Ä ENGINE 9 - 1

ENGINE

CONTENTS
page page

2.2/2.5L ENGINES . . . . . . . . . . . . . . . . . . . . . . . 8 3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . . 98

3.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 66 STANDARD SERVICE PROCEDURES . . . . . . . . . 1

STANDARD SERVICE PROCEDURES

INDEX
page page
Crankshaft Sprocket Bolt Access Plug . . . . . . . . . . 2 Lash Adjuster (Tappet) Noise Diagnosis . . . . . . . . 4
Engine Performance . . . . . . . . . . . . . . . . . . . . . . . 2 Measuring Main Bearing Clearance and Connecting
Form-In-Place Gaskets . . . . . . . . . . . . . . . . . . . . . 1 Rod Bearing Clearance . . . . . . . . . . . . . . . . . . . 3
Honing Cylinder Bores .......... . . . . . . . . . . . 2 Repair of Damaged or Worn Threads . . . . . . . . . . 4
Hydrostatic Locked Engine . . . . . . . . . . . . . . . . . . 5

FORM-IN-PLACE GASKETS tube. It is normally red in color. The anaerobic ma-

There are numerous places where form-in-place terial is for use between two machined surfaces. Do
gaskets are used on the engine. Care must be taken not used on flexible metal flanges.
when applying form-in-place gaskets to assure ob-
taining the desired results. Bead size, continuity, and GASKET DISASSEMBLY
location are of great importance. Too thin a bead can Parts assembled with form-in-place gaskets may be
result in leakage while too much can result in spill- disassembled without unusual effort. In some in-
over which can break off and obstruct fluid feed stances, it may be necessary to lightly tap the part
lines. A continuous bead of the proper width is essen- with a mallet or other suitable tool to break the seal
tial to obtain a leak-free joint. between the mating surfaces. A flat gasket scraper
Two types of form-in-place gasket materials are may also be lightly tapped into the joint but care
used in the engine area. Mopar Silicone Rubber Ad- must be taken not to damage the mating surfaces.
hesive Sealant and anaerobic gasket materials, each
have different properties and cannot be used inter- SURFACE PREPARATION
Scrape clean or wire brush all gasket surfaces re-
changeably.
moving all loose material. Inspect stamped parts to
MOPAR SILICONE RUBBER ADHESIVE assure gasket rails are flat. Flatten rails with a ham-
SEALANT mer on a flat plate if required. Gasket surfaces must
Mopar Silicone Rubber Adhesive Sealant or equiv- be free of oil and dirt. Make sure old gasket material
alent, normally black in color, is available in three is removed from blind attaching holes.
ounce tubes. Moisture in the air causes the Mopar
Silicone Rubber Adhesive Sealant material to cure.
FORM-IN-PLACE GASKET APPLICATION
Assembling parts using a form-in-place gasket re-
This material is normally used on flexible metal
flanges. It has a shelf life of one year and will not quires care but it’s easier then using precut gaskets.
properly cure if over age. Always inspect the package MOPAR Gasket Maker material should be applied
for the expiration date before use. sparingly 1mm(0.040 inch.) diameter or less of seal-
ant to one gasket surface. Be certain the material
MOPAR GASKET MAKER surrounds each mounting hole. Excess material can
MOPAR Gasket Maker is an anaerobic type gasket easily be wiped off. Components should be torqued in
material normally red in color. The material cures in place within 15 minutes. The use of a locating dowel
the absence of air when squeezed between two metal- is recommended during assembly to prevent smear-
lic surfaces. It will not cure if left in the uncovered ing the material off location.
9 - 2 ENGINE Ä

The MOPAR Silicone Rubber Adhesive Sealant ing a fire (Conventional Ignition System). For Direct
gasket material or equivalent should be applied in a Ignition System DIS disconnect the coil connector.
continuous bead approximately 3mm (0.120 inch) in (f) Be sure throttle blade is fully open during the
diameter. All mounting holes must be circled. For compression check.
corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 inch.) (g) Insert compression gage adaptor into the #1
drop is placed in the center of the gasket contact spark plug hole in cylinder head. Crank engine until
area. Uncured sealant may be removed with a shop maximum pressure is reached on gage. Record this
towels. Components should be torqued in place while pressure as #1 cylinder pressure.
the sealant is still wet to the touch (within 10 min- (h) Repeat Step G for all remaining cylinders.
utes). The usage of a locating dowel is recommended (i) Compression should not be less than (689kPa)
during assembly to prevent smearing of material off 100 psi and not vary more than 25 percent from
location. cylinder to cylinder.
(j) If one or more cylinders have abnormally low
CRANKSHAFT SPROCKET BOLT ACCESS PLUG compression pressures, repeat steps 3b through 3h.
An Access plug is located in the right inner fender (k) If the same cylinder or cylinders repeat an
shield. Remove the plug and insert proper size abnormally low reading on the second compression
socket, extension and rachet, when crankshaft rota- test, it could indicate the existence of a problem in
tion is necessary. the cylinder in question.
The recommended compression pressures are
ENGINE PERFORMANCE to be used only as a guide to diagnosing engine
If a loss of performance is noticed, ignition timing
problems. An engine should not be disassembled
should be checked. If ignition timing is retarded by
to determine the cause of low compression un-
9, 18 or 27° indicating 1, 2 or 3 (timing belt or chain)
less some malfunction is present.
teeth may have skipped, then, camshaft and acces-
(4) Clean or replace spark plugs as necessary and
sory shaft timing with the crankshaft should be
adjust gap as specified in Electrical Group 8. Tighten to
checked. Refer to Engine Timing Sprockets and Oil
specifications.
Seals of the Engine Section.
(5) Test resistance of spark plug cables. Refer to
To provide best vehicle performance and lowest ve-
Ignition System Secondary Circuit Inspection Electri-
hicle emissions, it is most important that the tune-up
cal Section Group 8.
be done accurately. Use the specifications listed on
(6) Inspect the primary wire. Test coil output volt-
the Vehicle Emission Control Information label
age, primary and secondary resistance. Replace parts
found in the engine compartment.
as necessary. Refer to Ignition System and make nec-
(1) Test cranking amperage draw. See Starting
essary adjustment.
Motor Cranking Amperage Draw Electrical Section
(7) Ignition timing should be set to specifications.
of this manual.
(See Specification Label in engine compartment).
(2) Tighten the intake manifold bolts to specifica-
(8) Test fuel pump for pressure and vacuum. Refer to
tions.
Fuel System Group 14, Specifications.
(3) Perform cylinder compression test.
(9) The air filter elements should be replaced as
(a) Check engine oil level and add oil if neces-
specified in Lubrication and Maintenance, Group 0.
sary.
(10) Inspect crankcase ventilation system as out
(b) Drive the vehicle until engine reaches normal
lined in Lubrication and Maintenance, Group 0. For
operating temperature.
emission controls see Emission Controls Group 25 for
(c) Select a route free from traffic and other
service procedures.
forms of congestion, observe all traffic laws, and ac-
celerate through the gears several times briskly. (11) Inspect and adjust accessory belt drives refer-
ring to Accessory Belt Drive in Cooling System, Group
CAUTION: Do not overspeed the engine. The higher 7 for proper adjustments.
engine speed may help clean out valve seat deposits (12) Road test vehicle as a final test.
which can prevent accurate compression readings.
HONING CYLINDER BORES
(d) Remove all spark plugs from engine. As Before honing, stuff plenty of clean shop towels
spark plugs are being removed, check electrodes for under the bores, over the crankshaft to keep abrasive
abnormal firing indicators fouled, hot, oily, etc. materials from entering crankcase area.
Record cylinder number of spark plug for future (1) Used carefully, the cylinder bore resizing hone
reference. C-823 equipped with 220 grit stones, is the best tool for
(e) Disconnect coil wire from distributor and se- this job. In addition to deglazing, it will reduce taper
cure to good ground to prevent a spark from start- and out-of-round as well as removing light
Ä ENGINE 9 - 3

scuffing, scoring or scratches. Usually a few strokes

will clean up a bore and maintain the required limits.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, Tool C-3501, equipped
with 280 grit stones (C-3501-3810) if the cylinder bore
is straight and round. 20-60 strokes depending on the
bore condition will be sufficient to provide a satisfac-
tory surface. Inspect cylinder walls after each 20
strokes. Using a light honing oil available from major
oil distributors. Do not use engine or transmission
oil, mineral spirits or kerosene.
(3) Honing should be done by moving the hone up Fig. 2 Plastigage Placed in Lower Shell
and down fast enough to get a cross-hatch pattern.
When hone marks intersect at 50-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 1).

Fig. 3 Clearance Measurement

MEASURING MAIN BEARING CLEARANCE AND
CONNECTING ROD BEARING CLEARANCE
PLASTIGAGE METHOD
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
(1) Remove oil film from surface to be checked.
Fig. 1 Cylinder Bore Cross-Hatch Pattern Plastigage is soluble in oil.
(4) A controlled hone motor speed between 200-300 (2) The total clearance of the main bearings can
RPM is necessary to obtain the proper cross-hatch only be determined by removing the weight of the
angle. The number of up and down strokes per minute crankshaft. This can be accomplished by either of
can be regulated to get the desired 50-60 degree angle. two methods:
Faster up and down strokes increase the cross-hatch PREFERRED METHOD — Shimming the bear-
angle. ings adjacent to the bearing to be checked in order to
(5) After honing, it is necessary that the block be remove the clearance between upper bearing shell
cleaned again to remove all traces of abrasive. and the crankshaft. This can be accomplished by
placing a minimum of 0.254mm (.010 inch) shim (e.
CAUTION: Be sure all abrasive are removed from g. cardboard, matchbook cover, etc.) between the
engine parts after honing. It is recommended that a bearing shell and the bearing cap on the adjacent
solution of soap and hot water be used with a brush bearings and snugging bolts to 14-20 NIm (10-15
and the parts then thoroughly dried. The bore can be ft.lb.)
considered clean when it can be wiped clean with a • When checking #1 main brg shim #2 main brg
white cloth and cloth remains clean. Oil the bores • When checking #2 main brg shim #1 & 3 main brg
after cleaning to prevent rusting. • When checking #3 main brg shim #2 & 4 main brg
• When checking #4 main brg shim #3 & 5 main brg
• When checking #5 main brg shim #4 main brg
9 - 4 ENGINE Ä

REMOVE ALL SHIMS BEFORE REASSEM- is accompanied by two scales. One scale is in
BLING ENGINE inches, the other is a metric scale.
ALTERNATIVE METHOD — With the weight of (6) Plastigage is available in a variety of clearance
the crankshaft being supported by a jack under the ranges. The 0.025-0.076mm (.001-.003 inch) is usually
counterweight adjacent to the bearing being checked. the most appropriate for checking engine bearing
(3) Place a piece of Plastigage across the entire proper specifications.
width of the bearing shell in the cap approximately
6.35 mm (1/4 inch) off center and away from the oil LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
holes (Fig. 2). (In addition, suspect areas can be A tappet-like noise may be produced from several
checked by placing the Plastigage in the suspect area). items. Check the following items.
Torque the bearing cap bolts of the bearing being (1) Engine oil level too high or too low. This may
checked to the proper specifications. cause aerated oil to enter the adjusters and cause them
(4) Remove the bearing cap and compare the width to be spongy.
of the flattened Plastigage (Fig. 3) with the metric scale (2) Insufficient running time after rebuilding cylin-
provided on the package. Locate the band closest to the der head. Low speed running up to 1 hour may be
same width. This band shows the amount of clearance required.
in thousandths of a millimeter. Differences in readings During this time, turn engine off and let set for a few
between the ends indicate the amount of taper present. minutes before restarting. Repeat this several times
Record all readings taken. Refer to Engine Specifica- after engine has reached normal operating tempera-
tions. Plastic-Gage generally is accompanied by ture.
two scales. One scale is in inches, the other is a (3) Low oil pressure.
metric scale. (4) The oil restrictor pressed into the vertical oil
(5) Plastigage is available in a variety of clearance passage to the cylinder head of Balance Shaft Engines
ranges. The 0.025-0.076mm (.001-.003 inch) is usually Only is plugged with debris.
the most appropriate for checking engine bearing (5) Air ingested into oil due to broken or cracked oil
proper specifications. pump pick up.
(6) Worn valve guides.
CONNECTING ROD BEARING CLEARANCE (7) Rocker arm ears contacting valve spring retainer
Engine crankshaft bearing clearances can be deter- (2.2/2.5L engines).
mined by use of Plastigage or equivalent. The following (8) Rocker arm loose, adjuster or tappet stuck or at
is the recommended procedure for the use of Plasti- maximum extension and still leaves lash in the system.
gage: (9) Faulty lash adjuster or tappet.
(1) Rotate the crankshaft until the connecting rod to (a) Check for sponginess while still installed in
be checked is at the bottom of its stroke. engine. Depress part of rocker arm just over adjuster
(2) Remove oil film from surface to be checked. or pushrod . Normal adjusters should feel very firm.
Plastigage is soluble in oil. Spongy adjusters can be depressed to the bottomed
(3) Place a piece of Plastigage across the entire position easily.
width of the bearing shell in the bearing cap approxi- (b) Remove suspected lash adjuster or tappet, pry
mately 6.35 mm (1/4 inch.) off center and away from off retainer cap or snap ring and disassemble. Do
the oil hole (Fig. 2). In addition, suspect areas can be not reuse retainer caps. Do not interchange parts
checked by placing plastigage in the suspect area. and make sure that care and cleanliness is exercised
(4) Before assembling the rod cap with Plastigage in in the handling of parts.
place, the crankshaft must be rotated until the con- (c) Clean out dirt and varnish with solvent.
necting being checked starts moving toward the top of (d) Reassemble with engine oil.
the engine. Only then should the cap be assembled and (e) Check for sponginess.
torqued to specifications. Do not rotate the crank- (f) If still spongy, replace with new adjuster.
shaft while assembling the cap or the Plastigage
may be smeared, giving inaccurate results. REPAIR OF DAMAGED OR WORN THREADS
(5) Remove the bearing cap and compare the width Damaged or worn threads (including aluminum head
of the flattened Plastigage (Fig. 3) with the metric spark plug threads) can be repaired. Essentially, this
scale provided on the package. Locate the band closest repair consists of drilling out worn or damaged
to the same width. This band shows the amount threads, tapping the hole with a special Heli-Coil (or
of clearance in thousandths of a millimeter. Differences equivalent) Tap, and installing an insert into the
in readings between the ends indicate the amount tapped hole. This brings the hole back to its original
of taper present. Record all readings taken. thread size.
Refer to Engine Specifications. Plastigage generally
Ä ENGINE 9 - 5

CAUTION: Be sure that the tapped holes maintain (4) With all spark plugs removed, rotate engine
the original centerline. crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
Heli-Coil tools and inserts are readily available
ant, fuel, oil or other).
from automotive parts jobbers.
(6) Make sure all fluid has been removed from the
HYDROSTATIC LOCKED ENGINE cylinders. Inspect engine for damage (i.e., Connecting
When an engine is suspected to be hydrostaticly Rods, Pistons, Valves etc.)
locked, regardless of what caused the problem, these (7) Repair engine or components as necessary to
steps should be used. prevent this problem from occurring again.

CAUTION: Do Not Use Starter Motor To Rotate En- CAUTION: Squirt approximately 1 teaspoon of oil
gine, severe damage may occur. into cylinders, rotate engine to lubricate the cylin-
der walls to prevent damage on restart.
(1) Inspect air cleaner, induction system and in-
take manifold to insure system is dry and clear of (8) Install new spark plugs.
foreign material. (9) Drain engine oil and remove oil filter.
(2) Remove negative battery cable.
(10) Fill engine with specified amount of approved
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will oil and install new oil filter.
catch any fluid that may possibly be in the cylinder (11) Connect negative battery cable.
under pressure. (12) Start engine and check for any leaks.
9 - 6 ENGINE Ä

ENGINE DIAGNOSIS—PERFORMANCE
Ä ENGINE 9 - 7

ENGINE DIAGNOSIS—MECHANICAL
9 - 8 2.2/2.5L ENGINE Ä

2.2/2.5L ENGINES

INDEX
page page
Balance Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Engine Core Plugs . . . . . . . . . . . . . . . . . . . . . . . 55
Camshaft and Crankshaft Timing Procedure . . . . 34 Engine Lubrication System . . . . . . . . . . . . . . . . . 56
Camshaft, Crankshaft and Intermediate Shafts Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . 20 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . 62
Camshafts Service .................... . . . 36 General Information . . . . . . . . . . . . . . . . . . . . . . . . 8
Checking Engine Oil Pressure . . . . . . . . . . . . . . . 60 Intermediate Shaft Service . . . . . . . . . . . . . . . . . . 47
Crankshaft Oil Seals Service . . . . . . . . . . . . . . . . 42 Lash Adjuster (Tappet) Noise . . . . . . . . . . . . . . . 37
Crankshaft Service . . . . . . . . . . . . . . . . . . . . . . . 43 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Crankshaft, Intermediate and Balance Shaft Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . 58
Cylinder Block, Piston and Connecting Rod
Assembly Service . . . . . . . . . . . . . . . . . . . . . . . 49 Solid Mount Compressor Bracket Service . . . . . . 14
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Timing System and Seals Service—
Cylinder Head and Valve Assembly Except Turbo III . . . . . . . . . . . . . . . . . . . . . . . . 18
Service—Except Turbo III . . . . . . . . . . . . . . . . . 22 Valve Components Replace—Cylinder Head
Cylinder Head and Valve Assembly Not Removed . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Service—Turbo III ................... . . . 31 Valve Service—Cylinder Head Removed . . . . . . . 27
Cylinder Head Components—In-Vehicle Service . 23 Valve Springs and Valve Stem Seals . . . . . . . . . 38
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2/2.5L ENGINE SPECIFICATION

GENERAL INFORMATION METHANOL FUEL COMPATIBILITY IDEN-

TIFICATION
ENGINE IDENTIFICATION NUMBER OR CODE Beginning this model year, Chrysler began produc-
The engine identification number is located on the ing AA-Body vehicles designed to operate on a mix-
rear of the cylinder block just below the cylinder ture of gasoline and methanol. These automobiles are
head (Fig. 1). referred to as Flexible Fuel vehicles.
Ä 2.2/2.5L ENGINE 9 - 9

main bearings, with number 3 flanged to control

thrust. The 60 mm diameter main and 50 mm diam-
eter crank pin journals (all) have undercut radiuses
fillets that are deep rolled for added strength. To op-
timize bearing loading 4 counterweights are used.
Hydrodynamic seals (installed in diecast aluminum
retainers) provide end sealing, where the crankshaft
exits the block. Anaerobic gasket material is used for
retainer-to-block sealing. No vibration damper is
used. A sintered iron (TBI engine and steel billet
Turbo III engines) timing belt sprocket is mounted
on the crankshaft nose. This sprocket provides mo-
tive power; via timing belt to the camshaft and inter-
mediate shaft sprockets (also sintered iron (TBI
engine and steel billet Turbo III engines) providing
timed valve, distributor, and oil pump actuation.
PISTONS: Some Chrysler pistons have cast-in
steel struts at the pin bosses for autothermic control.
All 2.2L and 2.5L piston tops have cuts to provide
valve clearance. Some pistons are dished to provide
various compression ratios. Standard 2.2L and 2.5L
Fig. 1 Engine Identification engines are designed for 9.5:1 and 8.9:1 compression
ratios respectively. The 2.5L piston is dished and is a
Flexible fuel vehicles can operate on a mixture of
lightweight design to enhance engine smoothness.
up to 85 percent methanol, 15 percent unleaded gas-
The 2.2L turbo III uses dished pistons providing a
oline. These vehicles also operate on mixtures con-
8.3:1 compression ratio. All standard 2.2/2.5L and
taining a lower percentage of methanol or just pure 2.5L FFV engines use pressed-in piston pins to at-
unleaded gasoline. tach forged steel connecting rods, 2.2L turbo III en-
Engine components which are required for safe op- gine uses a full floating piston pin and connecting
eration using fuel containing methanol alcohol are rod assembly.
identified by a standard green color and/or display PISTONS RINGS: The 2.2/2.5L engines share
the statement methanol compatible imprinted on the common piston rings throughout, including molybde-
component. To ensure continued safe operation, these num filled top ring for reliable compression sealing
components must be serviced only with genuine MO- and a tapered faced intermediate ring for additional
PAR replacement parts. cylinder pressure control. The 2.5L FFV engine fea-
Methanol compatible parts for the 2.5L FFV (Flex- ture all chrome rings for enhanced long term dura-
ible Fuel Vehicle) engine include, but are not limited bility under multi-fueled conditions.
to; the valve stem oil seals, all piston rings, the oil CYLINDER HEAD: The cylinder head is cast alu-
fill cap, the fuel injectors, fuel rail, fuel pressure reg- minum with in-line valves. The 2.2/2.5L and 2.5L
ulator, hoses and the vacuum control harness hose. FFV valves are arranged with alternating exhaust
BLOCK: All four cylinder cast iron blocks have and intake. The intake and exhaust ports are located
cast-in recesses in the bottom of each cylinder bore to in the rearward, facing side of the head. The Turbo
provide connecting rod clearance; especially needed III valves are arranged in two inline banks, with the
for 2.5L engines. The bores are also siamese to min- ports of the bank of two intake valves per cylinder
imize engine length. A coolant passage is drilled facing toward the radiator side of engine and ports of
cross-ways through the siamese section to enhance the bank of two exhaust valve per cylinder facing to-
between the bore cooling on some engine types. A ward the dash panel. The intake ports feed fast-burn
partial open deck is used for cooling and weight re- design combustion chambers (2.2/2.5L and 2.5L FFV
duction with oil filter, water pump, and distributor only) with the spark plug located close to the center
mounting bosses molded into the front (radiator side) line of the combustion chamber for optimum effi-
of the block. Nominal wall thickness is 4.5 mm. Five ciency. An integral oil gallery within the cylinder
main bearing bulkheads and a block skirt extending head supplies oil to the hydraulic lash adjusters,
3 mm below the crankshaft center line add to the camshaft, and valve mechanisms.
blocks high rigidity with light weight. CAMSHAFT: The nodular iron camshaft has five
CRANKSHAFT: A nodular cast iron crankshaft is bearing journals (2.2/2.5L and 2.5L FFV). The Turbo
used in TBI engines. A forged steel crankshaft is III employs dual camshafts that have nine bearing
used in the Turbo III engine. All engines have 5 journals. Flanges at the rear journal control cam-
9 - 10 2.2/2.5L ENGINE Ä

shaft end play. A sintered iron (TBI engine and steel INTAKE MANIFOLDS: All intake manifolds are
billet Turbo III engines) timing belt sprocket is aluminum castings, attached to the cylinder head
mounted on the cam nose, and a hydrodynamic oil with eight bolts. N.A. engines use a four branch de-
seal is used for oil control at the front of the cam- sign. This long branch fan design enhances low and
shaft. midspeed torque. It also features an integrally cast
ACCESSORY SHAFT: The iron accessory shaft
water crossover passage to warm incoming fuel/air
has two bearing journals and is housed in the for-
mixture, plus an EGR mounting boss and PCV inlet.
ward facing side of the block. A hydrodynamic seal,
installed in an aluminum housing attached to the The Turbo III engine intake manifold is a log type
block, provides retention, shaft thrust, and oil con- with tuned runners. The manifold is machined to ac-
trol. The accessory shaft is driven by the timing belt cept fuel injectors near the ports of each cylinder.
through a sintered iron (TBI engine and steel billet EXHAUST MANIFOLDS: The exhaust manifolds
Turbo III engines) sprocket mounted on the nose of are made of nodular cast iron for strength and high
the accessory shaft. The accessory shaft in turn temperatures. All naturally aspirated (N.A.) and tur-
drives the oil pump and distributor on 2.2/2.5L and bocharged engines exit exhaust gasses through a ma-
2.5L FFV and the oil pump only on Turbo III. chined, articulated joint connection to the exhaust
VALVES: The valves are actuated by roller cam pipe. 2.2/2.5L and 2.5L FFV manifolds intermesh
followers which pivot on stationary hydraulic lash with the intake manifold at the cylinder head.
adjusters. The valve train with 40.6 mm (1.60 inch) N.A. engines use a four branch design with cylin-
diameter intake valves and 35.4 mm (1.39 inch) di- ders one and four joined and cylinder two and three
ameter exhaust valves employ viton rubber valve joined to exit at the outlet.
stem seals except 2.5L FFv . the 2.5L FFV valve The Turbo III engine exhaust manifold also carries
stem seals are made of special rubber compound the turbocharger. This manifold has a modified log
which resist the deteriorating effects of methanol type collector with exhaust gasses directed to and
fuel by-products that enter the oil during combus- through the turbocharger to exit the conical (articu-
tion. Valve springs, spring retainers, and locks are lated joint) outlet machined into the turbocharger ex-
conventional. For Turbo III engines the valves are
haust elbow.
actuated by roller tipped rocker arms with hydraulic
ENGINE LUBRICATION: Refer to Group 0 Lu-
lash adjusters which pivot on a shaft. The valve train
brication and Maintenance for recommended oil to be
with 33.88 mm (1.33 in.) diameter intake valves are
used in various engine application. System is full
arranged in line opposite of the 29.26 mm (1.15 in.)
diameter exhaust valves employ locking valve stem flow filtration, pressure feed type. The oil pump is
seals. Valve springs, spring retainers, and locks are mounted within the crankcase and driven by the ac-
not interchangeable with other engines. cessory shaft. Pressurized oil is then routed through
BALANCE SHAFTS: 2.2 Turbo III and 2.5L en- the main oil gallery, running the length of the cylin-
gines are equipped with two counter rotating balance der block, supplying main and rod bearings with fur-
shafts installed in a carrier attached to the lower ther routing (for 2.2L turbo III and 2.5L engines) to
crankcase. The shafts are interconnect through the lower balance shaft assemblies. Pistons are lubri-
gears. These gears are driven by a short chain from cated from directed holes in the connecting rod as-
the crankshaft, to rotate at two times crankshaft semblies. Camshaft and valve mechanisms are
speed. This counterbalances certain engine recipro- lubricated from a full-length cylinder head oil gallery
cating forces. supplied from the crankcase main oil gallery.
Ä 2.2/2.5L ENGINE 9 - 11

Fig. 2 Engines
9 - 12 2.2/2.5L ENGINE Ä

ENGINE MOUNTS

Fig. 3 Engine Mounting

REMOVAL AND INSTALLATION LEFT SIDE MOUNT
(1) Raise vehicle on hoist and remove left front
RIGHT SIDE MOUNT wheel.
(1) Remove the right engine mount insulator ver- (2) Remove inter splash shield.
tical fasteners from frame rail. (3) Support the transmission with a transmission
(2) Remove the load on the engine motor mounts jack.
by carefully supporting the engine and transmission (4) Remove the insulator thru bolt from the mount.
assembly with a floor jack. (5) Remove the transmission mount fasteners and
(3) Remove the thru bolt from the insulator assem- remove mount.
bly. Remove insulator.
(6) Reverse removal procedure for installation. En-
(4) Reverse removal procedure for installation. Re-
sure that the slide tube is seated into the rail
fer to (Fig. 3) for bolt tightening specifications.
bracket guides. Refer to (Fig. 3) for bolt tightening
(5) Engine mount adjustment, Refer to Engine
specifications.
Mount Insulator Adjustment of this section.
(7) Engine mount adjustment, Refer to Engine
FRONT MOUNT Mount Insulator Adjustment of this section.
(1) Support the engine and transmission assembly
with a floor jack so it will not rotate. ENGINE MOUNT RUBBER INSULATORS
(2) Remove the thru bolt from the insulator and Insulator location on frame rail (right side) and
front crossmember mounting bracket. transmission bracket (left side) are adjustable to al-
(3) Remove the front engine mount bracket to low right/left drive train adjustment in relation to
front crossmember screws and nuts. Remove the in- drive shaft assembly length.
sulator assembly. Check and reposition right engine mount insulator
(4) Reverse removal procedure for installation. Re- (left engine mount insulator is floating type and will
fer to (Fig. 3) for bolt tightening specifications. adjust automatically (Fig. 4). Adjust drive train posi-
(5) Engine mount adjustment, Refer to Engine tion, if required, for the following conditions:
Mount Insulator Adjustment of this section.
Ä 2.2/2.5L ENGINE 9 - 13

• Drive shaft distress: See Driveshafts in Suspension, (9) Remove oil filter.
Group 2. (10) Disconnect fuel line, heater hose and acceler-
• Any front end structural damage (after repair). ator cable.
• Insulator replacement. (11) Disconnect all electrical connections and har-
nesses at throttle body and engine.
ENGINE MOUNT INSULATOR ADJUSTMENT (12) Manual Transmission
(1) Remove the load on the engine motor mounts by (a) Disconnect clutch cable.
carefully supporting the engine and transmission as- (b) Remove transmission case lower cover.
sembly with a floor jack. (c) Disconnect exhaust pipe at manifold.
(2) Loosen the right engine mount insulator vertical (d) Disconnect starter and lay aside.
fasteners, and the front engine mount bracket to front (e) Install transmission holding fixture.
crossmember screws and nuts. (13) Automatic Transmission
Left engine mount insulator is sleeved over (a) Disconnect exhaust pipe at manifold.
shaft and long support bolt to provide lateral (b) Disconnect starter and lay aside.
movement adjustment with engine weight re- (c) Remove transmission case lower cover.
moved or not. (d) Mark flex plate to torque converter.
(3) Pry the engine right or left as required to achieve (e) Remove screws holding torque converter to
the proper drive shaft assembly length. See Drive flex plate.
Shaft in Suspension Group 2 for driveshaft identifica- (14) Attach C clamp on front bottom of torque con-
tion and related assembly length measuring. verter housing to prevent torque converter from com-
(4) Tighten right engine mount insulator vertical ing out.
bolts to 68 NIm (50 ft. lbs.). Then tighten front engine (15) Install transmission holding fixture.
mount screws and nuts to 54 NIm (40 ft. lbs.) and (16) Remove right inner splash shield (Fig. 5).
center left engine mount insulator.
(5) Recheck drive shaft length.

Fig. 4 Left Insulator Movement

ENGINE ASSEMBLY
REMOVAL
(1) Disconnect battery. Fig. 5 Right Inner Splash Shield
(2) Scribe hood hinge outline on hood and remove
(17) Remove ground strap.
hood.
(18) To lower engine separate right engine
(3) Drain cooling system.
bracket from yoke bracket To raise engine remove
(4) Remove hoses from radiator and engine.
long bolt through yoke and insulator. IF INSULA-
(5) Remove radiator and fan assembly.
TOR TO RAIL SCREWS ARE TO BE REMOVED,
(6) Remove air cleaner and hoses.
MARK INSULATOR POSITION ON SIDE RAIL TO
(7) Remove air conditioning compressor mounting
INSURE EXACT INSTALLATION (Fig. 4).
bolts and set compressor aside, if equipped.
(19) Remove transmission case to cylinder block
(8) Remove power steering pump mounting bolts
mounting screws.
and set pump aside
9 - 14 2.2/2.5L ENGINE Ä

CAUTION: Make sure clutch cable has been discon- SOLID MOUNT COMPRESSOR BRACKET SERVICE
nected. When service procedures require solid mount
bracket removal and installation for example: cylin-
(20) Remove front engine mount screw and nut. der head removal, etc., it is important that bracket
(21) Remove manual transmission damper. fasteners numbered 1 through 7 (Fig. 4) be removed
(22) Remove left insulator through bolt from inside and installed in sequence, as instructed in Remove
wheelhouse or insulator bracket to transmission and Install.
screws.
(23) Remove engine from vehicle. ACCESSORIES REMOVAL
(1) Remove (and install/adjust) belts,see Accessory
INSTALLATION Drive Belts in Cooling System,Group 7.
(1) Install hoist to the engine and lower engine (2) Remove air conditioning compressor (in vehicle
into the engine compartment. with lines and set aside) (Fig. 6).
SEE: ENGINE MOUNT RUBBER INSULATORS, (3) Remove generator pivot bolt and remove gener-
THIS GROUP. ator (in vehicle: turn wiring side up and disconnect,
(2) Align engine mounts and install but do not then rotate generator, pulley end towards engine and
tighten until all mounting bolts have been installed. remove).
(3) Install transmission case to cylinder block (4) Remove air conditioner compressor belt idler.
mounting screws. Tighten to 95 NIm (70 ft. lbs.)
torque. SOLID MOUNT BRACKET—REMOVAL (FIG. 4)
(4) Remove engine hoist and transmission holding (1) Remove right engine mount yoke screw (see
fixture. Engine Remove Fig. 3) securing engine mount sup-
(5) Install ground strap. port strut to engine mount bracket.
(6) Install right inner splash shield. (2) Remove five side mounting bolts #1, #4 , #5,
(7) Connect starter. See Electrical Group 8 for in- #6, and #7 (Fig. 4).
stallation. (3) Remove front mounting nut, #2, and remove
(8) Connect exhaust system. See Exhaust Systems front bolt #3*.
Group 11 for installation. (4) Remove front mounting bolt and strut, rotate
(9) Manual Transmission: Install transmission solid mount bracket away from engine and slide
case lower cover. bracket on stud until #2 nut mounting stud until
Automatic Transmission: Remove C clamp from free. Remove spacer from stud.
torque converter housing. Align flexplate to torque
converter and install mounting screws. Tighten to 75 SOLID MOUNT BRACKET—INSTALLATION
NIm (55 ft. lbs.) torque. (1) Put spacer onto stud, then install bracket on
(10) Manual Transmission: Connect clutch cable. front (#2 nut) mounting stud and slide bracket over
See Clutch Group 6. timing belt cover into position.
(11) Install power steering pump. Refer to Cooling (2) Loosen assembly bracket to engine fasteners
System Group 7, Accessory Drive Section for belt (numbered #1 through #7 in Fig. 6).
tension adjustment. (3)
(12) Connect fuel line, heater hose, and accelerator
cable. CAUTION: Fasteners MUST BE TIGHTENED IN SE-
(13) Connect all electrical connections and har- QUENCE and to specified torque as follows :
nesses at throttle body and engine.
(14) Install oil filter. Fill engine crankcase with • First Bolt #1 to 3.3 NIm (30 in. lbs.)
proper oil to correct level. • Second Nut #2 and Bolt #3 to 54 NIm (40 ft. lbs.).
(15) Install air conditioning compressor (if • Third Bolts #1 (second tightening) #4 and #5 to
equipped). See Heater and Air Conditioning, Group 54 NIm (40 ft. lbs.).
24 for installation. • Fourth Bolts #6 and #7 to 54 NIm (40 ft. lbs.).
(16) Install air cleaner and hoses. (4) Install generator and compressor. Tighten com-
(17) Install radiator and shroud assembly . Install pressor mounting bracket bolts to 54 NIm (40 ft.
radiator hoses. Fill cooling system. See Cooling Sys- lbs.).
tem Group 7 for filling procedure.
(18) Install hood. SOLID MOUNT COMPRESSOR BRACKET
(19) Connect battery. SERVICE—TURBO III ENGINE
(20) Start engine and run until operating temper-
ature is reached. REMOVAL
(21) Adjust transmission linkage, if necessary. (1) Disconnect negative battery cable
Ä 2.2/2.5L ENGINE 9 - 15

Fig. 6 Solid Mount Compressor Bracket 2.2 & 2.5L Engines

(2) Remove Accessory Drive Belt. Refer to Cooling (7) Remove right engine mount yoke bolt. Remove
System Group 7 for procedure. the fasteners holding the strut into place. Remove
(3) Remove accessory drive belt idler pulley (Fig. strut from engine (Fig. 9).
7). (8) Remove accessory drive belt idler pulley
bracket (Fig. 9).
(9) Remove timing belt. Refer to procedure out-
lined in this section.
(10) Remove 2 bolts holding solid mount compres-
sor into place, Rotate bracket off engine (Fig. 7).

INSTALLATION
(1) Loosely assemble the bracket to engine with #1
and #2 bolts tighten to 3.3 NIm (30 in. lbs.) (Fig. 8).
(2) Install timing belt. Refer to procedure outlined
in this section. Install timing belt covers. Refer to
procedure outlined in this section.
(3) Install strut on stud. Tighten nut #3 and bolt
#4, torque to 54 NIm (40 ft. lbs.) (Fig. 9). Loosen #1
and #2 bolts, then torque to 54 NIm (40 ft. lbs.) (Fig.
10).Install yoke bolt and torque to 102 NIm (75 ft.
lbs.).
(4) Install accessory drive belt idler pulley and
bracket (Fig. 8).
(5) Install accessory drive belt tensioner pulley
(Fig. 7).
(6) Install generator (Fig. 8).
Fig. 7 Accessory Drive System
(7) Install air conditioning compressor (Fig. 8).
(4) Remove air conditioning compressor and set (8) Install accessory drive belt. Refer to Cooling
aside (Fig. 8). System Group 7 for procedure.
(5) Remove generator attaching bolts set aside (9) Connect negative battery cable.
(Fig. 8).
(6) Remove timing belt covers. Refer to procedure
outlined in this section.
9 - 16 2.2/2.5L ENGINE Ä

Fig. 8 Solid Mount Compressor Bracket—Turbo III Engine

Fig. 9 Accessory Drive Idler Pulley Bracket and Fig. 10 Compressor Bracket to Cylinder Head
Engine Strut Attaching Bolts
POWER STEERING/ACCESSORY DRIVE BELT (4) Remove Power Steering Pump bolts set pump
TENSIONER BRACKET aside (Fig. 11).
(5) Loosen timing belt tension. Refer to Camshaft
REMOVAL and Crankshaft Timing Service for procedure. Re-
(1) Remove Accessory Drive Belt. Refer to Cooling move timing belt idler pulley bolt (Fig. 12).
System Group 7 for procedure.
(2) Remove accessory drive belt tensioner pulley CAUTION: Camshaft and Crankshaft Timing may
(Fig. 7). have to be reset when procedure is completed Refer
(3) Remove Timing Belt covers. Refer to procedure to procedure outlined in this section.
outlined in this section.
Ä 2.2/2.5L ENGINE 9 - 17

Fig. 11 Power Steering Pump Attaching Bolts Fig. 13 Power Steering Pump/Accessory Drive Belt
Tensioner Bracket Attaching Bolts
Adjust as necessary following procedure outlined in
this section.
(6) Install power steering pump on bracket tighten
bolts to 28 NIm (250 in. lbs.) torque (Fig. 11).
(7) Install timing belt covers. Refer to procedure
outlined in this section.

CAUTION: Do not use impact wrench on accessory

drive belt tensioner bolt. It may cause damage to
tensioner arm.

(8) Install accessory drive belt tensioner pulley

bolt finger tight. Then tighten bolt to 54 NIm (40 ft.
lbs.) torque. Install accessory drive belt, Refer to
Cooling System Group 7 for procedure.
Fig. 12 Power Steering Pump Bracket and Timing
Belt Idler Bolt
(6) Remove Bracket bolts #2 and #3 from rear of
engine. Remove Bracket (Fig. 13).

INSTALLATION
(1) Loose assemble bracket to engine.
(2) Tighten bolts #2 and #3 to 3.3 NIm (30 in. lbs.)
(Fig. 13).
(3) Tighten timing belt idler pulley and tighten to
54 NIm (40 ft. lbs.) (Fig. 12).
(4) Tighten bolts 32 and #3 to 54 NIm (40 ft. lbs.)
(Fig. 13).
(5) Camshaft and Crankshaft timing should be
checked at this time.
9 - 18 2.2/2.5L ENGINE Ä

TIMING SYSTEM AND SEALS SERVICE—EXCEPT TURBO III

Fig. 1 Timing System and Seals

Fig. 3 Crankshaft and Water Pump Pulley

TIMING BELT SERVICE
(1) Remove Solid Mount Compressor Bracket. Re-
fer to procedure outlined in this section.
(2) Raise vehicle on a hoist and remove right inner
splash shield (Fig. 2).
Fig. 2 Right Inner Splash Shield (3) Remove screws retaining water pump pulley
Refer to (Fig. 1) for parts identification and torque and bolts retaining crankshaft pulley (Fig. 3) and lay
specifications pullies aside.
(4) Remove nuts holding cover to cylinder head.
Ä 2.2/2.5L ENGINE 9 - 19

Fig. 6 Remove Timing Belt

SERVICING FRONT OIL
SEALS—REPLACEMENT
(1) With timing belt removed, remove crankshaft
sprocket bolt.
(2) Remove crankshaft sprocket using Special Tool
Fig. 4 Timing Belt Cover C-4685, Insert and 5.9 inch long screw (Fig. 7).
(5) Remove screws holding cover to cylinder block. (3) Install crankshaft sprocket using plate L-4524,
(6) Remove both halves of timing belt cover and Thrust Bearing/washer and 5.9 inch long screw (Fig.
lay aside (Fig. 4) 7).
(7) Place a jack under engine.
(8) Separate right engine mount (Fig. 5) and raise
engine slightly.
(9) Loosen timing belt tensioner screw (Fig. 6) and
remove timing belt.

Fig. 5 Right Engine Mount

Fig. 7 Crankshaft Sprocket
9 - 20 2.2/2.5L ENGINE Ä

(4) Hold engine sprocket with Special Tool C-4687 and Camshaft seals using Special Tool C-4680. In-
(with adaptor Tool C-4687-1) while removing/install- stall seals until flush (Fig. 10).
ing screw (Fig. 8). The 2.5L Engine camshaft/inter-
mediate shaft sprockets have an off-set hub and are
identified with a six-hole pattern .

Fig. 10 Installing Crankshaft,Intermediate Shaft, and

Camshaft Seal
Fig. 8 Removing/Installing Camshaft or Intermediate
Shaft Sprocket Screw
CAMSHAFT, CRANKSHAFT AND INTERMEDIATE
SHAFTS TIMING PROCEDURE
(5) Remove crankshaft seal using Special Tool
6341. Remove intermediate and camshaft seals using
Special Tool C-4679 (Fig. 10).

CAUTION: Do not nick shaft seal surface or seal

bore.

(6) Shaft seal lip surface must be free of varnish,

dirt or nicks. Polish with 400 grit paper if necessary.
(7) Install engine crankshaft seal into retainer us-
ing Special Tool 6342 and 6343. Install Intermediate

Fig. 11 Crankshaft and Intermediate Shaft Timing

(1) Remove all spark plugs. Turn crankshaft and
intermediate shaft until markings on sprockets are
in line, see arrows (Fig. 11 ).
Fig. 9 Removing Crankshaft, Intermediate Shaft and
Camshaft Oil Seal
Ä 2.2/2.5L ENGINE 9 - 21

(2) Turn camshaft until arrows on hub are inline (8) Turn engine clockwise from TDC two crank revo-
with No. 1 camshaft cap to cylinder headline. Small lutions to TDC. Do not reverse rotate crankshaft
hole (arrow Fig. 12) must be in vertical center line. or attempt to rotate engine using cam or acces-
(3) Install timing belt. sory shaft attaching screw.
(9) Hold weighted wrench in position while tighten-
ing bolt on tensioner to 61 NIm (45 ft. lbs.) torque.
(10) Lower engine onto engine mount install mount-
ing bolts and tighten to specifications refer to (Fig. 3).
(11) Remove jack from under engine.
(12) Inspect foam stuffer block condition and posi-
tion (Fig. 14). Stuffer block should be intact and secure
within the engine bracket tunnel.
(13) Position both halves of timing belt cover to-
gether (Fig. 4).
(14) Install fasteners holding cover to cylinder head
and block. Tighten fasteners to 4 NIm (40 in. lbs.)
torque.
(15) Valve Timing Check; (timing belt cover in-
stalled). With number one cylinder at TDC, small hole
in sprocket must be centered in timing belt cover hole
Fig. 12 Camshaft Timing (Fig. 12). If hole is not aligned correctly perform
procedure again.
(4) Rotate crankshaft two full revolutions and re- (16) Install spark plugs.
check timing.

CAUTION: Do not allow oil or solvents to contact

the timing belt as they can deteriorate the rubber
and cause tooth skipping.

(5) Rotate crankshaft till number 1 cylinder is at

the TDC position.
(6) Put belt tension Special Tool C-4703 horizon-
tally on large hex of timing belt tensioner pulley and
loosen tensioner lock nut.
(7) Reset belt tension Special Tool C-4703 index if
necessary to have axis within 15° of horizontal. (Fig.
13)

Fig. 14 Foam Stuffer Block Location

Fig. 13 Adjusting Drive Belt Tension

9 - 22 2.2/2.5L ENGINE Ä

CYLINDER HEAD AND VALVE ASSEMBLY SERVICE—EXCEPT TURBO III

Fig. 1 Cylinder Head and Valve Assembly Service

Ä 2.2/2.5L ENGINE 9 - 23

Curtain is retained in position with rubber

bumpers (Fig. 1).

COVER SEALING AND INSTALLATION

Before installation, clean cylinder head and cover
mating surfaces. Make certain rails are flat.
(1) Install new end seals on valve cover.
(2) Apply form-in-place Mopar Silicone Rubber Ad-
hesive Sealant or equivalent gasket material to cyl-
inder head cover rail (Fig. 3). Refer to procedure
detailed in form-in-place gasket section of Standard
Service Procedures, in this Group.

Caution: Do not allow oil or solvents to contact the

timing belt as they can deteriorate the rubber and
cause tooth skipping.

(3) Install curtain, cover and end seal assembly to

head and tighten to 12 NIm (105 in.lbs.) torque.

CYLINDER HEAD COMPONENTS—IN-VEHICLE

SERVICE
Fig. 2 Cylinder Head Cover and Curtain Removal and installation of cylinder head or cam-
shaft require separation of camshaft timing sprocket
CYLINDER HEAD COVER AND CURTAIN from camshaft. To maintain camshaft, intermediate
A curtain aiding air/oil separation is installed on shaft, and crankshaft timing during service proce-
the cylinder head below the cylinder head cover dures, the timing belt is left indexed on the sprocket
(Figs. 1 and 2). while the assembly is suspended under light tension
(Fig. 4).
REMOVAL When removing the sprocket from the camshaft,
(1) Remove the cylinder head cover bolts (Fig. 2). you must maintain adequate tension on the sprocket
(2) Remove cylinder head cover and curtain from and belt assembly to prevent the belt from disengag-
cylinder head. Do not misplace the rubber bumpers ing with the intermediate or crankshaft timing
on curtain. sprockets. Refer to Timing System and Seals for re-
CLEANING
Before installation, clean cylinder head and cover
mating surfaces. Make certain the rails are flat.

CURTAIN INSTALLATION
Install curtain manifold side first with cutouts over
cam towers and contacting cylinder head floor, then
press opposite distributor side into position below cyl-
inder head rail.

Fig. 3 Cylinder Head Valve Cover Rail Sealing Fig. 4 Suspending Camshaft Sprocket
9 - 24 2.2/2.5L ENGINE Ä

shaft timing belt and sprocket removal and installa-

tion, and CYLINDER HEAD In Vehicle Service.

REMOVAL
(1) Remove the cylinder head cover and curtain.
(2) Mark rocker arms for reinstallation in the
same position (Fig. 6).
(3) Loosen camshaft bearing cap screws several
revolutions (Fig. 7).
(4) Jar camshaft at rear of cam to loosen (break
free) the bearing caps. Use a soft faced mallet.

CAUTION: Care should be exercised not to cock the

camshaft during removal. Cocking of the camshaft
could cause damage to the cam or bearing thrust
surfaces.

(5) Remove screws and caps such that cam does

not cock.

INSPECTION
Check bearing cap and oil feed holes for blockage.
Inspect bearing cap and cylinder head journals for
wear and/or oversize, Refer to CYLINDER HEAD,
Inspect and Specifications.

Fig. 5 Engine Sprocket Timing

moval and installation of camshaft sprocket proce-
dure and to Camshaft Service for removal and
installation of camshaft procedures.

CAUTION: Failure to maintain adequate tension on

camshaft, intermediate, and crankshaft sprocket
belt can result in lost engine timing. If timing is
lost, refer to Timing System and Seals and (Fig. 4).
Fig. 7 Camshaft Cap Removal Sequence
CAMSHAFT SERVICE
Refer to TIMING SYSTEM AND SEALS for cam-

Fig. 8 Camshaft

Fig. 6 Rocker Arm and Lash Adjuster

Ä 2.2/2.5L ENGINE 9 - 25

Camshaft bearing journals and lobe wear. Lobe

wear should not exceed .25mm (.010 inch). To mea-
sure cam lobe wear (Fig. 8), measure lobe diameter
in two places at the largest diameter (over the nose).
Take first reading with micrometer in unworn area
at the edge of the lobe. Take second reading in the
worn area where rocker arm contacts the lobe. Sub-
tract second reading from the first. The difference is
the cam lobe wear.

CAMSHAFT END PLAY

(1) Oil camshaft journals and install camshaft
without cam followers. Tighten screws to specified
torque.
(2) Using a suitable tool, move camshaft as far
rearward as it will go.
(3) Zero dial indicator (Fig. 9).
(4) Move camshaft as far forward as it will go.
(5) End play travel: 0.13 - 0.33mm (0.005 - 0.013
inch.).
(6) Remove bearing caps and camshaft. Fig. 10 Cam Tower Cap Sealing

Fig. 11 Camshaft Bearing Caps Installation

VALVE COMPONENTS REPLACE—CYLINDER
HEAD NOT REMOVED

ROCKER ARM AND HYDRAULIC LASH

Fig. 9 Camshaft End Play ADJUSTER

INSTALLATION REMOVAL
(1) Install cam followers in correct order as re- (1) Remove valve cover.
moved. (2) For each rocker arm, rotate cam until base cir-
(2) Align camshaft bearing caps in proper sequence cle is in contact with rocker arm. Depress valve
with Cap No. 1 at timing belt end and Cap No. 5 at spring using Special Tool C-4682 (Fig. 12) and slide
transmission end. Arrows on Caps No. 1, 2, 3, 4 rocker arm out. Keep rocker arms in order for reas-
must point toward timing belt to prevent cap break- sembly.
age (Fig. 11). (3) Remove hydraulic lash adjuster.
(3) Apply Mopar Gasket Maker to No.1 and No.5
bearing cap (Fig. 10). INSTALLATION
(4) Caps must be installed before camshaft seals (1) Install hydraulic lash adjusters making sure
are installed. that adjusters are at least partially full of oil. This is
indicated by little or no plunger travel when the lash
LASH ADJUSTER (TAPPET) NOISE adjuster is depressed.
A tappet-like noise may be produced from several (2) Rotate cam until base circle is in contact posi-
items. Refer to Lash Adjuster and Tappet Noise - Di- tion with rocker arm. Depress valve spring with Spe-
agnosis in Standard Service Procedures, this Group. cial Tool C-4682 (Fig. 12) and slide rocker arm in
place. Keep rockers in order. It is possible for the
9 - 26 2.2/2.5L ENGINE Ä

Fig. 12 Removing and Installing Valve Spring

Fig. 13 Valve Stem Seals
valve spring retainer locks to become dislocated
when depressing the valve spring.Check and make CYLINDER HEAD
sure the locks are in their proper location. REMOVAL
(3) Install valve cover as previously outlined in (1) Perform fuel system pressure release procedure
this section. before attempting any repairs.Refer to Fuel Sys-
tem Group 14
VALVE SPRINGS AND VALVE STEM SEALS
(2) Disconnect negative battery cable. Drain cool-
REMOVAL ing system. Refer to Cooling System, Group 7.
(1) Remove rocker arms as previously outlined in (3) Remove air cleaner and disconnect all vacuum
this section. lines, electrical wiring and fuel lines from throttle
(2) Rotate crankshaft until piston is at TDC on body.
compression. (4) Remove throttle linkage.
(3) With air hose attached to adapter tool installed (5) Loosen power steering pump and remove belt.
in spark plug hole, apply 90-120 psi air pressure. (6) Remove power brake vacuum hose from intake
(4) Using Special Tool C-4682 (Fig. 12) compress manifold.
valve springs and remove valve locks. (7) Remove water hoses from water crossover.
(5) Remove valve spring. (8) Raise vehicle and remove exhaust pipe from
(6) Remove valve stem seal by gently prying side- manifold.
to-side with a screwdriver blade. Once dislodged from (9) Remove power steering pump assembly and set
guide post, seal may be easily removed. aside.
(10) Disconnect coil wiring connector and coil wire
INSTALLATION from coil.
(11) Disconnect dipstick tube from thermostat
CAUTION: Flexible Fuel Vehicle Valve use unique housing and ROTATE bracket from stud.DO NOT
valve stem oil seals they are green in color. Stan- bend the bracket or tube.
dard valve stem oil seals are NOT to be interchanged (12) See Solid Mount Compressor Bracket in
with Flexible Fuel Vehicles engines. STANDARD SERVICE PROCEDURES, this Group.
(13) Remove cylinder head bolts.
(1) Install valve seals (Fig. 13) as outlined in step
(2) of Valve Gear Reassembly - After Valve Ser- INSPECT HEAD AND CAMSHAFT BEARING
vice in this section. JOURNALS
(2) Using Special Tool C-4682 compress valve (1) Cylinder head must be flat within 0.1mm (.004
springs only enough to install locks. Correct align- inch) (Fig. 14).
ment of tool is necessary to avoid nicking valve (2) Inspect camshaft journals for scoring and jour-
stems (air pressure required), piston at TDC. nal caps for oversize markings. When servicing cyl-
(3) Install rocker arms as previously outlined in inder head or camshaft, it is necessary to be certain
this section. that oversized camshafts are used only in oversized
heads.
Identify oversize components as follows:
Ä 2.2/2.5L ENGINE 9 - 27

Fig. 14 Checking Cylinder Head Flatness

Cylinder Head: Top of bearing caps painted green
and O/SJ stamped rearward of oil gallery plug on end
of head.
Camshaft: Barrel of camshaft painted green and
O/SJ stamped on end of shaft.
Fig. 15 Cylinder Head Gaskets
CLEANING
Remove all gasket material from cylinder head and
block. Be careful not gouge or scratch the aluminum
head sealing surface.

INSTALLATION

CAUTION: Head bolt diameter is 11mm. These bolts

are identified with 11 on the head of the bolt. 10mm
bolts will thread into the 11mm hole but will strip the
cylinder block bolt hole. Fig. 16 Checking Bolts for Stretching (Necking)
Since the Cylinder head bolts are torqued us- (4) Rotate dipstick tube or bracket onto stud.
ing a new procedure they should be examined Tighten bracket retaining nut to 23 NIm (200 in.
BEFORE reuse. If the threads are necked down lbs.)
the bolts should be replaced (Fig. 16).
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.
(1) Before installing the bolts the threads should be
oiled with engine oil.
(2) Install both bolts in each cap finger tight, then
alternately torque each bolt to assemble the cap prop-
erly.
(3) Tighten the cylinder head bolts in the sequence
shown in (Fig. 17). Using the 4 step torque turn
method, tighten according to the following values:
• First All to 61 NIm (45 ft. lbs.) Fig. 17 Cylinder Head Tightening Sequence
• Second All to 88 NIm (65 ft. lbs.) VALVE SERVICE—CYLINDER HEAD REMOVED
• Third All (again) to 88 NIm (65 ft., lbs.)
• Fourth + 1/4 Turn Do not use a torque wrench VALVES AND VALVE SPRINGS
for this step.
Bolt torque after 1/4 turn should be over 90 ft. lbs. If REMOVAL
not, replace the bolt. (1) With cylinder head removed, compress valve
9 - 28 2.2/2.5L ENGINE Ä

springs using Tool C-3422-B.

(2) Remove valve retaining locks, valve spring re-
tainers, valve stem seals and valve springs.
(3) Before removing valves,remove any burrs
from valve stem lock grooves to prevent damage
to the valve guides. Identify valves to insure instal-
lation in original location.

VALVE INSPECTION
(1) Clean valves thoroughly and discard burned,
warped and cracked valves.
(2) Measure valve stems for wear.
(3) If valve stems are worn more than 0.05 mm (.002 Fig. 19 Valve Guide Specification
inch.) replace valve. inch) so the valve guides may be reamed true in
relation to the valve seat. After reaming guides, the
VALVE GUIDES seat runout should be measured and resurfaced if
(1) Remove carbon and varnish deposits from inside necessary. Refer to Refacing Valves and Valve Seats.
of valve guides with a reliable guide cleaner. Replace cylinder head if guide does not clean
(2) Checking Valve Guide Wear:
up with 0.80 mm (.030 inch) oversize reamer, or if
• Insert valve with valve head positioned 10 mm (.400
guide is loose in cylinder head.
inch) above cylinder head gasket surface.
• Move valve to and from the indicator (Fig. 17). The
total dial indicator reading should not exceed the amount
specified in (Fig. 18). Readings should be taken for length-
wise and crosswise (with respect to cylinder head) move-
ment for each valve. Ream the guides for valves with
oversize stems if dial indicator reading is excessive or if
the stems are scuffed or scored.

Fig. 20 Testing Valve Spring with Tool C-647

TESTING VALVE SPRINGS
(1) Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should be
tested. As an example, the compression length of the
spring to be tested is 33.34mm (1-5/16 inches). Turn table
of Tool C-647 until surface is in line with the 33.34mm
Fig. 18 Checking Wear on Valve Guide—Typical (1-5/16 inch) mark on the threaded stud and the zero
(3) Service valves with oversize stems and oversize mark on the front. Place spring over stud on the table and
seals are available in 0.15mm, (.005 inch) 0.40mm, lift compressing lever to set tone device (Fig. 20). Pull on
(.015 inch) and 0.80mm(.031 inch) oversize. torque wrench until ping is heard. Take reading on torque
Oversize seals must be used with oversize wrench at this instant. Multiply this reading by two. This
valves. will give the spring load at test length. Fractional mea-
Reamers sizes to accommodate the oversize valve surements are indicated on the table for finer adjust-
stem are shown in (Fig. 18) ments. Refer to specifications to obtain specified height
(4) Slowly turn reamer by hand and clean guide thor- and allowable tensions. Discard the springs that do not
oughly before installing new valve. Do not attempt to meet specifications.
ream the valve guides from standard directly to
0.80mm (.030 inch). Use step procedure of 0.15mm
(.005 inch), 0.40mm (.015 inch) and 0.80mm (.030
Ä 2.2/2.5L ENGINE 9 - 29

(2) Inspect each valve spring for squareness with a Valve seats which are worn or burned can be re-
steel square and surface plate, test springs from both worked, provided that correct angle and seat width are
ends. If the spring is more than 1.5mm (1/16 inch) maintained. Otherwise cylinder head must be replaced.
out of square, install a new spring.

Fig. 21 Intake and Exhaust Valves

Fig. 23 Refacing Intake and Exhaust Valves

(6) When seat is properly positioned the width of
intake seats should be 1.75 to 2.25mm (0.69 to .088
inch) The width of the exhaust seats should be 1.50
to 2.00mm (.059 to .078 inch) (Fig. 24 Dimension 1).

Fig. 22 Valve Dimensions

REFACING VALVES AND VALVE SEATS
(1) The intake and exhaust valve seats and valve
face have a 45 degree angle.
(2) Inspect the remaining margin after the valves are
refaced (Fig. 23). Exhaust valves with less than
1.191mm (3/64 inch) margin and intake valves with less
than .794mm (1/32 inch) margin should be discarded. Fig. 24 Refacing Valve Seats
(3) When refacing valve seats, it is important that
(7) Check valve tip to spring seat dimensions after
the correct size valve guide pilot be used for reseating
grinding the valve seats or faces. Grind valve tip to get
stones. A true and complete surface must be obtained.
49.76 to 51.04mm (1.960 to 2.009 inch) over spring seat
(4) Measure the concentricity of valve seat using a when installed in the head (Fig. 25). The valve tip di-
valve seat dial indicator. Total runout should not ex- ameter should be no less than 7.0mm (0.275 inch), if
ceed. 051mm (.002 inch) (total indicator reading). necessary, the tip chamfer should be reground to pre-
(5) Inspect the valve seat with Prussian blue to deter- vent seal damage when the valve is installed.
mine 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 the
valve face, lower valve seat with a 15 degrees stone. If
the blue is transferred to the bottom edge of valve face
raise valve seat with a 65 degrees stone.
• Intake valve seat diameter 40.45mm (1.593 inch)
• Exhaust valve seat diameter 34.84mm (1.371 inch)
9 - 30 2.2/2.5L ENGINE Ä

CAUTION: Flexible Fuel Vehicles use unique valve

stem oil seals they are green in color. Standard
valve stem oil seals are NOT to be interchanged with
Flexible Fuel Vehicles engines.

(2) Install new valve stem seals on all valves. The

valve stem seals should be pushed firmly and
squarely over valve guide. The lower edge of the seal
should be resting on the valve guide boss.

CAUTION: When oversize valves are used, the cor-

responding oversize valve seal must also be used.
Fig. 25 Valve Tip to Spring Seat Dimensions Excessive guide wear may result if oversize seals
(8) Check the valve spring installed height after are not used with oversize valves.
refacing the valve and seat (Fig. 26).
(3) Install valve spring seats and springs and re-
CAUTION: If more than .5mm (.020 inch) must be tainers. Compress valve springs only enough to in-
stall locks, taking care not to misalign the direction
ground from the valve tip, check the clearance be-
of compression. Nicked valve stems may result from
tween the rocker arm and the valve spring retainer
misalignment of the valve spring compressor.
if below 1.25mm (.050 inch), grind the rocker arm
ears according to the procedure described in Refac- CAUTION: When depressing the valve spring retain-
ing Valves and Valve Seats. ers with Tool C-3422-B the locks can become dislo-
cated. Check to make sure both locks are in their
correct location after removing tool.

(4) Check installed height of springs. Measurement

is to be taken from the spring seat to the bottom of
the spring retainer. Correct height is 41.2mm to
42.7mm (1.62 to 1.68 inches). If seats have been re-
ground an additional spring seat may be required to
maintain correct installed spring height.
(5) Install adjusters, rocker arms in order, and
camshaft as previously described, see Camshaft-In-
stall. Check for clearance between the projecting ears
(either side of valve tip) of the rocker arms and the
valve spring retainers. At least 1.25 mm (.050 inch)
clearance must be present, if necessary, the rocker
arm ears may be ground to obtain this clearance
(Fig. 26).
Fig. 26 Checking Spring Installed Height and Spring
(6) Checking dry lash. Dry lash is the amount of
Retainer Clearance
clearance that exists between the base circle of an in-
CLEANING stalled cam and the rocker arm roller when the ad-
Clean all valve guides, valves and valve spring as- juster is drained of oil and completely collapsed.
semblies thoroughly with suitable cleaning solution Specified dry lash is 0.62 to 1.52 mm (.024 to .060
before reassembling. inch). To completely collapse adjuster for dry lash
measurement, pry off retainer cap, disassemble,
VALVE GEAR REASSEMBLY AFTER VALVE SERVICE drain the adjuster of oil, reassemble, and install. Af-
(1) Coat valve stems with lubrication oil and insert ter performing dry lash check, refill adjuster with oil
in cylinder head. (do not reuse retainer cap/s) and allow 10 minutes for
adjuster/s to bleed down before rotating cam.
Ä 2.2/2.5L ENGINE 9 - 31

CYLINDER HEAD AND VALVE ASSEMBLY

SERVICE—TURBO III
CYLINDER HEAD COVER SEALING
(1) Before installation, clean cylinder head and cover
mating surfaces. Make certain rails are flat.

Caution: Do not allow oil or solvents to contact the

timing belt as they can deteriorate the rubber and
cause tooth skipping.

Fig. 2 Checking Cylinder Head Flatness

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.

Fig. 1 Cylinder Head Valve Cover and Gasket As-

sembly
(2) Install covers and gasket assembly to head and
torque to 12 NIm (105 in.lbs.).

CYLINDER HEAD

REMOVAL
Refer to Intake and Exhaust Manifold Service in
Exhaust Systems and Intake Manifold Group 11 for
removal procedure for the intake and exhaust mani-
folds.
(1) The Timing Belt and Solid Mount Compressor
Mount Bracket must be removed before the cylinder
head can be removed. Refer to procedure outlined in
this group for service procedures.
(2) Remove cylinder head bolts.
(3) Cylinder head must be flat within 0.1mm (.004
inch) (Fig. 2).

INSTALLATION Fig. 3 Cylinder Head Gaskets

CAUTION: The Turbo III head gasket is not the same

as any other engine head gasket (Fig. 3).

CAUTION: Head bolt diameter is 11mm. These bolts

are Unique to this engine application they are not
interchangeable with other engines.

The Cylinder head bolts are torqued using a

new procedure they should be examined BE-
FORE reuse. If the threads are necked down the Fig. 4 Checking Bolts for Stretching—Necking
bolts should be replaced. (Fig. 4 ).
9 - 32 2.2/2.5L ENGINE Ä

TIMING BELT COVER SERVICE—TURBO III

ENGINE
REMOVAL
(1) Remove PCV tube and upper timing belt cover
screws (Fig. 1). Remove upper cover.
(2) Remove accessory drive belt. Refer to Cooling
System Group 7 for procedure.
(3) Raise vehicle on a hoist and remove right
wheel and inner splash shield (Fig. 2).

Fig. 5 Cylinder Head Tightening Sequence

Before installing the bolts, the threads should be
cleaned and oiled.
Tighten the cylinder head bolts in the sequence
shown in (Fig. 5 ). Using the 4 step torque turn
method, tighten according to the following values:
• First All to 61 NIm (45 ft. lbs.)
• Second All to 88 NIm (65 ft. lbs.)
• Third All (again) to 88 NIm (65 ft., lbs.)
• Fourth + 1/4 Turn Do not use torque wrench
for this step.
• Bolt torque after 1/4 turn should be over 90 ft. lbs.
If not, replace the bolt.
Refer to Intake and Exhaust Manifold Service in
Exhaust Systems and Intake Manifold Group 11 for
installation procedure.
Refer to the Timing Belt and Solid Mount Com-
pressor Mount Bracket service procedures in this Fig. 2 Right Inner Splash Shield
group for installations procedures.

Fig. 3 Crankshaft and Water Pump Pulleys

(4) Remove water pump pulley and crankshaft pul-
ley retaining bolts (Fig. 3), remove pulleys.
(5) Remove lower accessory drive belt idler and
tensioner pulley (Fig. 4).

Fig. 1 Timing Belt Cover Screws

Ä 2.2/2.5L ENGINE 9 - 33

CAUTION: Do not use a impact wrench to remove

pulley bolts.

(6) Remove lower timing belt cover fasteners (Fig.

1). Remove cover.

Fig. 5 Right Engine Mount—Typical

(3) Raise vehicle on a hoist. Remove lower acces-
sory drive belt idler pulley bracket assembly (Fig. 6).
(4) Loosen timing belt tensioner, remove timing
Fig. 4 Timing Belt Cover and Tensioner belt and idler pulley (Fig. 6).
(5) Lower vehicle
INSTALLATION
(1) Raise vehicle on hoist. Install lower timing belt
cover and tighten fasteners to 12 NIm (105 in. lbs.)
torque (Fig. 4).

CAUTION: Do not use impact wrench on accessory

drive belt tensioner bolt. It may cause damage to
tensioner arm. Accessory drive belt tensioner pul-
ley bolt must be installed finger tight.

(2) Install accessory drive belt tensioner pulley

bolt finger tight. Then tighten bolt to 54 NIm (40 ft.
lbs.) torque (Fig. 4).
(3) Install crankshaft and water pump pulleys
(Fig. 3).
(4) Install inner splash shield and wheel (Fig. 2).
(5) Install accessory drive belt. Refer to Cooling
System Group 7 for procedure.
(6) Install upper timing belt cover and tighten
screws to 4 NIm (36 in. lbs.) torque. Install PCV tube
(Fig. 1).

TIMING BELT Fig. 6 Remove Timing Belt

REMOVAL
(1) Remove timing belt cover refer to timing belt
cover service of this section for procedure.
(2) Lift engine with Engine Support Tool C-4852.
Separate right engine mount (Fig. 5).
9 - 34 2.2/2.5L ENGINE Ä

CAMSHAFT AND CRANKSHAFT TIMING

PROCEDURE
INSTALLATION
(1) Remove air cleaner fresh air duct.
(2) Remove ignition cable cover (Fig. 7).
(3) Remove valve covers and loosen rocker arm as-
semblies about 3 turns as shown in (Fig. 8).

CAUTION: Check lash adjuster for loose or missing

retainers before continuing service procedure.

(4) Align and pin both intake and exhaust cam

sprockets with 3/32 drills or pin punches (Fig. 9). Ac-
cessory Shaft does not need to be timed.
(5) Remove spark plugs.
Fig. 9 Camshafts Pinned Into Position

Fig. 7 Ignition Cable Cover

Fig. 10 Dial Indicator Located in Number 1 Cylinder

(10) Adjust tension to 445 N (110 lbs.) New belt or
311 N (70 lbs.) Used belt . Install belt tension gauge on
timing belt (Fig. 12) adjust tensioner until specified
tension is achieved.
Fig. 8 Rocker Arm Shaft Assemblies
CAUTION: Belt tension gauge must be installed be-
(6) Install a dial indicator in Number 1 spark plug tween the belt teeth to get a accurate reading.
hole (Fig. 10).
(7) Rotate crankshaft till number 1 piston is at (11) Rotate crankshaft clockwise 2 full revolutions
Top Dead Center. Mark the engine block for TDC and check alignment of camshaft and crankshaft tim-
reference. ing marks. Do not reverse rotate crankshaft or
(8) Install timing belt and idler pulley in sequence attempt to rotate engine using cam or accessory
shown in (Fig. 11). shaft attaching screw.
(9) Remove dial indicator from cylinder head (Fig.
10). Remove drills or pins from camshaft sprockets CAUTION: Do not allow oil or solvents to contact the
(Fig. 11). timing belt as they can deteriorate the rubber and
cause tooth skipping.
Ä 2.2/2.5L ENGINE 9 - 35

Fig. 13 Rocker Arm Shaft—Installation

Fig. 11 Camshafts and Crankshaft Timing Marks

Fig. 14 Foam Stuffer Block Location

(17) Lower vehicle. Install right engine mount (Fig.
5).
(18) Inspect foam stuffer block condition and posi-
tion (Fig. 14). Stuffer block should be intact and secure
within the engine bracket tunnel.
(19) Install upper timing belt cover and PCV tube.
Refer to procedure in this section.
(20) Install accessory drive belt. Refer to procedure
in this section.

SERVICING OIL SEALS

Fig. 12 Belt Tension Gauge Location Refer to servicing oil seals in this group for proce-
(12) Recheck belt tension, adjust if necessary. dures.
(13) Torque rocker arm shafts in sequence shown To service the intake cam seal (Turbo III) the
right engine mount must be removed. Refer to
(Fig. 13) to 12 NIm (105 in. lbs.) then to 24 NIm (210
engine mount removal of this Group.
in. lbs.).
(14) Install valve covers, spark plugs, ignition cables
and ignition cable cover.
(15) Install air cleaner fresh air duct.
(16) Raise vehicle. Install lower timing belt cover
and accessory drive belt tensioner pulley. Refer to
procedure in this section.
9 - 36 2.2/2.5L ENGINE Ä

CAMSHAFTS SERVICE
Cylinder Head must be removed from vehicle. Re-
fer to cylinder head removal for procedure.

REMOVAL
(1) Mark rocker arms shafts for reinstallation in
the same position (Fig. 1).
(2) Remove rocker arm assembly attaching bolts in
sequence (Fig. 1 ).
(3) Remove thrust plates from rear of camshafts
(Fig. 2).The intake camshaft uses a wider thrust
plate than exhaust camshaft.

CAUTION: Thrust plates are not the same thickness

and cannot be interchanged.

Fig. 3 Removing Camshaft Oil Seal

(6) Slide the camshaft out of the cylinder head. Be-
careful not scratch the bearing surfaces in the head
(Fig. 4).

CAUTION: Intake and Exhaust camshafts are not in-

terchangeable.

Fig. 1 Rocker Arm Shaft Removal Sequence

Fig. 4 Camshaft—Removal or Installation

INSPECTION
Camshaft lobe wear should not exceed .25mm (.010
inch). To measure cam lobe wear (Fig. 4), measure
lobe diameter in two places at the largest diameter
(over the nose). Take first reading with micrometer
in unworn area at the edge of the lobe. Take second
reading in the worn area where rocker arm contacts
the lobe. Subtract second reading from the first. The
Fig. 2 Camshaft Thrust Plates difference is the cam lobe wear.
(4) Before camshaft can be removed from cylinder
INSTALLATION
head the cam seal must be removed first. Becareful
(1) Lubricate camshaft journals with clean engine
not to damage seal surface of the camshaft.
oil. Carefully install camshaft into the head.
(5) Using a screwdriver place it against the side of
the cam lobe push the cam out of the head. The cam CAUTION: Camshafts are not interchangeable. The
seal will be pushed out by the cam (Fig. 3). intake cam has a wider thrust plate groove.
Ä 2.2/2.5L ENGINE 9 - 37

VALVE COMPONENTS REPLACE—CYLINDER HEAD

NOT REMOVED
ROCKER ARM AND HYDRAULIC LASH
ADJUSTER

REMOVAL

(1) Remove valve cover. Refer to procedure previ-

ously outlined in this section.
(2) Remove rocker arm shaft(s) in sequence shown
in (Fig. 6). Slide rocker off the shaft. Keep rocker
arms in order for reassembly.

CAUTION: Check lash adjusters for loose or miss-

ing retainers before continuing service procedure.
Fig. 5 Measuring Camshaft Lobe Wear
(2) Install thrust plates and tighten retaining nuts (3) Remove hydraulic lash adjuster.
to 6 NIm (55 in. lbs.).
(3) Install new camshaft oil seals flush with cylin-
der head surface.
Using seal installing special tool C-4680.

Fig. 7 Rocker Arm Shaft—Removal

Fig. 6 Checking Camshaft End Play

CAMSHAFT END PLAY
(1) Using a suitable tool, move camshaft as far
rearward as it will go.
(2) Zero dial indicator (Fig. 6).
(3) Move as far forward and backward as camshaft
will go.
(4) End play travel: 0.025-0.200mm (.001-.008 Fig. 8 Rocker Arm and Lash Adjuster
inch). Assembly—Right and Left
LASH ADJUSTER (TAPPET) NOISE
A tappet-like noise may be produced from several
items. See Lash Adjuster and Tappet Noise-DIAG-
NOSIS in STANDARD SERVICE PROCEDURES,
this Group.
9 - 38 2.2/2.5L ENGINE Ä

INSTALLATION (2) Remove valve retaining locks, valve spring re-

(1) Install rocker arm on the shaft in there origi- tainers, valve stem seals and valve springs.
nal position (Fig. 9). (3) Before removing valves, remove any burrs
(2) Install hydraulic lash adjusters making sure from valve stem lock grooves to prevent damage
that adjusters are at least partially full of oil. This is to the valve guides. Identify valves to insure instal-
indicated by little or no plunger travel when the lash lation in original location.
adjuster is depressed.
(3) Install rocker arm shaft assembly tighten in se-
quence shown in (Fig. 10).
(4) Install valve cover as previously outlined.

Fig. 11 Valve Spring Compressor

Fig. 9 Intake and Exhaust Rocker Arm Assemblies

Fig. 12 Valve Guide Specification

VALVE INSPECTION
(1) Clean valves thoroughly and discard burned,
warped and cracked valves.
(2) Measure valve stems for wear. Refer to (Fig. 14)
for specifications.
(3) Remove carbon and varnish deposits from inside
of valve guides with a reliable guide cleaner.

VALVE GUIDES
Measure valve guides in 3 places top, middle and
bottom (Fig. 13). Using a small hole gauge and a
Fig. 10 Rocker Arm Shaft—Installation micrometer, refer to (Fig. 12) for specifications.
Replace cylinder head if guides are not within
VALVE SPRINGS AND VALVE STEM SEALS
specifications.
VALVE SERVICE
• CYLINDER HEAD MUST BE REMOVED TO TESTING VALVE SPRINGS
SERVICE VALVE SPRINGS AND VALVE STEM (1) Refer to Testing Valve previously described in
SEALS. this Group for procedure. Test springs at 36.8 mm
(1-7/16 to 1-15/32 in.) 1000 N (225 lbs.) 6 40 N (9 lbs.).
VALVES AND VALVE SPRINGS Discard the springs that do not meet specifications.
(2) Inspect each valve spring for squareness with a
REMOVAL steel square and surface plate, test springs from both
(1) With cylinder head removed, compress valve ends. If the spring is more than 1.65mm (1/16 inch) out
springs using Valve Spring Compressor Tool of square, install a new spring. Spring free length is
C-3422-B with adopters 6537 and 6526 (Fig. 11). 53.2 mm 6.25 mm (2.094 in. 6.010 in.)
Ä 2.2/2.5L ENGINE 9 - 39

Fig. 13 Measuring Valve Guides

Fig. 15 Refacing Intake and Exhaust Valves

Valve seats which are worn or burned can be re-
worked, provided that correct angle and seat width
are maintained. Otherwise cylinder head must be re-
placed.
(6) When seat is properly positioned the width of
intake seats should be 1.87mm (0.73 inch) The width
of the exhaust seats should be 2.00mm (.078 inch)
(Fig. 16 Dimension 1).
(7) Check valve tip to spring seat dimensions A af-
ter grinding the valve seats or faces. Grind valve tip
to give 55.62 to 55.88 mm (2.190 to 2.200 inch.) over
Fig. 14 Valve Dimensions
spring seat when installed in the head (Fig. 17).
REFACING VALVES AND VALVE SEATS Check valve tip for scoring, if necessary, the tip
(1) The intake and exhaust valve seats and valve chamfer should be reground to prevent seal damage
face have a 45 degree angle. when the valve is installed.
(2) Inspect the remaining margin after the valves (8) Check the valve spring installed height B after
are refaced (Fig. 11). Exhaust valves with less than refacing the valve and seat (Fig. 17). Measurement B
1.07mm (3/64 inch) margin and intake valves with is to be taken from the spring seat to the bottom of
less than 1.06mm (3/64 inch) margin should be dis- the spring retainer. Correct height is 44.0mm (1.73
carded. inches).
(3) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be ob-
tained.
(4) Measure the concentricity of valve seat using a
valve seat dial indicator. Total runout should not ex-
ceed. 0.1 mm (.004 inch) (total indicator reading).
(5) Inspect the valve seat with Prussian blue to de-
termine 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 trans-
ferred to top edge of the valve face, lower valve seat
with a 15 degrees stone. If the blue is transferred to
the bottom edge of valve face raise valve seat with a Fig. 16 Refacing Valve Seats
65 degrees stone.
• Intake valve seat diameter 34.0mm (1.338 inch)
• Exhaust valve seat diameter 29.4mm (1.157 inch)
9 - 40 2.2/2.5L ENGINE Ä

VALVE GEAR REASSEMBLY AFTER VALVE

SERVICE
(1) Coat valve stems with lubrication oil and insert
in cylinder head.
(2) Install new valve stem seals on all valves. The
valve stem seals should be pushed firmly and
squarely over valve guide. The lower edge of the seal
should be resting on the valve guide boss.
(3) Install valve spring seats and springs and re-
tainers. Compress valve springs only enough to in-
stall locks, taking care not to misalign the direction
of compression. Nicked valve stems may result from
Fig. 17 Checking Valve Tip Height and Spring
misalignment of the valve spring compressor.
Installed Height
CAUTION: When depressing the valve spring retain-
ers with Valve Spring Compressor Tool C-3422-B
with adopters 6537 and 6526 (Fig. 11) the locks can
become dislocated. Check to make sure both locks
are in their correct location after removing tool.

(4) Check installed height of springs. Measurement

B is to be taken from the spring seat to the bottom of
the spring retainer. Correct height is 44.0mm (1.73
inches). If seats have been ground an additional
spring seat may be required to maintain correct in-
stalled spring height (Fig. 17).
(5) Install camshaft and rocker arms as previously
described, see Camshaft-Install.
Ä 2.2/2.5L ENGINE 9 - 41

CRANKSHAFT, INTERMEDIATE AND BALANCE SHAFT SERVICE

Fig. 1 Crankshaft Intermediate and Balance Shaft Assemblies and Oil Seals
9 - 42 2.2/2.5L ENGINE Ä

CRANKSHAFT OIL SEALS SERVICE

(1) Pry out rear seal with screwdriver. Be careful
not to nick or damage crankshaft flange seal surface
or retainer bore (Fig. 2).

Fig. 4 Rear Crankshaft Seal Retainer Sealing

Fig. 2 Removing Rear Crankshaft Oil Seal

(2) Place Special Tool C-4681 on crankshaft (Fig.
3).
(3) Lightly coat seal O.D. with Loctite Stud N’
Bearing Mount or equivalent.
(4) Place seal over Tool C-4681 and tap in place
with a plastic hammer.

Fig. 5 Front Crankshaft Oil Seal Retainer

Fig. 3 Installing Rear Crankshaft Oil Seal

REAR CRANKSHAFT SEAL RETAINER AND Fig. 6 Front Crankshaft Seal Retainer Sealing
OIL SEAL
When retainer removal is required, use Mopar Gas- For reassembly Mopar Gasket Maker is applied to
ket Maker applied as shown in (Fig. 4) to provide re- the retainer as shown in (Fig. 6). This material cures
tainer to block sealing during re-installation. in the absence of air providing retainer to block seal-
ing.
FRONT CRANKSHAFT SEAL RETAINER (2) Install retainer and tighten screws to 12 NIm
See Timing System and Seals Section for timing (105 in. lbs.).
belt covers, belt, crankshaft sprocket and oil seals re-
moval and installation.
(1) Remove retainer screws (Fig. 5).
Ä 2.2/2.5L ENGINE 9 - 43

CRANKSHAFT SERVICE MAIN BEARING SERVICE—CRANKSHAFT NOT

REMOVED
CRANKSHAFT MAIN BEARINGS
Bearing caps are not interchangeable and should REMOVAL
be marked at removal to insure correct assembly. (1) Remove oil pan and identify bearing caps before
Upper and lower bearing halves are NOT inter- removal.
changeable. Lower main bearing halves of 1, 2, 4 and (2) Remove bearing caps one at a time. Remove
5 are interchangeable. Upper main bearing halves of upper half of bearing by inserting Special Main Bear-
1, 2, 4 and 5 are interchangeable (Fig. 7). ing Tool C-3059 (Fig. 8) into the oil hole of crankshaft.
(3) Slowly rotate crankshaft clockwise, forcing out
CRANKSHAFT MAIN JOURNALS upper half of bearing shell.
The crankshaft journals should be checked for ex-
cessive wear, taper and scoring. Limits of taper or
out-of-round on any crankshaft journals should be
held to .025mm (.001 inch). Journal grinding should
not exceed .305mm (.012 inch) under the standard
journal diameter. Do NOT grind thrust faces of Num-
ber 3 main bearing. Do NOT nick crank pin or bear-
ing fillets. After grinding, remove rough edges from
crankshaft oil holes and clean out all passages.

CAUTION: With the nodular cast iron crankshafts

used it is important that the final paper or cloth pol-
ish after any journal regrind be in the same direc-
tion as normal rotation in the engine.

Upper and lower Number 3 bearing halves are

flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves Fig. 8 Removing and Installing Upper Main Bearing
in the engine (Fig. 7). All bearing cap bolts removed With Special Tool C-3059
during service procedures are to be cleaned and oiled INSTALLATION
before installation. Bearing shells are available in
Only one main bearing should be selectively
standard and the following undersized: 0.025mm
fitted while all other main bearing caps are prop-
(.001 inch), .051mm (.002 inch), .076mm (.003 inch),
erly tightened.
.254mm (.010 inch), and .305mm (.012 inch). Never
When installing a new upper bearing shell, slightly
install an undersize bearing that will reduce clear-
chamfer the sharp edges from the plain side.
ance below specifications.
(1) Start bearing in place, and insert Main Bearing
Tool C-3059 into oil hole of crankshaft (Fig. 8).
(2) Slowly rotate crankshaft counter-clockwise slid-
ing the bearing into position. Remove Special Main
Bearing Tool C-3059.

CHECKING CRANKSHAFT END PLAY

(1) Mount a dial indicator to front of engine, locating
probe on nose of crankshaft (Fig. 9).
(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 (Fig. 10) for specifications.

OPTIONAL CRANKSHAFT END PLAY CHECK

(1) Move crankshaft all the way to the rear of its
Fig. 7 Main Bearing Identification travel using a lever inserted between a main bearing
9 - 44 2.2/2.5L ENGINE Ä

Fig. 9 Checking Crankshaft End Play Fig. 11 Checking Crankshaft Oil Clearance with
cap and a crankshaft cheek, using care not to dam-
Plastigage
age any bearing surface. Do not loosen main bearing
cap.
(2) Use a feeler gauge between number three
thrust bearing and machined crankshaft surface to
determine end play.

Fig. 12 Installing Main Bearing Upper Shell

2, 4 and 5 main bearings are full groove to pro-
vide full time oiling to the connecting rod. Only
the number 3 is half-groove.
(3) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block tab
Fig. 10 Crankshaft Specifications slots.
CRANKSHAFT BEARING CLEARANCE (4) Oil the bearings and journals and install crank-
(1) Refer to Measuring Main, Connecting Rod shaft.
Bearing Clearance in Standard Service Procedures. (5) Install main bearing cap No. 1 on timing belt
Refer to (Fig. 10) for specifications. end.
(6) Install main bearing cap No. 5 on transmission
CAUTION: Do not rotate crankshaft or the Plasti- end.
gage maybe smeared. Since the main bearing bolts are torqued using
a new procedure they should be examined BE-
(2) Install the main bearing shells with the lubri- FORE reuse. If the threads are necked down the
cation groove in the cylinder block (Fig. 12). The 1, bolts should be replaced (Fig. 15).
Ä 2.2/2.5L ENGINE 9 - 45

BALANCE SHAFTS
2.2L Turbo III and 2.5L engines are equipped with
two counter rotating balance shafts installed in a
carrier attached to the lower crankcase (Fig. 1).
The shafts are interconnected through gears. These
gears are driven by a short chain from the crank-
shaft, to rotate at two times crankshaft speed. This
counterbalances certain engine reciprocating forces.

REMOVAL
Refer to Engine Lubrication and Timing System
and Seals Service of this group for removal procedure
Fig. 13 Main Bearing Caps
of necessary components to repair balance shafts.

Fig. 14 Installing Main Bearing Caps

Necking can be checked by holding a scale or straight
edge against the threads or by running a M11 x 1.50
nut the full length of the thread. If all the threads
do not contact the scale or if the nut does not run
down smoothly the bolt should be replaced.
(7) Before installing the bolts the threads should be Fig. 16 Chain Cover, Guide and Tensioner
oiled with engine oil. (1) Remove chain cover, guide and tensioner (Fig.
(8) Install both bolts in each cap finger tight, then 16). Also see Carrier Assembly Removal for service
alternately torque each bolt to assemble the cap prop- procedures requiring only temporary relocation of as-
erly. sembly.
(9) Tighten the bolts to 41 NIm plus 1/4 turn (30 (2) Remove balance shaft gear and chain sprocket
ft.lbs. plus 1/4 turn). (Fig. 14) retaining screws and crankshaft chain sprocket torx
screws. Remove chain and sprocket assembly. (Fig.
17)
(3) Remove gear cover retaining stud (double
ended to also retain chain guide). Remove cover and
balance shaft gears (Fig. 18).
(4) Remove carrier rear cover and balance shafts.
(Fig. 19).
(5) Remove six carrier to crankcase attaching bolts
to separate carrier (Fig. 1).

Fig. 15 Checking Bolts For Stretching (Necked

down)
9 - 46 2.2/2.5L ENGINE Ä

Fig. 17 Drive Chain and Sprockets Fig. 19 Balance Shaft(s) Remove/Install

INSTALLATION
Balance shaft and carrier assembly installation is
the reverse of the removal procedure. During instal-
lation crankshaft to balance shaft timing must be
established.

TIMING
(1) With balance shafts installed in carrier (Fig. 19)
position carrier on crankcase and install six attaching
bolts and tighten to 54 NIm (40 ft. lbs.).
(2) Turn balance shafts until both shaft key ways are
up Parallel to vertical centerline of engine. Install
short hub drive gear on sprocket driven shaft and long
hub gear on gear driven shaft. After installation gear
and balance shaft keyways must be up with gear
timing marks meshed as shown in (Fig. 20).
Fig. 18 Gear Cover and Gears
(3) Install gear cover and tighten double ended
BALANCE SHAFTS CARRIER ASSEMBLY stud/washer fastener to 12 NIm (105 in. lbs.).
(4) Install crankshaft sprocket and tighten socket
REMOVAL
head torx screws to 13 NIm (130 in. lbs.).
The following components will remain intact dur-
ing carrier removal. Gear cover, gears, balance shafts
and the rear cover.
(1) Remove chain cover and driven balance shaft
chain sprocket screw.
(2) Loosen tensioner pivot and adjusting screws,
move driven balance shaft inboard through driven
chain sprocket. Sprocket will hang in lower chain
loop.
(3) Remove carrier to crankcase attaching bolts to
remove carrier.

Fig. 20 Gear Timing

Ä 2.2/2.5L ENGINE 9 - 47

(5) Turn crankshaft until number one cylinder is CHAIN TENSIONING

at Top Dead Center (TDC). The timing marks on the (1) Install chain tensioner loosely assembled.
chain sprocket should line up with the parting line (2) Position guide on double ended stud making sure
on the left side of number one main bearing cap. tab on the guide fits into slot on the gear cover. Install
(Fig. 21). and tighten nut/washer assembly to 12 NIm (105 in.
(6) Place chain over crankshaft sprocket so that lbs.).
the nickel plated link of the chain is over the timing (3) Place a shim 1mm (.039 inch) thick x 70mm (2.75
mark on the crankshaft sprocket (Fig. 21). inch) long or between tensioner and chain. Push ten-
(7) Place balance shaft sprocket into the timing sioner and shim up against the chain. Apply firm
chain (Fig. 17) so that the timing mark on the pressure (5.5 to 6.6 lbs.) directly behind the ad-
sprocket (yellow dot) mates with the (lower) nickel justment slot to take up all slack (chain must have
plated link on the chain shoe radius contact as shown in Fig. 22).
(8) With balance shaft keyways pointing up 12 (4) With the load applied, tighten top tensioner bolt
o’clock) slide the balance shaft sprocket onto the nose first, then bottom pivot bolt. Tighten bolts to 12 NIm
of the balance shaft. The balance shaft may have to (105 in. lbs.), Remove shim.
be pushed in slightly to allow for clearance. (5) Install carrier covers and tighten screws to 12
NIm (105 in. lbs.).

Fig. 22 Chain Tension Adjustment

INTERMEDIATE SHAFT SERVICE
REMOVAL

Fig. 21 Balance Shaft Timing CAUTION: The oil pump and distributor must be
THE TIMING MARK ON THE SPROCKET, removed before attempting to remove intermediate
THE (LOWER) NICKEL PLATED LINK, AND shaft.
THE ARROW ON THE SIDE OF THE GEAR
(1) Hold sprocket with Tool C-4687 and adaptor Tool
COVER SHOULD LINE UP WHEN THE BAL-
C-4687-1 when removing or installing screw (Fig. 23).
ANCE SHAFTS ARE TIMED CORRECTLY.
(2) See Timing System and Seals for intermediate
(9) If the sprockets are timed correctly install the
seal removal and replacement.
balance shaft bolts and tighten to 28 NIm (250 in.
(3) Remove retainer screws (Fig. 24).
lbs.). A wood block placed between crankcase and
(4) Remove retainer and lay aside.
crankshaft counterbalance will prevent crankshaft
(5) Remove intermediate shaft.
and gear rotation.
9 - 48 2.2/2.5L ENGINE Ä

Fig. 23 Removing/Installing Intermediate Shaft Fig. 26 Intermediate Shaft Bushing, Front

Sprocket

Fig. 27 Intermediate Shaft Bushing—Rear

Fig. 24 Intermediate Shaft Retainer

Fig. 28 Intermediate Shaft Journal Specifications

(3) Install retaining screws and torque to 12 NIm
(105 in. lbs.).

INTERMEDIATE SHAFT BUSHING SERVICE

(1) Remove front bushing using Special Tool
C-4697-2 with Special Tool Handle C-4171 (Fig. 26).
(2) Install front bushing using Special Tool
C-4697-1 and Special Tool Handle C-4171 until tool
Fig. 25 Intermediate Shaft Retainer Sealing is flush with block.
INSTALLATION (3) Remove rear bushing using Special Tool
(1) Lubricate distributor drive gear when installing. C-4686-2 and Special Tool Handle C-4171 (Fig. 27).
(2) Apply Mopar Gasket Maker as shown in (Fig. (4) Install rear bushing using Special Tool
25) and install intermediate shaft retainer. C-4686-1 and Special Tool Handle C-4171 until tool
is flush with block.
Ä 2.2/2.5L ENGINE 9 - 49

CYLINDER BLOCK, PISTON AND CONNECTING ROD ASSEMBLY SERVICE

Fig. 1 Cylinder Block, Piston and Connecting Rod Assembly

PISTON AND CONNECTING ROD—REMOVAL
(1) Remove top ridge of cylinder bores with a reliable
ridge reamer before removing pistons from cylinder
block.Be sure to keep tops of pistons covered
during this operation. Mark piston with matching
cylinder number (Fig. 2).

Fig. 3 Identify Connecting Rod to Cylinder

(4) Squirt hole on connecting rod must face timing
belt end of engine.
(5) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(6) Remove connecting rod cap. Install connecting
Fig. 2 Piston Marking
rod bolt protectors on connecting rod bolts (Fig. 4).
(2) Remove oil pan. Ensure connecting rods and Push each piston and rod assembly out of cylinder
connecting rod caps for cylinder identification. Identify bore.
them if necessary (Fig. 3). Be careful not to nick crankshaft journals.
(3) Valve relief toward manifold side of engine. Tur- (7) After removal, install bearing cap on the mat-
bocharged engine pistons will have arrow towards ing rod.
front of engine.
9 - 50 2.2/2.5L ENGINE Ä

Fig. 4 Connecting Rod Protectors

CYLINDER BLOCK CLEANING AND
INSPECTION
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are installed, Refer to Engine Fig. 5 Checking Cylinder Bore Size
Core Oil and Cam Plugs. Honing Cylinder Bores outlined in the Standard
(3) Examine block and cylinder bores for cracks or Service Procedures for specification and proce-
fractures. dures.
Measure the cylinder bore at three levels in direc-
CYLINDER BORE INSPECTION tions A and B (Fig. 5). Top measurement should be
The cylinder walls should be checked for out-of- 10mm ( 3/8 inch) down and bottom measurement
round and taper with Tool C-119 (Fig. 5). The cylin- should be 10mm ( 3/8 inch.) up from bottom of bore.
der bore out-of-round is 0.050 mm (.002 inch) Refer to (Fig. 6) for specifications.
maximum and cylinder bore taper is .125 mm (.005
inch) maximum. If the cylinder walls are badly SIZING PISTONS
scuffed or scored, the cylinder block should be re- Piston and cylinder wall must be clean and dry.
bored and honed, and new pistons and rings fitted. Piston diameter should be measured 90 degrees to
Whatever type of boring equipment is used, boring piston pin at size location shown in (Fig. 7). Cylinder
and honing operation should be closely coordinated bores should be measured halfway down the cylinder
with the fitting of pistons and rings in order that bore and transverse to the engine crankshaft center
specified clearances may be maintained. Refer to line shown in (Fig. 5). Refer to (Fig. 6) for specifica-

Fig. 6 Piston Size Location and Clearance Chart

Ä 2.2/2.5L ENGINE 9 - 51

Fig. 9 2.2L Turbo III Piston

Chrysler engines use pistons designed specifically for
each engine model. Clearance and sizing locations vary
with respect to engine model.
Pistons and cylinder bores should be measured
at normal room temperature, 70°F. (21°C).

Fig. 7 Piston Installation and Sizing Information

Fig. 10 Piston Pin Lock Ring Removal

Notch—Turbo III Engine

Fig. 8 N.A. (Naturally Aspirated) Pistons

tions. Correct piston to bore clearance must be estab-
lished in order to assure quiet and economical
operation.
9 - 52 2.2/2.5L ENGINE Ä

PISTON PINS vided with the lock ring service package, to select
the correct lock rings from the package for your ap-
DISASSEMBLY plication.
Turbo III engine piston-pin-connecting rod assem- (2) Carefully, install one NEW lock ring with gap
blies should not be disassembled unless a malfunc- towards piston top in lock ring groove. Do not rein-
tion is present or a damaged assembly component is stall used lock rings.
to be replaced. (3) Position connecting rod and slide in lightly oil
WARNING: APPROVED SAFETY GLASSES piston pinch
MUST BE WORN DURING PISTON LOCK (4) Install second NEW lock ring with gap towards
RING REMOVAL OR INSTALLATION TO PRE- piston top in lock ring groove, use small screwdriver
VENT POSSIBLE INJURY FROM FLYING if needed.
PARTS.
CAUTION: BOTH lock rings must be FULLY
SEATED in lock ring grooves or engine failure will
occur.

(5) Check piston pin end play pin movement be-

tween lock rings in assembly.

Fig. 12 Piston Pin Specifications

Fig. 11 Engine Piston Pins—Turbo III, Naturally

Aspirated and Flexible Fuel Vehicles
(1) Carefully, remove piston pin lock rings from
piston, using a small screwdriver in removal notch
(Fig. 10).
(2) Discard used lock ring.
(3) Following lock ring removal, attempt to slide
pin out of piston. If pin does not slide out freely by
hand; Fig. 13 Piston Rings—Removing and Installing
• Check for burr on outer edge of lock ring groove. If
one is present, carefully scrape burr away with a PISTON RING—REMOVAL
knife or other hand tool, being careful not to damage (1) ID mark on face of upper and intermediate pis-
lock ring retaining groove. ton rings must point toward piston crown.
(4) Slide out piston pin to complete disassembly. (2) Using a suitable ring expander, remove upper
(5) Inspect components, discard damaged or exces- and intermediate piston rings (Fig. 13).
sively worn parts refer to specifications (Fig. 12). If a (3) Remove the upper oil ring side rail, lower oil
piston is replaced, a new pin should be used. ring side rail and then oil ring expander from piston.
(4) Clean ring grooves of any carbon deposits.
PISTON PINS

REASSEMBLY
(1) Different lock rings are used for turbocharged
engine applications. Consult the Service Note, pro-
Ä 2.2/2.5L ENGINE 9 - 53

Fig. 14 Piston Ring Gap Fig. 16 Piston Ring Specifications—Turbo III

Fig. 15 Piston Ring Groove Clearance Fig. 17 Piston Ring Specifications— Naturally
FITTING RINGS Aspirated and Flexible Fuel Vehicles
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12mm (.50 inch) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 14).
Refer to specifications (Fig. 16 and 17).
(2) Check piston ring to groove clearance: (Fig. 15).
Refer to specification (Figs. 16 and 17).

PISTON RINGS—INSTALLATION
(1) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Install rings with manufacturers
I.D. mark facing up, to the top of the piston (Fig. 13).

CAUTION: Install piston rings in the following or-

der:
Fig. 18 Installing Side Rail
(a) Oil ring expander. (2) Install the side rail by placing one end between
(b) Upper oil ring side rail. the piston ring groove and the expander. Hold end
(c) Lower oil ring side rail.
(d) No. 2 Intermediate piston ring.
(e) No. 1 Upper piston ring.
9 - 54 2.2/2.5L ENGINE Ä

firmly and press down the portion to be installed un- and tighten with the special wrench (Fig. 20). Be sure
til side rail is in position. Do not use a piston ring position of rings does not change during this
expander. (Fig. 19). operation .
(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. 8).
(5) Position piston ring end gaps as shown in (Fig.
19).
(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 impor-
tant for oil control.

Fig. 21 Piston Markings

(4) The valve cut should be toward the manifold side
of the engine (Fig. 21).
(5) Install connecting rod bolt protectors on rod bolts
(Fig. 4).
(6) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert rod
and piston into cylinder bore and guide rod over the
crankshaft journal.
(7) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(8) Install rod caps. Install nuts on cleaned and oiled
Fig. 19 Piston Ring End Gap Position rod bolts and tighten nuts to 54 NIm (40 ft. lb.) Plus 1/4
turn for N/A engines and 68 NIm (50 ft. lbs.) for turbo
PISTON AND CONNECTING ROD ASSEMBLY
INSTALLATION III engines.
(1) Before installing pistons and connecting rod as-
semblies into the bore, besure that compression ring
gaps are staggered so that neither is in line with oil
ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 19).

Fig. 20 Installing Piston

Fig. 22 Checking Connecting Rod Bearing Clear-
(3) Immerse the piston head and rings in clean en- ance
gine oil, slide the ring compressor, over the piston
Ä 2.2/2.5L ENGINE 9 - 55

CONNECTING RODS
(1) Follow procedure specified in the Standard Ser-
vice Procedures Section for Measuring Main Bearing
Clearance and Connecting Rod Bearing Clearance
(Fig. 22). Refer to specifications (Fig. 25).

CAUTION: Do not rotate crankshaft or the Plastic-

Gage may be smeared.

The rod bearing bolts should be examined be-

fore reuse. If the threads are necked down the
bolts should be replaced (Fig. 23).
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.

Fig. 24 Checking Connecting Rod Side Clearance

Fig. 23 Checking Bolts for Stretching (Necked)

(2) Before installing the nuts the threads should be
oiled with engine oil.
(3) Install nuts on each bolt finger tight than alter-
nately torque each nut to assemble the cap properly.
(4) Tighten the nuts to 54 NIm PLUS 1/4 turn (40 ft.
lbs. PLUS 1/4 turn) for N/A engines Do not use a
torque wrench for last step. and 68 NIm (50 ft. lbs.) Fig. 25 Connecting Rod Specifications
for Turbo III engines.
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 24). Refer to connecting rod specifica-
tions (Fig. 25).

ENGINE CORE PLUGS

REMOVAL
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup plug
(Fig. 26). With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig. 26).

CAUTION: Do not drive cup plug into the casting as

restricted cooling can result and cause serious en-
gine problems.
Fig. 26 Core Hole Plug Removal
INSTALLATION so that the sharp edge of the plug is at least 0.5mm
Thoroughly clean inside of cup plug hole in cylinder (.020 inch) inside the lead-in chamfer (Fig. 26).
block or head. Be sure to remove old sealer. Lightly coat It is in not necessary to wait for curing of the seal-
inside of cup plug hole with sealer. Make certain the ant. The cooling system can be refilled and the vehi-
new plug is cleaned of all oil or grease. Using proper cle placed in service immediately.
drive plug, drive plug into hole
9 - 56 2.2/2.5L ENGINE Ä

ENGINE LUBRICATION SYSTEM

Fig. 1 Engine Lubrication Components

Ä 2.2/2.5L ENGINE 9 - 57

Fig. 2 Engine Lubrication System

9 - 58 2.2/2.5L ENGINE Ä

OIL PAN arm shafts which feed oil to the lash adjusters. Oil is
A formed steel oil pan provides lower engine pro- feed thru the rocker arms to lubricate the rollers and
tection as well as serving as the engine oil reservoir the camshaft lobes.
(Fig. 1). Pan side flanges to block are sealed with
gaskets. The oil pickup tube for some 2.2L engines SPLASH LUBRICATION
have a circular strainer and cover. The 2.5L engine Oil returning to the pan from pressurized compo-
pickup is also unsupported and the lower end has a nents supplies lubrication to the valve stems. Cylinder
box type strainer (Fig. 4). bores and wrist pins are splash lubricated from di-
rected holes in the connecting rods.
PRESSURE LUBRICATION
Oil drawn up through the pickup tube is pressur- OIL PAN
ized by the pump and routed through the full flow
filter to the main oil gallery running the length of
REMOVAL
the cylinder block (Fig. 2). Modified oil pickup, pump (1) Drain engine oil and remove oil pan.
and check valve provide increased oil flow to the (2) Clean oil pan and all gasket surfaces.
main oil gallery. OIL PAN RAIL TO BLOCK SEALING
MAIN/ROD BEARINGS For all engines side gaskets (Fig. 1) are employed for
A diagonal hole in each bulkhead feeds oil to each rail sealing.
main bearing. Drilled passages within the crankshaft
route oil from main bearing journals to crankpin
journals.

ACCESSORY SHAFT
Two separate holes supply the accessory shaft for
the N/A engines. For Turbo III engines there is a slot
in the rear shaft bushing that squirts oil onto the
oil pump drive gears (Fig. 2).

BALANCE SHAFTS
The engine balance shafts are lubricated by an ad-
ditional hole that interconnects a passage in one leg
of the balance shaft carrier to route oil down to the
carrier oil gallery. This gallery directly supplies the
balance shafts front bearings and internal machined
passages in the shafts routes oil from front to rear Fig. 3 Sealing, Front and Rear End Seals
shaft bearing journals.
INSTALLATION
TURBOCHARGER (WHERE EQUIPPED) (1) Apply Mopar Silicone Rubber Adhesive Sealant
If turbocharger equipped, pressurized oil from the or equivalent at the front seal retainer parting line
main gallery to sending unit hex fitting is piped from (Fig. 3).
the fitting to the turbocharger bearing housing. (2) Install the oil pan side gaskets to the block. Use
From the housing a hose and tube connection to a heavy grease or Mopar Silicone Rubber Adhesive Seal-
machined hole in the block provides drainback. ant or equivalent to hold in place.
(3) Apply Mopar Silicone Rubber Adhesive Sealant
CAMSHAFT/HYDRAULIC LIFTERS or equivalent to ends of new oil pan end seals at
A vertical hole at the number five bulkhead routes junction of cylinder block pan rail gasket (Fig. 3).
pressurized oil through a restrictor up past a cylinder (4) Install pan and tighten to (12) M8 screws to 23
head bolt to an oil gallery running the length of the NIm (200 in. lbs.) and 1 M6 screws to 12 NIm (105 in.
cylinder head. For 2.2/2.5L and 2.5L FFV engines lbs.).
hydraulic adjusters are supplied directly from this
gallery while diagonal holes supply oil to the cam- OIL PUMP SERVICE
shaft journals. The camshaft journals are partially
slotted to allow a predetermined amount of pressur- OIL PICKUP
ized oil to pass into the bearing cap cavities with (1) Remove screw on pump cover holding oil pick-up
small holes directed to spray lubricate the camshaft tube to oil pump (Fig. 4).
lobes. For Turbo III engines oil is supplied thru oil (2) Remove oil pick-up tube. When reinstalling
galleries in the head to the camshafts and rocker make sure to use a new O-Ring on pickup tube.
Ä 2.2/2.5L ENGINE 9 - 59

inder block assembly (Fig. 5).

INSTALLATION
(1) Apply Mopar Gasket Maker to pump body-to-
block interface (machined surface).
(2) Lubricate oil pump rotor & shaft and drive
gear.
(3) Turn crankshaft and intermediate shaft until
markings on sprockets are in line (arrows Fig. 6).

Fig. 4 Oil Pick-Up

Fig. 6 Crankshaft and Intermediate Shaft Timing

(4) Slot in oil pump shaft must be parallel to cen-
ter line of crankshaft when intermediate shaft and
crankshaft are properly timed (Fig. 7).

Fig. 5 Oil Pump Assembly Fig. 7 Oil Pump Shaft Alignment

OIL PUMP (5) Install pump full depth and rotate back and
forth slightly to ensure proper positioning and align-
REMOVAL ment through full surface contact of pump and block
(1) Remove two (2) screws holding oil pump to cyl- machined interface surfaces (Fig. 5).
9 - 60 2.2/2.5L ENGINE Ä

CAUTION: Pump must be held in fully seated posi-

tion (described above) while installing screws.

(6) Tighten screws to 23 NIm (200 in. lbs.).

Fig. 10 Clearance Between Rotors

Clearance: 0.35mm (.014 inch) maximum (Fig. 11).

Fig. 8 Checking Rotor End Clearance

INSPECTION
(1) Check rotor end clearance with feeler gauge as
shown in (Fig. 8).
(2) Limits:
• 0.03mm (.001 inch) minimum.
• 0.09mm (.0035 inch) maximum.
(3) Thickness: 23.96mm (.9435 inch) minimum.
Outer Diameter: 62.7mm (2.469 inch) minimum (Fig.
9).
(4) Install with large chamfered edge in pump
body (Fig. 9).

Fig. 11 Outer Rotor Clearance

Clearance: 0.076mm (.003 inch) maximum (Fig.
12).
Oil pressure relief valve spring: Free length:
49.5mm (1.95 inch). Load: 89 N at 34mm. Load: (20
lbs. at 1.34 inch) (Fig. 13).
Thickness: 23.96mm (.9435 inch) Minimum (Fig.
14).

CHECKING ENGINE OIL PRESSURE

(1) Remove pressure sending unit and install Spe-
cial Tool S-94 with gauge assembly C-3292 (Fig. 15).
(2) Warm engine at high idle until thermostat
opens.
Fig. 9 Measuring Outer Rotor CAUTION: If oil pressure is 0 at idle, Do Not Run
Clearance: 0.20mm (.008 inch) maximum (Fig. 10). engine at 3000 RPM
Ä 2.2/2.5L ENGINE 9 - 61

Fig. 12 Oil Pump Cover

Fig. 15 Checking Oil Pump Pressure—Typical
FILTER

CAUTION: When servicing the oil filter (Fig. 16)

avoid deforming the filter can by installing the re-
move/install tool band strap against the can-to-base
lockseam. The lockseam joining the can to the base
is reinforced by the base plate.

Fig. 13 Oil Pressure Relief Valve

Fig. 14 Measuring Inner Rotor Thickness

(3) Oil Pressure: Curb Idle 25 kPa (4 psi) mini-
mum 3000 RPM 170-550 kPa (25-80 psi).
Fig. 16 Engine Oil Filter and Antidrain Back Valve
OIL FILTER (1) Turn counter clockwise to remove.
ANTI-DRAIN BACK VALVE (2) To install, lubricate new filter gasket. Check
Installation: Apply liquid (Teflon Type) sealant to filter mounting surface. The surface must be smooth,
valve-to-block threads (Fig. 16). Tighten assembly to flat and free of debris or old pieces of rubber. Screw
55 NIm (40 ft. lbs.). filter on until gasket contacts base. Tighten to 3/4 to
1 turn.
9 - 62 2.2/2.5L ENGINE Ä

ENGINE SPECIFICATIONS
Ä 2.2/2.5L ENGINE 9 - 63

ENGINE SPECIFICATIONS (CONT.)

9 - 64 2.2/2.5L ENGINE Ä

SPECIFICATIONS
Ä 2.2/2.5L ENGINE 9 - 65
9 - 66 3.0L ENGINE Ä

3.0L ENGINE

INDEX
page page
Accessory Drive Belt Service . . . . . . . . . . . . . . . . 70 Engine Specifications ................. .. . . 95
Auto Lash Adjuster . . . . . . . . . . . . . . . . . . . . . . . 75 General Information . . . . . . . . . . . . . . . . . . . .. . . 66
Camshaft Service . . . . . . . . . . . . . . . . . . . . . . . . 76 Oil Filter and Bracket ................. .. . . 94
Checking Engine Oil Pressure . . . . . . . . . . . . . . . 93 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 92
Crankshaft and Cylinder Block, Assembly Service . 86 Oil Pump Service . . . . . . . . . . . . . . . . . . . . .. . . 92
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Piston and Connecting Rod Assembly Service . . . 82
Cylinder Head and Camshaft Service . . . . . . . . . 75 Timing Belt Inspection—In Vehicle . . . . . . . . .. . . 72
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 69 Timing Belt Service . . . . . . . . . . . . . . . . . . . .. . . 72
Engine Lubrication System . . . . . . . . . . . . . . . . . 91 Valve Service . . . . . . . . . . . . . . . . . . . . . . . .. . . 80
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.0L ENGINE

main bearing cap. This single unit four bearing cap

is designed to control vibration of the cylinder block
GENERAL INFORMATION partition walls.
CRANKSHAFT: A six throw, five weight crank-
ENGINE IDENTIFICATION NUMBER OR CODE shaft is supported by four main bearings with num-
The engine identification number is located on the ber three being the thrust bearing. The six separate
rear of the cylinder block just below the cylinder
connecting rod throws pins reduce torque fluctua-
head (Fig. 1).
tions while a torsional vibration damper is used to
BLOCK: The cylinder block is a light weight de-
control torsion caused vibration of the crankshaft.
sign created by reducing thickness in many parts
Rubber lipped seals are used at front and rear. The
and a short 10 mm (3/8 inch) block skirt. High rigid-
front seal is retained in the oil pump case and the
ity is provided with ribs cast in the outer wall, a full
rear is retained in a block-mounted housing.
length water jacket, and a monoblock or beam type,
Ä 3.0L ENGINE 9 - 67

SPECIFICATIONS

ture cross-flow type intake and exhaust ports. Valve

guides and inserts are hardened cast iron. Valves of
heat resistance steel are arranged in a V with each
camshaft on center. To improve combustion speed the
chambers are a compact spherical design with a
squish area of approximately 30 percent of the piston
top area. The cylinder heads are common to either
cylinder bank by reversing the direction of installa-
tion.
CAMSHAFTS: Two overhead camshafts provide
valve actuation, one front (radiator side of cylinder
bank) and one rear. The front camshaft is provided
with a distributor drive and is longer. Both cam-
shafts are supported by four bearing journals, thrust
for the front camshaft is taken at journal two and
the rear at journal three. Front and rear camshaft
driving sprockets are interchangeable. The sprockets
and the engine water pump are driven by a single
notched timing belt.
ROCKER ARM SHAFTS: The shafts are retained
by the camshaft bearing journal caps. Four shafts are
used, one for each intake and exhaust rocker arm as-
Fig. 1 Engine Identification sembly on each cylinder head. The hollow shafts pro-
PISTONS: Are aluminum alloy with a steel strut, vide a duct for lubricating oil flow from the cylinder
short height, and thin wall so as to be autothermic head to the valve mechanisms.
and light weight. The piston head with valve re- ROCKER ARMS: Are of light weight die-cast
cesses, in combination with the cylinder head, forms with roller type follower operating against the cam
a compact spherical head with clearance for total shaft. The valve actuating end of the rocker arms are
valve lift with pistons at top dead center. The piston machined to retain hydraulic lash adjusters, elimi-
skirt, top and second ring lands are finished to a ta- nating valve lash adjustment.
pered roughness for oil retention and high resistance VALVES: Are made of heat resistant steel and are
to scuffing. Piston pins, press-fitted into place, join further treated to resist heat.
the pistons to the connecting rods. VALVE SPRINGS: Are especially designed to be
CYLINDER HEAD: The alloy cylinder heads fea- short. The valve spring wire cross-section is oval
9 - 68 3.0L ENGINE Ä

Fig. 2 Engine Mounting

shaped and provides the same spring tension as ENGINE MOUNTS
longer springs. Valve spring retainers, locks and
seals are conventional. REMOVAL AND INSTALLATION
INTAKE MANIFOLD: The aluminum alloy man-
RIGHT SIDE MOUNT
ifold is a cross type with long runners to improve in-
(1) Remove the right engine mount insulator ver-
ertia. The runners, attaching below at the cylinder
tical fasteners from frame rail.
head, also attach above and support an air plenum.
(2) Remove the load on the engine motor mounts
The air plenum chamber absorbs air pulsations cre- by carefully supporting the engine and transmission
ated during the suction phase of each cylinder. assembly with a floor jack.
EXHAUST MANIFOLDS: Both manifolds are a (3) Remove the thru bolt from the insulator assem-
log style made of ductile cast iron. Exhaust gasses, bly. Remove insulator.
collected from the front cylinder bank, leave the (4) Reverse removal procedure for installation. Re-
front manifold through an end outlet and are fed fer to (Fig. 2) for bolt tightening specifications.
through an upper crossover tube to the rear mani- (5) Engine mount adjustment, Refer to Engine
fold. The collected exhaust from both manifolds are Mount Insulator Adjustment of this section.
combined, and exit to the exhaust pipe through an
articulated joint. FRONT MOUNT
ENGINE LUBRICATION: System is a full flow (1) Support the engine and transmission assembly
filtration, pressure feed type. The oil pump is with a floor jack so it will not rotate.
mounted in the chaincase cover. The pump inner ro- (2) Remove the thru bolt from the insulator and
tor is driven by the crankshaft. The engine oil pan front crossmember mounting bracket.
contains a baffle plate to control oil level fluctuation (3) Remove the front engine mount bracket to
front crossmember screws and nuts. Remove the in-
during engine operation.
sulator assembly.
(4) Reverse removal procedure for installation. Re-
fer to (Fig. 2) for bolt tightening specifications.
(5) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
Ä 3.0L ENGINE 9 - 69

LEFT SIDE MOUNT

(1) Raise vehicle on hoist and remove left front
wheel.
(2) Remove inter splash shield.
(3) Support the transmission with a transmission
jack.
(4) Remove the insulator thru bolt from the mount.
(5) Remove the transmission mount fasteners and
remove mount.
(6) Reverse removal procedure for installation. En-
sure that the slide tube is seated into the rail
bracket guides. Refer to (Fig. 3) for bolt tightening
specifications.
(7) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.

ENGINE MOUNT RUBBER INSULATORS Fig. 3 Left Insulator Movement

Insulator location on (right side) and transmission (3) Drain cooling system. Refer to Cooling System
bracket (left side) are adjustable to allow right/left Group 7 for draining procedure.
drive train adjustment in relation to drive shaft as- (4) Disconnect all electrical connections.
sembly length. (5) Remove coolant hoses from radiator and en-
Check and reposition right engine mount insulator gine.
(left engine mount insulator is floating type and will (6) Remove radiator and fan assembly.
adjust automatically (Fig. 3). Adjust drive train posi- (7) See Fuel System Group 14, For procedures to
tion, if required, for the following conditions: release fuel pressure, disconnect fuel lines and accel-
• Drive shaft distress: See Driveshafts in Suspen- erator cable.
sion, Group 2. (8) Remove air cleaner assembly.
• Any front end structural damage (after repair). (9) Hoist vehicle and drain engine oil.
• Insulator replacement.
(10) Remove air conditioning compressor mounting
ENGINE MOUNT INSULATOR ADJUSTMENT bolts and set compressor aside.
(1) Remove the load on the engine motor mounts (11) Disconnect exhaust pipe at manifold.
by carefully supporting the engine and transmission (12) Remove transmission inspection cover and
assembly with a floor jack. mark flex plate to torque converter position.
(2) Loosen the right engine mount insulator yoke (13) Remove screws holding torque converter to
screw and two turns on yoke nut, then loosen the flex plate and attach C-clamp on bottom of converter
front engine mount bracket to front crossmember housing to prevent torque converter from coming out.
screws and nuts. (14) Remove power steering pump mounting bolts
Left engine mount insulator is sleeved over and set pump aside.
shaft and long support bolt to provide lateral (15) Remove two lower transmission to block
movement adjustment with engine weight re- screws.
moved or not. (16) Remove starter.
(3) Pry the engine right or left as required to (17) Lower vehicles and disconnect vacuum lines
achieve the proper drive shaft assembly length. See and ground strap.
Drive Shaft in Suspension Group 2 for driveshaft (18) Install transmission holding fixture.
identification and related assembly length measur- (19) Attach engine lifting hoist and support en-
ing. gine.
(4) Tighten right engine mount insulator yoke nut (20) Remove upper transmission case to block
to 102 NIm (75 ft. lbs.). Then tighten front engine bolts.
mount screws and nuts to 54 NIm (40 ft. lbs.) and
(21) See Engine Mounting in (Fig. 2) and separate
center left engine mount insulator.
mount/insulators as follows:
(5) Recheck drive shaft length.
(a) Mark RIGHT insulator on right yoke and en-
ENGINE ASSEMBLY gine plate supports. Remove insulator to rails
screws.
REMOVAL (b) Remove FRONT engine mount through bolt
(1) Disconnect battery. and nut.
(2) Mark hood position at hinges and remove hood.
9 - 70 3.0L ENGINE Ä

Fig. 4 Accessories Mounting Brackets

(c) Remove LEFT insulator through bolt from in- (13) Install radiator and fan assembly. Connect fan
side wheelhouse or insulator bracket to transmis- motor electrical lead. Install radiator hoses. Fill cool-
sion screws. ing system. Refer to Cooling System Group 7 for fill-
(22) Remove engine. ing procedure.
(14) Fill engine crankcase with proper oil to cor-
INSTALLATION rect level.
(1) Attach hoist and lower engine into engine com- (15) Install hood.
partment. (16) Connect battery.
(2) Align engine mounts and install but do not (17) Start engine and run until operating temper-
tighten until all mounting bolts have been installed. ature is reached.
Tighten bolts to torque specified in (Fig. 2). (18) Adjust transmission or linkage if necessary.
(3) Install transmission case to cylinder block,
tighten bolts to 102 NIm (75 ft. lbs.) torque. ACCESSORY DRIVE BELT SERVICE
(4) Remove engine hoist and transmission holding
fixture. REMOVAL
(5) Remove C clamp from torque converter hous- (1) Loosen Adjusting Lock Nut (Fig. 6).
ing. Align flex plate to torque converter and install (2) Turn adjusting jack screw counterclockwise to
mounting screws. Tighten to 75 NIm (55 ft. lbs.) reduce belt tension. Remove belt.
(6) Install transmission inspection cover. (3) Inspect drive belt for wear and damage (Fig. 5).
(7) Connect exhaust system at manifold. (4) Installation: Adjust belt tension to 5/16 deflec-
(8) Install starter. tion between pulleys (Fig. 6).
(9) Install power steering pump and air condition- (5) Install breaker bar into 1/2 square opening in
ing compressor. For belt installation Refer to Acces- tensioner.
sory Belt Drive in Cooling System Group 7. (6) Rotate tensioner clockwise to remove and in-
(10) Lower vehicle and connect all vacuum lines. stall belt (Fig. 7).
(11) Connect all electrical connections including
ground strap.
(12) Connect fuel lines and accelerator cable.
Ä 3.0L ENGINE 9 - 71

(3) Remove steering pump/generator belt tensioner

mounting bolt and remove automatic belt tensioner.

Fig. 5 Drive Belt Inspection

Fig. 8 Right Inner Splash Shield—Typical

Fig. 6 Air Conditioning Belt

Fig. 9 Crankshaft Drive Pulleys

(4) Remove two steering pump to engine mounting
bracket screws and one rear support lock nut.
(5) Lay power steering pump aside.
Fig. 7 Generator/Power Steering Belt (6) Raise vehicle and remove right inner splash
shield (Fig. 8).
ENGINE MOUNT BRACKET
(7) Remove crankshaft drive pulleys and torsional
REMOVAL damper (Fig. 9).
(1) Remove air conditioning compressor to mount- (8) Lower vehicle and place a jack under engine.
ing bracket screws and lay compressor aside (Fig. 4).
(2) Remove screws attaching air conditioning com-
pressor mounting bracket and adjustable drive belt
tensioner from block and engine mounting bracket.
Remove both assemblies.
9 - 72 3.0L ENGINE Ä

(9) Mark support assembly to engine bracket if as- (2) Inspect both sides of the timing belt drive &
sembly is to be used again. Separate engine mount back. Replace belt if any of the following conditions
insulator from engine mount bracket (Fig. 10). Raise exist.
engine slightly. • Hardening of back rubber back side is glossy with-
(10) Remove engine mount bracket (Fig. 10). out resilience and leaves no indent when pressed
with fingernail.
• Cracks on rubber back.
• Cracks or peeling of canvas.
• Cracks on rib root.
• Cracks on belt sides.
• Missing teeth.
• Abnormal wear of belt sides. The sides are normal
if they are sharp as if cut by a knife (Fig. 12).
(3) If none of the above conditions are seen on the
belt, the belt cover can be reinstalled.

Fig. 10 Right Engine Mount and Engine Mount

Bracket
(11) Remove timing belt covers (Fig. 11).

Fig. 12 Timing Belt Inspection

TIMING BELT SERVICE
REMOVAL
(1) Mark belt running direction for installation
(Fig. 14).
(2) Loosen timing belt tensioner bolt (Fig. 16) and
remove timing belt.
(3) Remove crankshaft sprocket flange shield (Fig.
9).

CAMSHAFT SPROCKETS

REMOVAL
(1) Hold camshaft sprocket with Spanner Tool
Fig. 11 Timing Belt Covers MB990775 loosen and remove bolt and washer (Fig.
15).
TIMING BELT INSPECTION—IN VEHICLE (2) Remove camshaft sprocket from camshaft.
(1) Remove the upper front outer timing belt cover
by loosening the three attaching bolts. (Fig. 11).
Ä 3.0L ENGINE 9 - 73

Fig. 13 Timing Belt System

Fig. 14 Timing Belt Engine Sprocket Timing

9 - 74 3.0L ENGINE Ä

INSTALLATION (2) Hook spring upper end to water pump pin and
(1) Place camshaft sprocket on camshaft. lower end to tensioner bracket with hook out (Fig. 16).
(2) Install bolt and washer to camshaft. Using
Spanner Tool MB990775 hold camshaft sprocket and
torque bolt to 95 NIm (70 ft. lbs.) (Fig. 15).

Fig. 17 Positioning Belt Tensioner

(3) Turn timing belt tensioner counter-clockwise full
travel in adjustment slot and tighten bolt to tempo-
Fig. 15 Camshaft Sprockets rarily hold this position (Fig. 17).
TIMING BELT TENSIONER
INSTALLATION—TIMING BELT
(1) Install timing belt on crankshaft sprocket first
and while keeping belt tight on tension side (Fig. 14)
install belt on the front (radiator side) camshaft
sprocket.
(2) Then, install on the water pump pulley and on
the rear camshaft sprocket and finally on the timing
belt tensioner.
(3) Apply rotating force to the front camshaft
sprocket in opposite direction to tension the belt ten-
sion side, check that all timing marks are lined up (Fig.
14).
(4) Install crankshaft sprocket flange (Fig. 12).
(5) Loosen tensioner bolt and allow spring to tension
timing belt.
(6) Turn crankshaft two full turns in clockwise di-
Fig. 16 Timing Belt Tensioner rection. Turn smoothly and in clockwise direction
ONLY.
(1) Install timing belt tensioner and tensioner
(7) Again line up the timing marks on the sprockets
spring.
and tighten the timing belt tensioner locking bolt to 25
NIm (250 in. lbs.) torque.
(8) Reassembly belt covers, engine bracket, insula-
tor, crankshaft pulleys, accessories and accessory drive
belts in reverse order.
Ä 3.0L ENGINE 9 - 75

CYLINDER HEAD AND CAMSHAFT SERVICE

Fig. 1 Cylinder Head-Camshaft-Valves

CYLINDER HEAD COVER

REMOVE
(1) Remove air cleaner assembly.
(2) Disconnect battery and relocate spark plug
wires.
(3) Remove vacuum connections.
(4) Remove rocker cover screws and remove cover
(Fig. 2).

INSTALL
(1) Clean cylinder head and cover mating surfaces.
Install new gasket.
(2) See (Fig. 2) and apply sealant such as Mopar
Silicone Rubber Adhesive Sealant to cover ends.
(3) Install cover and tighten cover bolt washer and Fig. 2 Rocker Cover
gasket assembly to 10 NIm (88 in. lbs.).
FUNCTION CHECK
Check auto adjusters for free play by inserting a
AUTO LASH ADJUSTER small wire through the air bleed hole in the rocker
The automatic lash adjusters are precision units in-
arm and VERY LIGHTLY pushing the auto ad-
stalled in machined openings in the valve actuating
juster ball check down (Fig. 3). While lightly holding
ends of the rocker arms. Do not disassemble the auto the check ball down move the rocker up and down to
lash adjuster. check for free play. If there is no play replace the ad-
juster.
9 - 76 3.0L ENGINE Ä

Fig. 3 Auto Lash Adjuster Check

Fig. 5 Check Camshafts
(2) Front cylinder head camshaft check the tooth
surface of the distributor drive gear teeth of the cam-
shaft and replace if abnormal wear is evident (Fig.
5).
(3) Check the cam surface for abnormal wear and
damage and replace if defective. Also measure the
cam height (Fig. 5) and replace if out of limit, stan-
dard value is 41.25 mm (1.624 inch), wear limit is
40.75 mm (1.604 inch).

CAMSHAFT INSTALL
Lubricate camshaft journals and cams with engine
oil and install camshaft on cylinder head.

Fig. 4 Auto Lash Adjuster Retainers

CAMSHAFT SERVICE
SEE AUTO LASH ADJUSTER FUNCTION
CHECK BEFORE DISASSEMBLY

REMOVAL
(1) Install auto lash adjuster retainers. (Fig. 4).
(2) Remove distributor extension (Fig. 1).
(3) When removing camshaft bearing caps do not Fig. 6 Inspect Rocker Arms
remove the bolts from the bearing caps. Remove the
rocker arm, rocker shafts and bearing cap as an as- ROCKER ARMS
sembly. (1) Check rocker arms for wear or damage (Fig. 6).
Replace as necessary. Also see Auto Lash Adjuster.
CAMSHAFT INSPECTION
(1) Inspect camshaft bearing journals for damage ROCKER ARM SHAFTS
and binding (Fig. 5). If journals are binding,also The rocker arm shaft is hollow and is used as a lu-
check the cylinder head for damage (Fig. 1). Also brication oil duct. The rocker arm shaft on the inlet
check cylinder head oil holes for clogging.
Ä 3.0L ENGINE 9 - 77

Fig. 7 Rocker Arm Shaft Identification

side has a 3mm diameter oil passage hole from the
cylinder head. The exhaust side does not have this
oil passage (Fig. 7).
(1) Check the rocker arm mounting portion of the Fig. 9 Number One Camshaft Bearing Cap
shafts for wear or damage. Replace if heavily dam-
aged or worn. ASSEMBLE ROCKER ASSEMBLY
Install the rocker arms, bearing caps and springs.
(2) Check oil holes for clogging with small wire,
Springs are the same and can be used at all
clean as required (Fig. 7).
locations on the rocker arm shafts (Figs. 8 and 10).
REASSEMBLE Insert bolts in number four bearing cap to retain
assembly.

INSTALL ROCKER ARM SHAFT ASSEMBLY

(1) Apply Mopar Silicone Rubber Adhesive Sealant
at bearing cap ends as shown in (Fig. 8).
(2) Install the rocker arm shaft assembly making
sure that the arrow mark on the bearing cap and the
arrow mark on the cylinder head are in the same
direction (Fig. 8).
The direction of arrow marks on the front and
rear assemblies are opposite to each other.
(3) Tighten bearing cap bolts in the following order
to 10 NIm (85 in. lbs.). First #3, then #2, #1 and #4.
(4) Repeat step 3 increasing the torque to 20 NIm
(180 in.lbs.).
(5) Install distributor drive adaptor assembly (Fig.
11).

CAMSHAFT OIL SEAL SERVICE— ENGINE

OUT OF VEHICLE
(1) Apply light coat of engine oil to the camshaft oil
seal lip.
(2) Install the oil seal using camshaft oil seal in-
Fig. 8 Camshaft Bearing Caps Position staller tool MD998713 (Fig. 12).
(1) Align the camshaft bearing caps with arrows CAMSHAFT END SEAL (PLUG) SERVICE— IN
(depending on cylinder bank) directed as shown in VEHICLE SERVICE
(Fig. 8) and in numerical order. (1) Remove air cleaner assembly from engine.
Identify number one bearing cap number one and (2) Use a small punch and a hammer, carefully
number four caps are similar (Fig. 9). remove cam plug from cylinder head.
(2) Install rocker shafts so that bearing cap num- (3) Clean the area of the cylinder head where the
ber one with end notches positioned as shown in Fig- new cam plug will be installed.
ure 9 that the machined portion of the rocker shaft is (4) Apply a light coating of Mopar Silicone Rubber
facing down. Adhesive Sealant to the outer diameter of the NEW
(3) Insert attaching bolts to retain assembly. cam plug.
(5) Using a suitable installing tool and a hammer,
9 - 78 3.0L ENGINE Ä

Fig. 10 Assemble Rocker Arm and Shafts

Fig. 11 Distributor Drive

install the new cam plug to a depth of 0.5mm (0.020
inch) below the surface of the cylinder head.
(6) Replace air cleaner assembly.

CAMSHAFT END SEAL (PLUG) SERVICE —

OUT OF VEHICLE SERVICE Fig. 12 Install Camshaft Oil Seal
Install end seal plug with Special Tool MD998306. CYLINDER HEAD
(Fig. 13).
REMOVAL
(1) See Timing System this group for disassembly
and remove camshaft sprockets.
Ä 3.0L ENGINE 9 - 79

Fig. 15 Check Cylinder Head

INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 15).
Fig. 13 Install Camshaft End Seal—Plug (4) Cylinder head must be flat within;
(2) See Camshaft Rocker Arms Removal. • Standard dimension = less than 0.05mm (.002
(3) Remove upper intake manifold assembly. Refer inch)
to Intake and Exhaust Manifolds, Group 11. • Service Limit = 0.2mm (.008 inch)
(4) Remove distributor. • Grinding Limit = Maximum of 0.2 mm (.008 inch)
(5) Remove exhaust manifolds and cross over Refer is permitted.
to Intake and Exhaust Manifolds, Group 11.
CAUTION: This is a combined total dimension of
stock removal from cylinder head if any and block
top surface.

Fig. 14 Cylinder Head Bolt Removal Sequence

(6) Remove cylinder head bolts in sequence shown
in (Fig. 14) and remove cylinder head. Fig. 16 Cylinder Head Bolt Tightening Sequence
9 - 80 3.0L ENGINE Ä

INSTALLATION
(1) Clean surfaces of head and block, install head
gasket over locating dowels.
(2) Install head on locating dowels.
(3) Install 10mm allen hex head bolts with wash-
ers.
(4) Tighten bolts in the order shown in (Fig. 16).
When tightening the cylinder head bolts, tighten
gradually, working in two or three steps and finally
tighten to specified torque of 108 NIm (80 ft. lbs.).

VALVE SERVICE Fig. 19 Valve Inspection

VALVE AND VALVE SPRINGS VALVES
(1) Check valve stem tip for pitting or depression
at point A (Fig. 19).
(2) Check for wear and ridge wear at Point B.
(3) Check for even contact (at face center) with
valve seat, Point C.
(4) Check margin. Replace valve if margin is out of
specification (Fig. 20).
(5) Check valve guide height (Fig. 20).

Fig. 17 Remove Valves

Fig. 20 Valve Guide Height

(6) Measure valve stem to guide clearance. Refer
to specification (Fig. 21).
(7) Measure Valve spring free length and square-
ness (Fig. 22). Refer to (Fig. 21) for specifications.

VALVE SEAT INSPECTION

Inspect the valve seat with Prussian blue to deter-
mine where the valve contacts the seat. To do this,
Fig. 18 Remove Valve Stem Seals coat valve seat LIGHTLY with Prussian blue then
(1) With suitable valve spring compressor, remove set valve in place. Rotate the valve with light pres-
spring retainer locks, retainer, valve spring, spring sure. If the blue is transferred to the center of valve
seat and valve (Fig. 17). face, contact is satisfactory. If the blue is transferred
(2) Remove valve stem seals with suitable tool to top edge of the valve face, lower valve seat with a
(Fig. 18). Do not reuse valve stem seals. 15 degrees stone. If the blue is transferred to the bot-
tom edge of valve face raise valve seat with a 65 de-
gree stone.
(1) Install valve spring seat.
Ä 3.0L ENGINE 9 - 81

Fig. 23 Valve Seat Reconditioning

Fig. 21 Valve Specification

Fig. 24 Install Valve Stem Seals

Fig. 22 Valve Spring

(2) Using suitable tool install seal by tapping
lightly until seal is in place. (Fig. 24).
(3) Install valve spring with the enamelled ends
facing the rocker arms (Fig. 25).

CAUTION: During reassembly, compressing the Fig. 25 Installed Valve Spring Position
valve spring more than necessary to install valve
spring retainer locks can cause the retainer to be
forced against the stem seal and damaging it.
9 - 82 3.0L ENGINE Ä

PISTON AND CONNECTING ROD ASSEMBLY SERVICE

Fig. 1 Pistons, Connecting Rods

(1) Mark Identify Pistons.The pistons are not in-
terchangeable from bank to bank(Fig. 2). Pistons
with the letter R and arrow toward the front of en-
gine are to be installed in cylinders 1-3-5. Pistons
with the letter L and arrow toward the front of en-
gine are to be installed in cylinders 2-4-6.

Fig. 3 Mark Matching Parts

be 12mm (.50 inch) down and bottom measurement
should be 10mm (.38 inch) up.
(2) Standard bore dimension: 91.1mm (3.587 inch)
(3) Maximum out-of-round or taper: 0.02mm (.0008
inch)
Fig. 2 Mark Pistons FITTING PISTONS
(2) Mark connecting rod and cap with cylinder Measure approximately 2mm (.080 inch) above the
number (Fig. 3). bottom of the piston skirt and across the thrust face.
(3) Remove piston rings (Fig. 4). (Fig. 6), See Boring Cylinder in Cylinder Block.

CYLINDER BORE INSPECTION FITTING PISTON RINGS

(1) Measure the cylinder bore at three levels in di- (1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
rections A and B (Fig. 5). Top measurement should
ring gap measurement must be made with the ring
positioning at least 16mm (0.63 inch) from bottom of
Ä 3.0L ENGINE 9 - 83

cylinder bore. Check gap with feeler gauge (Fig. 7).

Refer to (Fig. 8) for specification.
(2) Check piston ring to groove clearance; Refer to
Piston Ring Specification Chart (Fig. 8).

Fig. 4 Remove Piston Rings

Fig. 7 Check Gap on Piston Rings

Fig. 8 Piston Ring Specification Chart

Fig. 5 Checking Cylinder Bore Size

Fig. 9 Piston Ring Clearance

Fig. 6 Piston Clearance and Wear
9 - 84 3.0L ENGINE Ä

PISTON RINGS—INSTALLATION
(1) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Install rings with manufacturers
mark and size mark facing up, to the top of the pis-
ton (Fig. 10).

Fig. 12 Installing Upper and Intermediate Rings

Fig. 10 Piston Ring Installation

CAUTION: Install piston rings in the following or-
der:

(a) Oil ring expander.

(b) Upper oil ring side rail.
(c) Lower oil ring side rail.
(d) No. 2 Intermediate piston ring.
(e) No. 1 Upper piston ring.

Fig. 13 Piston Ring End Gap Position

(5) Position piston ring end gaps as shown in (Fig.
13).
(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.
(7) Connecting rod front mark 72 must always face
forward, toward timing belt end. (Fig. 14)
(8) Install the piston and connecting rod assembly
into there respective bore from the cylinder block
top.

CAUTION: Piston assemblies are not to be inter-

Fig. 11 Installing Side Rail changed from bank to bank.
(2) Install the side rail by placing one end between (9) Check alignment marks made during disassem-
the piston ring groove and the expander. Hold end bly and that bearing position notches new or used
firmly and press down the portion to be installed un- are on the same side as shown in (Fig. 15).
til side rail is in position. Do Not use a piston ring
expander (Fig. 11). CONNECTING ROD CLEARANCE
(3) Install upper side rail first and then the lower (1) Following procedures specified in the Standard
side rail. Service Procedures Section for Measuring Main Bear-
(4) Install No. 2 piston ring and then No. 1 piston ing Clearance and Connecting Rod Bearing Clear-
ring (Fig. 12). ance. (Fig. 16). Refer to (Fig. 18) for specifications.
Ä 3.0L ENGINE 9 - 85

Fig. 14 Identify Piston/Rod Assembly for Cylinder

Installation Fig. 16 Connecting Rod Checking Bearing
Clearance

Fig. 15 Connecting Rod and Cap

Fig. 17 Checking Connecting Rod Side Clearance
(2) Tighten nuts to 52 NIm (38 ft. lbs.).
(3) Remove connecting rod cap and measure Plas-
tigage (Fig. 16).

CAUTION: Do not rotate crankshaft or the Plasti-

gage may be smeared.

CONNECTING ROD SIDE CLEARANCE

Using a feeler gauge, check connecting rod side
clearance (Fig. 17). Refer to (Fig. 18) for specifica-
tion.
Fig. 18 Connecting Rod Clearance Specifications
9 - 86 3.0L ENGINE Ä

CRANKSHAFT AND CYLINDER BLOCK, ASSEMBLY SERVICE

Fig. 1 Crankshaft and Cylinder Block

CRANKSHAFT SERVICE
The crankshaft is supported in four main bearings.
All upper bearing shells in the crankcase have oil
grooves. All lower bearing shells in stalled in the
monoblock main bearing cap are plain. Crankshaft
end play is controlled by thrust washers on the num-
ber three main bearing journal.

CRANKSHAFT—REMOVAL
(1) Remove front mounted oil pump assembly and
gasket (Figs. 1 and 2).
(2) Remove rear oil seal retainer and seal as as-
sembly (Fig. 3).
(3) Release monoblock main bearing cap bolts
evenly. Remove lower bearing shells and identify for
reassembly. Fig. 2 Oil Pump Assembly
(4) Lift out crankshaft and remove upper thrust CRANKSHAFT OIL CLEARANCE
washers from each side of number three main bear-
ing in the crankcase (Fig. 1). MECHANICAL MEASUREMENT
Measure the journal outside diameter and the main
INSPECTION bearing inside diameter (Figs. 4 and 5). If the clear-
Visually check the main and connecting rod bear- ance exceeds the specifications limit (Fig. 6). Replace
ing journals for wear, scuffs or scoring and replace if the main bearing(s) and if necessary replace the
necessary. crankshaft.
Ä 3.0L ENGINE 9 - 87

Fig. 3 Rear Seal Assembly

Fig. 6 Crankshaft Clearance Specification
(4) Install the main bearing cap carefully and
tighten the bolts to specified torque.

CAUTION: Do not rotate crankshaft or the plasti-

gage will be smeared.

Fig. 4 Measure Crankshaft Journal O.D.

Fig. 7 Measure Oil Clearance with Plastigage

(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. 8). Refer to
specification (Fig. 6) for proper clearances. Also see
Measuring Main and Connecting Rod Bearing Clear-
ance in Standard Service Procedures.

CRANKSHAFT BEARINGS

INSTALLATION
Fig. 5 Measure Main Bearing I.D. (1) Install upper main bearing shells making cer-
PLASTIGAGE MEASUREMENT tain oil holes are in alignment, and bearing tabs seat
(1) Remove oil from journal and bearing shell. in block tabs. All upper bearings have oil grooves
(2) Install crankshaft. (Fig. 9).
(3) Cut plastigage to same length as width of the THRUST BEARINGS. Crankshaft thrust bear-
bearing and place it in parallel with the journal axis. ings (washers) are installed at journal #3 separately
(Fig. 7). from the radial bearings. Thrust bearings shown in
9 - 88 3.0L ENGINE Ä

(4) Install lower main bearing shells without oil

grooves in monoblock cap.
(5) Install one pair of thrust washers in cap. Refer
to Thrust Bearings (Fig. 9).
(6) Carefully install bearing cap with arrows (Fig.
10) toward timing belt end.
(7) Oil the bearing cap bolt threads, install and
tighten bolts progressively in sequence shown in
(Fig. 9) to 80 NIm (60 ft. lbs.) torque.

CHECKING CRANKSHAFT END PLAY

(1) Mount a dial indicator to front of engine, locat-
ing probe on nose of crankshaft (Fig. 11).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
Fig. 8 Measuring Clearance (4) Move crankshaft all the way to the front and
read the dial indicator. Refer to (Fig. 6) for specifica-
(Fig. 9) are different, one has end positioning tabs, tion.
while the other is plain. One pair of each thrust
washers are installed into the block and one pair CRANKSHAFT OIL SEALS SERVICE
into the main bearing cap (Fig. 9).
(2) Apply a thin film of grease to plain side of REAR CRANKSHAFT SEAL RETAINER
thrust washers and position them on each side of (1) Install rear crankshaft oil seal in housing with
number three main bearing. Grooved surface towards Special Tool MD998718 (Fig. 12).
crankshaft. (2) Apply (Mopar Silicone Rubber Adhesive Seal-
ant or equivalent) to oil seal housing (Fig. 13) per
(3) Oil the bearings and journals and install crank-
procedure detailed in form-in-place gasket section in
shaft.
Standard Service Procedures.

Fig. 9 Install Main Bearings

Ä 3.0L ENGINE 9 - 89

Fig. 10 Crankshaft Main Bearing Cap

Fig. 11 Checking Crankshaft End Play Fig. 12 Install Crankshaft Rear Oil Seal
(3) Apply light coating of engine oil to the entire CAUTION: Install bolts, depending on length in lo-
circumference of oil seal lip. cations shown in (Fig. 14).
(4) Install seal assembly on cylinder block and
tighten bolts to 12 NIm (104 in. lbs.) (2) Using front crankshaft oil seal installer Special
Tool MB998306 install oil seal in oil pump (Fig. 15).
FRONT CRANKSHAFT OIL PUMP AND OIL
SEAL CYLINDER BLOCK
(1) Install oil pump gasket and oil pump case Inspect cylinder block for scratches, cracks and rust
(Figs. 1 and 14). or corrosion, and repair or replace as required.
9 - 90 3.0L ENGINE Ä

• Standard Value: 0.05 mm (.002 inch)

• Service Limit 0.1 mm (.003 inch)

CAUTION: Maximum of 0.2mm (.008 inch) is permit-

ted. This is a combined total dimension of stock re-
moval from cylinder head (if any) and block top
surface.

Fig. 13 Apply Sealant to Oil Seal Housing

Fig. 16 Distortion Check

BORING CYLINDER
Examine cylinder walls for scuffs, scoring and mea-
sure cylinder bore for out-of-round or taper. If defec-
tive, bore cylinder to oversize. Measure at points
Fig. 14 Oil Pump shown in (Fig. 17).
Four oversize pistons are available (0.25mm (.010
inch) 0.50mm (.020 inch) 0.75mm (.030 inch) and
1.0mm (.039 inch). Determine oversize piston on ba-
sis of largest cylinder bore.

Fig. 17 Measure Cylinder Bore

Fig. 15 Crankshaft Front Oil Seal (1) Bore to specified clearance between the piston
O.D. and cylinder. The measuring point of the piston
(1) Clean cylinder block and check top surface for O.D. is shown in (Fig. 18).
distortion with a straight edge and thickness gauge (2) Based on measured piston O.D., calculate bor-
(Fig. 16). ing finish dimension. Boring finish dimension equals
(2) Top surface must be flat within: piston O.D. plus 0.03 to 0.05 mm (.0012 to .002 inch)
Ä 3.0L ENGINE 9 - 91

(clearance between piston O.D. and cylinder) minus

0.02 mm which is the boring margin.
(3) Bore all cylinders to calculated boring finish di-
mension. Then bore the final finish dimension (piston
O.D. plus cylinder clearance).
(4) Check clearance between piston and cylinder,
clearance should be 0.03 to 0.05 mm (.0012 to .002
inch).

Fig. 18 Measure Piston

ENGINE LUBRICATION SYSTEM

Fig. 1 Engine Oiling

The lubrication system is a full flow filtration pres- gallery in the cylinder block. This gallery also feeds
sure feed type. Oil, stored in the oil pan, is taken in oil under pressure to the cylinder heads. It then
and discharged by a internal gear type oil pump di- flows from a camshaft bearing cap on each cylinder
rectly coupled to the crankshaft and its pressure is head through passages in the rocker shafts to the
regulated by a relief valve. The oil is fed through an rocker arm pivots, auto lash adjusters, and camshaft
oil filter and to the crankshaft journals from the oil journals (Fig. 1).
9 - 92 3.0L ENGINE Ä

OIL PUMP SERVICE

The oil pump assembly is mounted on the timing
belt end of the cylinder block with the inner pump
rotor indexed and installed on the crankshaft nose.
(Fig. 5).
The oil pump case also retains the crankshaft front
oil seal and provides oil pan front end closure.

Fig. 2 Oil Pan

OIL PAN
The oil pan is made of sheet metal and is provided
with a baffle-plate to prevent fluctuations in the oil
level while the vehicle is running (Fig. 2).

Fig. 5 Oil Pump-Installed

REMOVAL
Remove accessory drive system. Refer to Accessory
Drive Service in this group.
Remove 5 bolts that attach oil pump to block (Fig.
6).

Fig. 3 Oil Pan Sealing

OIL PAN SEALING AND INSTALLATION
Oil pan to crankcase sealing is provided with Mo-
par Silicone Rubber Adhesive Sealant or equivalent
gasket material. See Form-In-Place Gaskets in Stan-
dard Service Procedures.
(1) Apply sealant as shown in (Fig. 3).
(2) Install pan and tighten screws to 6 NIm (50 in.
lbs.) in sequence shown in (Fig. 4).

Fig. 6 Oil Pump Assembly

INSPECTION OIL PUMP
(1) Check oil pump case for damage and remove
rear cover.
(2) Remove pump rotors and inspect case for exces-
sive wear.
(3) Measure clearance between case and inner ro-
tor (Fig. 8).
Fig. 4 Oil Pan Screw Tightening Sequence (4) Insert the rotor into the oil pump case (Figs. 9
and 10) and measure clearance with a feeler gauge
as indicated.
Ä 3.0L ENGINE 9 - 93

Fig. 7 Oil Pump Components Fig. 10 Checking Rotor End Clearance

(2) Check for broken relief spring.

INSTALLATION
(1) Clean block and pump surfaces.
(2) Install new gasket (Fig. 7) make sure correct
length bolts are used (Fig. 6).
(3) Torque bolts to 13 NIm (120 in. lbs.).

CHECKING ENGINE OIL PRESSURE

Check oil pressure using gauge at oil pressure
switch location. Oil pressure should be 41 kPa ( 6
psi.) at idle or 241 to 517 kPa (35 to 75 psi.) at 3000
RPM.
(1) Remove pressure sending unit and install oil
pressure gauge. (Fig. 11)
Fig. 8 Inner Rotor to Case
CAUTION: If oil pressure is 0 at idle, Do Not Run
(5) Replace if out of limits. engine at 3000 RPM.

(2) Warm engine at high idle until thermostat

opens.

Fig. 9 Checking Clearance-Between Outer Rotor and

Case
OIL RELIEF PLUNGER
(1) Check that the oil relief plunger slides Fig. 11 Checking Oil Pump Pressure
smoothly.
9 - 94 3.0L ENGINE Ä

Fig. 12 Oil Filter and Bracket

OIL FILTER AND BRACKET
BRACKET

INSPECTION
(1) Check the oil filter mounting surface. The sur-
face must be smooth, flat and free of debris or old
pieces of rubber (Fig. 12).
(2) Check bracket for cracks and oil leaks.

OIL FILTER

CAUTION: When servicing the oil filter (Fig. 16)

avoid deforming the filter can by installing the re-
move/install tool band strap against the can-to-base
lockseam. The lockseam joining the can to the base
is reinforced by the base plate.

(1) Turn counter clockwise to remove.

(2) To install, lubricate new filter gasket. Screw
filter on until gasket contacts base. Tighten 1 turn.
Ä 3.0L ENGINE 9 - 95

ENGINE SPECIFICATIONS
9 - 96 3.0L ENGINE Ä

ENGINE SPECIFICATIONS (CONT.)

Ä 3.0L ENGINE 9 - 97

TORQUE
9 - 98 3.3/3.8L ENGINE Ä

3.3/3.8L ENGINE

INDEX
page page
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Camshaft Bearings—Engine Removed From Engine Specifications . . . . . . . . . . . . . . . . . . . . . 126
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 General Information . . . . . . . . . . . . . . . . . . . . . . . 98
Checking Engine Oil Pressure . . . . . . . . . . . . . . 125 Hydraulic Tappets . . . . . . . . . . . . . . . . . . . . . . . 108
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . 118 Installing Piston and Connecting Rod Assembly . 117
Crankshaft Oil Seals Service . . . . . . . . . . . . . . . 121 Intake Manifold Sealing . . . . . . . . . . . . . . . . . . . 104
Crankshaft Service .................. . . . . 118 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Cylinder Block, Piston and Connecting Rod Oil Pan Service . . . . . . . . . . . . . . . . . . . . . . . . . 122
Assembly Service . . . . . . . . . . . . . . . . . . . . . . 114 Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . 123
Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . . . . 102 Rocker Arms and Shaft Assembly . . . . . . . . . . . 102
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 101 Timing Chain Cover, Oil Seal and Chain . . . . . . 109
Engine Core Oil and Cam Plugs . . . . . . . . . . . . 113 Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Engine Lubrication System ............ . . . . 122 Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
SPECIFICATIONS

GENERAL INFORMATION being the thrust bearing. Crankshaft end sealing is

provided by front and rear rubber seal.
ENGINE IDENTIFICATION NUMBER OR CODE PISTONS: The pistons are cast aluminum alloy.
The engine identification number is located on the Three rings are used. Piston pins, press fitted into
rear of the cylinder block just below the cylinder place, join the pistons to forged steel connecting rods.
head (Fig. 2). CAMSHAFT: The nodular iron camshaft is
ENGINE: The 3.3L (201 Cubic. Inches.) and 3.8L mounted in four steel backed babbitt bearings. A
(231 Cubic. Inches.) displacement engines are 60° V thrust plate located in front of the first bearing, and
type six cylinder power plant with cast iron cylinder bolted to the block, controls end play. Silent timing
block and aluminum cylinder heads (Fig. 1). Firing chain drives the camshaft. This chain is enclosed by
order for these engines is 1-2-3-4-5-6. High turbu- a cast aluminum cover which also carries a front
lence cylinder heads allow a 8.9-1 compression ratio. crankshaft seal, provides front oil pan closure, water
CRANKSHAFT: The nodular iron crankshaft is pump mounting.
supported by four main bearings, with number two
Ä 3.3/3.8L ENGINE 9 - 99

Fig. 1 3.3/3.8L V-6 Engine

casting with individual primary runners leading
from a plenum to the cylinders. The manifold is de-
signed to boost torque in the 3600 rpm range and
contributes to the engine’s broad, flat torque curve,
which was desired for excellent engine tractability,
response and usable power output.
The intake manifold is also cored with upper level
EGR passages for balanced cylinder to cylinder EGR
distribution.
VALVE TRAIN: Valve train design incorporates
the use of hydraulic roller tappets. Rocker arms are
installed on a rocker arm shaft attached to the cylin-
der head with four bolts and retainers. Viton valve
stem seals provide valve sealing. Conventional type
pushrods, retainers and valve stem locks are used.
Unique beehive style valve spring are used with
lightweight retainers for improved high RPM perfor-
mance.
EXHAUST MANIFOLDS: Exhaust manifolds are
log type with a crossover and is attached directly to
the cylinder heads.
Fig. 2 Engine Identification
CYLINDER HEADS: Cylinder heads incorporate ENGINE MOUNTS
valve shrouding to create turbulence-producing com-
REMOVAL AND INSTALLATION
bustion chambers, described as fast burn. Valve seat
and guides are inserts. A steel flanged composition RIGHT SIDE MOUNT
type gasket is used between head and block. (1) Remove the right engine mount insulator ver-
VALVE COVERS: The covers are sealed with tical fasteners from frame rail.
steel reinforced silicon rubber gaskets. (2) Remove the load on the engine motor mounts
INTAKE MANIFOLD: The intake manifold is a by carefully supporting the engine and transmission
tuned two-piece semi-permanent mold aluminum assembly with a floor jack.
9 - 100 3.3/3.8L ENGINE Ä

Fig. 3 Engine Mounting

(3) Remove the thru bolt from the insulator assem- (5) Remove the transmission mount fasteners and
bly. Remove insulator. remove mount.
(4) Reverse removal procedure for installation. Re- (6) Reverse removal procedure for installation. En-
fer to (Fig. 3) for bolt tightening specifications. sure that the slide tube is seated into the rail
(5) Engine mount adjustment, Refer to Engine bracket guides. Refer to (Fig. 3) for bolt tightening
Mount Insulator Adjustment of this section. specifications.
(7) Engine mount adjustment, Refer to Engine
FRONT MOUNT Mount Insulator Adjustment of this section.
(1) Support the engine and transmission assembly
with a floor jack so it will not rotate. ENGINE MOUNT RUBBER INSULATORS
(2) Remove the thru bolt from the insulator and Insulator location on yoke bracket to engine plate
front crossmember mounting bracket. (right side) and transmission bracket (left side) are
(3) Remove the front engine mount bracket to adjustable to allow right/left drive train adjustment
front crossmember screws and nuts. Remove the in- in relation to drive shaft assembly length.
sulator assembly. Check and reposition right engine mount insulator
(4) Reverse removal procedure for installation. Re- (left engine mount insulator is floating type and will
fer to (Fig. 3) for bolt tightening specifications. adjust automatically (Fig. 4). Adjust drive train posi-
(5) Engine mount adjustment, Refer to Engine tion, if required, for the following conditions:
Mount Insulator Adjustment of this section. • Drive shaft distress: See Driveshafts in Suspen-
sion, Group 2.
LEFT SIDE MOUNT • Any front end structural damage (after repair).
(1) Raise vehicle on hoist and remove left front • Insulator replacement.
wheel.
(2) Remove inter splash shield. ENGINE MOUNT INSULATOR ADJUSTMENT
(3) Support the transmission with a transmission (1) Remove the load on the engine motor mounts
jack. by carefully supporting the engine and transmission
(4) Remove the insulator thru bolt from the mount. assembly with a floor jack.
Ä 3.3/3.8L ENGINE 9 - 101

(2) Loosen the right engine mount insulator yoke (13) Remove screws holding torque converter to
screw and 2 turns on yoke nut, then loosen the front flex plate and attach C-clamp on bottom of converter
engine mount bracket to front crossmember screws and housing to prevent torque converter from counting
nuts. out.
Left engine mount insulator is sleeved over (14) Remove power steering pump mounting bolts
shaft and long support bolt to provide lateral and set pump aside.
movement adjustment with engine weight re- (15) Remove two lower transmission to block
moved or not. screws.
(3) Pry the engine right or left as required to achieve (16) Remove starter.
the proper drive shaft assembly length. See Drive (17) Lower vehicles and disconnect vacuum lines
Shaft in Suspension Group 2 for driveshaft identifica- and ground strap.
(18) Install transmission holding fixture.
tion and related assembly length measuring.
(19) Attach engine lifting hoist and support en-
(4) Tighten right engine mount insulator yoke nut to
gine.
102 NIm (75 ft. lbs.). Then tighten front engine mount
(20) Remove upper transmission case to block
screws and nuts to 54 NIm (40 ft. lbs.) and center left
bolts.
engine mount insulator. (21) See Engine Mounting in (Fig. 3) and separate
(5) Recheck drive shaft length. mount/insulators as follows:
(a) Mark RIGHT insulator on right rails sup-
ports. Remove insulator to rails screws.
(b) Remove FRONT engine mount through bolt
and nut.
(c) Remove LEFT insulator through bolt from in-
side wheelhouse or insulator bracket to transmis-
sion screws.
(22) Remove engine.

INSTALLATION
(1) Attach hoist and lower engine into engine com-
partment.
(2) Align engine mounts and install but do not
tighten until all mounting bolts have been installed.
Tighten bolts to torque specified in (Fig. 3).
(3) Install transmission case to cylinder block,
Fig. 4 Left Insulator Movement tighten bolts to 102 NIm (75 ft. lbs.) torque.
(4) Remove engine hoist and transmission holding
ENGINE ASSEMBLY fixture.
(5) Remove C-clamp from torque converter hous-
REMOVAL
ing. Align flex plate to torque converter and install
(1) Disconnect battery.
mounting screws. Tighten to 75 NIm (55 ft. lb-
(2) Mark hood position at hinges and remove hood.
s.)torque. Refer to Group 21 transaxle for the all
(3) Drain cooling system. Refer to Cooling System,
wheel drive installation procedure.
Group 7 for procedure. (6) Install transmission inspection cover.
(4) Disconnect all electrical connections. (7) Connect exhaust system at manifold.
(5) Remove coolant hoses from radiator and engine. (8) Install starter.
(6) Remove radiator and fan assembly. (9) Install power steering pump and air condition-
(7) See Fuel System, Group 14, to release fuel pres- ing compressor. For belt installation see Accessory
sure. Disconnect fuel lines and accelerator cable. Belt Drive in Cooling System Group 7.
(8) Remove air cleaner assembly. (10) Lower vehicle and connect all vacuum lines.
(9) Hoist vehicle and drain engine oil. (11) Connect all electrical connections including
(10) Remove air conditioning compressor mounting ground strap.
bolts and set compressor aside. (12) Connect fuel lines and accelerator cable.
(11) Disconnect exhaust pipe at manifold. (13) Install radiator and fan assembly. Reconnect
(12) Remove transmission inspection cover and fan motor electrical lead. Reinstall radiator hoses.
mark flex plate to torque converter position. For disas- Fill cooling system. See Cooling System Group 7 for
sembly procedure for the all wheel drive vehicle refer to filling procedure.
Group 21 Transaxle. (14) Fill engine crankcase with proper oil to cor-
rect level.
9 - 102 3.3/3.8L ENGINE Ä

(15) Install hood. (5) Install spark plug wires.

(16) Connect battery. (6) Install upper intake manifold assembly. Refer to
(17) Start engine and run until operating temper- Exhaust Systems and Intake Manifolds Group 11.
ature is reached.
(18) Adjust transmission or linkage if necessary. CYLINDER HEADS
The alloy aluminum cylinder heads shown in (Fig. 6)
ROCKER ARMS AND SHAFT ASSEMBLY are held in place by 9 bolts. The spark plugs are located
in peak of the wedge between the valves.
REMOVAL
(1) Remove upper intake manifold assembly. Refer
to Intake and Exhaust Manifolds, Group 11.
(2) Disconnect spark plug wires by pulling on the
boot straight out in line with plug.
(3) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
(4) Remove cylinder head cover and gasket.
(5) Remove four rocker shaft bolts and retainers.
(6) Remove rocker arms and shaft assembly.
(7) If rocker arm assemblies are disassembled for
cleaning or replacement. Assemble rocker arms in
their original position.Refer to (Fig. 5) for rocker arm
for positioning on the shaft.

Fig. 6 Cylinder Head Assembly

REMOVAL
(1) Drain cooling system refer to Cooling System
Group 7 for procedure and disconnect negative battery
cable.
Remove intake manifold, and throttle body. Refer to
Group 11 Exhaust System and Intake Manifold.
(2) Disconnect coil wires, sending unit wire, heater
hoses and by-pass hose.
(3) Remove closed ventilation system, evaporation
control system and cylinder head covers.
(4) Remove exhaust manifolds.
(5) Remove rocker arm and shaft assemblies. Re-
move push rods and identify to insure installation
in original locations.
Fig. 5 Rocker Arm Location Left Blank (6) Remove the 9 head bolts from each cylinder head
INSTALLATION and remove cylinder heads (Fig. 7).
(1) Install rocker arm and shaft assemblies with
the stamped steel retainers in the four positions,
tighten to 28 NIm (250 in. lbs.) (Fig. 5).
WARNING: THE ROCKER ARM SHAFT
SHOULD BE TORQUED DOWN SLOWLY,
STARTING WITH THE CENTERMOST BOLTS.
ALLOW 20 MINUTES TAPPET BLEED DOWN
TIME AFTER INSTALLATION OF THE
ROCKER SHAFTS BEFORE ENGINE OPERA-
TION.
(2) Clean cylinder head cover gasket surface. In-
spect cover for distortion and straighten if necessary.
(3) Clean head rail if necessary. Install a new gas-
ket and tighten cylinder head cover fasteners to 12
NIm (105 in. lbs.).
(4) Install closed crankcase ventilation system and
evaporation control system. Fig. 7 Cylinder Head Bolts Location
Ä 3.3/3.8L ENGINE 9 - 103

INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 8).
(4) Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out of flatness exceeds
.019mm (.00075 inch). times the span length in inches
in any direction, either replace head or lightly machine
the head surface. As an example, if a 12 inch span is
1mm (.004 inch) out of flat, allowable is 12 x .019mm
(.00075 inch) equals .22mm (.009 in.) This amount of
out of flat is acceptable.
*Maximum of 0.2 mm (.008 inch) for grinding is
permitted.

CAUTION: This is a combined total dimension of Fig. 9 Head Gasket Installation

stock removal from cylinder head and block top
surface.

Fig. 10 Checking Bolts for Stretching (Necking)

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

Fig. 8 Check Cylinder Head

INSTALLATION
(1) Clean all surfaces of cylinder block and cylinder
heads.
(2) Install new gaskets on cylinder block (Fig. 9).
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 should be replaced (Fig. 10).
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. Fig. 11 Cylinder Head Tightening Sequence
(3) Tighten the cylinder head bolts 1 thru 8 in the
sequence shown in (Fig. 11). Using the 4 step torque (5) Tighten head bolt number 9 (Fig. 11) to 33 NIm
turn method, tighten according to the following values: (25 ft. lbs.) after head bolts 1 thru 8 have been tighten
• First-All to 61 NIm (45 ft. lbs.) to specifications.
• Second-All to 88 NIm (65 ft. lbs.) (6) Inspect push rods and replace worn or bent rods.
• Third-All (again) to 88 NIm (65 ft. lbs.) (7) Install push rods, rocker arm and shaft assem-
• Fourth + 1/4 Turn Do not use a torque wrench blies with the stamped steel retainers in the four
for this step positions, tighten to 28 NIm (250 in. lbs.) (Fig. 12).
9 - 104 3.3/3.8L ENGINE Ä

(8) Place new cylinder head cover gaskets in position are in place. Refer to Group 11 Exhaust System and
and install cylinder head covers. Tighten to 12 NIm Intake Manifold to complete Intake Manifold Assem-
(105 in. lbs.). bly.
(5) Install exhaust manifolds and tighten bolts to
27 NIm (20 ft. lb.) and nuts to 20 NIm (15 ft. lbs.).
(6) Adjust spark plugs to specification in Electrical
Section, Group 8, and install the plugs.

Fig. 12 Rocker Arm Shaft Retainers

INTAKE MANIFOLD SEALING
The intake manifold gasket is a one-piece stamped
steel gasket with a sealer applied from the manufac-
turer. This gasket has end seals incorporated with it.
WARNING: INTAKE MANIFOLD GASKET IS
MADE OF VERY THIN METAL AND MAY CAUSE
PERSONAL INJURY, HANDLE WITH CARE.
(1) Clean all surfaces of cylinder block and cylinder
heads. Fig. 14 Intake Manifold Gasket Retainers
(2) Place a drop ( about 1/4 in. diameter) of Mopar
Silicone Rubber Adhesive Sealant or equivalent, onto
each of the four manifold to cylinder head gasket
corners (Fig. 13).

Fig. 15 Intake Manifold Removal and Installation

VALVE SERVICE
VALVES AND VALVE SPRINGS
Fig. 13 Intake Manifold Gasket Sealing The valves are arranged in line in the cylinder
heads and inclined 18 degrees. The rocker shaft sup-
(3) Carefully install the intake manifold gasket (Fig.
port are cast integral with the heads.
14). Torque end seal retainer screws to 12 NIm (105 in.
lbs.). REMOVAL
(4) Install intake manifold and (8) bolts and torque (1) With cylinder head removed, compress valve
to 1 NIm (10 in. lbs.). Then tighten bolts to 22 NIm springs using Valve Spring Compressor Tool
(200 in. lbs.) in sequence shown in (Fig. 15). Then C-3422-B with adapter 6412 as shown in (Fig. 16).
tighten again to 22 NIm (200 in. lbs.). After intake (2) Remove valve retaining locks, valve spring re-
manifold is in place, inspect to make sure seals tainers, valve stem seals and valve springs.
Ä 3.3/3.8L ENGINE 9 - 105

(3) Before removing valves,remove any burrs

from valve stem lock grooves to prevent damage
to the valve guides. Identify valves to insure instal-
lation in original location.

Fig. 18 Intake and Exhaust Valves

(c) Move valve to and from the indicator. Refer to
specifications (Fig. 19).
Ream the guides for valves with oversized stems if
Fig. 16 Compress Valve Springs with Special Tool dial indicator reading is excessive or if the stems are
C-3422B with adapter 6412 scuffed or scored.
(5) Service valves with oversize stems and over size
VALVE INSPECTION seals are available in 0.15mm (.005 inch), 0.40mm,
(1) Clean valves thoroughly and discard burned, (.015 inch) and 0.80mm (.030 inch) oversize.
warped and cracked valves. Oversize seals must be used with oversize
(2) Measure valve stems for wear. Refer to specifica- valves.
tions (Fig. 19). Reamers to accommodate the oversize valve stem are
Valve stems are chrome plated and should not as follows:
be polished.
(3) Remove carbon and varnish deposits from inside
of valve guides with a reliable guide cleaner.
(4) Measure valve stem guide clearance as follows:
(a) Install valve into cylinder head so it is 14mm
(.551 inch) off the valve seat. A small piece of hose
may be used to hold valve in place.
(b) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 17).

Fig. 19 Valve Guide Specifications

(6) Slowly turn reamer by hand and clean guide
thoroughly before installing new valve. Do not at-
tempt to ream the valve guides from standard
directly to 0.80mm (.030 inch) Use step procedure
of 0.15mm (.005 inch), 0.40mm (.015 inch) and
0.80mm (.030 inch) so the valve guides may be
reamed true in relation to the valve seat. After
reaming guides, the seat runout should be mea-
sured and resurfaced if necessary. See Refacing
Valves and Valve Seats.

VALVE GUIDES
Replace cylinder head if guide does not clean
Fig. 17 Measuring Valve Guide Wear up with 0.80mm (.030 inch) oversize reamer, or if
guide is loose in cylinder head.
9 - 106 3.3/3.8L ENGINE Ä

Fig. 20 Valve Dimensions Fig. 22 Refacing Valve Seats

REFACING VALVES AND VALVE SEATS this, coat valve seat LIGHTLY with Prussian blue
The intake and exhaust valves have a 44-1/2 to 45 then set valve in place. Rotate the valve with light
degree face angle. The valve seats have a 45 to 45- pressure. If the blue is transferred to the center of
1/2 degree face angle. The valve face and valve seat valve face, contact is satisfactory. If the blue is trans-
angles are shown in (Fig. 21). ferred to top edge of valve face,lower valve seat with a
15 degree stone. If the blue is transferred to the bottom
VALVES edge of valve face raise valve seat with a 65 degrees
(1) Inspect the remaining margin after the valves stone.
are refaced Refer to specifications (Fig. 20). Valve seats which are worn or burned can be
reworked, provided that correct angle and seat
VALVE SEATS width are maintained. Otherwise cylinder head
must be replaced.
CAUTION: Do not un-shroud cylinder head from (4) When seat is properly positioned the width of
around the valve during valve seat refacing (Fig. intake seats should be 1.75 to 2.25mm (0.69 to .088
22). inch) The width of the exhaust seats should be 1.50 to
2.00mm (.059 to .078 inch) (Fig. 21)
(1) When refacing valve seats, it is important that
(5) Check the valve spring installed height after
the correct size valve guide pilot be used for reseat-
refacing the valve and seat (Fig. 24).
ing stones. A true and complete surface must be ob-
tained. TESTING VALVE SPRINGS
(2) Measure the concentricity of valve seat using Whenever valves have been removed for inspection,
dial indicator. Total runout should not exceed reconditioning or replacement, valve springs should be
.051mm (.002 inch) total indicator reading. tested (Fig. 23). As an example; the compression

Fig. 21 Valve Seats

(3) Inspect the valve seat with Prussian blue to de-
termine where the valve contacts the seat. To do Fig. 23 Testing Valve Spring with Tool C-647
Ä 3.3/3.8L ENGINE 9 - 107

length of the spring to be tested is 33.34mm (1-5/16

inches). Turn table of Tool C-647 until surface is in line
with the 33.34mm (1-5/16 inch) 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. Discard
the springs that do not meet specifications.

VALVE INSTALLATION
(1) Coat valve stems with clean engine oil and insert
them in cylinder head.
Fig. 25 Installing Valve, Cup Seal, Spring and Re-
(2) Check valve tip to spring seat dimension A after
tainer
grinding the valve seats or faces. Grind valve tip to give
49.541 to 51.271 mm (1.950 to 2.018 inch.) over spring (3) Remove Air Cleaner Cover and hose assembly.
seat when installed in the head (Fig. 17). Check valve (4) Remove Intake Manifold; Refer to
tip for scoring, if necessary, the tip chamfer should be Intake/Exhaust Manifold 3.3/3.8L Engine Group 11
reground to prevent seal damage when the valve is Exhaust System and Intake Manifolds of this manual
installed. for removal procedure.
(3) Install new cup seals on all valve stems and over (5) Remove cylinder head covers and spark plugs.
valve guides (Fig. 24). Install valve springs and valve (6) Remove connector wire from ignition coils.
retainers. (7) Using suitable socket and flex handle at crank-
shaft pulley retaining screw, turn engine so the num-
ber 1 piston is at Top Dead Center on the compression
stroke.
(8) Remove rocker arms with rocker shaft and in-
stall a dummy shaft. The rocker arms should not be
disturbed and left on shaft.
(9) With air hose attached to spark plug adapter
installed in number 1 spark plug hole, apply 90 to 100
psi air pressure (620.5 to 689 kPa). This is to hold
valves into place while servicing components.
(10) Using Tool C-4682 or Equivalent compress
valve spring and remove retainer valve locks and valve
Fig. 24 Checking Valve Installed Height
spring.
(4) Compress valve springs with Valve Spring Com- (11) The intake valve stem seals should be pushed
pressor Tool C-3422-B, with adapter 6412 install locks firmly and squarely over the valve guide using the
and release tool. If valves and/or seats are re- valve stem as guide. Do Not Force seal against top of
ground, measure the installed height of springs guide. When installing the valve retainer locks, com-
dimension B, make sure measurements is taken press the spring only enough to install the locks.
from top of spring seat to the bottom surface of
spring retainer. If height is greater than 1-19/32 CAUTION:Do not pinch seal between retainer and top
inches, (40.6mm), install a 1/32 inch (.794mm) of valve guide.
spacer in head counterbore to bring spring
height back to normal 1-17/32 to 1-19/32 inch (39.1 (12) Follow the same procedure on the remaining 5
to 40.6mm). cylinders using the firing sequence 1-2-3-4-5-6. Make
sure piston in cylinder is at TDC on the valve
REPLACE VALVE STEM SEALS OR VALVE spring that is being covered.
SPRINGS, CYLINDER HEAD NOT REMOVED (13) Remove spark plug adapter tool .
(1) Perform fuel system pressure release procedure (14) Remove dummy shaft and install rocker shaft
before attempting any repairs assembly and tighten screws to 28 NIm (250 in. lbs.).
(2) Disconnect negative battery cable.
9 - 108 3.3/3.8L ENGINE Ä

(15) Install rocker arm covers tighten screws to 14 cation system from the intake strainer to the pump
NIm (120 in. lbs.) and connector to ignition coils. cover, including the relief valve retainer cap. When
(16) Install Intake Manifold; Refer to Intake Mani- tappet noise is due to aeration, it may be intermittent
fold Installation 3.3/3.8L Engine, Group 11 Exhaust or constant, and usually more than one tappet will be
System and Intake Manifold. noisy. When oil level and leaks have been corrected,
engine should be operated at fast idle to allow all of the
HYDRAULIC TAPPETS air inside of the tappets to be bled out.
The valve train includes roller tappet assemblies,
aligning yokes and yoke retainer. VALVE TRAIN NOISE DIAGNOSIS
Roller tappet alignment is maintained by machined To determine source of valve train noise, operate
flats on tappet body being fitted in pairs into six engine at idle with cylinder head covers removed and
aligning yokes. The yokes are secured by an alignment listen for source of the noise.
yoke retainer (Fig. 26). Worn valve guides or cocked springs are some-
times mistaken for noisy tappets. If such is the
case, noise may be dampened by applying side
thrust on the valve spring. If noise is not appre-
ciably 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 tappet noise ranges from light noise to a heavy
click. A light noise is usually caused by excessive
leakdown around the unit plunger which will necessi-
tate replacing the tappet, or by the plunger partially
sticking in the tappet body cylinder. A heavy click is
caused either by a tappet check valve not seating, or by
foreign particles becoming wedged between the
plunger and the tappet body causing the plunger to
Fig. 26 Roller Tappets Aligning Yoke and Retainer stick in the down position. This heavy click will be
PRELIMINARY STEP TO CHECKING THE HY- accompanied by excessive clearance between the valve
DRAULIC TAPPETS stem and rocker arm as valve closes. In either case,
Before disassembling any part of the engine to cor- tappet assembly should be removed for inspection and
rect tappet noise, read the oil pressure at the gauge. cleaning.
Install a reliable gauge at pressure sending unit if
vehicle has no oil pressure gauge and check the oil level TAPPET REMOVAL
in the oil pan. The pressure should be between 30 and (1) Refer to Cylinder Head Removal of this section to
80 psi (206.8 to 551.6 kPa) at 2000 rpm. remove intake manifold and cylinder heads for access
The oil level in the pan should never be above the to tappets for service.
MAX mark on dipstick, or below the MIN mark. Either (2) Remove yoke retainer and aligning yokes.
of these two conditions could be responsible for noisy (3) Use Tool C-4129 to remove tappets from their
tappets. Oil Level Check: stop engine after reach- bores. If all tappets are to be removed, identify tappets
ing normal operating temperature. Allow 5 min- to insure installation in original location.
utes to stabilize oil level, check dipstick. If the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore
OIL LEVEL TOO HIGH to next oversize and replace with oversize tap-
If oil level is above the MAX mark on dip stick, it is pet.
possible for the connecting rods to dip into the oil while
engine is running and create foam. Foam in oil pan CAUTION: The plunger and tappet bodies are not
would be fed to the hydraulic tappets by the oil pump interchangeable. The plunger and valve must always
causing them to become soft and allow valves to seat be fitted to the original body. It is advisable to work on
noisily. one tappet at a time to avoid mixing of parts. Mixed
OIL LEVEL TOO LOW parts are not compatible. Do not disassemble a tap-
Low oil level may allow pump to take in air which pet on a dirty work bench.
when fed to the tappets, causes them to become soft
and allows valves to seat noisily. Any leaks on intake DISASSEMBLY (FIG. 27)
side of pump through which air can be drawn will (1) Pry out plunger retainer spring clip.
create the same tappet action. Check the lubri-
Ä 3.3/3.8L ENGINE 9 - 109

(2) Clean varnish deposits from inside of tappet (7) Place a 5.08mm (.200 inch) spacer between the
body above plunger cap. valve stem tip of #2 intake valve and rocker arm
(3) Invert tappet body and remove plunger cap, pad. Allow tappet to bleed down to give a solid tap-
plunger, flat or ball check valve, check valve spring, pet effect.
check valve retainer and plunger spring. Check valve (8) Install a dial indicator so plunger contacts the
could be flat or ball. #2 intake valve spring retainer as nearly perpendic-
ular as possible. Zero the indicator.
(9) Rotate the engine clockwise until the in take
valve has lifted .254mm (0.010 inch).

CAUTION: Do not turn crankshaft any further clock-

wise as intake valve might bottom and result in se-
rious damage.

(10) Degree wheel should read 3 degrees BTDC to

4 degrees ATDC.
Fig. 27 Hydraulic Roller Tappet Assembly
TIMING CHAIN COVER, OIL SEAL AND CHAIN
CLEANING AND ASSEMBLY
(1) Clean all tappet parts in a solvent that will re- COVER
move all varnish and carbon.
(2) Replace tappets that are unfit for further ser- REMOVAL
vice with new assemblies. (1) Disconnect battery.
(3) If plunger shows signs of scoring or wear, valve (2) Drain cooling system. Refer to Cooling System
is pitted, or valve seat on end of plunger indicates Group 7 for procedure.
any condition that would prevent valve from seating, (3) Support engine and remove right engine
install a new tappet assembly. mount.
(4) Assemble tappets (Fig. 27). (4) Raise vehicle on hoist. Drain engine oil.
(5) Remove oil pan and oil pump pick-up. It may
INSTALLATION necessary to remove transmission inspection cover.
(1) Lubricate tappets. (6) Remove right wheel and inner splash shield.
(2) Install tappets in their original positions. (7) Remove drive belt. Refer to Cooling System
(3) With roller tappets, install aligning yokes with Group 7 for procedure.
(Fig. 26). (8) Remove A/C compressor and set aside.
(4) Install yoke retainer and torque screws to 12 (9) Remove A/C compressor mounting bracket.
NIm (105 in. lbs.) (Fig. 26). (10) Remove crankshaft pulley (Fig. 1).
(5) Install cylinder heads. Refer to cylinder head
installation of this section for procedure.
(6) Start and operate engine. Warm up to normal
operating temperature.

CAUTION: To prevent damage to valve mechanism,

engine must not be run above fast idle until all hy-
draulic tappets have filled with oil and have become
quiet.

VALVE TIMING
(1) Remove front valve 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 into #2 Fig. 1 Removing Crankshaft Pulley
spark plug hole. Using the indicator find TDC on the (11) Remove idler pulley from engine bracket.
compression stroke. (12) Remove engine bracket (Fig. 2).
(5) Position the degree wheel to zero. (13) Remove cam sensor from chain case cover
(6) Remove dial indicator from spark plug hole. (Fig. 3).
9 - 110 3.3/3.8L ENGINE Ä

Fig. 2 Engine Bracket Fig. 3 Timing Chain Case Cover

(14) Remove chain case cover (Fig. 3).

MEASURING TIMING CHAIN FOR STRETCH

(1) Place a scale next to timing chain so that any
movement of chain may be measured.
(2) Place a torque wrench and socket on camshaft
sprocket attaching bolt and apply torque in direction of
crankshaft rotation to take up slack; 41 NIm (30 ft. lb.)
with cylinder head installed or 20 NIm (15 ft. lb.) with
cylinder heads removed. With a torque applied to
the camshaft sprocket bolt, crankshaft should
not be permitted to move. It may be necessary to
block crankshaft to prevent rotation.
(3) Holding a scale even, with dimension reading as
shown (Fig. 4 ), along edge of chain links. Apply torque
in the reverse direction to 41 NIm (30 ft. lbs.) with
Fig. 4 Measuring Timing Chain Wear and Stretch
cylinder heads installed, or 20 NIm (15 ft. lbs.) with
cylinder heads removed. Check amount of chain move- (11) Using straight edge to check alignment of tim-
ment (Fig. 4). ing marks (Fig. 5).
(4) Install a new timing chain, if its movement (12) Install camshaft bolt and washer. Tighten to 54
exceeds 3.175mm (1/8 inch) (Fig. 4). NIm (40 ft. lbs.).
(5) If chain is not satisfactory, remove camshaft (13) Rotate crankshaft 2 revolutions. Timing marks
sprocket attaching bolt, and remove timing chain with should line up. If timing marks do not line up remove
camshaft sprocket. cam sprocket and realign.
(6) Using a suitable puller remove the crankshaft (14) Check camshaft endplay. With new thrust plate
sprocket. Be careful not to damage the crankshaft specification is .0127 to .304 mm (.005 to .012 inches.).
surface. Old thrust plate specification is .31 mm (.012 inch.)
(7) Position a new crankshaft sprocket on the shaft, maximum. If not within these limits install new thrust
plate.
install sprocket with suitable tool and mallet. Be sure
(15) Install timing chain snubber. Tighten retaining
sprocket is seated into position.
screws to 12 NIm (105 in. lbs.). These bolts are
(8) Rotate crankshaft so the timing arrow is to the
20mm long for this model year, they should not
12 O’clock position.
be interchanged with previous year engines.
(9) Place timing chain around camshaft sprocket
and place the timing mark to the 6 O’clock position. INSTALLATION
(10) Align the dark colored links with the dot on the (1) Be sure mating surfaces of chain case cover and
camshaft sprocket, place timing chain around crank- cylinder block are clean and free from burrs. Crank-
shaft sprocket with the dark colored link lined up with shaft oil seal must be removed to insure correct oil
the dot on the sprocket and install camshaft sprocket pump engagement.
into position. (2) Use a new cover gasket, O-rings. (Fig. 6).
Ä 3.3/3.8L ENGINE 9 - 111

Fig. 5 Alignment of Timing Marks Fig. 7 Install Crankshaft Oil Seal

(3) Rotate crankshaft so that the oil pump drive
flats are vertical.
(4) Position oil pump inner rotor so the mating
flats are in the same position as the crankshaft drive
flats (Fig. 6).
(5) Install cover onto crankshaft. Make sure the oil
pump is engaged on the crankshaft correctly or se-
vere damage may result.
(6) Install chain case cover screws and torque to 27
NIm (20 ft. lbs.).
(7) Install crankshaft oil seal (Fig. 7).
(8) Install crankshaft pulley (Fig. 8).

Fig. 8 Installing Crankshaft Pulley

(11) Install cam sensor Refer to Ignition System
Group 8D for installation procedure.
(12) Install A/C compressor mounting bracket.
(13) Install A/C compressor.
(14) Install drive belt Refer to Cooling System
Group 7 for installation procedure.
(15) Install inner splash shield and wheel.
(16) Install oil pump pick-up and oil pan and
transmission inspection cover if removed.
(17) Install engine mount.
(18) Fill crankcase with oil to proper level.
(19) Fill cooling system Refer to Cooling System
Group 7 for procedure.
(20) Connect battery.

TIMING CHAIN COVER EXTERNAL OIL SEAL

REMOVAL
Fig. 6 Timing Chain Case Cover Gaskets and (1) Raise vehicle on hoist. Remove right wheel and
O-Rings inner splash shield.
(9) Install engine bracket (Fig. 2) torque screws to (2) Remove drive belt. (Refer to Cooling System
54 NIm (40 ft. lbs.). Group 7) for procedure.
(10) Install idler pulley on engine bracket. (3) Remove crankshaft pulley (Fig. 1).
9 - 112 3.3/3.8L ENGINE Ä

(4) Using Tool C-4991 to remove oil seal (Fig. 9).

Be careful not to damage that crankshaft seal sur-
face of cover.

Fig. 10 Camshaft Thrust Plate

Fig. 9 Removing Crankshaft Oil Seal

INSTALLATION
(1) Install new seal by using Tool C-4992 (Fig. 7). Fig. 11 Camshaft and Sprocket Assembly
(2) Place seal into opening with seal spring to- Whenever an engine has been rebuilt or a new
wards the inside of engine. Install seal until flush camshaft or tappets have been installed, add one
with cover. pint of Chrysler Crankcase Conditioner or
(3) Install crankshaft pulley using plate L-4524. equivalent to engine oil to aid in break in. The oil
Thrust Bearing/washer and 5.9 inch screw (Fig. 8). mixture should be left in engine for a minimum
(4) Install drive belt (Refer to Cooling System of 805km (500 miles) and drained at the next
Group 7) for installation procedure. normal oil change.
(5) Install inner splash shield and wheel. (2) Install camshaft thrust plate with two screws as
shown in (Fig. 10). Tighten to 12 NIm (105 in. lbs.)
CAMSHAFT torque.
REMOVAL—ENGINE REMOVED FROM (3) Rotate crankshaft so the timing arrow is to the
VEHICLE 12 O’clock position.
Remove intake manifold, cylinder head covers, cyl- (4) Place timing chain around camshaft sprocket
inder heads, timing chain case cover and timing and place the timing mark to the 6 O’clock position.
chain. (5) Align the dark colored links with the dot on the
(1) Remove rocker arm and shaft assemblies. camshaft sprocket, place timing chain around crank-
(2) Remove push rods and tappets; identify so each shaft sprocket with the dark colored link lined up with
part will be replaced in its original location. the dot on the sprocket and install camshaft sprocket
(3) Remove camshaft thrust plate (Fig. 10). into position.
(4) Install a long bolt into front of camshaft to fa- (6) Using straight edge to check alignment of timing
cilitate removal of the camshaft; remove camshaft, marks (Fig. 5).
being careful not to damage cam bearing with the (7) Install the camshaft bolt. Tighten bolt to 54 NIm
cam lobes. (40 ft. lbs.).
(8) Rotate crankshaft 2 revolutions. Timing marks
INSTALLATION should line up. If timing marks do not line up, remove
(1) Lubricate camshaft lobes and camshaft bearing
cam sprocket and realign.
journals and insert the camshaft to within 2 inches
of its final position in cylinder block.
Ä 3.3/3.8L ENGINE 9 - 113

(9) Measure camshaft end play. End Play should

measure .0127 to .304 mm (.005 to .012 inches.) .310
mm (.012 inch. Max.). If not within limits install a new
thrust plate.
(10) Each tappet reused must be installed in the
same position from which it was removed. When
camshaft is replaced, all of the tappets must be
replaced.

Fig. 13 Removed Installation of Camshaft Bearings

with Tool C-3132A—Typical
ENGINE CORE OIL AND CAM PLUGS
REMOVAL
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 suit-
able tool and remove plug (Fig. 14).

CAUTION: Do not drive cup plug into the casting as

restricted cooling can result and cause serious en-
gine problems.
Fig. 12 Alignment of Timing Marks
CAMSHAFT BEARINGS—ENGINE REMOVED FROM
VEHICLE
REMOVAL
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
(2) Install proper size adapters and horseshoe wash-
ers (part of Tool C-3132-A) at back of each bearing shell
to be removed and drive out bearing shells (Fig. 13).

INSTALLATION
(1) Install new camshaft bearings with Tool
C-3132-A by sliding the new camshaft bearing shell
over proper adapter.
(2) Position rear bearing in the tool. Install horse-
shoe lock and by reversing removal procedure, care- Fig. 14 Core Hole Plug Removal
fully drive bearing shell into place. INSTALLATION
(3) Install remaining bearings in the same manner. Thoroughly clean inside of cup plug hole in cylin-
Bearings must be carefully aligned to bring oil holes der block or head. Be sure to remove old sealer.
into full register with oil passages from the main Lightly coat inside of cup plug hole with Loctite Stud
bearing. Number two bearing must index with the oil N’ Bearing Mount or equivalent. Make certain the
passage to the left cylinder head and Number three new plug is cleaned of all oil or grease. Using proper
bearing must index with the oil passage to the right drive plug, drive plug into hole so that the sharp
cylinder head. If the camshaft bearing shell oil holes edge of the plug is at least 0.5mm (.020 inch) inside
are not in exact alignment, remove and reinstall them the lead-in chamfer.
correctly. Install a new core hole plug at the rear of It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
camshaft. Be sure this plug does not leak.
placed in service immediately.
9 - 114 3.3/3.8L ENGINE Ä

CYLINDER BLOCK, PISTON AND CONNECTING ROD ASSEMBLY SERVICE

Fig. 1 Cylinder Block, Piston and Connecting Rod Assembly

Fig. 2 Identify Connecting Rod to Cylinder

CYLINDER BLOCK

PISTON—REMOVAL
(1) Remove top ridge of cylinder bores with a reliable Fig. 3 Connecting Rod Protectors
ridge reamer before removing pistons from cylinder
block. Be sure to keep tops of pistons covered (3) Remove connecting rod cap. Install connecting
during this operation. Pistons and connecting rod bolt protectors on connecting rod bolts (Fig. 3).
rods must be removed from top of cylinder block. Push each piston and rod assembly out of cylinder
When removing piston and connecting rod as- bore.
semblies from the engine, rotate crankshaft so Be careful not to nick crankshaft journals.
that each connecting rod is centered in cylinder (4) After removal, install bearing cap on the mat-
bore. ing rod.
(2) Inspect connecting rods and connecting rod caps
CLEANING AND INSPECTION
for cylinder identification. Identify them if necessary.
(1) Clean cylinder block thoroughly and check all
(Fig. 2)
core hole plugs for evidence of leaking.
(2) If new core plugs are installed, see Engine Core
Oil and Cam Plugs.
(3) Examine block for cracks or fractures.
Ä 3.3/3.8L ENGINE 9 - 115

Fig. 5 Cylinder Bore and Piston Specifications

Fig. 4 Checking Cylinder Bore Size

CYLINDER BORE INSPECTION
The cylinder walls should be checked for out- of-
round and taper with Tool C-119 (Fig. 4). If the cylinder
walls are badly scuffed or scored, the cylinder block
should be replaced. Fig. 6 Piston Measurements
Measure the cylinder bore at three levels in direc-
FITTING RINGS
tions A and B (Fig. 4). Top measurement should be
(1) Wipe cylinder bore clean. Insert ring and push
12mm (.50 inch) down and bottom measurement
down with piston to ensure it is square in bore. The
should be 12mm (.50 inch.) up from bottom of bore. ring gap measurement must be made with the ring
Refer to (Fig. 5) for specifications. positioning at least 12mm (.50 inch) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 7).
FINISHED PISTONS
All pistons are machined to the same weight in
grams, to maintain piston balance. For cylinder bores
which have been honed, new pistons and connecting
rod assemblies are available for service.

FITTING PISTONS
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. 6). Cylinder
bores should be measured halfway down the cylinder
bore and transverse to the engine crankshaft center
line shown in (Fig. 4). Refer to (Fig. 5) for specifica-
tions.
Pistons and cylinder bores should be measured
at normal room temperature, 70°F (21°C)
Fig. 7 Check Gap on Piston Rings
PISTON PINS
The piston pin rotates in the piston only, and is
retained by the press interference fit of the piston pin
in the connecting rod. The piston pin is not to be
removed damage to the piston may result.
9 - 116 3.3/3.8L ENGINE Ä

Refer to specifications (Fig. 8).

Fig. 10 Piston Ring Installation

Fig. 8 Piston Ring Specifications (3) Install upper side rail first and then the lower
(2) Check piston ring to groove clearance: (Fig. 9). side rail.
Refer to specification (Fig. 8). (4) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 12).

Fig. 9 Measuring Piston Ring Side Clearance

Fig. 11 Installing Side Rail
PISTON RINGS—INSTALLATION
(1) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Install rings with manufacturers
I.D. mark facing up, to the top of the piston (Fig. 10).

CAUTION: Install piston rings in the following or-

der:

(a) Oil ring expander.

(b) Upper oil ring side rail.
(c) Lower oil ring side rail.
(d) No. 2 Intermediate piston ring.
(e) 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 un-
til side rail is in position. Do not use a piston ring
expander. (Fig. 11).
Fig. 12 Installing Upper and Intermediate Rings
Ä 3.3/3.8L ENGINE 9 - 117

(5) Position piston ring end gaps as shown in (Fig.

13).
(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.

Fig. 15 Piston I.D. Notches

(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod over
the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
Fig. 13 Piston Ring End Gap Position hammer handle. At the same time, guide connecting
INSTALLING PISTON AND CONNECTING ROD AS- rod into position on connecting rod journal.
SEMBLY (7) The notch or groove on top of piston must be
(1) Before installing pistons and connecting rod as- pointing toward front of engine (Fig. 15).
semblies into the bore, besure that compression ring (8) Install rod caps. Install nuts on cleaned and
gaps are staggered so that neither is in line with oil oiled rod bolts and tighten nuts to 54 NIm (40 ft. lb.)
ring rail gap. Plus 1/4 turn.
(2) Before installing the ring compressor, make sure
the oil ring expander ends are butted and the rail gaps
located as shown in (Fig. 14).

Fig. 14 Installing Piston

(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
and tighten with the special wrench. Be sure position
of rings does not change during this operation. Fig. 16 Checking Connecting Rod Bearing
(4) Install connecting rod bolt protectors on rod Clearance
bolts. (Fig. 3)
9 - 118 3.3/3.8L ENGINE Ä

CONNECTING RODS
INSTALLATION OF CONNECTING ROD BEAR-
INGS
Fit all rods on one bank until complete.
The bearing caps are not interchangeable and should
be marked at removal to insure 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.
Limits of taper or out-of-round on any crankshaft
Fig. 18 Connecting Rod Specifications
journals should be held to .025mm (.001 inch). Bear-
ings are available in .025mm (.001 inch), .051mm (.002
inch),.076mm (.003 inch), .254mm (.010 inch) and
.305mm (.012 inch) undersize. Install the bearings
in pairs. Do not use a new bearing half with an
old bearing half. Do not file the rods or bearing
caps.
(1) Follow procedure specified in the Standard Ser-
vice Procedure Section for Measuring Main Bearing
Clearance and Connecting Rod Bearing Clearance
(Fig. 16).
The rod bearing bolts should be examined be- Fig. 19 Check for Stretched (Necked) Bolts
fore reuse. If the threads are necked down the
CRANKSHAFT SERVICE
bolts should be replaced (Fig. 19).
Necking can be checked by holding a scale or straight CRANKSHAFT MAIN BEARINGS
edge against the threads. If all the threads do not Bearing caps are not interchangeable and should
contact the scale the bolt should be replaced. be marked at removal to insure correct assembly.
(2) Before installing the nuts the threads should be (Fig. 1) Upper and lower bearing halves are NOT in-
oiled with engine oil. terchangeable. Lower main bearing halves of 1, 3
(3) Install nuts on each bolt finger tight then alter- and 4 are interchangeable. Upper main bearing
nately torque each nut to assemble the cap properly. halves of 1, 3 and 4 are interchangeable.
(4) Tighten the nuts to 54 NIm PLUS 1/4 turn (40 ft.
lbs. PLUS 1/4 turn). CRANKSHAFT MAIN JOURNALS
(5) Using a feeler gauge, check connecting rod side The crankshaft journals should be checked for ex-
clearance (Fig. 17). Refer to (Fig. 18) for specifications. cessive wear, taper and scoring. (Fig. 6) Limits of
taper or out-of-round on any crankshaft journals
should be held to .025mm (.001 inch). Journal grind-
ing should not exceed .305mm (.012 inch) under the
standard journal diameter. Do NOT grind thrust
faces of Number 2 main bearing. Do NOT nick crank
pin or bearing fillets. After grinding, remove rough
edges from crankshaft oil holes and clean out all pas-
sages.

CAUTION: With the nodular cast iron crankshafts

used it is important that the final paper or cloth pol-
ish after any journal regrind be in the same direc-
tion as normal rotation in the engine.

Upper and lower Number 2 bearing halves are

flanged to carry the crankshaft thrust loads and are
Fig. 17 Checking Connecting Rod Side Clearance NOT interchangeable with any other bearing halves
in the engine (Fig. 2). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
Ä 3.3/3.8L ENGINE 9 - 119

Fig. 1 Main Bearing Cap Identification Fig. 3 Removing and Installing Upper Main Bearing
before installation. Bearing shells are available in With Special Tool C-3059
standard and the following undersizes: 0.025mm (.001 (1) Start bearing in place, and insert Main Bearing
inch), .051mm (.002 inch), .076mm (.003 inch), .254mm Tool C-3059 into oil hole of crankshaft (Fig. 3).
(.010 inch), and .305mm (.012 inch). Never install an (2) Slowly rotate crankshaft counter-clockwise slid-
undersize bearing that will reduce clearance below ing the bearing into position. Remove Special Main
specifications. Bearing Tool C-3059.
(3) Install each main cap and tighten bolts finger
tight.
(4) Tighten number 1, 3 and 4 main cap bolts to 41
NIm + 1/4 Turn (30 ft. lbs.+ 1/4 Turn).
(5) Rotate the crankshaft until number 6 piston is
at TDC.
(6) 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 a appropriate tool between the rear of
the cylinder block and rear crankshaft counter-
weight. This will hold the crankshaft in it’s most
forward position.
Fig. 2 Main Bearing Identification
(d) Tighten the #2 Thrust Bearing cap bolts to
REMOVAL 41 NIm + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove
(1) Remove oil pan and identify bearing caps before the holding tool.
removal.
(2) Remove bearing caps one at a time. Remove CHECKING CRANKSHAFT END PLAY
upper half of bearing by inserting Special Main Bear- (1) Mount a dial indicator to front of engine, locat-
ing Tool C-3059. (Fig. 3) into the oil hole of crankshaft. ing probe on nose of crankshaft (Fig. 4).
(3) Slowly rotate crankshaft clockwise, forcing out (2) Move crankshaft all the way to the rear of its
upper half of bearing shell. travel.
(3) Zero the dial indicator.
INSTALLATION (4) Move crankshaft all the way to the front and
Only one main bearing should be selectively read the dial indicator. Refer to (Fig. 5) for specifica-
fitted while all other main bearing caps are prop- tion.
erly tightened.
When installing a new upper bearing shell, slightly CRANKSHAFT END PLAY CHECK—OPTIONAL
chamfer the sharp edges from the plain side. (1) Move crankshaft all the way to the rear of its
travel using a lever inserted between a main bearing
9 - 120 3.3/3.8L ENGINE Ä

Fig. 4 Checking Crankshaft End Play Fig. 6 Measure Crankshaft Journal O.D.
cap and a crankshaft cheek using care not to damage (4) Install the main bearing cap carefully and
any bearing surface.Do notloosen main bearing cap. tighten the bolts to specified torque.
(2) Use a feeler gauge between number 2 thrust
bearing and machined crankshaft surface to deter- CAUTION: Do not rotate crankshaft or the plasti-
mine end play. Refer to (Fig. 5) for specification. gage 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. 7). Refer to
specification (Fig. 5) for proper clearances. If the
clearance exceeds the specified limits. Replace the
main bearing(s) and if necessary have the crankshaft
machined to next undersize. Also see Measuring
Main and Connecting Rod Bearing Clearance in
Standard Service Procedures.

Fig. 5 Crankshaft specification

CRANKSHAFT OIL CLEARANCE
(1) Measure the journal outside diameter as shown
in (Fig. 6). Refer to specification (Fig. 5).
Fig. 7 Measuring Bearing Clearance with Plastigage
PLASTIGAGE (OIL CLEARANCE) CAUTION: Do not rotate crankshaft or the Plasti-
MEASUREMENT gage may be smeared.
(1) Remove oil from journal and bearing shell.
(2) Install crankshaft.
(3) Cut plastigage to same length as width of the
bearing and place it in parallel with the journal axis
(Fig. 7).
Ä 3.3/3.8L ENGINE 9 - 121

CRANKSHAFT OIL SEALS SERVICE

REMOVAL
Pry out rear seal with screwdriver. Be careful not
to nick or damage crankshaft flange seal surface or
retainer bore (Fig. 8).

Fig. 9 Installing Rear Crankshaft Oil Seal

Fig. 8 Removing Rear Crankshaft Oil Seal

INSTALLATION
(1) Place Special Seal Pilot Tool C-4681 on crank-
shaft (Fig. 9).
(2) Lightly coat seal O.D. with Loctite Stud N’
Bearing Mount or equivalent.
(3) Place seal over Special Seal Pilot Tool C-4681
and tap in place with a plastic hammer.

REAR CRANKSHAFT SEAL RETAINER

When retainer removal is required, remove re-
tainer clean engine block and retainer of old gasket.
Make sure surfaces are clean and free of oil. Install
new gasket and tighten screws to 12 NIm (105 in.
lbs.).
9 - 122 3.3/3.8L ENGINE Ä

ENGINE LUBRICATION SYSTEM

Fig. 1 Engine Oiling System

The lubrication system is a full flow filtration pres- INSTALLATION
sure feed type. Oil from the oil pan is pumped by a (1) Install oil pick-up tube into Chain Case Cover
internal gear type oil pump directly coupled to the tighten screw to 28 NIm (250 in. lbs.) (Fig. 2).
crankshaft. Its pressure is regulated by a relief valve (2) Apply a 1/8 inch bead of Mopar Silicone Rubber
located in the Chain Case Cover. The oil is pumped Adhesive Sealant or equivalent, at the parting line of
through an oil filter and feeds a main oil galley.This the chain case cover and the rear seal retainer (Fig. 3).
oil gallery feeds oil under pressure to the main and (3) Use a new pan gasket (Fig. 4).
rod bearings, camshaft bearings. Passages in the cyl- (4) Install pan and tighten screws to 23 NIm (200 in.
inder block feed oil to the hydraulic lifters and lb.).
rocker shaft brackets which feeds the rocker arm piv-
ots (Fig. 1).

OIL PAN SERVICE

REMOVAL
(1) Disconnect negative battery cable, remove en-
gine oil dipstick.
(2) Raise vehicle. Drain engine oil.
(3) Remove oil pan screws and remove oil pan.

CLEANING AND INSPECTION

(1) Clean oil pan in solvent and wipe dry with a
clean cloth. Clean all gasket material from mounting
surfaces of pan and block.
(2) Inspect oil drain plug and plug hole for stripped
or damaged threads and repair as necessary. Install Fig. 2 Oil Pump Pick-up Tube Service
a new drain plug gasket. Tighten to 27 NIm (20 ft.
lb.). (5) Lower vehicle and install oil dipstick.
(3) Inspect oil pan mounting flange for bends or (6) Connect negative battery cable.
distortion. Straighten flange if necessary. (7) Fill crankcase with oil to proper level.
(4) Clean oil screen and pipe in clean solvent. In-
spect condition of screen.
Ä 3.3/3.8L ENGINE 9 - 123

Fig. 3 Oil Pan Sealing Fig. 5 Oil Pressure Relief Valve

OIL PUMP SERVICE INSPECTION AND REPAIR
It is necessary to remove the oil pan, oil pickup (1) Clean all parts thoroughly. Mating surface of
and chain case cover (CCC) to service the oil pump the chain case cover (CCC) should be smooth. Re-
rotors. The oil pump pressure relief valve can be ser- place pump cover if scratched or grooved.
viced by removing the oil pan and oil pickup tube. (2) Lay a straightedge across the pump cover sur-
Refer to Timing Chain Cover Removal and Installa- face (Fig. 7). If a .076mm (.003 inch) feeler gauge can
tion of this section for procedures. be inserted between cover and straight edge, cover
should be replaced.
DISASSEMBLY (3) Measure thickness and diameter of outer rotor.
(1) To remove the relief valve, proceed as follows: If outer rotor thickness measures 7.64mm (0.0301
(a) Drill a 3.175mm (1/8 inch) hole into the relief inch.) or less (Fig. 8), or if the diameter is 79.95mm
valve retainer cap and insert a self-threading sheet (3.148 inches.) or less, replace outer rotor.
metal screw into cap. (4) If inner rotor measures 7.64mm (.301 inch) or
(b) Clamp screw into a vise and while supporting less replace inner rotor (Fig. 9).
chain case cover (CCC), remove cap by tapping
CCC using a soft hammer. Discard retainer cap
and remove spring and relief valve (Fig. 5).

Fig. 6 Oil Pump

(5) Slide outer rotor into CCC, press to one side
Fig. 4 Oil Pan Gasket Installation with fingers and measure clearance between rotor
and CCC (Fig. 10). If measurement is .39mm (.015
(2) Remove oil pump cover screws, and lift off inch) or more, replace CCC only if outer rotor is in
cover. specification.
(3) Remove pump rotors. (6) Install inner rotor into CCC. If clearance be-
(4) Wash all parts in a suitable solvent and inspect tween inner and outer rotors (Fig. 11) is .203mm
carefully for damage or wear (Fig. 6). (.008 inch) or more, replace both rotors.
9 - 124 3.3/3.8L ENGINE Ä

Fig. 7 Checking Oil Pump Cover Flatness Fig. 9 Measuring Inner Rotor Thickness
(7) Place a straightedge across the face of the CCC, (3) Prime oil pump before installation by filling ro-
between bolt holes. If a feeler gauge of .102mm (.004 tor cavity with engine oil.
inch) or more can be inserted between rotors and the (4) Install chain case cover slowly refer to Timing
straightedge, replace pump assembly (Fig. 12). ONLY Chain Cover Installation of this section.
if rotors are in specs.
(8) Inspect oil pressure relief valve plunger for scor-
ing and free operation in its bore. Small marks may be
removed with 400-grit wet or dry sandpaper.
(9) The relief valve spring has a free length of
approximately 49.5mm (1.95 inches) it should test
between 19.5 and 20.5 pounds when compressed to
34mm (1-11/32 inches). Replace spring that fails to
meet specifications (Fig. 5).

Fig. 10 Measuring Outer Rotor Clearance in

Housing

Fig. 8 Measuring Outer Rotor Thickness

(10) If oil pressure is low and pump is within speci-
fications, inspect for worn engine bearings or other
reasons for oil pressure loss.

OIL PUMP ASSEMBLY AND INSTALLATION

(1) Assemble pump, using new parts as required.
Install the inner rotor with chamfer facing the
cast iron oil pump cover. Fig. 11 Measuring Clearance Between Rotors
(2) Tighten cover screws to 12 NIm (105 in. lbs.).
Ä 3.3/3.8L ENGINE 9 - 125

Fig. 12 Measuring Clearance Over Rotors

Fig. 13 Checking Oil Pump Pressure
CHECKING ENGINE OIL PRESSURE (4) Install and tighten filter to 20 NIm (15 ft. lbs.)
Check oil pressure using gauge at oil pressure torque after gasket contacts base. Use filter wrench
switch location. Oil pressure should be 34.47 kPa ( 5 if necessary.
psi.) at idle or 205 to 551 kPa (30 to 80 psi.) at 3000 (5) Start engine and check for leaks.
RPM.
(1) Remove pressure sending unit and install oil
pressure gauge (Fig. 13).

CAUTION: If oil pressure is 0 at idle, Do Not Run

engine at 3000 RPM.

(2) Warm engine at high idle until thermostat

opens.

OIL FILTER
CAUTION: When servicing the oil filter (Fig. 16) Fig. 14 Oil Filter
avoid deforming the filter can by installing the re-
move/install tool band strap against the can-to-base
lockseam. The lockseam joining the can to the base
is reinforced by the base plate.

(1) Using Tool C-4065, unscrew filter from base

and discard (Fig. 14).
(2) Wipe base clean, then inspect gasket contact
surface.
(3) Lubricate gasket of new filter with clean en-
gine oil.
9 - 126 3.3/3.8L ENGINE Ä

ENGINE SPECIFICATIONS
Ä 3.3/3.8L ENGINE 9 - 127

ENGINE SPECIFICATIONS (CONT.)

9 - 128 3.3/3.8L ENGINE Ä

ENGINE SPECIFICATIONS (CONT.)

Ä 3.3/3.8L ENGINE 9 - 129

ENGINE SPECIFICATIONS (CONT.)

9 - 130 3.3/3.8L ENGINE Ä

TORQUE