE: Plastigage is available in a variety of clearance ranges. Use the most

appropriate range for the specifications you are checking.

3. Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale provided
on the package. Locate the band closest to the same width. This band shows the amount of clearance in
thousandths of a millimeter. Differences in readings between the ends indicate the amount of taper
present. Record all readings taken. Compare clearance measurements to specs found in engine
specifications (Refer to SPECIFICATIONS). Plastigage generally is accompanied by two scales. One
scale is in inches, the other is a metric scale.
4. Install the proper crankshaft bearings to achieve the specified bearing clearances.

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

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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. Mopar® Engine
RTV GEN II, Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties
and can not be used in place of the other.

Mopar® ENGINE RTV GEN II is used to seal components exposed to engine oil. This material is a specially
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.

Mopar® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing
properties to seal components exposed to automatic transmission fluid, engine 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.

Mopar® 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.

Mopar® BED PLATE SEALANT is a unique (green-in-color) anaerobic type gasket material that is specially
made to seal the area between the bedplate and cylinder block without disturbing the bearing clearance or
alignment of these components. The material cures slowly in the absence of air when torqued between two
metallic surfaces, and will rapidly cure when heat is applied.

Mopar® GASKET SEALANT is a slow drying, permanently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined
parts under all temperatures. This material is used on engines with multilayer steel (MLS) cylinder head
gaskets. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or
4oz./16 oz. can w/applicator.

SEALER APPLICATION

Mopar® 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 surrounds each mounting hole. Excess material can easily be wiped off.
Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during
assembly to prevent smearing material off the location.

Mopar® 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.

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Mopar® 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 and head

NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing
surface.

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Fig. 9: Identifying Proper Tool Usage For Surface Preparation

Courtesy of DAIMLERCHRYSLER CORP.

High speed power tool with an abrasive pad or a wire brush (Fig. 9)

Only use the following for cleaning gasket surfaces:

Solvent or a commercially available gasket remover

Plastic or wood scraper (Fig. 9)
Drill motor with 3M Roloc(tm) Bristle Disc (white or yellow) (Fig. 9)

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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.

STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE

When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following
steps should be used.

CAUTION: DO NOT use starter motor to rotate the engine, severe damage may occur.

1. Inspect air cleaner, induction system and intake manifold to insure system is dry and clear of foreign
material.
2. Remove negative battery cable.
3. Place a shop towel around the spark plugs when removing them from the engine. This will catch any fluid
that may possibly be in the cylinder under pressure.
4. With all spark plugs removed, rotate engine crankshaft using a breaker bar and socket.
5. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other).
6. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.).

CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotate
engine to lubricate the cylinder walls to prevent damage on restart.

7. Repair engine or components as necessary to prevent this problem from re-occurring.

8. Install new spark plugs.
9. Drain engine oil and remove oil filter.
10. Install a new oil filter.
11. Fill engine with specified amount of approved oil.
12. Connect negative battery cable.
13. Start engine and check for any leaks.

STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS

Damaged or worn threads (excluding spark plug and camshaft bearing cap attaching threads) can be repaired.
Essentially, this repair consists of drilling out worn or damaged threads, tapping the hole with a special Heli-
Coil Tap, (or equivalent) and installing an insert into the tapped hole. This brings the hole back to its original
thread size.

CAUTION: Be sure that the tapped holes maintain the original center line.

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Heli-Coil tools and inserts are readily available from automotive parts jobbers.

STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS

CAUTION: Do not drive cup plug into the casting as restricted cooling can result and
cause serious engine problems.

Using a blunt tool such as a drift and a hammer, strike the bottom edge of the cup plug. With the cup plug
rotated, grasp firmly with pliers or other suitable tool and remove plug (Fig. 10).

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Fig. 10: Removing Core Hole Plug

Courtesy of DAIMLERCHRYSLER CORP.

Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat
inside of cup plug hole with Mopar® Stud and Bearing Mount. Make certain the new plug is cleaned of all oil
or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm
(0.020 in.) inside the lead-in chamfer.

It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in
service immediately.

REMOVAL - ENGINE ASSEMBLY

1. Perform fuel pressure release procedure (Refer to STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE PROCEDURE ).
2. Disconnect negative battery cable.
3. Remove air cleaner and hoses.
4. Disconnect the fuel line from fuel rail (Refer to QUICK CONNECT FITTING ).
5. Remove the wiper module (Refer to WIPER MODULE ).
6. Block off heater hoses to the rear heater system using pinch-off pliers (if equipped).
7. Drain the cooling system (Refer to STANDARD PROCEDURE ).
8. Disconnect the heater hoses.
9. Remove the radiator upper support crossmember (Refer to GRILLE OPENING REINFORCEMENT ).
10. Remove the radiator fans (Refer to RADIATOR FAN ).
11. Disconnect the throttle cables from the throttle body.
12. Disconnect the MAP, IAC, and TPS electrical connectors.
13. Disconnect the EGR transducer electrical connector (if equipped).
14. Disconnect the vacuum hoses from throttle body.
15. Disconnect the brake booster and speed control vacuum hoses.
16. Disengage wire harness clip from the right side engine mount.
17. Remove the power steering reservoir from mounting position and set aside. Do not disconnect hose.
18. Disconnect ground strap from rear of cylinder head.
19. Disconnect engine coolant temperature (ECT) sensor and ignition coil electrical connectors.
20. Disconnect the fuel injector electrical harness connector and disengage clip from support bracket.
21. Disconnect camshaft and crankshaft position sensor electrical connectors.
22. Evacuate air conditioning system. Refer to STANDARD PROCEDURE - FRONT .
23. Disconnect A/C compressor electrical connector.
24. Disconnect the A/C lines from compressor. Cover and seal all openings of hoses and compressor.
25. Remove the radiator upper hose.
26. Disengage electrical harness clip at transaxle dipstick tube.
27. Remove transaxle dipstick tube. Seal opening using a suitable plug.

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NOTE: When the transaxle cooler lines are removed from the rolled-groove type
fittings at the transaxle, damage to the inner wall of the hose will occur. To
prevent potential leakage, the cooler hoses must be cut off flush at the
transaxle fitting, and a service cooler hose splice kit must be installed
upon reassembly.

28. Using a blade or suitable hose cutter, cut transaxle oil cooler lines off flush with fittings. Plug cooler lines
and fittings to prevent debris from entering transaxle or cooler circuit. A service splice kit will be
installed upon reassembly.
29. Disconnect transaxle shift linkage and electrical connectors.
30. Raise vehicle on hoist and drain the engine oil.
31. Remove the axle shafts. (Refer to REMOVAL, DISASSEMBLY, REASSEMBLY &
INSTALLATION ).
32. Remove crossmember cradle plate (Fig. 11).

Fig. 11: Removing Crossmember Cradle Plate

Courtesy of DAIMLERCHRYSLER CORP.

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33. AWD equipped: Remove the power transfer unit (PTU) (Refer to REMOVAL & OVERHAUL &
INSTALLATION - POWER TRANSFER UNIT ).
34. Disconnect exhaust pipe from the manifold (Fig. 12).

Fig. 12: Disconnecting Catalytic Converter From Exhaust Manifold

Courtesy of DAIMLERCHRYSLER CORP.

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35. Remove front engine mount and bracket as an assembly.

36. Remove the engine rear mount bracket.
37. Remove the engine to transaxle struts (Fig. 13).

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Fig. 13: Removing Powertrain Supports And Dust Cover

Courtesy of DAIMLERCHRYSLER CORP.

38. Remove transaxle case cover (Fig. 13).

39. Remove flex plate to torque converter bolts. Mark torque converter to flex plate for orientation for
reassembly.
40. Remove the power steering pressure hose support clip attaching bolt.
41. Disconnect the knock sensor electrical connector (3.8L only).
42. Disconnect the engine block heater electrical connector (if equipped).
43. Remove the accessory belt splash shield.
44. Remove accessory drive belt (Refer to REMOVAL & INSTALLATION ).
45. Disconnect the radiator lower hose.
46. Remove air conditioning compressor from engine.
47. Remove the generator (Refer to REMOVAL & INSTALLATION ).
48. Remove the water pump pulley attaching bolts and position pulley between pump hub and housing.
49. Disconnect the oil pressure switch electrical connector.
50. Disconnect wiring harness support clip from engine oil dipstick tube.
51. Install Special Tools 6912 and 8444 Adapters on the right side (rear) of engine block (Fig. 14).

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Fig. 14: Identifying Adapter Tools Mounted On Block

Courtesy of DAIMLERCHRYSLER CORP.

52. Lower the vehicle.

53. Remove the power steering pump and set aside.
54. Raise vehicle enough to allow engine dolly Special Tool 6135 and cradle Special Tool 6710 with post
Special Tool 6848 and adaptor Special Tool 6909 to be installed under vehicle (Fig. 17).
55. Loosen cradle/post mounts to allow movement for positioning posts into locating holes on the engine
(Fig. 15) and (Fig. 16). Slowly lower vehicle and position cradle/post mounts until the engine is resting
on posts. Tighten all cradle/post mounts to cradle frame. This will keep mounts from moving when
removing or installing engine and transmission.

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Fig. 15: Positioning Special Tool 6848 For Use With Adapters 8444 & 6912
Courtesy of DAIMLERCHRYSLER CORP.

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2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

Fig. 16: Identifying Special Tools 6848 With Adapters 6909

Courtesy of DAIMLERCHRYSLER CORP.

56. Lower vehicle so the weight of ONLY THE ENGINE AND TRANSMISSION is on the cradle.
57. Install and secure the safety straps to the cradle fixture and around the engine (Fig. 17).

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Fig. 17: Positioning Engine Cradle Support Post Mounts

Courtesy of DAIMLERCHRYSLER CORP.

58. Remove the engine right side mount to engine attaching bolts (Fig. 18).

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Fig. 18: Installing Right Mount To Engine

Courtesy of DAIMLERCHRYSLER CORP.

59. Remove the left mount through bolt (Fig. 19).

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 2004 Chrysler Town & Country
2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

Fig. 19: Installing Left Mount To Frame Bracket

Courtesy of DAIMLERCHRYSLER CORP.

60. Raise vehicle slowly. It is necessary to move the engine/transmission assembly with the dolly to allow for
removal around body flanges.

INSTALLATION - ENGINE ASSEMBLY

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1. Position engine and transmission assembly under vehicle. Slowly lower the vehicle down over the engine
and transmission. It is necessary to move the engine/transmission assembly with the dolly for clearance
around body flanges.
2. Align engine and transmission mounts to attaching points. Install mounting bolts at the right engine
mount (Fig. 18) and left transmission mount (Fig. 19).
3. Remove the safety straps from around engine.
4. Slowly raise vehicle enough to remove the engine dolly and cradle Special Tools 6135, 6710, 6848 and
6909 (Fig. 17).
5. Remove Special Tools 6912 and 8444 (Fig. 14).
6. Lower the vehicle.
7. Install power steering pump and pressure line support.
8. Install the generator and wiring harness (Refer to REMOVAL & INSTALLATION ).
9. Raise vehicle.
10. Attach wiring harness support clip to the engine oil dipstick tube.
11. Connect oil pressure switch electrical connector.
12. Install the A/C compressor.
13. Install the water pump pulley.
14. Connect the radiator lower hose.
15. Install the accessory drive belt and splash shield (Refer to REMOVAL & INSTALLATION ).
16. Connect the engine block heater electrical connector (if equipped).
17. Connect the knock sensor electrical connector (3.8L only).
18. Install the torque converter to flex plate bolts.
19. Install the transaxle case cover (Fig. 13).
20. Install the powertrain struts (Fig. 13).
21. Install the engine rear mount bracket.
22. Install the engine front mount and bracket assembly.
23. AWD equipped; Install the power transfer unit (PTU) (Refer to REMOVAL & OVERHAUL &
INSTALLATION - POWER TRANSFER UNIT ).
24. Install the axle shafts (Refer to REMOVAL, DISASSEMBLY, REASSEMBLY &
INSTALLATION ).
25. Connect exhaust pipe to manifold (Fig. 12).
26. Install crossmember cradle plate (Fig. 11).
27. Lower vehicle.
28. Connect transaxle shift linkage.
29. Connect transaxle electrical connectors.
30. Remove plugs from transmission cooler hoses and install transaxle oil cooler line service splice kit. Refer
to instructions included with kit.
31. Install transaxle dipstick tube and attach electrical harness clip.
32. Connect the A/C lines to compressor.

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33. Connect the A/C compressor electrical connector.

34. Evacuate and recharge A/C system.
35. Connect crankshaft and camshaft position sensors.
36. Connect the fuel injector electrical harness connector and engage clip to support bracket.
37. Connect engine coolant temperature (ECT) sensor and ignition coil electrical connectors.
38. Connect the ground strap to rear of cylinder head.
39. Install power steering reservoir.
40. Engage wire harness clip to engine right side mount.
41. Connect the brake booster and speed control vacuum hoses.
42. Connect the vacuum hoses to the throttle body.
43. Connect the EGR transducer electrical connector (if equipped).
44. Connect the TPS, IAC, and MAP sensor electrical connectors.
45. Connect throttle cables to throttle body.
46. Install the radiator fans (Refer to RADIATOR FAN ).
47. Connect the radiator upper hose.
48. Connect the heater hoses. Remove pinch-off pliers from the rear heater hoses (if equipped).
49. Install the radiator upper support crossmember (Refer to GRILLE OPENING REINFORCEMENT ).
50. Install the wiper module (Refer to WIPER MODULE ).
51. Connect the fuel line to fuel rail (Refer to FUEL LINES ).
52. Install the air cleaner and hoses.
53. Install new oil filter. Fill engine crankcase with proper oil to correct level.
54. Connect negative cable to battery.
55. Fill the cooling system (Refer to STANDARD PROCEDURE ).
56. Start engine and run until operating temperature is reached.
57. Adjust transmission linkage, if necessary.

SPECIFICATIONS

3.3/3.8L ENGINE

GENERAL DESCRIPTION

GENERAL DESCRIPTION SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Engine Type 60° V-6 Engine
Number of Cylinders 6
Displacement 3.3L 3.3Liters 201 cu.in.
Displacement 3.8L 3.8 Liters 231 cu. in.
Bore 3.3L 93.0 mm 201 cu.in.

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Bore 3.8L 96.0 mm 3.779 cu.in.

Stroke 3.3L 81 mm 3.188 in.
Stroke 87 mm 3.425 in.
Compression Ratio 3.3L - 9.35:1
Compression Ratio 3.8L - 9.6:1
Firing Order - 1-2-3-4-5-6
Compression Pressure-Minimum 689.5 kPa 100 psi.
Cylinder Compression (Max. Difference Between Cylinders - 25%

CYLINDER BLOCK

CYLINDER BLOCK SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Cylinder Bore Diameter (Standard) 3.3L 92.993-93.007 mm 3.661-3.6617 in.
Cylinder Bore Diameter (Standard) 3.8L 95.993-96.007 mm 3.7792-3.780 in.
Out of Round (Service Limits) 0.076 mm 0.003 in.
Taper (Service Limits) 0.051 mm 0.002 in.
Lifter Bore Diameter 22.980-23.010 mm 0.905-0.906 in.
Deck Surface Flatness (Max.) 0.1 mm 0.004 in.

CRANKSHAFT

CRANKSHAFT SPECIFICATIONS
DESCRIPTION SPECIFICATION
Metric Standard
Connecting Rod Journal Diameter 57.979-58.005 mm 2.2827-2.2837 in.
Main Bearing Journal Diameter 63.993-64.013 mm 2.5194-2.5202 in.
Journal Out-of-Round (Max.) 0.025 mm 0.001 in.
Journal Taper (Max.) 0.025 mm 0.001 in
End Play 0.09-0.24 mm 0.0036-0.0095 in.
Wear Limit 0.381 mm 0.015 in.
Main Bearing Diametrical Clearance 1-2-3-4 0.011-0.055 mm 0.0005-0.0022 in.
Wear Limit 0.076 mm 0.003 in.

CONNECTING RODS

CONNECTING RODS SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Bearing Clearance 0.019-0.065 mm. 0.017-0.020 in.
Wear Limit 0.074 mm 0.003 in.
Side Clearance 0.13-0.32 mm 0.005-0.013 in.

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Wear Limit 0.38 mm 0.015 in.

PISTONS

PISTONS SPECIFICATIONS
DESCRIPTION SPECIFICATION
Metric Standard
Piston Diameter 3.3L-Measured 39.8 mm (1.567 in) From Piston 92.968-92.998
3.660-3.661 in.
Top mm.
Piston Diameter 3.8L-Measured 33.01 mm (1.30 in) From Piston 95.968-95.998
3.778-3.779 in.
Top mm.
Clearance in Bore @ Size Location (New) -0.005-0.039 mm -0.0002-0.0015 in.
12.77 +/- 0.1764
Weight 3.3L 362 +/- 5 grams
oz.
15.03 +/- 0.1764
Weight 3.8L 426 +/- 5 grams
oz.

PISTON PINS

PISTON PINS SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Type Press Fit in Rod (Serviced as a Assembly)
Clearance in Piston @ 21C (70°F) 0.006-0.019 mm 0.0002-0.0007 in.
Clearance in Connecting Rod Interference Fit
Diameter 22.87-22.88 mm 0.9007-0.9009 in.
Length 3.3L 67.25-67.75 mm 2.648-2.667 in.
Length 3.8L 71.25-71.75 mm 2.805-2.824 in.

PISTON RINGS

PISTON RINGS SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Ring End Gap
0.18-0.38 mm 0.007-0.015 in.
Top Compression Ring
0.28-0.57 mm 0.011-0.022 in.
Second Compression Ring
0.23-0.78 mm 0.009-0.030 in.
Oil Control (Steel Rails)
Wear Limit-Compression Rings 1.0 mm 0.039 in.
Wear Limit-Oil Control Steel Rails 1.88 mm 0.074 in.
Ring Side Clearance 0.030-0.080 mm 0.0012-0.0031 in.
Top Compression Ring 3.3L 0.030-0.069 mm 0.0012-0.0027 in.
Top Compression Ring 3.8L 0.030-0.095 mm 0.0012-0.0037 in.
Second Compression Ring 3.3L 0.041-0.085 mm 0.0016-0.0033 in.

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Second Compression Ring 3.8L 0.039-0.200 mm 0.0015-0.0078 in.

Oil Ring (Steel Ring)
Wear Limit-Top Ring 0.10 mm 0.004 in.
Wear Limit-2nd Ring 0.13 mm 0.005
Wear Limit Oil Ring Pack 0.266 mm 0.009
Ring Width-Top Compression Ring 3.3L 1.46-1.49 mm 0.0575-0.058 in.
Ring Width-Top Compression Ring 3.8L 1.175-1.190 mm 0.0462-0.0468
Ring End Gap
Ring Width-2nd Compression 1.46-1.49 mm 0.0575-0.058 in.
Ring 3.3L and 3.8L
Ring Width-Oil Ring (Steel Rails) 3.3L 0.435-0.490 mm -.017-0.019 in.
Ring Width-Oil Ring (Steel Rails) 3.8L 0.435-0.510 mm 0.017-0.020

CAMSHAFT

CAMSHAFT SPECIFICATIONS
DESCRIPTION SPECIFICATION
Metric Standard
Journal Diameter
#1 50.724-50.775 mm 1.997-1.999 in.
#2 50.317-50.368 mm 1.9809-1.9829 in.
#3 49.936-49.987 mm 1.9659-1.9679 in.
#4 49.530-49.581 mm 1.9499-1.9520 in.
Bearing Clearance-Diametrical 0.025-0.101 mm 0.001-0.004 in.
Bearing Clearance 0.127 mm 0.005 in.
(Max.Allowable)
End Play 0.254-0.508 mm 0.010-0.020 in.
Camshaft Bearing Diameter
#1 50.800-50.825 1.9999-2.0009 in.
#2 50.393-50.419 mm 1.9839-1.9849 in.
#3 50.013-50.038 mm 1.9690-1.9699 in.
#4 49.606-49.632 mm 1.9529-1.954 in.
Exhaust Valve Timing
Closes-3.3L (ATDC) - 13°
Closes-3.8L (ATDC) - 18°
Opens-3.3L (BBDC) - 43°
Opens-3.8L (BBDC) - 46°
Duration-3.3L - 236°
Duration-3.8L - 244°
Intake Valve Timing
Closes-3.3L (ABDC) - 52°
Closes-3.8L (ABDC) - 63°

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Opens-3.3L (ATDC) - 6°
Opens-3.8L (ATDC) - 1°
Duration-3.3L - 226°
Duration-3.8L - 242°
Valve Overlap-3.3L - 7°
Valve Overlap-3.8L - 17°

HYDRAULIC LIFTER

HYDRAULIC LIFTER SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Type Hydraulic Roller
Outside Diameter 22.949-22.962 mm 0.903-0.904 in.
Clearance in Block 0.020-0.061 mm 0.0007-0.0024 in.

CYLINDER HEAD

CYLINDER HEAD SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Gasket Thickness (Compressed) 0.65-0.75 mm 0.0007-0.0024 in.

VALVES

VALVES SPECIFICATIONS
DESCRIPTION SPECIFICATION
Metric Standard
Face Angle-Intake - 45-45.5°
Face Angle-Exhaust - 45-45.5°
Head Diameter-Intake 47.87-48.13 mm 1.88-1.89 in.
Head Diameter-Exhaust 35.37-35.63 mm 1.39-1.40 in.
Valve Lift (Zero Lash)-Intake and Exhaust-3.3L 9.80 mm 0.385 in.
Valve Lift (Zero Lash)-Intake and Exhaust-3.8L 11.0 mm 0.433 in.
Valve Length-Intake 125.84-126.6 mm 4.95-4.98 in.
Valve Length-Exhaust 127.20-127.96 5.00-5.04 in.
Valve Stem to Tip Height (valve tip to spring seat washer)-Intake 48.1-49.7 mm 1.89-1.95 in.
Valve Stem to Tip Height (valve tip to spring seat washer)-Exhaust 48.53-50.09 mm 1.91-1.97 in.

VALVE SEAT

VALVE SEAT SPECIFICATIONS

DESCRIPTION SPECIFICATION

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Metric Standard
Angle - 44.5-45°
Run Out (Service Limits) 0.0762 mm 0.003 in.
Width-Intake and Exhaust 1.50-2.00 mm 0.057-0.078 in.

VALVE GUIDE

VALVE GUIDE SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Guide Bore Diameter (Std.) 6.975-7.00 mm 0.274-0.275 in.

VALVE MARGIN

VALVE MARGIN SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Intake 0.825-0.973 mm 0.032-0.038 in.
Exhaust 1.565-1.713 mm 0.061-0.067 in.

VALVE STEM DIAMETER

VALVE STEM DIAMETER SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Intake (Standard) 6.935-6.953 mm 0.2718-0.2725 in.
Exhaust (Standard) 6.906-6.924 mm 0.2718-0.2725 in.

VALVE STEM TO GUIDE CLEARANCE

VALVE STEM TO GUIDE CLEARANCE SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Intake 0.025-0.065 mm 0.001-0.0025 in.
Exhaust 0.059-0.094 mm 0.002-0.0037 in.
Max Allowable-Intake (Rocking Method) 0.247 mm 0.010 in.
Max Allowable-Exhaust (Rocking Method) 0.414 mm 0.016 in.

PUSH RODS

PUSH RODS SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Length 135.438 mm 5.33 in.

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VALVE SPRING

VALVE SPRING SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Free Length-Type A 51.4 mm 2.02 in.
Free Length-Type B 53.4 mm 2.10 in.
Wire Diameter Type A 3.95-4.77 mm 0.15-0.19 in.
Wire Diameter Type B 4.19-4.29 mm 0.16-0.17 in.
Number of Coils Type A 7.52
Number of Coils Type B 7.25
Spring Tension (Valve Closed) Type A 376.4-424.4 N @ 41.9 mm 84.6-95.6 lbs. @ 1.65 in.
Spring Tension (Valve Open) Type A 863.9-959.9 N @ 41.9 mm 194.2-215.8 lbs. @ 1.65 in.
Spring Tension (Valve Closed) Type B 377-423 N @ 41.9 mm 84.8-95.2 lbs. @ 1.65 in.
Spring Tension (Valve Open) Type B 880-962 N @ 30.91 mm 197.9-216.3 lbs. @ 122 in.
Installed Height 41.1-42.7 mm 1.61-1.68 in

LUBRICATION

LUBRICATION SPECIFICATIONS
DESCRIPTION SPECIFICATION
Metric Standard
At Curb Idle Speed(1) (Minimum with engine at operating temperature) 34.47 kPa 5 psi
At 3000 RPM 205-551 kPa 30-80 psi
Oil Filter By-Pass Valve Setting 62-103 kPa 9-15 psi
Oil Pressure Switch Actuating Pressure 14-28 Kpa 2-4 psi
CAUTION:
(1) If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm.

OIL PUMP

OIL PUMP SPECIFICATIONS

DESCRIPTION SPECIFICATION
Metric Standard
Clearance Over rotors-Inner and Outer 0.10 mm 0.004 in.
Cover Out-Of-Flat (Max.) 0.025 mm 0.001 in.
Inner Rotor Thickness 7.64 mm 0.301 in.
Outer Rotor Thickness (Min) 7.64 mm 0.301 in.
Outer Rotor Clearance (Max) 0.039 mm 0.015 in.
Outer Rotor Diameter (Min) 79.95 mm 3.148 in.
Tip Clearance Between Rotors (Max) 0.20 mm 0.008 in.

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2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

SPECIAL TOOLS

3.3/3.8L ENGINE

Fig. 20: Identifying Dolly 6135 (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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Fig. 21: Identifying Cradle 6710A (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

Fig. 22: Identifying Adapter 6909A (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

Fig. 23: Identifying Adapter 8444 (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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Fig. 24: Identifying Adapter 6912 (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

Fig. 25: Identifying Puller 1026 (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

Fig. 26: Identifying Insert, Crankshaft 8450 (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

Fig. 27: Identifying Crankshaft Damper/Sprocket Installer 8452 (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
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Fig. 28: Identifying Indicator, Cylinder Bore C-119 (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
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Fig. 29: Identifying Tester - Valve Spring C-647 (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
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Fig. 30: Identifying Compressor, Valve Spring In-vehicle 8453 (Special Tool)
Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

Fig. 31: Identifying Valve Spring Compressor Off-vehicle C-3422-D (Special Tool)
Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
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Fig. 32: Identifying Adapter, Valve Spring Compressor Off-Vehicle 8464 (Special Tool)
Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

Fig. 33: Identifying Remover, Valve Tappet C-4129 - A (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

Fig. 34: Identifying Remover, Crankshaft Front Seal 6341A (Special Tool)
Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

Fig. 35: Identifying Installer, Crankshaft Front Seal C-4992 (Special Tool)
Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

Fig. 36: Identifying Remover And Installer, Crankshaft Main Bearing C-3059 (Special Tool)
Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

Fig. 37: Identifying Rear Crankshaft Oil Seal Installer 6926 (Special Tool)
Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
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Fig. 38: Identifying Oil Pressure Gauge C-3292 (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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 2004 Chrysler Town & Country
2004 ENGINE Overhaul - Caravan & Town & Country - 3.3L/3.8L

Fig. 39: Identifying Adapter 8406 (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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Fig. 40: Identifying Cooling System Tester 7700 (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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Fig. 41: Identifying Combustion Leak Tester C-3685-A (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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Fig. 42: Identifying Pressure Transducer Ch7059 (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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Fig. 43: Identifying Compression Test Adapter 8116 (Special Tool)

Courtesy of DAIMLERCHRYSLER CORP.

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Fig. 44: Identifying DRBIII® With PEP Module OT-CH6010A (Special Tool)
Courtesy of DAIMLERCHRYSLER CORP.

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AIR CLEANER ELEMENT

REMOVAL

1. Unsnap 2 clips.
2. Lift cover and pull toward the engine and remove cover tabs from air box.
3. Lift cover and remove the element (Fig. 45).

Fig. 45: Lifting Air Box Cover

Courtesy of DAIMLERCHRYSLER CORP.

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INSTALLATION

1. Install the air filter element into air box (Fig. 45).
2. Move cover so that the tabs insert into the air box.
3. Push cover down and snap the 2 clips.

AIR CLEANER HOUSING

REMOVAL

1. Disconnect the negative battery cable.

2. Disconnect the inlet air temperature sensor (Fig. 46).

Fig. 46: Disconnecting Inlet Air Temperature Sensor

Courtesy of DAIMLERCHRYSLER CORP.

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3. Remove the inlet hose to throttle body.

4. Remove the bolt for air box at upper radiator cross member.
5. Pull air box up and off over the single locating pin.
6. Remove air box from vehicle

INSTALLATION

1. Install air box into vehicle and onto the locating pin.
2. Install bolt to hold air box to the upper radiator cross member.
3. Install the inlet hose to the throttle body.
4. Connect the inlet air temperature sensor (Fig. 46).
5. Connect the negative battery cable.

CYLINDER HEAD
DESCRIPTION

The aluminum cylinder heads (Fig. 47) are designed to create high flow combustion chambers to improve
performance, while minimizing the change to the burn rate in the chamber. The cylinder head incorporates the
combustion chamber. Two valves per-cylinder are used with inserted valve seats and guides. A multi-layer steel
(MLS) type gasket is used between the cylinder head and engine block.

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Fig. 47: Identifying Cylinder Head And Components

Courtesy of DAIMLERCHRYSLER CORP.

DIAGNOSIS AND TESTING-CYLINDER HEAD GASKET

A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent
water jacket.

Possible indications of the cylinder head gasket leaking between adjacent cylinders are:

Loss of engine power

Engine misfiring
Poor fuel economy

Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:

Engine overheating
Loss of coolant
Excessive steam (white smoke) emitting from exhaust
Coolant foaming

CYLINDER-TO-CYLINDER LEAKAGE TEST

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To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in
Cylinder Compression Pressure Test (Refer to DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST). An engine cylinder head gasket leaking between adjacent cylinders
will result in approximately a 50-70% reduction in compression pressure.

CYLINDER-TO-WATER JACKET LEAKAGE TEST

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH

COOLANT PRESSURE CAP REMOVED.

VISUAL TEST METHOD

With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat
opens.

If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.

COOLING SYSTEM TESTER METHOD

WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP

FAST. EXCESSIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE
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.

CHEMICAL TEST METHOD

Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent.
Perform test following the procedures supplied with the tool kit.

REMOVAL - CYLINDER HEAD

1. Drain the cooling system. (Refer to STANDARD PROCEDURE - COOLING SYSTEM

DRAINING )
2. Disconnect negative cable from battery.
3. Remove upper and lower intake manifolds. (Refer to INTAKE MANIFOLD)

WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND

MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE.

4. Remove the cylinder head covers. (Refer to CYLINDER HEAD COVER(S))

5. Remove the spark plugs from cylinder head.
6. Remove the dipstick and tube (Fig. 48).

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Fig. 48: Removing Dipstick & Tube

Courtesy of DAIMLERCHRYSLER CORP.

7. Remove exhaust manifold(s). (Refer to EXHAUST MANIFOLD - RIGHT and EXHAUST

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MANIFOLD - LEFT)
8. Remove rocker arm and shaft assemblies. (Refer to ROCKER ARMS) Remove push rods and mark
positions to ensure installation in original locations .
9. Remove the eight head bolts from each cylinder head and remove cylinder heads (Fig. 52).

CLEANING

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.

NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Remove all gasket material from cylinder head and block (Refer to STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION). Be careful not to gouge or scratch the aluminum head sealing
surface.

Clean all engine oil passages.

INSPECTION

1. Before cleaning, check for leaks, damage and cracks.

2. Clean cylinder head and oil passages.
3. Check cylinder head for flatness (Fig. 49).

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Fig. 49: Checking Cylinder Head Flatness - Typical

Courtesy of DAIMLERCHRYSLER CORP.

4. Cylinder head must be flat within:

Standard dimension = less than 0.05 mm (0.002 inch.)
Service Limit = 0.2 mm (0.008 inch.)
Grinding Limit = Maximum of 0.2 mm (0.008 inch.) is permitted.

CAUTION: 0.20 mm (0.008 in.) MAX is a combined total dimension of the

stock removal limit from cylinder head and block top surface
(Deck) together.

INSTALLATION - CYLINDER HEAD

1. Clean all sealing surfaces of engine block and cylinder heads. (Refer to CLEANING)
2. Position new gasket(s) on engine block (Fig. 50). The left bank gasket is identified with the "L" stamped
in the exposed area of the gasket located at front of engine (shown in (Fig. 50)). The right bank gasket is
identified with a "R" stamped in the exposed area of the gasket also, but is located at the rear of the
engine.

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Fig. 50: Installing Head Gasket

Courtesy of DAIMLERCHRYSLER CORP.

3. The cylinder head bolts are torqued using the torque yield method, they should be examined
BEFORE reuse. If the threads are necked down, the bolts must be replaced (Fig. 51).

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Fig. 51: Checking Bolts For Stretching

Courtesy of DAIMLERCHRYSLER CORP.

4. Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not
contact the scale the bolt should be replaced.
5. Tighten the cylinder head bolts 1-8 in the sequence shown in (Fig. 52). Using the 4 step torque turn
method, tighten according to the following values:
Step 1: Bolts 1-8 to 61 N.m (45 ft. lbs.)
Step 2: Bolts 1-8 to 88 N.m (65 ft. lbs.)
Step 3: Bolts 1-8 (again) to 88 N.m (65 ft. lbs.)
Step 4: Bolts 1-8 turn an additional 1/4 Turn.

(Do not use a torque wrench for this step.)

NOTE: Bolt torque after 1/4 turn should be over 122 N.m (90 ft. lbs.). If not,
replace the bolt.

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Fig. 52: Identifying Cylinder Head Tightening Sequence

Courtesy of DAIMLERCHRYSLER CORP.

6. Inspect push rods and replace worn or bent rods.

7. Install the push rods.
8. Install the rocker arm and shaft assemblies. (Refer to ROCKER ARMS)
9. Install the cylinder head covers. (Refer to CYLINDER HEAD COVER(S))
10. Install the exhaust manifolds. (Refer to EXHAUST MANIFOLD - RIGHT and EXHAUST
MANIFOLD - LEFT)
11. Install new O-ring on dipstick tube. Install dipstick tube assembly (Fig. 48).
12. Install the spark plugs.
13. Install upper and lower intake manifolds. (Refer to INTAKE MANIFOLD)
14. Fill the cooling system. (Refer to STANDARD PROCEDURE - COOLING SYSTEM FILLING )
15. Connect negative cable to battery.

CYLINDER HEAD COVER(S)

DESCRIPTION

The cylinder head covers are made of stamped steel. The covers are sealed with steel reinforced silicon rubber
gaskets. The cylinder head cover uses rubber isolators at each fastener location (Fig. 53).

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Fig. 53: Removing Cylinder Head Cover

Courtesy of DAIMLERCHRYSLER CORP.

NOTE: Due to the tight packaging near the cylinder head covers, which makes spill
clean-up difficult, a spill during an engine oil change may be misinterpreted as
an oil leak. When investigating an oil leak in the location of the cylinder head
covers and intake manifold, follow the procedure found in Oil Leak Diagnosis
(Refer to DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION) for
determining the source of a leak.

CYLINDER HEAD COVER-RIGHT

REMOVAL

1. Disconnect negative cable from battery.

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2. Remove the wiper module. (Refer to WIPER MODULE )

3. Disconnect spark plug wires from plugs.
4. Disconnect PCV hose from cylinder head cover (Fig. 54).

Fig. 54: Removing PCV Hose

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Courtesy of DAIMLERCHRYSLER CORP.

5. Remove cylinder head cover bolts.

6. Remove cylinder head cover and gasket (Fig. 53).

INSTALLATION

1. Clean cylinder head and cover mating surfaces. Inspect cylinder head cover surface for flatness. Replace
gasket as necessary.
2. Inspect seal on the cover bolt for wear or damage (Fig. 55). Replace bolt assembly as necessary.

NOTE: The cylinder head cover bolts contain a torque limiter sleeve and a seal
(Fig. 55). The seal and torque sleeve is replaced with the bolt.

Fig. 55: Removing Cylinder Head Cover Gasket

Courtesy of DAIMLERCHRYSLER CORP.

3. Assemble gasket to cylinder cover by inserting the bolt assemblies through each bolt hole on the cover

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and gasket (Fig. 55).

4. Install cylinder head cover and bolts (Fig. 56).

Fig. 56: Installing Cylinder Head Cover

Courtesy of DAIMLERCHRYSLER CORP.

5. Tighten cylinder head cover bolts to 12 N.m (105 in. lbs.) (Fig. 56).
6. Connect PCV hose to cylinder head cover.
7. Connect spark plug wires to spark plugs.
8. Install wiper module. (Refer to WIPER MODULE )
9. Connect negative cable to battery.

CYLINDER HEAD COVER-LEFT

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REMOVAL

1. Disconnect spark plug wires from spark plugs.

2. Disconnect crankcase vent hose from cylinder head cover.
3. Remove cylinder head cover bolts.
4. Remove cylinder head cover and gasket.

INSTALLATION

1. Clean cylinder head and cover mating surfaces. Inspect cylinder head cover surface for flatness. Replace
gasket as necessary.
2. Assemble gasket to cylinder cover by inserting the fasteners through each bolt hole on cover and gasket
(Fig. 55).
3. Install the cylinder head cover and bolts (Fig. 56).
4. Tighten cylinder head cover bolts to 12 N.m (105 in. lbs.) (Fig. 56).
5. Connect crankcase vent hose.
6. Connect spark plug wires to spark plugs.

INTAKE/EXHAUST VALVES & SEATS

DESCRIPTION

The valves have chrome plated valve stems with four-bead lock grooves. The valve stem seals are made of
Viton rubber.

OPERATION

The two valves per cylinder are opened using hydraulic lifters, push rods, and rocker arms.

STANDARD PROCEDURE - REFACING VALVES AND VALVE SEATS

The intake and exhaust valves and seats are machined to specific angles (Fig. 57).

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Fig. 57: Checking Valve Face And Seat

Courtesy of DAIMLERCHRYSLER CORP.

VALVES

1. Inspect the remaining margin after the valves are refaced (Fig. 58). (Refer to SPECIFICATIONS)

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Fig. 58: Inspecting Valve Margin

Courtesy of DAIMLERCHRYSLER CORP.

VALVE SEATS

CAUTION: Remove metal from valve seat only. Do not remove material from cylinder
head (Fig. 59).

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Fig. 59: Refacing Valve Seats

Courtesy of DAIMLERCHRYSLER CORP.

1. When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating
stones. A true and complete surface must be obtained.
2. Measure the concentricity of valve seat using dial indicator (Fig. 60). Total runout should not exceed
0.051 mm (0.002 in.) total indicator reading.

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Fig. 60: Measuring Valve Seat Runout

Courtesy of DAIMLERCHRYSLER CORP.

3. Inspect the valve seat using Prussian blue to determine where the valve contacts the seat. To do this, coat
valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If
the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top
edge of valve face, lower valve seat with a 15 degree stone. If the blue is transferred to the bottom edge of
valve face raise valve seat with a 65 degrees stone.

NOTE: Valve seats which are worn or burned can be reworked, provided that
correct angle and seat width are maintained. Otherwise cylinder head must
be replaced.

4. When seat is properly positioned the width of intake and exhaust seats should be 1.50-2.00 mm (0.059-
0.078 in.) (Fig. 57).
5. After grinding the valve seats or faces, install the valve in cylinder head and check valve installed height

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by measuring from valve tip to spring seat (Fig. 61). Remove valve from cylinder head and grind valve
tip until within specifications. Check valve tip for scoring. The tip chamfer should be reground (if
necessary) to prevent seal damage when the valve is installed.

Fig. 61: Checking Valve And Spring Installed Height

Courtesy of DAIMLERCHRYSLER CORP.

6. Check the valve spring installed height after refacing the valve and seat (Fig. 61).

If valves and/or seats are reground, measure the installed height of springs (Fig. 61), make sure
measurements are taken from top of spring seat to the bottom surface of spring retainer. If height
is greater than specifications, install a 0.794 mm (0.0312 in.) spacer in head counterbore to bring
spring height back within specifications.

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REMOVAL

1. With cylinder head removed, compress valve springs using Valve Spring Compressor Tool C-3422-D
with adapter 8464 (Refer to SPECIAL TOOLS).
2. Remove valve retaining locks.
3. Slowly release valve spring compressor. Remove valve spring retainer, valve spring, and valve stem seal.
4. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the
valve guides . Identify valves to insure installation in original location.

CLEANING

1. Clean all valves thoroughly and discard burned, warped and cracked valves.

INSPECTION

VALVES

1. Clean and inspect valves thoroughly. Replace burned, warped and cracked valves.
2. Measure valve stems for wear (Fig. 62). For valve specifications, (Refer to SPECIAL TOOLS).

NOTE: Valve stems are chrome plated and should not be polished (Fig. 62).

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Fig. 62: Identifying Intake And Exhaust Valves

Courtesy of DAIMLERCHRYSLER CORP.

VALVE GUIDES

1. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
2. Measure valve stem-to-guide clearance as follows:
3. Install valve into cylinder head so it is 15 mm (0.590 inch.) off the valve seat. A small piece of hose may
be used to hold valve in place.
4. Attach dial indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured
(Fig. 63).

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Fig. 63: Measuring Valve Guide Wear

Courtesy of DAIMLERCHRYSLER CORP.

5. Move valve to and from the indicator. For clerance specifications, (Refer to SPECIFICATIONS).

NOTE: Replace cylinder head if stem-to-guide clearance exceeds specifications,

or if guide is loose in cylinder head.

INSTALLATION

1. Coat valve stems with clean engine oil and insert them in cylinder head.
2. Install valve spring seat on head (Fig. 64).

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Fig. 64: Identifying Valve Components

Courtesy of DAIMLERCHRYSLER CORP.

3. Install new seals on all valve stems and over valve guides (Fig. 64). Install valve springs and valve
retainers (Fig. 64).
4. Install the valve springs. (Refer to VALVE SPRINGS)

VALVE SPRINGS
DESCRIPTION

There are two interchangeable, floating (spring rotates during operation), valve spring designs. Type A may be
identified by the counterclockwise (spring spirals down and to the left) appearance, And Type B may be
identified by the clockwise (spring spirals down and to the right) appearance. Both of the valve springs are a
bee-hive shaped design but have different specifications (Fig. 65). The springs are seated on a steel washer on
the cylinder head with retainers and locks retaining the springs (Fig. 64). The springs are installed with the
smaller diameter against spring retainer (Fig. 65).

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Fig. 65: Identifying Valve Spring - Type A

Courtesy of DAIMLERCHRYSLER CORP.

OPERATION

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The valve spring returns the valve against its seat for a positive seal of the combustion chamber.

REMOVAL

REMOVAL - CYLINDER HEAD OFF

1. With the cylinder head on a bench, position Special Tool C-3422-D with 8464 Adapter on the valve and
spring retainer (Fig. 66).

Fig. 66: Removing/Installing Valve Spring

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Courtesy of DAIMLERCHRYSLER CORP.

2. Compress the spring only enough to remove the valve retainer locks.
3. Slowly release the spring tension and remove the valve spring and retainer.
4. For removal of the valve stem seal (Refer to VALVE STEM SEALS).

REMOVAL - CYLINDER HEAD ON

1. Disconnect negative cable from battery.

2. Remove spark plug wires and all spark plugs.
3. Remove cylinder head cover(s). (Refer to CYLINDER HEAD COVER(S))
4. Remove rocker arms and shaft. (Refer to ROCKER ARMS)
5. Rotate engine until the piston in the cylinder bore requiring spring removal is at TDC.
6. Install Special Tool 8453 to the cylinder head (Fig. 67). Tighten the attaching bolts to 23 N.m (200 in.
lbs.).

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Fig. 67: Removing/Installing Valve Spring (Head On)

Courtesy of DAIMLERCHRYSLER CORP.

7. Install a spark plug adapter in the spark plug hole. Connect air hose that can supply 620.5-689 kPa (90-
100 psi) of air pressure to adapter. This is to hold valves in place while servicing components.
8. Locate the forcing screw and spring retainer adapter assembly over the spring requiring removal (Fig.
67).
9. Slowly turn the forcing screw clockwise (compressing the valve spring) until the valve keepers can be
removed.
10. Turn forcing screw counterclockwise to relieve spring tension. Remove retainer and valve spring.
11. Repeat procedure for each cylinder requiring valve spring removal.

INSPECTION

NOTE: The are two different types of valve springs used that are interchangable, but

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have different specifications(Refer to DESCRIPTION).

Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be
tested (Fig. 68). As an example; the compression length of a spring to be tested is 38.00 mm (1.496 in.). Turn
the table of Tool C-647 until surface is in line with the 38.00 mm (1.496 in.) mark on the threaded stud and the
zero mark on the front. Place spring over stud on the table and lift compressing 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
adjustments. Refer to SPECIFICATIONS to obtain specified height and allowable tensions. Replace any
springs that do not meet specifications.

Fig. 68: Testing Valve Spring

Courtesy of DAIMLERCHRYSLER CORP.

INSTALLATION

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INSTALLATION - CYLINDER HEAD OFF

1. If removed, install a new valve stem seal (Refer to VALVE STEM SEALS).
2. Position valve spring and retainer on spring seat.
3. Using Special Tool C-3422-D with 8464 Adapter (Fig. 66), compress the spring only enough to install the
valve retainer locks. Install valve retainer locks.
4. Slowly release the spring tension. Ensure the retainer locks are seated properly (Fig. 69).

Fig. 69: Installing Valve Spring Using Special Tool

Courtesy of DAIMLERCHRYSLER CORP.

INSTALLATION - CYLINDER HEAD ON

1. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve
stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress

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the spring only enough to install the locks (Fig. 69).

CAUTION: Do not pinch seal between retainer and top of valve guide.

2. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6. Make
sure piston in cylinder is at TDC on the valve spring that is being covered.
3. Remove spark plug adapter tool.
4. Install rocker arms and shaft assembly. (Refer to ROCKER ARMS)
5. Install cylinder head covers. (Refer to CYLINDER HEAD COVER(S))
6. Install spark plugs and connect wires.
7. Connect negative cable to battery.

ROCKER ARMS
DESCRIPTION

DESCRIPTION - ROCKER ARMS

The rocker arms are installed on the rocker arm shaft. The rocker arms and shaft assembly is attached to the
cylinder head with seven billeted bolts and retainers. The rocker arms are made of stamped steel.

DESCRIPTION - PUSHRODS

The pushrods are made of steel and are a hollow design. The pushrods are positioned between the hydraulic
lifter and the rocker arm.

OPERATION

OPERATION - ROCKER ARMS

The rocker arm pivots on the rocker shaft. Rocker arms are used to translate up and down motions provided by
the camshaft, hydraulic lifter, and pushrod on one end, into a down and up motions on the valve stem on the
opposing end.

OPERATION - PUSHRODS

The pushrod is a solid link between the hydraulic lifter and the rocker arm. Also, the pushrod supplies engine
oil from the hydraulic lifter to the rocker arm.

REMOVAL - ROCKER ARMS AND SHAFT

1. Remove the cylinder head cover(s). (Refer to CYLINDER HEAD COVER(S))

NOTE: Rocker arm shaft bolts are captured to the shaft.

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2. Loosen the rocker shaft bolts (Fig. 70), rotating one turn each, until all valve spring pressure is relieved.

Fig. 70: Removing Rocker Arms And Shaft Assembly

Courtesy of DAIMLERCHRYSLER CORP.

3. Remove the rocker arms and shaft assembly (Fig. 70).

4. For rocker arm disassembly procedures, (Refer to ROCKER ARMS).

DISASSEMBLY - ROCKER ARMS AND SHAFT

CAUTION: Do not attempt to drive the billeted bolt from the rocker shaft. This can
damage the rocker arm retainer and bolt assembly.

1. Remove the rocker arm retainer and bolt by performing the following procedure:
a. Using adjustable pliers, grip the edges of the retainer (Fig. 71).

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Fig. 71: Removing Rocker Arm Retainer

Courtesy of DAIMLERCHRYSLER CORP.

b. Apply an upward force with a slight rocking motion until the retainer disengages from shaft (Fig.
71).
2. Remove rocker arms (Fig. 72). Identify the component locations for reassembly in original locations.

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Fig. 72: Positioning Rocker Arm And Shaft Assemblies On Pedestal Mounts
Courtesy of DAIMLERCHRYSLER CORP.

ASSEMBLY - ROCKER ARMS AND SHAFT

1. Install rocker arms on the shaft (Fig. 72). Install in the orginal positions if re-used. Ensure the rocker
shaft, all the retainers and washers are properly positioned and installed in the correct locations (Fig. 72).
2. Install rocker arms and shaft to the cylinder head. (Refer to ROCKER ARMS)

INSTALLATION - ROCKER ARMS AND SHAFT

CAUTION: Ensure the longer shaft retaining bolt is installed in the proper location on
the rocker shaft. (Refer to ROCKER ARMS)

1. Position the rocker arm and shaft assemblies on the pedestal mounts.

CAUTION: Ensure all pushrods are properly located on the lifter and the rocker
arm socket.

2. Align each rocker arm socket with each push rod end.

CAUTION: The rocker arm shaft should be tightened down slowly, starting with
the center bolts. Allow 20 minutes lifter bleed down time after

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installation of the rocker shafts before engine operation.

3. Slowly tighten rocker shaft bolts evenly until shaft is seated. Tighten bolts to 23 N.m (200 in. lbs.) (Fig.
73).

Fig. 73: Tightening Rocker Arms And Shaft Bolts

Courtesy of DAIMLERCHRYSLER CORP.

4. Install the cylinder head cover(s). (Refer to CYLINDER HEAD COVER(S))

VALVE STEM SEALS

DESCRIPTION

The valve stem seals are made of Viton rubber. The seals are positioned over the valve stem and seated on the
valve guide (Fig. 74).

REMOVAL

1. Remove the valve springs. (Refer to VALVE SPRINGS)

2. Remove the valve stem seal (Fig. 74).

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Fig. 74: Removing Valve Stem Seal

Courtesy of DAIMLERCHRYSLER CORP.

INSTALLATION

1. Install the valve stem seal squarely over the valve guide, using the valve stem as a guide (Fig. 74). Do not
force the seal against top of the valve guide.
2. Install the valve spring. (Refer to VALVE SPRINGS)

ENGINE BLOCK
DESCRIPTION

The cylinder block is made of cast iron and is a deep skirt design.

STANDARD PROCEDURE - CYLINDER BORE HONING

1. Used carefully, the cylinder bore resizing hone, recommended tool C-823 or equivalent, equipped with
220 grit stones, is the best tool for this honing procedure. In addition to deglazing, it will reduce taper and
out-of-round as well as removing light scuffing, scoring or scratches. Usually a few strokes will clean up
a bore and maintain the required limits.

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2. Deglazing of the cylinder walls may be done using a cylinder surfacing hone, recommended tool C-3501
or equivalent, equipped with 280 grit stones, if the cylinder bore is straight and round. 20-60 strokes
depending on the bore condition, will be sufficient to provide a satisfactory surface. Use a light honing
oil. Do not use engine or transmission oil, mineral spirits or kerosene. Inspect cylinder walls after
each 20 strokes.
3. Honing should be done by moving the hone up and down fast enough to get a cross-hatch pattern. When
hone marks intersect at 40-60 degrees, the cross hatch angle is most satisfactory for proper seating of
rings (Fig. 75).

Fig. 75: Identifying Cylinder Bore Cross-Hatch Pattern

Courtesy of DAIMLERCHRYSLER CORP.

4. A controlled hone motor speed between 200-300 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 40-60 degree
angle. Faster up and down strokes increase the cross-hatch angle.

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CAUTION: Ensure all abrasives are removed from engine parts after honing. It is
recommended that a solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore can be
considered clean when it can be wiped clean with a white cloth and
cloth remains clean. Oil the bores after cleaning to prevent rusting.

5. After honing, it is necessary that the block be cleaned again to remove all traces of abrasive.

CLEANING

Clean cylinder block thoroughly using a suitable cleaning solvent.

INSPECTION

ENGINE BLOCK

1. Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking.
2. If new core plugs are to be installed, (Refer to STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS).
3. Examine block and cylinder bores for cracks or fractures.
4. Check block deck surfaces for flatness. Deck surface must be within service limit of 0.1 mm (0.004 in.).

CYLINDER BORE

NOTE: The cylinder bores should be measured at normal room temperature, 21 °C (70°
F).

The cylinder walls should be checked for out-of-round and taper with Tool C119 or equivalent (Fig. 76) (Refer
to SPECIFICATIONS). If the cylinder walls are badly scuffed or scored, the cylinder block should be
replaced, and new pistons and rings fitted.

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Fig. 76: Checking Cylinder Bore Size

Courtesy of DAIMLERCHRYSLER CORP.

Measure the cylinder bore at three levels in directions A and B (Fig. 76). Top measurement should be 10 mm
(3/8 in.) down and bottom measurement should be 10 mm (3/8 in.) up from bottom of bore. (Refer to
SPECIFICATIONS).

HYDRAULIC LIFTERS (CAM IN BLOCK)

DESCRIPTION

The hydraulic lifters are a roller type design and are positioned in the cylinder block. The lifters are aligned and
retained by a yoke and a retainer (Fig. 77).

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Lifter alignment is maintained by machined flats on lifter body. Lifters are fitted in pairs into six aligning yokes.
The aligning yokes are secured by a yoke retainer (Fig. 77).

DIAGNOSIS AND TESTING - HYDRAULIC LIFTERS

HYDRAULIC LIFTERS DIAGNOSIS - PRELIMINARY STEP

Before disassembling any part of the engine to correct lifter noise, check the engine oil pressure. (Refer to
DIAGNOSIS AND TESTING - ENGINE OIL PRESSURE).

Check engine oil level. The oil level in the pan should never be above the MAX mark on dipstick, or below the
MIN mark. Either of these two conditions could cause noisy lifters.

OIL LEVEL TOO HIGH

If oil level is above the MAX mark on dipstick, it is possible for the connecting rods to dip into the oil while
engine is running and create foaming. Foam in oil pan would be fed to the hydraulic lifters by the oil pump
causing them to become soft and allow valves to seat noisily.

OIL LEVEL TOO LOW

Low oil level may allow pump to take in air which when fed to the lifters it causes them to become soft and
allows valves to seat noisily. Any leaks on intake side of pump, through which air can be drawn, will create the
same lifter noise. Check the lubrication system from the intake strainer to the oil pump cover, including the
relief valve retainer cap. When lifter noise is due to aeration, it may be intermittent or constant, and usually
more than one lifter will be noisy. When oil level and leaks have been corrected, the engine should be operated
at fast idle to allow all of the air inside of the lifters to be bled out.

VALVE TRAIN NOISE

To determine source of valve train noise, operate engine at idle with cylinder head covers removed and listen
for source of the noise.

NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy lifters.
If such is the case, noise may be dampened by applying side thrust on the valve
spring. If noise is not appreciably reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets and push rod ends for wear.

Valve lifter noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leak-
down around the unit plunger which will necessitate replacing the lifter, or by the plunger partially sticking in
the lifter body cylinder. A heavy click is caused either by a lifter check valve not seating, or by foreign particles
becoming wedged between the plunger and the lifter body causing the plunger to stick in the down position.
This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve
closes. In either case, lifter assembly should be removed for inspection.

REMOVAL

1. Remove the cylinder head(s). (Refer to CYLINDER HEAD).

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2. Remove the yoke retainer and aligning yokes (Fig. 77).

Fig. 77: Lifter Aligning Yoke And Retainer

Courtesy of DAIMLERCHRYSLER CORP.

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3. Remove the hydraulic lifters. If necessary use Special Tool C-4129, or equivalent to remove lifters from
bores. If lifters are to be reused, identify each lifter to ensure installation in original location.

INSTALLATION

1. Lubricate the lifters with engine oil.

NOTE: Position the lifter in bore with the lubrication hole facing upward (Fig. 78).

Fig. 78: Identifying Lifter Lubrication Hole

Courtesy of DAIMLERCHRYSLER CORP.

2. Install the hydraulic lifters with the lubrication hole facing upward towards middle of block (Fig. 78).
Install lifters in original positions, if reused.
3. Install lifter aligning yokes (Fig. 77).

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4. Install yoke retainer and torque screws to 12 N.m (105 in. lbs.) (Fig. 77).
5. Install the cylinder heads. (Refer to CYLINDER HEAD).

CAUTION: To prevent damage to valve mechanism, engine must not be run

above fast idle until all hydraulic lifters have filled with oil and have
become quiet.

6. Start and operate engine. Warm up to normal operating temperature.

CAMSHAFT & BEARINGS (IN BLOCK)

DESCRIPTION

The nodular iron camshaft is mounted in the engine block and supported with four steel backed aluminum
bearings (Fig. 79). A thrust plate, located in front of the first bearing, is bolted to the block and controls the
camshaft end play (Fig. 79). To distinguish camshafts between the 3.3L and 3.8L engines, a cast-in ring is
located between the rear bearing journal and rear lobe (Fig. 80). The 3.3L engine application is as-cast only.
The 3.8L engine application the cast ring is machined off.

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Fig. 79: Removing & Installing Camshaft And Bearings

Courtesy of DAIMLERCHRYSLER CORP.

Fig. 80: Identifying Camshaft

Courtesy of DAIMLERCHRYSLER CORP.

OPERATION

The camshaft is driven by the crankshaft through a timing chain and sprockets. The camshaft has precisely
machined (egg-shaped) lobes to provide accurate valve timing and duration.

REMOVAL

1. Remove the engine assembly from vehicle (Refer to ENGINE 3.3/3.8L).

2. Remove the cylinder heads (Refer to REMOVAL).
3. Remove the timing chain and camshaft sprocket (Refer to TIMING CHAIN AND SPROCKETS).
4. Remove the hydraulic lifters (Refer to HYDRAULIC LIFTERS (CAM IN BLOCK)). Identify each
tappet for reinstallation in original location.

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5. Remove camshaft thrust plate (Fig. 79).

6. Install a long bolt into front of camshaft to facilitate removal of the camshaft.

NOTE: The camshaft bearings are serviced with the engine block.

7. Remove the camshaft (Fig. 79), being careful not to damage cam bearings with the cam lobes.

INSPECTION

NOTE: If camshaft is replaced due to lobe wear or damage, always replace the
lifters.

Fig. 81: Checking Camshaft For Wear (Typical)

Courtesy of DAIMLERCHRYSLER CORP.

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1. Check the cam lobes and bearing surfaces for abnormal wear and damage (Fig. 81). Replace camshaft as
required.
2. Measure the lobe actual wear (unworn area - wear zone = actual wear) (Fig. 81) and replace camshaft if
out of limit. Standard value is 0.0254 mm (0.001 in.), wear limit is 0.254 mm (0.010 in.).

INSTALLATION

1. Lubricate camshaft lobes and camshaft bearing journals with engine oil.
2. Install a long bolt into the camshaft to assist in the installation of the camshaft.
3. Carefully install the camshaft in engine block.
4. Install camshaft thrust plate and bolts (Fig. 79). Tighten to 12 N.m (105 in. lbs.) torque.
5. Measure camshaft end play. (Refer to SPECIFICATIONS) If not within specifications, replace thrust
plate.
6. Install the timing chain and sprockets. (Refer to TIMING CHAIN AND SPROCKETS).

NOTE: When camshaft is replaced, all of the hydraulic lifters must be replaced
also.

7. Install the hydraulic lifters (Refer to HYDRAULIC LIFTERS (CAM IN BLOCK)). Each lifter reused
must be installed in the same position from which it was removed.
8. Install the timing chain cover. (Refer to TIMING CHAIN COVER).
9. Install the cylinder heads. (Refer to CYLINDER HEAD).
10. Install the cylinder head covers. (Refer to CYLINDER HEAD COVER(S)).
11. Install the lower and upper intake manifolds. (Refer to INTAKE MANIFOLD).
12. Install the engine assembly. (Refer to ENGINE 3.3/3.8L).

PISTON & CONNECTING ROD

DESCRIPTION

The pistons are made of cast aluminum alloy and are a strutless, short skirt design. The piston rings consist of
two compression rings and a three piece oil ring. Piston pins connect the piston to the forged steel connecting
rods. The piston pins are a press fit into the connecting rod.

STANDARD PROCEDURE

STANDARD PROCEDURE - FITTING CONNECTING RODS

NOTE: The connecting rod cap bolts should be examined before reuse. Bolt stretch
can be checked by holding a scale or straight edge against the threads. If all the
threads do not contact the scale the bolt must be replaced (Fig. 82).

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Fig. 82: Check For Stretched (Necked) Bolts

Courtesy of DAIMLERCHRYSLER CORP.

The bearing caps are not interchangeable or reversible, and should be marked at removal to ensure correct
reassembly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods
and caps. Install cap with the tangs on the same side as the rod. For connecting rod bearing fitting (Refer to
CONNECTING ROD BEARINGS). Fit all connecting rods on one bank until complete.

1. Before installing the nuts the threads should be oiled with engine oil.
2. Install nuts finger tight on each bolt then alternately torque each nut to assemble the cap properly.
3. Tighten the nuts to 54 N.m PLUS 1/4 turn (40 ft. lbs. PLUS 1/4 turn).
4. Using a feeler gauge, check connecting rod side clearance (Fig. 83). Refer to Engine Specifications
(Refer to SPECIFICATIONS).

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Fig. 83: Checking Connecting Rod Side Clearance

Courtesy of DAIMLERCHRYSLER CORP.

STANDARD PROCEDURE - FITTING PISTONS

The piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston
pin at size location shown in (Fig. 84). Cylinder bores should be measured halfway down the cylinder bore and
transverse to the engine crankshaft center line shown in (Fig. 85). Refer to Engine Specifications (Refer to
SPECIFICATIONS). Pistons and cylinder bores should be measured at normal room temperature, 21°C
(70°F).

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Fig. 84: Identifying Piston Measurement Locations

Courtesy of DAIMLERCHRYSLER CORP.

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Fig. 85: Checking Cylinder Bore Size

Courtesy of DAIMLERCHRYSLER CORP.

REMOVAL

1. Disconnect negative cable from battery.

2. Remove the cylinder heads. (Refer to CYLINDER HEAD).
3. Remove the oil pan. (Refer to OIL PAN).
4. Remove the top ridge of cylinder bores with a reliable ridge reamer, if necessary, before removing pistons
from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and
connecting rods must be removed from top of cylinder block. When removing piston and
connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is

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centered in cylinder bore.

5. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them, if necessary
(Fig. 86).

Fig. 86: Identify Connecting Rod To Cylinder Identification Mark

Courtesy of DAIMLERCHRYSLER CORP.

6. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts (Fig. 87).

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Fig. 87: Identifying Connecting Rod Protectors

Courtesy of DAIMLERCHRYSLER CORP.

NOTE: Be careful not to nick crankshaft journals.

7. Remove each piston and connecting rod assembly out of the cylinder bore.
8. After removal, install bearing cap on the mating rod.

INSTALLATION

1. Before installing pistons and connecting rod assemblies into the bore, ensure that compression ring gaps
are staggered so that neither is in line with oil ring rail gap (Fig. 88).

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Fig. 88: Identifying Piston Ring End Gap Position

Courtesy of DAIMLERCHRYSLER CORP.

2. Before installing the ring compressor, ensure the oil ring expander ends are butted and the rail gaps
located as shown in (Fig. 88).
3. Lubricate the piston and rings with clean engine oil. Position a ring compressor over the piston and rings,
and tighten the compressor (Fig. 89). Be sure position of rings does not change during this operation.

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Fig. 89: Installing Piston And Connecting Rod

Courtesy of DAIMLERCHRYSLER CORP.

4. Position upper bearing onto connecting rod. Lubricate bearing with oil.
5. Install connecting rod bolt protectors (rubber hose or equivalent) on the connecting rod bolts (Fig. 89).
6. The pistons are marked with a "F" located near the piston pin. Install piston with this mark positioned to
front of engine on both cylinder banks. The connecting rod oil squirt hole faces the major thrust (right)
side of the engine block (Fig. 90).
7. Rotate crankshaft until the connecting rod journal is located in the center of the cylinder bore. Insert
connecting rod and piston into cylinder bore. Carefully guide connecting rod over the crankshaft journal
(Fig. 89).
8. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod
into position on connecting rod journal.
9. Install lower bearing shell and connecting rod cap (Fig. 89). Install nuts on cleaned and oiled rod bolts
and tighten to 54 N-m (40 ft. lbs.) plus 1/4 turn.

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10. Repeat procedure for each piston and connecting rod installation.
11. Install the cylinder heads. (Refer to CYLINDER HEAD).
12. Install the oil pan. (Refer to OIL PAN).
13. Fill engine crankcase with proper oil to correct level.
14. Connect negative cable to battery.

Fig. 90: Identifying Piston and Connecting Rod Positioning (Front View Of Engine)
Courtesy of DAIMLERCHRYSLER CORP.

CONNECTING ROD BEARINGS

STANDARD PROCEDURE - MEASURING CONNECTING ROD BEARING CLEARANCE

The bearing caps are not interchangeable and should be marked at removal to ensure correct assembly. The
bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Install
cap with the tangs on the same side as the rod. Fit all rods on one bank until complete. Connecting rod bearings
are available in the standard size and the following undersizes: 0.025 mm (0.001 in.) and 0.250 mm (0.010 in.).

CAUTION: Install the bearings in pairs. Do not use a new bearing half with an old

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bearing half. Do not file the rods or bearing caps.

Measure connecting rod journal for taper and out-of-round. (Refer to INSPECTION).

The connecting rod bearing clearances can be determined by use of Plastigage or the equivalent. The following
is the recommended procedure for the use of Plastigage:

1. Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke.
2. Remove oil film from surface to be checked. Plastigage is soluble in oil.
3. Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap approximately
6.35 mm (1/4 in.) off center and away from the oil hole. In addition, suspect areas can be checked by
placing Plastigage in that area.
4. Assemble the rod cap with Plastigage in place. Tighten the rod cap to the specified torque. Do not rotate
the crankshaft while assembling the cap or the Plastigage may be smeared, giving inaccurate
results.
5. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the
package (Fig. 91). Locate the band closest to the same width. This band indicates the amount of oil
clearance. Differences in readings between the ends indicate the amount of taper present. Record all
readings taken. Refer to Engine Specifications (Refer to SPECIFICATIONS). Plastigage generally is
accompanied by two scales. One scale is in inches, the other is a metric scale. If the bearing
clearance exceeds wear limit specification, replace the bearing.

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Fig. 91: Measuring Connecting Rod Bearing Clearance

Courtesy of DAIMLERCHRYSLER CORP.

PISTON RINGS
STANDARD PROCEDURE - PISTON RING FITTING

1. Wipe cylinder bore clean. Insert the ring and push down with piston to ensure squareness in bore to
approximately 12 mm (0.50 in.) from top of cylinder bore. Check ring gap with a feeler gauge (Fig. 92).
For clearance specification (Refer to SPECIFICATIONS).

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Fig. 92: Checking Piston Ring Gap

Courtesy of DAIMLERCHRYSLER CORP.

2. Check piston ring to groove side clearance (Fig. 93). For clearance specification (Refer to
SPECIFICATIONS).

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Fig. 93: Checking Piston Ring Side Clearance

Courtesy of DAIMLERCHRYSLER CORP.

REMOVAL

1. Remove piston and connecting rod. (Refer to PISTON & CONNECTING ROD).
2. Remove No. 1 and No. 2 piston rings from piston using a ring expander tool (Fig. 94).

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Fig. 94: Removing Piston Ring

Courtesy of DAIMLERCHRYSLER CORP.

3. Remove upper oil ring side rail (Fig. 95).

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Fig. 95: Removing Oil Ring Side Rail

Courtesy of DAIMLERCHRYSLER CORP.

4. Remove lower oil ring side rail (Fig. 95).

5. Remove oil ring expander (Fig. 95).

INSTALLATION

1. Install rings with manufacturers I.D. mark (if present) facing up, to the top of the piston (Fig. 96).

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Fig. 96: Installing Piston Ring

Courtesy of DAIMLERCHRYSLER CORP.

CAUTION: Install piston rings in the following order:

1. Oil ring expander.

2. Upper oil ring side rail.

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3. Lower oil ring side rail.

4. No. 2 Intermediate piston ring.
5. No. 1 Upper piston ring.
2. Install the side rail by placing one end between the piston ring groove and the expander. Hold end firmly
and press down the portion to be installed until side rail is in position. Do not use a piston ring
expander (Fig. 95).
3. Install upper side rail first and then the lower side rail.
4. Install No. 2 piston ring and then No. 1 piston ring (Fig. 94).
5. Position piston ring end gaps as shown in (Fig. 97).

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Fig. 97: Positioning Piston Ring End Gap

Courtesy of DAIMLERCHRYSLER CORP.

6. Position oil ring expander gap at least 45° From the side rail gaps but not on the piston pin center or on
the thrust direction. Staggering ring gap is important for oil control.

CRANKSHAFT MAIN BEARINGS

STANDARD PROCEDURE - MAIN BEARING FITTING

Bearing caps are not interchangeable and should be marked at removal to insure correct assembly (Fig. 98).
Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of 1, 3 and 4 are
interchangeable. Upper main bearing halves of 1, 3 and 4 are interchangeable.

Fig. 98: Main Bearing Cap Identification

Courtesy of DAIMLERCHRYSLER CORP.

Upper and lower number 2 bearing halves are flanged to carry the crankshaft thrust loads and are NOT
interchangeable with any other bearing halves in the engine (Fig. 99). All bearing cap bolts removed during
service procedures are to be cleaned and lubricated with engine oil before installation. Bearing shells are

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available in standard and the following undersizes: 0.025 mm (0.001 in.) and 0.254 mm (0.010 in). Never install
an undersize bearing that will reduce clearance below specifications.

Fig. 99: Main Bearing Identification

Courtesy of DAIMLERCHRYSLER CORP.

CRANKSHAFT BEARING OIL CLEARANCE

Inspect the crankshaft bearing journals.

Engine crankshaft bearing clearances can be determined by use of Plastigage or the equivalent. The following is
the recommended procedures for the use of Plastigage with the engine in the vehicle or engine on a repair stand.

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PLASTIGAGE METHOD-ENGINE IN-VEHICLE

NOTE: The total clearance of the main bearings can only be determined with the engine
in the vehicle by removing the weight of the crankshaft. This can be
accomplished by either of two following methods:

1. Preferred method:
a. Shim the bearings adjacent to the bearing to be checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be accomplished by placing a minimum of 0.254
mm (0.010 in.) shim (e. g. cardboard, matchbook cover, etc.) between the bearing shell and the
bearing cap on the adjacent bearings and tightening bolts to 14-20 N.m (10-15 ft. lbs.).
When checking #1 main bearing shim #2 main bearing.
When checking #2 main bearing shim #1 & #3 main bearing.
When checking #3 main bearing shim #2 & #4 main bearing.
When checking #4 main bearing shim #3 main bearing.

NOTE: Remove all shims before reassembling engine.

2. Alternative Method:
a. Support the weight of the crankshaft with a jack under the counterweight adjacent to the bearing
being checked.
3. Remove oil film from surface to be checked. Plastigage is soluble in oil.
4. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6.35 mm
(1/4 in.) off center and away from the oil holes (Fig. 100). (In addition, suspected areas can be checked
by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being
checked to the proper specifications.

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Fig. 100: Plastigage Placed In Lower

Courtesy of DAIMLERCHRYSLER CORP.

NOTE: Plastigage is available in a variety of clearance ranges. Use the most

appropriate range for the specifications you are checking.

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Fig. 101: Clearance Measurement

Courtesy of DAIMLERCHRYSLER CORP.

5. Remove the bearing cap and compare the width of the flattened Plastigage (Fig. 101) with the scale
provided on the package. Locate the band closest to the same width. This band shows the amount of
clearance in thousandths. Differences in readings between the ends indicate the amount of taper present.
Record all readings taken. (Refer to SPECIFICATIONS) Plastigage generally is accompanied by two
scales. One scale is in inches, the other is a metric scale.

PLASTIGAGE METHOD-ENGINE OUT-OF-VEHICLE

1. With engine in the inverted position (crankshaft up) and mounted on a repair stand, remove main journal
cap.
2. Remove oil from journal and bearing shell.
3. Cut Plastigage to same length as width of the bearing and place it in parallel with the journal axis (Fig.
100).
4. Carefully install the main bearing cap and tighten the bolts to specified torque.

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CAUTION: Do not rotate crankshaft or the Plastigage will be smeared.

5. Carefully remove the bearing cap and measure the width of the Plastigage at the widest part using the
scale on the Plastigage package (Fig. 101). Refer to Engine Specifications for proper clearances (Refer to
SPECIFICATIONS). If the clearance exceeds the specified limits, replace the main bearing) with the
appropriate size, and if necessary, have the crankshaft machined to next undersize.

REMOVAL - CRANKSHAFT MAIN BEARINGS

1. Remove the oil pan. (Refer to OIL PAN)

2. Identify main bearing caps before removal.
3. Remove bearing caps one at a time. Remove upper half of bearing by inserting Special Main Bearing
Tool C-3059 (Fig. 102) into the oil hole of crankshaft.

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Fig. 102: Removing/Installing Upper Main Bearing With Special Tool C-3059
Courtesy of DAIMLERCHRYSLER CORP.

4. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell.

INSTALLATION - CRANKSHAFT MAIN BEARINGS

NOTE: One main bearing should be selectively fitted while all other main bearing caps
are properly tightened.

1. For main bearing fitting procedure, (Refer to STANDARD PROCEDURE - MAIN BEARING
FITTING).
2. Start bearing in place, and insert Main Bearing Tool C-3059 into oil hole of crankshaft (Fig. 102).

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3. Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Special Main
Bearing Tool C-3059.

NOTE: The main cap bolts should be examined before reuse. Bolt stretch can be
checked by holding a scale or straight edge against the threads. If all the
threads do not contact the scale the bolt must be replaced (Fig. 103).

Fig. 103: Check For Stretched (Necked) Bolts

Courtesy of DAIMLERCHRYSLER CORP.

4. Inspect main cap bolts for stretching (Fig. 103). Replace bolts that are stretched.
5. Install each main cap and tighten bolts finger tight.
6. Tighten number 1, 3 and 4 main cap bolts to 41 N.m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn).
7. Rotate the crankshaft until the number 6 piston is at TDC.
8. To ensure correct thrust bearing alignment the following procedure must be done:
a. Move crankshaft all the way to the rear of its travel.
b. Then, move crankshaft all the way to the front of its travel.
c. Wedge an appropriate tool between the rear of the cylinder block and rear crankshaft
counterweight. This will hold the crankshaft in it's most forward position.
d. Tighten the #2 Thrust Bearing cap bolts to 41 N.m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove the

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holding tool.
9. Install oil pan. (Refer to OIL PAN).
10. Fill engine crankcase with proper oil to correct level.

CRANKSHAFT
DESCRIPTION

DESCRIPTION - 3.3L

The nodular iron crankshaft is supported by four main bearings, with number two position the thrust bearing
(Fig. 106). Crankshaft end sealing is provided by front and rear rubber seals.

DESCRIPTION - 3.8L

The nodular iron crankshaft is supported by four main bearings, with number two position providing thrust
bearing location (Fig. 105). Each main bearing cap has two vertical retaining bolts. The two center main caps
have horizontal bolts to add increased rigidity to the lower engine block (Fig. 105). Crankshaft end sealing is
provided by front and rear rubber seals.

STANDARD PROCEDURE - MEASURING CRANKSHAFT END PLAY

1. Mount a dial indicator to front of engine with the locating probe on nose of crankshaft (Fig. 104).

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Fig. 104: Checking Crankshaft End Play-Typical

Courtesy of DAIMLERCHRYSLER CORP.

2. Move crankshaft all the way to the rear of its travel.

3. Zero the dial indicator.
4. Move crankshaft all the way to the front and read the dial indicator. (Refer to SPECIFICATIONS) for
end play specification.

REMOVAL

1. Remove the engine assembly (Refer to ENGINE 3.3/3.8L).

2. Separate transaxle from engine.
3. Mount engine on an engine stand.
4. Remove the oil filter.
5. Remove the oil pan and oil pick-up tube (Refer to OIL PAN).
6. Remove the timing chain cover (Refer to TIMING CHAIN COVER).
7. Remove timing chain and sprockets (Refer to TIMING CHAIN AND SPROCKETS).
8. Remove crankshaft rear oil seal and retainer (Refer to CRANKSHAFT OIL SEAL - REAR).

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9. Rotate the crankshaft until connecting rod cap is accessible.

10. Mark connecting rod cap position using a suitable marker/scribe tool.
11. Remove connecting rod bearing cap. Use care to prevent damage to the crankshaft bearing surfaces.
12. Repeat removal procedure for each connecting rod cap.

NOTE: Install new cross bolt and washer assembly (3.8L engine only) upon
reassembly.

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Fig. 105: Crankshaft And Block - 3.8L

Courtesy of DAIMLERCHRYSLER CORP.

13. Remove and discard the main bearing cross bolts and washers (3.8L engine only) (Fig. 105).

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14. Remove the main bearing cap bolts

15. Remove the main bearing caps.
16. Remove the crankshaft from engine block (Fig. 106) or (Fig. 105).

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Fig. 106: Crankshaft And Block - 3.3L

Courtesy of DAIMLERCHRYSLER CORP.

INSTALLATION

1. For main bearing identification, refer to (Fig. 99). Lubricate with engine oil and install the crankshaft
main bearing halves in the engine block.
2. Position the crankshaft in engine block (Fig. 106) or (Fig. 105).
3. Perform main bearing fitting procedure (Refer to CRANKSHAFT MAIN BEARINGS).

NOTE: The main cap bolts should be examined before reuse. Bolt stretch can be
checked by holding a scale or straight edge against the threads. If all the
threads do not contact the scale the bolt must be replaced (Fig. 107).

Fig. 107: Check For Stretched (Necked) Bolts

Courtesy of DAIMLERCHRYSLER CORP.

4. Inspect main cap bolts for stretching (Fig. 107). Replace bolts that are stretched.
5. Install the main bearing caps and bolts. Tighten bolts to 41 N.m (30 ft. lbs.) plus Y° turn.

NOTE: Install new cross bolt and washer assembly (3.8L engine only) upon

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reassembly.

6. Install and tighten the NEW cross bolts and washer assemblies (3.8L engine only) to 61 N-m (45 ft. lbs.)
(Fig. 105).
7. Position and install the connecting rod and bearing caps on the crankshaft (Refer to CONNECTING
ROD BEARINGS).
8. Install the crankshaft rear oil seal (Refer to CRANKSHAFT OIL SEAL - REAR).
9. Install the crankshaft sprocket (Refer to TIMING CHAIN AND SPROCKETS).
10. Install the timing chain and camshaft sprocket (Refer to TIMING CHAIN AND SPROCKETS).
11. Install the timing chain cover (Refer to TIMING CHAIN COVER).
12. Install the oil pick-up tube and oil pan (Refer to OIL PAN).
13. Install the transaxle to the engine.
14. Install the engine assembly (Refer to ENGINE 3.3/3.8L).

CRANKSHAFT OIL SEAL - FRONT

REMOVAL

1. Disconnect negative cable from battery.

2. Raise vehicle on hoist. Remove right wheel and inner splash shield.
3. Remove accessory drive belt. (Refer to REMOVAL & INSTALLATION ).
4. Remove crankshaft damper. (Refer to VIBRATION DAMPER).
5. Position Special Tool 6341A on crankshaft nose. Carefully screw the tool into the seal until it engages
firmly (Fig. 108). Be careful not to damage that crankshaft seal surface of cover

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Fig. 108: Engaging Tool Into Seal

Courtesy of DAIMLERCHRYSLER CORP.

6. Remove oil seal by turning the forcing screw until the seal disengages from the cover (Fig. 109).

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Fig. 109: Removing Crankshaft Front Seal

Courtesy of DAIMLERCHRYSLER CORP.

INSTALLATION

1. Position Special Tool C-4992-2 Guide, on the crankshaft nose (Fig. 110).

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Fig. 110: Installing Crankshaft Front Seal

Courtesy of DAIMLERCHRYSLER CORP.

2. Position new seal over the guide with the seal spring in the direction of the engine front cover (Fig. 110).
3. Install seal using Special Tool C-4992-1 until seal is flush with cover. (Fig. 110).
4. Install crankshaft damper. (Refer to VIBRATION DAMPER).
5. Install accessory drive belt. (Refer to REMOVAL & INSTALLATION ).
6. Install inner splash shield and right front wheel.
7. Lower vehicle and connect negative cable to battery.

CRANKSHAFT OIL SEAL - REAR

REMOVAL

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1. Remove the transaxle. Refer to appropriate TRANSAXLE AND POWER TRANSFER UNIT article for
procedure.
2. Remove the flex plate. (Refer to FLEX PLATE).

CAUTION: Do not permit the pry tool blade to contact crankshaft seal surface.
Contact of the pry tool blade against crankshaft edge (chamfer) is
permitted.

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Fig. 111: Crankshaft Rear Oil Seal - Removal

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Courtesy of DAIMLERCHRYSLER CORP.

3. Insert a 3/16 flat bladed pry tool between the dust lip and the metal case of the crankshaft seal. Angle the
pry tool (Fig. 111) through the dust lip against metal case of the seal. Pry out seal.

INSTALLATION

CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup

with 400 grit sand paper to prevent seal damage during installation of new
seal.

1. Place Special Tool 6926-1 magnetic pilot tool on crankshaft (Fig. 112).

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Fig. 112: Installing Rear Crankshaft Oil Seal

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Courtesy of DAIMLERCHRYSLER CORP.

2. Place seal over Special Tool 6926-1 Pilot. Using Special Tool 6926-2 Installer with C-4171 Handle, drive
seal into the retainer housing (Fig. 112).
3. Install the flex plate. (Refer to FLEX PLATE).
4. Install transaxle. Refer to appropriate TRANSAXLE AND POWER TRANSFER UNIT article for
procedure.

CRANKSHAFT REAR OIL SEAL RETAINER

REMOVAL

1. Remove crankshaft rear oil seal (Refer to CRANKSHAFT OIL SEAL - REAR).
2. Remove oil pan (Refer to OIL PAN).
3. Remove oil seal retainer screws (Fig. 113).

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Fig. 113: Crankshaft Rear Oil Seal

Courtesy of DAIMLERCHRYSLER CORP.

4. Remove oil seal retainer (Fig. 113).

5. Clean engine block and retainer of oil and gasket material. Make sure surfaces are clean and free of oil.

INSTALLATION

1. Position new gasket and install retainer on block (Fig. 113). Tighten attaching screws to 12 N-m (105 in.
lbs.).
2. Install oil pan (Refer to OIL PAN).
3. Install oil seal (Refer to CRANKSHAFT OIL SEAL - REAR).

VIBRATION DAMPER
REMOVAL

1. Disconnect negative cable from battery.

2. Raise vehicle on hoist.
3. Remove the right front wheel and inner splash shield.
4. Remove the accessory drive belt. (Refer to REMOVAL & INSTALLATION ).
5. Remove vibration damper bolt.
6. Insert Special Tool 8450 into crankshaft nose (Fig. 114).

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Fig. 114: Removing Vibration Damper

Courtesy of DAIMLERCHRYSLER CORP.

7. Position 3-jaw puller Special Tool 1026 on damper as shown in (Fig. 114). Turn puller forcing screw
until damper releases from crankshaft.
8. Remove the crankshaft vibration damper.

INSTALLATION

NOTE: To minimize friction and prolong tool life, lubricate the threads on the
forcing screw of Special Tool 8452.

1. Install crankshaft vibration damper using the forcing screw, nut, and thrust bearing/washer from Special
Tool 8452 (Fig. 115).
2. Position vibration damper on crankshaft.
3. Screw Special Tool 8452 into crankshaft until the bolt seats. Turn the nut to install damper until it seats

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fully.

Fig. 115: Installing Vibration Damper

Courtesy of DAIMLERCHRYSLER CORP.

4. Remove Special Tool 8452.

5. Install vibration damper bolt. Torque bolt to 54 N.m (40 ft. lbs.).
6. Install the accessory drive belt. (Refer to REMOVAL & INSTALLATION ).
7. Install inner splash shield and right front wheel.
8. Connect negative cable to battery.

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FLEX PLATE
REMOVAL

1. Remove the transaxle (Refer to REMOVAL & OVERHAUL & INSTALLATION - 41TE & 41AE
AUTOMATIC TRANSMISSION ).
2. Remove flex plate attaching bolts.
3. Remove the flex plate (Fig. 116).

Fig. 116: Removing/Installing Flex Plate

Courtesy of DAIMLERCHRYSLER CORP.

INSTALLATION

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1. Position flex plate with backing plate on the crankshaft (Fig. 116).
2. Apply Mopar(r) Lock & Seal Adhesive to the flex plate bolts.
3. Install flex plate bolts (Fig. 116). Tighten bolts to 95 N.m (70 ft. lbs.).
4. Install the transaxle (Refer to REMOVAL & OVERHAUL & INSTALLATION - 41TE & 41AE
AUTOMATIC TRANSMISSION ).

ENGINE MOUNTING
DESCRIPTION

The engine mounting system consist of four mounts; right and a left side support the powertrain, and a front and
a rear mount control powertrain torque. The right side mount is a hydro-type (Fig. 117), all others are of molded
rubber material.

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Fig. 117: Identifying Engine Hydro-type Mount - Right Side

Courtesy of DAIMLERCHRYSLER CORP.

FRONT MOUNT

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REMOVAL

1. Support the engine and transmission assembly with a floor jack so it will not rotate.
2. Remove the front engine mount through bolt from the insulator and front crossmember mounting bracket
(Fig. 118).

Fig. 118: Removing Engine Mounting - Front

Courtesy of DAIMLERCHRYSLER CORP.

3. Remove six screws from air dam to allow access to the front mount screws.
4. Remove the front engine mount screws and remove the insulator assembly (Fig. 118).
5. Remove the front mounting bracket, if necessary (Fig. 118).

INSTALLATION

1. Install the front mounting bracket, if removed (Fig. 118).

2. Install the front engine mount through bolt from the insulator and front crossmember mounting bracket
(Fig. 118).
3. Install the insulator assembly and mounting screws (Fig. 118).

LEFT MOUNT

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REMOVAL

1. Raise the vehicle on hoist.

2. Remove the left front wheel.
3. Remove the left mount through bolt access cover.
4. Support the transaxle with a suitable jack.
5. Remove the engine front mount through bolt to allow left mount removal clearance (Fig. 118).
6. Remove the left mount through frame rail bolt (Fig. 119).

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Fig. 119: Removing Left Mount To Bracket

Courtesy of DAIMLERCHRYSLER CORP.

7. Lower transaxle for access to horizontal bolts.

8. Remove the horizontal bolts from the mount to the transaxle (Fig. 120).

Fig. 120: Removing Left Mount - 41TE Transaxle

Courtesy of DAIMLERCHRYSLER CORP.

NOTE: To remove mount, additional lowering of transaxle may be required.

9. Remove left mount.

INSTALLATION

1. Install left mount on transaxle (Fig. 120).

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2. Raise transaxle with jack until left mount is in position.

3. Install left mount through bolt (Fig. 119).
4. Install left mount through bolt access cover.
5. Install front mount through bolt (Fig. 118).
6. Install left front wheel.
7. Lower vehicle.

REAR MOUNT
REMOVAL

1. Raise vehicle on hoist.

2. Remove the rear mount heat shield (Fig. 121).

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Fig. 121: Removing Rear Mount Heat Shield

Courtesy of DAIMLERCHRYSLER CORP.

3. Remove the through bolt from the mount and rear mount bracket (Fig. 122).

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Fig. 122: Removing Rear Mount

Courtesy of DAIMLERCHRYSLER CORP.

4. Remove the mount bolts (Fig. 122).

5. Remove the rear mount (Fig. 122).
6. For rear mount bracket removal, remove the bolts attaching bracket to transaxle (Fig. 123).

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Fig. 123: Removing Rear Mount Bracket - (All Engines)

Courtesy of DAIMLERCHRYSLER CORP.

7. Remove rear mount bracket.

INSTALLATION

1. Install rear mount bracket, if removed (Fig. 123).

2. Install the rear mount and bolts (Fig. 122). Tighten bolts to 54 N-m (40 ft. lbs.).
3. Install the mount through bolt to the mount and bracket (Fig. 122). Tighten through bolt to 54 N.m (40 ft.
lbs.).
4. Install the rear mount heat shield (Fig. 121).
5. Lower vehicle on hoist.

RIGHT MOUNT
REMOVAL

1. Remove air cleaner housing lid and clean air hose from throttle body.
2. Remove air cleaner element and housing.
3. Disconnect make-up air hose from cylinder head cover.
4. Remove the load on the right engine mount by carefully supporting the engine assembly with a floor jack.

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5. Disconnect electrical harness support clips from engine mount bracket.

6. Remove the bolts attaching the engine mount to the frame rail (Fig. 124).

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Fig. 124: Removing Right Engine Mount

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Courtesy of DAIMLERCHRYSLER CORP.

7. Remove the three bolts attaching the engine mount to the engine bracket (Fig. 124).
8. Remove the right engine mount (Fig. 124).

INSTALLATION

1. Install engine bracket (if removed). Tighten bolts to 33 N.m (24 ft. lbs.).
2. Position right engine mount and install frame rail to mount bolts (Fig. 124). Tighten bolts to 68 N.m (50
ft. lbs.).
3. Install the mount to engine bracket bolts and tighten to 54 N.m (40 ft. lbs.). (Fig. 124)
4. Connect electrical harness support clips to engine mount bracket.
5. Remove jack from under engine.
6. Connect make-up air hose to cylinder head cover.
7. Install air cleaner housing and element.
8. Install air cleaner housing lid and clean air tube to throttle body.

LUBRICATION
DESCRIPTION

The lubrication system is a full flow filtration pressure feed type. The oil pump is mounted in the timing chain
cover and is driven by the crankshaft.

OPERATION

Oil from the oil pan is pumped by a internal gear type oil pump directly coupled to the crankshaft. The pressure
is regulated by a relief valve located in the timing chain cover. The oil is pumped through an oil filter and feeds
a main oil gallery. This oil gallery feeds oil under pressure to the main and rod bearings, camshaft bearings.
Passages in the cylinder block feed oil to the hydraulic lifters and rocker shaft brackets which feeds the rocker
arm pivots (Fig. 125).

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Fig. 125: Identifying Engine Oiling System

Courtesy of DAIMLERCHRYSLER CORP.

DIAGNOSIS AND TESTING - ENGINE OIL PRESSURE

1. Disconnect and remove oil pressure switch (Refer to OIL PRESSURE SWITCH).
2. Install Special Tools C-3292 Gauge with 8406 Adaptor. For Special Tool identification, (Refer to
SPECIAL TOOLS).
3. Start engine and record oil pressure. Refer to Oil Pressure in Engine Specifications for the correct
pressure (Refer to SPECIFICATIONS).

OIL
STANDARD PROCEDURE

STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE

Change engine oil at mileage and time intervals described in the Maintenance Schedule.

WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID
PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL
COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY
WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN

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WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH

PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED
ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT
AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.

Run engine until achieving normal operating temperature.

1. Position the vehicle on a level surface and turn engine off.

2. Open hood, remove oil fill cap (Fig. 126).

Fig. 126: Identifying Engine Oil Level Dipstick And Fill Locations
Courtesy of DAIMLERCHRYSLER CORP.

3. Hoist and support vehicle on safety stands.

4. Place a suitable drain pan under crankcase drain (Fig. 127).

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Fig. 127: Locating Engine Oil Drain Plug And Oil Filter
Courtesy of DAIMLERCHRYSLER CORP.

5. Remove drain plug from crankcase (Fig. 127) and allow oil to drain into pan. Inspect drain plug threads
for stretching or other damage. Replace drain plug and gasket if damaged.
6. Remove oil filter. (Refer to OIL FILTER).
7. Install and tighten drain plug in crankcase.
8. Install new oil filter. (Refer to OIL FILTER).
9. Lower vehicle and fill crankcase with specified type and amount of engine oil.
10. Install oil fill cap.
11. Start engine and inspect for leaks.
12. Stop engine and inspect oil level.

NOTE: Care should be exercised when disposing used engine oil after it has been
drained from a vehicle engine. Refer to the WARNING listed above.

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STANDARD PROCEDURE - ENGINE OIL LEVEL CHECK

The best time to check engine oil level is after it has sat overnight, or if the engine has been running, allow the
engine to be shut off for at least 5 minutes before checking oil level.

Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading (Fig.
126). Add only when the level is at or below the ADD mark.

OIL COOLER & LINES

DESCRIPTION

An engine oil cooler is used on 3.3/3.8L engines (Heavy Duty Cooling Only) (Fig. 128). The cooler is a
coolant-to-oil type and mounted between the oil filter and engine block.

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Fig. 128: Identifying Engine Oil Cooler - 3.3/3.8L (Heavy Duty Cooling)
Courtesy of DAIMLERCHRYSLER CORP.

OPERATION

Engine oil travels from the oil filter and into the oil cooler. Engine oil then exits the cooler into the main
gallery. Engine coolant flows into the cooler from the heater return tube and exits into the water pump inlet.

REMOVAL

1. Drain cooling system (Refer to STANDARD PROCEDURE ).

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2. Disconnect oil cooler inlet and outlet hoses (Fig. 129).

Fig. 129: Disconnecting Engine Oil Cooler Hoses

Courtesy of DAIMLERCHRYSLER CORP.

3. Remove oil filter.

4. Remove oil cooler attachment fitting (Fig. 128).
5. Remove oil cooler.

INSTALLATION

NOTE: Position the flat side of oil cooler parallel to oil pan rail.

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1. Lubricate seal and position oil cooler to connector fitting on oil filter adapter (Fig. 128).
2. Install oil cooler attachment fitting and tighten to 27 N.m (20 ft. lbs.) (Fig. 128).
3. Install oil filter.
4. Connect oil cooler inlet and outlet hoses (Fig. 129).
5. Fill cooling system (Refer to STANDARD PROCEDURE ).

OIL FILTER
REMOVAL

CAUTION: When servicing the oil filter avoid deforming the filter can by installing the
remove/install tool band strap against the can-to-base lock seam. The lock
seam joining the can to the base is reinforced by the base plate.

1. Using suitable oil filter wrench, turn filter counterclockwise to remove from oil filter adapter (Fig. 130).
Properly discard used oil filter.

INSTALLATION

1. Wipe oil filter adapter base clean and inspect gasket contact surface.
2. Lubricate gasket of new filter with clean engine oil.
3. Install new filter until gasket contacts base (Fig. 130). Tighten filter 1 turn or 20 N.m (15 ft. lbs.). Use
filter wrench if necessary.
4. Start engine and check for leaks.

OIL FILTER ADAPTER

REMOVAL

1. Raise vehicle on hoist.

2. Remove the oil filter.
3. Disconnect oil pressure switch electrical connector.
4. Remove oil filter adapter attaching bolts (Fig. 130).

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Fig. 130: Removing Oil Filter Adapter

Courtesy of DAIMLERCHRYSLER CORP.

5. Remove oil filter adapter and seal (Fig. 130).

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INSTALLATION

1. Clean oil filter adapter and install new seal.

2. Position adapter on engine block and install bolts (Fig. 130).
3. Tighten adapter bolts to 28 N.m (250 in. lbs.).
4. Connect oil pressure switch electrical connector (Fig. 130).
5. Install the oil filter.
6. Lower vehicle on hoist.
7. Start engine and allow to run approximately 2 minutes.
8. Turn off engine and check oil level. Adjust oil level as necessary.

OIL PAN
REMOVAL

1. Disconnect negative cable from battery and remove engine oil dipstick.
2. Raise vehicle on hoist and drain engine oil.
3. Remove drive belt splash shield.
4. Remove strut to transaxle attaching bolt (Fig. 131). Loosen strut to engine block attaching bolts.

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Fig. 131: Removing Powertrain Struts And Transaxle Case Cover

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Courtesy of DAIMLERCHRYSLER CORP.

5. Remove transaxle case cover (Fig. 131).

6. Remove oil pan fasteners (Fig. 132).

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Fig. 132: Removing Oil Pan

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Courtesy of DAIMLERCHRYSLER CORP.

7. Remove the oil pan and gasket (Fig. 132).

CLEANING

1. Clean oil pan with solvent and wipe dry with a clean cloth.
2. Clean all gasket material from mounting surfaces of pan and block.
3. Clean oil screen and pick-up tube in clean solvent.

INSPECTION

1. Inspect oil drain plug and plug hole for stripped or damaged threads and repair as necessary. Install a new
drain plug gasket. Tighten to 27 N.m (20 ft. lbs.).
2. Inspect oil pan mounting flange for bends or distortion. Straighten flange if necessary.
3. Inspect condition of oil screen and pick-up tube.

INSTALLATION

1. Clean sealing surfaces and apply a 1/8 inch bead of Mopar® Engine RTV GEN II at the parting line of
the chain case cover and the rear seal retainer (Fig. 133).

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Fig. 133: Sealing Oil Pan

Courtesy of DAIMLERCHRYSLER CORP.

2. Position a new pan gasket on oil pan (Fig. 132).

3. Install oil pan and tighten fasteners to 12 N.m (105 in. lbs.) (Fig. 132).
4. Install cover to transaxle case (Fig. 131).
5. Install the strut bolt to transaxle housing (Fig. 131). Tighten all bending brace bolts.
6. Install the drive belt splash shield.
7. Lower vehicle and install oil dipstick.
8. Connect negative cable to battery.
9. Fill crankcase with oil to proper level.

OIL PRESSURE RELIEF VALVE

REMOVAL

1. Remove oil pan (Refer to OIL PAN).

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2. Drill a 3.175 mm (1/8 in.) hole in the center of the retainer cap (Fig. 134). Insert a self-threading sheet
metal screw into the cap.

Fig. 134: Identifying Oil Pressure Relief Valve

Courtesy of DAIMLERCHRYSLER CORP.

3. Using suitable pliers, remove cap and discard.

4. Remove spring and relief valve (Fig. 134).

INSTALLATION

1. Clean relief valve, spring and bore.

NOTE: Lubricate relief valve with clean engine oil before installing.

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2. Install relief valve and spring into housing.

3. Install new retainer cap until flush with sealing surface.
4. Install oil pan (Refer to OIL PAN).
5. Fill crankcase with proper oil to correct level.

OIL PRESSURE SWITCH

DESCRIPTION

The engine oil pressure switch is located on the lower left front side of the engine. It screws into the oil filter
adapter. The normally closed switch provides an input through a single wire to the low pressure indicator light
on the instrument cluster.

OPERATION

The oil pressure switch provides a ground for the instrument cluster low oil pressure indicator light. The switch
receives oil pressure input from the engine main oil gallery. When engine oil pressure is greater than 27.5 Kpa
(4 psi), the switch contacts open, providing a open circuit to the low pressure indicator light. For wiring circuits
and diagnostic information, (Refer to Appropriate Wiring/Diagnostic Information).

REMOVAL

1. Raise vehicle on hoist.

2. Disconnect electrical connector from switch.
3. Remove oil pressure switch (Fig. 135).

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Fig. 135: Identifying Oil Filter Adapter

Courtesy of DAIMLERCHRYSLER CORP.

INSTALLATION

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1. Install oil pressure switch. Torque oil pressure switch to 23 N.m (200 in. lbs.) (Fig. 135).
2. Connect electrical connector to switch.
3. Lower the vehicle.
4. Start engine and check for leaks.
5. Check engine oil level. Adjust as necessary.

OIL PUMP
DESCRIPTION

The oil pump is located in the timing chain cover. It is driven by the crankshaft.

REMOVAL

The oil pump is contained within the timing chain cover housing (Fig. 136).

1. Remove oil pan. (Refer to OIL PAN).

2. Remove the timing chain cover. (Refer to TIMING CHAIN COVER).
3. Disassemble oil pump from timing chain cover. (Refer to DISASSEMBLY).
4. Clean and Inspect oil pump components. (Refer to CLEANING) (Refer to INSPECTION).

DISASSEMBLY

1. Remove oil pump cover screws, and lift off cover (Fig. 136).
2. Remove oil pump rotors (Fig. 136).

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Fig. 136: Removing Oil Pump

Courtesy of DAIMLERCHRYSLER CORP.

3. Clean and inspect oil pump components. (Refer to CLEANING) (Refer to INSPECTION).

CLEANING

1. Clean all parts thoroughly in a suitable solvent.

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INSPECTION

1. Inspect mating surface of the chain case cover. Surface should be smooth. Replace cover if scratched or
grooved.
2. Lay a straightedge across the pump cover surface (Fig. 137). If a 0.025 mm (0.001 in.) feeler gauge can
be inserted between cover and straight edge, cover should be replaced.

Fig. 137: Checking Oil Pump Cover Flatness

Courtesy of DAIMLERCHRYSLER CORP.

3. Measure thickness and diameter of outer rotor. If outer rotor thickness measures 7.64 mm (0.301 in.) or
less (Fig. 138), or if the diameter is 79.95 mm (3.148 in.) or less, replace outer rotor.

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Fig. 138: Measuring Outer Rotor Thickness

Courtesy of DAIMLERCHRYSLER CORP.

4. If inner rotor thickness measures 7.64 mm (0.301 in.) or less, replace inner rotor (Fig. 139).

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Fig. 139: Measuring Inner Rotor Thickness

Courtesy of DAIMLERCHRYSLER CORP.

5. Install outer rotor into chain case cover. Press rotor to one side with fingers and measure clearance
between rotor and chain case cover (Fig. 140). If measurement is 0.39 mm (0.015 in.) or more, replace
chain case cover, only if outer rotor is in specification.

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Fig. 140: Measuring Outer Rotor Clearance In Housing

Courtesy of DAIMLERCHRYSLER CORP.

6. Install inner rotor into chain case cover. If clearance between inner and outer rotors (Fig. 141) is 0.203
mm (0.008 in.) or more, replace both rotors.

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Fig. 141: Measuring Clearance Between Rotors

Courtesy of DAIMLERCHRYSLER CORP.

7. Place a straightedge across the face of the chain case cover, between bolt holes. If a feeler gauge of 0.10
mm (0.004 in.) or more can be inserted between rotors and the straightedge, replace pump assembly (Fig.
142). ONLY if rotors are in specs.

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Fig. 142: Measuring Clearance Over Rotors

Courtesy of DAIMLERCHRYSLER CORP.

8. Remove oil pressure relief valve. (Refer to OIL PRESSURE RELIEF VALVE).
9. Inspect oil pressure relief valve and bore. Inspect for scoring, pitting and free valve operation in bore
(Fig. 143). Small marks may be removed with 400-grit wet or dry sandpaper.

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Fig. 143: Oil Pressure Relief Valve

Courtesy of DAIMLERCHRYSLER CORP.

10. The relief valve spring has a free length of approximately 49.5 mm (1.95 inches) it should test between
19.5 and 20.5 pounds when compressed to 34 mm (1-11/32 inches). Replace spring that fails to meet
specifications.
11. If oil pressure is low and pump is within specifications, inspect for worn engine bearings or other reasons
for oil pressure loss.

ASSEMBLY

1. Assemble pump, using new parts as required. Install the inner rotor with chamfer facing the cast iron
oil pump cover.
2. Prime oil pump before installation by filling rotor cavity with engine oil.
3. Install cover and tighten screws to 12 N.m (105 in. lbs.).

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4. If removed, install the oil pressure relief valve. (Refer to OIL PRESSURE RELIEF VALVE).

INSTALLATION

1. Install oil pump. (Refer to ASSEMBLY).

2. Install timing chain cover (Refer to TIMING CHAIN COVER) and oil pan (Refer to OIL PAN).

INTAKE MANIFOLD
DESCRIPTION

The intake system is made up of an upper and lower intake manifold. The upper intake manifold is made of a
composite for both the 3.3L engine and for the 3.8L engine (Fig. 149). The lower intake manifold is common
between the two engines (Fig. 153). It also provides coolant crossover between cylinder heads and houses the
coolant thermostat (Fig. 153).

The intake manifold utilizes a compact design with very low restriction and outstanding flow balance. This
design allows the engine to perform with a wide torque curve while increasing higher rpm horsepower.

If, for some reason, the molded-in vacuum ports break, the composite manifold can be salvaged. The vacuum
ports are designed to break at the shoulder, if overloaded. Additional material in the shoulder area provides
sufficient stock to repair. For more information and procedure, (Refer to STANDARD PROCEDURE). Also,
if the special screws that attach the MAP sensor, power steering reservoir, throttle cable bracket, and the EGR
tube become stripped, an oversized screw is available to repair the stripped-out condition. For more information
and procedure, (Refer to STANDARD PROCEDURE).

DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS

An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more
cylinders may not be functioning.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT

STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS
NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE
CLOTHING.

1. Start the engine.

2. Spray a small stream of water (Spray Bottle) at the suspected leak area.
3. If engine RPM'S change, the area of the suspected leak has been found.
4. Repair as required.

INTAKE MANIFOLD - UPPER

STANDARD PROCEDURE

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STANDARD PROCEDURE - MANIFOLD STRIPPED THREAD REPAIR

The composite upper intake manifold thread bosses, if stripped out, can be repaired by utilizing a repair screw
available through Mopar® parts. Repair screws are available for the following manifold attached components:

MAP sensor
Power steering reservoir
EGR tube
Throttle cable bracket

The repair screws require a unique tightening torque specification from the original screw. Refer to the
following chart for specification.

TORQUE SPECIFICATION
DESCRIPTION TORQUE(1)
STRIP-OUT REPAIR SCREWS ONLY
MAP Sensor Repair Screw 4 N.m (35 in. lbs.)
Power Steering Reservoir Repair Screw 9 N.m (80 in. lbs.)
EGR Tube Attaching Repair Screw 9 N.m (80 in. lbs.)
Throttle Cable Bracket Repair Screw 9 N.m (80 in. lbs.)
(1) * install Slowly Using Hand Tools Only

STANDARD PROCEDURE - INTAKE MANIFOLD VACUUM PORT REPAIR

The composite intake manifold vacuum ports can be repaired. Although, if the manifold plenum chamber is
damaged or cracked, the manifold must be replaced.

To repair a broken or damaged vacuum nipple (port) on the composite intake manifold, perform the following
procedure:

NOTE: While performing this procedure, avoid getting the manifold material residue
into the plenum chamber.

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Fig. 144: Oil Pressure Relief Valve

Courtesy of DAIMLERCHRYSLER CORP.

1. File or sand the remaining port back until a flat surface is obtained (plane normal to nipple (port) axis).
2. Drill out the nipple (port) base using a 7/16" (brake booster port) or 11/32" (LDP/speed control port) drill
bit (Fig. 145).

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Fig. 145: Intake Manifold Port Repair

Courtesy of DAIMLERCHRYSLER CORP.

3. Using a 1/4"-18 NPT (brake booster port) or 1/8"-18 NPT (LDP/speed control port) pipe tap, cut internal
threads (Fig. 145). Use caution to start tap in a axis same as original nipple.
4. Apply Mopar® Thread Sealant to threads of repair nipple(s).
5. Install repair nipple(s). Do not over torque repair nipple(s).

REMOVAL - UPPER INTAKE MANIFOLD

1. Disconnect battery negative cable.

2. Disconnect inlet air temperature (LAT) sensor electrical connector.
3. Remove air inlet resonator to throttle body hose assembly.
4. Disconnect throttle and speed control cables from throttle body (Refer to THROTTLE CONTROL
CABLE ).
5. Disconnect make-up air hose support clip from throttle cable bracket.
6. Disconnect the automatic idle speed (AIS) motor and throttle position sensor (TPS) wiring connectors
from throttle body.
7. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
8. Disconnect the vapor purge vacuum hose from throttle body.
9. Disconnect the PCV hose (Fig. 146).

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Fig. 146: Locating PCV & Hose

Courtesy of DAIMLERCHRYSLER CORP.

10. Remove the power steering reservoir attaching bolts and only loosen the nut (Fig. 147). Lift reservoir up
to disengage lower mount from stud. Set reservoir aside. Do not disconnect hose.

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Fig. 147: Removing Power Steering Fluid Reservoir

Courtesy of DAIMLERCHRYSLER CORP.

11. Disconnect the brake booster and leak detection pump (LDP) hoses from intake manifold (Fig. 148).

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Fig. 148: Disconnecting Brake Booster & LDP Vacuum Hoses

Courtesy of DAIMLERCHRYSLER CORP.

12. Remove intake manifold bolts and remove the manifold (Fig. 149).

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Fig. 149: Removing Intake Manifold - Upper

Courtesy of DAIMLERCHRYSLER CORP.

13. Cover the lower intake manifold with a suitable cover while the upper manifold is removed.
14. Clean and inspect the upper intake manifold (Refer to CLEANING) and (Refer to INSPECTION).

CLEANING

1. Discard gasket(s).
2. Clean all sealing surfaces.

INSPECTION

Check manifold for:

Damage and cracks.

Mounting surface distortion by using a straightedge and thickness gauge.

INSTALLATION - UPPER INTAKE MANIFOLD

1. If the following components were removed from manifold, install and tighten to specifications:

CAUTION: The special screws used for the composite manifold attached
components must be installed slowly using hand tools only. This
requirement is to prevent the melting of material that causes stripped
threads. If threads become stripped, an oversize repair screw is
available. For more information and procedure (Refer to STANDARD
PROCEDURE).

MAP sensor - 1.7 N.m (15 in. lbs.)

Throttle cable bracket - 5.6 N.m (50 in. lbs.)
2. Remove covering on lower intake manifold and clean surfaces.
3. Inspect manifold gasket condition. Gaskets can be re-used, if not damaged. To replace, remove gasket
from upper manifold (Fig. 149). Position new gasket in seal channel and press lightly in-place. Repeat
procedure for each gasket position.
4. Position upper manifold on lower manifold (Fig. 149). Apply Mopar® Lock & Seal Adhesive (Medium
Strength Threadlocker) to each upper intake manifold bolt. Install and tighten bolts to 12 N.m (105 in.
lbs.) following torque sequence in (Fig. 150).

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Fig. 150: Identifying Upper Manifold Tightening Sequence

Courtesy of DAIMLERCHRYSLER CORP.

5. Connect the MAP sensor electrical connector.

6. Connect the brake booster and LDP vacuum hose to intake manifold (Fig. 148).

CAUTION: The special screws used for attaching the EGR tube and power
steering reservoir to the manifold must be installed slowly using
hand tools only. This requirement is to prevent the melting of
material that causes stripped threads. If threads become stripped, an
oversize repair screw is available. For more information and
procedure (Refer to STANDARD PROCEDURE).

7. Install the power steering reservoir (Fig. 147). Tighten screws to manifold to 5.6 N.m (50 in. lbs.).
8. Connect throttle and speed control cables to throttle body (Refer to THROTTLE CONTROL CABLE ).
9. Attach make up air hose clip into the hole in the throttle cable bracket.
10. Connect the wiring connectors to the throttle position sensor (TPS) and Automatic Idle Speed (AIS)
motor.
11. Install air cleaner and air inlet hose assembly.
12. Connect the inlet air temperature (LAT) sensor electrical connector.

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13. Connect battery negative cable.

INTAKE MANIFOLD - LOWER

REMOVAL - LOWER INTAKE MANIFOLD

1. Perform fuel system pressure release procedure (before attempting any repairs ). (Refer to
STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE ).
2. Drain the cooling system. (Refer to STANDARD PROCEDURE ).
3. Remove the upper intake manifold. (Refer to INTAKE MANIFOLD - UPPER).
4. Remove the fuel line. (Refer to FUEL LINES ) (Refer to QUICK CONNECT FITTING ).
5. Remove ignition coil and bracket (Fig. 151).

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Fig. 151: Removing Fuel Rail And Ignition Coil & Bracket
Courtesy of DAIMLERCHRYSLER CORP.

6. Disconnect heater supply hose and engine coolant temperature sensor (Fig. 152).

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Fig. 152: Locating ECT Sensor & Heater Supply

Courtesy of DAIMLERCHRYSLER CORP.

7. Disconnect the fuel injector wire harness.

8. Remove the fuel injectors and rail assembly (Fig. 151).
9. Remove radiator upper hose.
10. Remove the intake manifold bolts.

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WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND

MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE.

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Fig. 153: Removing Intake Manifold - Lower

Courtesy of DAIMLERCHRYSLER CORP.

11. Remove lower intake manifold (Fig. 153).

12. Remove intake manifold seal retainers screws (Fig. 153). Remove intake manifold gasket.
13. Inspect and clean manifold. (Refer to INSPECTION) (Refer to CLEANING).

CLEANING

1. Discard gasket(s).
2. Clean all sealing surfaces.

INSPECTION

Check for:

Damage and cracks of each section.

Clogged water passages in end cross-overs (if equipped).
Check for cylinder head mounting surface distortion using a straightedge and thickness gauge. (Refer to
CYLINDER HEAD).

INSTALLATION - LOWER INTAKE MANIFOLD

1. Place a bead (approximately 1/4 in. diameter) of Mopar® Engine RTV GEN II onto each of the four
manifold to cylinder head gasket corners (Fig. 154).

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Fig. 154: Sealing Intake Manifold Gasket

Courtesy of DAIMLERCHRYSLER CORP.

2. Carefully install the new intake manifold gasket (Fig. 153). Tighten end seal retainer screws to 12 N.m
(105 in. lbs.).
3. Install lower intake manifold (Fig. 153). Install the bolts and torque to 1 N.m (10 in. lbs.). Then torque
bolts to 22 N.m (200 in. lbs.) in sequence shown in (Fig. 155). Then torque again to 22 N.m (200 in. lbs.).
After intake manifold is in place, inspect to make sure seals are in place.
4. Install the fuel injectors and rail assembly. (Refer to FUEL RAIL ).
5. Connect fuel injector electrical harness.
6. Connect the engine coolant temperature sensor (Fig. 152).
7. Connect the heater supply (Fig. 152) and radiator upper hoses to manifold.
8. Connect the fuel line. (Refer to QUICK CONNECT FITTING ).
9. Install the upper intake manifold. (Refer to INSTALLATION).
10. Connect negative battery cable.

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Fig. 155: Identifying Lower Manifold Tightening Sequence

Courtesy of DAIMLERCHRYSLER CORP.

11. Fill the cooling system. (Refer to STANDARD PROCEDURE ).

EXHAUST MANIFOLD - RIGHT

REMOVAL

1. Disconnect battery negative cable.

2. Remove the wiper module. (Refer to WIPER MODULE ).
3. Disconnect spark plug wires.
4. Remove bolts fastening crossover pipe to exhaust manifold (Fig. 156).

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Fig. 156: Removing Cross-Over Pipe

Courtesy of DAIMLERCHRYSLER CORP.

5. Disconnect and remove the upstream oxygen sensor (Fig. 157).

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Fig. 157: Removing Exhaust Manifold - Right

Courtesy of DAIMLERCHRYSLER CORP.

6. Remove the heat shield attaching screws (Fig. 157).

7. Remove the upper heat shield (Fig. 157).
8. Raise vehicle on hoist and remove drive belt shield.
9. Loosen the power steering pump support strut lower bolt (Fig. 158).

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Fig. 158: Identifying P/S Pump Strut

Courtesy of DAIMLERCHRYSLER CORP.

10. Disconnect downstream oxygen sensor connector.

11. Disconnect catalytic converter pipe from exhaust manifold (Fig. 159).

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Fig. 159: Disconnecting Catalytic Converter To Exhaust Manifold

Courtesy of DAIMLERCHRYSLER CORP.

12. Lower vehicle and remove the power steering pump support strut upper bolt (Fig. 158).
13. Remove bolts attaching exhaust manifold to cylinder head and remove manifold (Fig. 157).
14. Inspect and clean manifold. (Refer to CLEANING) (Refer to INSPECTION).

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CLEANING

1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head.

INSPECTION

Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface and
exhaust crossover mounting surface with a straightedge and thickness gauge (Fig. 160).

Fig. 160: Checking Exhaust Manifold Mounting

Courtesy of DAIMLERCHRYSLER CORP.

Manifold surface flatness limits should not exceed 1.0 mm (0.039 in.).

INSTALLATION

1. Position exhaust manifold on cylinder head and install bolts to center runner (cylinder #3) and initial

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tighten to 2.8 N.m (25 in. lbs.) (Fig. 157)

NOTE: Inspect crossover pipe fasteners for damage from heat and corrosion. The
cross-over bolts are made of a special stainless steel alloy. If replacement
is required, OEM bolts are highly recommended.

2. Using a new gasket, attach crossover pipe to exhaust manifold and tighten bolts to 41 N.m (30 ft. lbs.)
(Fig. 156).
3. Install the remaining manifold attaching bolts. Tighten all bolts to 23 N.m (200 in. lbs.).
4. Position the power steering pump support strut and install upper bolt (Fig. 158).
5. Install heat shield and attaching screws (Fig. 157).
6. Install and connect upstream oxygen sensor (Fig. 157).
7. Raise the vehicle.
8. Attach catalytic converter pipe to exhaust manifold using new gasket and tighten bolts to 37 N.m (27 ft.
lbs.) (Fig. 159).
9. Connect downstream oxygen sensor connector.
10. Tighten the power steering pump support strut lower bolt (Fig. 158).
11. Install the belt splash shield and lower the vehicle.
12. Install the wiper module. (Refer to WIPER MODULE ).
13. Connect battery negative cable.

EXHAUST MANIFOLD - LEFT

REMOVAL

1. Disconnect battery negative cable.

2. Remove bolts attaching crossover pipe to exhaust manifold (Fig. 161).

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Fig. 161: Removing Cross-Over Pipe

Courtesy of DAIMLERCHRYSLER CORP.

3. Disconnect left cylinder bank spark plug wires.

4. Remove heat shield attaching bolts (Fig. 162).

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Fig. 162: Removing Exhaust Manifold - Left

Courtesy of DAIMLERCHRYSLER CORP.

5. Remove bolts attaching exhaust manifold to cylinder head (Fig. 162).

6. Remove the exhaust manifold (Fig. 162).
7. Inspect and clean manifold. (Refer to INSPECTION) (Refer to CLEANING).

CLEANING

1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head.

INSPECTION

Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface and
exhaust crossover mounting surface with a straightedge and thickness gauge (Fig. 163).

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Manifold surface flatness limits should not exceed 1.0 mm (0.039 in.).

Fig. 163: Checking Exhaust Manifold Mounting

Courtesy of DAIMLERCHRYSLER CORP.

INSTALLATION

1. Position exhaust manifold on cylinder head (Fig. 162). Install bolts to center runner (cylinder #4) and
initial tighten to 2.8 N.m (25 in. lbs.).

NOTE: Inspect crossover pipe fasteners for damage from heat and corrosion. The
cross-over bolts are made of a special stainless steel alloy. If replacement
is required, OEM bolts are highly recommended.

2. Using a new gasket, attach crossover pipe to exhaust manifold and tighten bolts to 41 N.m (30 ft. lbs.)
(Fig. 161).
3. Position heat shield on manifold (Fig. 162).

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4. Install the remaining manifold attaching bolts. Tighten all bolts to 23 N.m (200 in. lbs.).
5. Install and tighten heat shield attaching nut to 12 N.m (105 in. lbs.) (Fig. 162).
6. Connect battery negative cable.

VALVE TIMING
STANDARD PROCEDURE

STANDARD PROCEDURE - VALVE TIMING VERIFICATION

1. Remove front cylinder head cover and all 6 spark plugs.

2. Rotate engine until the #2 piston is at TDC of the compression stroke.
3. Install a degree wheel on the crankshaft pulley.
4. With proper adaptor, install a dial indicator into #2 spark plug hole. Using the indicator find TDC on the
compression stroke.
5. Position the degree wheel to zero.
6. Remove dial indicator from spark plug hole.
7. Place a 5.08 mm (0.200 in.) spacer between the valve stem tip of #2 intake valve and rocker arm pad.
Allow tappet to bleed down to give a solid tappet effect.
8. Install a dial indicator so plunger contacts the #2 intake valve spring retainer as nearly perpendicular as
possible. Zero the indicator.

CAUTION: Do not turn crankshaft any further clockwise as intake valve might
bottom and result in serious damage.

9. Rotate the engine clockwise until the intake valve has lifted.254 mm (0.010 in.).
10. Degree wheel should read 6 degrees BTDC to 6 degrees ATDC.

STANDARD PROCEDURE - MEASURING TIMING CHAIN WEAR

NOTE: This procedure must be performed with the timing chain cover removed (Refer
to TIMING CHAIN COVER).

1. Position a scale next to timing chain so that any movement of chain may be measured (Fig. 164).

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Fig. 164: Checking Exhaust Manifold Mounting

Courtesy of DAIMLERCHRYSLER CORP.

NOTE: With torque applied to the camshaft sprocket bolt, crankshaft should not
be permitted to move. It may be necessary to block crankshaft to prevent
rotation.

2. Position a torque wrench and socket on the camshaft sprocket attaching bolt. Apply force in the direction
of crankshaft rotation to take up slack to the following torque:
41 N.m (30 ft. lb.) with cylinder heads installed
20 N.m (15 ft. lb.) with cylinder heads removed
3. Holding a measuring scale along edge of chain links (Fig. 164).
4. Apply force in the reverse direction to the following torque:
41 N.m (30 ft. lb.) with cylinder heads installed
20 N.m (15 ft. lb.) with cylinder heads removed
5. Measure amount of sprocket/chain movement.

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6. Install a new timing chain and sprockets if movement exceeds 3.175 mm (1/8 in.).

TIMING CHAIN COVER

REMOVAL

1. Disconnect negative cable from battery.

2. Drain cooling system. (Refer to STANDARD PROCEDURE ).
3. Raise vehicle on hoist.
4. Drain engine oil.
5. Remove right wheel and inner splash shield.
6. Remove oil pan. (Refer to OIL PAN).
7. Remove oil pick-up tube (Fig. 165).

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Fig. 165: Removing Oil Pickup Tube

Courtesy of DAIMLERCHRYSLER CORP.

8. Remove accessory drive belt. (Refer to REMOVAL & INSTALLATION ).

9. Remove A/C compressor and set aside.
10. Remove crankshaft vibration damper. (Refer to VIBRATION DAMPER).
11. Remove radiator lower hose.
12. Remove heater hose from timing chain cover housing (Fig. 166) or water pump inlet tube (if engine oil
cooler equipped) (Fig. 167).

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Fig. 166: Removing Heater Return Hose (Without Engine Oil Cooler)
Courtesy of DAIMLERCHRYSLER CORP.

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Fig. 167: Removing Heater Hoses 3.3/3.8L (With Engine Oil Cooler)
Courtesy of DAIMLERCHRYSLER CORP.

13. Remove the right side engine mount. (Refer to RIGHT MOUNT).
14. Remove idler pulley from engine bracket (Fig. 168).

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Fig. 168: Removing Engine Mount Bracket

Courtesy of DAIMLERCHRYSLER CORP.

15. Remove the engine mount bracket (Fig. 168).

16. Remove camshaft position sensor from timing chain cover (Fig. 168).

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17. Remove the water pump for cover removal clearance. (Refer to WATER PUMP - 3.3/3.8L ).
18. Remove the bolt attaching the power steering pump support strut to the front cover (Fig. 169).

Fig. 169: Removing Power Steering Pump Strut

Courtesy of DAIMLERCHRYSLER CORP.

19. Remove the timing chain cover fasteners. Remove timing chain cover (Fig. 170).

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Fig. 170: Removing Timing Chain Cover And Gasket

Courtesy of DAIMLERCHRYSLER CORP.

INSTALLATION

1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. Crankshaft
oil seal must be removed to insure correct oil pump engagement.

NOTE: DO NOT USE SEALER ON COVER GASKET

2. Position new gasket on timing cover (Fig. 170). Adhere new gasket to chain case cover, making sure that
the lower edge of the gasket is flush to 0.5 mm (0.020 in.) passed the lower edge of the cover.
3. Rotate crankshaft so that the oil pump drive flats are in the vertical position.

CAUTION: Make sure the oil pump is engaged on the crankshaft correctly or
severe damage may result.

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4. Position oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats (Fig.
170).
5. Install timing cover (Fig. 170).
6. Install timing chain cover bolts. Tighten M8 bolts to 27 N.m (20 ft. lbs.) and M10 bolts to 54 N.m (40 ft.
lbs.) (Fig. 171).

Fig. 171: Identifying Timing Chain Cover Bolt Locations

Courtesy of DAIMLERCHRYSLER CORP.

7. Install crankshaft front oil seal. (Refer to CRANKSHAFT OIL SEAL - FRONT).
8. Install water pump and pulley. (Refer to WATER PUMP - 3.3/3.8L ).
9. Install crankshaft vibration damper. (Refer to VIBRATION DAMPER).
10. Install engine mount bracket (Fig. 168) and tighten M10 to 54 N.m (40 ft. lbs.), M8 bolt to 28 N.m (21 ft.
lb. lbs.).
11. Install idler pulley on engine mount bracket (Fig. 168).
12. Install right side engine mount. (Refer to RIGHT MOUNT).
13. Install camshaft position sensor (Refer to CAMSHAFT POSITION SENSOR ).
14. Connect the heater return hose at rear of timing chain cover (Fig. 166) or at water pump inlet tube (if

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engine oil cooler equipped) (Fig. 167).

15. Connect the radiator lower hose.
16. Install A/C compressor.
17. Install accessory drive belt. (Refer to REMOVAL & INSTALLATION ).
18. Install oil pump pick-up tube with new O-ring. Tighten attaching bolt to 28 N.m (250 in. lbs.).
19. Install oil pan. (Refer to OIL PAN).
20. Install inner splash shield and right front wheel.
21. Fill crankcase with engine oil to proper level.
22. Fill cooling system. (Refer to STANDARD PROCEDURE ).
23. Connect negative cable to battery.

TIMING CHAIN AND SPROCKETS

REMOVAL

REMOVAL - TIMING CHAIN AND CAMSHAFT SPROCKET

1. Disconnect negative cable from battery.

2. Remove the timing chain cover. (Refer to TIMING CHAIN COVER).
3. Rotate engine by turning crankshaft until the timing marks are aligned as shown in (Fig. 172).

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Fig. 172: Identifying Timing Mark Alignment

Courtesy of DAIMLERCHRYSLER CORP.

4. Remove camshaft sprocket attaching bolt.

5. Remove the timing chain with camshaft sprocket.

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6. Remove the crankshaft sprocket. (Refer to REMOVAL - TIMING CHAIN AND CAMSHAFT
SPROCKET).

REMOVAL - CRANKSHAFT SPROCKET

1. Remove the timing chain. (Refer to REMOVAL - TIMING CHAIN AND CAMSHAFT
SPROCKET).
2. Using Special Tools 8539, 5048-6, and 5048-1, remove the crankshaft sprocket while holding the
crankshaft from turning (Fig. 173). Be careful not to damage the crankshaft surfaces.

Fig. 173: Removing Crankshaft Sprocket

Courtesy of DAIMLERCHRYSLER CORP.

INSTALLATION

INSTALLATION - CRANKSHAFT SPROCKET

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1. Position the sprocket on the crankshaft (timing mark out) with the timing slot aligned with the timing pin.
2. Install sprocket using Special Tool 8452 (Fig. 174). Install sprocket until it is fully seats on the
crankshaft.

Fig. 174: Installing Crankshaft Sprocket

Courtesy of DAIMLERCHRYSLER CORP.

3. Install the timing chain and camshaft sprocket. (Refer to INSTALLATION - TIMING CHAIN AND
CAMSHAFT SPROCKET).

INSTALLATION - TIMING CHAIN AND CAMSHAFT SPROCKET

1. Rotate crankshaft so the timing arrow is to the 12 o'clock position (Fig. 172).

NOTE: Lubricate timing chain and sprockets with clean engine oil before

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installation.

2. While holding camshaft sprocket and chain in hand, place timing chain around the sprocket, aligning the
plated link with the dot on the sprocket. Position the timing arrow to the 6 o'clock position (Fig. 172).
3. Place timing chain around crankshaft sprocket with the plated link lined up with the dot on the sprocket.
Install camshaft sprocket into position.
4. Use a straight edge to check alignment of timing marks.
5. Install camshaft sprocket bolt and washer. Tighten bolt to 54 N.m (40 ft. lbs.).
6. Rotate crankshaft 2 revolutions and check timing mark alignment (Fig. 172). If timing marks do not line
up, remove camshaft sprocket and realign.
7. Install the timing chain cover. (Refer to TIMING CHAIN COVER).
8. Connect negative cable to battery.

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