Engine

NS ENGINE 9-1
ENGINE
TABLE OF CONTENTS
page page
2.4L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 128

3.0L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.4L ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION CYLINDER BORE AND PISTON—SIZING. . . . . . . 20

2.4L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PISTON RING—FITTING . . . . . . . . . . . . . . . . . . . 20
CYLINDER BLOCK AND BEDPLATE . . . . . . . . . . . 2 VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . 21
BALANCE SHAFTS AND CARRIER ASSEMBLY . . . 3 REMOVAL AND INSTALLATION
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE MOUNT—FRONT . . . . . . . . . . . . . . . . . . 24
PISTON AND CONNECTING ROD . . . . . . . . . . . . . 4 ENGINE MOUNT—LEFT . . . . . . . . . . . . . . . . . . . 25
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . 4 ENGINE MOUNT—RIGHT . . . . . . . . . . . . . . . . . . 25
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ENGINE MOUNT—REAR . . . . . . . . . . . . . . . . . . . 25
VALVE AND VALVE SPRING . . . . . . . . . . . . . . . . . 5 STRUCTURAL COLLAR . . . . . . . . . . . . . . . . . . . . 26
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 5 ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 26
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 5 INTAKE MANIFOLD—UPPER . . . . . . . . . . . . . . . . 29
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . 5 INTAKE MANIFOLD—LOWER . . . . . . . . . . . . . . . 31
DIAGNOSIS AND TESTING EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . 33
ENGINE DIAGNOSIS—INTRODUCTION. . . . . . . . . 6 CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . 33
ENGINE DIAGNOSIS—PERFORMANCE . . . . . . . . 7 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ENGINE DIAGNOSIS—MECHANICAL . . . . . . . . . . 8 CAMSHAFT FOLLOWER . . . . . . . . . . . . . . . . . . . 35
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 10 BALANCE SHAFTS AND CARRIER ASSEMBLY . . 36
CYLINDER COMPRESSION PRESSURE TEST . . 10 HYDRAULIC LASH ADJUSTER . . . . . . . . . . . . . . 39
CYLINDER COMBUSTION PRESSURE VALVE SPRINGS AND VALVE SEALS IN
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 10 VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CYLINDER HEAD GASKET FAILURE CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 40
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 VALVE AND VALVE SPRING . . . . . . . . . . . . . . . . 41
LASH ADJUSTER (TAPPET) NOISE CRANKSHAFT DAMPER . . . . . . . . . . . . . . . . . . . 42
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 TIMING BELT COVER . . . . . . . . . . . . . . . . . . . . . 43
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . . 12 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . 13 TIMING BELT TENSIONER ASSEMBLY . . . . . . . . 46
SERVICE PROCEDURES CAMSHAFT OIL SEAL—FRONT . . . . . . . . . . . . . . 47
ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 CRANKSHAFT OIL SEAL—FRONT. . . . . . . . . . . . 48
ENGINE OIL SERVICE . . . . . . . . . . . . . . . . . . . . . 13 CRANKSHAFT OIL SEAL—REAR. . . . . . . . . . . . . 49
FORM-IN-PLACE GASKETS & SEALERS . . . . . . . 14 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ENGINE GASKET SURFACE PREPARATION . . . . 15 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
HYDROSTATIC LOCKED ENGINE . . . . . . . . . . . . 15 OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
CYLINDER BORE—HONING . . . . . . . . . . . . . . . . 16 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
MAIN BEARING—FITTING . . . . . . . . . . . . . . . . . . 16 PISTON AND CONNECTING ROD . . . . . . . . . . . . 55
CRANKSHAFT END PLAY . . . . . . . . . . . . . . . . . . 18 ENGINE CORE AND OIL GALLERY PLUGS . . . . . 57
CONNECTING ROD AND BEARING—FITTING. . . 19
9-2 2.4L ENGINE NS
DISASSEMBLY AND ASSEMBLY OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 61
CLEANING AND INSPECTION SPECIFICATIONS
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 58 2.4L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . 58 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 58 SPECIAL TOOLS
VALVE AND VALVE SPRING . . . . . . . . . . . . . . . . 59 2.4L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
DESCRIPTION AND OPERATION
2.4L ENGINE
DESCRIPTION
Fig. 1 2.4L Engine
The 2.4 Liter (148 cu. in.) in-line four cylinder

engine is a double over head camshaft with hydraulic
lifters and four valve per cylinder design (Fig. 1). The
engine is free-wheeling; meaning it has provisions for
piston-to-valve clearance. However valve-to-valve
interference can occur, if camshafts are rotated inde-
pendently.
The cylinders are numbered from front of the
engine to the rear. The firing order is 1–3–4–2.
The engine identification number is located on the
rear of the cylinder block (Fig. 2).
CYLINDER BLOCK AND BEDPLATE Fig. 2 Engine Identification

1 – ENGINE IDENTIFICATION LOCATION
DESCRIPTION
The cast iron cylinder block is a two-piece assem- stronger lower end and increased cylinder block
bly, encompassing the cylinder block and bedplate. rigidity. The rear oil seal retainer is integral with the
The bedplate incorporates the main bearing caps and block. The bedplate and block are serviced as an
bolts to the cylinder block. This design offers a much assembly.
NS 2.4L ENGINE 9-3
DESCRIPTION AND OPERATION (Continued)
OPERATION
The balance shaft are driven by the crankshaft via
a roller chain and sprockets. The balance shaft are
connected by tapered gears. The dual counter rotat-
ing shafts decrease second order vertical shaking
forces caused by component movement.
CRANKSHAFT
DESCRIPTION
The crankshaft is made of nodular cast iron and
includes five main bearing journals and four connect-
Fig. 3 Cylinder Block and Bedplate ing rod journals (Fig. 5). The number three journal is
1 – CYLINDER BLOCK the location for the thrust bearing. The mains and
2 – BEDPLATE connecting rod journals have undercut fillet radiuses
that are rolled for added strength. To optimize bear-
ing loading, eight counterweights are used.
BALANCE SHAFTS AND CARRIER ASSEMBLY
DESCRIPTION OPERATION
The crankshaft transfers force generated by com-
The 2.4L engine is equipped with two cast iron bal-
bustion within the cylinder to the flywheel or flex-
ance shafts installed in a cast aluminum carrier
plate.
attached to the lower cylinder block (Fig. 4).
Fig. 4 Balance Shafts and Carrier Assembly

1 – SPROCKET 7 – GEAR COVER
2 – TENSIONER 8 – CHAIN COVER
3 – CARRIER 9 – SPROCKET
4 – REAR COVER 10 – GUIDE
5 – BALANCE SHAFTS 11 – CHAIN
6 – GEARS
9-4 2.4L ENGINE NS
OPERATION
The cylinder head closes the combustion chamber,
allowing the pistons to compress the air/fuel mixture
for ignition. The valves are actuated by the lobe pro-
files on the camshaft to open and close at specified
duration to either allow clean air in the combustion
chamber or the exhaust gases out; depending on the
stroke of the engine.
CAMSHAFT
DESCRIPTION
Both nodular iron camshafts have six bearing jour-
nal surfaces and two cam lobes per cylinder (Fig. 6).
Flanges at the rear journals control camshaft end
play. Provision for a cam position sensor is located on
the intake camshaft on the rear of the cylinder head.
A hydrodynamic oil seal is used for oil control at the
front of the camshaft.
Fig. 5 Crankshaft
1 – MAIN BEARING JOURNALS
2 – COUNTER BALANCE WEIGHTS
PISTON AND CONNECTING ROD

DESCRIPTION
The pistons are made of a cast aluminum alloy.
The pistons have pressed-in pins attached to forged
powdered metal connecting rods. The pistons pin is
offset 1 mm (0.0394 in.) towards the thrust side of
the piston. The connecting rods are a cracked cap
design and are not repairable. Hex head cap screws
are used to provide alignment and durability in the
assembly. The pistons and connecting rods are ser-
viced as an assembly
OPERATION
The piston and connecting rod is the link between
the combustion force to the crankshaft.
CYLINDER HEAD Fig. 6 Camshafts

1 – CAMSHAFT BEARING CAPS
DESCRIPTION 2 – PLUG
The cross flow designed, aluminum cylinder head 3 – CAMSHAFT
contains dual over head camshaft with four valves 4 – CYLINDER HEAD
per cylinder. The valves are arrange in two in-line 5 – CAMSHAFT OIL SEAL
banks. The intake valves face toward the front of the
vehicle. The exhaust valves face the dash panel. The
OPERATION
cylinder head incorporates powdered metal valve
The camshaft is driven by the crankshaft via drive
guides and seats. The cylinder head is sealed to the
sprockets and belt. The camshaft has precisely
block using a multi-layer steel head gasket and
machined lobes to provide accurate valve timing and
retaining bolts.
duration.
Integral oil galleries providing lubrication passages
to the hydraulic lash adjusters, camshafts, and valve
mechanisms.
NS 2.4L ENGINE 9-5
VALVE AND VALVE SPRING EXHAUST MANIFOLD

DESCRIPTION DESCRIPTION
The four valves per cylinder are opened by using The exhaust manifold is made of nodular cast iron
roller rocker arms which pivot on hydraulic lash for strength and high temperatures. The manifold
adjusters. The valves have chrome plated valve attaches to the cylinder head.
stems. Viton rubber valve stem seals are integral
with the spring seats. OPERATION
The valve springs, spring retainers, and locks are The exhaust manifold collects the exhaust gasses
the conventional design. exiting the combustion chambers. Then it channels
the exhaust gasses to the exhaust pipe attached to
INTAKE MANIFOLD the manifold.
DESCRIPTION ENGINE LUBRICATION SYSTEM

The intake manifold is a two piece aluminum cast-
ing (Fig. 7) that attaches to the cylinder head with DESCRIPTION
fasteners. The manifold is a long branch design to The lubrication system is a full-flow filtration,
enhance low and mid-range torque pressure feed type. The oil pump (Fig. 8) is mounted
in the front engine cover and driven by the crank-
OPERATION shaft.
The intake manifold directs and delivers air to the
combustion chambers. This air allows the fuel deliv- OPERATION
ered by the fuel injectors to ignite, thus producing Engine oil drawn up through the pickup tube and
power. is pressurized by the oil pump and routed through
the full-flow filter to the main oil gallery running the
length of the cylinder block. A diagonal hole in each
bulkhead feeds oil to each main bearing. Drilled pas-
sages within the crankshaft route oil from main bear-
ing journals to connecting rod journals. Balance shaft
lubrication is provided through an oil passage from
the number one main bearing cap through the bal-
ance shaft carrier support leg. This passage directly
supplies oil to the front bearings and internal
machined passages in the shafts that routes oil from
front to the rear shaft bearing journals. A vertical
hole at the number five bulkhead routes pressurized
oil through a restrictor up past a cylinder head bolt
to an oil gallery running the length of the cylinder
head. The camshaft journals are partially slotted to
allow a predetermined amount of pressurized oil to
pass into the bearing cap cavities with small holes
Fig. 7 Intake Manifold—Upper and Lower
directed to spray lubricate the camshaft lobes. Oil
1 – UPPER INTAKE MANIFOLD
2 – LOWER INTAKE MANIFOLD
returning to the pan from pressurized components
supplies lubrication to the valve stems. Cylinder
bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars.
9-6 2.4L ENGINE NS
Fig. 8 Lubrication Components

1 – OIL PAN GASKET 5 – OIL PICK-UP TUBE
2 – O-RING 6 – DRAIN PLUG
3 – OIL PUMP BODY 7 – OIL PAN
4 – FILTER
DIAGNOSIS AND TESTING Additional tests and diagnostic procedures may be

necessary for specific engine malfunctions that can-
ENGINE DIAGNOSIS—INTRODUCTION not be isolated with the Service Diagnosis charts.
Engine diagnosis is helpful in determining the Information concerning additional tests and diagno-
causes of malfunctions not detected and remedied by sis is provided within the following:
routine maintenance. • Cylinder Compression Pressure Test
These malfunctions may be classified as either • Cylinder Combustion Pressure Leakage Test
mechanical (e.g., a strange noise), or performance • Cylinder Head Gasket Failure Diagnosis
(e.g., engine idles rough and stalls). • Intake Manifold Leakage Diagnosis
Refer to the Service Diagnosis—Mechanical Chart • Lash Adjuster (Tappet) Noise Diagnosis
and the Service Diagnosis—Performance Chart, for • Engine Oil Leak Inspection
possible causes and corrections of malfunctions. Refer
to FUEL SYSTEM for the fuel system diagnosis.
NS 2.4L ENGINE 9-7
DIAGNOSIS AND TESTING (Continued)
ENGINE DIAGNOSIS—PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. Refer to BATTERY.
2. Corroded or loose battery 2. Clean and tighten battery
connections. connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. Refer to
STARTING.
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
Refer to IGNITION SYSTEM.
5. Incorrect spark plug gap. 5. Set gap. Refer to IGNITION
SYSTEM.
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. Refer to FUEL SYSTEM.
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain or a loose camshaft
sprocket.
ENGINE STALLS OR IDLES 1. Idle speed too low. 1. Test minimum air flow. Refer to
ROUGH FUEL SYSTEM.
2. Incorrect fuel mixture. 2. Refer to FUEL SYSTEM.

3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty coil(s). 4. Test and replace as necessary.
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. Refer to
IGNITION SYSTEM.
filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
Refer to FUEL SYSTEM.
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
7. Burned, warped, or pitted valves. 7. Replace valves.
8. Plugged or restricted exhaust 8. Install new parts, as necessary.
system.
9-8 2.4L ENGINE NS
ENGINE MISSES ON 1. Dirty or incorrectly gapped spark 1. Clean spark plugs and set gap.
ACCELERATION plugs. Refer to IGNITION SYSTEM.
2. Contamination in Fuel System. 2. Clean fuel system and replace

fuel filter.
ENGINE MISSES AT HIGH SPEED 1. Dirty or incorrect spark plug gap. 1. Clean spark plugs and set gap.
3. Dirty fuel injector(s). Test and replace as necessary.
filter.
ENGINE DIAGNOSIS—MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil
crankcase. level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.

3. Low oil pressure. 3. Check and correct engine oil
level.
4. Dirt in tappets/lash adjusters. 4. Replace rocker arm/hydraulic
lash adjuster assembly.
5. Worn rocker arms. 5. Inspect oil supply to rocker arms.
6. Worn tappets/lash adjusters. 6. Install new rocker arm/hydraulic
7. Worn valve guides. 7. Ream guides and install new
valves with oversize stems.
8. Excessive runout of valve seats 8. Grind valve seats and valves.
on valve faces.
9. Missing adjuster pivot. 9. Replace rocker arm/hydraulic
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
4. Excessive bearing clearance. 4. Measure bearings for correct
clearance. Repair as necessary.
5. Connecting rod journal 5. Replace crankshaft or grind
out-of-round. surface.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
NS 2.4L ENGINE 9-9
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.

5. Excessive end play. 5. Check thrust bearing for wear on
flanges.
6. Crankshaft journal out-of-round 6. Replace crankshaft or grind
or worn. journals.
7. Loose flywheel or torque 7. Tighten to correct torque.
converter.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sending unit. 2. Install new sending unit.

3. Low oil pressure. 3. Check sending unit and main
bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean,
or replace.
8. Oil pump suction tube loose. 8. Remove oil pan and install new
tube or clean, if necessary.
9. Oil pump cover warped or 9. Install new oil pump.
cracked.
clearance.
OIL LEAKS 1. Misaligned or deteriorated 1. Replace gasket(s).

gaskets.
2. Loose fastener, broken or porous 2. Tighten, repair or replace the
metal part. part.
3. Misaligned or deteriorated cup or 3. Replace as necessary.
threaded plug.
9 - 10 2.4L ENGINE NS
OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as
PLUGS FOULED necessary. Refer to EMISSION
CONTROL SYSTEMS.
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Install new rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guide(s). 5. Ream guide(s) and replace
valve(s) with oversize valve(s) and
seal(s).
6. Valve stem seal(s) worn or 6. Replace seal(s).
damaged.
INTAKE MANIFOLD LEAKAGE DIAGNOSIS (4) Disconnect coil wire from distributor and
An intake manifold air leak is characterized by secure to good ground to prevent a spark from start-
lower than normal manifold vacuum. Also, one or ing a fire (Conventional Ignition System). For Direct
more cylinders may not be functioning. Ignition System DIS disconnect the coil connector.
(5) Be sure throttle blade is fully open during the
WARNING: USE EXTREME CAUTION WHEN THE compression check.
ENGINE IS OPERATING. DO NOT STAND IN A (6) Insert compression gage adaptor Special Tool
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR 8116 or the equivalent, into the #1 spark plug hole in
HANDS NEAR THE PULLEYS, BELTS OR THE FAN. cylinder head. Connect the 0–500 psi (Blue) pressure
DO NOT WEAR LOOSE CLOTHING. transducer with cable adaptors to the DRBIIIt.
(7) Crank engine until maximum pressure is
(1) Start the engine. reached on gage. Record this pressure as #1 cylinder
(2) Spray a small stream of water (Spray Bottle) at pressure.
the suspected leak area. (8) Repeat the previous step for all remaining cyl-
(3) If engine RPM’S change, the area of the sus- inders.
pected leak has been found. (9) Compression should not be less than 689 kPa
(4) Repair as required. (100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
CYLINDER COMPRESSION PRESSURE TEST (10) If one or more cylinders have abnormally low
The results of a cylinder compression pressure test compression pressures, repeat the compression test.
can be utilized to diagnose several engine malfunc- (11) If the same cylinder or cylinders repeat an
tions. abnormally low reading on the second compression
Ensure the battery is completely charged and the test, it could indicate the existence of a problem in
engine starter motor is in good operating condition. the cylinder in question. The recommended com-
Otherwise the indicated compression pressures may pression pressures are to be used only as a
not be valid for diagnosis purposes. guide to diagnosing engine problems. An engine
(1) Check engine oil level and add oil if necessary. should not be disassembled to determine the
(2) Drive the vehicle until engine reaches normal cause of low compression unless some malfunc-
operating temperature. Select a route free from traf- tion is present.
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times CYLINDER COMBUSTION PRESSURE LEAKAGE
briskly. TEST
(3) Remove all spark plugs from engine. As spark The combustion pressure leakage test provides an
plugs are being removed, check electrodes for abnor- accurate means for determining engine condition.
mal firing indicators fouled, hot, oily, etc. Record cyl- Combustion pressure leakage testing will detect:
inder number of spark plug for future reference. • Exhaust and intake valve leaks (improper seating).
NS 2.4L ENGINE 9 - 11
• Leaks between adjacent cylinders or into water section. An engine cylinder head gasket leaking
jacket. between adjacent cylinders will result in approxi-
• Any causes for combustion/compression pressure mately a 50–70% reduction in compression pressure.
loss.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE WARNING: USE EXTREME CAUTION WHEN THE
BECAUSE SERIOUS BURNS FROM COOLANT CAN ENGINE IS OPERATING WITH COOLANT PRES-
OCCUR. SURE CAP REMOVED.
Check the coolant level and fill as required. DO

NOT install the radiator cap. VISUAL TEST METHOD
Start and operate the engine until it attains nor- With the engine cool, remove the coolant pressure
mal operating temperature, then turn the engine cap. Start the engine and allow it to warm up until
OFF. thermostat opens.
Clean spark plug recesses with compressed air. If a large combustion/compression pressure leak
Remove the spark plugs. exists, bubbles will be visible in the coolant.
Remove the oil filler cap.
Remove the air cleaner. COOLING SYSTEM TESTER METHOD
Calibrate the tester according to the manufactur-
er’s instructions. The shop air source for testing WARNING: WITH COOLING SYSTEM TESTER IN
should maintain 483 kPa (70 psi) minimum, 1,379 PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
kPa (200 psi) maximum, with 552 kPa (80 psi) rec- SIVE PRESSURE BUILT UP, BY CONTINUOUS
ommended. ENGINE OPERATION, MUST BE RELEASED TO A
Perform the test procedures on each cylinder SAFE PRESSURE POINT. NEVER PERMIT PRES-
according to the tester manufacturer’s instructions. SURE TO EXCEED 138 kPa (20 psi).
While testing, listen for pressurized air escaping
Install Cooling System Tester 7700 or equivalent to
through the throttle body, tailpipe and oil filler cap
pressure cap neck. Start the engine and observe the
opening. Check for bubbles in the radiator coolant.
tester’s pressure gauge. If gauge pulsates with every
All gauge pressure indications should be equal,
power stroke of a cylinder a combustion pressure
with no more than 25% leakage per cylinder.
leak is evident.
FOR EXAMPLE: At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main- CHEMICAL TEST METHOD
tained in the cylinder.
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
CYLINDER HEAD GASKET FAILURE DIAGNOSIS equivalent. Perform test following the procedures
A cylinder head gasket leak can be located between
supplied with the tool kit.
adjacent cylinders or between a cylinder and the
adjacent water jacket.
• Possible indications of the cylinder head gasket
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-like noise may be produced from several
leaking between adjacent cylinders are:
items. Check the following items.
• Loss of engine power
(1) Engine oil level too high or too low. This may
• Engine misfiring
cause aerated oil to enter the adjusters and cause
• Poor fuel economy
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
leaking between a cylinder and an adjacent water
der head. Low speed running up to 1 hour may be
jacket are:
required.
• Engine overheating
(3) During this time, turn engine off and let set for
• Loss of coolant
a few minutes before restarting. Repeat this several
• Excessive steam (white smoke) emitting from
times after engine has reached normal operating
exhaust
temperature.
• Coolant foaming
(4) Low oil pressure.
CYLINDER-TO-CYLINDER LEAKAGE TEST (5) The oil restrictor pressed into the vertical oil
passage to the cylinder head is plugged with debris.
To determine if an engine cylinder head gasket is
(6) Air ingested into oil due to broken or cracked
leaking between adjacent cylinders, follow the proce-
oil pump pick up.
dures in Cylinder Compression Pressure Test in this
(7) Worn valve guides. • If the leakage occurs at the crankshaft rear oil
(8) Rocker arm ears contacting valve spring seal area, refer to the section, Inspection for Rear
retainer. Seal Area Leak.
(9) Rocker arm loose, adjuster stuck or at maxi- (6) If no leaks are detected, turn off the air supply.
mum extension and still leaves lash in the system. Remove the air hose, all plugs, and caps. Install the
(10) Faulty lash adjuster. PCV valve and fresh air hose (make-up air). Proceed
a. Check lash adjusters for sponginess while to next step.
installed in cylinder head. Depress part of rocker (7) Clean the oil off the suspect oil leak area using
arm over adjuster. Normal adjusters should feel very a suitable solvent. Drive the vehicle at various
firm. Spongy adjusters can be bottomed out easily. speeds approximately 24 km (15 miles). Inspect the
b. Remove suspected lash adjusters, and replace as engine for signs of an oil leak by using a black light.
necessary.
NOTE: If oil leakage is observed at the dipstick
ENGINE OIL LEAK INSPECTION tube to block location; remove the tube, clean and
Begin with a thorough visual inspection of the reseal using MoparT Stud & Bearing Mount (press
engine, particularly at the area of the suspected leak. fit tube applications only), and for O-ring style
If an oil leak source is not readily identifiable, the tubes, remove tube and replace the O-ring seal.
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
swell, temporarily stopping the leak.
source of an oil leak in the rear seal area of the
(2) Add an oil soluble dye (use as recommended by
engine, a more involved inspection is necessary. The
manufacturer). Start the engine and let idle for
following steps should be followed to help pinpoint
approximately 15 minutes. Check the oil dipstick to
the source of the leak.
make sure the dye is thoroughly mixed as indicated
If the leakage occurs at the crankshaft rear oil seal
with a bright yellow color under a black light.
area:
(3) Using a black light, inspect the entire engine
(1) Disconnect the battery.
for fluorescent dye, particularly at the suspected area
(2) Raise the vehicle.
of oil leak. If the oil leak is found and identified,
(3) Remove torque converter or clutch housing
repair per service manual instructions.
cover and inspect rear of block for evidence of oil.
(4) If dye is not observed, drive the vehicle at var-
Use a black light to check for the oil leak. If a leak is
ious speeds for approximately 24 km (15 miles), and
present in this area, remove transmission for further
repeat inspection.
inspection.
(5) If the oil leak source is not positively
(a) Circular spray pattern generally indicates
identified at this time, proceed with the air leak
seal leakage or crankshaft damage.
detection test method as follows:
(b) Where leakage tends to run straight down,
• Disconnect the fresh air hose (make-up air) at
possible causes are a porous block, oil gallery cup
the cylinder head cover and plug or cap the nipple on
plug, bedplate to cylinder block mating surfaces
the cover.
and seal bore. See proper repair procedures for
• Remove the PCV valve hose from the cylinder
these items.
head cover. Cap or plug the PCV valve nipple on the
(4) If no leaks are detected, pressurize the crank-
cover.
case as previously described.
• Attach an air hose with pressure gauge and reg-
ulator to the dipstick tube. CAUTION: Do not exceed 20.6 kPa (3 psi).
CAUTION: Do not subject the engine assembly to (5) If the leak is not detected, very slowly turn the
more than 20.6 kpa (3 PSI) of test pressure. crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
• Gradually apply air pressure from 1 psi to 2.5
slowly turning the crankshaft, it is possible the
psi maximum while applying soapy water at the sus-
crankshaft seal surface is damaged. The seal area on
pected source. Adjust the regulator to the suitable
the crankshaft could have minor nicks or scratches
test pressure that provides the best bubbles which
that can be polished out with emery cloth.
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
CAUTION: Use extreme caution when crankshaft Checking the oil while the vehicle is on level
polishing is necessary to remove minor nicks and ground, will improve the accuracy of the oil level
scratches. The crankshaft seal flange is especially readings. For 2.4L engine, maintain the oil level
machined to complement the function of the rear oil between the MIN and MAX markings on the dipstick
seal. (Fig. 10). Adding one quart of oil when the reading is
at the MIN mark will result in a MAX reading on
(6) For bubbles that remain steady with shaft these engines.
rotation, no further inspection can be done until dis-
assembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified, refer to Crank-
shaft Oil Seal—Rear for proper replacement proce-
dures.
ENGINE OIL PRESSURE

(1) Disconnect and remove oil pressure sending
unit.
(2) Install Special Tools C-3292 Gauge with 8406
Adaptor.
(3) Start engine and record oil pressure. Refer to
Fig. 10 2.4L Engine Oil Dipstick
Oil Pressure in Engine Specifications for the correct
1 – MIN OIL MARK
pressure.
ENGINE OIL SERVICE

SERVICE PROCEDURES
WARNING: NEW OR USED ENGINE OIL CAN BE
ENGINE OIL IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
Checking Oil Level CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
To assure proper engine lubrication, the engine oil INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
must be maintained at the correct level. Check the YOUR HEALTH. THOROUGHLY WASH EXPOSED
oil level at regular intervals, such as every fuel stop. SKIN WITH SOAP AND WATER. DO NOT WASH
The best time to check the oil level is about 5 min- SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
utes after a fully warmed-up engine is shut off, or SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
before starting the vehicle after it has sat overnight. NOT POLLUTE, DISPOSE OF USED ENGINE OIL
Refer to (Fig. 9) for engine oil fill and dipstick loca- PROPERLY. CONTACT YOUR DEALER OR GOVERN-
tions. MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
ENGINE OIL SPECIFICATION

CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED

Use an engine oil that is API Service Grade Certi-
fied. MOPARt provides engine oils that conforms to
this service grade.
SAE VISCOSITY
Fig. 9 2.4L Engine Oil Fill and Dipstick Locations An SAE viscosity grade is used to specify the vis-
1 – ENGINE OIL FILL
cosity of engine oil. Use only, engine oils with multi-
2 – ENGINE OIL DIPSTICK ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
SERVICE PROCEDURES (Continued)
cates the cold-to-hot temperature viscosity range. (5) Remove drain plug from crankcase and allow
SAE 5W-30 engine oil is preferred. Select an engine oil to drain into pan. Inspect drain plug threads for
oil that is best suited to your particular temperature stretching or other damage. Replace drain plug and
range and variation (Fig. 11). gasket if damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this sec-
tion.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
FORM-IN-PLACE GASKETS & SEALERS

There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results. Do not use form-in-
Fig. 11 Temperature/Engine Oil Viscosity place gasket material unless specified. Bead size,
continuity, and location are of great importance. Too
ENERGY CONSERVING OIL thin a bead can result in leakage while too much can
An Energy Conserving type oil is recommended for result in spill-over which can break off and obstruct
gasoline engines. The designation of ENERGY CON- fluid feed lines. A continuous bead of the proper
SERVING is located on the label of the engine oil width is essential to obtain a leak-free gasket.
container. There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
CONTAINER IDENTIFICATION Engine RTV GEN II, Mopart ATF-RTV, and Mopart
Standard engine oil identification notations have Gasket Maker gasket materials, each have different
been adopted to aid in the proper selection of engine properties and can not be used in place of the other.
oil. The identifying notations are located on the label MOPARt ENGINE RTV GEN II
of engine oil plastic bottles and the top of engine oil Mopart Engine RTV GEN II is used to seal com-
cans (Fig. 12). ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARt ATF RTV
Mopart ATF RTV is a specifically designed black
Fig. 12 Engine Oil Container Standard Notations silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
ENGINE OIL CHANGE
matic transmission fluid, engine coolants, and
Change engine oil at mileage and time intervals
moisture. This material is available in three ounce
described in the Maintenance Schedule.
tubes and has a shelf life of one year. After one year
TO CHANGE ENGINE OIL this material will not properly cure. Always inspect
the package for the expiration date before use.
Run engine until achieving normal operating tem-
MOPARt GASKET MAKER
perature.
Mopart Gasket Maker is an anaerobic type gasket
(1) Position the vehicle on a level surface and turn
material. The material cures in the absence of air
engine off.
when squeezed between two metallic surfaces. It will
(2) Hoist and support vehicle on safety stands.
not cure if left in the uncovered tube. The anaerobic
Refer to Hoisting and Jacking Recommendations.
material is for use between two machined surfaces.
(3) Remove the oil fill cap.
Do not use on flexible metal flanges.
(4) Place a suitable drain pan under crankcase
MOPARt BED PLATE SEALANT
drain.
Mopart Bed Plate Sealant is a unique (green-in- Never use the following to clean gasket surfaces:
color) anaerobic type gasket material that is specially • Metal scraper
made to seal the area between the bedplate and cyl- • Abrasive pad or paper to clean cylinder block
inder block without disturbing the bearing clearance and head
or alignment of these components. The material • High speed power tool with an abrasive pad or a
cures slowly in the absence of air when torqued wire brush (Fig. 13)
between two metallic surfaces, and will rapidly cure
when heat is applied. NOTE: Multi-Layer Steel (MLS) head gaskets
MOPARt GASKET SEALANT require a scratch free sealing surface.
Mopart Gasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for Only use the following for cleaning gasket surfaces:
sealing threaded fittings and gaskets against leakage • Solvent or a commercially available gasket
of oil and coolant. Can be used on threaded and remover
machined parts under all temperatures. This mate- • Plastic or wood scraper (Fig. 13)
rial is used on engines with multi-layer steel (MLS) • Drill motor with 3M Rolocy Bristle Disc (white
cylinder head gaskets. This material also will pre- or yellow) (Fig. 13)
vent corrosion. Mopart Gasket Sealant is available in
CAUTION: Excessive pressure or high RPM
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
(beyond the recommended speed), can damage the
sealing surfaces. The mild (white, 120 grit) bristle
FORM-IN-PLACE GASKET AND SEALER
disc is recommended. If necessary, the medium
APPLICATION (yellow, 80 grit) bristle disc may be used on cast
Assembling parts using a form-in-place gasket iron surfaces with care.
requires care but it’s easier then using precut gas-
kets.
Mopart Gasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
Mopart Engine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to Fig. 13 Proper Tool Usage For Surface Preparation
prevent smearing material off the location. 1 – ABRASIVE PAD
Mopart Gasket Sealant in an aerosol can should be 2 – 3M ROLOCY BRISTLE DISC
applied using a thin, even coat sprayed completely 3 – PLASTIC/WOOD SCRAPER
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the HYDROSTATIC LOCKED ENGINE
sealing surfaces. Material in an aerosol can should be When an engine is suspected to be hydrostatically
used on engines with multi-layer steel gaskets. locked, regardless of what caused the problem, the
following steps should be used.
ENGINE GASKET SURFACE PREPARATION
CAUTION: DO NOT use starter motor to rotate the
To ensure engine gasket sealing, proper surface
engine, severe damage may occur.
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.)
(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil Fig. 14 Cylinder Bore Cross-Hatch Pattern
into the cylinders, rotate engine to lubricate the cyl- 1 – CROSS-HATCH PATTERN
inder walls to prevent damage on restart.
degree angle. Faster up and down strokes increase
(8) Install new spark plugs. the cross-hatch angle.
(9) Drain engine oil and remove oil filter. (5) After honing, it is necessary that the block be
(10) Fill engine with specified amount of approved cleaned again to remove all traces of abrasive.
oil and install new oil filter.
(11) Connect negative battery cable. CAUTION: Ensure all abrasives are removed from
(12) Start engine and check for any leaks. engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
CYLINDER BORE—HONING brush and the parts then thoroughly dried. The bore
(1) Used carefully, the cylinder bore resizing hone, can be considered clean when it can be wiped
recommended tool C-823 or equivalent, equipped clean with a white cloth and cloth remains clean.
with 220 grit stones, is the best tool for this honing Oil the bores after cleaning to prevent rusting.
procedure. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes MAIN BEARING—FITTING
will clean up a bore and maintain the required lim- For crankshaft specifications, refer to Engine Spec-
its. ifications.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool CRANKSHAFT MAIN BEARINGS
C-3501 or equivalent, equipped with 280 grit stones, The crankshaft is supported in five main bearings.
if the cylinder bore is straight and round. 20–60 All upper and lower bearing shells in the crankcase
strokes depending on the bore condition, will be suf- have oil grooves. Crankshaft end play is controlled by
ficient to provide a satisfactory surface. Inspect cyl- a flanged bearing on the number three main bearing
inder walls after each 20 strokes, using a light journal (Fig. 15).
honing oil. Do not use engine or transmission oil, Upper and lower Number 3 bearing halves are
mineral spirits or kerosene. flanged to carry the crankshaft thrust loads and are
(3) Honing should be done by moving the hone up NOT interchangeable with any other bearing halves
and down fast enough to get a cross-hatch pattern. in the engine (Fig. 15). All bearing cap bolts removed
When hone marks intersect at 50-60 degrees, the during service procedures are to be cleaned and oiled
cross hatch angle is most satisfactory for proper seat- before installation. Bearing shells are available in
ing of rings (Fig. 14). standard and the following undersized: 0.025 mm
(4) A controlled hone motor speed between (0.001 in.) and 0.250 mm (0.010 in.). Never install an
200–300 RPM is necessary to obtain the proper cross- undersize bearing that will reduce clearance below
hatch angle. The number of up and down strokes per specifications. Replace or machine the crankshaft as
minute can be regulated to get the desired 50–60 necessary to obtain proper bearing clearances.
Fig. 15 Main Bearing Identification Fig. 16 Measuring Main Bearing Clearance

1 – OIL GROOVE
MAIN BEARING INSTALLATION
2 – MAIN BEARINGS
3 – OIL HOLE
MAIN BEARING CLEARANCE

(1) With engine in the inverted position (crank-
shaft up) and mounted on a repair stand, remove
bedplate and lower main bearings.
(2) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(3) Clean bedplate to cylinder block sealing loca-
tions.
(4) Place a piece of Plastigage across the entire
width of the bearing surface at each main bearing
location, approximately 6.35 mm (1/4 in.) off center
and away from the oil holes.
(5) Position bedplate (dry—no sealer) on cylinder
block and torque the bolts in sequence to proper
specifications. Refer to Main Bearing Installation
procedure below. Fig. 17 Installing Main Bearing Upper Shell
(6) Remove the bedplate and compare the width of 1 – LUBRICATION GROOVES
2 – OIL HOLES
the flattened Plastigage (Fig. 16) with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount (1) Install the main bearing shells with the lubri-
of clearance in thousandths of a millimeter. Differ- cation groove in the cylinder block (Fig. 17).
ences in readings between the ends indicate the (2) Make certain oil holes in block line up with oil
amount of taper present. Record all readings taken. holes in bearings. Bearing tabs must seat in the
Refer to Engine Specifications. Plastigage gener- block tab slots.
ally is accompanied by two scales. One scale is
in inches, the other is a metric scale. CAUTION: Do not get oil on the bedplate mating
surface. It will may effect the sealer ability to seal
NOTE: Plastigage is available in a variety of clear- the bedplate to cylinder block.
ance ranges. Use the most appropriate range for
the specifications you are checking. (3) Oil the bearings and journals and install
crankshaft.
CAUTION: Use only the specified anaerobic sealer (8) To ensure correct thrust bearing alignment,
on the bedplate or damage may occur to the perform the following steps:
engine. Ensure that both cylinder block and bed- • Step 1: Rotate crankshaft until number 4 piston
plate surfaces are clean. is at TDC.
• Step 2: Move crankshaft rearward to limits of
(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of travel.
anaerobic sealer Mopart Bed Plate Sealant to cylin- • Step 3: Then, move crankshaft forward to limits
der block as shown in (Fig. 18). of travel.
• Step 4: Wedge an appropriate tool between the
rear of the cylinder block (NOT BED PLATE) and
the rear crankshaft counterweight. This will hold the
crankshaft in it’s furthest forward position.
• Step 5: Install and tighten bolts (1–10) in
sequence shown in (Fig. 19) to 41 N·m (30 ft. lbs.).
• Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1–10) again to 41 N·m (30 ft.
lbs.) + 1/4 turn in sequence shown in (Fig. 19).
(10) Install main bearing bedplate to engine block
bolts (11–20), and torque each bolt to 28 N·m (20 ft.
lbs.) in sequence shown in (Fig. 19).
(11) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N·m (50 in. lbs.).
Fig. 18 Main Bearing Caps/Bedplate Sealing
CRANKSHAFT END PLAY
Fig. 19 Main Bearing Caps/Bedplate Torque

Sequence
(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are Fig. 20 Checking Crankshaft End Play—Typical
seated into the bedplate slots. Install the main bear- (1) Mount a dial indicator to front of engine, locat-
ing/bedplate into engine block. ing probe on nose of crankshaft (Fig. 20).
(6) Before installing bolts, lubricate the threads (2) Move crankshaft all the way to the rear of its
with clean engine oil, wipe off any excess oil. travel.
(7) Install main bearing bedplate to engine block (3) Zero the dial indicator.
bolts 11, 17 and 20 finger tight. Tighten these bolts (4) Move crankshaft all the way to the front and
down together until the bedplate contacts the cylin- read the dial indicator. Refer to Engine Specifications
der block. for end play specification.
OPTIONAL CRANKSHAFT END PLAY CHECK
(1) Move crankshaft all the way to the rear of its
travel using a lever inserted between a main bearing
cap and a crankshaft cheek, using care not to dam-
age any bearing surface. DO NOT loosen main bear-
ing cap.
(2) Use a feeler gauge between number three
thrust bearing and machined crankshaft surface to
determine end play.
CONNECTING ROD AND BEARING—FITTING

CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be Fig. 21 Connecting Rod Bearing Clearance
determined by use of Plastigage or equivalent. CONNECTING ROD SIDE CLEARANCE
Replacement bearings are available in the standard (1) Before installing the NEW bolts the threads
size and the following undersizes: 0.025 mm (0.001 should be oiled with clean engine oil.
in.) and 0.250 mm (0.010 in.). The following is the
recommended procedure for the use of Plastigage: NOTE: The connecting rod bolts should not be
(1) Rotate the crankshaft until the connecting rod reused.
to be checked is at the bottom of its stroke.
(2) Remove oil film from surface to be checked. (2) Install each bolt finger tight than alternately
Plastigage is soluble in oil. torque each bolt to assemble the cap properly.
(3) Place a piece of Plastigage across the entire (3) Tighten the bolts to 27 N·m PLUS 1/4 turn (20
width of the bearing shell in the bearing cap approx- ft. lbs. PLUS 1/4 turn) Do not use a torque
imately 6.35 mm (1/4 in.) off center and away from wrench for last step.
the oil hole. In addition, suspect areas can be (4) Using a feeler gauge, check connecting rod side
checked by placing Plastigage in that area. clearance (Fig. 22). Refer to Engine Specifications for
(4) Assemble the rod cap with Plastigage in place. connecting rod specifications.
Tighten the rod cap to 27 N·m (20 ft. lbs.). Do not
angle torque bolts the additional 1/4 turn, at this
time.
NOTE: Do not rotate the crankshaft while assem-

bling the cap or the Plastigage may be smeared,
giving inaccurate results.
(5) Remove the bearing cap and compare the width

of the flattened Plastigage (Fig. 21) with the scale
provided on the package. Locate the band closest to
the same width. This band indicates the amount of
oil clearance. Differences in readings between the
ends indicate the amount of taper present. Record all
readings taken. Refer to Engine Specifications. Plas-
tigage generally is accompanied by two scales.
One scale is in inches, the other is a metric
scale. If the bearing clearance exceeds wear Fig. 22 Connecting Rod Side Clearance
limit specification, replace the bearing.
CYLINDER BORE AND PISTON—SIZING PISTON RING—FITTING

Piston and cylinder wall must be clean and dry. (1) Wipe cylinder bore clean. Insert ring and push
Piston diameter should be measured 90 degrees to down with piston to ensure it is square in bore. The
piston pin about 14 mm (9/16 inch.) from the bottom ring gap measurement must be made with the ring
of the skirt as shown in (Fig. 24). Cylinder bores positioning at least 12 mm (0.50 inch) from bottom of
should be measured halfway down the cylinder bore cylinder bore. Check gap with feeler gauge (Fig. 25).
and transverse to the engine crankshaft center line Refer to Engine Specifications.
shown in (Fig. 23). Refer to for Engine Specifications.
Correct piston to bore clearance must be established
in order to assure quiet and economical operation.
DaimlerChrysler engines use pistons designed spe-
cifically for each engine model. Clearance and sizing
locations vary with respect to engine model.
NOTE: Pistons and cylinder bores should be mea-

sured at normal room temperature, 70°F (21°C).
Fig. 25 Piston Ring Gap

1 – FEELER GAUGE
(2) Check piston ring to groove side clearance (Fig.

26). Refer to Engine Specifications.
Fig. 23 Checking Cylinder Bore Size
Fig. 26 Piston Ring Side Clearance

1 – FEELER GAUGE
Fig. 24 Piston Measurement

PISTON RINGS—INSTALLATION
Fig. 28 Installing Side Rail

1 – SIDE RAIL END
Fig. 27 Piston Ring Installation
1 – NO. 1 PISTON RING
3 – SIDE RAIL
4 – OIL RING
5 – SPACER EXPANDER
(1) Install rings with manufacturers I. D. mark

facing up, to the top of the piston (Fig. 27).
CAUTION: Install piston rings in the following

order:
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. 29 Piston Ring End Gap Position
(2) Install the side rail by placing one end between 1 – GAP OF LOWER SIDE RAIL
the piston ring groove and the expander. Hold end 2 – NO. 1 RING GAP
firmly and press down the portion to be installed 3 – GAP OF UPPER SIDE RAIL
until side rail is in position. Do not use a piston 4 – NO. 2 RING GAP AND SPACER EXPANDER GAP
ring expander (Fig. 28).
(3) Install upper side rail first and then the lower VALVE SERVICE
side rail.
(4) Install No. 2 piston ring and then No. 1 piston VALVE REMOVAL
ring. (1) With cylinder head removed, compress valve
(5) Position piston ring end gaps as shown in (Fig. springs using Special Tool C-3422-B or equivalent.
29). (2) Remove valve retaining locks, valve spring
(6) Position oil ring expander gap at least 45° from retainers, valve stem seals and valve springs.
the side rail gaps but not on the piston pin center or (3) Before removing valves, remove any burrs
on the thrust direction. Staggering ring gap is impor- from valve stem lock grooves to prevent dam-
tant for oil control. age to the valve guides. Identify valves to insure
installation in original location.
VALVE INSPECTION TESTING VALVE SPRINGS
(1) Clean valves thoroughly and discard burned, (1) Whenever valves have been removed for inspec-
warped and cracked valves. tion, reconditioning or replacement, valve springs
(2) Measure valve stems for wear. Measure stem should be tested. As an example, the compression
about 60 mm beneath the valve lock grooves. length of the spring to be tested is 33.34 mm (1 5/16
(3) If valve stems are worn more than 0.05 mm inches). Turn tool table until surface is in line with
(0.002 in.), replace valve. the 33.34 mm (1 5/16 in.) mark on the threaded stud
and the zero mark on the front. Place spring over
VALVE GUIDES stud on the table and lift compressing lever to set
(1) Remove carbon and varnish deposits from tone device (Fig. 32). Pull on torque wrench until
inside of valve guides with a reliable guide cleaner. ping is heard. Take reading on torque wrench at this
(2) Using a small hole gauge and a micrometer, instant. Multiply this reading by two. This will give
measure valve guides in 3 places top, middle and bot- the spring load at test length. Fractional measure-
tom (Fig. 30). Refer to Engine Specifications in this ments are indicated on the table for finer adjust-
section. Replace guides if they are not within specifi- ments. Discard the springs that do not meet
cation. specifications. The Following specifications apply to
(3) Check valve guide height (Fig. 31). both intake and exhaust valve springs;
• Valve Closed Nominal Tension—76 lbs. @ 38.0
mm (1.50 in.)
• Valve Open Nominal Tension—136 lbs. @ 29.75
mm (1.17 in.)
Fig. 30 Checking Wear on Valve Guide—Typical

1 – TOP
2 – MIDDLE
3 – BOTTOM
4 – CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS
Fig. 32 Testing Valve Springs

1 – TORQUE WRENCH
2 – VALVE SPRING TESTER
(2) Inspect each valve spring for squareness with a

steel square and surface plate, test springs from both
ends. If the spring is more than 1.5 mm (1/16 inch)
out of square, install a new spring.
REFACING VALVES AND VALVE SEATS

(1) The intake and exhaust valve seats and valve
face have a 45 and a 45 1/2 degree angles.
(2) Inspect the remaining margin after the valves
Fig. 31 Valve Guide Height
are refaced (Fig. 33). Intake valves with less than 1.2
1 – VALVE GUIDE
mm (3/64 inch.) margin and Exhaust valves with less
2 – 13.25 - 13.75 MM (.521 -.541 IN.)
3 – SPRING SEAT
than 0.9 mm (1/32 inch.) margin should be discarded.
(3) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
Fig. 33 Refacing Intake and Exhaust Valves

Intake and Exhaust Valves 1 – VALVE FACE
1 – MARGIN 2 – VALVE MARGIN
2 – FACE
3 – STEM
4 – VALVE SPRING RETAINER LOCK GROOVE
ing stones. A true and complete surface must be

obtained.
(4) Measure the concentricity of valve seat and
valve guide using a valve seat runout dial indicator.
Total runout should not exceed. 0.051 mm (0.002
inch.) (total indicator reading).
(5) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of the valve face, lower valve seat
with a 15 degrees stone. If the blue is transferred to Fig. 34 Refacing Valve Seats
the bottom edge of valve face raise valve seat with a
65 degrees stone.
• Intake valve seat diameter is 34.37 34.63 mm
(1.158 1.363 inch.)
• Exhaust valve seat diameter is 29.37 29.63 mm
(1.156 1.166 inch.)
(6) Valve seats which are worn or burned can be
reworked, provided that correct angle and seat width
are maintained. Otherwise the cylinder head must be
replaced.
(7) When seat is properly positioned the width of
intake and exhaust seats should be 0.9 to 1.3 mm
(0.35 to 0.051 inch.) (Fig. 34). Fig. 35 Checking Spring Installed Height and Valve
(8) Check valve tip height dimensions A after Tip Height Dimensions
grinding the valve seats or faces (Fig. 35). Grind 1 – GARTER SPRING
valve tip to 47.99 mm (1.889 in.) for exhaust valve 2 – VALVE SPRING SEAT
3 – CYLINDER HEAD SURFACE
and 48.04 mm (1.891 in.) for intake valve when
installed in the head. The valve tip chamfer may
need to be reground to prevent seal damage when
the valve is installed.
2000 NS Service Manual
SERVICE PROCEDURES (Continued) Publication No. 81-370-0005
TSB 26-01-00 January, 2000
VALVE INSTALLATION (6) Checking dry lash. Dry lash is the amount of
(1) Coat valve stems with clean engine oil and clearance that exists between the base circle of an
insert in cylinder head. installed cam and the rocker arm roller when the
(2) Install new valve stem seals on all valves using adjuster is drained of oil and completely collapsed.
a valve stem seal tool (Fig. 36). The valve stem seals Specified dry lash is 1.17 mm (0.046 in.) for intake
should be pushed firmly and squarely over valve and 1.28 mm (0.050 in.) for exhaust. After performing
guide. dry lash check, refill adjuster with oil and allow 10
minutes for adjuster/s to bleed down before rotating
cam.
REMOVAL AND INSTALLATION

ENGINE MOUNT—FRONT
REMOVAL
(1) Support the engine and transaxle assembly
with a floor jack so it will not rotate.
(2) Remove the front engine mount through bolt
from the insulator and front crossmember mounting
bracket (Fig. 37).
Fig. 36 Valve Stem Oil Seal Special Tool C-4745 (3) Remove six screws from air dam to allow
1 – VALVE SEAL TOOL access to the front mount screws.
2 – VALVE STEM (4) Remove the front engine mount screws and
remove the insulator assembly.
CAUTION: When oversize valves are used, the cor- (5) Remove the front mounting bracket, if neces-
responding oversize valve seal must also be used. sary (Fig. 37).
Excessive guide wear may result if oversize seals
are not used with oversize valves. INSTALLATION
(1) Reverse removal procedure for installation and
(3) Install valve springs and retainers. Compress tighten fasteners (Fig. 37) to the following torque.
valve springs only enough to install locks, taking • (A) to 28 N·m (21 ft. lbs.)
care not to misalign the direction of compression. • (B) to 68 N·m (50 ft. lbs.)
Nicked valve stems may result from misalignment of • (C) to 54 N·m (40 ft. lbs.)
the valve spring compressor. (2) Install six screws to air dam and tighten to 12
N·m (105 in. lbs.)
CAUTION: When depressing the valve spring
retainers with valve spring compressor the locks
can become dislocated. Check to make sure both
locks are in their correct location after removing
tool.
(4) Check the valve spring installed height B after

refacing the valve and seat (Fig. 35). Make sure mea-
surements are taken from top of spring seat to the
bottom surface of spring retainer. If height is greater
than 38.75 mm (1.525 in.), install a.762 mm (0.030
inch.) spacer under the valve spring seat to bring
spring height back within specification.
(5) Install rocker arm shafts as previously
described in this section.
Fig. 37 Engine Mounting-Front

REMOVAL AND INSTALLATION (Continued)
ENGINE MOUNT—LEFT (3) Remove the load on the engine mounts by care-
fully supporting the engine and transaxle assembly
REMOVAL with a floor jack.
(1) Raise vehicle on hoist and remove left front (4) Remove the vertical and horizontal fasteners
wheel. from the engine side bracket. Remove the mount
(2) Support the transaxle with a jack. assembly.
(3) Remove the insulator through bolt from the
mount. INSTALLATION
(4) Remove the transaxle mount fasteners and (1) Reverse removal procedure for installation.
remove mount (Fig. 38). Tighten assembly in the following order:
a. Engine mount to rail fasteners to 68 N·m (50 ft.
INSTALLATION lbs.).
(1) Reverse removal procedure for installation. b. The vertical engine fastener to 102 N·m (75 ft.
(2) Tighten mount to transaxle bolts to 55 N·m (40 lbs.).
ft. lbs.) c. The horizontal fastener to 150 N·m (111 ft. lbs.).
(3) Tighten through bolt to 75 N·m (55 ft. lbs.)
(Fig. 38).
Fig. 39 Engine Mounting—Right Side

1 – VERTICAL FASTENER
Fig. 38 Typical Engine Mounting—Left 2 – DO NOT REMOVE THIS NUT
1 – MOUNT TO TRANSMISSION FASTENERS 3 – HORIZONTAL FASTENER
ENGINE MOUNT—RIGHT ENGINE MOUNT—REAR

REMOVAL REMOVAL
(1) Raise vehicle on hoist and remove the left front
NOTE: Right mount should only be serviced as an wheel.
assembly to prevent noise, vibration and harshness (2) Support the transaxle with a jack so it will not
concerns. rotate.
(3) Remove the insulator thru bolt from the mount
(1) Remove the purge duty solenoid and wiring and rear suspension crossmember.
harness from engine mount bracket. (4) Remove the four mount fasteners and remove
(2) Remove the two right engine mount insulator the mount.
vertical fasteners from frame rail and loosen the one
horizontal fastener. Do not remove the large nut
located at the end of the core (Fig. 39).
INSTALLATION
(1) Reverse the removal procedure for installation.
Refer to (Fig. 40).
Fig. 41 Structural Collar and Bending Strut—

Removal and Installation
• Step 4: Install bolt 2, through strut and collar,
hand start only.
• Step 5: Install bolt 6, strut to cylinder block,
hand tight only.
• Step 6: Install the remaining collar to oil pan
bolt 5, hand tight only.
• Step 7: Final torque collar to transaxle bolts 1 –
Fig. 40 Engine Mounting—Rear 3, to 101 N·m (75 ft. lbs.)
1 – TOP ENGINE MOUNT FASTENERS • Step 8: Install bolts 7 and 8, through strut and
2 – SIDE ENGINE MOUNT FASTENERS into cylinder block.
• Step 9: Final torque bolts 4 – 8 to 61 N·m (45 ft.
lbs.).
STRUCTURAL COLLAR
(2) Install front torque bracket. Tighten torque
bracket to bending strut bolts to 33 N·m (24 ft. lbs.)
REMOVAL
and front engine mount through bolt to 61 N·m (45
(1) Raise vehicle on hoist.
ft. lbs.).
(2) Remove front engine torque bracket from bend-
(3) Lower vehicle.
ing strut and front insulator mount.
(3) Remove bolts attaching bending strut to engine
and transaxle.
ENGINE ASSEMBLY
(4) Remove bolts attaching collar and strut to engine,
oil pan, and transaxle. Remove strut and collar.
REMOVAL
(1) Perform fuel pressure release procedure and
remove fuel line to fuel rail. Refer to FUEL SYSTEM
INSTALLATION for procedures.
CAUTION: Torque procedure for the structural col- (2) Disconnect battery.
lar and bending strut must be followed or damage (3) Remove Air cleaner and hoses.
could occur to oil pan, collar, and/or bending strut. (4) Drain cooling system. Refer to COOLING SYS-
(1) Perform the following steps for installing struc- TEM for procedure.
tural collar and bending strut. Refer to (Fig. 41) : (5) Remove upper radiator hose and remove radia-
• Step 1: Place collar into position between tran- tor fans. Refer to COOLING SYSTEM for procedure.
saxle and oil pan. Install collar to transaxle bolt 1, (6) Remove lower radiator hose.
hand start only. (7) Disconnect automatic transmission cooler lines
• Step 2: Install collar to oil pan bolt 4, hand and plug, if equipped.
tight only. (8) Disconnect transmission shift linkage.
• Step 3: Position bending strut in place and (9) Disconnect throttle body linkage.
hand start only bolt 3 into the upper transaxle (10) Disconnect engine wiring harness.
hole. (11) Disconnect heater hoses.
(12) Discharge Air Conditioning System. Refer to (2) Align engine and transmission mounts to
HEATING AND AIR CONDITIONING for procedure. attaching points. Install mounting bolts at the right
(13) Hoist vehicle and remove right inner splash engine and left transmission mounts. Refer to proce-
shield. Remove wheels and tires. dures in this section.
(14) Loosen power steering belt for pump removal. (3) Slowly raise vehicle enough to remove the
Refer to COOLING SYSTEM for procedure. engine dolly and cradle Special Tools 6135 and 6710.
(15) Remove axle shafts. Refer to DIFFERENTIAL (4) Install axle shafts. Refer to DIFFERENTIAL
AND DRIVELINE for procedure. AND DRIVELINE for procedure.
(16) Disconnect exhaust pipe from manifold. (5) Install transmission and engine braces and
(17) Remove front and rear engine mount brackets splash shields.
from the body. (6) Connect exhaust system to manifold. Refer to
(18) Remove bending braces and front engine EXHAUST SYSTEM for procedure and torque speci-
mount bracket. Remove transmission inspection fications.
cover. (7) Install power steering pump. Refer to COOL-
(19) Mark flex plate to torque converter and ING SYSTEM, Accessory Drive Section for belt ten-
remove torque converter bolts. sion adjustment.
(20) Install front engine mount bracket. (8) Install A/C compressor hoses. Refer to
(21) Lower vehicle. HEATER AND AIR CONDITIONING for procedure.
(22) Remove power steering pump. Set pump (9) Install accessory drive belts. Refer to COOL-
aside. ING SYSTEM, Accessory Drive Section for belt ten-
(23) Remove A/C lines at compressor and cap. sion adjustment.
(24) Remove ground straps to body. (10) Install front and rear engine mounts. Refer to
(25) Raise vehicle enough to allow engine dolly procedure in this section.
Special Tool 6135, cradle Special Tool 6710 with (11) Install inner splash shield. Install wheels and
Posts Special Tool 6848 and Adaptor Special Tool tires.
8130 to be installed under vehicle (Fig. 42). (12) Connect automatic transmission cooler lines,
(26) Loosen cradle posts to allow movement for and shift linkage. Refer to TRANSAXLE AND
proper positioning. Locate two rear posts (right side POWER TRANSFER UNIT for procedures.
of engine) into the holes on the engine bedplate. (13) Connect fuel line and heater hoses.
Locate the two front posts (left side of engine) on the (14) Install ground straps.
front engine bracket and A/C compressor bracket (15) Connect engine and throttle body connections
(Fig. 42). Lower vehicle and position cradle mounts and harnesses. Refer to FUEL SYSTEM for proce-
until the engine is resting on mounts. Tighten dures.
mounts to cradle frame. This will keep mounts from (16) Connect throttle body linkage. Refer to FUEL
moving when removing or installing engine and SYSTEM for procedure.
transmission. (17) Install radiator fans, radiator hoses and fill
(27) Lower vehicle so the weight of ONLY THE cooling system. Refer to COOLING SYSTEM for pro-
ENGINE AND TRANSMISSION are on the cradle. cedures.
(28) Remove engine and transmission mount bolts. (18) Connect battery.
(29) Raise vehicle slowly. It may be necessary to (19) Install air cleaner and hoses.
move the engine/transmission assembly on the cradle (20) Install oil filter. Fill engine crankcase with
to allow for removal around the body. proper oil to correct level.
(21) Start engine and run until operating temper-
INSTALLATION ature is reached.
(1) Position engine and transmission assembly (22) Adjust transmission linkage, if necessary.
under vehicle and slowly lower the vehicle over the
engine and transmission.
Fig. 42 Positioning Engine Cradle Support Post Mounts—Typical

1 – SPECIAL TOOL POSTS 6848 4 – SPECIAL TOOL 6710 CRADLE
2 – SPECIAL TOOL 6135 DOLLY 5 – SPECIAL TOOL ADAPTER 8130
3 – SPECIAL TOOL POSTS 6848
INTAKE MANIFOLD—UPPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect air intake tube and resonator box
from throttle body and remove.
(3) Remove connector from throttle position sensor
(TPS) (Fig. 43).
(4) Remove connector from idle air control (IAC)
motor (Fig. 43).
(5) Remove connector from MAP sensor (Fig. 48).
Fig. 44 Vacuum Line Connections

1 – PURGE SOLENOID HOSE
2 – PCV VALVE HOSE
Fig. 43 Throttle Body Electrical Connectors

1 – IDLE AIR CONTROL MOTOR CONNECTOR
2 – TPS CONNECTOR
(6) Remove vacuum lines for purge solenoid and

PCV valve at intake manifold (Fig. 44).
(7) Remove vacuum lines for power brake booster
and speed control vacuum reservoir at upper intake
manifold fittings (Fig. 45). Fig. 45 Vacuum Fitting at Rear of Upper Intake
(8) Remove throttle cable and speed control cable Manifold
(if equipped) from throttle lever (Fig. 46). 1 – VACUUM FITTING
(9) Remove throttle cables from bracket by com-
pressing retaining tabs.
(10) Remove two top bolts from intake manifold to (14) Remove upper intake manifold bolts. Remove
rear support bracket and EGR tube (Fig. 47). upper intake manifold.
(11) Remove upper bolt from intake manifold to
front support bracket (Fig. 48). CAUTION: Cover intake manifold to prevent foreign
(12) Remove dipstick. material from entering engine.
(13) Remove dipstick tube.
CAUTION: Moving the dipstick tube will cause dam- INSTALLATION

age to the sealer, causing an oil leak. Dipstick tube (1) Install new upper intake manifold gasket.
must be sealed at cylinder block.
NOTE: Center outboard fastener is a double stud.
Fig. 46 Throttle Cable Attachment to Throttle Body

1 – RETAINER TABS
2 – THROTTLE LEVER
Fig. 48 Intake Manifold Front Support Bracket and

Map Sensor
1 – UPPER INTAKE MANIFOLD
2 – MAP SENSOR
3 – INTAKE MANIFOLD FRONT SUPPORT BRACKET
(4) Install dipstick.

(5) Install upper bolt in intake manifold to front
support bracket (Fig. 48). Torque to 28 N·m (250 in.
lbs.).
(6) Install a new EGR tube gasket at intake man-
ifold connection.
(7) Install two upper bolts at intake manifold to
rear support bracket and EGR tube (Fig. 47). Tighten
bolts to 28 N·m (250 in. lbs.).
(8) Install throttle cables in bracket.
(9) Install throttle cable and speed control cable (if
Fig. 47 Intake Manifold Rear Support Bracket equipped) to throttle lever.
1 – UPPER INTAKE MANIFOLD (10) Install vacuum lines for power brake booster
2 – EGR TUBE and speed control vacuum reservoir at upper intake
3 – THROTTLE BODY manifold fittings.
4 – INTAKE MANIFOLD REAR SUPPORT BRACKET (11) Install vacuum lines for purge solenoid and
PCV valve.
(2) Tighten upper intake manifold fasteners start- (12) Install electrical connectors for MAP sensor,
ing at center and progressing outward in both direc- throttle position sensor (TPS), and idle air control
tions. Tighten bolts to 28 N·m (250 in. lbs.). Repeat (IAC) motor.
this procedures until all fasteners are at specified (13) Install air intake tube and resonator box to
torque. throttle body.
(3) Install dipstick tube. Seal tube to cylinder (14) Connect negative cable to battery.
block using Mopart Stud & Bearing Mount Adhesive.
Tighten dipstick tube fastener to 12 N·m (105 in.
lbs.).
INTAKE MANIFOLD—LOWER
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs. Refer to FUEL
SYSTEM for procedure.
(2) Remove upper intake manifold. Refer to proce-
dure in this section.
CAUTION: Cover intake manifold to prevent foreign Fig. 50 Fuel Line Quick Disconnect
material from entering engine. 1 – QUICK CONNECT FITTING
2 – GENERATOR
(3) Disconnect electrical connector from intake air 3 – CHASSIS FUEL LINE
temperature sensor (Fig. 49).
(6) Remove heater, and upper radiator hoses at

intake manifold.
(7) Disconnect coolant temperature sensor (Fig.
51).
(8) Remove the accessory drive belt. Refer to
Accessory Drive belt Removal and Installation in
COOLING SYSTEM for procedure.
(9) Remove fasteners attaching generator bracket
to cylinder head, and block.
Fig. 49 Intake Air Temperature Sensor

1 – TPS
2 – IAC
3 – EGR VALVE
4 – CAMSHAFT SENSOR
5 – INTAKE AIR TEMPERATURE
6 – EGR TUBE
(4) Remove fuel hose quick connect fitting from the

chassis tube (Fig. 50). Refer to FUEL SYSTEM for
procedure.
WARNING: WRAP A SHOP TOWEL AROUND

HOSES TO CATCH ANY GASOLINE SPILLAGE. Fig. 51 Coolant Temperature Sensor—2.4L
1 – MAP SENSOR
(5) Drain cooling system. Refer to COOLING SYS- 2 – COOLANT TEMPERATURE SENSOR
TEM for procedure.
(10) Remove intake manifold center support INSTALLATION
bracket bolts (Y bracket) (Fig. 52).
If the following items were removed, install and
torque to:
• Fuel Rail Bolts 22 N·m (200 in. lbs.)
• Engine Outlet Connector Bolts 28 N·m (250 in.
lbs.)
• Coolant Temperature Sensor 7 N·m (60 in. lbs.)
• Intake Air Temperature Sensor 28 N·m (250 in.
lbs.)
(1) Using a new intake gasket, position intake
manifold on the engine and install retaining bolts.
(2) Tighten intake manifold fasteners in the follow-
ing sequence (Fig. 53). Torque to 23 N·m (200 in.
lbs.). Repeat this procedure until all bolts are at
specified torque.
(3) Install intake manifold center support bracket
bolts (Y bracket) and tighten to:
• Fastener to block 54 N·m (40 ft. lbs.)
• Fastener to intake 28 N·m (250 in. lbs.)
(4) Install fuel hose quick connect fitting to chassis
Fig. 52 Intake Manifold Center Support Bracket tubes. Refer to FUEL SYSTEM for procedure. Push
1 – RADIATOR CORE SUPPORT the fitting onto the chassis tube until it clicks into
2 – UPPER INTAKE MANIFOLD place. Pull on the fitting to ensure complete inser-
3 – INTAKE MANIFOLD CENTER SUPPORT BRACKET tion.
(5) Connect fuel injector harness.
(11) Disconnect fuel injector harness. (6) Install generator bracket to cylinder head and
(12) Remove lower intake manifold fasteners (Fig. block.
53). Remove the manifold from engine. (7) Install accessory drive belt. Refer to COOLING
(8) Connect coolant temperature sensor electrical
connector (Fig. 51).
(9) Install upper radiator and heater hoses.
(10) Fill cooling system. Refer to COOLING SYS-
TEM for procedure.
(11) Connect intake air temperature sensor electri-
cal connector (Fig. 49).
(12) Install upper intake manifold. Refer to proce-
CAUTION: When using the ASD Fuel System Test,

the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
the ignition switch is turned to the Off position.
(13) With the ignition key in ON position, access

Fig. 53 Intake Manifold Tightening Sequence the DRB scan tool ASD Fuel System Test to pressur-
(13) Inspect and clean manifold. Refer to Cleaning ize the fuel system. Check for leaks.
and Inspection in this section for procedures.
EXHAUST MANIFOLD
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold at the flex-joint.
(2) Disconnect oxygen sensor lead wire at the rear
of exhaust manifold (Fig. 54).
(3) Remove the bolts attaching the manifold to the
cylinder head. Remove exhaust manifold (Fig. 54).
Fig. 55 Ignition Coil and Ground Strap

1 – IGNITION COIL FASTENERS
2 – GROUND STRAP
Fig. 54 Exhaust Manifold Tightening Sequence

(4) Inspect and clean manifold. Refer to Cleaning
INSTALLATION
(1) Install exhaust manifold with a new gasket.
Tighten attaching nuts in the sequence shown in
(Fig. 54) to 20 N·m (175 in. lbs.).
(2) Attach exhaust pipe to exhaust manifold and Fig. 56 Cylinder Head Cover Gasket and Spark Plug
tighten fasteners to 37 N·m (27 ft. lbs.). Seals
(3) Connect heated oxygen sensor lead (Fig. 54). 1 – ONE PIECE RUBBER GASKET
2 – SPARK PLUG WELL SEALS
CYLINDER HEAD COVER
REMOVAL INSTALLATION
(1) Remove upper intake manifold. Refer to proce- NOTE: Replace spark plug well seals when install-
dure in this section. ing a new cylinder head cover gasket.
(2) Remove nuts attaching front and rear intake
manifold supports from cylinder head cover attaching (1) Clean all sealing surfaces.
studs. (2) Install new cylinder head cover gaskets and
(3) Remove ignition coil pack and plug wires (Fig. spark plug seals (Fig. 56).
55). Remove ground strap.
(4) Remove the cylinder head cover fasteners. CAUTION: Do not allow oil or solvents to contact
(5) Remove cylinder head cover from cylinder the timing belt as they can deteriorate the rubber
head. and cause tooth skipping.
(3) Apply Mopart Engine RTV GEN II at the cam-
shaft cap corners and at the top edge of the 1/2
round seal.
(4) Install cylinder head cover assembly to head
and tighten fasteners in sequence shown in (Fig. 57).
Using the 3 step torque method:
(a) Tighten all fasteners to 4.5 N·m (40 in. lbs.)
(b) Tighten all fasteners to 9.0 N·m (80 in. lbs.)
(c) Tighten all fasteners to 12 N·m (105 in. lbs.)
Fig. 58 Camshaft Bearing Cap Identification
Fig. 57 Cylinder Head Cover Tightening Sequence

(5) Install ignition coil pack and plug wires.
Tighten fasteners to 12 N·m (105 in. lbs.).
(6) Install ground strap.
(7) Install front and rear intake manifold support
brackets and attaching nuts, but do not tighten at
this time.
(8) Install upper intake manifold. Refer to proce-
(9) Final torque intake manifold support nuts to Fig. 59 Camshaft Bearing Cap—Removal
28 N·m (250 in. lbs.). 1 – REMOVE OUTSIDE BEARING CAPS FIRST
CAMSHAFT
CAMSHAFT END PLAY
REMOVAL (1) Oil camshaft journals and install camshaft
(1) Remove cylinder head cover using procedure in WITHOUT cam follower assemblies. Install rear cam
this section. caps and tighten screws to specified torque.
(2) Remove camshaft position sensor and camshaft (2) Using a suitable tool, move camshaft as far
target magnet. Refer to IGNITION SYSTEM for pro- rearward as it will go.
cedure. (3) Zero dial indicator (Fig. 60).
(3) Remove timing belt, sprockets and covers. (4) Move camshaft as far forward as it will go.
Refer to procedures in this section. (5) End play travel: 0.05–0.15 mm (0.002–0.010
(4) Bearing caps are identified for location. in.).
Remove the outside bearing caps first (Fig. 58). (5) If end play is excessive, check cylinder head
(5) Loosen the camshaft bearing cap attaching fas- and camshaft for wear; replace as necessary.
teners in sequence shown (Fig. 59), one camshaft at a
time. INSTALLATION
CAUTION: Camshafts are not interchangeable. The CAUTION: Ensure that NONE of the pistons are at
left (intake) camshaft thrust bearing face (No. 6) top dead center when installing the camshafts.
spacing is wider.
(1) Lubricate all camshaft bearing journals, cam
(6) Identify the camshafts before removing from followers, and camshafts.
the head. The camshafts are not interchangeable. (2) Install cam followers and camshafts.
Fig. 60 Camshaft End Play Fig. 62 Camshaft Bearing Cap Sealing

(3) Install right and left camshaft bearing caps No. 1 – 1.5 mm (.060 in.) DIAMETER BEAD OF MOPAR GASKET
MAKER
2–5 and right No. 6. Tighten the M6 fasteners to 12
N·m (105 in. lbs.) in sequence shown in (Fig. 61).
(4) Apply Mopart Gasket Maker to No. 1 and left (3) Remove camshaft. Refer to procedure in this
No. 6 bearing caps as shown in (Fig. 62). section.
(5) Install the outer bearing caps and tighten the
CAUTION: If cam follower assemblies are to be
M8 fasteners to 24 N·m (215 in. lbs.).
reused, always mark position for reassembly in
NOTE: Bearing end caps must be installed before their original positions.
seals can be installed.
(4) Remove cam follower assemblies from cylinder
(6) Install camshaft seals, timing belt, and sprock- head.
ets. Refer to procedure in this section.
INSPECTION
(7) Install camshaft target magnet and camshaft
position sensor. Refer to IGNITION SYSTEM for pro- Inspect the cam follower assembly for wear or
cedure. damage (Fig. 63). Replace as necessary.
(8) Install cylinder head cover using procedure in
this section.
Fig. 63 Cam Follower Assembly

1 – TIP
2 – LASH ADJUSTER POCKET
Fig. 61 Camshaft Bearing Cap Tightening Sequence 3 – ROLLER
CAMSHAFT FOLLOWER
INSTALLATION
REMOVAL (1) Lubricate with clean oil and install cam fol-
(1) Remove cylinder head cover using procedure in lower assemblies in their original position on the
this section. hydraulic adjuster and valve stem (Fig. 64).
(2) Remove timing belt, sprockets and covers using (2) Install the camshafts. Refer to procedure in
procedure in this section. this section.
(3) Install timing belt, sprockets and covers using (2) Remove chain cover, guide and tensioner (Fig.
procedures in this section. 65). Also see Carrier Assembly Removal for service
(4) Install cylinder head cover using procedure in procedures requiring only temporary relocation of
this section. assembly.
Fig. 64 Cam Follower Assemblies—Installation

BALANCE SHAFTS AND CARRIER ASSEMBLY
BALANCE SHAFTS
REMOVAL
(1) Drain engine oil and remove oil pan. Refer to
procedures in this section.
Fig. 66 Drive Chain and Sprockets
1 – NICKEL PLATED LINK AND MARK
2 – GEAR/SPROCKET SCREWS
3 – NICKEL PLATED LINK AND DOT
(3) Remove gear/sprocket retaining screws.

(4) Remove chain and sprocket assembly (Fig. 66).
Using two wide pry bars, work the sprocket back and
forth until it is off the shaft.
(5) Remove gear cover retaining stud (double
ended to also retain chain guide), gear cover, and bal-
ance shaft gears (Fig. 65).
(6) Remove rear cover and balance shafts (Fig. 68).
(7) Remove four carrier to crankcase attaching
bolts to separate carrier from engine bedplate.
BALANCE SHAFT CARRIER

REMOVAL
The following components will remain intact dur-
ing carrier removal. Gear cover, gears, balance shafts
Fig. 65 Chain Cover, Guide and Tensioner and the rear cover (Fig. 68).
1 – STUD (1) Remove chain cover and driven balance shaft
2 – TENSIONER (ADJUSTER) chain sprocket screw.
3 – GEAR COVER
(2) Loosen tensioner pivot and adjusting screws,
4 – ADJUST SCREW
move driven balance shaft inboard through driven
5 – PIVOT SCREW
6 – CHAIN COVER (CUTAWAY)
chain sprocket. Sprocket will hang in lower chain
7 – GUIDE loop.
(3) Remove carrier to crankcase attaching bolts to
remove carrier.
BALANCE SHAFT 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. Refer to Timing procedure in
this section.
BALANCE SHAFT TIMING

(1) With balance shafts installed in carrier (Fig.
68) position carrier on crankcase and install four
attaching bolts and tighten to 54 N·m (40 ft. lbs.).
(2) Turn balance shafts until both shaft key ways
Fig. 67 Gear Cover and Gears are up, parallel to vertical centerline of engine.
1 – STUD (DOUBLE ENDED) Install short hub drive gear on sprocket driven shaft
2 – DRIVE GEAR and long hub gear on gear driven shaft. After instal-
3 – DRIVEN GEAR lation gear and balance shaft keyways must be up
4 – CARRIER DOWEL with gear timing marks meshed as shown in (Fig.
5 – GEAR(S) 69).
6 – GEAR COVER
Fig. 68 Balance Shaft(s)—Removal/Installation

1 – SPROCKET 7 – GEAR COVER
2 – TENSIONER 8 – CHAIN COVER
3 – CARRIER 9 – SPROCKET
4 – REAR COVER 10 – GUIDE
5 – BALANCE SHAFTS 11 – CHAIN
6 – GEARS
(7) Place balance shaft sprocket into the timing
chain (Fig. 71) so that the timing mark on the
sprocket (dot) mates with the (lower) nickel plated
link on the chain.
NOTE: The lower plated link is 8 links from the

upper link.
(8) With balance shaft keyways pointing up (12

o’clock) slide the balance shaft sprocket onto the nose
of the balance shaft. The balance shaft may have to
be pushed in slightly to allow for clearance.
Fig. 69 Gear Timing
1 – KEY WAYS UP
2 – GEAR ALIGNMENT DOTS
Fig. 70 Crankshaft Sprocket—Installation

1 – ALIGN FLAT ON SPROCKET WITH FLAT ON CRANKSHAFT
WITH SPROCKET FACING FRONT
2 – SPECIAL TOOL NO. 6052 Fig. 71 Balance Shaft Timing
3 – DRIVE SPROCKET 1 – MARK ON SPROCKET
2 – KEYWAYS UP
3 – ALIGN MARKS
(3) Install gear cover and tighten double ended
4 – PLATED LINK
stud/washer fastener to 12 N·m (105 in. lbs.).
5 – PARTING LINE (BEDPLATE TO BLOCK)
(4) Install crankshaft sprocket using Special Tool 6 – PLATED LINK
6052 (Fig. 70).
(5) Turn crankshaft until number one cylinder is
at Top Dead Center (TDC). The timing marks on the NOTE: THE TIMING MARK ON THE SPROCKET,
chain sprocket should line up with the parting line THE (LOWER) NICKEL PLATED LINK, AND THE
on the left side of number one main bearing cap. ARROW ON THE SIDE OF THE GEAR COVER
(Fig. 71). SHOULD LINE UP WHEN THE BALANCE SHAFTS
(6) Place chain over crankshaft sprocket so that ARE TIMED CORRECTLY.
the nickel plated link of the chain is over the number
1 cylinder timing mark on the crankshaft sprocket (9) If the sprockets are timed correctly, install the
(Fig. 71). balance shaft bolts and tighten to 28 N·m (250 in.
lbs.). A wood block placed between crankcase and
crankshaft counterbalance will prevent crankshaft (2) Remove camshafts and cam follower assem-
and gear rotation. blies. Refer to camshaft removal procedure in this
(10) CHAIN TENSIONING: section to gain access to cam followers and lash
(a) Install chain tensioner loosely assembled. adjusters.
(b) Position guide on double ended stud making (3) Mark hydraulic lash adjusters for reassembly
sure tab on the guide fits into slot on the gear in their original position. Lash adjusters are serviced
cover. Install and tighten nut/washer assembly to as an assembly.
12 N·m (105 in. lbs.).
(c) Place a shim 1 mm (0.039 in.) thick x 70 mm INSTALLATION
(2.75 in.) long or between tensioner and chain. (1) Install hydraulic lash adjuster assembly mak-
Push tensioner and shim up against the chain. ing sure adjusters are at least partially full of oil.
Apply firm pressure (5.5 to 6.6 lbs.) directly This is indicated by little or no plunger travel when
behind the adjustment slot to take up all the lash adjuster is depressed.
slack. Chain must have shoe radius contact as (2) Install following components following proce-
shown in (Fig. 72). dures in this section:
(d) With the load applied, tighten top tensioner • cam follower assemblies
bolt first, then bottom pivot bolt. Tighten bolts to • camshafts
12 N·m (105 in. lbs.). Remove shim. • cylinder head cover
(e) Install carrier covers and tighten screws to
12 N·m (105 in. lbs.). VALVE SPRINGS AND VALVE SEALS IN
(11) Install oil pan. VEHICLE
(12) Fill engine crankcase with proper oil to cor-
rect level. REMOVAL
(1) Remove camshafts. Refer to procedure in this
section.
(2) Rotate crankshaft until piston is at TDC on
compression.
(3) With air hose attached to adapter tool installed
in spark plug hole, apply 90-120 psi air pressure.
(4) Using Special Tool MD-998772-A with adapter
6779 (Fig. 73), compress valve springs and remove
valve locks.
(5) Remove valve spring(s).
(6) Remove valve stem seal(s) by a using valve
stem seal tool.
Fig. 72 Chain Tension Adjustment

1 – 1MM (0.039 IN.) SHIM
2 – TENSIONER (ADJUSTER) BOLT
3 – PIVOT BOLT
HYDRAULIC LASH ADJUSTER

Fig. 73 Valve Spring—Removal/Installation
REMOVAL 1 – VALVE SPRING COMPRESSOR MD 998772A
(1) Remove cylinder head cover. Refer to procedure 2 – AIR HOSE
in this section.
INSTALLATION (11) Remove fastener attaching dipstick tube to
(1) Install valve seal/valve spring seat assembly intake manifold.
(Fig. 74). Push the assembly down to seat it onto the
valve guide. CAUTION: Moving the dipstick tube will cause dam-
(2) Install valve spring and retainer, use Special age to the sealer, creating on oil leak. Dipstick tube
Tool MD-998772-A with adapter 6779 to compress must be sealed at the cylinder block.
valve springs only enough to install locks (Fig. 73).
(12) Remove dipstick and tube.
Correct alignment of tool is necessary to avoid nick-
(13) Remove accessory drive belts. Refer to COOL-
ing valve stems.
ING SYSTEM for procedure.
(3) Remove air hose and install spark plugs.
(14) Remove power brake vacuum hose from
(4) Install camshafts and cylinder head cover.
intake manifold.
Refer to procedures in this section.
(15) Raise vehicle and remove exhaust pipe from
manifold.
(16) Remove power steering pump reservoir and
line support bracket from cylinder head and set
aside.
(17) Disconnect coil pack wiring connector and
remove coil pack and plug wires from engine.
(18) Remove cam sensor and fuel injectors wiring
connectors.
(19) Remove timing belt and camshaft sprockets.
(20) Remove timing belt idler pulley and rear tim-
ing belt cover.
(21) Remove cylinder head cover using procedure
in this section.
(22) Remove camshafts and cam followers. Refer to
Fig. 74 Valve Stem Seal/Valve Spring Seat (23) Remove cylinder head bolts and remove cylin-
1 – VALVE RETAINING LOCKS der head from engine block.
2 – VALVE SPRING (24) Inspect and clean cylinder head. Refer to
3 – VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY Cleaning and Inspection in this section for proce-
4 – VALVE SPRING RETAINER dures.
CYLINDER HEAD INSTALLATION

NOTE: The Cylinder head bolts should be exam-
REMOVAL ined BEFORE reuse. If the threads are necked
(1) Perform fuel system pressure release procedure down, the bolts should be replaced (Fig. 75).
before attempting any repairs. Refer to FUEL
SYSTEM for procedure. Necking can be checked by holding a scale or
(2) Disconnect negative cable from battery. straight edge against the threads. If all the threads
(3) Drain cooling system. Refer to COOLING SYS- do not contact the scale, the bolt should be replaced.
TEM for procedure. (1) Before installing the bolts, the threads should
(4) Remove air inlet tube and housing. be coated with engine oil.
(5) Disconnect all vacuum lines, electrical wiring, (2) Tighten the cylinder head bolts in the sequence
ground straps, and fuel line. shown in (Fig. 76). Using the 4 step torque turn
(6) Remove throttle linkage. Refer to FUEL SYS- method, tighten according to the following values:
TEM for procedure. • First All to 34 N·m (25 ft. lbs.)
(7) Remove throttle body support and intake man- • Second All to 68 N·m (50 ft. lbs.)
ifold support brackets. • Third All to 68 N·m (50 ft. lbs.)
(8) Remove EGR tube (if equipped).
(9) Remove heater tube support bracket from cyl- CAUTION: Do not use a torque wrench for the fol-
inder head. lowing step.
(10) Disconnect upper radiator and heater hoses
from intake manifold water outlet connections. • Fourth Turn an additional 1/4 Turn,
(15) Connect upper radiator and heater hoses to
intake manifold water outlet connections.
(16) Using new gaskets, install EGR tube (if
equipped) and tighten fasteners to 11 N·m (95 in.
lbs.).
(17) Apply Mopart Stud & Bearing Mount Adhe-
sive to the dipstick tube. Install dipstick tube in
block.
(18) Install fastener attaching dipstick tube to
intake manifold and tighten to 12 N·m (105 in. lbs.).
(19) Install throttle linkage. Refer to FUEL SYS-
Fig. 75 Checking Bolts for Stretching (Necking) TEM for procedures.
1 – STRETCHED BOLT (20) Install air inlet tube and housing.
2 – THREADS ARE NOT STRAIGHT ON LINE (21) Connect all vacuum lines, electrical wiring,
3 – THREADS ARE STRAIGHT ON LINE
ground straps and fuel line.
4 – UNSTRETCHED BOLT
(22) Fill cooling system. Refer to COOLING SYS-
TEM for procedure.
(23) Connect negative cable to battery.
VALVE AND VALVE SPRING

REMOVAL
(1) With cylinder head removed, compress valve
springs using a universal valve spring compressor.
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(3) Before removing valves, remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides. Identify valves to insure
Fig. 76 Cylinder Head Tightening Sequence (4) Inspect and clean the valves. Refer to Cleaning
and Inspection in this section for procedure.
(3) Install camshafts and cam followers. Refer to
procedures in this section. INSTALLATION
(4) Install cylinder head cover using procedure in (1) Coat valve stems with clean engine oil and
this section. insert in cylinder head.
(5) Install rear timing belt cover and timing belt (2) Install new valve stem seals on all valves using
idler pulley. a valve stem seal tool (Fig. 77). The valve stem seals
(6) Install timing belt and camshaft sprockets. should be pushed firmly and squarely over valve
Refer to procedures in this section. guide.
(7) Install cam sensor and fuel injectors wiring
connectors. CAUTION: When oversize valves are used, the cor-
(8) Install coil pack and plug wires onto the responding oversize valve seal must also be used.
engine. Connect coil pack wiring connector. Excessive guide wear may result if oversize seals
(9) Install power steering pump reservoir and line are not used with oversize valves.
support bracket to cylinder head.
(10) Raise vehicle and install the exhaust pipe to (3) Install valve springs and retainers. Compress
the manifold. valve springs only enough to install locks, taking
(11) Install power brake vacuum hose to the intake care not to misalign the direction of compression.
manifold. Nicked valve stems may result from misalignment of
(12) Install accessory drive belts. Refer to COOL- the valve spring compressor.
(13) Install throttle body support and intake man- CAUTION: When depressing the valve spring
ifold support brackets. retainers with valve spring compressor the locks
(14) Install heater tube support bracket to cylinder can become dislocated. Ensure both locks are in
head. the correct location after removing tool.
Fig. 77 Valve Stem Oil Seal Tool

1 – VALVE SEAL TOOL
2 – VALVE STEM Fig. 79 Crankshaft Damper—Removal
1 – SPECIAL TOOL 1026
2 – SPECIAL TOOL 6827–A INSERT
(4) Check the valve spring installed height B after
refacing the valve and seat (Fig. 78). Make sure mea-
surements are taken from top of spring seat to the INSTALLATION
bottom surface of spring retainer. If height is greater (1) Install crankshaft damper using M12 1.75 x
than 38.75 mm (1.525 in.), install a 0.762 mm (0.030 150 mm bolt, washer, thrust bearing and nut from
in.) spacer under the valve spring seat to bring Special Tool 6792.
spring height back within specification.
NOTE: Lubricate the threads of the M12 1.75 x 150
mm bolt before beginning to press the damper on.
(2) Install crankshaft damper bolt and tighten to

142 N·m (105 ft. lbs.) (Fig. 80).
(3) Install accessory drive belts. Refer to COOL-
ING SYSTEM for procedures.
Fig. 78 Checking Spring Installed Height and Valve

Tip Height Dimensions
1 – GARTER SPRING
2 – VALVE SPRING SEAT
3 – CYLINDER HEAD SURFACE
CRANKSHAFT DAMPER
REMOVAL
ING SYSTEM for procedures.
Fig. 80 Crankshaft Damper—Installation
(2) Remove crankshaft damper bolt.
1 – M12–1.75 3 150 MM BOLT, WASHER AND THRUST
(3) Remove damper by using Special Tool 1026 and BEARING FROM SPECIAL TOOL 6792
Insert 6827–A (Fig. 79).
TIMING BELT COVER (3) Remove timing belt, idler pulley, and camshaft
sprockets. Refer to procedures in this section.
FRONT COVER (4) Remove rear cover fasteners and remove cover
from engine (Fig. 82).
REMOVAL
(1) Remove crankshaft damper. Refer to procedure
in this section.
(2) Remove generator belt idler pulley for lower
cover removal.
(3) Remove front timing belt cover fasteners (Fig.
81) and remove covers.
Fig. 82 Rear Timing Belt Cover Fasteners

1 – REAR COVER TO CYLINDER HEAD FASTENERS
2 – REAR COVER TO ENGINE BLOCK FASTENERS
3 – BELT TENSIONER
INSTALLATION
Fig. 81 Front Timing Belt Cover
1 – UPPER TIMING BELT COVER FASTENERS (1) Install rear timing belt cover and fasteners
2 – ENGINE BRACKET FASTENERS (Fig. 82).
3 – LOWER TIMING BELT COVER FASTENERS (2) Install camshaft sprockets. While holding
sprocket with Special Tools C-4687 and C-4687-1,
tighten center bolt to 101 N·m (75 ft. lbs.).
INSTALLATION
(3) Install timing belt idler pulley and tighten
(1) Install front timing belt covers (Fig. 81). mounting bolt to 61 N·m (45 ft. lbs.).
Tighten bolts to 4.5 N·m (40 in. lbs.). (4) Install timing belt. Refer to procedure in this
(2) Install generator belt idler pulley and tighten section.
bolt to 54 N·m (40 ft. lbs.) (5) Install engine mount bracket and tighten bolts
(3) Install crankshaft damper. Refer to procedure to 61 N·m (45 ft. lbs.).
in this section. (6) Install front covers.
REAR COVER TIMING BELT
REMOVAL
REMOVAL
(1) Remove front covers.
(1) Raise vehicle on hoist. Remove right front
(2) Remove engine mount bracket (Fig. 81).
wheel.
(2) Remove right inner splash shield. (9) Before the removal of the timing belt, rotate
(3) Remove accessory drive belts. Refer to COOL- crankshaft until TDC mark on oil pump housing
ING SYSTEM for procedure. aligns with TDC mark on crankshaft sprocket (trail-
(4) Remove crankshaft damper bolt, and remove ing edge of sprocket tooth) (Fig. 84).
damper. Refer to Removal and Installation procedure
in this section. NOTE: The crankshaft sprocket mark is located on
(5) Remove generator belt idler pulley. the trailing edge of the sprocket tooth. Failure to
(6) Remove lower timing belt cover fasteners and align trailing edge of sprocket tooth to mark on oil
remove cover (Fig. 83). pump housing will cause the camshaft marks to be
(7) Lower vehicle and remove upper timing belt misaligned (Fig. 84).
cover fasteners and remove cover.
Fig. 84 Crankshaft and Camshaft Timing

1 – CAMSHAFT TIMING MARKS
2 – CRANKSHAFT TDC MARKS
Fig. 83 Timing Belt Covers
3 – TRAILING EDGE OF SPROCKET TOOTH
1 – UPPER TIMING BELT COVER FASTENERS
2 – ENGINE BRACKET FASTENERS
3 – LOWER TIMING BELT COVER FASTENERS (10) Install 6 mm Allen wrench into belt tensioner.
Before rotating the tensioner insert the long end of a
(8) Remove right engine mount and support 1/8” or 3 mm Allen wrench into the pin hole on the
bracket. Refer to Removal and Installation procedure front of the tensioner (Fig. 85). While rotating the
in this section. tensioner counterclockwise push in lightly on the 1/8”
or 3 mm Allen wrench, until it slides into the locking
CAUTION: When aligning crankshaft and camshaft hole.
timing marks always rotate engine from crankshaft. (11) Remove timing belt.
Camshaft should not be rotated after timing belt is
removed. Damage to valve components may occur.
Always align timing marks before removing timing
belt.
NOTE: A new tensioner is held in the wound posi-
tion by a pull pin.
(5) Remove the pull pin or Allen wrench from the

belt tensioner.
(6) Once timing belt has been installed and ten-
sioner released, rotate crankshaft two (2) complete
revolutions. Verify that the TDC marks on crank-
shaft and timing marks on the camshafts are aligned
as shown in (Fig. 88).
(7) Install right engine mount and support
bracket. Refer to Removal and Installation procedure
in this section.
(8) Install upper timing belt cover bolts 4.5 N·m
(40 in. lbs.).
(9) Install the lower timing belt cover bolts 4.5
N·m (40 in. lbs.).
(10) Install generator belt idler pulley and tighten
bolt 54 N·m (40 ft. lbs.).
(11) Install crankshaft damper. Refer to procedure
in this section.
Fig. 85 Locking Timing Belt Tensioner ING SYSTEM for procedure.
1 – 1/8 OR 3mm ALLEN WRENCH (13) Install right inner splash shield.
2 – BELT TENSIONER (14) Install right front wheel.
3 – 6mm ALLEN WRENCH
CAUTION: If timing belt was damaged due to incor-

rect tracking (alignment), the belt tensioner assem-
bly must be replace. Refer to Timing Belt Tensioner
Assembly Removal and Installation procedure out-
lined in this section.
INSTALLATION
(1) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing.
(2) Set camshafts timing marks so that the
exhaust camshaft sprocket is a 1/2 notch below the
intake camshaft sprocket (Fig. 86).
CAUTION: Ensure that the arrows on both cam- Fig. 86 Camshaft Sprocket Alignment For Belt
shaft sprockets are facing up. Installation
1 – CAMSHAFT SPROCKET-EXHAUST
(3) Install timing belt. Starting at the crankshaft, 2 – CAMSHAFT SPROCKET-INTAKE
go around the water pump sprocket, idler pulley, 3 – 1/2 NOTCH LOCATION
camshaft sprockets and then around the tensioner
(Fig. 87).
(4) Move the exhaust camshaft sprocket counter-
clockwise (Fig. 87) to align marks and take up belt
slack.
Fig. 88 Crankshaft and Camshaft Timing

1 – CAMSHAFT TIMING MARKS
2 – CRANKSHAFT TDC MARKS
3 – TRAILING EDGE OF SPROCKET TOOTH
Fig. 87 Timing Belt—Installation

1 – ROTATE CAMSHAFT SPROCKET TO TAKE UP BELT SLACK
2 – CAMSHAFT TIMING MARKS 1/2 NOTCH LOCATION
3 – CRANKSHAFT AT TDC
4 – INSTALL BELT IN THIS DIRECTION
TIMING BELT TENSIONER ASSEMBLY

REMOVAL
(1) Remove timing belt. Refer to Removal and
Installation procedure in this section. Fig. 89 Camshaft Sprockets—Removal/Installation
(2) Remove timing belt idler pulley. 1 – ADAPTER C-4687–1
(3) Hold camshaft sprocket with Special Tools 2 – SPECIAL TOOL C-4687
C-4687 and C-4687-1 Adapter, while removing bolt
(Fig. 89). Remove both cam sprockets. INSTALLATION
(4) Remove rear timing belt cover fasteners and
(1) Align timing belt tensioner assembly to engine
remove cover from engine (Fig. 90).
and install lower mounting bolt but do not tighten
(5) Remove lower bolt attaching timing belt ten-
(Fig. 91). To properly align tensioner assembly—in-
sioner assembly to engine and remove tensioner as
stall one of the engine bracket mounting bolts (M10)
an assembly (Fig. 91).
5 to 7 turns into the tensioner’s upper mounting loca-
tion (Fig. 91).
Fig. 91 Timing Belt Tensioner Assembly—Removal/

Installation
1 – TIMING BELT TENSIONER ASSEMBLY
2 – TENSIONER ASSEMBLY UPPER BOLT
3 – TENSIONER ASSEMBLY LOWER BOLT
Fig. 90 Rear Timing Belt Cover Fasteners

1 – REAR COVER TO CYLINDER HEAD FASTENERS
CAMSHAFT OIL SEAL—FRONT
2 – REAR COVER TO ENGINE BLOCK FASTENERS
3 – BELT TENSIONER REMOVAL
(1) Remove front timing belt covers and timing
belt. Refer to procedures in this section.
(2) Torque the tensioner’s lower mounting bolt to (2) Hold camshaft sprocket with Special Tools
61 N·m (45 ft. lbs.). Remove the upper bolt used for C-4687 and 4687-1 while removing center bolt (Fig.
tensioner alignment. 92).
(3) Install rear timing belt cover and fasteners. (3) Remove rear timing belt cover. Refer to proce-
(4) Install timing belt idler pulley and tighten dure in this section.
mounting bolt to 61 N·m (45 ft. lbs.). (4) Remove camshaft seal using Special Tool
(5) Install camshaft sprockets. Use Special Tools C-4679-A (Fig. 93).
C-4687 and C-4687-1 Adapter to hold camshaft
sprockets (Fig. 89) and tighten attaching bolts to 101
N·m (75 ft. lbs.).
(6) Install timing belt. Refer to procedure in this
section.
Fig. 92 Camshaft Sprocket—Removal/Installation

1 – ADAPTER C-4687–1
2 – SPECIAL TOOL C-4687
CRANKSHAFT OIL SEAL—FRONT

REMOVAL
(1) Using Special Tool 1026 and Insert 6827-A,
remove crankshaft damper (Fig. 95).
(2) Remove timing belt. Refer to procedures in this
section.
(3) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 96).
CAUTION: Do not nick shaft seal surface or seal

bore.
(4) Using Tool 6771 to remove front crankshaft oil

seal (Fig. 97). Be careful not to damage the seal sur-
face of cover.
Fig. 93 Camshaft Oil Seal—Removal With C-4679-A
CAUTION: Do not nick shaft seal surface or seal

bore
INSTALLATION
(1) Shaft seal surface must be free of varnish, dirt
or nicks. Polish with 400 grit paper if necessary.
(2) Install camshaft seal into cylinder head using
Special Tool MD-998306 until flush with head (Fig.
94).
Fig. 95 Crankshaft Damper—Removal

2 – SPECIAL TOOL 6827–A INSERT
Fig. 94 Camshaft Seal—Installation

1 – SPECIAL TOOL MD 998306
(3) Install rear timing belt cover. Refer to proce-

(4) Install camshaft sprocket. While holding
Fig. 96 Crankshaft Sprocket—Removal
sprocket with Special Tools C-4687 and 4687-1,
tighten center bolt to 101 N·m (75 ft. lbs.) (Fig. 92).
2 – CRANKSHAFT SPROCKET
(5) Install timing belt and front timing belt covers.
Fig. 97 Front Crankshaft Oil Seal—Removal

2 – REAR TIMING BELT COVER
INSTALLATION
(1) Install new seal by using Special Tool 6780
(Fig. 98).
(2) Place seal into opening with seal spring
towards the inside of engine. Install seal until flush
with cover.
(3) Install crankshaft sprocket using Special Tool
6792 (Fig. 99). Fig. 98 Front Crankshaft Oil Seal—Installation
(4) Install timing belt and timing belt covers. Refer 1 – PROTECTOR
to procedures in this section. 2 – SEAL
(5) Install crankshaft damper (Fig. 100). Use 3 – SPECIAL TOOL 6780
thrust bearing/washer and 12M 1.75 x 150 mm bolt
from Special Tool 6792. Install crankshaft damper
bolt and tighten to 142 N·m (105 ft. lbs.).
CRANKSHAFT OIL SEAL—REAR

REMOVAL
(1) Remove transaxle. Refer to TRANSAXLE for
procedure.
(2) Remove flex plate.
(3) Insert a 3/16 flat bladed screwdriver between
the dust lip and the metal case of the crankshaft
seal. Angle the screwdriver (Fig. 101) through the
dust lip against metal case of the seal. Pry out seal.
CAUTION: Do not permit the screwdriver blade to

contact crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (cham-
fer) is permitted.
2 – TIGHTEN NUT TO INSTALL
INSTALLATION
CAUTION: If burr or scratch is present on the
crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installa-
tion of new seal.
NOTE: When installing seal, no lube on seal is

needed.
(1) Place Special Tool 6926-1 Seal Guide on crank-

shaft (Fig. 102).
(2) Position seal over guide tool (Fig. 102). Guide
tool should remain on crankshaft during installation
of seal. Ensure that the lip of the seal is facing
Fig. 100 Crankshaft Damper—Installation towards the crankcase during installation.
1 – M12–1.75 3 150 MM BOLT, WASHER AND THRUST
BEARING FROM SPECIAL TOOL 6792 CAUTION: If the seal is driven into the block past
flush, this may cause an oil leak.
(3) Drive the seal into the block using Special Tool
6926-2 and handle C-4171 (Fig. 103) until the tool
bottoms out against the block (Fig. 104).
Fig. 101 Rear Crankshaft Oil Seal—Removal

1 – REAR CRANKSHAFT SEAL
2 – ENGINE BLOCK
3 – ENGINE BLOCK
Fig. 102 Rear Crankshaft Seal and Special Tool
4 – REAR CRANKSHAFT SEAL METAL CASE
6926-1
5 – PRY IN THIS DIRECTION
1 – SPECIAL TOOL 6926–1 PILOT
6 – CRANKSHAFT
2 – SEAL
7 – SCREWDRIVER
8 – REAR CRANKSHAFT SEAL DUST LIP
9 – SCREWDRIVER
Fig. 103 Crankshaft Seal and Special Tools 6926-2 &

C-4171
1 – SPECIAL TOOL 6926–1 PILOT
2 – SEAL
3 – SPECIAL TOOL 6926–2 INSTALLER
Fig. 104 Rear Crankshaft Seal—Installation
1 – SPECIAL TOOL 6926–2 INSTALLER
(4) Install flex plate. Apply Mopart Lock & Seal
Adhesive to bolt threads and tighten bolts to 95 N·m
(70 ft. lbs.).
(5) Install transaxle. Refer to TRANSAXLE for
procedure.
OIL PAN
REMOVAL
(1) Raise vehicle on hoist and drain engine oil.
(2) Remove right inner splash shield.
(3) Remove bolts attaching dust shield to transaxle
housing. Remove dust shield.
(4) Remove oil pan.
(5) Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Apply Mopart Engine RTV GEN II at the oil Fig. 105 Oil Pan Sealing
pump to engine block parting line (Fig. 105). 1 – PLACE A 3 MM (1/8 INCH.) BEAD OF SEALANT AT THE
PARTING LINE OF THE OIL PUMP BODY TO ENGINE
(2) Install the oil pan gasket to the block (Fig. BLOCK
106).
(3) Install pan and tighten the screws to 12 N·m
(105 in. lbs.).
(4) Install dust shield.
(5) Lower vehicle and fill engine crankcase with
proper oil to correct level.
INSTALLATION
Fig. 106 Oil Pan Gasket Installation

1 – OIL PICK-UP TUBE
2 – OIL PAN GASKET
3 – SEALER Fig. 107 Installing Main Bearing Upper Shell
1 – LUBRICATION GROOVES
2 – OIL HOLES
CRANKSHAFT
(1) Install the main bearing shells with the lubri-
REMOVAL cation groove in the cylinder block (Fig. 107).
(2) Make certain oil holes in block line up with oil
NOTE: Crankshaft can not be removed when
hole in bearings and bearing tabs seat in the block
engine is in vehicle.
tab slots.
(1) Remove engine assembly from vehicle. Refer to
CAUTION: Do not get oil on the bedplate mating
procedure in this section.
surface. It will may effect the sealer ability to seal
(2) Separate engine from transaxle.
the bedplate to cylinder block.
(3) Remove flex plate and crankshaft rear oil seal.
(4) Mount engine on a repair stand. (3) Oil the bearings and journals. Install crank-
(5) Remove oil filter and oil pan. Refer to proce- shaft.
(6) Remove timing belt cover, timing belt and oil CAUTION: Use only the specified anaerobic sealer
pump. Refer to procedures in this section. on the bedplate or damage may occur to the
(7) Remove balance shafts assembly. Refer to pro- engine.
cedure in this section.
(8) Remove all main bearing cap bedplate bolts (4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of
from the engine block. Refer to procedure in this sec- Mopart Bed Plate Sealant to cylinder block as shown
tion. in (Fig. 108).
(9) Using a mallet gently tap the bedplate loose (5) Install lower main bearings into main bearing
from the engine block dowel pins. cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots. Install the main bear-
CAUTION: Do not pry up on one side of the bed- ing/bedplate into engine block.
plate. Damage may occur to cylinder block to bed- (6) Before installing the bolts the threads should
plate alignment and thrust bearing. be oiled with clean engine oil, wipe off any excess oil.
(10) Bedplate should be removed evenly from the bolts 11, 17, and 20 finger tight. Tighten these bolts
cylinder block dowel pins to prevent damage to the down together until the bedplate contacts the cylin-
dowel pins and thrust bearing. der block.
(11) Lift out crankshaft from cylinder block. Do not (8) To ensure correct thrust bearing alignment,
damage the main bearings or journals when remov- perform the following steps:
ing the crankshaft. • Step 1: Rotate crankshaft until number 4 piston
is at TDC.
(15) Install crankshaft rear oil seal. Refer to proce-
Adhesive to bolt threads and tighten to 95 N·m (70
ft. lbs.).
(17) Attach transaxle to engine. Tighten attaching
bolts to 101 N·m (75 ft. lbs.).
(18) Install engine assembly. Refer to procedure in
this section.
OIL FILTER
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall tool band strap against the can to base lock
Fig. 108 Bedplate Sealing seam. The lock seam joining the can to the base is
reinforced by the base plate.
(1) Turn counterclockwise to remove.

(2) To install, lubricate new filter gasket. Check
filter mounting surface. The surface must be smooth,
flat and free of debris or old pieces of rubber. Screw
filter on until the gasket contacts base. Tighten to 21
N·m (15 ft. lbs.).
OIL PUMP
REMOVAL
(2) Remove Timing Belt. Refer to procedure in this
section.
Fig. 109 Bedplate Torque Sequence (3) Remove Oil Pan. Refer to procedure in this sec-
• Step 2: Move crankshaft rearward to limits of tion.
travel. (4) Remove Crankshaft Sprocket using Special Tool
• Step 3: Then, move crankshaft forward to limits 6793 and insert C-4685-C2 (Fig. 110).
of travel.
• Step 4: Wedge an appropriate tool between the
rear of the cylinder block (NOT BED PLATE) and
the rear crankshaft counterweight. This will hold the
crankshaft in it’s furthest forward position.
• Step 5: Install and tighten bolts (1 – 10) in
sequence shown in (Fig. 109) to 41 N·m (30 ft. lbs.).
• Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1 – 10) again to 41 N·m (30 ft.
lbs.) +1/4 turn in sequence shown in (Fig. 109).
bolts (11 through 20), and torque each bolt to 28 N·m
(20 ft. lbs.) in sequence shown in (Fig. 109).
(11) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N·m (50 in. lbs.). Fig. 110 Crankshaft Sprocket—Removal
(12) Install balance shaft assembly. 1 – SPECIAL TOOL 6793
(13) Install oil pump, timing belt and covers. 2 – CRANKSHAFT SPROCKET
(14) Install oil pan and oil filter.
Fig. 111 Oil Pump and Pick-up Tube

1 – OIL PAN GASKET 5 – OIL PICK-UP TUBE
2 – O-RING 6 – DRAIN PLUG
3 – OIL PUMP BODY 7 – OIL PAN
4 – FILTER
(5) Remove oil pick-up tube.

(6) Remove oil pump, (Fig. 111) and front crank-
shaft seal.
INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.
(2) Apply Mopart Gasket Maker to oil pump as
shown in (Fig. 112). Install oil ring into oil pump
body discharge passage.
(3) Prime oil pump before installation.
(4) Align oil pump rotor flats with flats on crank-
shaft as you install the oil pump to the block.
NOTE: Front crankshaft seal MUST be out of pump

to align, or damage may result.
Fig. 112 Oil Pump Sealing
1 – APPLY GASKET MAKER TO OIL PUMP BODY FLANGE
(5) Install new front crankshaft seal using Special
Tool 6780 (Fig. 113).

2 – TIGHTEN NUT TO INSTALL
Fig. 113 Front Crankshaft Seal—Installation

1 – PROTECTOR
2 – SEAL
Fig. 115 Piston Markings

(6) Install crankshaft sprocket using Special Tool 1 – DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA
6792 (Fig. 114).
(7) Install oil pump pick-up tube.
(2) Remove oil pan. Scribe the cylinder number on
(8) Install oil pan. Refer to procedure in this sec-
the side of the rod and cap (Fig. 116) for identifica-
tion.
tion.
(9) Install Timing Belt. Refer to procedure in this
(3) Pistons have a directional stamping in the
section.
front half of the piston facing towards the front of
engine.
PISTON AND CONNECTING ROD (4) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
REMOVAL
each connecting rod is centered in cylinder bore.
NOTE: Cylinder Head must be removed before Pis- (5) Remove Balance Shaft Assembly. Refer to Bal-
tons and Rods. Refer to Cylinder Head Removal in ance Shaft Removal in this section.
this section. (6) Remove connecting rod cap bolts. Push each
piston and rod assembly out of cylinder bore.
(1) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl- NOTE: Be careful not to nick crankshaft journals.
inder block. Be sure to keep tops of pistons
(7) After removal, install bearing cap on the mat-
covered during this operation. Mark piston with
ing rod.
matching cylinder number (Fig. 115).
(8) Piston and Rods are serviced as an assembly.
Fig. 116 Identify Connecting Rod to Cylinder

Fig. 118 Piston—Installation
INSTALLATION
(1) Before installing pistons and connecting rod (6) Tap the piston down in cylinder bore, using a
assemblies into the bore, be sure that compression hammer handle. At the same time, guide connecting
ring gaps are staggered so that neither is in line with rod into position on connecting rod journal.
oil ring rail gap.
(2) Before installing the ring compressor, make NOTE: The connecting rod cap bolts should not be
sure the oil ring expander ends are butted and the reused.
rail gaps located as shown in (Fig. 117). As viewed
(7) Before installing the NEW bolts the threads
from top.
should be coated with clean engine oil.
(8) Install each bolt finger tight than alternately
torque each bolt to assemble the cap properly.
CAUTION: Do not use a torque wrench for second

part of last step.
(9) Tighten the bolts to 27 N·m PLUS 1/4 turn (20

ft. lbs. PLUS 1/4 turn).
(10) Using a feeler gauge, check connecting rod
side clearance (Fig. 119).
Fig. 117 Piston Ring End Gap Position

1 – GAP OF LOWER SIDE RAIL
2 – NO. 1 RING GAP
3 – GAP OF UPPER SIDE RAIL
4 – NO. 2 RING GAP AND SPACER EXPANDER GAP
(3) Immerse the piston head and rings in clean

engine oil, slide the ring compressor, over the piston
(Fig. 118). Be sure position of rings does not
change during this operation.
(4) The directional stamp on the piston should face
toward the front of the engine (Fig. 115). Fig. 119 Checking Connecting Rod Side Clearance
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston assembly into cylinder bore and guide
rod over the crankshaft journal.
ENGINE CORE AND OIL GALLERY PLUGS DISASSEMBLY AND ASSEMBLY

REMOVAL OIL PUMP
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup DISASSEMBLY
plug rotated, grasp firmly with pliers or other suit- (1) To remove the relief valve, proceed as follows:
able tool and remove plug (Fig. 120). (a) Remove the threaded retainer cap and gasket
from the oil pump (Fig. 121).
CAUTION: Do not drive cup plug into the casting (b) Remove spring and relief valve.
as restricted flow can result and cause serious
engine problems.
Fig. 121 Oil Pressure Relief Valve

1 – GASKET
2 – RETAINER CAP
Fig. 120 Core Hole Plug Removal 3 – SPRING
1 – CYLINDER BLOCK 4 – OIL PUMP BODY
2 – REMOVE PLUG WITH PLIERS 5 – RELIEF VALVE
3 – STRIKE HERE WITH HAMMER
4 – DRIFT PUNCH (2) Remove oil pump cover screws, and lift off
5 – CUP PLUG
cover.
(3) Remove pump rotors.
INSTALLATION (4) Wash all parts in a suitable solvent and inspect
Thoroughly clean inside of cup plug hole in cylin- carefully for damage or wear.
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopart ASSEMBLY
Stud & Bearing Mount or equivalent. Make certain (1) Assemble pump, using new parts as required.
the new plug is cleaned of all oil or grease. Using a Install the inner rotor with chamfer facing the
proper drive tool, drive plug into oil gallery hole so cast iron oil pump cover.
that the sharp edge of the plug is at least 0.5 mm (2) Prime oil pump before installation by filling
(0.020 in.) inside the lead-in chamfer. rotor cavity with engine oil.
(3) Install cover and tighten screws to 12 N·m (105
in. lbs.).
CAUTION: Oil pump pressure relief valve must be

installed as shown in (Fig. 121) or serious damage
may occur.
(4) Install relief valve, spring, gasket and cap as

shown in (Fig. 121). Tighten retainer cap to 41 N·m
(30 ft. lbs.).
CLEANING AND INSPECTION Clean all engine oil passages.

INTAKE MANIFOLD preparation must be performed, especially with the
CLEANING steel cylinder head gaskets.
Remove the gasket material from the manifold sur-
NOTE: Multi-Layer Steel (MLS) head gaskets
faces.
require a scratch free sealing surface.
Be careful not to gouge or scratch the sealing sur-
face. Use only the following for cleaning gasket surfaces:
• Solvent or a commercially available gasket
INSPECTION remover
Check for: • Plastic or wood scraper (Fig. 123)
• Damage and cracks of each section. • Drill motor with 3M Rolocy Bristle Disc (white
• Clogged water passages in end cross-overs (if or yellow) (Fig. 123)
equipped).
• Check for cylinder head mounting surface distor- CAUTION: Excessive pressure or high RPM can
tion using a straightedge and thickness gauge. Refer damage the sealing surfaces. The mild (white, 120
to Cylinder Head—Inspection. grit) bristle disc is recommended. If necessary, the
medium (yellow, 80 grit) bristle disc may be used
EXHAUST MANIFOLD on cast iron surfaces with care.
CLEANING
faces (if equipped). Be careful not to gouge or scratch
the sealing surface.
INSPECTION
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust cross-over mounting surface
with a straightedge and thickness gauge (Fig. 122).
Fig. 123 Proper Tool Usage For Surface Preparation

1 – ABRASIVE PAD
2 – 3M ROLOCY BRISTLE DISC
3 – PLASTIC/WOOD SCRAPER
INSPECTION
(1) Cylinder head must be flat within 0.1 mm
Fig. 122 Check Exhaust Manifold Mounting (0.004 in.) (Fig. 124).
1 – CROSSOVER PIPE MOUNTING SURFACE (2) Inspect camshaft bearing journals for scoring.
CYLINDER HEAD VALVE GUIDES

(1) Remove carbon and varnish deposits from
CLEANING inside of valve guides with a reliable guide cleaner.
Remove all gasket material from cylinder head and (2) Using a small hole gauge and a micrometer,
block. Be careful not to gouge or scratch the alumi- measure valve guides in 3 places top, middle and bot-
num head sealing surface. tom (Fig. 125). Refer to Engine Specifications.
Replace guides if they are not within specification.
CLEANING AND INSPECTION (Continued)

Fig. 124 Checking Cylinder Head Flatness 1 – VALVE GUIDE
1 – FEELER GAUGE 2 – 13.25 - 13.75 MM (.521 -.541 IN.)
2 – STRAIGHT EDGE 3 – SPRING SEAT
(3) Check valve guide height (Fig. 126). VALVE SPRINGS

(1) Whenever valves have been removed for inspec-
tion, reconditioning or replacement, valve springs
should be tested for correct tension. Discard the
springs that do not meet specifications. The following
specifications apply to both intake and exhaust
valves springs:
• Valve Closed Nominal Tension—76 lbs. @ 38.0
mm (1.50 in.)
• Valve Open Nominal Tension—136 lbs. @ 29.75
mm (1.17 in.)
(2) Inspect each valve spring for squareness with a
Fig. 125 Checking Wear on Valve Guide—Typical steel square and surface plate, test springs from both
1 – TOP ends. If the spring is more than 1.5 mm (1/16 inch)
2 – MIDDLE out of square, install a new spring.
3 – BOTTOM
4 – CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS CRANKSHAFT
INSPECTION
VALVE AND VALVE SPRING The crankshaft journals should be checked for
excessive wear, taper and scoring (Fig. 127). Limits of
VALVES taper or out-of-round on any crankshaft journals
(1) Clean valves thoroughly and discard burned, should be held to.025 mm (.001 inch). Journal grind-
warped and cracked valves. ing should not exceed.305 mm (.012 inch) under the
(2) Measure valve stems for wear. Measure stem standard journal diameter. DO NOT grind thrust
about 60 mm beneath the valve lock grooves. faces of Number 3 main bearing. DO NOT nick
(3) If valve stems are worn more than 0.05 mm crank pin or bearing fillets. After grinding, remove
(0.002 in.), replace the valve. 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.
Fig. 128 Oil Pump

1 – O-RING
2 – SEAL
3 – INNER ROTOR
Fig. 127 Crankshaft Journal Measurements 4 – OIL PUMP COVER
5 – FASTENER
OIL PUMP
6 – OUTER ROTOR
7 – OIL PUMP BODY
CLEANING
Clean all parts thoroughly.
INSPECTION
(1) Inspect the mating surface of the oil pump.
Surface should be smooth (Fig. 128). Replace pump
cover if scratched or grooved.
(2) Lay a straightedge across the pump cover sur-
face (Fig. 129). If a 0.025 mm (0.001 in.) feeler gauge
can be inserted between cover and straight edge,
cover should be replaced.
(3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 9.40 mm (0.370 in.)
or less (Fig. 130), or if the diameter is 79.95 mm
(3.148 in.) or less, replace outer rotor.
(4) If inner rotor measures 9.40 mm (0.370 in.) or
less replace inner rotor (Fig. 131).
(1) Slide outer rotor into pump housing, press to
one side with fingers and measure clearance between Fig. 129 Checking Oil Pump Cover Flatness
1 – STRAIGHT EDGE
rotor and housing (Fig. 132). If measurement is 0.39
2 – FEELER GAUGE
mm (0.015 in.) or more, replace housing only if outer
3 – OIL PUMP COVER
rotor is in specification.
(2) Install inner rotor into pump housing. If clear-
ance between inner and outer rotors (Fig. 133) is (4) Inspect oil pressure relief valve plunger for
0.203 mm (0.008 in.) or more, replace both rotors. scoring and free operation in its bore. Small marks
(3) Place a straightedge across the face of the may be removed with 400 grit wet or dry sandpaper.
pump housing, between bolt holes. If a feeler gauge (5) The relief valve spring has a free length of
of 0.102 mm (0.004 in.), or more can be inserted approximately 60.7 mm (2.39 inches) it should test
between rotors and the straightedge, replace pump between 18 and 19 pounds when compressed to 40.5
assembly (Fig. 134), ONLY if rotors are in specifica- mm (1.60 inches). Replace spring that fails to meet
tions. specifications.
Fig. 130 Measuring Outer Rotor Thickness Fig. 133 Measuring Clearance Between Rotors
1 – FEELER GAUGE
2 – INNER ROTOR
3 – OUTER ROTOR
Fig. 131 Measuring Inner Rotor Thickness

(6) If oil pressure is low and pump is within spec-
ifications, inspect for worn engine bearings or other
reasons for oil pressure loss. Fig. 134 Measuring Clearance Over Rotors
1 – FEELER GAUGE
2 – STRAIGHT EDGE
CYLINDER BLOCK
CLEANING
Clean cylinder block thoroughly.
INSPECTION
Inspect all core hole plugs for evidence of leaking
and replace as necessary. Examine block and cylinder
bores for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Tool C119 (Fig. 135). The cyl-
inder bore out-of-round is 0.050 mm (0.002 in.)
maximum and cylinder bore taper is 0.051 mm (0.002
Fig. 132 Measuring Outer Rotor Clearance in Housing
in.) maximum. If the cylinder walls are badly scuffed
1 – FEELER GAUGE
or scored, the cylinder block should be replaced, and
2 – OUTER ROTOR
new pistons and rings fitted.
DESCRIPTION SPECIFICATION
Cylinder Block
Cylinder Bore Diameter 87.4924–87.5076 mm
(3.4446–3.4452 in.)
Out-of-Round (Max.) 0.051 mm
(0.002 in.)
Taper (Max.) 0.051 mm
(0.002 in.)
Pistons
Piston Diameter 87.463–87.481 mm
(3.4434–3.4441 in.)
Clearance @ 14 mm 0.024–0.057 mm
(9/16 in.) from bottom of
skirt (0.0009–0.0022 in.)
Weight 332–346 grams
(11.85–12.20 oz.)
Fig. 135 Checking Cylinder Bore Size Land Clearance 0.614–0.664 mm

(Diametrical) (0.024–0.026 in.)
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 135). Top measurement should be Piston Length 60.3 mm
10 mm (3/8 in.) down and bottom measurement (2.374 in.)
should be 10 mm (3/8 in.) up from bottom of bore. Piston Ring Groove 4.640–4.784 mm
Refer to Engine Specifications. Depth No. 1 (0.182–0.188 in.)
Piston Ring Groove 4.575–4.719 mm
SPECIFICATIONS Depth No. 2 (0.180–0.185 in.)
2.4L ENGINE Piston Ring Groove 4.097–4.236 mm
Depth No. 3 (0.161–0.166 in.)
DESCRIPTION SPECIFICATION Piston Pins
General Specification Clearance in Piston 0.005–0.018 mm
Type In-Line OHV, DOHC (0.0002–0.0008 in.)
Number of Cylinders 4 Clearance in Connecting Interference
Rod
Displacement 2.4 Liters
Diameter 21.998–22.003 mm
(148 cu. in.)
(0.8660–0.8662 in.)
Bore 87.5 mm
End Play None
(3.445 in.)
Length 72.75–73.25 mm
Stroke 101.0 mm
(2.864–2.883 in.)
(3.976 in.)
Piston Rings
Compression Ratio 9.4:1
Ring Gap—Top 0.25–0.51 mm
Firing Order 1-3-4-2
Compression Ring (0.0098–0.020 in.)
Compression Pressure 1172–1551 kPa
Wear Limit 0.8 mm
(170–225 psi)
(0.031 in.)
Max. Variation Between 25%
Cylinders Ring Gap—2nd 0.23–0.48 mm
Compression Ring (0.009–0.018 in.)
SPECIFICATIONS (Continued)
DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Wear Limit 0.8 mm Wear Limit 0.37 mm
(0.031 in.) (0.015 in.)
Ring Gap—Oil Control 0.25–0.64 mm Main Bearing Diametrical 0.018–0.058 mm
Steel Rails (0.0098–0.025 in.) Clearance (0.0007–0.0023 in.)
Wear Limit 1.0 mm Hydraulic Lash Adjuster
(0.039 in.) Body Diameter 15.901–15.913 mm
Ring Side Clearance— 0.030–0.080 mm (0.626–0.6264 in.)
Compression Rings (0.0011–0.0031 in.) Plunger Travel Minimum 3.0 mm
Wear Limit 0.10 mm (Dry) (0.118 in.)
(0.004 in.) Cylinder Head Camshaft Bearing Bore Diameter
Ring Side Clearance—Oil 0.012–0.178 mm Journals No.1–6 26.020–26.041 mm
Ring Pack (0.0004–0.0070 in.) (1.024–1.025 in.)
Ring Width— 1.47–1.50 mm
Camshaft
Compression Rings (0.057–0.059 in.)
Journal Diameter No. 1–6 25.951–25.970 mm
Ring Width—Oil Ring 2.72–2.88 mm
Pack (1.021–1.022 in.)
(0.107–0.1133 in.)
Bearing Clearance— 0.069–0.071 mm
Connecting Rod Diametrical (0.0027–0.003 in.)
Bearing Clearance 0.025–0.071 mm
End Play 0.05–0.17 mm
(0.0009–0.0027 in.)
(0.0019–0.0066 in.)
Wear Limit 0.075 mm
Lift (Zero Lash)
(0.003 in.)
Intake 8.25 mm
Bore Diameter—Piston 20.96–20.98 mm
(0.324 in.)
Pin (0.8252–0.8260 in.)
Exhaust 6.52 mm
Bore Diameter— 53.007–52.993 mm
(0.256 in.)
Crankshaft End (2.0868–2.0863 in.)
Intake Valve Timing*
Side Clearance 0.13–0.38 mm
Closes (ABDC) 51°
(0.005–0.015 in.)
Opens (BTDC) 1°
Wear Limit 0.40 mm
Duration 232°
(0.016 in.)
Exhaust Valve Timing*
Weight—Total (Less 565.8 grams
Bearing) (19.96 oz.) Closes (ATDC) 8°
Opens (BBDC) 52°
Crankshaft
Duration 240°
Connecting Rod Journal 49.984–50.000 mm
Diameter Valve Overlap 9°
(1.968–1.9685 in.)
*All readings in crankshaft degrees, at 0.5 mm (0.019
Main Bearing Journal 59.992–60.008 mm
in.) of valve lift.
Diameter (2.362–2.3625 in.)
Cylinder Head
Journal Out-of-Round 0.0035 mm
(Max.) Material Cast Aluminum
(0.0001 in.)
Gasket Thickness 1.15 mm
Journal Taper (Max.) 0.0038 mm
(Compressed) (0.045 in.)
(0.0001 in.)
End Play 0.09–0.24 mm Valve Seat
(0.0035–0.0094 in.) Angle 45°

Seat Diameter—Intake 33 mm Exhaust 0.985–1.315 mm
(1.299 in.) (0.038–0.051 in.)
Seat Diameter—Exhaust 28 mm Service Limit 1.05 mm
(1.102 in.) (3/64 in.)
Runout (Max.) 0.05 mm Valve Stem Tip Height
(0.002 in.) Intake 48.04 mm
Valve Seat Width—Intake 0.9–1.3 mm (1.891 in.)
and Exhaust (0.035–0.051 in.) Exhaust 47.99 mm
Service Limit—Intake 2.0 mm (1.889 in.)
(0.079 in.)
Valve Stem to Guide Clearance
Service Limit—Exhaust 2.5 mm
Intake 0.048–0.066 mm
(0.098 in.)
(0.0018–0.0025 in.)
Valve Guide Max. Allowable 0.076 mm
Diameter I. D. 5.975–6.000 mm (0.003 in.)
(0.235–0.236 in.) Service Limit 0.25 mm
Guide Bore Diameter 11.0–11.02 mm (0.010 in.)
(0.4330–0.4338 in.) Exhaust 0.0736–0.094 mm
Guide Height (spring seat 13.25–13.75 mm (0.0029–0.0037 in.)
to guide tip) (0.521–0.541 in.) Max. Allowable 0.101 mm
Valves (0.004 in.)
Face Angle—Intake and 44.5—45° Service Limit 0.25 mm
Exhaust (0.010 in.)
Head Diameter—Intake 34.67–34.93 mm
Valve Springs
1.364–1.375 in.)
Free Length (Approx.) 48.4 mm
Head Diameter—Exhaust 30.37–30.63 mm
(1.905 in.)
(1.195–1.205 in.)
Nominal Force (Valve 338 N @ 38.0 mm
Valve Length (Overall) Closed) (75.98 lbs. @ 1.496 in.)
—Intake 112.76–113.32 mm
Nominal Force (Valve 607 N @ 29.75 mm
(4.439–4.461 in.) Open) (136 lbs. @ 1.172 in.)
—Exhaust 109.59–110.09 mm Installed Height 38.00 mm
(4.314–4.334 in.) (1.496 in.)
Valve Stem Diameter Number of Coils 7.82
—Intake 5.934–5.952 mm Wire Diameter 3.86 mm
(0.2337–0.2344 in.) (1.496 in.)
—Exhaust 5.906–5.924 mm Oil Pump
(0.2326–0.2333 in.) Clearance Over Rotors 0.10 mm
Valve Margin (Max.)
Intake 1.285–1.615 mm (0.004 in.)
(0.050–0.063 Cover Out-of-Flat (Max.) 0.025 mm
Service Limit 0.95 mm (0.001 in.)
(1/32 in.) Inner Rotor Thickness 9.40 mm
(Min.)
DESCRIPTION SPECIFICATION DESCRIPTION N·m Ft. In.

(0.370 in.) Lbs. Lbs.
Outer Rotor Thickness 9.40 mm Cylinder Head—Bolts Refer to Procedure
(Min.) Cylinder Head Cover— 12 — 105
(0.370 in.) Bolts
Outer Rotor Clearance 0.039 mm Drive Plate to Crankshaft 95 70 —
(Max.) Engine Mount Bracket 61 45 —
Right—Bolts
(0.015 in.)
Engine Mount Front and
Outer Rotor Diameter 79.95 mm 61 45 —
Rear—Through Bolt
(Min.)
Engine Mount Front
(3.148 in.) 33 24 —
Bracket to Engine—Bolts
Tip Clearance Between 0.20 mm
Engine Mount Front
Rotors (Max.) (0.008 in.) Bracket Strut
Oil Pressure —Long Bolts 110 80 —
At Curb Idle Speed* 25 kPa —Short Bolts 61 45 —
(4 psi) Engine Mount Rear
110 80 —
At 3000 rpm 170–550 kPa Bracket—Bolts
(25–80 psi) Exhaust Manifold to 23 — 200
Cylinder Head—Bolts
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm. Exhaust Manifold Heat 12 — 105
Shield—Bolts
TORQUE Intake Manifold—Bolts 27 20 —
Oil Filter 20 15 —
DESCRIPTION N·m Ft. In. Oil Pan—Bolts 12 — 105
Lbs. Lbs. Oil Pan Drain—Plug 27 20 —
Balance Shaft Carrier to 54 40 — Oil Pump to Block—Bolts 28 — 250
Block—Bolts Oil Pump Cover 12 — 105
Balance Shaft Gear 12 — 105 Plate—Bolts
Cover—Double Ended Oil Pump Pick-up 28 — 250
Fastener Tube—Bolt
Balance Shaft Sprocket— 28 — 250 Oil Pump Relief 41 30 —
Bolt Valve—Cap
Balance Shaft Chain 12 — 105 Spark Plugs 28 — 250
Tensioner—Bolts
Timing Belt Covers
Balance Shaft Carrier 12 — 105
Cover—Bolts —Outer Cover to Inner 4.5 — 40
Cover Bolts
Camshaft Sprocket—Bolt 101 75 —
—Inner Cover Bolts 12 — 105
Connecting Rod 27 +1⁄4 20 —
Cap—Bolts turn +1⁄4 Timing Belt Tensioner 61 45 —
turn Assembly—Bolts
Crankshaft Main Bearing
Cap/Bedplate
—M8 Bolts 34 — 250
—M11 Bolts 41 +1⁄4 30 —
Turn +1⁄4
Turn
Crankshaft Damper 136 100 —
SPECIAL TOOLS
2.4L ENGINE
Post Kit Engine Cradle 6848
Puller 1026
Camshaft Sprocket Remover/Installer C-4687
Crankshaft Damper Removal Insert 6827-A
Camshaft Sprocket Remover/Installer Adapter

C-4687-1
Dolly 6135
Camshaft Seal Remover C-4679-A
Cradle 6710
Camshaft Seal Installer MD-998306

SPECIAL TOOLS (Continued)
Crankshaft Damper Installer 6792 Crankshaft Sprocket Remover Insert C-4685-C2
Crankshaft Seal Remover 6771

Valve Spring Compressor MD-998772-A
Rear Crankshaft Seal Guide and Installer 6926-1 and

6926-2
Valve Spring Compressor Adapter 6779
Cylinder Bore Gage C-119

Balance Shaft Sprocket Installer 6052
Crankshaft Sprocket Remover 6793
Post Kit Engine Cradle 6848

Adaptor 8406
Post Adapter 8130
Cooling System Tester 7700
Front Crankshaft Oil Seal Installer 6780
Combustion Leak Tester C-3685-A
Oil Pressure Gage C-3292
Adaptor 8116
3.0L ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION

3.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . 91
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 70 ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 93
PISTON AND CONNECTING ROD . . . . . . . . . . . . 70 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 94
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 72 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . 98
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 CRANKSHAFT DAMPER . . . . . . . . . . . . . . . . . . . 99
ROCKER ARMS AND SHAFTS . . . . . . . . . . . . . . . 73 CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . 99
VALVE AND VALVE SPRING . . . . . . . . . . . . . . . . 73 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 73 ROCKER ARMS AND SHAFTS . . . . . . . . . . . . . . 101
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . 73 LASH ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . 102
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . 73 CAMSHAFT SEAL . . . . . . . . . . . . . . . . . . . . . . . 102
DIAGNOSIS AND TESTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 103
ENGINE DIAGNOSIS—INTRODUCTION. . . . . . . . 76 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
ENGINE DIAGNOSIS—PERFORMANCE . . . . . . . 76 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
ENGINE DIAGNOSIS—MECHANICAL . . . . . . . . . 78 PISTON AND CONNECTING ROD . . . . . . . . . . . 108
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 79 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 111
CYLINDER COMPRESSION PRESSURE TEST . . 80 CRANKSHAFT OIL SEAL AND RETAINER—
CYLINDER COMBUSTION PRESSURE REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 80 CRANKSHAFT OIL SEAL—FRONT . . . . . . . . . . . 115
CYLINDER HEAD GASKET FAILURE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 OIL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
LASH ADJUSTER (TAPPET) NOISE OIL FILTER ADAPTER . . . . . . . . . . . . . . . . . . . . 116
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 ENGINE CORE AND OIL GALLERY PLUGS . . . . 117
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . . 81 DISASSEMBLY AND ASSEMBLY
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . 82 ROCKER ARMS AND SHAFTS . . . . . . . . . . . . . . 117
SERVICE PROCEDURES CLEANING AND INSPECTION
ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
ENGINE OIL SERVICE . . . . . . . . . . . . . . . . . . . . . 83 ROCKER ARMS AND SHAFTS . . . . . . . . . . . . . . 120
FORM-IN-PLACE GASKETS & SEALERS . . . . . . . 84 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 121
ENGINE GASKET SURFACE PREPARATION . . . . 85 CYLINDER BORE. . . . . . . . . . . . . . . . . . . . . . . . 121
HYDROSTATIC LOCKED ENGINE . . . . . . . . . . . . 85 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
LASH ADJUSTER. . . . . . . . . . . . . . . . . . . . . . . . . 85 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
CYLINDER BORE—HONING . . . . . . . . . . . . . . . . 86 SPECIFICATIONS
CRANKSHAFT MAIN BEARING—FITTING . . . . . . 86 3.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
CRANKSHAFT END PLAY . . . . . . . . . . . . . . . . . . 88 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
CONNECTING ROD AND BEARING—FITTING. . . 88 SPECIAL TOOLS
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . 89 3.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
DESCRIPTION AND OPERATION The firing order is 1–2–3–4–5–6. The cylinders are
numbered from the front of the engine to the rear.
3.0L ENGINE The front cylinder bank is numbered 2, 4, and 6. The
rear cylinder bank is numbered 1, 3, and 5.
DESCRIPTION The engine identification number is located on the
The 3.0 Liter (181 cu. in.) 60° V-6 engine is a single rear of the cylinder block just below the cylinder
overhead camshaft (per bank) design (Fig. 1). The head (Fig. 2).
engine does have free-wheeling valve train.
Fig. 1 3.0L Engine

CYLINDER BLOCK
DESCRIPTION
The cast iron cylinder block is a partial open
design to improve cooling and weight reduction (Fig.
3). High rigidity is provided with ribs cast in the
outer wall, and a monoblock or beam type main bear-
ing cap system. This single unit four bearing main
cap is designed to control vibration of the cylinder
block partition walls.

DESCRIPTION
The pistons are made of aluminum alloy with
cast-in steel struts at the pin bosses for autothermic
control (Fig. 4). The piston rings consist of a chrome-
plated, barrel faced design for the top ring, the sec-
ond ring is a cast iron tapered face design and the oil
ring is a chrome faced three piece design. Piston pins
are press-fitted into place, to join the pistons to the
Fig. 2 Engine Identification forged steel connecting rods. The large end of the
1 – 3.0L ENGINE connecting rod has a oil jet hole for lubrication of the
thrust side of the cylinder.
Fig. 3 Cylinder Block and Crankshaft

1 – GASKET 5 – THRUST BEARINGS (2 PAIRS)
2 – SEAL 6 – MAIN BEARING MONOBLOCK CAP
3 – CASE 7 – SEAL
4 – UPPER BEARING (GROOVED) 8 – OIL PUMP ASSEMBLY
Fig. 4 Piston and Connecting Rod

CYLINDER HEAD CAMSHAFT

The aluminum alloy cylinder heads feature cross- Two overhead camshafts provide valve actuation,
flow type intake and exhaust ports (Fig. 5). Valve one front (radiator side of cylinder bank) and one
guides and inserts are hardened cast iron. Valves of rear (Fig. 5). The front camshaft is provided with a
heat resistance steel are arranged in a V with each distributor drive and is longer. Both camshafts are
camshaft on center. To improve combustion speed the supported by four bearing journals, thrust for the
chambers are a compact spherical design with a front camshaft is taken at journal two and the rear
squish area of approximately 30 percent of the piston at journal three. Front and rear camshaft driving
top area. The cylinder heads are common to either cyl- sprockets are interchangeable.
inder bank by reversing the direction of installation.
OPERATION
OPERATION The camshafts are driven by the crankshaft via
The cylinder head closes the combustion chamber, drive sprockets and a belt. The camshafts have pre-
allowing the pistons to compress the air/fuel mixture cisely machined lobes to provide accurate valve tim-
for ignition. The valves are actuated by the lobe pro- ing and duration.
duration to either allow clean air in the combustion
chamber or the exhaust gases out; depending on the
stroke of the engine.
Fig. 5 Cylinder Heads and Camshafts

1 – BREATHER HOSE 6 – COVER
2 – ROCKER COVER 7 – O-RING
3 – ROCKER ARM SHAFT ASSEMBLY 8 – DISTRIBUTOR ADAPTOR
4 – ROCKER COVER 9 – SEAL
5 – LASH ADJUSTER 10 – CAMSHAFT (REAR)
ROCKER ARMS AND SHAFTS EXHAUST MANIFOLD

The rocker arms are made of light weight die-cast The exhaust manifolds are a log style made of duc-
with roller type follower operating against the cam- tile cast iron.
shaft (Fig. 5). The valve actuating end of the rocker
arms are machined to retain hydraulic lash adjust- OPERATION
ers, eliminating valve lash adjustment. The exhaust manifold collects the exhaust gasses
The shafts are retained by the camshaft bearing exiting the combustion chambers. Exhaust gasses col-
journal caps. Four rocker shafts are used, one for lected from the front cylinder bank leave the front
each intake and exhaust rocker arm assembly on manifold through an end outlet and are fed through
each cylinder head. The hollow shafts provide a duct an upper crossover tube to the rear manifold. The
for lubricating oil flow from the cylinder head to the collected exhaust gasses from both manifolds are
valve mechanisms. combined and exit to the exhaust pipe through an
articulated joint.
VALVE AND VALVE SPRING
ENGINE LUBRICATION SYSTEM
DESCRIPTION
The valves are made of heat resistant steel. The DESCRIPTION
valve springs are especially designed to be short. The The lubrication system is a full flow filtration pres-
valve spring wire cross-section is oval shaped and pro- sure feed type. The trochoid type oil pump is
vides the same spring tension as longer springs. Valve mounted to the front of the engine block and is
spring retainers, locks and seals are conventional. directly coupled to the crankshaft.
INTAKE MANIFOLD OPERATION

Engine oil, stored in the oil pan, is taken in and
DESCRIPTION discharged by the oil pump. Oil pressure is regulated
The aluminum alloy manifold is a cross type with by a relief valve located in the oil pump housing. The
long runners to improve inertia (Fig. 6). The runners, oil is fed through an oil filter and to the crankshaft
attaching below at the cylinder head, also attach journals from the oil gallery in the cylinder block.
above and support an air plenum. The air plenum This gallery also feeds oil under pressure to the cyl-
chamber absorbs air pulsations created during the inder heads and camshaft journals. It then flows
suction phase of each cylinder. from the cylinder head passages to the rocker shafts
to the rocker arm pivots and auto lash adjusters (Fig.
OPERATION 7).
The intake manifold directs and delivers air to the
combustion chambers. This air allows the fuel deliv-
ered by the fuel injectors to ignite, thus producing
power.
Fig. 6 Intake and Exhaust Manifold

1 – AIR INTAKE PLENUM 10 – GASKET (MANIFOLD)
2 – 15 N·m (130 IN. LBS.) 11 – 69 N·m (51 FT. LBS.)
3 – 20 N·m (174 IN. LBS.) 12 – GASKET
4 – EXHAUST CROSSOVER PIPE 13 – REAR EXHAUST MANIFOLD
5 – GASKET (CROSSOVER) 14 – 22 N·m (191 IN. LBS.)
6 – HEAT SHIELD 15 – GASKET (CROSSOVER)
7 – 15 N·m (130 IN. LBS.) 16 – INTAKE (CROSS) MANIFOLD
8 – 20 N·m (174 IN. LBS.) 17 – GASKET
9 – FRONT
Fig. 7 Engine Lubrication System

1 – CYLINDER HEAD BOLTS 5 – RELIEF VALVE
2 – CAMSHAFT JOURNALS 6 – PUMP
3 – FILTER 7 – PICKUP
4 – MAIN GALLERY 8 – CAMSHAFT JOURNALS

STARTING.
SYSTEM.
filter.
sprocket.
ROUGH FUEL SYSTEM.
IGNITION SYSTEM.

filter.
cylinder.
system.

fuel filter.
filter.
crankcase. level.

level.
on valve faces.

flanges.
or worn. journals.
converter.

or replace.
cracked.
clearance.

gaskets.

metal part. part.
threaded plug.
CONTROL SYSTEMS.
rings.
seal(s).
damaged.
INTAKE MANIFOLD LEAKAGE DIAGNOSIS (1) Start the engine.

An intake manifold air leak is characterized by (2) Spray a small stream of water (Spray Bottle) at
lower than normal manifold vacuum. Also, one or the suspected leak area.
more cylinders may not be functioning. (3) If engine RPM’S change, the area of the sus-
pected leak has been found.
WARNING: USE EXTREME CAUTION WHEN THE (4) Repair as required.
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
CYLINDER COMPRESSION PRESSURE TEST • Any causes for combustion/compression pressure

The results of a cylinder compression pressure test loss.
can be utilized to diagnose several engine malfunc-
tions.
WITH THE SYSTEM HOT AND UNDER PRESSURE
Ensure the battery is completely charged and the
BECAUSE SERIOUS BURNS FROM COOLANT CAN
engine starter motor is in good operating condition.
OCCUR.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes. Check the coolant level and fill as required. DO
(1) Check engine oil level and add oil if necessary. NOT install the radiator cap.
(2) Drive the vehicle until engine reaches normal Start and operate the engine until it attains nor-
operating temperature. Select a route free from traf- mal operating temperature, then turn the engine
fic and other forms of congestion, observe all traffic OFF.
laws, and accelerate through the gears several times Clean spark plug recesses with compressed air.
briskly. Remove the spark plugs.
(3) Remove all spark plugs from engine. As spark Remove the oil filler cap.
plugs are being removed, check electrodes for abnor- Remove the air cleaner.
mal firing indicators fouled, hot, oily, etc. Record cyl- Calibrate the tester according to the manufactur-
inder number of spark plug for future reference. er’s instructions. The shop air source for testing
(4) Disconnect coil wire from distributor and should maintain 483 kPa (70 psi) minimum, 1,379
secure to good ground to prevent a spark from start- kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ing a fire (Conventional Ignition System). For Direct ommended.
Ignition System DIS disconnect the coil connector. Perform the test procedures on each cylinder
(5) Be sure throttle blade is fully open during the according to the tester manufacturer’s instructions.
compression check. While testing, listen for pressurized air escaping
(6) Insert compression gage adaptor Special Tool through the throttle body, tailpipe and oil filler cap
8116 or the equivalent, into the #1 spark plug hole in opening. Check for bubbles in the radiator coolant.
cylinder head. Connect the 0–500 psi (Blue) pressure All gauge pressure indications should be equal,
transducer with cable adaptors to the DRBIIIt. with no more than 25% leakage per cylinder.
(7) Crank engine until maximum pressure is FOR EXAMPLE: At 552 kPa (80 psi) input pres-
reached on gage. Record this pressure as #1 cylinder sure, a minimum of 414 kPa (60 psi) should be main-
pressure. tained in the cylinder.
(8) Repeat the previous step for all remaining cyl-
inders.
CYLINDER HEAD GASKET FAILURE DIAGNOSIS
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
jacket are:
should not be disassembled to determine the
cause of low compression unless some malfunc-
• Loss of coolant
tion is present.
exhaust
CYLINDER COMBUSTION PRESSURE LEAKAGE • Coolant foaming
TEST
The combustion pressure leakage test provides an CYLINDER-TO-CYLINDER LEAKAGE TEST
accurate means for determining engine condition. To determine if an engine cylinder head gasket is
Combustion pressure leakage testing will detect: leaking between adjacent cylinders, follow the proce-
• Exhaust and intake valve leaks (improper seating). dures in Cylinder Compression Pressure Test in this
jacket.
between adjacent cylinders will result in approxi- (8) Rocker arm ears contacting valve spring
mately a 50–70% reduction in compression pressure. retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
CYLINDER-TO-WATER JACKET LEAKAGE TEST mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
WARNING: USE EXTREME CAUTION WHEN THE a. Check lash adjusters for sponginess while
ENGINE IS OPERATING WITH COOLANT PRES- installed in cylinder head. Depress part of rocker
SURE CAP REMOVED. arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
b. Remove suspected lash adjusters, and replace as
VISUAL TEST METHOD
necessary.
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until ENGINE OIL LEAK INSPECTION
thermostat opens.
Begin with a thorough visual inspection of the
If a large combustion/compression pressure leak
engine, particularly at the area of the suspected leak.
exists, bubbles will be visible in the coolant.
If an oil leak source is not readily identifiable, the
COOLING SYSTEM TESTER METHOD following steps should be followed:
WARNING: WITH COOLING SYSTEM TESTER IN time because some solvents may cause rubber to
PLACE, PRESSURE WILL BUILD UP FAST. EXCES- swell, temporarily stopping the leak.
SIVE PRESSURE BUILT UP, BY CONTINUOUS (2) Add an oil soluble dye (use as recommended by
ENGINE OPERATION, MUST BE RELEASED TO A manufacturer). Start the engine and let idle for
SAFE PRESSURE POINT. NEVER PERMIT PRES- approximately 15 minutes. Check the oil dipstick to
SURE TO EXCEED 138 kPa (20 psi). make sure the dye is thoroughly mixed as indicated
Install Cooling System Tester 7700 or equivalent to (3) Using a black light, inspect the entire engine
pressure cap neck. Start the engine and observe the for fluorescent dye, particularly at the suspected area
tester’s pressure gauge. If gauge pulsates with every of oil leak. If the oil leak is found and identified,
power stroke of a cylinder a combustion pressure repair per service manual instructions.
leak is evident. (4) If dye is not observed, drive the vehicle at var-
CHEMICAL TEST METHOD repeat inspection.
Combustion leaks into the cooling system can also (5) If the oil leak source is not positively
be checked by using Bloc-Chek Kit C-3685-A or identified at this time, proceed with the air leak
equivalent. Perform test following the procedures detection test method as follows:
supplied with the tool kit. • Disconnect the fresh air hose (make-up air) at
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS the cover.
A tappet-like noise may be produced from several • Remove the PCV valve hose from the cylinder
items. Check the following items. head cover. Cap or plug the PCV valve nipple on the
(1) Engine oil level too high or too low. This may cover.
cause aerated oil to enter the adjusters and cause • Attach an air hose with pressure gauge and reg-
them to be spongy. ulator to the dipstick tube.
der head. Low speed running up to 1 hour may be CAUTION: Do not subject the engine assembly to
required. more than 20.6 kpa (3 PSI) of test pressure.
temperature.
(5) The oil restrictor pressed into the vertical oil
procedures.
• If the leakage occurs at the crankshaft rear oil
oil pump pick up.
seal area, refer to the section, Inspection for Rear
(7) Worn valve guides.
Seal Area Leak.
(6) If no leaks are detected, turn off the air supply. (6) For bubbles that remain steady with shaft
Remove the air hose, all plugs, and caps. Install the rotation, no further inspection can be done until dis-
PCV valve and fresh air hose (make-up air). Proceed assembled.
to next step. (7) After the oil leak root cause and appropriate
(7) Clean the oil off the suspect oil leak area using corrective action have been identified, refer to Crank-
a suitable solvent. Drive the vehicle at various shaft Oil Seal—Rear for proper replacement proce-
speeds approximately 24 km (15 miles). Inspect the dures.
engine for signs of an oil leak by using a black light.
ENGINE OIL PRESSURE
NOTE: If oil leakage is observed at the dipstick (1) Disconnect and remove oil pressure sending
tube to block location; remove the tube, clean and unit.
reseal using MoparT Stud & Bearing Mount (press (2) Install Special Tools C-3292 Gauge with a 1/8
fit tube applications only), and for O-ring style NPT to 1/4 NPT adaptor (Fig. 8).
tubes, remove tube and replace the O-ring seal. (3) Start engine and record oil pressure. Refer to
INSPECTION FOR REAR SEAL AREA LEAKS pressure.
area:
inspection.
seal leakage or crankshaft damage. Fig. 8 Checking Engine Oil Pressure
(b) Where leakage tends to run straight down, 1 – OIL PRESSURE GAUGE
possible causes are a porous block, oil gallery cup 2 – OIL FILTER
these items. SERVICE PROCEDURES
case as previously described. ENGINE OIL
CAUTION: Do not exceed 20.6 kPa (3 psi). Checking Oil Level
To assure proper engine lubrication, the engine oil
(5) If the leak is not detected, very slowly turn the must be maintained at the correct level. Check the
crankshaft and watch for leakage. If a leak is oil level at regular intervals, such as every fuel stop.
detected between the crankshaft and seal while The best time to check the oil level is about 5 min-
slowly turning the crankshaft, it is possible the utes after a fully warmed-up engine is shut off, or
crankshaft seal surface is damaged. The seal area on before starting the vehicle after it has sat overnight.
the crankshaft could have minor nicks or scratches Refer to (Fig. 9) for engine oil fill and dipstick loca-
that can be polished out with emery cloth. tions.
Checking the oil while the vehicle is on level
CAUTION: Use extreme caution when crankshaft ground, will improve the accuracy of the oil level
polishing is necessary to remove minor nicks and readings. For the 3.0L engine, add one full quart
scratches. The crankshaft seal flange is especially when the level on the dipstick is at or below the ADD
machined to complement the function of the rear oil mark (Fig. 10).
seal.
ENGINE OIL SPECIFICATION
API SERVICE GRADE CERTIFIED

this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
ple viscosities such as 5W-30 or 10W-30. These are
Fig. 9 3.0L Engine Oil Fill and Dipstick Locations specified with a dual SAE viscosity grade which indi-
1 – ENGINE OIL DIPSTICK cates the cold-to-hot temperature viscosity range.
2 – ENGINE OIL FILL SAE 5W-30 engine oil is preferred. Select an engine
oil that is best suited to your particular temperature
range and variation (Fig. 11).
Fig. 10 3.0L Engine Oil Dipstick

1 – ADD OIL MARK
2 – FULL RANGE MARK Fig. 11 Temperature/Engine Oil Viscosity
ENERGY CONSERVING OIL
ENGINE OIL SERVICE An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
WARNING: NEW OR USED ENGINE OIL CAN BE SERVING is located on the label of the engine oil
IRRITATING TO THE SKIN. AVOID PROLONGED OR container.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY CONTAINER IDENTIFICATION
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO Standard engine oil identification notations have
YOUR HEALTH. THOROUGHLY WASH EXPOSED been adopted to aid in the proper selection of engine
SKIN WITH SOAP AND WATER. DO NOT WASH oil. The identifying notations are located on the label
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR of engine oil plastic bottles and the top of engine oil
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO cans (Fig. 12).
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN- ENGINE OIL CHANGE
MENT AGENCY FOR LOCATION OF COLLECTION Change engine oil at mileage and time intervals
CENTER IN YOUR AREA. described in the Maintenance Schedule.
TO CHANGE ENGINE OIL

perature.
inspect the package for the expiration date before
use.
MOPARt ATF RTV
Mopart ATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
Fig. 12 Engine Oil Container Standard Notations the package for the expiration date before use.
(1) Position the vehicle on a level surface and turn MOPARt GASKET MAKER
engine off. Mopart Gasket Maker is an anaerobic type gasket
(2) Hoist and support vehicle on safety stands. material. The material cures in the absence of air
Refer to Hoisting and Jacking Recommendations. when squeezed between two metallic surfaces. It will
(3) Remove the oil fill cap. not cure if left in the uncovered tube. The anaerobic
(4) Place a suitable drain pan under crankcase material is for use between two machined surfaces.
drain. Do not use on flexible metal flanges.
(5) Remove drain plug from crankcase and allow MOPARt BED PLATE SEALANT
oil to drain into pan. Inspect drain plug threads for Mopart Bed Plate Sealant is a unique (green-in-
stretching or other damage. Replace drain plug and color) anaerobic type gasket material that is specially
gasket if damaged. made to seal the area between the bedplate and cyl-
(6) Install drain plug in crankcase. inder block without disturbing the bearing clearance
(7) Lower vehicle and fill crankcase with specified or alignment of these components. The material
type and amount of engine oil described in this sec- cures slowly in the absence of air when torqued
tion. between two metallic surfaces, and will rapidly cure
(8) Install oil fill cap. when heat is applied.
(9) Start engine and inspect for leaks. MOPARt GASKET SEALANT
(10) Stop engine and inspect oil level. Mopart Gasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
FORM-IN-PLACE GASKETS & SEALERS sealing threaded fittings and gaskets against leakage
There are numerous places where form-in-place of oil and coolant. Can be used on threaded and
gaskets are used on the engine. Care must be taken machined parts under all temperatures. This mate-
when applying form-in-place gaskets to assure rial is used on engines with multi-layer steel (MLS)
obtaining the desired results. Do not use form-in- cylinder head gaskets. This material also will pre-
place gasket material unless specified. Bead size, vent corrosion. Mopart Gasket Sealant is available in
continuity, and location are of great importance. Too a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct FORM-IN-PLACE GASKET AND SEALER
fluid feed lines. A continuous bead of the proper APPLICATION
width is essential to obtain a leak-free gasket. Assembling parts using a form-in-place gasket
There are numerous types of form-in-place gasket requires care but it’s easier then using precut gas-
materials that are used in the engine area. Mopart kets.
Engine RTV GEN II, Mopart ATF-RTV, and Mopart Mopart Gasket Maker material should be applied
Gasket Maker gasket materials, each have different sparingly 1 mm (0.040 in.) diameter or less of sealant
properties and can not be used in place of the other. to one gasket surface. Be certain the material sur-
MOPARt ENGINE RTV GEN II rounds each mounting hole. Excess material can eas-
Mopart Engine RTV GEN II is used to seal com- ily be wiped off. Components should be torqued in
ponents exposed to engine oil. This material is a spe- place within 15 minutes. The use of a locating dowel
cially designed black silicone rubber RTV that is recommended during assembly to prevent smear-
retains adhesion and sealing properties when ing material off the location.
exposed to engine oil. Moisture in the air causes the Mopart Engine RTV GEN II or ATF RTV gasket
material to cure. This material is available in three material should be applied in a continuous bead
ounce tubes and has a shelf life of one year. After one approximately 3 mm (0.120 in.) in diameter. All
year this material will not properly cure. Always mounting holes must be circled. For corner sealing, a
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
Mopart Gasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
ENGINE GASKET SURFACE PREPARATION

preparation must be performed, especially with the
steel cylinder head gaskets.
Never use the following to clean gasket surfaces:
1 – ABRASIVE PAD
• Metal scraper 2 – 3M ROLOCY BRISTLE DISC
• Abrasive pad or paper to clean cylinder block 3 – PLASTIC/WOOD SCRAPER
and head
• High speed power tool with an abrasive pad or a
wire brush (Fig. 13) (3) Place a shop towel around the spark plugs
NOTE: Multi-Layer Steel (MLS) head gaskets any fluid that may possibly be in the cylinder under
require a scratch free sealing surface. pressure.
Only use the following for cleaning gasket surfaces: crankshaft using a breaker bar and socket.
• Solvent or a commercially available gasket (5) Identify the fluid in the cylinder(s) (i.e., cool-
remover ant, fuel, oil or other).
• Plastic or wood scraper (Fig. 13) (6) Make sure all fluid has been removed from the
• Drill motor with 3M Rolocy Bristle Disc (white cylinders. Inspect engine for damage (i.e., connecting
or yellow) (Fig. 13) rods, pistons, valves, etc.)
(7) Repair engine or components as necessary to
CAUTION: Excessive pressure or high RPM prevent this problem from re-occurring.
sealing surfaces. The mild (white, 120 grit) bristle CAUTION: Squirt approximately one teaspoon of oil
disc is recommended. If necessary, the medium into the cylinders, rotate engine to lubricate the cyl-
(yellow, 80 grit) bristle disc may be used on cast inder walls to prevent damage on restart.
iron surfaces with care.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
HYDROSTATIC LOCKED ENGINE (10) Fill engine with specified amount of approved
When an engine is suspected to be hydrostatically oil and install new oil filter.
locked, regardless of what caused the problem, the (11) Connect negative battery cable.
following steps should be used. (12) Start engine and check for any leaks.
CAUTION: DO NOT use starter motor to rotate the LASH ADJUSTER

engine, severe damage may occur. The hydraulic lash adjusters are precision units
installed in machined openings in the valve actuating
(1) Inspect air cleaner, induction system and ends of the rocker arms. Do not disassemble the lash
intake manifold to insure system is dry and clear of adjuster.
foreign material.
(2) Remove negative battery cable.
FUNCTION CHECK
Check auto adjusters for free play by inserting a
small wire through the air bleed hole in the rocker
arm and very lightly pushing the auto adjuster ball
check down (Fig. 14). While lightly holding the check
ball down move the rocker up and down to check for
free play. If there is no play, replace the lash
adjuster.
Fig. 15 Cylinder Bore Cross-Hatch Pattern

1 – CROSS-HATCH PATTERN
hatch angle. The number of up and down strokes per

minute can be regulated to get the desired 50–60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from

engine parts after honing. It is recommended that a
Fig. 14 Lash Adjuster—Function Check solution of soap and hot water be used with a
CYLINDER BORE—HONING brush and the parts then thoroughly dried. The bore
(1) Used carefully, the cylinder bore resizing hone, can be considered clean when it can be wiped
recommended tool C-823 or equivalent, equipped clean with a white cloth and cloth remains clean.
with 220 grit stones, is the best tool for this honing Oil the bores after cleaning to prevent rusting.
procedure. In addition to deglazing, it will reduce
scuffing, scoring or scratches. Usually a few strokes CRANKSHAFT MAIN BEARING—FITTING
will clean up a bore and maintain the required lim-
its. MAIN BEARING JOURNAL MEASUREMENT
(2) Deglazing of the cylinder walls may be done Measure the journal outside diameter for out-of-
using a cylinder surfacing hone, recommended tool round and taper (Fig. 16). Refer to Engine Specifica-
C-3501 or equivalent, equipped with 280 grit stones, tions. If measurements exceed the specifications
if the cylinder bore is straight and round. 20–60 limit, machine or replace the crankshaft as necces-
strokes depending on the bore condition, will be suf- sary.
ficient to provide a satisfactory surface. Inspect cyl-
inder walls after each 20 strokes, using a light PLASTIGAGE MEASUREMENT
honing oil. Do not use engine or transmission oil, (1) Remove oil from journal and bearing shell.
mineral spirits or kerosene. (2) Install crankshaft.
(3) Honing should be done by moving the hone up (3) Cut plastigage to same length as width of the
and down fast enough to get a cross-hatch pattern. bearing and place it in parallel with the journal axis
When hone marks intersect at 50-60 degrees, the (Fig. 17).
cross hatch angle is most satisfactory for proper seat- (4) Install the main bearing cap carefully and
ing of rings (Fig. 15). tighten the bolts to specified torque.
(4) A controlled hone motor speed between
CAUTION: Do not rotate crankshaft or the plasti-
200–300 RPM is necessary to obtain the proper cross-
gage will be smeared.
Fig. 16 Measure Crankshaft Journal O. D. Fig. 18 Measuring Clearance

NOTE: Service Replacement parts have identifica-
tion marks, but factory-assembled parts have no
identification marks. Service crankshaft identifica-
tion will have marks at counterweights (Fig. 19).
Fig. 17 Measure Oil Clearance with Plastigage

1 – PLASTIC GAUGE
(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. 18). Refer to
Engine Specifications for proper clearance. Also see
Measuring Main and Connecting Rod Bearing Clear- Fig. 19 Crankshaft Size Identification
ances in Standard Service Procedures.
MAIN JOURNAL SIZE IDENTIFICATION
CRANKSHAFT BEARING INSTALLATION
SERVICE PART JOURNAL OUTER
When replacing the bearings, select and install the
MARKING (Fig. 20) DIAMETER
proper bearing by using the following procedure.
(1) Measure the crankshaft journal diameter and 59.994–60.000 mm
0
confirm its classification from the Main Journal Size (2.3620–2.3622 in.)
Identification Chart. In the case of a bearing sup- 59.988–59.994 mm
plied as a service part, the identification is embossed 1
at the position show in (Fig. 20). (2.3617–2.3620 in.)
59.982–59.988 mm
2
(2.3615–2.3617 in.)
CRANKSHAFT END PLAY

(1) Mount a dial indicator to front of engine, locat-
ing probe on nose of crankshaft (Fig. 22).
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Engine Specifications
Fig. 20 Bearing Identification in this section.
1 – IDENTIFICATION MARK
(2) The identification mark for the diameter of the

cylinder block bearing bore is embossed as shown in
(Fig. 21), starting from the # 1 mark at the front of
the engine.
Fig. 22 Checking Crankshaft End Play

CONNECTING ROD AND BEARING—FITTING
CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be
determined by use of Plastigage or equivalent. The
Fig. 21 Cylinder Block Bearing Bore Markings
following is the recommended procedure for the use
(3) Select and install the bearings according to of Plastigage:
these marks. Using the chart below, select the proper (1) Rotate the crankshaft until the connecting rod
bearing by using the markings on the crankshaft and to be checked is at the bottom of its stroke.
block. For a example: (2) Remove oil film from surface to be checked.
(a) If the crankshaft journal outer diameter is Plastigage is soluble in oil.
60.000 mm (2.3622 in.), the service part classifica- (3) Place a piece of Plastigage across the entire
tion will be “0” and the identification mark will be width of the bearing shell in the bearing cap approx-
“0”. imately 6.35 mm (1/4 in.) off center and away from
(b) If the identification mark for the cylinder the oil hole. In addition, suspect areas can be
block main bore is “II”, select the bearing “2” checked by placing Plastigage in that area.
according the chart below. (4) Assemble the rod cap with Plastigage in place.
Block Identification Mark Tighten the rod cap to the specified torque. Do not
rotate the crankshaft while assembling the cap
I II III or the Plastigage may be smeared, giving inac-
Main 0 1 2 3 curate results.
Journal (5) Remove the bearing cap and compare the width
1 2 3 4
Identifi- of the flattened Plastigage with the scale provided on
cation Mark 2 3 4 5 the package (Fig. 23). Locate the band closest to the
same width. This band indicates the amount of oil
clearance. Differences in readings between the ends
indicate the amount of taper present. Record all
One scale is in inches, the other is a metric VALVE SERVICE
scale. If the bearing clearance exceeds wear (1) With suitable valve spring compressor, remove
limit specification, replace the bearing. spring retainer locks, retainer, valve spring, spring
seat and valve (Fig. 25).
Fig. 25 Remove Valves

(2) Remove valve stem seals with suitable tool
(Fig. 26). Do not reuse valve stem seals.
Fig. 23 Connecting Rod—Checking Bearing

Clearance
CONNECTING ROD SIDE CLEARANCE
(1) Install connecting rod, bearings and cap.
Tighten rod bolts to specifications.
Using a feeler gauge, check connecting rod side
clearance (Fig. 24). Refer to Engine Specifications in
this section.
Fig. 26 Remove Valve Stem Seals

VALVES
(1) Check valve stem tip for pitting or depression
at point A (Fig. 27).
(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 (Fig. 27). Replace valve if mar-
gin is out of specification. Refer to Engine Specifica-
tions in this section.
Fig. 24 Checking Connecting Rod Side Clearance (5) Check valve guide height (Fig. 28).
(6) Measure valve stem to guide clearance. Refer
to Engine Specifications in this section.
(7) Measure valve spring free length and square-
ness (Fig. 29). Refer to Engine Specifications in this
section.
VALVE SEAT
Fig. 27 Valve Inspection

1 – C IS A SEAT CONTACT MARK AND IS NOT FULL WIDTH OF
THE FACE Fig. 30 Valve Seat Reconditioning
2 – MARGIN
Inspect the valve seat with Prussian blue to deter-
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 pres-
sure. 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 bot-
tom edge of valve face raise valve seat with a 65
degree stone (Fig. 30).
INSTALLATION
(1) Install valve spring seat.
(2) Using suitable tool install seal by tapping
lightly until seal is in place (Fig. 31).
(3) Install valve spring with the enamelled ends
facing the rocker arms (Fig. 32).
1 – SPRING SEAT CAUTION: During reassembly, compressing the
2 – VALVE GUIDE 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.
Fig. 29 Valve Spring

1 – LENGTH
Fig. 31 Install Valve Stem Seals

1 – SPECIAL TOOL MD-998729
Fig. 32 Installed Valve Spring Position Fig. 33 Engine Mount—Right

1 – ENAMELED END
2 – PURGE DUTY SOLENOID MOUNT
2 – SPRING RETAINER
3 – HORIZONTAL FASTENER
3 – STEM SEAL
4 – DO NOT REMOVE THIS NUT
4 – SPRING SEAT
INSTALLATION
(1) Reverse removal procedure for installation.
REMOVAL AND INSTALLATION Tighten assembly in the following order:
(a) Engine mount to rail fasteners to 68 N·m (50
ENGINE MOUNTS ft. lbs.).
(b) The vertical engine fastener to 102 N·m (75
RIGHT SIDE MOUNT ft. lbs.).
(c) The horizontal fastener to 150 N·m (111 ft.
REMOVAL lbs.).
(2) Install the purge duty solenoid and wiring har-
NOTE: Right mount should only be serviced as an ness to the engine mount.
assembly to prevent noise, vibration and harshness
concerns. FRONT MOUNT
(1) Remove the purge duty solenoid and wiring REMOVAL
harness from engine mount. (1) Support the engine and transmission assembly
(2) Remove the two right engine mount insulator with a floor jack so it will not rotate.
vertical fasteners and loosen the horizontal fastener. (2) Remove the front engine mount through bolt
Do Not remove the large nut on the end of the from the insulator and front crossmember mounting
core from the frame rail (Fig. 33). bracket (Fig. 34).
(3) Remove the load on the engine motor mounts (3) Remove six screws from air dam to allow
by carefully supporting the engine and transmission access to the front mount screws.
assembly with a floor jack. (4) Remove the front engine mount screws and
(4) Remove the vertical and horizontal fasteners remove the insulator assembly.
from the engine side bracket. Remove the engine (5) Remove the front mounting bracket, if neces-
mount assembly. sary (Fig. 34).
REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-0005
TSB 26-01-00 January, 2000
INSTALLATION
(1) Reverse removal procedure for installation and
tighten fasteners (Fig. 34) to the following torque:
• (A) and (B) to 102 N·m (75 ft. lbs.)
• (C) and (D) to 68 N·m (50 ft. lbs.)
• (E) to 54 N·m (40 ft. lbs.)
(2) Install six screws to air dam and tighten to 12
N·m (105 in. lbs.).
Fig. 35 Engine Mount—Left

1 – MOUNT TO TRANSMISSION FASTENERS
Fig. 34 Engine Mount—Front

LEFT SIDE MOUNT
REMOVAL
(1) Raise vehicle on hoist and remove left front
wheel.
(2) Support the transmission with a transmission
jack.
mount.
(4) Remove the transmission mount fasteners and
remove mount.
INSTALLATION
(2) Tighten mount to transmission bolts to 55 N·m
(40 ft. lbs.) (Fig. 35). Fig. 36 Engine Mount—Rear
Tighten through bolt to 75 N·m (55 ft. lbs.) 1 – TOP ENGINE MOUNT FASTENERS
2 – SIDE ENGINE MOUNT FASTENERS
REAR MOUNT
(1) Raise vehicle on hoist. (1) Install rear engine mount (Fig. 36).
(2) Support the transmission with a transmission (2) Install the insulator through bolt to the mount
jack so it will not rotate. and suspension crossmember.
(3) Remove the insulator through bolt from the (3) Remove transmission jack and lower vehicle.
mount and suspension crossmember.
(4) Remove the four transmission mount fasteners
and remove the mount (Fig. 36).
ENGINE ASSEMBLY (28) Lower vehicle so the weight of ONLY THE

ENGINE AND TRANSMISSION is on the cradle.
REMOVAL (29) Remove right engine mount assembly and left
(1) Perform fuel pressure release procedure and transmission mount through bolt. Refer to Engine
remove fuel line to fuel rail. Refer to FUEL SYSTEM Mounts in this section.
for procedures. (30) Raise vehicle slowly. It may be necessary to
(2) Disconnect battery. move the engine/transmission assembly on the cradle
(3) Remove air cleaner and hoses. to allow for removal around body flanges.
(4) Remove battery cover, battery and battery tray,
with integral vacuum reservoir, from vehicle.
(5) Block off heater hoses to rear heater assembly,
if equipped.
(6) Drain cooling system. Refer to COOLING SYS-
TEM for procedure.
(7) Disconnect heater hoses.
(8) Remove fan module and radiator. Refer to
COOLING SYSTEM for procedure.
(9) Disconnect transmission shift linkage.
(10) Disconnect throttle body linkage and vacuum
hoses from throttle body.
(11) Remove accessory drive belts. Refer to Acces-
sory Drive System located in COOLING SYSTEM for
procedure.
(12) Remove air conditioning compressor from
engine and set it aside.
(13) Disconnect generator wiring harness and
remove generator.
(14) Hoist vehicle and remove axle shafts. Refer to
DIFFERENTIAL AND DRIVELINE for procedure.
(15) Remove right and left inner splash shields.
(16) Disconnect exhaust pipe from manifold. Fig. 37 Positioning Engine Cradle Support Post
(17) Remove front engine mount and bracket as an Mounts—Typical
assembly. 1 – SPECIAL TOOL ENGINE CRADLE NO. 6710
(18) Remove rear transmission mount and bracket. 2 – SPECIAL TOOL ENGINE DOLLY NO. 6135
(19) Remove power steering pump and bracket 3 – SPECIAL TOOL ENGINE CRADLE NO. 6710
assembly. 4 – SPECIAL TOOL ADJUSTABLE POSTS NO. 6848
(20) Remove wiring harness and connectors from
front of engine.
INSTALLATION
(21) Remove bending braces and install Special
(1) Position engine and transmission assembly
Tool 6910 on engine.
under vehicle and slowly lower the vehicle over the
(22) Remove transaxle inspection cover and mark
engine and transmission. It may be necessary to
flex plate to torque converter.
move the engine/transmission assembly with the cra-
(23) Remove flex plate to torque converter bolts.
dle for clearance around body flanges.
(24) Lower the vehicle.
(2) Align engine and transmission mounts to
(25) Remove ground straps to body.
attaching points. Install mounting bolts at the right
(26) Raise vehicle enough to allow engine dolly
engine and left transmission mounts. Refer to proce-
Special Tool 6135 and cradle Special Tool 6710 with
dures in this section.
post Special Tool 6848 and adaptor Special Tool 6909
(3) Slowly raise vehicle enough to remove the
to be installed under vehicle (Fig. 37).
engine dolly and cradle Special Tools 6135, 6710,
(27) Loosen cradle engine mounts to allow move-
6848 and 6909.
ment for positioning onto engine locating holes on the
(4) Remove Special tools 6910 and install bending
engine. Lower vehicle and position cradle mounts
braces.
until the engine is resting on mounts. Tighten
(5) Lower vehicle. Install generator and wiring
mounts to cradle frame. This will keep mounts from
harness.
moving when removing or installing engine and
(6) Connect wiring harness on the front of the
transmission.
engine.
(7) Install air conditioning compressor.
(8) Install power steering pump and bracket and
accessory drive belt. Refer to COOLING SYSTEM for
accessory drive belt installation.
(9) Raise vehicle and install axle shafts. Refer to
DIFFERENTIAL AND DRIVELINE for procedure.
(10) Install transmission and engine mount and
bracket assemblies. Refer to Engine Mounts in this
section for procedure.
(11) Connect exhaust system to manifold. Refer to
EXHAUST SYSTEM for procedure and torque speci-
fications.
(12) Install left and right inner splash shields.
(13) Connect automatic transmission shifter link-
age. Refer to TRANSAXLE AND POWER TRANS-
FER UNIT for procedures.
(14) Lower vehicle and connect fuel line and Fig. 38 Throttle Cable Attachment
heater hoses. Remove plugs from rear heater hoses 1 – PCV HOSE
and install, if equipped. 2 – THROTTLE CABLE
(15) Install ground straps. Connect engine and 3 – THROTTLE CABLE BRACKET
throttle body connections and harnesses. 4 – ATTACHING SCREWS
(16) Connect throttle body linkage. Refer to FUEL
(7) Remove automatic idle speed (AIS) motor and
(17) Install radiator and fan module assembly.
throttle position sensor (TPS) wiring connectors from
Install radiator hoses. Fill cooling system. Refer to
throttle body (Fig. 40).
COOLING SYSTEM for procedures.
(18) Install battery tray, battery and cover.
(19) Install air cleaner and hoses.
(20) Install oil filter. Fill engine crankcase with
proper oil to correct level.
ature is reached.
INTAKE MANIFOLD
REMOVAL
(1) Perform fuel system pressure release procedure
(before attempting any repairs). Refer to FUEL
(3) Drain cooling system—only if lower intake
manifold is to be removed. Refer to COOLING SYS-
TEM for procedure. Fig. 39 EGR Tube
(4) Remove air inlet resonator to throttle body 1 – EGR SOLENOID
hose. 2 – EGR VALVE
(5) Remove throttle and speed control cables (Fig. 3 – EGR TUBE
4 – TRANSDUCER
38).
(6) Remove EGR tube to exhaust manifold connec-
tion (Fig. 39). (8) Remove vacuum hose harness from throttle
body.
(9) Remove PCV and brake booster hoses from
upper intake plenum.
(11) Remove wiring connectors from coolant tem-
perature sensor (Fig. 42).
Fig. 40 Electrical and Vacuum Connections to

Throttle Body
1 – THROTTLE POSITION SENSOR (TPS) Fig. 42 Coolant Temperature Sensor Electrical
2 – IDLE AIR CONTROL MOTOR Connections
1 – FUEL LINE
(10) Remove ignition coil from intake plenum (Fig. 2 – MAP SENSOR
41). 3 – VACCUM HOSES
4 – ENGINE COOLANT TEMPERATURE SENSOR
5 – ENGINE TEMPERATURE SENDING UNIT
(12) Remove vacuum connections from upper

intake plenum vacuum connector.
(13) Remove fuel hose from fuel rail (Fig. 42).
WARNING: WRAP SHOP TOWELS AROUND HOSES

TO CATCH ANY GASOLINE SPILLAGE.
(14) Remove fasteners from upper intake plenum

to lower intake manifold (Fig. 43).
Fig. 41 Ignition Coil

1 – INTAKE MANIFOLD
2 – IGNITION COIL
3 – IGNITION CABLE
4 – IGNITION COIL BRACKET FASTENERS
5 – ELECTRICAL CONNECTOR
Fig. 43 Air Intake Plenum to Intake Manifold

Attaching Bolts
1 – FASTENERS (4 EACH SIDE)
2 – AIR INTAKE PLENUM
(15) Remove upper air intake plenum (Fig. 44). (19) Separate radiator hose from thermostat hous-
ing and heater hose from heater pipe.
(20) Remove nut and washer assemblies and
remove intake manifold (Fig. 46).
INSTALLATION
(1) Position new intake manifold gaskets on cylin-
der head and install lower intake (cross) manifold.
(2) Install nuts and washers and tighten in several
steps in order shown in (Fig. 47) to 20 N·m (174 in.
lbs.).
(3) Make sure the injector holes are clean and all
plugs have been removed.
(4) Lubricate injector O-ring with a drop of clean
engine oil to ease installation.
(5) Put the tip of each injector into their ports.
Fig. 44 Removing Air Intake Plenum Push the assembly into place until the injectors are
1 – AIR INTAKE PLENUM seated in the ports.
2 – INTAKE RUNNERS (6) Install the fuel rail attaching bolts and torque
3 – GASKET to 13 N·m (115 in. lbs.).
(7) Install fuel supply and the vacuum crossover
(16) Cover lower intake manifold with suitable tube hold-down bolt. Torque to 10 N·m (95 in. lbs.).
cover when servicing (Fig. 45). (8) Remove covering from lower intake manifold
and clean surface.
(9) Place intake manifold gaskets with beaded
sealant side up on lower manifold. Position upper
intake plenum in place. Install attaching fasteners
and tighten fasteners in several steps in sequence
shown (Fig. 48) to 15 N·m (130 in. lbs.).
(10) Connect fuel line to fuel rail and tighten
clamp (Fig. 42).
(11) Connect vacuum harness to upper intake ple-
num.
(12) Connect and coolant temperature sensor elec-
trical connector to sensor (Fig. 42).
(13) Connect PCV and brake booster supply hose
to upper intake plenum.
(14) Connect automatic idle speed (AIS) motor and
throttle position sensor (TPS) electrical connectors
(Fig. 40).
Fig. 45 Vacuum Connections for Fuel Rail and Fuel (15) Connect vacuum vapor harness to throttle
Pressure Regulator body (Fig. 40).
1 – LOWER MANIFOLD MUST BE COVERED DURING SERVICE (16) Install EGR tube and gasket to exhaust man-
2 – CANISTER PURGE VAPOR HOSE ifold connection (Fig. 39).
(17) Install throttle and speed control cables (Fig.
(17) Disconnect fuel injector wiring harness from 38).
engine wiring harness. (18) Install air inlet resonator hose assembly to
(18) Remove fuel rail attaching bolts and lift fuel throttle body.
rail assembly from intake manifold. (19) Install radiator to thermostat housing hose
and heater hose to heater pipe nipple.
Fig. 46 Intake and Exhaust Manifolds

1 – AIR INTAKE PLENUM 10 – GASKET (MANIFOLD)
2 – 15 N·m (130 IN. LBS.) 11 – 69 N·m (51 FT. LBS.)
3 – 20 N·m (174 IN. LBS.) 12 – GASKET
4 – EXHAUST CROSSOVER PIPE 13 – REAR EXHAUST MANIFOLD
5 – GASKET (CROSSOVER) 14 – 22 N·m (191 IN. LBS.)
6 – HEAT SHIELD 15 – GASKET (CROSSOVER)
7 – 15 N·m (130 IN. LBS.) 16 – INTAKE (CROSS) MANIFOLD
8 – 20 N·m (174 IN. LBS.) 17 – GASKET
9 – FRONT
Fig. 47 Fastener Tightening Sequence for Lower Fig. 48 Intake Manifold Plenum Tightening
Intake Manifold Sequence
(20) If drained, fill cooling system. Refer to COOL-
(21) Connect negative battery cable.
(22) With the DRB Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.

The Auto Shutdown (ASD) Relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
Fig. 50 Rear Exhaust Manifold Heat Shield

EXHAUST MANIFOLD 1 – FASTENERS
2 – HEAT SHIELD
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
rear (cowl side) exhaust manifold at the flex-joint.
(2) Disconnect oxygen sensor lead wire at the rear
exhaust manifold (Fig. 49).
(3) Remove bolts attaching crossover pipe to man-
ifold (Fig. 51).
(4) Remove rear heat shield (Fig. 50).
(5) Remove nuts attaching rear manifold to cylin-
der head and remove manifold.
Fig. 51 Crossover Pipe

1 – CROSSOVER PIPE
2 – REAR EXHAUST MANIFOLD
3 – 69 N·m (51 FT. LBS.)
Fig. 49 Disconnect Up Stream Heated Oxygen

Sensor Connection
1 – UP STREAM HEATED OXYGEN SENSOR ELECTRICAL
CONNECTION
(6) Lower vehicle and remove screws attaching

front heat shield to front manifold (Fig. 52).
(7) Remove bolts fastening crossover pipe to front
exhaust manifold and nuts fastening manifold to cyl-
inder head. Remove assemblies.
(8) Inspect and clean manifolds. Refer to Cleaning Fig. 52 Front Exhaust Manifold Heat Shield
and Inspection in this section for procedures. 1 – HEAT SHIELD
2 – FASTENERS
INSTALLATION
Install the gaskets with the numbers 1-3-5
embossed on the top on the rear bank and those with
numbers 2-4-6 on the front (Radiator side) bank (Fig.
53).
(1) Install rear exhaust manifold and tighten
attaching nuts to 20 N·m (175 in. lbs.).
(2) Attach exhaust pipe to exhaust manifold and
tighten bolts to 28 N·m (250 in. lbs.)
(3) Attach crossover pipe to exhaust manifold and
tighten bolt to 69 N·m (51 ft. lbs.) (Fig. 51)
(4) Install rear exhaust manifold heat shield (Fig.
50).
(5) Connect heated oxygen sensor lead (Fig. 49).
(6) Install front exhaust manifold and attach
exhaust crossover.
(7) Install front exhaust manifold heat shield and
tighten attaching screws to 15 N·m (130 in. lbs.) (Fig.
52).
Fig. 54 Crankshaft Damper and Pulley

1 – CRANKSHAFT BOLT AND WASHER
2 – CRANKSHAFT SPROCKET
3 – METAL SHIELD
4 – CRANKSHAFT PULLEY AND DAMPER
(4) Install drive belt splash shield and lower vehi-

cle.
CYLINDER HEAD COVER

Fig. 53 Identify Exhaust Manifold Gaskets
REMOVAL
CRANKSHAFT DAMPER
CYLINDER HEAD COVER—FRONT
REMOVAL (1) Remove air inlet resonator.
(1) Raise vehicle and remove accessory drive belt (2) Remove dipstick tube.
splash shield. (3) Disconnect and relocate secondary ignition
(2) Remove accessory drive belts. Refer to COOL- wires.
ING SYSTEM for procedures. (4) Remove vacuum connections.
(3) Remove crankshaft bolt and washer (Fig. 54). (5) Remove cylinder head cover screws and remove
cover (Fig. 55).
NOTE: Crankshaft damper is a “slip fit”, and does
not require use of a puller to remove. CYLINDER HEAD COVER—REAR
(4) Remove crankshaft damper (Fig. 54). (2) Remove wiper unit. Refer to WINDSHIELD
WIPERS AND WASHERS for procedure.
INSTALLATION (3) Remove accessory drive belt. Refer to COOL-
(1) Install crankshaft damper (Fig. 54). ING SYSTEM for procedure.
(2) Install crankshaft damper bolt and washer (4) Disconnect generator wiring and remove gener-
(Fig. 54). Tighten to 135 N·m (100 ft. lbs.). ator.
(3) Install accessory drive belts. Refer to COOL- (5) Disconnect and relocate secondary ignition
ING SYSTEM for procedures. wires.
(6) Remove cylinder head cover screws and remove (7) Install wiper unit. Refer to WINDSHIELD
cover (Fig. 55). WIPERS AND WASHERS for procedure.
CAMSHAFT
REMOVAL
(1) Remove cylinder head covers, timing belt, and
camshaft sprockets. Refer to procedures in this sec-
tion.
NOTE: SEE AUTO LASH ADJUSTER FUNCTION

CHECK BEFORE DISASSEMBLY
(2) Remove distributor and drive adaptor housing.

(3) Install Special Tool MD-998443, auto lash
adjuster retainers (Fig. 56).
Fig. 55 Cylinder Head Cover

1 – COVER GASKET
2 – WASHER
3 – APPLY SEALANT
4 – 10 N·M (88 IN. LBS.)
5 – 1.5 mm (1/16 INCH) BEAD OF SEALANT 3/8 INCH LONG IN
FOUR PLACES
INSTALLATION
CYLINDER HEAD COVER—FRONT
(1) Clean cylinder head and cover sealing surfaces.
Inspect gasket and replace as necessary.
(2) Apply Mopart Engine RTV GEN II to cover
ends (Fig. 55). Fig. 56 Auto Lash Adjuster Retainers
(3) Install cover. Tighten cover fasteners to 10 N·m
(88 in. lbs.). (4) Remove distributor adaptor (Fig. 57).
(4) Connect vacuum connections. (5) When removing camshaft bearing caps, do not
(5) Connect secondary ignition wires. remove the bolts from the bearing caps. Remove the
(6) Install dipstick tube. rocker arm, rocker shafts and bearing cap as an
(7) Install air inlet resonator. assembly.
(6) Remove camshaft and oil seals.
CYLINDER HEAD COVER—REAR
(1) Clean cylinder head and cover sealing surfaces. INSTALLATION
Inspect gasket and replace as necessary. (1) Lubricate camshaft journals and cams with
(2) Apply Mopart Engine RTV GEN II to cover engine oil.
ends (Fig. 55). (2) Install camshaft(s) on cylinder head(s) (Fig.
(3) Install cover. Tighten cover fasteners to 10 N·m 57).
(88 in. lbs.). (3) Install rocker arm, rocker shafts and bearing
(4) Connect secondary ignition wires. caps as an assembly (Fig. 57).
(5) Install generator and connect wiring. (4) Remove Special Tool MD-998443, auto lash
(6) Install accessory drive belt. Refer to COOLING adjuster retainers (Fig. 56).
SYSTEM for procedure. (5) Install distributor drive adaptor housing and
distributor (Fig. 57).
Fig. 57 Cylinder Heads and Camshafts

1 – BREATHER HOSE 6 – COVER
2 – ROCKER COVER 7 – O-RING
3 – ROCKER ARM SHAFT ASSEMBLY 8 – DISTRIBUTOR ADAPTOR
4 – ROCKER COVER 9 – SEAL
5 – LASH ADJUSTER 10 – CAMSHAFT (REAR)
(6) Install camshaft oil seals

(7) Install cylinder head covers, camshaft sprock-
ets, and timing belt. Refer to procedures in this sec-
tion.
ROCKER ARMS AND SHAFTS

REMOVAL
(1) Remove cylinder head cover(s). Refer to proce-
(2) Install Special Tool MD-998443, Lash Adjuster
Retainers (Fig. 58).
(3) Remove rocker arm and shaft assembly from
cylinder head.
(4) Disassemble rocker arm(s) from shafts.
INSTALLATION Fig. 58 Auto Lash Adjuster Retainers

(1) Assemble rocker arm(s) to shafts. (3) Install the rocker arm shaft assembly making
(2) Apply Mopart Engine RTV GEN II at bearing sure that the arrow mark on the bearing cap and the
cap ends as shown in (Fig. 59).
arrow mark on the cylinder head are in the same
direction (Fig. 59).
Fig. 60 Lash Adjuster

1 – AUTO-LASH ADJUSTER
(3) Install rocker arms and shafts. Refer to proce-

CAMSHAFT SEAL
REMOVAL
CAMSHAFT OIL SEAL (FRONT)
(2) Remove generator and bracket (right side).
Fig. 59 Rocker Arm Shaft Direction (3) Remove timing belt inner cover (left side).
1 – ARROW MARK (BEARING CAP)
(4) Using an appropriate pry tool, remove seal(s).
2 – ARROW MARK (CYLINDER HEAD)
3 – APPLY SEALANT
CAMSHAFT END SEAL (PLUG)
4 – ARROW MARK (BEARING CAP) (1) Remove air cleaner assembly from engine.
(2) Remove upper intake manifold plenum. Refer
to Intake Manifold in this section.
NOTE: The direction of arrow marks on the front
(3) Use a small punch and a hammer, carefully
and rear assemblies are opposite to each other.
remove cam plug from cylinder head.
(4) Tighten bearing cap bolts in the following order
to 10 N·m (85 in. lbs.). First #3, then #2, #1 and #4.
INSTALLATION
(5) Repeat previous step, increasing the torque to
CAMSHAFT OIL SEAL (FRONT)
20 N·m (180 in. lbs.).
(6) Remove Special Tool MD-998443, Lash (1) Apply light coat of engine oil to the camshaft
Adjuster Retainers. oil seal lip.
(7) Install cylinder head covers. Refer to procedure (2) Install the oil seal using camshaft oil seal
in this section. installer tool MD-998713 (Fig. 61).
(3) Install generator bracket and generator (right
side).
LASH ADJUSTER
(4) Install timing belt inner cover (left side).
(5) Install camshaft sprockets and timing belt.
REMOVAL
Refer to procedures in this section
(1) Remove rocker arms and shafts. Refer to proce-
dure in this section. CAMSHAFT END SEAL (PLUG)
(2) Remove Special Tools MD-998443 Lash
(1) Clean the area of the cylinder head where the
Adjuster Retainers from each rocker arm and remove
new cam plug will be installed.
lash adjuster (Fig. 60).
(2) Apply a light coating of Mopart Engine RTV
GEN II to the outer diameter of the NEW cam plug.
INSTALLATION (3) Using Special Tool MD-998306 (Fig. 62), or
(1) Lubricate lash adjuster with clean engine oil other suitable installation tool and a hammer, install
and install in rocker arm (Fig. 60). the new cam plug to a depth of 0.5 mm (0.020 in.)
(2) Install Special Tool MD-998443 Lash Adjuster below the surface of the cylinder head.
Retainers to each rocker arm.
CYLINDER HEAD
REMOVAL
Refer to timing belt in this section for procedure.
(2) Remove cylinder head covers, rocker arms and
shafts. Refer to procedures in this section.
(3) Remove intake manifold and plenum. Refer to
(4) Remove distributor.
(5) Remove exhaust manifolds and crossover. Refer
to procedures in this section.
Fig. 61 Camshaft Oil Seal—Installation

2 – SEAL
3 – CAMSHAFT
(4) Install upper intake manifold plenum. Refer to

Intake Manifold in this section.
(5) Replace air cleaner assembly.
Fig. 63 Cylinder Head Bolt Removal Sequence

1 – CYLINDER HEAD BOLT AND WASHER
2 – 10 mm ALLEN HEX
(6) Remove cylinder head bolts in sequence shown

in (Fig. 63). Remove cylinder head.
INSTALLATION
(1) Clean surfaces of head and block, install head
gasket over locating dowels.
(2) Install head on locating dowels.
(3) Install 10 mm Allen hex head bolts with wash-
ers.
CAUTION: Attach the cylinder head bolt washer in

the direction shown in (Fig. 64).
(4) Tighten bolts in the order shown in (Fig. 65).

Fig. 62 Camshaft End Seal Plug—Installation When tightening the cylinder head bolts, tighten
1 – SPECIAL TOOL MD-998306 gradually, working in two or three steps and final
2 – MALLET tighten to specified torque of 108 N·m (80 ft. lbs.).
(5) Install rocker arms and cylinder head covers.
(6) Install camshaft sprockets and timing belt.
Fig. 64 Cylinder Head Bolt Washer
Fig. 66 Accessory Drive Belt Splash Shield

1 – ATTACHING SCREW
2 – ATTACHING SCREWS
3 – SPLASH SHIELD
Fig. 65 Cylinder Head Bolt Tightening Sequence

1 – CYLINDER HEAD BOLT AND WASHER
2 – 10 mm ALLEN HEX
(7) Install exhaust manifolds and crossover pipe.

(8) Install distributor.
(9) Install intake manifold and plenum.
TIMING BELT
REMOVAL Fig. 67 Timing Belt Covers
(1) Raise vehicle and remove accessory drive belt 1 – BRACKET HARNESS CLIP
splash shield (Fig. 66). 2 – REAR COVER D BOLTS
(2) Remove accessory drive belts. Refer to COOL- 3 – COVER (REAR REFERENCE)
ING SYSTEM for procedure. 4 – BRACKET HARNESS CLIP
(3) Remove crankshaft pulley and damper (Fig. 5 – UPPER FRONT COVER (OUTER)
68). 6 – UPPER REAR COVER
(4) Support engine and remove right side engine 7 – LOWER COVER
mount. Refer to procedure in this section.
(5) Remove engine support bracket (Fig. 67). (8) Loosen timing belt tensioner bolt (Fig. 71) and
(6) Remove timing belt covers (Fig. 67). remove timing belt.
(7) Mark belt running direction for installation (9) Remove crankshaft sprocket flange shield (Fig.
(Fig. 69). 68).
Fig. 68 Timing Belt System

1 – ENGINE SUPPORT BRACKET 10 – TIMING BELT
2 – TIMING BELT COVER (UPPER OUTER-B) 11 – CRANKSHAFT SPROCKET
3 – TIMING BELT TENSIONER 12 – FLANGE
4 – CAMSHAFT SPROCKET 13 – TIMING BELT COVER (UPPER OUTER-A)
5 – GENERATOR BRACKET 14 – TIMING BELT COVER (FRONT LOWER)
6 – SUPPORT-A 15 – ACCESS COVER
7 – SUPPORT-B 16 – TORSIONAL DAMPER
8 – BRACKET 17 – CRANKSHAFT PULLY (A)
9 – TIMING BELT COVER (INNER-A) 18 – CRANKSHAFT PULLY (B)
CAMSHAFT SPROCKETS TIMING BELT TENSIONER

To remove camshaft sprockets: (1) Install timing belt tensioner and tensioner
1. Hold camshaft sprocket with Spanner Tool spring.
MB-990775. Loosen and remove bolt and washer (2) Hook spring upper end to water pump pin and
(Fig. 70). lower end to tensioner bracket with hook out (Fig.
2. Remove camshaft sprocket from camshaft. 71).
To install camshaft sprockets: (3) Turn timing belt tensioner counterclockwise
3. Place camshaft sprocket on camshaft. full travel in adjustment slot and tighten bolt to tem-
4. Install bolt and washer to camshaft. Using porarily hold this position (Fig. 72).
Spanner Tool MB-990775, hold camshaft sprocket
and torque bolt to 95 N·m (70 ft. lbs.) (Fig. 70). INSTALLATION
(1) Install timing belt on crankshaft sprocket and
keep belt tight on tension side (Fig. 69). Install belt
on the front (radiator side) camshaft sprocket. Install
belt on the water pump pulley, rear camshaft
sprocket and finally on the timing belt tensioner.
Fig. 69 Timing Belt Engine Sprocket Timing

1 – TIMING MARK 8 – TENSION SIDE
2 – TIMING MARK (GENERATOR BRACKET) 9 – TIMING MARK (OIL PUMP)
3 – WATER PUMP PULLEY 10 – TIMING MARK
4 – TIMING MARK 11 – CRANKSHAFT SPROCKET
5 – TIMING MARK (TIMING BELT COVER INNER (A) 12 – TIMING BELT TENSIONER
6 – MARK BELT 13 – CAMSHAFT SPROCKET (REAR)
7 – CAMSHAFT SPROCKET (FRONT)
(2) Rotate the front camshaft sprocket in opposite

direction to take up belt slack. Check that all timing
marks are aligned (Fig. 69).
(3) Install crankshaft sprocket flange (Fig. 68).
(4) Loosen tensioner bolt and allow spring to ten-
sion timing belt.
(5) Turn crankshaft two full turns in clockwise
direction. Turn smoothly and in clockwise direc-
tion ONLY.
(6) Align the timing marks on the sprockets and
tighten the timing belt tensioner locking bolt to 28
N·m (250 in. lbs.) torque.
(7) Install timing belt covers.
(8) Install engine support bracket.
(9) Install right side engine mount.
(10) Install crankshaft damper and pulleys (Fig.
Fig. 70 Camshaft Sprockets 68). Tighten damper center bolt to 135 N·m (100 ft.
lbs.).
Fig. 71 Timing Belt Tensioner Fig. 73 Engine Mount Bracket—Front

1 – BELT TENSIONER 1 – FRONT ENGINE MOUNT BRACKET
2 – TENSIONER SPRING 2 – FRONT ENGINE MOUNT
(7) Remove oil pan bolts.

(8) Remove oil pan.
INSTALLATION
(1) Clean oil pan and all gasket surfaces.
Oil pan to crankcase sealing is provided with
Mopart Engine RTV GEN II, or equivalent gasket
material.
(2) Apply sealant as shown in (Fig. 74).
Fig. 72 Positioning Belt Tensioner

(12) Install accessory drive belt splash shield (Fig.
66). Fig. 74 Oil Pan Sealing
1 – 3 mm DIAMETER OF SEALANT
OIL PAN 2 – SEALANT MUST NOT BE FORCED OUT FROM THIS
FLANGE AREA
REMOVAL
(1) Disconnect negative cable from battery. (3) Install pan and tighten screws to 6 N·m (50 in.
(2) Raise vehicle on hoist and drain engine oil. lbs.) in sequence shown in (Fig. 75).
(3) Remove starter. Refer to STARTER for proce- (4) Install torque converter dust shield.
dure. (5) Install engine to transaxle bending braces.
(4) Remove front engine mount bracket (Fig. 73). (6) Install front engine mount bracket (Fig. 73).
(5) Remove engine to transaxle bending braces. (7) Install starter. Refer to STARTER for proce-
(6) Remove torque converter dust shield. dure.
(8) Lower vehicle and fill engine crankcase with (3) Mark connecting rod and cap with cylinder
proper oil to correct level. number (Fig. 78).
(9) Connect negative cable to battery. (4) Remove piston rings (Fig. 79).
Fig. 75 Oil Pan Screw Tightening Sequence

(1) Remove the following components; referring to
procedures in this section:
• Intake manifold/plenum Fig. 77 Mark Pistons
• Cylinder head covers 1 – “R” FORWARD FOR CYLINDERS 1-3-5
• Timing belt
• Cylinder heads
• Oil pan FITTING PISTONS
(2) Identify and mark pistons. The pistons are Measure approximately 2 mm (0.080 in.) above the
not interchangeable from bank to bank (Fig. 77). bottom of the piston skirt and across the thrust face
(2) Pistons with the letter R and arrow toward the (Fig. 80).
front of engine are to be installed in cylinders 1-3-5.
Pistons with the letter L and arrow toward the front
of engine are to be installed in cylinders 2-4-6.
Fig. 76 Pistons and Connecting Rods

FITTING PISTON RINGS
(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 16 mm (0.63 in.) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 81).
Refer to Piston Ring Specification Chart.
(2) Check piston ring to groove clearance (Fig. 82).
Refer to Engine Specifications in this section.
Fig. 78 Mark Matching Parts

1 – CYLINDER NUMBER
Fig. 81 Check Gap on Piston Rings

1 – FEELER GAUGE
Fig. 79 Remove Piston Rings
Fig. 82 Piston Ring Clearance
Fig. 80 Piston Clearance and Wear

PISTON RINGS—INSTALLATION (2) Install the side rail by placing one end between
(1) The No. 1 and No. 2 piston rings have a differ- the piston ring groove and the expander. Hold end
ent cross section. Install rings with manufacturers firmly and press down the portion to be installed
mark and size mark facing up, to the top of the pis- until side rail is in position. Do not use a piston
ton (Fig. 83). ring expander (Fig. 84).
(3) Install upper side rail first and then the lower
side rail.
(4) Using a piston ring expander, install No. 2 pis-
ton ring and then No. 1 piston ring (Fig. 85).
Fig. 83 Piston Ring—Installation

3 – SIDE RAIL Fig. 85 Installing Upper and Intermediate Rings
4 – SPACER EXPANDER
1 – NO. 1 RING
5 – OIL RING
2 – NO. 2 RING - INSTALL FIRST
CAUTION: Install piston rings in the following

order:
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. 86 Piston Ring End Gap Position

1 – SIDE RAIL UPPER
3 – PISTON PIN
4 – SIDE RAIL LOWER
5 – NO. 2 RING GAP AND SPACER EXPANDER GAP
(5) Position piston ring end gaps as shown in (Fig.

Fig. 84 Side Rail—Installation 86).
1 – SIDE RAIL END
(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 (10) Install the following components; referring to
forward, toward timing belt end. (Fig. 87) procedures in this section:
(8) Install the piston and connecting rod assembly • Oil pan
into there respective bore from the cylinder block top. • Cylinder heads
• Timing belt
CAUTION: Piston assemblies are not to be inter- • Cylinder head covers
changed from bank to bank. • Intake manifold/plenum
CRANKSHAFT
REMOVAL
(1) Remove engine assembly from vehicle. Refer to
procedure in this section.
(2) Remove timing belt and sprockets. Refer to pro-
cedures in this section.
(3) Remove front mounted oil pump assembly and
gasket (Fig. 89) and (Fig. 90).
(4) Remove rear oil seal retainer and seal as
assembly (Fig. 91).
(5) Release mono-block main bearing cap bolts
evenly. Remove lower bearing shells and identify for
reassembly.
Fig. 87 Identify Piston and Rod Assembly for (6) Lift out crankshaft and remove upper thrust
Cylinder Installation washers from each side of number three main bear-
1 – FRONT MARK “72” ing in the crankcase (Fig. 89).
INSTALLATION
(1) Install upper main bearing shells making cer-
tain oil holes are in alignment, and bearing tabs seat
in block tabs. All upper bearings have oil grooves
(Fig. 92).
(2) THRUST BEARINGS. Crankshaft thrust
bearings (washers) are installed at journal #3 sepa-
rately from the radial bearings. Thrust bearings
shown in (Fig. 92) are different, one has end position-
ing tabs, while the other is plain. One pair of each
thrust washers are installed into the block and one
pair into the main bearing cap (Fig. 92).
(3) Apply a thin film of grease to plain side of
thrust washers and position them on each side of
number three main bearing. Grooved surface towards
crankshaft.
Fig. 88 Connecting Rod and Cap (4) Oil the bearings and journals and install
1 – CYLINDER NUMBER
crankshaft.
2 – NOTCHES TO HOLD BEARING (5) Install lower main bearing shells without oil
grooves in mono-block cap.
(6) Install one pair of thrust washers in cap. Refer
(9) Check alignment marks made during disassem- to Thrust Bearings (Fig. 92).
bly and that bearing position notches new or used (7) Carefully install bearing cap with arrows (Fig.
are on the same side as shown in (Fig. 88). 93) toward timing belt end.
Fig. 89 Crankshaft and Cylinder Block

1 – GASKET 5 – THRUST BEARINGS (2 PAIRS)
2 – SEAL 6 – MAIN BEARING MONOBLOCK CAP
3 – CASE 7 – SEAL
4 – UPPER BEARING (GROOVED) 8 – OIL PUMP ASSEMBLY
Fig. 90 Oil Pump Assembly

1 – L= 25 (1 IN.) Fig. 91 Rear Seal Assembly
2 – L= 55 (2 1/8 IN.) 1 – 10mm (104 IN. LBS.)
3 – L= 60 (2 3/8 IN.)
4 – L= 55 (2 1/8 IN.)
Fig. 92 Main Bearings—Installation

1 – GROOVED 4 – MONOBLOCK MAIN BEARING CAP
2 – THRUST BEARING WITH TAB 5 – THRUST BEARING WITHOUT TAB
3 – PLAIN
(8) Oil the bearing cap bolt threads, install and (4) Remove bolts attaching oil seal retainer (Fig.
tighten bolts progressively in sequence shown in (Fig. 94).
93) to 80 N·m (60 ft. lbs.) torque. (5) Remove oil seal from retainer.
(9) Install rear oil seal retainer and seal. Refer to
procedure in this section. INSTALLATION
(10) Install oil pump assembly and gasket (Fig. 89) (1) Install oil seal in housing with Special Tool
and (Fig. 90). MD-998718 (Fig. 95).
(11) Install timing belt and sprockets. Refer to pro- (2) Apply Mopart Engine RTV GEN II or equiva-
cedures in this section. lent to oil seal housing (Fig. 96).
(12) Install engine assembly. Refer to procedure in (3) Apply light coating of engine oil to the entire
this section. circumference of oil seal lip.
(4) Install seal assembly on cylinder block and
CRANKSHAFT OIL SEAL AND RETAINER— tighten bolts to 12 N·m (104 in. lbs.).
REAR (5) Install oil pan.
REMOVAL Adhesive to bolt threads and tighten to 95 N·m (70
(1) Remove transaxle from vehicle. Refer to TRAN- ft. lbs.).
SAXLE AND POWER TRANSFER UNIT for proce- (7) Install transaxle. Refer to TRANSAXLE AND
dure. POWER TRANSFER UNIT for procedure.
(2) Remove flex plate.
(3) Remove oil pan. Refer to procedure in this sec-
tion.
Fig. 93 Crankshaft Main Bearing Cap
Fig. 95 Rear Crankshaft Oil Seal—Installation

Fig. 94 Crankshaft Oil Seal Retainer
1 – 10mm (104 IN. LBS.)
2 – SEAL
3 – HOUSING
Fig. 96 Apply Sealant to Oil Seal Housing

1 – MOPAR SILICONE RUBBER ADHESIVE SEALANT

REMOVAL
(1) Remove crankshaft damper. Refer to procedure
in this section.
(2) Remove timing belt covers and timing belt.
(3) Remove crankshaft sprocket and key.
Fig. 97 Crankshaft Front Oil Seal—Installation
(4) Pry out the front oil seal with a flat tip screw-
1 – PUMP CASE
driver. Cover the end of the screwdriver with a shop 2 – SEAL
towel. 3 – GUIDE
4 – CRANKSHAFT
CAUTION: Be careful not to nick or damage crank- 5 – SPECIAL TOOL MD-998717
shaft flange surface or oil pump housing.
INSTALLATION
(1) Install front oil seal into oil pump housing
using oil seal installer Special Tool MD-998717 (Fig.
97).
(2) Install crankshaft key and sprocket.
(3) Install timing belt and covers. Refer to proce-
(4) Install crankshaft damper. Refer to procedure
in this section
OIL PUMP
REMOVAL
ING SYSTEM for procedure. Fig. 98 Oil Pump Assembly
(2) Remove crankshaft damper and timing belt. 1 – L= 25 (1 IN.)
Refer to procedures in this section. 2 – L= 55 (2 1/8 IN.)
(3) Remove crankshaft sprocket and key. 3 – L= 60 (2 3/8 IN.)
(4) Remove 5 bolts that attach oil pump to block 4 – L= 55 (2 1/8 IN.)
(Fig. 98).
(5) Remove oil pump and gasket.
INSTALLATION (2) Check adaptor for cracks and oil leaks.
(1) Clean block and pump surfaces.
(2) Install new gasket (Fig. 99) make sure correct
length bolts are used (Fig. 98).
(3) Torque bolts to 13 N·m (120 in. lbs.).
Fig. 100 Oil Filter

1 – 15 N·m (130 IN. LBS.)
2 – GASKET
3 – BRACKET
4 – FILTER
Fig. 99 Oil Pump Components
1 – PUMP COVER
2 – GASKET (3) Wipe base clean.
3 – SCREW 9 N·m (104 IN. LBS.) (4) Lubricate gasket of new filter with clean
4 – OUTER ROTOR engine oil.
5 – INNER ROTOR (5) Install new filter until gasket contacts base.
6 – SPRING Tighten filter 1 turn or 20 N·m (15 ft. lbs.). Use filter
7 – PLUG–49 N·m (36 FT. LBS.) wrench if necessary.
8 – RELIEF PLUNGER (6) Start engine and check for leaks.
9 – SEAL
10 – OIL PUMP CASE
OIL FILTER ADAPTER
(4) Install crankshaft key and sprocket. REMOVAL
(5) Install timing belt. (1) Remove oil filter using a suitable oil filter
(6) Install crankshaft damper. wrench. Turn filter counterclockwise to remove from
(7) Install accessory drive belts. Refer to COOL- base. Properly discard filter.
ING SYSTEM for procedure. (2) Remove bolts attaching oil filter adapter to cyl-
inder block (Fig. 101).
OIL FILTER (3) Remove adapter and gasket.
(1) Check the oil filter adapter mounting surfaces.
CAUTION: When servicing the oil filter avoid The surface must be smooth, flat and free of debris.
deforming the filter. Install the remove/install tool (2) Clean all mounting surfaces.
band strap against the can-to-base lock seam. The (3) Install adapter and gasket to cylinder block.
lock seam joining the can-to-base is reinforced by Tighten mounting screws to 15 N·m (130 in. lbs.).
the base plate. (4) Lubricate gasket of oil filter with clean engine
oil.
(1) Using a suitable oil filter wrench, turn filter (5) Install oil filter until gasket contacts base.
counterclockwise to remove from base. Properly dis- Tighten filter 1 turn or 20 N·m (15 ft. lbs.). Use filter
card filter. wrench if necessary.
(6) Start engine and check for leaks.
INSTALLATION
(1) Check the oil filter mounting surface. The sur-
face must be smooth, flat and free of debris or old
pieces of rubber (Fig. 100).
INSTALLATION
Thoroughly clean inside of cup plug hole in cylin-
Lightly coat inside of cup plug hole with Mopart
Stud & Bearing Mount or equivalent. Make certain
the new plug is cleaned of all oil or grease. Using a
proper drive tool, drive plug into oil gallery hole so
that the sharp edge of the plug is at least 0.5 mm
(0.020 in.) inside the lead-in chamfer.
DISASSEMBLY AND ASSEMBLY

Fig. 101 Oil Filter Adapter

DISASSEMBLE
(1) Disassemble rocker arms and shafts by first
1 – 15 N·m (130 IN. LBS.)
2 – GASKET removing bolts from bearing caps.
3 – BRACKET
4 – FILTER NOTE: Identify each component for reinstallation in
the original position.
ENGINE CORE AND OIL GALLERY PLUGS (2) Remove bearing caps, waved washers, springs,
and rocker arms (Fig. 106).
REMOVAL (3) Clean and inspect all components for damage
Using a blunt tool such as a drift and a hammer, and wear. Refer to procedures in this section.
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit- ASSEMBLE
able tool and remove plug (Fig. 102). The rocker arm shaft is hollow and is used as a
lubrication oil duct. The rocker arm shaft on the
CAUTION: Do not drive cup plug into the casting inlet side has a 3 mm (0.188 in.) diameter oil pas-
as restricted flow can result and cause serious sage hole from the cylinder head. The exhaust side
engine problems. does not have this oil passage (Fig. 103).
Fig. 103 Rocker Arm Shaft Identification
Fig. 102 Core Hole Plug Removal

1 – CYLINDER BLOCK
2 – REMOVE PLUG WITH PLIERS
3 – STRIKE HERE WITH HAMMER
4 – DRIFT PUNCH
5 – CUP PLUG
DISASSEMBLY AND ASSEMBLY (Continued)
(1) Align the camshaft bearing caps with arrows (3) Install attaching bolts in the number one bear-
(depending on cylinder bank) directed as shown in ing cap to retain assembly.
(Fig. 104) and in numerical order. Identify number
one bearing cap; number one and number four caps
are similar (Fig. 105).
Fig. 105 Number One Camshaft Bearing Cap

1 – NOTCH
2 – CAP NUMBER
3 – BEARING CAP NO. 1
(4) Install the rocker arms, bearing caps, waved

washers, and springs. The waved washers are located
between the bearing caps and rocker arms (Fig. 107).
Position the flat area of the washer to the rocker arm
side as shown in (Fig. 107). The springs are the same
Fig. 104 Camshaft Bearing Caps Position length except for one (Fig. 106). This spring is
1 – ARROW MARK (BEARING CAP) shorter in length and is identified with white paint
2 – ARROW MARK (CYLINDER HEAD) marks at both ends.
3 – APPLY SEALANT
(5) Insert bolts in each bearing cap to retain
4 – ARROW MARK (BEARING CAP)
assembly.
(2) Install rocker shafts so that bearing cap num-

ber one with end notches positioned as shown in (Fig.
105) and the machined portion of the rocker shaft is
facing down.
Fig. 106 Rocker Arms and Shafts

1 –
CAP NO. 3 6 – ROCKER ARM
2 –
CAP NO. 4 7 – WAVED WASHER
3 –
SPRING — SHORTER IN LENGTH 8 – CAP NO. 1
4 –
CAP NO. 2 WITH OIL INLET (INTAKE) FROM CYLINDER 9 – SHAFTS
HEAD
5 – SPRING
NOTE: If none of the above conditions are seen on
the belt, the belt cover can be installed.
Fig. 108 Timing Belt Inspection

1 – PEELING
2 – TOOTH MISSING AND CANVAS FIBER EXPOSED
3 – RUBBER EXPOSED
4 – CRACKS
5 – PEELING
Fig. 107 Waved Washer Locations and Position 6 – ROUNDED EDGE
1 – FLAT TO ROCKER ARM SIDE 7 – ABNORMAL WEAR (FLUFFY STRAND)
2 – WAVED WASHER

CLEANING AND INSPECTION ROCKER ARMS
(1) Disassemble and check rocker arms for wear or
TIMING BELT damage (Fig. 110). Replace as necessary.
INSPECTION ROCKER ARM SHAFTS

(1) Remove the upper front outer timing belt cover The rocker arm shaft is hollow and is used as a
by loosening the three attaching bolts (Fig. 109). lubrication oil duct. The rocker arm shaft on the
(2) Inspect both sides of the timing belt drive & inlet side has a 3 mm (0.188 in.) diameter oil pas-
back. Replace belt if any of the following conditions sage hole from the cylinder head. The exhaust side
exist: does not have this oil passage (Fig. 111).
• Rubber back side is glossy, hardened back with- (1) Inspect the rocker arm mounting portion of the
out resilience and leaves no indent when pressed shafts for wear or damage. Replace if heavily dam-
with fingernail. aged or worn.
• Cracks on rubber back. (2) Check oil holes for clogging with small wire,
• Cracks or peeling of canvas. clean as required (Fig. 111).
• Cracks on rib root.
• Missing teeth.
• The sides are normal if they are sharp as if cut
by a knife (Fig. 108).
CYLINDER HEAD
CLEANING AND INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
Fig. 109 Timing Belt Covers

1 – BRACKET HARNESS CLIP
Fig. 112 Check Cylinder Head
2 – REAR COVER D BOLTS (3) Check cylinder head for flatness (Fig. 112).
3 – COVER (REAR REFERENCE) (4) Cylinder head must be flat within:
4 – BRACKET HARNESS CLIP • Standard dimension = less than 0.05 mm (.002
5 – UPPER FRONT COVER (OUTER)
in.)
6 – UPPER REAR COVER
• Service Limit = 0.2 mm (.008 in.)
7 – LOWER COVER
• Grinding Limit = Maximum of 0.2 mm (.008 in.)
is permitted.
CAUTION: This is a combined total dimension of

stock removal from cylinder head if any and block
top surface.
CYLINDER BORE
INSPECTION
(1) Measure the cylinder bore at three levels in
directions A and B (Fig. 113). Top measurement
Fig. 110 Inspect Rocker Arms should be 12 mm (0.50 in.) down and bottom mea-
1 – AUTO-LASH ADJUSTER surement should be 10 mm (0.38 in.) up.
(2) Standard bore dimension: 91.1 mm (3.587 in.)
(3) Maximum out-of-round or taper: 0.02 mm
(0.0008 in.).
CAMSHAFT
INSPECTION
(1) Inspect camshaft bearing journals for damage
and binding (Fig. 114). If journals are binding, also
check the cylinder head for damage. Also check cyl-
inder head oil holes for clogging.
(2) Front cylinder head camshaft check the tooth
Fig. 111 Rocker Arm Shaft Identification surface of the distributor drive gear teeth of the cam-
(2) Remove pump rotors and inspect case for exces-
sive wear.
(3) Measure clearance between case and inner
rotor (Fig. 115).
Fig. 115 Inner Rotor to Case

1 – CASE
2 – INNER ROTOR
shaft and replace if abnormal wear is evident (Fig.
(4) Insert the rotor into the oil pump case and
114).
measure clearance between outer rotor and case with
(3) Check the cam surface for abnormal wear and
a feeler gauge (Fig. 116). Replace if out of specifica-
damage and replace if defective. Also measure the
tions.
cam bearing journals (Fig. 114) and replace if out of
limit. Refer to Engine Specifications in this section.
Fig. 116 Measuring Clearance Between Outer Rotor

and Case
1 – 0.10 TO 0.18 mm (0.004 TO 0.007 INCH)
(5) Using a feeler gauge, measure clearance

between inner rotor tip and outer rotor (Fig. 117).
Clearance specification is: 0.06 - 0.18 mm (0.003 -
Fig. 114 Checking Camshafts 0.007 in.). Replace both rotors if not within specifica-
tions
OIL PUMP (6) Place a straightedge across face of pump hous-
(1) Check oil pump case for damage. Remove rear ing (Fig. 118). Clearance specification is: 0.04 - 0.10
oil pump cover.
Bore 91.1 mm
(3.587 in.)
Stroke 76.0 mm
(2.992 in.)
Compression Ratio 8.85:1
Firing Order 1-2-3-4-5-6
Compression Pressure 1227 kPa
(at 250–400 rpm) (178 psi)
Compression Pressure 689 kPa
(Minimum) (100 psi)
Variation Between 25%
Fig. 117 Measuring Clearance Between Rotors Cylinders (Maximum)
Cylinder Block
Cylinder Bore Diameter 9101
(3.587 in.)
Out-of-Round (Max.) 0.01 mm
(0.0004 in.)
Taper (Max.) 0.01 mm
(0.0004 in.)
Flatness of Top Surface 0.05 mm
(0.002 in.)
Service Limit 0.1 mm
(0.004 in.)
Grinding Limit* 0.2 mm
Fig. 118 Measuring Clearance Over Rotors
(0.008 in.)
mm (0.0015 - 0.0039 in.). Replace oil pump assembly
if not within specifications. *Includes the combined surface grinding of cylinder
head and block.
OIL RELIEF PLUNGER Pistons
(1) Check that the oil relief plunger slides
Piston Diameter 91.06–91.09 mm
smoothly.
(2) Check for broken relief spring. (3.5851–3.563 in.)
Clearance in Cylinder 0.03–0.05 mm
SPECIFICATIONS (0.0012–0.002 in.)
Piston Pins
3.0L ENGINE Press-in Load (at room 7350–17200 N
temperature) (1652–3858 lbs.)
DESCRIPTION SPECIFICATION Diameter 22.0 mm
General Specification (0.87 in.)
Type 60° V-6 SOHC (Per Piston Rings
Bank)
Ring Gap—Top 0.30–0.45 mm
Number of Cylinders 6 Compression Ring (0.0012–0.018 in.)
Displacement 3.0 Liters
Wear Limit 0.8 mm
(181 cu. in.)
(0.031 in.)

Ring Gap—2nd 0.45–0.60 mm Main Bearing Diametrical 0.018–0.036 mm
Compression Ring (0.018–0.024 in.) Clearance (0.0007–0.0014 in.)
Wear Limit 0.8 mm Wear Limit 0.1 mm
(0.031 in.) (0.0039 in.)
Ring Gap—Oil Control 0.20–0.60 mm Camshaft
Steel Rails (0.008–0.024 in.) Journal Diameter 41.25 mm
Wear Limit 0.10 mm (1.624 in.)
(0.004 in.) Wear Limit 40.75 mm
Ring Side Clearance— 0.03–0.07 mm (1.604 in.)
Top Compression Ring (0.0012–0.0028 in.) End Play 0.1–0.2 mm
Wear Limit 0.10 mm (0.004–0.008 in.)
Ring Side Clearance— 0.02–0.06 mm (0.004–0.008 in.)
2nd Compression Ring (0.0008–0.0024 in.) Intake Valve Timing*
Wear Limit 0.10 mm Closes (ABDC) 59°
(0.004 in.) Opens (BTDC) 19°
Connecting Rod Exhaust Valve Timing*
Bearing Diametrical 0.018–0.036 mm Closes (ATDC) 19°
Clearance (0.0007–0.0014 in.) Opens (BBDC) 59°
Side Clearance (big end) 0.10–0.25 mm Cylinder Head
(0.004–0.010 in.) Flatness of Gasket 0.05 mm
Wear Limit 0.40 mm Surface (0.002 in.)
(0.0158 in.) Grinding Limit of Gasket 0.2 mm
Length (Center-to-Center) 140.9–141.0 mm Surface* (0.008 in.)
(5.547–5.551 in.) *Includes the combined surface grinding of cylinder
Parallelism (Twist) 0.05 mm head and block.
(0.0019 in.) Valve Seat
Torsion 0.10 mm Angle 44–44°.3’
(0.004 in.) Valve Seat Width—Intake 0.9–1.3 mm
Crankshaft and Exhaust (0.035–0.051 in.)
Connecting Rod Journal 49.98–50.0 mm Sinkage—Service Limit 0.2 mm
Diameter (1.968–1.969 in.) (0.078 in.)
Main Bearing Journal 59.98–60.00 mm Valve Guide
Diameter (2.361–2.362 in.) Diameter—Inner 8.000–8.018 mm
Journal Out-of-Round 0.03 mm (0.314–0.315 in.)
(Max.) (0.001 in.) Diameter—Outer 13.055–13.065 mm
Journal Taper (Max.) 0.005 mm (0.514–0.5143 in.)
(0.0002 in.) Guide Height (spring seat 14.45–14.75 mm
End Play 0.05–0.25 mm to guide tip) (0.568–0.580 in.)
(0.002–0.0098 in.) Guide Overall Length— 44 mm
Wear Limit 0.3 mm Intake (1.732 in.)
(0.012 in.)

Guide Overall Length— 48 mm Service Limit 48.8 mm
Exhaust (1.889 in.) (1.921 in.)
Valves Installed Height 40.4 mm
Face Angle Intake and 45–45° 30’ (1.59 in.)
Exhaust Spring Load at Installed 321 N
Valve Length (Overall)— 103.0 mm Height (73 lbs.)
Intake 4.055 in.) Out-of-Squareness 2° or less
Valve Length (Overall)— 102.7 mm Service Limit 4° Max.
Exhaust (4.043 in.) Oil Pump
Valve Stem Diameter— 7.960–7.975 mm Tip Clearance Between 0.150 mm
Intake (0.313–0.314 in.) Rotors (0.0068 in.)
Valve Stem Diameter— 7.930–7.950 mm Clearance Over Rotors 0.077 mm
Exhaust (0.312–0.3125 in.) (0.003 in.)
Valve Head Diameter— 48.64–48.90 mm Outer Rotor to Case 0.19 mm
Intake (1.915–1.925 in.) Clearance (0.007 in.)
Valve Head Diameter— 40.01–40.26 mm Service Limit 0.35 mm
Exhaust (1.575–1.585 in.) (0.0138 in.)
Valve Margin Cover Out-of-Flat (Max.) 0.076 mm
Intake 1.2 mm (0.003 in.)
(0.047 in) Inner Rotor Thickness 18.92 mm
Service Limit 0.7 mm (Min.) (0.744 in.)
(0.027 in.) Outer Rotor Diameter 82.45 mm
Exhaust 2.0 mm (Min.) (3.246 in.)
(0.079 in.) Outer Rotor Thickness 18.92 mm
Service Limit 1.5 mm (Min.) (0.744 in.)
(0.059 in.) Oil Pressure
Valve Stem Tip Height At Curb Idle Speed and 68.9 kPa
Intake and Exhaust 49.02 mm Engine at Operating
Temperature (10 psi)
(1.929 in.)
At 3000 rpm* 310–517 kPa
Valve Stem to Guide Clearance
(45–75 psi)
Intake 0.03–0.06 mm
(0.001–0.002 in.) at 3000 rpm.
(0.004 in.) TORQUE
Exhaust 0.05–0.09 mm
(0.0019–0.003 in.) DESCRIPTION N·m Ft. In.
Lbs. Lbs.
(0.0071 in.)
Camshaft Bearing 20 — 180
Valve Springs Cap/Rocker Arm
Free Length (Approx.) 49.8 mm Shaft—Bolts*
(1.960 in.) Connecting Rod 52 38 —
Cap—Bolts
DESCRIPTION N·m Ft. In. SPECIAL TOOLS

Lbs. Lbs.
Crankshaft Main Bearing 83 61 —
3.0L ENGINE
Cap—Bolts*
Crankshaft Damper 135 100 —
Cylinder Head—Bolts* 108 80 —
Cylinder Head Cover— 10 — 88
Bolts
Distributor Hold 13 — 115
Down—Nut
Distributor Adaptor—Bolts 13 — 115
Drive Plate to Crankshaft 95 70 — Dolly 6135
Engine Mount Bracket 41 30 —
Right—Bolts
Engine Mounting Refer to Procedure
Exhaust Manifold to 20 — 175
Cylinder Head—Bolts
Exhaust Manifold Heat 15 — 130
Shield—Bolts
Exhaust Manifold 69 51 —
Crossover—Bolts
Intake Manifold Upper— 15 — 130 Cradle 6710
Bolts*
Intake Manifold Lower— 20 — 174
Nuts*
Oil Filter Adaptor—Bolts 15 — 130
Oil Pan—Bolts 6 — 50
Oil Pan Drain—Plug 39 29 —
Oil Pump to Block—Bolts 15 — 130
Oil Pump Cover 9 — 104 Adaptor 6909
Plate—Bolts
Oil Pump Relief Valve 49 36 —
Cap
Oil Pump Pick-up 22 — 191
Tube—Bolt
Oil Dipstick Housing—Bolt 48 35 —
Oil Seal Retainer—Bolts 11 — 97
Spark Plug 28 20 —
Timing Belt Cover—Bolts 14 — 115
Timing Belt Tensioner— 28 — 250 Adaptor 6910
Bolt
Water Pump to Block— 27 — 240
Bolts
*Tightening Sequence Required. Refer to procedures.
Camshaft Seal Installer MD-998713

Front Crankshaft Seal Installer MD-998717
Camshaft End Plug Installer MD-998306 Spanner Camshaft Sprocket MB-990775

Lash Adjuster Retainers MD-998443
Valve Stem Seal Installer MD-998729
Adaptor 8116
Rear Crankshaft Seal Installer MD-998718
9 - 128 3.3/3.8L ENGINE NS
3.3/3.8L ENGINE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION MEASURING TIMING CHAIN FOR STRETCH. . . 150

3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 129 REMOVAL AND INSTALLATION
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . 129 ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . 151
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 129 ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . 152
PISTON AND CONNECTING ROD . . . . . . . . . . . 130 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 154
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 130 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 158
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 130 CRANKSHAFT DAMPER . . . . . . . . . . . . . . . . . . 159
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 160
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 130 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 161
PUSHRODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 ROCKER ARMS AND SHAFT . . . . . . . . . . . . . . . 162
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 131 VALVE STEM SEALS OR SPRINGS—
ROCKER ARMS AND SHAFT . . . . . . . . . . . . . . . 131 CYLINDER HEAD NOT REMOVED . . . . . . . . . 162
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 131 VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 163
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 131 HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 163
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . 131 TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . . 164
DIAGNOSIS AND TESTING TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 166
ENGINE DIAGNOSIS—INTRODUCTION. . . . . . . 132 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
ENGINE DIAGNOSIS—PERFORMANCE . . . . . . 133 CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . 167
ENGINE DIAGNOSIS—MECHANICAL. . . . . . . . . 134 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . 136 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
CYLINDER COMPRESSION PRESSURE TEST . 136 OIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . 169
CYLINDER COMBUSTION PRESSURE PISTON AND CONNECTING ROD . . . . . . . . . . . 169
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 136 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 171
CYLINDER HEAD GASKET FAILURE CRANKSHAFT OIL SEAL—FRONT. . . . . . . . . . . 171
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . 137 CRANKSHAFT OIL SEAL—REAR . . . . . . . . . . . . 173
LASH ADJUSTER (TAPPET) NOISE CRANKSHAFT OIL SEAL RETAINER—REAR . . . 173
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . 137 OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . 138 ENGINE CORE AND OIL GALLERY PLUGS . . . . 174
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 139 DISASSEMBLY AND ASSEMBLY
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . 139 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
SERVICE PROCEDURES CLEANING AND INSPECTION
ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 175
ENGINE OIL SERVICE . . . . . . . . . . . . . . . . . . . . 140 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 175
FORM-IN-PLACE GASKETS & SEALERS . . . . . . 141 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 175
ENGINE GASKET SURFACE PREPARATION . . . 142 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
HYDROSTATIC LOCKED ENGINE . . . . . . . . . . . 142 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
CYLINDER BORE—HONING . . . . . . . . . . . . . . . 143 CYLINDER BLOCK AND BORE . . . . . . . . . . . . . 178
CRANKSHAFT MAIN BEARING—FITTING . . . . . 144 SPECIFICATIONS
CRANKSHAFT END PLAY . . . . . . . . . . . . . . . . . 145 3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 178
PISTON AND RING—FITTING . . . . . . . . . . . . . . 146 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
CONNECTING ROD AND BEARING—FITTING. . 146 SPECIAL TOOLS
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 148 3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 182
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . 150
NS 3.3/3.8L ENGINE 9 - 129
DESCRIPTION AND OPERATION

3.3/3.8L ENGINE
DESCRIPTION
The 3.3 Liter (152 cu. in.) and 3.8 Liter (231 cu.
in.) engines are 60° V-6 engines with cast iron cylin-
der blocks and aluminum cylinder heads (Fig. 1). The
engine uses a single, block mounted camshaft with
pushrods to actuate the valves. These engines do not
have provisions for a free wheeling valve train.
The firing order is 1–2–3–4–5–6. The cylinders are
numbered from the front of the engine to the rear.
The front cylinder bank is numbered 2, 4, and 6. The
rear cylinder bank is numbered 1, 3, and 5.
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 2).
CYLINDER BLOCK
DESCRIPTION Fig. 2 Engine Identification
The cylinder block is made of cast iron and is a
bearing. Crankshaft end sealing is provided by front
deep skirt design.
and rear rubber seals.
CRANKSHAFT OPERATION
The crankshaft converts the reciprocating power
DESCRIPTION
generated by combustion within the cylinder into
The nodular iron crankshaft is supported by four
rotary power to the flywheel or flexplate.
main bearings, with number two position the thrust
Fig. 1 3.3/3.8L V-6 Engines

9 - 130 3.3/3.8L ENGINE NS

DESCRIPTION
The pistons are made of cast aluminum alloy and
are a strutless, short skirt design. The piston rings
consist of two compression rings and a three piece oil
ring. Piston pins connect the piston to the forged
steel connecting rods. The piston pins are a press fit
into the connecting rod.
OPERATION
The piston and connecting rod is the link between
the combustion chamber and the crankshaft.
CYLINDER HEAD
DESCRIPTION
The aluminum cylinder heads are designed to cre-
ate high flow combustion chambers to improve per-
formance, while minimizing the change to the burn
rate of the chamber. The cylinder head incorporates
the combustion chamber. Two valves per-cylinder are Fig. 3 Cylinder Head Cover
used with integral valve seats and guides. A steel 1 – ISOLATED CYLINDER HEAD COVER
flanged composition type gasket is used between
head and block.
OPERATION
The camshaft is driven by the crankshaft through
OPERATION
a timing chain and sprockets. The camshaft has pre-
The cylinder head closes the combustion chamber,
cisely machined (egg-shaped) lobes to provide accu-
allowing the pistons to compress the air/fuel mixture
rate valve timing and duration.
for ignition. The valves are actuated by the lobe pro-
duration to either allow clean air in, or the exhaust
HYDRAULIC TAPPETS
gases out of the combustion chamber.
DESCRIPTION
The hydraulic tappets are a roller type design and
CYLINDER HEAD COVER are positioned in the cylinder block. The tappets are
retained by an alignment yoke and a retainer (Fig.
DESCRIPTION
4).
The cylinder head covers are made of stamped
steel. The covers are sealed with steel reinforced sil-
icon rubber gaskets. The cylinder head cover uses
rubber isolators at each fastener location (Fig. 3).
CAMSHAFT
DESCRIPTION
The nodular iron camshaft is mounted in the
engine block and supported with four steel backed
babbitt bearings. A thrust plate, located in front of
the first bearing, is bolted to the block and controls
the camshaft end play.
Fig. 4 Hydraulic Tappets

1 – YOKE RETAINER
2 – ALIGNING YOKE
NS 3.3/3.8L ENGINE 9 - 131
PUSHRODS INTAKE MANIFOLD

The pushrods are made of steel and are a hollow The intake manifold is a tuned two-piece alumi-
design. The pushrods are positioned between the num casting with individual primary runners leading
hydraulic tappet and the rocker arm. from a plenum to the cylinders. The lower intake
attaches to the cylinder heads and the upper intake
OPERATION attaches to the lower intake. The manifold is
The pushrod is a solid link between the hydraulic designed to boost torque in the 3600 RPM range and
tappet and the rocker arm. Also, the pushrod sup- contributes to the engine’s broad, flat torque curve,
plies engine oil from the hydraulic tappet to the which was desired for excellent engine tractability,
rocker arm. response and usable power output.
VALVES AND VALVE SPRINGS OPERATION

The intake manifold directs and delivers air to
DESCRIPTION combustion chambers. The air allows the fuel deliv-
The valves have chrome plated valve stems. The ered by the fuel injectors to ignite, thus producing
valve stem seals are Viton rubber with integral valve power.
seats.
The valve springs are made of chrome silicone EXHAUST MANIFOLD
alloy wire and are a “beehive” shape design. The
springs are common between intake and exhaust. DESCRIPTION
The exhaust manifolds are log type and made of
OPERATION nodular cast iron. The exhaust manifolds are
The two valves per cylinder are opened by using attached directly to the cylinder heads and a cross-
roller hydraulic tappets, push rods, and rocker arms. over pipe connects the two manifolds.
The valve springs provide tension on the valve and
valvetrain to properly close the valve. OPERATION
The exhaust manifolds collects the exhaust gases
ROCKER ARMS AND SHAFT exiting the combustion chambers. It then channels
the exhaust gasses to the exhaust pipe that is
DESCRIPTION attached to the rear (right side) manifold.
The rocker arms are installed on the rocker arm
shaft and attached to the cylinder head with four ENGINE LUBRICATION SYSTEM
bolts and retainers. The rocker arms are made of
stamped steel. DESCRIPTION
The lubrication system is a full flow filtration pres-
OPERATION sure feed type. The oil pump is mounted in the front
The rocker arm pivots on the rocker shaft. Rocker engine cover and is driven by the crankshaft
arms are used to change upward force provided by
the camshaft, hydraulic tappet, and pushrod on one OPERATION
end, into a downward force on the valve stem on the Oil from the oil pan is pumped by a internal gear
other end. type oil pump directly coupled to the crankshaft. The
pressure is regulated by a relief valve located in the
chain case cover. The oil is pumped through an oil fil-
ter and feeds a main oil galley. This oil gallery feeds
oil under pressure to the main and rod bearings,
camshaft bearings. Passages in the cylinder block
feed oil to the hydraulic lifters and rocker shaft
brackets which feeds the rocker arm pivots (Fig. 5).
9 - 132 3.3/3.8L ENGINE NS
Fig. 5 Engine Oiling System

1 – OIL SUPPLY FOR BALL SOCKET THROUGH PUSH ROD 6 – OUTER ROTOR
2 – ROCKER SHAFT 7 – INNER ROTOR
3 – OIL SUPPLY PASSAGE FROM SHAFT TO ROCKER ARM 8 – RELIEF VALVE
SADDLE 9 – OIL PAN
4 – OIL FLOWS TO ONLY ONE BRACKET ON EACH HEAD. 10 – OIL SCREEN
BRACKET IS SECOND FROM REAR ON RIGHT HEAD.
BRACKET IS SECOND FROM FRONT ON LEFT HEAD 11 – OIL PUMP CASE
5 – CRANKSHAFT

NS 3.3/3.8L ENGINE 9 - 133
STARTING.
SYSTEM.
filter.
sprocket.
ROUGH FUEL SYSTEM.

IGNITION SYSTEM.
filter.
cylinder.
system.
9 - 134 3.3/3.8L ENGINE NS

fuel filter.
filter.
crankcase. level.

level.
on valve faces.
NS 3.3/3.8L ENGINE 9 - 135

flanges.
or worn. journals.
converter.

or replace.
cracked.
clearance.

gaskets.
metal part. part.
threaded plug.
9 - 136 3.3/3.8L ENGINE NS
CONTROL SYSTEMS.
rings.
seal(s).
damaged.
INTAKE MANIFOLD LEAKAGE DIAGNOSIS (4) Disconnect coil wire from distributor and
An intake manifold air leak is characterized by secure to good ground to prevent a spark from start-
lower than normal manifold vacuum. Also, one or ing a fire (Conventional Ignition System). For Direct
more cylinders may not be functioning. Ignition System DIS disconnect the coil connector.
(5) Be sure throttle blade is fully open during the
WARNING: USE EXTREME CAUTION WHEN THE compression check.
ENGINE IS OPERATING. DO NOT STAND IN A (6) Insert compression gage adaptor Special Tool
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR 8116 or the equivalent, into the #1 spark plug hole in
HANDS NEAR THE PULLEYS, BELTS OR THE FAN. cylinder head. Connect the 0–500 psi (Blue) pressure
DO NOT WEAR LOOSE CLOTHING. transducer with cable adaptors to the DRBIIIt.
(7) Crank engine until maximum pressure is
(1) Start the engine. reached on gage. Record this pressure as #1 cylinder
(2) Spray a small stream of water (Spray Bottle) at pressure.
the suspected leak area. (8) Repeat the previous step for all remaining cyl-
(3) If engine RPM’S change, the area of the sus- inders.
pected leak has been found. (9) Compression should not be less than 689 kPa
(4) Repair as required. (100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
CYLINDER COMPRESSION PRESSURE TEST (10) If one or more cylinders have abnormally low
The results of a cylinder compression pressure test compression pressures, repeat the compression test.
can be utilized to diagnose several engine malfunc- (11) If the same cylinder or cylinders repeat an
tions. abnormally low reading on the second compression
Ensure the battery is completely charged and the test, it could indicate the existence of a problem in
engine starter motor is in good operating condition. the cylinder in question. The recommended com-
Otherwise the indicated compression pressures may pression pressures are to be used only as a
not be valid for diagnosis purposes. guide to diagnosing engine problems. An engine
(1) Check engine oil level and add oil if necessary. should not be disassembled to determine the
(2) Drive the vehicle until engine reaches normal cause of low compression unless some malfunc-
operating temperature. Select a route free from traf- tion is present.
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times CYLINDER COMBUSTION PRESSURE LEAKAGE
briskly. TEST
(3) Remove all spark plugs from engine. As spark The combustion pressure leakage test provides an
plugs are being removed, check electrodes for abnor- accurate means for determining engine condition.
mal firing indicators fouled, hot, oily, etc. Record cyl- Combustion pressure leakage testing will detect:
inder number of spark plug for future reference. • Exhaust and intake valve leaks (improper seat-
ing).
NS 3.3/3.8L ENGINE 9 - 137
jacket. between adjacent cylinders will result in approxi-
• Any causes for combustion/compression pressure mately a 50–70% reduction in compression pressure.
loss.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WITH THE SYSTEM HOT AND UNDER PRESSURE WARNING: USE EXTREME CAUTION WHEN THE
BECAUSE SERIOUS BURNS FROM COOLANT CAN ENGINE IS OPERATING WITH COOLANT PRES-
OCCUR. SURE CAP REMOVED.
Check the coolant level and fill as required. DO

NOT install the radiator cap. VISUAL TEST METHOD
Start and operate the engine until it attains nor- With the engine cool, remove the coolant pressure
mal operating temperature, then turn the engine cap. Start the engine and allow it to warm up until
OFF. thermostat opens.
Clean spark plug recesses with compressed air. If a large combustion/compression pressure leak
Remove the spark plugs. exists, bubbles will be visible in the coolant.
Remove the oil filler cap.
Remove the air cleaner. COOLING SYSTEM TESTER METHOD
Calibrate the tester according to the manufactur-
er’s instructions. The shop air source for testing WARNING: WITH COOLING SYSTEM TESTER IN
should maintain 483 kPa (70 psi) minimum, 1,379 PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
kPa (200 psi) maximum, with 552 kPa (80 psi) rec- SIVE PRESSURE BUILT UP, BY CONTINUOUS
ommended. ENGINE OPERATION, MUST BE RELEASED TO A
Perform the test procedures on each cylinder SAFE PRESSURE POINT. NEVER PERMIT PRES-
according to the tester manufacturer’s instructions. SURE TO EXCEED 138 kPa (20 psi).
While testing, listen for pressurized air escaping
Install Cooling System Tester 7700 or equivalent to
through the throttle body, tailpipe and oil filler cap
pressure cap neck. Start the engine and observe the
opening. Check for bubbles in the radiator coolant.
tester’s pressure gauge. If gauge pulsates with every
All gauge pressure indications should be equal,
power stroke of a cylinder a combustion pressure
with no more than 25% leakage per cylinder.
leak is evident.
FOR EXAMPLE: At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main- CHEMICAL TEST METHOD
tained in the cylinder.
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
CYLINDER HEAD GASKET FAILURE DIAGNOSIS equivalent. Perform test following the procedures
supplied with the tool kit.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
der head. Low speed running up to 1 hour may be
jacket are:
required.
• Loss of coolant
exhaust
temperature.
• Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST (5) The oil restrictor pressed into the vertical oil
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
oil pump pick up.
dures in Cylinder Compression Pressure Test in this
9 - 138 3.3/3.8L ENGINE NS
(7) Worn valve guides. • If the leakage occurs at the crankshaft rear oil
(8) Rocker arm ears contacting valve spring seal area, refer to the section, Inspection for Rear
retainer. Seal Area Leak.
(9) Rocker arm loose, adjuster stuck or at maxi- (6) If no leaks are detected, turn off the air supply.
mum extension and still leaves lash in the system. Remove the air hose, all plugs, and caps. Install the
(10) Faulty lash adjuster. PCV valve and fresh air hose (make-up air). Proceed
a. Check lash adjusters for sponginess while to next step.
installed in cylinder head. Depress part of rocker (7) Clean the oil off the suspect oil leak area using
arm over adjuster. Normal adjusters should feel very a suitable solvent. Drive the vehicle at various
firm. Spongy adjusters can be bottomed out easily. speeds approximately 24 km (15 miles). Inspect the
b. Remove suspected lash adjusters, and replace as engine for signs of an oil leak by using a black light.
necessary.
NOTE: If oil leakage is observed at the dipstick
ENGINE OIL LEAK INSPECTION tube to block location; remove the tube, clean and
Begin with a thorough visual inspection of the reseal using MoparT Stud & Bearing Mount (press
engine, particularly at the area of the suspected leak. fit tube applications only), and for O-ring style
If an oil leak source is not readily identifiable, the tubes, remove tube and replace the O-ring seal.
following steps should be followed:
time because some solvents may cause rubber to
INSPECTION FOR REAR SEAL AREA LEAKS
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
area:
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var-
repeat inspection.
inspection.
(5) If the oil leak source is not positively
identified at this time, proceed with the air leak
seal leakage or crankshaft damage.
detection test method as follows:
(b) Where leakage tends to run straight down,
• Disconnect the fresh air hose (make-up air) at
possible causes are a porous block, oil gallery cup
the cover.
• Remove the PCV valve hose from the cylinder
these items.
head cover. Cap or plug the PCV valve nipple on the
cover.
case as previously described.
• Attach an air hose with pressure gauge and reg-
ulator to the dipstick tube. CAUTION: Do not exceed 20.6 kPa (3 psi).
CAUTION: Do not subject the engine assembly to (5) If the leak is not detected, very slowly turn the
more than 20.6 kpa (3 PSI) of test pressure. crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
procedures.
NS 3.3/3.8L ENGINE 9 - 139
CAUTION: Use extreme caution when crankshaft OIL LEVEL TOO HIGH
polishing is necessary to remove minor nicks and If oil level is above the MAX mark on dip stick, it
scratches. The crankshaft seal flange is especially is possible for the connecting rods to dip into the oil
machined to complement the function of the rear oil while engine is running and create foam. Foam in oil
seal. pan would be fed to the hydraulic tappets by the oil
pump causing them to become soft and allow valves
(6) For bubbles that remain steady with shaft to seat noisily.
rotation, no further inspection can be done until dis-
assembled. OIL LEVEL TOO LOW
(7) After the oil leak root cause and appropriate Low oil level may allow pump to take in air which
corrective action have been identified, refer to Crank- when fed to the tappets, causes them to become soft
shaft Oil Seal—Rear for proper replacement proce- and allows valves to seat noisily. Any leaks on intake
dures. side of pump through which air can be drawn will
create the same tappet action. Check the lubrication
HYDRAULIC TAPPETS system from the intake strainer to the pump cover,
The valve train includes roller tappet assemblies, including the relief valve retainer cap. When tappet
aligning yokes and yoke retainer. noise is due to aeration, it may be intermittent or
Roller tappet alignment is maintained by machined constant, and usually more than one tappet will be
flats on tappet body being fitted in pairs into six noisy. When oil level and leaks have been corrected,
aligning yokes. The yokes are secured by an align- engine should be operated at fast idle to allow all of
ment yoke retainer (Fig. 6). the air inside of the tappets to be bled out.
VALVE TRAIN NOISE DIAGNOSIS

To determine source of valve train noise, operate
engine at idle with cylinder head covers removed and
listen for source of the noise.
NOTE: Worn valve guides or cocked springs are

sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly 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

Fig. 6 Roller Tappets Aligning Yoke and Retainer
heavy click. A light noise is usually caused by exces-
1 – YOKE RETAINER
2 – ALIGNING YOKE
sive leak-down around the unit plunger which will
necessitate replacing the tappet, or by the plunger
partially sticking in the tappet body cylinder. A heavy
PRELIMINARY STEP TO CHECKING THE click is caused either by a tappet check valve not
HYDRAULIC TAPPETS seating, or by foreign particles becoming wedged
Before disassembling any part of the engine to cor- between the plunger and the tappet body causing the
rect tappet noise, read the oil pressure at the gauge. plunger to stick in the down position. This heavy
Install a reliable gauge at pressure sending unit if click will be accompanied by excessive clearance
vehicle has no oil pressure gauge and check the oil between the valve stem and rocker arm as valve
level in the oil pan. The pressure should be between closes. In either case, tappet assembly should be
30 and 80 psi (206.8 to 551.6 kPa) at 2000 rpm. removed for inspection and cleaning.
The oil level in the pan should never be above the
MAX mark on dipstick, or below the MIN mark. ENGINE OIL PRESSURE
Either of these two conditions could be responsible (1) Disconnect and remove oil pressure sending
for noisy tappets. Oil Level Check: stop engine unit.
after reaching normal operating temperature. (2) Install Special Tools C-3292 Gauge with 8406
Allow 5 minutes to stabilize oil level, check dipstick. Adaptor (Fig. 7).
9 - 140 3.3/3.8L ENGINE NS
(3) Start engine and record oil pressure. Refer to
pressure.
Fig. 8 3.3/3.8L Engine Oil Fill and Dipstick Locations

1 – ENGINE OIL FILL
2 – ENGINE OIL DIPSTICK
Fig. 7 Checking Oil Pressure

1 – OIL FILTER
2 – OIL PRESSURE GAUGE
SERVICE PROCEDURES
ENGINE OIL
Checking Oil Level
To assure proper engine lubrication, the engine oil
must be maintained at the correct level. Check the
oil level at regular intervals, such as every fuel stop.
Fig. 9 3.3/3.8L Engine Oil Dipstick
The best time to check the oil level is about 5 min-
1 – MIN OIL MARK
utes after a fully warmed-up engine is shut off, or
before starting the vehicle after it has sat overnight.
Refer to (Fig. 8), for engine oil fill and dipstick loca- NOT POLLUTE, DISPOSE OF USED ENGINE OIL
tions. PROPERLY. CONTACT YOUR DEALER OR GOVERN-
Checking the oil while the vehicle is on level MENT AGENCY FOR LOCATION OF COLLECTION
ground, will improve the accuracy of the oil level CENTER IN YOUR AREA.
readings. For the, 3.3/3.8L engines, maintain the oil
level between the MIN and MAX markings on the
dipstick (Fig. 9). Adding one quart of oil when the ENGINE OIL SPECIFICATION
reading is at the MIN mark will result in a MAX
reading on these engines.
ENGINE OIL SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE API SERVICE GRADE CERTIFIED
IRRITATING TO THE SKIN. AVOID PROLONGED OR
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
this service grade.
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED SAE VISCOSITY
SKIN WITH SOAP AND WATER. DO NOT WASH
An SAE viscosity grade is used to specify the vis-
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
ple viscosities such as 5W-30 or 10W-30. These are
NS 3.3/3.8L ENGINE 9 - 141
specified with a dual SAE viscosity grade which indi- CAUTION: If Flexible Fuel engine oil is not used
cates the cold-to-hot temperature viscosity range. when using E-85 fuel, engine wear or damage may
SAE 5W-30 engine oil is preferred. Select an engine result.
oil that is best suited to your particular temperature
range and variation (Fig. 10).
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule.
TO CHANGE ENGINE OIL

perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(3) Remove the oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
Fig. 10 Temperature/Engine Oil Viscosity (5) Remove drain plug from crankcase and allow
ENERGY CONSERVING OIL oil to drain into pan. Inspect drain plug threads for
An Energy Conserving type oil is recommended for stretching or other damage. Replace drain plug and
gasoline engines. The designation of ENERGY CON- gasket if damaged.
SERVING is located on the label of the engine oil (6) Install drain plug in crankcase.
container. (7) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this sec-
CONTAINER IDENTIFICATION tion.
Standard engine oil identification notations have (8) Install oil fill cap.
been adopted to aid in the proper selection of engine (9) Start engine and inspect for leaks.
oil. The identifying notations are located on the label (10) Stop engine and inspect oil level.
of engine oil plastic bottles and the top of engine oil
cans (Fig. 11). FORM-IN-PLACE GASKETS & SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results. Do not use form-in-
place gasket material unless specified. Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
Fig. 11 Engine Oil Container Standard Notations There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
FLEXIBLE FUEL ENGINE OIL—3.3L ENGINE Engine RTV GEN II, Mopart ATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
Engine Oil Selection for Operating on E-85 Fuel
properties and can not be used in place of the other.
If vehicle operates on E-85 fuel either full or part- MOPARt ENGINE RTV GEN II
time, use only Mopart Flexible Fuel 5W-30 engine oil Mopart Engine RTV GEN II is used to seal com-
or an equivalent that meets DaimlerChrysler Stan- ponents exposed to engine oil. This material is a spe-
dard MS-9214. Equivalent commercial Flexible Fuel cially designed black silicone rubber RTV that
engine oils may be labeled as Multi-Fuel, Variable retains adhesion and sealing properties when
Fuel, Flexible Fuel, etc. These engine oils may be exposed to engine oil. Moisture in the air causes the
satisfactory if they meet the DaimlerChrysler Stan- material to cure. This material is available in three
dard. ounce tubes and has a shelf life of one year. After one
SAE 5W-30 engine oil is preferred for use in Flex- year this material will not properly cure. Always
ible Fuel engines.
9 - 142 3.3/3.8L ENGINE NS
inspect the package for the expiration date before center of the gasket contact area. Uncured sealant
use. may be removed with a shop towel. Components
MOPARt ATF RTV should be torqued in place while the sealant is still
Mopart ATF RTV is a specifically designed black wet to the touch (within 10 minutes). The usage of a
silicone rubber RTV that retains adhesion and seal- locating dowel is recommended during assembly to
ing properties to seal components exposed to auto- prevent smearing material off the location.
matic transmission fluid, engine coolants, and Mopart Gasket Sealant in an aerosol can should be
moisture. This material is available in three ounce applied using a thin, even coat sprayed completely
tubes and has a shelf life of one year. After one year over both surfaces to be joined, and both sides of a
this material will not properly cure. Always inspect gasket. Then proceed with assembly. Material in a
the package for the expiration date before use. can w/applicator can be brushed on evenly over the
MOPARt GASKET MAKER sealing surfaces. Material in an aerosol can should be
Mopart Gasket Maker is an anaerobic type gasket used on engines with multi-layer steel gaskets.
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will ENGINE GASKET SURFACE PREPARATION
not cure if left in the uncovered tube. The anaerobic To ensure engine gasket sealing, proper surface
material is for use between two machined surfaces. preparation must be performed, especially with the
Do not use on flexible metal flanges. use of aluminum engine components and multi-layer
MOPARt BED PLATE SEALANT steel cylinder head gaskets.
Mopart Bed Plate Sealant is a unique (green-in- Never use the following to clean gasket surfaces:
color) anaerobic type gasket material that is specially • Metal scraper
made to seal the area between the bedplate and cyl- • Abrasive pad or paper to clean cylinder block
inder block without disturbing the bearing clearance and head
or alignment of these components. The material • High speed power tool with an abrasive pad or a
cures slowly in the absence of air when torqued wire brush (Fig. 12)
between two metallic surfaces, and will rapidly cure
when heat is applied. NOTE: Multi-Layer Steel (MLS) head gaskets
MOPARt GASKET SEALANT require a scratch free sealing surface.
Mopart Gasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for Only use the following for cleaning gasket surfaces:
sealing threaded fittings and gaskets against leakage • Solvent or a commercially available gasket
of oil and coolant. Can be used on threaded and remover
machined parts under all temperatures. This mate- • Plastic or wood scraper (Fig. 12)
rial is used on engines with multi-layer steel (MLS) • Drill motor with 3M Rolocy Bristle Disc (white
cylinder head gaskets. This material also will pre- or yellow) (Fig. 12)
vent corrosion. Mopart Gasket Sealant is available in
CAUTION: Excessive pressure or high RPM
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER sealing surfaces. The mild (white, 120 grit) bristle
disc is recommended. If necessary, the medium
APPLICATION (yellow, 80 grit) bristle disc may be used on cast
Assembling parts using a form-in-place gasket
iron surfaces with care.
requires care but it’s easier then using precut gas-
kets.
Mopart Gasket Maker material should be applied HYDROSTATIC LOCKED ENGINE
sparingly 1 mm (0.040 in.) diameter or less of sealant When an engine is suspected to be hydrostatically
to one gasket surface. Be certain the material sur- locked, regardless of what caused the problem, the
rounds each mounting hole. Excess material can eas- following steps should be used.
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel CAUTION: DO NOT use starter motor to rotate the
is recommended during assembly to prevent smear- engine, severe damage may occur.
ing material off the location.
Mopart Engine RTV GEN II or ATF RTV gasket (1) Inspect air cleaner, induction system and
material should be applied in a continuous bead intake manifold to insure system is dry and clear of
approximately 3 mm (0.120 in.) in diameter. All foreign material.
mounting holes must be circled. For corner sealing, a (2) Remove negative battery cable.
NS 3.3/3.8L ENGINE 9 - 143
will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20–60
strokes depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Inspect cyl-
inder walls after each 20 strokes, using a light
honing oil. Do not use engine or transmission oil,
mineral spirits or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a 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. 13).

1 – ABRASIVE PAD
2 – 3M ROLOCY BRISTLE DISC
3 – PLASTIC/WOOD SCRAPER
(3) Place a shop towel around the spark plugs

any fluid that may possibly be in the cylinder under
pressure.
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.) Fig. 13 Cylinder Bore Cross-Hatch Pattern
(7) Repair engine or components as necessary to 1 – CROSS-HATCH PATTERN
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil (4) A controlled hone motor speed between
into the cylinders, rotate engine to lubricate the cyl- 200–300 RPM is necessary to obtain the proper cross-
inder walls to prevent damage on restart. hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50–60
(8) Install new spark plugs. degree angle. Faster up and down strokes increase
(9) Drain engine oil and remove oil filter. the cross-hatch angle.
(10) Fill engine with specified amount of approved (5) After honing, it is necessary that the block be
oil and install new oil filter. cleaned again to remove all traces of abrasive.
(12) Start engine and check for any leaks. CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
CYLINDER BORE—HONING solution of soap and hot water be used with a
(1) Used carefully, the cylinder bore resizing hone, brush and the parts then thoroughly dried. The bore
recommended tool C-823 or equivalent, equipped can be considered clean when it can be wiped
with 220 grit stones, is the best tool for this honing clean with a white cloth and cloth remains clean.
procedure. In addition to deglazing, it will reduce Oil the bores after cleaning to prevent rusting.
scuffing, scoring or scratches. Usually a few strokes
9 - 144 3.3/3.8L ENGINE NS
CRANKSHAFT MAIN BEARING—FITTING

MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to insure correct assembly
(Fig. 15). Upper and lower bearing halves are NOT
interchangeable. Lower main bearing halves of 1, 3
and 4 are interchangeable. Upper main bearing
halves of 1, 3 and 4 are interchangeable.
CRANKSHAFT MAIN JOURNALS

Measure the journal outside diameter as shown in
(Fig. 14). Refer to Engine Specifications in this sec-
tion.
The crankshaft journals should be checked for
excessive wear, taper and scoring. (Fig. 14) Limits of
taper or out-of-round on any crankshaft journals Fig. 15 Main Bearing Cap Identification
should be held to 0.025 mm (0.001 in.). Journal
grinding should not exceed 0.305 mm (0.012 in.)
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 passages.
Fig. 16 Main Bearing Identification

1 – OIL GROOVES
2 – OIL HOLES
3 – UPPER BEARINGS
4 – LOWER BEARINGS
CRANKSHAFT OIL CLEARANCE

Fig. 14 Measure Crankshaft Journal O. D. Engine crankshaft bearing clearances can be deter-
CAUTION: With the nodular cast iron crankshafts mined by use of Plastigage or the equivalent. The fol-
used it is important that the final paper or cloth pol- lowing is the recommended procedures for the use of
ish after any journal regrind be in the same direc- Plastigage with the engine in the vehicle or engine
tion as normal rotation in the engine. on a repair stand.
Upper and lower Number 2 bearing halves are PLASTIGAGE METHOD—ENGINE IN-VEHICLE
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves NOTE: The total clearance of the main bearings can
in the engine (Fig. 16). All bearing cap bolts removed only be determined with the engine in the vehicle
during service procedures are to be cleaned and oiled by removing the weight of the crankshaft. This can
before installation. Bearing shells are available in be accomplished by either of two following meth-
standard and the following undersizes: 0.025 mm ods:
(0.001 in.) and 0.254 mm (0.010 in). Never install an
undersize bearing that will reduce clearance below (1) Preferred method:
specifications.
NS 3.3/3.8L ENGINE 9 - 145
a. Shim the bearings adjacent to the bearing to be
checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be
accomplished by placing a minimum of 0.254 mm
(0.010 in.) shim (e. g. cardboard, matchbook cover,
etc.) between the bearing shell and the bearing cap
on the adjacent bearings and tightening bolts to
14-20 N·m (10-15 ft. lbs.).
b. When checking #1 main bearing shim #2 main
bearing.
c. When checking #2 main bearing shim #1 & #3
main bearing.
d. When checking #3 main bearing shim #2 & #4 Fig. 17 Plastigage Placed in Lower Shell
main bearing. 1 – PLASTIGAGE
e. When checking #4 main bearing shim #3 main
bearing.
NOTE: Remove all shims before reassembling

engine.
(2) Alternative Method:

a. Support the weight of the crankshaft with a
jack under the counterweight adjacent to the bearing
being checked.
width of the bearing shell in the cap approximately Fig. 18 Clearance Measurement
6.35 mm (1/4 in.) off center and away from the oil (4) Carefully install the main bearing cap and
holes (Fig. 17). (In addition, suspected areas can be tighten the bolts to specified torque.
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing CAUTION: Do not rotate crankshaft or the Plasti-
being checked to the proper specifications. gage will be smeared.
of the flattened Plastigage (Fig. 18) with the metric (5) Carefully remove the bearing cap and measure
scale provided on the package. Locate the band clos- the width of the Plastigage at the widest part using
est to the same width. This band shows the amount the scale on the Plastigage package (Fig. 19). Refer
of clearance in thousandths of a millimeter. Differ- to Engine Specifications in this section for proper
ences in readings between the ends indicate the clearances. If the clearance exceeds the specified lim-
amount of taper present. Record all readings taken. its, replace the main bearing(s) with the appropriate
Refer to Engine Specifications. Plastigage gener- size, and if necessary, have the crankshaft machined
ally is accompanied by two scales. One scale is to next undersize.
in inches, the other is a metric scale.
CAUTION: Do not rotate crankshaft or the Plasti-
NOTE: Plastigage is available in a variety of clear- gage may be smeared.
ance ranges. Use the most appropriate range for
the specifications you are checking.
CRANKSHAFT END PLAY
PLASTIGAGE METHOD—ENGINE OUT-OF-VEHICLE DIAL INDICATOR METHOD
(1) With engine in the inverted position (crank- (1) Mount a dial indicator to front of engine, locat-
shaft up) and mounted on a repair stand, remove ing probe on nose of crankshaft (Fig. 20).
main journal cap. (2) Move crankshaft all the way to the rear of its
(2) Remove oil from journal and bearing shell. travel.
(3) Cut Plastigage to same length as width of the (3) Zero the dial indicator.
bearing and place it in parallel with the journal axis
(Fig. 17).
9 - 146 3.3/3.8L ENGINE NS
inder bores should be measured halfway down the
cylinder bore and transverse to the engine crankshaft
center line shown in (Fig. 21). Refer to Engine Spec-
ifications in this section. Pistons and cylinder
bores should be measured at normal room tem-
perature, 70°F (21°C).
Fig. 19 Measuring Bearing Clearance with

Plastigage
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Crankshaft Specifi-
cation Chart.
Fig. 20 Checking Crankshaft End Play

FEELER GAUGE METHOD
Fig. 22 Piston Measurements
1 – SIZE LOCATIONS
travel using a lever inserted between a main bearing
cap and a crankshaft cheek using care not to damage
any bearing surface. Do not loosen main bearing FITTING RINGS
cap. (1) Wipe cylinder bore clean. Insert ring and push
(2) Use a feeler gauge between number 2 thrust down with piston to ensure it is square in bore. The
bearing and machined crankshaft surface to deter- ring gap measurement must be made with the ring
mine end play. Refer to Engine Specification in this positioning at least 12 mm (0.50 in.) from bottom of
section. cylinder bore. Check gap with feeler gauge (Fig. 23).
PISTON AND RING—FITTING (2) Check piston ring to groove clearance: (Fig. 24).
Refer to Engine Specification in this section.
FITTING PISTONS
The piston and cylinder wall must be clean and CONNECTING ROD AND BEARING—FITTING
dry. Piston diameter should be measured 90 degrees The bearing caps are not interchangeable and
to piston pin at size location shown in (Fig. 22). Cyl- should be marked at removal to ensure correct
NS 3.3/3.8L ENGINE 9 - 147
MEASURING BEARING CLEARANCE
The connecting rod bearing clearances can be
determined by use of Plastigage or the equivalent.
The following is the recommended procedure for the
use of Plastigage:
(1) Rotate the crankshaft until the connecting rod
to be checked is at the bottom of its stroke.
width of the bearing shell in the bearing cap approx-
imately 6.35 mm (1/4 in.) off center and away from
the oil hole. In addition, suspect areas can be
checked by placing Plastigage in that area.
(4) Assemble the rod cap with Plastigage in place.
Tighten the rod cap to the specified torque. Do not
Fig. 23 Check Gap on Piston Rings rotate the crankshaft while assembling the cap
1 – FEELER GAUGE or the Plastigage may be smeared, giving inac-
curate results.
of the flattened Plastigage with the scale provided on
the package (Fig. 25). Locate the band closest to the
same width. This band indicates the amount of oil
clearance. Differences in readings between the ends
indicate the amount of taper present. Record all
One scale is in inches, the other is a metric
scale. If the bearing clearance exceeds wear
limit specification, replace the bearing.
Fig. 24 Measuring Piston Ring Side Clearance

1 – FEELER GAUGE
assembly. The bearing shells must be installed with

the tangs inserted into the machined grooves in the
rods and caps. Install cap with the tangs on the same
side as the rod. Fit all rods on one bank until com-
plete. Connecting rod bearings are available in the
standard size and the following undersizes: 0.025
mm (0.001 in.) and 0.250 mm (0.010 in.).
CAUTION: Install the bearings in pairs. Do not use

a new bearing half with an old bearing half. Do not
file the rods or bearing caps.
Measure connecting rod journal for taper and out-

of-round. Refer to Engine Specifications in this sec-
tion. Fig. 25 Checking Connecting Rod Bearing
Clearance
9 - 148 3.3/3.8L ENGINE NS
FITTING CONNECTING ROD (2) Measure valve stems for wear. Refer to Engine
Specifications in this section.
NOTE: The rod bearing bolts should be examined
before reuse. If the threads are necked down, the CAUTION: Valve stems are chrome plated and
bolts should be replaced. Necking can be checked should not be polished.
by holding a scale or straight edge against the
threads. If all the threads do not contact the scale (3) Remove carbon and varnish deposits from
the bolt should be replaced (Fig. 26). 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 14 mm
(0.551 in.) 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. 28).
(5) Move valve to and from the indicator. Refer to
Engine Specification in this section.
(6) Ream the guides for valves with oversized
stems if dial indicator reading is excessive or if the
Fig. 26 Check for Stretched (Necked) Bolts stems are scuffed or scored.
1 – STRETCHED BOLT (7) Service valves with oversize stems and over
2 – THREADS ARE NOT STRAIGHT ON LINE size seals are available in 0.15 mm (0.005 in.), 0.40
mm, (0.015 in.) and 0.80 mm (0.030 in.) oversize.
NOTE: Oversize seals must be used with oversize
(1) Before installing the nuts the threads should valves.
be oiled with engine oil.
(2) Install nuts finger tight on each bolt then alter- (8) Refer to Valve Guide Specification Chart for
nately torque each nut to assemble the cap properly. reamer size to accommodate the oversize valve
(3) Tighten the nuts to 54 N·m PLUS 1/4 turn (40 stems.
ft. lbs. PLUS 1/4 turn).
(4) Using a feeler gauge, check connecting rod side
clearance (Fig. 27). Refer to Engine Specifications in
this section.
Fig. 28 Measuring Valve Guide Wear

(9) Slowly turn reamer by hand and clean guide
thoroughly before installing new valve. Do not
attempt to ream the valve guides from standard
Fig. 27 Checking Connecting Rod Side Clearance directly to 0.80 mm (0.030 in.) Use step proce-
VALVE SERVICE dure of 0.15 mm (0.005 in.), 0.40 mm (0.015 in.)
and 0.80 mm (0.030 in.) so the valve guides may
VALVE INSPECTION be reamed true in relation to the valve seat.
(1) Clean valves thoroughly and discard burned, After reaming guides, the seat runout should be
warped and cracked valves. measured and resurfaced if necessary. See
Refacing Valves and Valve Seats.
NS 3.3/3.8L ENGINE 9 - 149
VALVES
(1) Inspect the remaining margin after the valves
are refaced. Refer to Engine Specifications in this
section.
VALVE SEATS
CAUTION: Remove metal from valve seat only. Do

not remove metal from cylinder head (Fig. 31).
(1) 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
obtained.
(2) Measure the concentricity of valve seat using
Fig. 29 Intake and Exhaust Valves dial indicator. Total runout should not exceed 0.051
1 – MARGIN mm (0.002 in.) total indicator reading.
2 – FACE
3 – STEM
4 – VALVE SPRING RETAINER LOCK GROOVES
5 – INTAKE VALVE
6 – EXHAUST VALVE
VALVE GUIDE SPECIFICATION CHART

Intake Valve Exhaust Valve
Dial Indicator
Reading 0.247 mm 0.414 mm
(Maximum): (0.009 in.) (0.016 in.)
Valve Guide Valve Guide Size

Reamer
Oversize Fig. 30 Valve Seats
0.15 mm 8.125 - 8.150 mm

(0.005 in.) (0.3198 - 0.3208 in.)
0.40 mm 8.375 - 8.400 mm
(0.015 in.) (0.3297 - 0.3307 in.)
0.80 mm 8.775 - 8.800 mm
(0.030 in.) (0.3454 - 0.3464 in.)
VALVE GUIDES
NOTE: Replace cylinder head if guide does not

clean up with 0.80 mm (0.030 in.) oversize reamer,
or if guide is loose in cylinder head.
Fig. 31 Refacing Valve Seats

REFACING VALVES AND VALVE SEATS 1 – REFACING STONE MUST NOT CUT INTO CYLINDER HEAD
The intake and exhaust valves have a 44-1/2 to 45 2 – STONE
degree face angle. The valve seats have a 45 to 45-1/2 3 – PILOT
degree face angle. The valve face and valve seat 4 – SEAT
angles are shown in (Fig. 30).
9 - 150 3.3/3.8L ENGINE NS
(3) Inspect the valve seat using Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of valve face, lower valve seat with
a 15 degree stone. If the blue is transferred to the
bottom edge of valve face raise valve seat with a 65
degrees stone.
NOTE: Valve seats which are worn or burned can

be reworked, provided that correct angle and seat
width are maintained. Otherwise cylinder head must
be replaced.
(4) When seat is properly positioned the width of Fig. 32 Testing Valve Springs
intake seats should be 1.75 to 2.25 mm (0.69 to 0.088 1 – SPECIAL TOOL C-647
in.) The width of the exhaust seats should be 1.50 to
2.00 mm (0.059 to 0.078 in.) (Fig. 30).
(5) Check the valve spring installed height after
refacing the valve and seat (Fig. 33).
TESTING VALVE SPRINGS

Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested (Fig. 32). As an example; the compression
length of the spring to be tested is 33.34 mm (1-5/16
inches). Turn table of Tool C-647 until surface is in
line with the 33.34 mm (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 Fig. 33 Checking Valve Installed Height
lever to set tone device. Pull on torque wrench until 1 – SPRING RETAINER
ping is heard. Take reading on torque wrench at this 2 – CYLINDER HEAD SURFACE
instant. Multiply this reading by two. This will give 3 – SPRING SEAT SURFACE
the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjust-
(8) Install a dial indicator so plunger contacts the
ments. Refer to specifications to obtain specified
#2 intake valve spring retainer as nearly perpendic-
height and allowable tensions. Discard the springs
ular as possible. Zero the indicator.
that do not meet specifications.
(9) Rotate the engine clockwise until the intake
valve has lifted.254 mm (0.010 in.).
VALVE TIMING
(1) Remove front cylinder head cover and all 6 CAUTION: Do not turn crankshaft any further clock-
spark plugs. wise as intake valve might bottom and result in
(2) Rotate engine until the #2 piston is at TDC of serious damage.
the compression stroke.
(3) Install a degree wheel on the crankshaft pulley. (10) Degree wheel should read 6 degrees BTDC to
(4) With proper adaptor, install a dial indicator 6 degrees ATDC.
into #2 spark plug hole. Using the indicator find TDC
on the compression stroke. MEASURING TIMING CHAIN FOR STRETCH
(5) Position the degree wheel to zero. (1) Place a scale next to timing chain so that any
(6) Remove dial indicator from spark plug hole. movement of chain may be measured.
(7) Place a 5.08 mm (0.200 in.) spacer between the (2) Place a torque wrench and socket on camshaft
valve stem tip of #2 intake valve and rocker arm pad. sprocket attaching bolt and apply torque in direction
Allow tappet to bleed down to give a solid tappet of crankshaft rotation to take up slack; 41 N·m (30 ft.
effect. lb.) with cylinder head installed or 20 N·m (15 ft. lb.)
with cylinder heads removed. With a torque
NS 3.3/3.8L ENGINE 9 - 151
SERVICE PROCEDURES (Continued) Publication No. 81-370-0005
TSB 26-01-00 January, 2000
applied to the camshaft sprocket bolt, crank-

shaft 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. 34), along edge of chain links. Apply
torque in the reverse direction to 41 N·m (30 ft. lbs.)
with cylinder heads installed, or 20 N·m (15 ft. lbs.)
with cylinder heads removed. Check amount of chain
movement.
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
(5) If chain is not satisfactory, refer to Timing
Chain Removal and Installation in this section.
Fig. 35 Engine Mount—Right

2 – PURGE DUTY SOLENOID MOUNT
3 – HORIZONTAL FASTENER
4 – DO NOT REMOVE THIS NUT
(4) Remove the vertical and horizontal fasteners

from the engine side bracket. Remove the engine
mount assembly
INSTALLATION
Tighten assembly in the following order:
a. Engine mount to rail fasteners to 68 N·m (50 ft.
Fig. 34 Measuring Timing Chain Wear and Stretch lbs.).
1 – TORQUE WRENCH b. The vertical engine fastener to 102 N·m (75 ft.
lbs.).
c. The horizontal fastener to 150 N·m (111 ft. lbs.).
REMOVAL AND INSTALLATION (2) Install the purge duty solenoid and wiring har-
ness to the engine mount.
ENGINE MOUNTS
FRONT MOUNT
RIGHT SIDE MOUNT
REMOVAL
REMOVAL (1) Support the engine and transmission assembly
with a floor jack so it will not rotate.
NOTE: Right mount should only be serviced as an (2) Remove the front engine mount through bolt
assembly to prevent noise, vibration and harshness from the insulator and front crossmember mounting
concerns. bracket (Fig. 36).
(3) Remove six screws from air dam to allow
(1) Remove the purge duty solenoid and wiring access to the front mount screws.
harness from engine mount. (4) Remove the front engine mount screws and
(2) Remove the two right engine mount insulator remove the insulator assembly.
vertical fasteners and loosen the horizontal fastener, (5) Remove the front mounting bracket, if neces-
Do Not remove the large nut on the end of the core sary (Fig. 36).
from frame rail (Fig. 35).
(3) Remove the load on the engine motor mounts INSTALLATION
by carefully supporting the engine and transmission (1) Reverse removal procedure for installation and
assembly with a floor jack. tighten fasteners (Fig. 36) to the following torque:
• (A), (C), and (D) to 68 N·m (50 ft. lbs.)
9 - 152 3.3/3.8L ENGINE NS
REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-0005
TSB 26-01-00 January, 2000
• (B) to 102 N·m (75 ft. lbs.)

• (E) to 54 N·m (40 ft. lbs.)
(2) Install six screws to air dam and tighten to 12
N·m (105 in. lbs.).
Fig. 37 Engine Mounting—Left

1 – MOUNT TO TRANSMISSION FASTENERS
Fig. 36 Engine Mounting—Front

LEFT SIDE MOUNT
REMOVAL
(1) Raise vehicle on hoist and remove left front
wheel.
jack.
mount.
(4) Remove the transmission mount fasteners and
remove mount.
INSTALLATION
(2) Tighten mount to transmission bolts to 55 N·m
(40 ft. lbs.).
(3) Tighten through bolt to 75 N·m (55 ft. lbs.)
(Fig. 37).
REAR MOUNT
Fig. 38 Engine Mounting—Rear
1 – TOP ENGINE MOUNT FASTENERS
REMOVAL
2 – SIDE ENGINE MOUNT FASTENERS
jack so it will not rotate. ENGINE ASSEMBLY
mount and rear suspension crossmember. REMOVAL
(4) Remove the four transmission mount fasteners (1) Perform fuel pressure release procedure. Refer
and remove the mount. to FUEL SYSTEM for procedure. Remove fuel line to
fuel rail.
INSTALLATION (2) Disconnect battery.
(1) Reverse the removal procedure for installation. (3) Remove air cleaner and hoses.
Refer to (Fig. 38). Tighten through bolt to 75 N·m (55 (4) Remove battery cover, battery and battery tray,
ft. lbs.). with integral vacuum reservoir, from vehicle.
NS 3.3/3.8L ENGINE 9 - 153
(5) Block off heater hoses to rear heater assembly, (25) Remove driveplate to torque converter bolts.
if equipped. (26) Lower the vehicle.
(6) Drain cooling system. Refer to COOLING SYS- (27) Remove ground straps to body.
TEM for procedure. (28) Raise vehicle enough to allow engine dolly
(7) Disconnect heater hoses. Special Tool 6135 and cradle Special Tool 6710 with
(8) Remove fan module and radiator. Refer to post Special Tool 6848 and adaptor Special Tool 6909
COOLING SYSTEM for procedure. to be installed under vehicle (Fig. 40).
(9) Disconnect transmission shift linkage. (29) Loosen cradle engine mounts to allow move-
(10) Disconnect throttle body linkage and vacuum ment for positioning onto engine locating holes on the
hoses from throttle body. engine. Lower vehicle and position cradle mounts
(11) Remove accessory drive belts. Refer to Acces- until the engine is resting on mounts. Tighten
sory Drive Belts located in COOLING SYSTEM for mounts to cradle frame. This will keep mounts from
procedure. moving when removing or installing engine and
(12) Remove air conditioning compressor from transmission.
engine and set it aside. (30) Lower vehicle so the weight of ONLY THE
(13) Disconnect generator wiring harness and ENGINE AND TRANSMISSION is on the cradle.
remove generator. (31) Remove right engine mount assembly and left
(14) Hoist vehicle and remove right and left inner transmission mount through bolt. Refer to procedures
splash shields. in this section.
(15) Remove crossmember cradle plate (Fig. 39). (32) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the cradle
to allow for removal around body flanges.
Fig. 39 Crossmember Cradle Plate

1 – CRADLE PLATE
(16) Remove axle shafts. Refer to DIFFERENTIAL

AND DRIVELINE for procedure.
(17) AWD equipped: Mark orientation and sepa-
rate propeller shaft from power transfer unit. Refer
to DIFFERENTIAL AND DRIVELINE for procedure.
Fig. 40 Positioning Engine Cradle Support Post
(18) Disconnect exhaust pipe from manifold.
Mounts—Typical
(19) Remove front engine mount and bracket as an
1 – SPECIAL TOOL ENGINE CRADLE NO. 6710
assembly.
2 – SPECIAL TOOL ENGINE DOLLY NO. 6135
(20) Remove rear transmission mount and bracket. 3 – SPECIAL TOOL ENGINE CRADLE NO. 6710
(21) Remove power steering pump and bracket 4 – SPECIAL TOOL ADJUSTABLE POSTS NO. 6848
assembly.
(22) Remove wiring harness and connectors from
front of engine. INSTALLATION
(23) Remove bending braces and install Special (1) Position engine and transmission assembly
Tool 6912 Adapters on engine. under vehicle and slowly lower the vehicle over the
(24) Remove transmission inspection cover and engine and transmission. It may be necessary to
mark flex plate to torque converter.
9 - 154 3.3/3.8L ENGINE NS
move the engine/transmission assembly with the cra- INTAKE MANIFOLD
dle for clearance around body flanges.
(2) Align engine and transmission mounts to REMOVAL
attaching points. Install mounting bolts at the right (1) Remove windshield wiper module. Refer to
engine and left transmission mounts. Refer to proce- WINDSHIELD WIPERS AND WASHERS for proce-
dures in this section. dure.
(3) Slowly raise vehicle enough to remove the (2) Perform fuel system pressure release procedure
engine dolly and cradle Special Tools 6135, 6710, (before attempting any repairs). Refer to FUEL
6848 and 6909 (Fig. 40). SYSTEM for procedure.
(4) Remove Special Tools 6912 and install bending (3) Drain the cooling system—only if lower intake
braces. manifold is to be removed. Refer to COOLING SYS-
(5) Lower vehicle. Install generator and wiring TEM for procedure.
harness. (4) Remove air inlet resonator to throttle body
(6) Connect wiring harness on the front of the hose assembly.
engine. (5) Remove throttle cable. Refer to FUEL SYSTEM
(7) Install Air Conditioning Compressor. for procedure.
(8) Install power steering pump and bracket. (6) Remove wiring harness from throttle cable
(9) Install accessory drive belt. Refer to COOLING bracket.
SYSTEM for procedure. (7) Remove automatic idle speed (AIS) motor and
(10) Raise vehicle and install axle shafts. Refer to throttle position sensor (TPS) wiring connectors from
DIFFERENTIAL AND DRIVELINE for procedure. throttle body (Fig. 41).
(11) Install transmission and engine mount and (8) Remove EGR transducer connector.
bracket assemblies. Refer to procedure in this sec-
tion.
(12) AWD equipped; Install propeller shaft to
power transfer unit. Refer to DIFFERENTIAL AND
DRIVELINE for procedure.
(13) Connect exhaust system to manifold. Refer to
EXHAUST SYSTEM for procedure and torque speci-
fications.
(14) Install crossmember cradle plate (Fig. 39).
(15) Install left and right inner splash shields.
(16) Connect automatic transmission shifter link-
age. Refer to TRANSAXLE AND POWER TRANS-
FER UNIT for procedures.
(17) Lower vehicle and connect fuel line and
heater hoses. Remove plugs from rear heater hoses
and install, if equipped.
(18) Install ground straps. Connect engine and
throttle body connections and harnesses.
(19) Connect throttle body linkage. Refer to FUEL
(20) Install radiator, fan module assembly, and
radiator hoses. Fill cooling system. Refer to COOL-
ING SYSTEM for filling procedures. Fig. 41 Electrical and Vacuum Connection to
(21) Install battery tray, battery and cover. Throttle Body
(22) Install air cleaner and hoses. 1 – THROTTLE BODY
(23) Install oil filter. Fill engine crankcase with 2 – THROTTLE POSITION SENSOR
proper oil to correct level. 3 – IDLE AIR CONTROL MOTOR
ature is reached.
(26) Adjust transmission linkage, if necessary.
NS 3.3/3.8L ENGINE 9 - 155
(9) Remove vacuum hose harness from throttle (15) Remove the engine mounted ground strap.
body (Fig. 41). (16) Remove the fuel hose quick connect fitting
(10) Remove PCV and brake booster hoses from air from the fuel line by using an open end wrench push-
intake plenum. ing in on the plastic ring located on the end of the
(11) Disconnect MAP Sensor electrical connection fittings. Gently pull the fitting from the fuel line
(Fig. 42). (Fig. 44).
(12) Remove EGR tube flange from intake plenum.
(13) Remove vacuum harness connectors from WARNING: WRAP A SHOP TOWEL AROUND
intake plenum (Fig. 42). HOSES TO CATCH ANY GASOLINE SPILLAGE DUR-
ING REMOVAL.
Fig. 42 Vacuum and Electrical Connections to Intake

Manifold Fig. 44 Quick Connect Fuel Fitting to Fuel Line
1 – MAP SENSOR 1 – QUICK CONNECT FITTING
2 – ELECTRICAL CONNECTOR 2 – GENERATOR
3 – INTAKE MANIFOLD 3 – CHASSIS FUEL LINE
Fig. 43 Intake Manifold Plenum Support Bracket Fig. 45 Ignition Coils

1 – INTAKE PLENUM SUPPORT BRACKET 1 – IGNITION COILS FASTENERS
2 – IGNITION COILS ELECTRICAL CONNECTOR
(14) Remove cylinder head to intake plenum strut

(Fig. 43).
9 - 156 3.3/3.8L ENGINE NS
(17) Remove direct ignition system (DIS) coils and (22) Disconnect cam sensor and coolant tempera-
generator bracket to intake manifold bolt (Fig. 45). ture sensor (Fig. 48).
(18) Remove bolts from generator to intake mani- (23) Remove fuel injector wiring clip from intake
fold bracket. Loosen top generator mounting bolt, manifold water tube.
and move bracket up so intake manifold can clear
mounting studs (Fig. 46).
(19) Remove intake manifold bolts and remove the
manifold (Fig. 46).
(20) Cover intake manifold with suitable cover
when servicing (Fig. 47).
Fig. 46 Intake Manifold Plenum Fasteners Fig. 48 Coolant Temperature Sensor Electrical
1 – INTAKE MANIFOLD PLENUM BOLTS Connector
2 – INTAKE MANIFOLD PLENUM STUDS/NUTS
1 – ENGINE COOLANT TEMPERATURE SENSOR
Fig. 47 Fuel Rail Attaching Bolts

1 – FUEL RAIL RETAINER BRACKET SCREW
2 – FUEL RAIL ATTACHING BOLTS (4)
3 – LOWER INTAKE MANIFOLD MUST BE COVERED DURING
SERVICE
(21) Remove fuel tube retainer bracket screw and Fig. 49 Fuel Rail Removal
fuel rail attaching bolts (Fig. 47). Spread the retainer 1 – INTAKE MANIFOLD MUST BE COVERED DURING SERVICE
bracket to allow fuel tube removal clearance. 2 – INJECTOR TUBES WILL ROTATE FOR RAIL REMOVAL
NS 3.3/3.8L ENGINE 9 - 157
(24) Remove fuel rail. Be careful not to damage (2) Place a drop (approximately 1/4 in. diameter) of
the rubber injector O-rings upon removal from their Mopart Engine RTV GEN II onto each of the four
ports (Fig. 49). manifold to cylinder head gasket corners (Fig. 52).
(25) Remove upper radiator hose, bypass hose and (3) Carefully install the new intake manifold gas-
rear intake manifold hose (Fig. 50). ket (Fig. 51). Torque end seal retainer screws to 12
(26) Remove intake manifold bolts. Remove intake N·m (105 in. lbs.).
manifold.
WARNING: INTAKE MANIFOLD GASKET IS MADE

OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(28) Remove intake manifold seal retainers screws

(Fig. 51). Remove intake manifold gasket.
Fig. 52 Intake Manifold Gasket Sealing

1 – 6.35 mm (1/4 INCH) BEAD OF SEALANT IN EACH CORNER
WHERE CYLINDER HEAD MEETS ENGINE BLOCK
(4) Install intake manifold and bolts and torque to

1 N·m (10 in. lbs.). Then torque bolts to 22 N·m (200
in. lbs.) in sequence shown in (Fig. 50). Then torque
again to 22 N·m (200 in. lbs.). After intake manifold
is in place, inspect to make sure seals are in
Fig. 50 Intake Manifold Removal and Installation place.
(5) Make sure the injector holes are clean and all
plugs have been removed.
(6) Lube injector O-ring with a drop of clean
engine oil to ease installation.
(7) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports (Fig. 49).
(8) Install the fuel rail attaching bolts and torque
to 22 N·m (200 in. lbs.) (Fig. 47).
(9) Install fuel tube retaining bracket screw and
torque to 4 N·m (35 in. lbs.) (Fig. 47).
(10) Connect cam sensor and coolant temperature
sensor (Fig. 48).
(11) Remove covering on lower intake manifold
and clean surface.
(12) Position the new intake manifold gasket on
lower manifold. Install upper manifold into place and
Fig. 51 Intake Manifold Gasket tighten bolts and nuts only finger tight, at this time.
1 – INTAKE MANIFOLD GASKET AND END SEAL RETAINERS
NOTE: At no time should the studs be replaced
INSTALLATION with a bolt and washer.
(1) Clean all surfaces of cylinder block and cylin-
der heads.
9 - 158 3.3/3.8L ENGINE NS
(13) Install the generator bracket to intake mani- (3) Remove generator. Refer to CHARGING SYS-
fold bolt and the cylinder head to intake manifold TEM for procedure.
strut bolts. (Do not torque.) (4) Raise vehicle and disconnect exhaust pipe from
(14) Torque intake manifold bolts to 28 N·m (250 rear (cowl side) exhaust manifold at flex-joint.
in. lbs.) following torque sequence in (Fig. 46). (5) Disconnect down stream oxygen sensor connec-
(15) Torque generator bracket to intake manifold tor.
bolt to 54 N·m (40 ft. lbs.). (6) Lower exhaust system to gain access to rear
(16) Torque the cylinder head to intake manifold manifold.
strut bolts to 54 N·m (40 ft. lbs.) (Fig. 43). (7) Separate EGR tube from rear manifold and dis-
(17) Connect ground strap and MAP sensor electri- connect Heated Oxygen Sensor lead wire (Fig. 53).
cal connector. (8) Remove heat shield from rear engine mount.
(18) Connect vacuum harness to intake plenum (9) Remove Generator/Power Steering Support
(Fig. 42). Strut (Fig. 53).
(19) Using a new gasket, connect the EGR tube (10) Remove bolts attaching crossover pipe to man-
flange to the intake manifold and torque to 22 N·m ifold (Fig. 53).
(200 in. lbs.). (11) Disconnect up stream oxygen sensor connec-
(20) Clip wiring harness into the hole in the throt- tor.
tle cable bracket. (12) Remove bolts attaching rear manifold to cylin-
(21) Connect the wiring connectors to the throttle der head and remove manifold.
position sensor (TPS) and Automatic Idle Speed (AIS) (13) Lower vehicle and remove screws attaching
motor (Fig. 41). front heat shield to front manifold (Fig. 54).
(22) Connect vacuum harness to throttle body (Fig. (14) Remove bolts fastening crossover pipe to front
41). exhaust manifold and nuts fastening manifold to cyl-
(23) Install the direct ignition system (DIS) coils. inder head. Remove assemblies (Fig. 55).
Torque fasteners to 12 N·m (105 in. lbs.) (Fig. 45). (15) Inspect and clean manifold. Refer to Cleaning
(24) Lubricate the end of the chassis fuel tube and Inspection in this section for procedures.
with 30 wt. oil. Connect fuel supply hose to chassis
fuel tube assembly. Pull back on the quick connect
fitting to ensure complete insertion (Fig. 44).
(25) Install throttle cable. Refer to FUEL SYSTEM
for procedure.
(26) Connect fuel injector wiring harness.
(27) Install air cleaner and hose assembly.
(29) If drained, fill cooling system. Refer to COOL-
(30) With the DRB Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.

The Auto Shutdown (ASD) Relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected. Fig. 53 EGR Tube, Heated Oxygen Sensor and
Generator/Power Steering Strut
(31) Install windshield wiper module. Refer to 1 – HEATED OXYGEN SENSOR ELECTRICAL CONNECTOR
WINDSHIELD WIPERS AND WASHERS for proce- 2 – ALTERNATOR/POWER STEERING SUPPORT STRUT
3 – EXHAUST CROSSOVER BOLTS
dure.
4 – EGR TUBE
EXHAUST MANIFOLD
INSTALLATION
REMOVAL (1) Install rear exhaust manifold and tighten
(1) Disconnect battery negative cable. attaching bolts to 23 N·m (200 in. lbs.).
(2) Remove accessory drive belt. Refer to Accessory (2) Install generator. Refer to CHARGING SYS-
Drive section located in COOLING SYSTEM for pro- TEM for procedure.
cedure.
NS 3.3/3.8L ENGINE 9 - 159
NOTE: If dipstick tube was disturbed, the tube to
block seal may be damaged. To reseal the dipstick
tube, remove the tube, clean, and reseal using
MoparT Stud & Bearing Mount Adhesive.
(7) Attach exhaust crossover with a new gasket

and tighten fasteners to 54 N·m (40 ft. lbs.) (Fig. 55).
(8) Connect up stream oxygen sensor connector.
(9) Install exhaust system.
(10) Attach exhaust pipe to exhaust manifold
using new gasket and tighten bolts to 28 N·m (250
in. lbs.).
(11) Connect downstream oxygen sensor connector.
Fig. 54 Heat Shield—Front (12) Install front manifold heat shield and tighten
1 – HEAT SHIELD attaching screws to 12 N·m (105 in. lbs.) (Fig. 54).
2 – FASTENERS (13) Install accessory drive belt. Refer to Accessory
Drive section located in COOLING SYSTEM for pro-
cedure.
(14) Connect battery negative cable.
CRANKSHAFT DAMPER
REMOVAL
(3) Remove right wheel and inner splash shield.
(4) Remove drive belt. Refer to COOLING SYS-
TEM for procedure.
(5) Remove crankshaft pulley (Fig. 56).
Fig. 55 Crossover Pipe

1 – CROSSOVER PIPE
2 – CROSSOVER BOLTS (4)
NOTE: Inspect crossover pipe fasteners for dam-

age from heat and corrosion. Replace if necessary.
(3) Using new gasket, attach crossover pipe to

exhaust manifold and tighten bolts to 54 N·m (40 ft.
lbs.) (Fig. 53).
(4) Connect oxygen sensor lead (Fig. 53).
(5) Install EGR Tube and Generator/Power Steer- Fig. 56 Crankshaft Damper—Removal
ing Strut (Fig. 53). 1 – SPECIAL TOOL 1023
(6) Install front exhaust manifold and tighten 2 – SPECIAL TOOL L-4524-1 FROM KIT C-4685-C
attaching bolts to 23 N·m (200 in. lbs.).
9 - 160 3.3/3.8L ENGINE NS
INSTALLATION
(1) Install crankshaft pulley using Special Tool
C-4685-C1 Bolt with thrust bearing/washer and nut
(Fig. 57).
(2) Install drive belt. Refer to COOLING SYSTEM
for procedure.
(3) Install inner splash shield and wheel.
Fig. 58 Cylinder Head Cover

1 – ISOLATED CYLINDER HEAD COVER

INSTALLATION
1 – SPECIAL TOOL C-4685–C1
FRONT CYLINDER HEAD COVER

CYLINDER HEAD COVER (1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
REMOVAL Replace gasket as necessary.
(2) Install cylinder head cover and bolts.
FRONT CYLINDER HEAD COVER (3) Tighten cylinder head cover bolts to 10 N·m (90
(1) Disconnect ignition cables from spark plugs. in. lbs.) (Fig. 58).
(2) Disconnect crankcase vent hose from cylinder (4) Connect crankcase vent hose.
head cover. (5) Connect ignition cables to spark plugs.
(3) Remove front cylinder head cover bolts.
(4) Remove cylinder head cover and gasket (Fig. REAR CYLINDER HEAD COVER
58). (1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
REAR CYLINDER HEAD COVER Replace gasket as necessary.
(1) Disconnect negative cable from battery. (2) Install cylinder head cover and bolts.
(2) Remove Wiper Unit. Refer to WINDSHIELD (3) Tighten cylinder head cover bolts to 10 N·m (90
WIPERS AND WASHERS for procedure. in. lbs.) (Fig. 58).
(3) Remove intake manifold upper plenum. Refer (4) Connect PCV hose from cylinder head cover.
to this section for procedure. (5) Install intake manifold upper plenum. Refer to
(4) Disconnect PCV hose from cylinder head cover. this section for procedure.
(5) Remove rear cylinder head cover bolts (6) Install Wiper Unit. Refer to WINDSHIELD
(6) Remove cylinder head cover and gasket (Fig. WIPERS AND WASHERS for procedure.
58). (7) Connect negative cable to battery.
NS 3.3/3.8L ENGINE 9 - 161
CYLINDER HEAD
REMOVAL
TEM for procedure.
(3) Remove upper and lower intake manifolds.
Refer to procedure in this section.
WARNING: INTAKE MANIFOLD GASKET IS MADE

OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(4) Disconnect coil wires, sending unit wire, heater

hoses and bypass hose.
(5) Remove PCV system hoses, evaporation control
system hose and cylinder head covers. Fig. 60 Head Gasket Installation
(6) Remove exhaust manifolds. Refer to procedure 1 – GASKET LOCATION IDENTIFICATION MUST BE SEEN
in this section.
(7) Remove rocker arm and shaft assemblies.
Remove push rods and mark positions to ensure
installation in original locations.
(8) Remove the nine head bolts from each cylinder
head and remove cylinder heads (Fig. 59).
Fig. 61 Checking Bolts for Stretching (Necking)

1 – STRETCHED BOLT
2 – THREADS ARE NOT STRAIGHT ON LINE
turn method, tighten according to the following val-

ues:
• Step 1: Bolts 1 – 8 to 61 N·m (45 ft. lbs.)
• Step 2: Bolts 1 – 8 to 88 N·m (65 ft. lbs.)
Fig. 59 Cylinder Head Bolts Location and
• Step 3: Bolts 1 – 8 (again) to 88 N·m (65 ft. lbs.)
Tightening Sequence
• Step 4: Bolts 1 – 8 turn an additional 1/4 Turn.
INSTALLATION (Do not use a torque wrench for this step.)
(1) Clean all sealing surfaces of cylinder block and
cylinder heads. NOTE: Bolt torque after 1/4 turn should be over 122
(2) Install new gaskets on cylinder block (Fig. 60). N·m (90 ft. lbs.). If not, replace the bolt.
(3) The cylinder head bolts are torqued using
the torque yield method, they should be exam- (6) Tighten head bolt number 9 (Fig. 59) to 33 N·m
ined BEFORE reuse. If the threads are necked (25 ft. lbs.) after head bolts 1 – 8 have been tighten
down, the bolts should be replaced (Fig. 61). to specifications.
(4) Necking can be checked by holding a scale or (7) Inspect push rods and replace worn or bent
straight edge against the threads. If all the threads rods.
do not contact the scale the bolt should be replaced. (8) Install push rods, rocker arm and shaft assem-
(5) Tighten the cylinder head bolts 1 - 8 in the blies with the stamped steel retainers in the four
sequence shown in (Fig. 59). Using the 4 step torque positions, tighten to 28 N·m (250 in. lbs.) (Fig. 62).
9 - 162 3.3/3.8L ENGINE NS
(9) Place new cylinder head cover gaskets in posi-
tion and install cylinder head covers. Tighten to 12
N·m (105 in. lbs.).
Fig. 62 Rocker Arm Shaft Retainers

1 – STAMPED RETAINERS
2 – COMMON ROCKER ARMS Fig. 63 Rocker Arm Location Left Bank
1 – COMMON ROCKER ARMS
(10) Install exhaust manifolds and tighten bolts to

27 N·m (20 ft. lbs.) and nuts to 20 N·m (15 ft. lbs.). (2) Clean cylinder head cover gasket surface.
(11) Install upper and lower intake manifolds. Inspect cover for distortion and straighten, if neces-
Refer to procedure in this section. sary.
(12) Connect ignition cables, ignition coil connec- (3) Clean cylinder head sealing surfaces. Install a
tor, and sending unit connector. new gasket and tighten cylinder head cover fasteners
(13) Connect heater and coolant by-pass hose. to 12 N·m (105 in. lbs.).
(14) Fill cooling system. Refer to COOLING SYS- (4) Install crankcase ventilation system.
TEM for procedure. (5) Install spark plug wires.
(15) Connect negative cable to battery. (6) Install upper intake manifold assembly. Refer
to procedure in this section.
ROCKER ARMS AND SHAFT
VALVE STEM SEALS OR SPRINGS—CYLINDER
REMOVAL HEAD NOT REMOVED
(1) Remove upper intake manifold assembly. Refer (1) Perform fuel system pressure release procedure
to procedure in this section. before attempting any repairs
(2) Disconnect spark plug wires by pulling on the (2) Disconnect negative cable from battery.
boot straight out in line with plug. (3) Remove air cleaner cover and hose assembly.
(3) Disconnect crankcase ventilation system. (4) Remove upper intake manifold. Refer to proce-
(4) Remove cylinder head cover and gasket. dure in this section.
(5) Remove four rocker shaft bolts and retainers. (5) Remove cylinder head covers and spark plugs.
(6) Remove rocker arms and shaft assembly. (6) Remove electrical connector from ignition coils.
(7) If rocker arm assemblies are disassembled for (7) Using suitable socket and flex handle at crank-
cleaning or replacement, assemble rocker arms in shaft pulley retaining screw, turn engine so the num-
their original position. Refer to (Fig. 63) for rocker ber 1 piston is at TDC on the compression stroke.
arm for positioning on the shaft. (8) Remove rocker arms with rocker shaft and
install a dummy shaft. The rocker arms should not
INSTALLATION be disturbed and left on shaft.
(1) Install rocker arm and shaft assemblies with (9) With air hose attached to spark plug adapter
the stamped steel retainers in the four positions, installed in number 1 spark plug hole, apply 90 to
tighten to 28 N·m (250 in. lbs.) (Fig. 63). 100 psi air pressure (620.5 to 689 kPa). This is to
hold valves in place while servicing components.
CAUTION: THE ROCKER ARM SHAFT SHOULD BE (10) Using Tool C-4682 or equivalent, compress
TORQUED DOWN SLOWLY, STARTING WITH THE valve spring and remove retainer valve locks and
CENTER BOLTS. ALLOW 20 MINUTES TAPPET valve spring.
BLEED DOWN TIME AFTER INSTALLATION OF THE (11) The intake valve stem seals should be pushed
ROCKER SHAFTS BEFORE ENGINE OPERATION. firmly and squarely over the valve guide using the
valve stem as guide. Do Not Force seal against top
NS 3.3/3.8L ENGINE 9 - 163
of guide. When installing the valve retainer locks,
compress the spring only enough to install the
locks.
CAUTION: Do not pinch seal between retainer and

top of valve guide.
(12) Follow the same procedure on the remaining 5

cylinders using the firing sequence 1-2-3-4-5-6. Make
sure piston in cylinder is at TDC on the valve
spring that is being covered.
(13) Remove spark plug adapter tool.
(14) Remove dummy shaft and install rocker shaft Fig. 64 Checking Valve Installed Height
assembly and tighten screws to 28 N·m (250 in. lbs.). 1 – SPRING RETAINER
(15) Install cylinder head covers tighten screws to 2 – CYLINDER HEAD SURFACE
14 N·m (120 in. lbs.) and electrical connector to igni- 3 – SPRING SEAT SURFACE
tion coils.
(16) Install intake manifold. Refer to procedure in inch (.794 mm) spacer in head counterbore to
this section. bring spring height back to normal 1-17/32 to
(17) Connect negative cable to battery. 1-19/32 inch (39.1 to 40.6 mm).
VALVES AND VALVE SPRINGS

REMOVAL
(1) With cylinder head removed, compress valve
springs using Valve Spring Compressor Tool
C-3422-B with adapter 6412.
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(3) Before removing valves, remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides. Identify valves to insure
VALVE INSTALLATION
(1) Coat valve stems with clean engine oil and
insert them in cylinder head.
(2) Check valve tip to spring seat dimensions A Fig. 65 Valve Seal and Spring—Installation
after grinding the valve seats or faces. Grind valve 1 – RETAINER
tip to give 49.541 to 51.271 mm (1.950 to 2.018 in.) 2 – BEE HIVE STYLE SPRING
3 – VALVE
over spring seat when installed in the head (Fig. 64).
4 – VALVE STEM SEAL
Check valve tip for scoring, if necessary, the tip
5 – VALVE SPRING SEAT SPACER
chamfer should be reground to prevent seal damage
when the valve is installed.
(3) Install valve spring seat spacer on head (Fig. HYDRAULIC TAPPETS
65).
(4) Install new cup seals on all valve stems and REMOVAL
over valve guides (Fig. 64). Install valve springs and Cylinder head must be removed to gain access to
valve retainers (Fig. 65). hydraulic tappets for service.
(5) Compress valve springs with Valve Spring (1) Remove cylinder head. Refer to procedure in
Compressor Tool C-3422-B, with adapter 6412 install this section.
locks and release tool. If valves and/or seats are (2) Remove yoke retainer and aligning yokes.
reground, measure the installed height of (3) Use Special Tool C-4129, or equivalent to
springs dimension B, make sure measurements remove tappets from their bores. If all tappets are to
are taken from top of spring seat to the bottom be reused, identify tappets to insure installation in
surface of spring retainer. If height is greater original location.
than 1-19/32 inches, (40.6 mm), install a 1/32
9 - 164 3.3/3.8L ENGINE NS
INSTALLATION (11) Remove crankshaft damper (Fig. 67).
(1) Lubricate tappets.
Fig. 66 Roller Tappets Aligning Yoke and Retainer

Fig. 67 Crankshaft Damper—Removal
1 – YOKE RETAINER
2 – ALIGNING YOKE
2 – SPECIAL TOOL L-4524-1 FROM KIT C-4685-C
(2) Install hydraulic tappets. Install tappets in

(12) Remove lower radiator and heater hoses from
their original positions, if reused.
chain cover housing.
(3) Install tappet aligning yokes (Fig. 66).
(13) Remove idler pulley from engine bracket.
(4) Install yoke retainer and torque screws to 12
(14) Remove coolant by-pass hose from chain cover
N·m (105 in. lbs.) (Fig. 66).
housing.
(5) Install cylinder heads. Refer to procedure in
(15) Support the engine.
this section.
(16) Remove the right side engine mount. Refer to
(6) Start and operate engine. Warm up to normal
Engine Mounts in this section.
operating temperature.
(17) Remove the engine mount bracket (Fig. 68).
CAUTION: To prevent damage to valve mechanism, (18) Remove cam sensor from timing chain cover
engine must not be run above fast idle until all (Fig. 69).
hydraulic tappets have filled with oil and have (19) Remove the water pump pulley.
become quiet. (20) Remove the timing chain cover (Fig. 69).
TIMING CHAIN COVER

REMOVAL
TEM for procedure.
(3) Support engine and remove right engine
mount.
(5) Drain engine oil.
(6) Remove right wheel and inner splash shield.
(7) Remove transaxle inspection cover.
(8) Remove oil pan and oil pump pick-up tube.
(9) Remove accessory drive belt. Refer to COOL-
ING SYSTEM for procedure. Fig. 68 Engine Bracket
(10) Remove A/C compressor and set aside. 1 – ENGINE BRACKET
2 – ENGINE BRACKET FASTENERS (3)
NS 3.3/3.8L ENGINE 9 - 165
Fig. 69 Timing Chain Case Cover

1 – CAM SENSOR
2 – CHAIN CASE COVER
3 – FASTENERS (7)
INSTALLATION Fig. 70 Timing Chain Case Cover Gaskets and

(1) Be sure mating surfaces of chain case cover O-Rings
and cylinder block are clean and free from burrs. 1 – COOLANT PASSAGE
Crankshaft oil seal must be removed to insure cor- 2 – O-RINGS
rect oil pump engagement. 3 – OIL PUMP TO ENGINE OUTLET
4 – OIL PUMP ASSEMBLY
NOTE: DO NOT USE SEALER ON COVER GASKET 5 – COOLANT PASSAGE
6 – O-RING
(2) Use a new cover gasket, and O-rings (Fig. 70). 7 – GASKET
Adhere new gasket to chain case cover, making sure
that the lower edge of the gasket is flush to 0.5 mm
(0.020 in.) passed the lower edge of the cover. Refer
to Oil Pan sealing in this section.
(3) Rotate crankshaft so that the oil pump drive
flats are in the vertical position.
(4) Position oil pump inner rotor so the mating
flats are in the same position as the crankshaft drive
flats (Fig. 70).
CAUTION: Make sure the oil pump is engaged on

the crankshaft correctly or severe damage may
result.
(5) Install cover onto crankshaft.

(6) Install timing chain cover screws and torque to
27 N·m (20 ft. lbs.) (Fig. 69).
(7) Install crankshaft oil seal (Fig. 71).
(8) Install water pump pulley. Fig. 71 Crankshaft Oil Seal—Installation
(9) Install crankshaft damper (Fig. 72). 1 – SEAL
2 – CRANKSHAFT SEAL INSTALLING TOOL C-4992
9 - 166 3.3/3.8L ENGINE NS
Fig. 72 Crankshaft Damper—Installation Fig. 73 Timing Marks Alignment

1 – DOT
2 – COLORED LINK
(10) Install engine bracket (Fig. 68) and torque 3 – COLORED LINK
fasteners to 54 N·m (40 ft. lbs.). 4 – ALIGN ARROWS
(11) Install right side engine mount. Refer to
Engine Mounts in this section. INSTALLATION
(12) Install idler pulley on engine bracket. (1) Position a new crankshaft sprocket on the
(13) Install cam sensor. Refer to IGNITION SYS- crankshaft. Install sprocket with Special Tool C-4965,
TEM for procedure. or equivalent and mallet. Be sure sprocket is seated
(14) Install coolant by-pass, heater, and lower radi- into position.
ator hoses. (2) Rotate crankshaft so the timing arrow is to the
(15) Install A/C compressor. 12 o’clock position (Fig. 73).
(16) Install accessory drive belt. Refer to COOL-
ING SYSTEM for procedure. NOTE: Lubricate timing chain and sprockets with
(17) Install oil pump pick-up tube with new clean engine oil before installation.
O-ring. Tighten attaching bolt to 28 N·m (250 in.
lbs.). (3) While holding camshaft sprocket and chain in
(18) Install oil pan and transaxle inspection cover. hand, place timing chain around the sprocket, align-
(19) Install inner splash shield and wheel. ing the colored link with the dot on the sprocket.
(20) Fill crankcase with oil to proper level. Position the timing arrow to the 6 o’clock position.
(21) Fill cooling system. Refer to COOLING SYS- (4) Place timing chain around crankshaft sprocket
TEM for procedure. with the colored link lined up with the dot on the
(22) Connect negative cable to battery. sprocket. Install camshaft sprocket into position.
(5) Use a straight edge to check alignment of tim-
TIMING CHAIN ing marks (Fig. 73).
(6) Install camshaft sprocket bolt and washer.
REMOVAL Tighten bolt to 54 N·m (40 ft. lbs.).
(1) Disconnect negative cable from battery. (7) Rotate crankshaft 2 revolutions. Timing marks
(2) Remove timing chain cover. Refer to procedure should line up. If timing marks do not line up,
in this section. remove cam sprocket and realign.
(3) Rotate engine until timing marks are aligned (8) Check camshaft end play. Refer to Engine
as shown in (Fig. 73). Specifications in this section. If not within these lim-
(4) Remove camshaft sprocket attaching bolt and its, install new thrust plate.
timing chain with camshaft sprocket. (9) Install timing chain cover. Refer to procedure
(5) Using a suitable puller, remove the crankshaft in this section.
sprocket while holding the crankshaft from turning. (10) Connect negative cable to battery.
Be careful not to damage the crankshaft surfaces.
NS 3.3/3.8L ENGINE 9 - 167
CAMSHAFT
REMOVAL
(1) Remove engine from vehicle. Refer to procedure
in this section.
Remove intake manifold, cylinder head covers, cyl-
inder heads, timing chain case cover, and timing
chain. Refer to procedures in this section.
(2) Remove hydraulic tappets. Identify each tappet
for reinstallation into it’s original location.
(3) Remove camshaft thrust plate (Fig. 74).
(4) Install a long bolt into front of camshaft to
facilitate removal of the camshaft; remove camshaft,
being careful not to damage cam bearings with the
cam lobes.
Fig. 75 Alignment of Timing Marks

1 – DOT
2 – COLORED LINK
3 – COLORED LINK
4 – ALIGN ARROWS
(6) Place timing chain around crankshaft sprocket

with the colored link lined up with the dot on the
sprocket. Install the camshaft sprocket into position.
(7) Use a straight edge to check alignment of tim-
ing marks (Fig. 75).
(8) Install the camshaft sprocket bolt and washer.
Tighten bolt to 54 N·m (40 ft. lbs.).
(9) Rotate crankshaft two revolutions. Timing
marks should line up. If timing marks do not line up,
remove cam sprocket and realign.
Fig. 74 Camshaft Thrust Plate
(10) Measure camshaft end play. Refer to Engine
1 – OIL GALLERY CUP PLUGS
Specifications in this section. If not within limits
2 – CAMSHAFT THRUST PLATE
3 – OIL FEED GALLERY FROM PUMP
install a new thrust plate.
NOTE: When camshaft is replaced, all of the tap-

INSTALLATION pets must be replaced.
(1) Lubricate camshaft lobes and camshaft bearing
journals. (11) Install hydraulic tappets. Each tappet reused
(2) Insert the camshaft to within 2 inches of its must be installed in the same position from which it
final position in cylinder block. was removed.
(3) Install camshaft thrust plate with two screws (12) Install timing chain, timing chain cover, cylin-
as shown in (Fig. 74). Tighten to 12 N·m (105 in. lbs.) der heads, cylinder head covers, and intake manifold.
torque. Refer to procedures in this section.
(4) Rotate crankshaft so the timing arrow on (13) Install engine assembly. Refer to procedure in
crankshaft sprocket is at the 12 o’clock position. this section.
NOTE: Lubricate timing chain and sprockets with CAMSHAFT BEARINGS

clean engine oil before installation.
REMOVAL
(5) While holding camshaft sprocket and chain in (1) With engine removed from vehicle and com-
hand, place timing chain around the sprocket, align- pletely disassembled, drive out rear cam bearing core
ing the colored link with the dot on the sprocket. hole plug.
Position the timing arrow to the 6 o’clock position. (2) Install proper size adapters and horseshoe
washers (part of Tool C-3132-A) at back of each bear-
9 - 168 3.3/3.8L ENGINE NS
ing shell to be removed and drive out bearing shells INSTALLATION
(Fig. 76). (1) Clean surfaces and apply a 1/8 inch bead of
Mopart Engine RTV GEN II at the parting line of
the chain case cover and the rear seal retainer (Fig.
77).
(2) Use a new pan gasket (Fig. 78).
(3) Install pan and tighten screws to 12 N·m (105
in. lbs.).
Fig. 76 Removal/Installation of Camshaft Bearings

with Tool C-3132-A—Typical
1 – SPECIAL TOOL C-3132A
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. 77 Oil Pan Sealing
fully drive bearing shell into place.
1 – PLACE A 1/8 INCH BEAD OF SEALER AT THE PARTING
(3) Install remaining bearings in the same man- LINE OF CHAIN CASE COVER AND REAR SEAL RETAINER
ner. Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. Number two bearing must index with
the oil passage to the left cylinder head and Number
three bearing must index with the oil passage to the
right cylinder head. If the camshaft bearing shell oil
holes are not in exact alignment, remove and rein-
stall them correctly. Install a new core hole plug at
the rear of camshaft. Be sure this plug does not
leak.
OIL PAN
REMOVAL
(1) Disconnect negative cable from battery and
remove engine oil dipstick.
(2) Raise vehicle on hoist and drain engine oil.
(3) Remove bending brace to transaxle attaching
Fig. 78 Oil Pan Gasket Installation
bolt. 1 – OIL PICK-UP TUBE
(4) Remove bolts attaching dust cover to transaxle 2 – OIL PAN GASKET
housing. Lower dust cover to gain access to oil pan
bolts.
(5) Remove oil pan screws and remove oil pan. (4) Install dust shield and bending brace to tran-
saxle housing.
(5) Lower vehicle and install oil dipstick.
(7) Fill crankcase with oil to proper level.
NS 3.3/3.8L ENGINE 9 - 169
OIL PUMP
The oil pump is contained within the timing chain
cover housing (Fig. 79).
REMOVAL
(1) Remove oil pan and timing chain cover. Refer
to procedures in this section.
(2) Remove oil pump cover and rotors. Refer to Oil
Pump Disassembly in this section for procedures.
(3) Clean and Inspect oil pump components. Refer
to Oil Pump Cleaning and Inspection in this section.
Fig. 80 Oil Pressure Relief Valve

1 – RELIEF VALVE
2 – SPRING
3 – RETAINER CAP
INSTALLATION
(1) Clean relief valve, spring and bore.
NOTE: Lubricate relief valve with clean engine oil

before installing.
Fig. 79 Oil Pump
(2) Install relief valve and spring into housing.
1 – CHAIN CASE COVER (CCC)
2 – OIL PUMP INNER ROTOR
(3) Install new retainer cap until flush with seal-
3 – SCREW ing surface.
4 – OIL PUMP COVER (4) Install oil pan. Refer to procedures in this sec-
5 – OIL PUMP OUTER ROTOR tion.
(5) Fill crankcase with proper oil to correct level.
INSTALLATION PISTON AND CONNECTING ROD
(1) Install oil pump. Refer to Oil Pump Assembly
in this section for procedures. REMOVAL
(2) Install timing chain cover and oil pan. Refer to (1) Disconnect negative cable from battery.
procedures in this section. (2) Remove cylinder heads and oil pan. Refer to
OIL PRESSURE RELIEF VALVE (3) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
REMOVAL inder block. Be sure to keep tops of pistons
(1) Drain engine oil and remove oil pan. Refer to covered during this operation. Pistons and con-
procedures in this section. necting rods must be removed from top of cyl-
(2) Drill a 3.175 mm (1/8 in.) hole in the center of inder block. When removing piston and
the retainer cap (Fig. 80). Insert a self-threading connecting rod assemblies from the engine,
sheet metal screw into the cap. rotate crankshaft so that each connecting rod
(3) Using suitable pliers, remove cap and discard. is centered in cylinder bore.
(4) Remove spring and relief valve (Fig. 80).
9 - 170 3.3/3.8L ENGINE NS
(4) Inspect connecting rods and connecting rod
caps for cylinder identification. Identify them, if nec-
essary (Fig. 81).
Fig. 81 Identify Connecting Rod to Cylinder

1 – CYLINDER NUMBER Fig. 83 Piston Ring End Gap Position
1 – SIDE RAIL UPPER
(5) Remove connecting rod cap. Install connecting 3 – PISTON PIN
rod bolt protectors on connecting rod bolts (Fig. 82). 4 – SIDE RAIL LOWER
Push each piston and rod assembly out of cylinder 5 – NO. 2 RING GAP AND SPACER EXPANDER GAP
bore.
(2) Before installing the ring compressor, make
NOTE: Be careful not to nick crankshaft journals.
sure the oil ring expander ends are butted and the
(6) After removal, install bearing cap on the mat- rail gaps located as shown in (Fig. 83).
ing rod.
Fig. 84 Piston—Installation
(3) Lubricate the piston and rings with clean
engine oil. Position a ring compressor over the piston
and rings, and tighten the compressor. Be sure posi-
Fig. 82 Connecting Rod Protectors
tion of rings does not change during this oper-
1 – COVER ROD BOLTS WITH A SUITABLE COVERING WHEN
REMOVING OR INSTALLING PISTON ASSEMBLY ation.
(4) Install connecting rod bolt protectors on rod
bolts (Fig. 82).
INSTALLING PISTON AND CONNECTING ROD (5) Rotate crankshaft so that the connecting rod
ASSEMBLY journal is on the center of the cylinder bore. Insert
(1) Before installing pistons and connecting rod rod and piston into cylinder bore and guide rod over
assemblies into the bore, be sure that compression the crankshaft journal (Fig. 84).
ring gaps are staggered so that neither is in line with (6) Tap the piston down in cylinder bore, using a
oil ring rail gap (Fig. 83). hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
NS 3.3/3.8L ENGINE 9 - 171
Fig. 85 Piston I. D. Notches

1 – GASKET LOCATION IDENTIFICATION MUST BE SEEN
Fig. 86 Removing and Installing Upper Main Bearing
2 – PISTON NOTCHES MUST FACE TOWARD THE FRONT OF With Special Tool C-3059
ENGINE 1 – SPECIAL TOOL C-3059
2 – BEARING
(7) The notch or groove on top of piston must be 4 – BEARING
pointing toward front of engine (Fig. 85).
(8) Install rod caps. Install nuts on cleaned and
oiled rod bolts and tighten nuts to 54 N·m (40 ft. lbs.) (3) Slowly rotate crankshaft counterclockwise slid-
Plus 1/4 turn. ing the bearing into position. Remove Special Main
(9) Repeat procedure for each piston and rod Bearing Tool C-3059.
installation. (4) Install each main cap and tighten bolts finger
(10) Install cylinder heads and oil pan. tight.
(11) Fill engine crankcase with proper oil to cor- (5) Tighten number 1, 3 and 4 main cap bolts to 41
rect level. N·m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn).
(12) Connect negative cable to battery. (6) Rotate the crankshaft until the number 6 pis-
ton is at TDC.
CRANKSHAFT (7) To ensure correct thrust bearing alignment the
following procedure must be done:
REMOVAL a. Move crankshaft all the way to the rear of its
(1) Remove oil pan and identify bearing caps travel.
before removal. b. Then, move crankshaft all the way to the front
(2) Remove bearing caps one at a time. Remove of its travel.
upper half of bearing by inserting Special Main Bear- c. Wedge a appropriate tool between the rear of
ing Tool C-3059. (Fig. 86) into the oil hole of crank- the cylinder block and rear crankshaft counter-
shaft. weight. This will hold the crankshaft in it’s most for-
(3) Slowly rotate crankshaft clockwise, forcing out ward position.
upper half of bearing shell. d. Tighten the #2 Thrust Bearing cap bolts to 41
N·m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove the
INSTALLATION holding tool.
(8) Install oil pan.
NOTE: Only one main bearing should be selectively (9) Fill engine crankcase with proper oil to correct
fitted while all other main bearing caps are properly level.
tightened.
(1) For main bearing fitting procedure, refer to
Main Bearing—Fitting in this section. REMOVAL
When installing a new upper bearing shell, slightly (1) Disconnect negative cable from battery.
chamfer the sharp edges from the plain side. (2) Raise vehicle on hoist. Remove right wheel and
(2) Start bearing in place, and insert Main Bearing inner splash shield.
Tool C-3059 into oil hole of crankshaft (Fig. 86).
9 - 172 3.3/3.8L ENGINE NS
(3) Remove accessory drive belt. Refer to COOL- INSTALLATION
ING SYSTEM for procedure. (1) Install new seal using Special Tool C-4992 (Fig.
(4) Remove crankshaft damper (Fig. 87). 89).
Fig. 87 Crankshaft Damper—Removal Fig. 89 Crankshaft Oil Seal—Installation

1 – SEAL
2 – SPECIAL TOOL L-4524-1 FROM KIT C-4685-C
2 – CRANKSHAFT SEAL INSTALLING TOOL C-4992
(5) Remove oil seal using Special Tool 6341A (Fig. (2) Place seal into opening with seal spring
88). Be careful not to damage that crankshaft seal towards the inside of engine. Install seal until flush
surface of cover. with cover.
(3) Install crankshaft pulley using Special Tool
C-4685-C1 Bolt, with thrust bearing/washer and nut
(Fig. 90).

Fig. 88 Front Crankshaft Oil Seal—Removal

(4) Install accessory drive belt. Refer to COOLING
1 – CRANKSHAFT SEAL REMOVAL SPECIAL TOOL 6341A
(5) Install inner splash shield and wheel.
(6) Lower vehicle and connect negative cable to
battery.
NS 3.3/3.8L ENGINE 9 - 173
CRANKSHAFT OIL SEAL—REAR

REMOVAL
(1) Remove transaxle. Refer to TRANSAXLE AND
POWER TRANSFER UNIT for procedure.
(2) Remove drive plate.
(3) Insert a 3/16 flat bladed pry tool between the
dust lip and the metal case of the crankshaft seal.
Angle the pry tool (Fig. 91) through the dust lip
against metal case of the seal. Pry out seal.
CAUTION: Do not permit the pry tool blade to con-

tact crankshaft seal surface. Contact of the pry tool
blade against crankshaft edge (chamfer) is permit-
ted.
Fig. 92 Rear Crankshaft Oil Seal—Installation

1 – SPECIAL TOOLS:
2 – C-4171 HANDLE
3 – 6926–2 INSTALLER
4 – 6926–1 GUIDE
5 – SEAL
Fig. 91 Rear Crankshaft Oil Seal—Removal (4) Clean engine block and retainer of oil and gas-
ket material. Make sure surfaces are clean and free
INSTALLATION of oil.
CAUTION: If burr or scratch is present on the INSTALLATION
crankshaft edge (chamfer), cleanup with 400 grit (1) Position new gasket and install retainer on
sand paper to prevent seal damage during installa- block. Tighten attaching screws to 12 N·m (105 in.
tion of new seal. lbs.).
(2) Install oil seal. Refer to procedures in this sec-
(1) Place Special Tool 6926-1 magnetic pilot tool on
tion.
crankshaft (Fig. 92).
(2) Place seal over Special Tool 6926-1 Pilot. Using
Special Tool 6926-2 Installer with C-4171 Handle,
OIL FILTER
drive seal into the retainer housing (Fig. 92).
CAUTION: When servicing the oil filter (Fig. 93)
(3) Install drive plate. Tighten bolts to 95 N·m (70
avoid deforming the filter can by installing the
ft. lbs.).
remove/install tool band strap against the can-to-
(4) Install transaxle. Refer to TRANSAXLE AND
base lock seam. The lock seam joining the can to
POWER TRANSFER UNIT for procedure.
the base is reinforced by the base plate.
CRANKSHAFT OIL SEAL RETAINER—REAR (1) Using suitable oil filter wrench, turn filter
counterclockwise to remove from base. Properly dis-
REMOVAL card filter.
(1) Remove crankshaft rear oil seal. Refer to pro- (2) Wipe base clean, then inspect gasket contact
cedures in this section. surface.
(2) Remove oil seal retainer screws.
(3) Remove oil seal retainer.
9 - 174 3.3/3.8L ENGINE NS
(3) Lubricate gasket of new filter with clean
engine oil.
(4) Install new filter until gasket contacts base.
Tighten filter 1 turn or 20 N·m (15 ft. lbs.). Use filter
wrench if necessary.
(5) Start engine and check for leaks.
Fig. 94 Core Hole Plug Removal

1 – CYLINDER BLOCK
Fig. 93 Oil Filter 2 – REMOVE PLUG WITH PLIERS
1 – OIL FILTER 3 – STRIKE HERE WITH HAMMER
2 – COOLANT TUBE 4 – DRIFT PUNCH
5 – CUP PLUG
ENGINE CORE AND OIL GALLERY PLUGS

DISASSEMBLY
REMOVAL
OIL PUMP
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup (1) Remove oil pump cover screws, and lift off
plug rotated, grasp firmly with pliers or other suit- cover (Fig. 95).
able tool and remove plug (Fig. 94). (2) Remove pump rotors (Fig. 95).
(3) Wash all parts in a suitable solvent and inspect
CAUTION: Do not drive cup plug into the casting carefully for damage or wear. Refer to Oil Pump
as restricted flow can result and cause serious Cleaning and Inspection in this section.
engine problems.
INSTALLATION
Thoroughly clean inside of cup plug hole in cylin-
Lightly coat inside of cup plug hole with Mopart
Stud & Bearing Mount or equivalent. Make certain
the new plug is cleaned of all oil or grease. Using a
proper drive tool, drive plug into oil gallery hole so
that the sharp edge of the plug is at least 0.5 mm
(0.020 in.) inside the lead-in chamfer.
DISASSEMBLY AND ASSEMBLY

OIL PUMP Fig. 95 Oil Pump
It is necessary to remove the oil pan, oil pickup 1 – CHAIN CASE COVER (CCC)
and chain case cover to service the oil pump rotors. 2 – OIL PUMP INNER ROTOR
The oil pump pressure relief valve can be serviced by 3 – SCREW
removing the oil pan and oil pickup tube. Refer to 4 – OIL PUMP COVER
Timing Chain Cover in this section for procedures. 5 – OIL PUMP OUTER ROTOR
NS 3.3/3.8L ENGINE 9 - 175
OIL PRESSURE RELIEF VALVE CLEANING AND INSPECTION
(1) Remove the relief valve by drilling a 3.175 mm
(1/8 inch) hole into the relief valve retainer cap. INTAKE MANIFOLD
(2) Insert a self-threading sheet metal screw into
cap. CLEANING
(3) Clamp screw into a vise and while supporting Remove the gasket material from the manifold sur-
chain case cover, remove cap by tapping chain case faces.
cover using a soft hammer. Discard retainer cap and Be careful not to gouge or scratch the sealing sur-
remove spring and relief valve (Fig. 96). face.
(4) Wash all parts in a suitable solvent and inspect
carefully for damage or wear. Refer to Oil Pump INSPECTION
Cleaning and Inspection in this section. Check for:
• Damage and cracks of each section.
• Clogged water passages in end cross-overs (if
equipped).
• Check for cylinder head mounting surface distor-
tion using a straightedge and thickness gauge. Refer
to Cylinder Head—Inspection.
EXHAUST MANIFOLD
CLEANING
faces (if equipped). Be careful not to gouge or scratch
the sealing surface.
INSPECTION
Inspect exhaust manifolds for damage or cracks
Fig. 96 Oil Pressure Relief Valve and check distortion of the cylinder head mounting
1 – RELIEF VALVE surface and exhaust cross-over mounting surface
2 – SPRING with a straightedge and thickness gauge (Fig. 97).
3 – RETAINER CAP
ASSEMBLY
OIL PUMP
(1) Assemble pump, using new parts as required.
Install the inner rotor with chamfer facing the
oil pump cover (Fig. 95).
(2) Tighten cover screws to 12 N·m (105 in. lbs.).
(3) Prime oil pump before installation by filling
rotor cavity with clean engine oil.
OIL PRESSURE RELIEF VALVE

(1) Clean relief valve, spring and housing.
NOTE: Lubricate relief valve with clean engine oil Fig. 97 Check Exhaust Manifold Mounting
before installing. 1 – CROSSOVER PIPE MOUNTING SURFACE
(2) Install relief valve and spring into housing

(chain case cover) (Fig. 96). CYLINDER HEAD
(3) Install new retainer cap until flush with seal- (1) Before cleaning, check for leaks, damage and
ing surface. cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 98).
9 - 176 3.3/3.8L ENGINE NS
(4) Inspect all surfaces with a straightedge if there (2) Lay a straightedge across the pump cover sur-
is any reason to suspect leakage. If out of flatness face (Fig. 99). If a 0.025 mm (0.001 in.) feeler gauge
exceeds 0.019 mm (0.00075 in.) times the span length can be inserted between cover and straight edge,
in inches, in any direction, either replace head or cover should be replaced.
lightly machine the head surface. As an example, if a (3) Measure thickness and diameter of outer rotor.
12 inch span is 0.1 mm (.004 in.) out of flat, allow- If outer rotor thickness measures 7.64 mm (0.301 in.)
able is 12 x.019 mm (.00075 in.) equals.22 mm (.009 or less (Fig. 100), or if the diameter is 79.95 mm
in.) This amount of out of flat is acceptable. Maxi- (3.148 in.) or less, replace outer rotor.
mum of 0.2 mm (.008 in.) for grinding is permitted. (4) If inner rotor measures 7.64 mm (0.301 in.) or
less, replace inner rotor (Fig. 101).
CAUTION: This is a combined total dimension of
stock removal from cylinder head and block top
surface.
Fig. 99 Checking Oil Pump Cover Flatness

1 – FEELER GAUGE
2 – OIL PUMP COVER
Fig. 98 Check Cylinder Head 3 – STRAIGHT EDGE
OIL PAN
(5) Slide outer rotor into chain case cover, press to
CLEANING one side with fingers and measure clearance between
(1) Clean oil pan in solvent and wipe dry with a rotor and chain case cover (Fig. 102). If measurement
clean cloth. Clean all gasket material from mounting is 0.39 mm (0.015 in.) or more, replace chain case
surfaces of pan and block. cover only if outer rotor is in specification.
(2) Clean oil screen and pipe in clean solvent. (6) Install inner rotor into chain case cover. If
clearance between inner and outer rotors (Fig. 103) is
INSPECTION 0.203 mm (0.008 in.) or more, replace both rotors.
(1) Inspect oil drain plug and plug hole for (7) Place a straightedge across the face of the
stripped or damaged threads and repair as necessary. chain case cover, between bolt holes. If a feeler gauge
Install a new drain plug gasket. Tighten to 27 N·m of 0.10 mm (0.004 in.) or more can be inserted
(20 ft. lbs.). between rotors and the straightedge, replace pump
(2) Inspect oil pan mounting flange for bends or assembly (Fig. 104). ONLY if rotors are in specs.
distortion. Straighten flange if necessary. (8) Inspect oil pressure relief valve and bore.
(3) Inspect condition of oil screen and pipe. Inspect for scoring, pitting and free valve operation
in bore (Fig. 105). Small marks may be removed with
OIL PUMP 400-grit wet or dry sandpaper.
(9) The relief valve spring has a free length of
CLEANING approximately 49.5 mm (1.95 inches) it should test
(1) Clean all parts thoroughly. between 19.5 and 20.5 pounds when compressed to
34 mm (1-11/32 inches). Replace spring that fails to
INSPECTION meet specifications.
(1) Inspect mating surface of the chain case cover. (10) If oil pressure is low and pump is within spec-
Surface should be smooth. Replace cover if scratched ifications, inspect for worn engine bearings or other
or grooved. reasons for oil pressure loss.
NS 3.3/3.8L ENGINE 9 - 177
Fig. 100 Measuring Outer Rotor Thickness Fig. 103 Measuring Clearance Between Rotors
1 – FEELER GAUGE
2 – INNER ROTOR
3 – OUTER ROTOR
Fig. 101 Measuring Inner Rotor Thickness
Fig. 104 Measuring Clearance Over Rotors

1 – FEELER GAUGE
2 – STRAIGHT EDGE
Fig. 102 Measuring Outer Rotor Clearance in

Housing
1 – FEELER GAUGE
2 – OUTER ROTOR
9 - 178 3.3/3.8L ENGINE NS
inder walls are badly scuffed or scored, the cylinder
block should be replaced.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 106). Top measurement should be
12 mm (0.50 in.) down and bottom measurement
should be 12 mm (0.50 in.) up from bottom of bore.
SPECIFICATIONS
3.3/3.8L ENGINE
General Specification
Fig. 105 Oil Pressure Relief Valve Type 60° V-6 Engine
1 – RELIEF VALVE
Number of Cylinders 6
2 – SPRING
3 – RETAINER CAP Displacement
—3.3L 3.3 Liters
CYLINDER BLOCK AND BORE (201 cu. in.)
—3.8L 3.8 Liters
CLEANING
Clean cylinder block thoroughly. (231 cu. in.)
Bore
—3.3L 93.0 mm
(3.66 in.)
—3.8L 96.0 mm
(3.779 in.)
Stroke
—3.3L 81.0 mm
(3.188 in.)
—3.8L 87.0 mm
(3.425 in.)
Compression Ratio
—3.3L 8.9:1
—3.8L 9.6:1
Firing Order 1-2-3-4-5-6
Cylinder Number (Front
to Rear)
—Front Bank 2,4,6
Fig. 106 Checking Cylinder Bore Size —Rear Bank 1,3,5
CYLINDER BORE INSPECTION Compression Pressure— 689.5 kPa
Examine block for cracks or fractures. Check all Minimum (100 psi)
core hole plugs for evidence of leaking and replace as
necessary. Max. Variation Between 25%
The cylinder walls should be checked for out-of- Cylinders
round and taper with Tool C-119 (Fig. 106). If the cyl-
NS 3.3/3.8L ENGINE 9 - 179

Cylinder Block —3.8L 71.25–71.75
Cylinder Bore Diameter (2.805–2.824 in.)
(Standard) Piston Rings
—3.3L 92.993–93.0007 mm Ring Gap—Top 0.30–0.55 mm
(3.661–3.6617 in.) Compression Ring (0.0118–0.0217 in.)
—3.8L 95.993–96.007 mm Wear Limit 1.0 mm
(3.7792–3.780 in.) (0.039 in.)
Out-of-Round (Max.) 0.076 mm Ring Gap—2nd 0.30–0.55 mm
(0.003 in.) Compression Ring (0.0118–0.0217 in.)
Taper (Max.) 0.051 mm Wear Limit 1.0 mm
(0.002 in.) (0.039 in.)
Cylinder Bore Oversize 0.508 mm Ring Gap—Oil Control 0.25–1.00 mm
(Max.) Steel Rails (0.0098–0.0394 in.)
Tappet Bore Diameter 22.9896–23.0099 mm (0.074 in.)
(0.9051–0.9059 in.) Ring Side Clearance— 0.030–0.095 mm
Pistons Compression Rings (0.0012–0.0037 in.)
Piston Diameter Wear Limit 0.10 mm
—3.3L 92.950–92.968 mm (0.004 in.)
(3.6594–3.6602 in.) Ring Side Clearance—Oil 0.014–0.226 mm
Ring Pack (0.0005–0.0089 in.)
—3.8L 95.950–95.968 mm
(3.7776–3.7783 in.) Wear Limit 0.266 mm
Clearance in Bore @ 0.025–0.057 mm (0.009 in.)
Size Location (0.001–0.0022 in.) Ring Width— 1.46–1.50 mm
Compression Rings (0.0575–0.0591 in.)
Weight (11.47–11.82 oz.)
—3.3L 381 65 grams Ring Width—Oil Ring 0.510 mm
(Steel Rails) (0.0201 in.)
(13.4394 60.1764 oz.)
—3.8L 438 65 grams Connecting Rod
Bearing Clearance 0.019–0.073 mm
(15.4501 60.1764 oz.)
(0.0008–0.0029 in.)
Piston Pins
Wear Limit 0.074 mm
Type Press Fit in Rod
(Serviced as an (0.003 in.)
Assembly) Side Clearance 0.13–0.32 mm
Clearance in Piston @ 0.006–0.019 mm (0.005–0.013 in.)
21° C (70° F) (0.0002–0.0007 in.) Wear Limit 0.38 mm
Clearance in Connecting (Interference Fit) (0.015 in.)
Rod
Crankshaft
Diameter 22.87–22.88 mm
Connecting Rod Journal 57.979–58.005 mm
(0.9007–0.9009 in.) Diameter (2.2827–2.2837 in.)
Length
Main Bearing Journal 63.992–64.013 mm
—3.3L 67.25–67.75 mm Diameter (2.5194–2.5202 in.)
(2.648–2.667 in.)
9 - 180 3.3/3.8L ENGINE NS

Journal Out-of-Round 0.025 mm No. 4 49.606–49.632 mm
(Max.) (0.001 in.) (1.9529–1.954 in.)
Journal Taper (Max.) 0.025 mm Exhaust Valve Timing
(0.001 in.) Closes (ATDC) 12°
End Play 0.09–0.24 mm Opens (BBDC) 48°
(0.0036–0.0095 in.) Duration 240°
Wear Limit 0.381 mm Intake Valve Timing
(0.015 in.) Closes (BTDC 58°
Main Bearing Diametrical Opens (ATDC) 2°
Clearance
Duration 240°
—No. 1, 3, 4 0.011–0.055 mm
Valve Overlap 14°
(0.0005–0.0022 in.)
Cylinder Head
—No. 2 (thrust) 0.011–0.059 mm
Gasket Thickness 1.78 mm
(0.0005–0.0024 (Compressed) (0.070 in.)
Wear Limit 0.076 mm
Valve Seat
(0.003 in.)
Angle 45–45.5°
Camshaft Valve Seat Runout (Max.) 0.0762 mm
Journal Diameter (0.003 in.)
No.1 50.724–50.775 mm Valve Seat Width—Intake 1.75–2.25 mm
(1.997–1.999 in.) (0.069–0.088 in.)
No.2 50.317–50.368 mm Valve Seat Width— 1.50–2.00 mm
(1.9809–1.9829 in.) Exhaust
No.3 49.936–49.987 mm (0.057–0.078 in.)
(1.9659–1.9679 in.) Valve Guide
No.4 49.530–49.581 mm Guide Bore Diameter 7.975–8.00 mm
(1.9499–1.9520 in.) (Std.) (0.314–0.315 in.)
Bearing Clearance— 0.025–0.101 mm Valves
Diametrical (0.001–0.004 in.) Valve Lift (Zero 10.16 mm
Bearing Clearance (Max. 0.127 mm Lash)—Intake
allowable) (0.005 in.) (0.40 in.)
End Play 0.127–0.304 mm Valve Lift (Zero 10.16 mm
(0.005–0.012 in.) Lash)—Exhaust
(Max. allowable) 0.304 mm (0.40 in.)
(0.012 in.) Face Angle—Intake 44.5°
Camshaft Bearing Face Angle—Exhaust 44.5°
Diameter Head Diameter—Intake 45.5 mm
No. 1 50.800–50.825 mm (1.79 in.)
(1.9999–2.0009 in.) Head Diameter—Exhaust 37.5 mm
No. 2 50.393–50.419 mm (1.476 in.)
(1.9839–1.9849 in.) Valve Margin
No. 3 50.013–50.038 mm Intake 0.794 mm
(1.9690–1.9699 in.) (0.031 in.)
NS 3.3/3.8L ENGINE 9 - 181

Exhaust 1.191 mm Number of Coils 6.8
(0.0469 in.) Spring Tension (Valve 420.5–440 N @ 39.8 mm
Closed) (95–100 lbs. @ 1.57 in.)
Valve Length (Overall)
Intake 127.005–128.036 mm Spring Tension (Valve 910–1007.6 N @ 29.69
Open) mm
(5.000–5.041 in.)
(207–229 lbs. @ 1.169
—Minimum 124.892 mm
in.)
(4.916 in.) Installed Height 41.2–42.7 mm
Exhaust 127.825–128.465 mm (1.622–1.681 in.)
(5.032–5.058 in.)
Oil Pump
—Minimum 125.512 mm
Clearance Over 0.10 mm
(4.941 in.) Rotors—Inner and Outer
(Max.) (0.004 in.)
Valve Stem Tip Height
Intake 49.541–51.271 mm Cover Out-of-Flat (Max.) 0.025 mm
(1.950–2.018 in.) (0.001 in.)
Exhaust 49.541–51.271 mm Inner Rotor Thickness 7.64 mm
(Min.)
(1.950–2.018 in.)
(0.301 in.)
Valve Stem Diameter
Outer Rotor Thickness 7.64 mm
Intake (Standard) 7.906–7.924 mm (Min.)
(0.3112–0.3119 in.)
(0.301 in.)
Exhaust (Standard) 7.935–7.953 mm
Outer Rotor Clearance 0.039 mm
(0.312–0.313 in.) (Max.)
Valve Stem to Guide Clearance (0.015 in.)
Intake 0.025–0.095 mm Outer Rotor Diameter 79.95 mm
(0.001–0.003 in.) (Min.)
Max. Allowable (Rocking 0.247 mm (3.148 in.)
Method) (0.010 in.) Tip Clearance Between 0.20 mm
Rotors (Max.) (0.008 in.)
Exhaust 0.051–0.175 mm
(0.002–0.006 in.) Oil Pressure
Max. Allowable (Rocking 0.414 mm At Curb Idle Speed* 34.47 kPa
Method) (0.016 in.) (Minimum with engine at
operating temerature) (5 psi)
Valves for Service 0.015 mm (0.005 in.)
(Oversize Stem At 3000 rpm 205–551 kPa
0.40 mm (0.015 in.)
Diameters) (30–80 psi)
0.80 mm (0.030 in.)
Oil Filter By-pas Valve 62–103 kPa
Valve Springs Setting (9–15 psi)
Free Length (Approx.) 48.5 mm
Oil Pressure Switch 14–28 kPa
(1.909 in.) Actuating Pressure (2–4 psi)
Wire Diameter 4.75 mm
(0.187 in.) at 3000 rpm.
9 - 182 3.3/3.8L ENGINE NS
TORQUE SPECIAL TOOLS
DESCRIPTION N·m Ft. In. 3.3/3.8L ENGINE

Lbs. Lbs.
Camshaft Thrust 12 — 105
Plate—Bolts
Connecting Rod 54 +1⁄4 40 —
Cap—Bolts turn +1⁄4
turn
Crankshaft Main Bearing 41 +1⁄4 30 —
Cap—Bolts turn +1⁄4 Dolly 6135
turn
Crankshaft Oil Seal 12 — 105
Retainer Rear—Bolts
Crankshaft Damper—Bolt 54 40 —
Cylinder Head—Bolts Refer to Procedure
Cylinder Head Cover— 12 — 105
Bolts
Drive Plate to Crankshaft 95 70 —
Engine Mounting Refer to Procedure
Cradle 6710
Exhaust Manifold—Bolts 23 — 200
Exhaust Crossover 33 25 —
Pipe—Bolts
Intake Manifold Lower— 23 — 200
Bolts
Intake Manifold Gasket 12 — 105
Retainer—Bolts
Intake Manifold Upper— 28 — 250
Bolts
Oil Filter Attaching Nipple 41 30 — Adaptor 6909
Oil Pan—Bolts 12 — 105
Oil Pan Drain—Plug 27 20 —
Oil Pump Cover 12 — 105
Plate—Bolts
Oil Pump Pick-up 28 — 250
Tube—Bolt
Oil Dipstick Housing—Bolt 48 35 —
Rocker Arm Shaft—Bolts 28 — 250
Spark Plug 27 20 — Adaptor 6912
Tappet Retainer 12 — 105
Yoke—Bolts
Timing Chain Case Cover
—M8 Bolt 27 20 —
—M10 Bolt 54 40 —
Water Pump—Bolts 12 — 105
NS 3.3/3.8L ENGINE 9 - 183
Valve Spring Compressor—In Vehicle C-4682
Puller 1023
Valve Spring Compressor C-3422–B

Insert Crankshaft Pulley Remover L-4524-1
Adaptor Valve Compressor 6412

Crankshaft Damper Installer Bolt C-4685-C1
Valve Tappet Remover/Installer C-4129

Indicator, Cylinder Bore C-119
Front Crankshaft Seal Remover 6341A

Tester Valve Spring C-647
9 - 184 3.3/3.8L ENGINE NS
Rear Crankshaft Seal Guide and Installer 6926-1 and

6926-2
Front Crankshaft Seal Installer C-4992
Adaptor 8406
Camshaft Bearing Remover and Installer C-3132–A
Crankshaft Sprocket Installer C-4965
Crankshaft Main Bearing Remover and Installer

C-3059
Adaptor 8116

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NS ENGINE 9-1

2.4L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 128

DESCRIPTION AND OPERATION CYLINDER BORE AND PISTON—SIZING. . . . . . . 20

DISASSEMBLY AND ASSEMBLY OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

DESCRIPTION AND OPERATION

Fig. 1 2.4L Engine

The 2.4 Liter (148 cu. in.) in-line four cylinder

CYLINDER BLOCK AND BEDPLATE Fig. 2 Engine Identification

Fig. 4 Balance Shafts and Carrier Assembly

PISTON AND CONNECTING ROD

CYLINDER HEAD Fig. 6 Camshafts

VALVE AND VALVE SPRING EXHAUST MANIFOLD

DESCRIPTION ENGINE LUBRICATION SYSTEM

Fig. 8 Lubrication Components

DIAGNOSIS AND TESTING Additional tests and diagnostic procedures may be

CONDITION POSSIBLE CAUSE CORRECTION

2. Incorrect fuel mixture. 2. Refer to FUEL SYSTEM.

CONDITION POSSIBLE CAUSE CORRECTION

2. Contamination in Fuel System. 2. Clean fuel system and replace

CONDITION POSSIBLE CAUSES CORRECTION

2. Thin or diluted oil. 2. Change oil to correct viscosity.

CONDITION POSSIBLE CAUSES CORRECTION

2. Low oil pressure. 2. Check engine oil level. Inspect oil

2. Faulty oil pressure sending unit. 2. Install new sending unit.

OIL LEAKS 1. Misaligned or deteriorated 1. Replace gasket(s).

CONDITION POSSIBLE CAUSES CORRECTION

Check the coolant level and fill as required. DO

ENGINE OIL PRESSURE

ENGINE OIL SERVICE

ENGINE OIL SPECIFICATION

API SERVICE GRADE CERTIFIED

FORM-IN-PLACE GASKETS & SEALERS

Fig. 15 Main Bearing Identification Fig. 16 Measuring Main Bearing Clearance

MAIN BEARING CLEARANCE

Fig. 19 Main Bearing Caps/Bedplate Torque

CONNECTING ROD AND BEARING—FITTING

NOTE: Do not rotate the crankshaft while assem-

(5) Remove the bearing cap and compare the width

CYLINDER BORE AND PISTON—SIZING PISTON RING—FITTING

NOTE: Pistons and cylinder bores should be mea-

Fig. 25 Piston Ring Gap

(2) Check piston ring to groove side clearance (Fig.

Fig. 23 Checking Cylinder Bore Size

Fig. 26 Piston Ring Side Clearance

Fig. 24 Piston Measurement

Fig. 28 Installing Side Rail

(1) Install rings with manufacturers I. D. mark

CAUTION: Install piston rings in the following

a. Oil ring expander.

Fig. 30 Checking Wear on Valve Guide—Typical

Fig. 32 Testing Valve Springs

(2) Inspect each valve spring for squareness with a

REFACING VALVES AND VALVE SEATS

Fig. 33 Refacing Intake and Exhaust Valves

ing stones. A true and complete surface must be

REMOVAL AND INSTALLATION

(4) Check the valve spring installed height B after

Fig. 37 Engine Mounting-Front

Fig. 39 Engine Mounting—Right Side