Ezg 9

ENGINE
CONTENTS
page page
4. 0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. 2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5. 9L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
ENGINE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD SERVICE INFORMATION . . . . . . . . . . 1
STANDARD SERVICE INFORMATION
INDEX
page page
GENERAL INFORMATION
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE PERFORMANCE . . . . . . . . . . . . . . . . . . 2
FORM-IN-PLACE GASKETSGASOLINE
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HONING CYLINDER BORES . . . . . . . . . . . . . . . . 2
HYDROSTATIC LOCK . . . . . . . . . . . . . . . . . . . . . 4
MEASURING WITH PLASTIGAGE . . . . . . . . . . . . 3
REPAIR DAMAGED OR WORN THREADS . . . . . . 4
SERVICE ENGINE ASSEMBLY
(SHORT BLOCK) . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
FORM-IN-PLACE GASKETSGASOLINE ENGINES
There are several pl aces where form-i n-pl ace gas-
kets are used on the engi ne. DO NOT use form-in-
place gasket material unless specified. Care
must be taken when appl yi ng form-i n-pl ace gaskets.
Bead si ze, conti nui ty, and l ocati on are of great i mpor-
tance. Too-thi n a bead can resul t i n l eakage, whi l e
too much can resul t i n spi l l -over. A conti nuous bead
of the proper wi dth i s essenti al to obtai n a l eak-free
joi nt.
Two types of form-i n-pl ace gasket materi al s are
used i n the engi ne area (Mopar Si l i cone Rubber
Adhesi ve Seal ant and Mopar Gasket Maker). Each
has di fferent properti es and they cannot be used
i nterchangeabl y.
MOPAR SILICONE RUBBER ADHESIVE
SEALANT
Mopar Si l i cone Rubber Adhesi ve Seal ant, nor-
mal l y bl ack i n col or, i s avai l abl e i n both three ounce
tubes and four and one-hal f ounce power tubes. Moi s-
ture i n the ai r causes the seal ant materi al to cure.
Thi s materi al i s normal l y used on fl exi bl e metal
fl anges. The regul ar tubes have a shel f l i fe of one
year and the power tubes a two year shel f l i fe, and
wi l l not properl y cure i f over-aged. Al ways i nspect
the package for the expi rati on date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker, normal l y red i n col or, i s
avai l abl e i n si x-cc tubes. Thi s anaerobi c type gasket
materi al cures i n the absence of ai r when squeezed
between smooth machi ned metal l i c surfaces. I t wi l l
not cure i f l eft i n the uncovered tube. DO NOT use
on fl exi bl e metal fl anges.
SURFACE PREPARATION
Parts assembl ed wi th form-i n-pl ace gaskets may be
di sassembl ed wi thout unusual effort. I n some
i nstances, i t may be necessary to l i ghtl y tap the part
wi th a mal l et, or other sui tabl e tool , to break the seal
between the mati ng surfaces. A fl at gasket-scraper
may al so be l i ghtl y tapped i nto the joi nt, but care
must be taken not to damage the mati ng surfaces.
Scrape or wi re brush al l gasket surfaces to remove
al l l oose materi al . I nspect stamped parts to ensure
that gasket rai l s are fl at. Fl atten rai l s wi th a ham-
mer on a fl at pl ate, i f requi red. Gasket surfaces must
be free of oi l and di rt. Be sure the ol d gasket mate-
ri al i s removed from bl i nd attachi ng hol es.
ZJ ENGINE 9 - 1
GASKET APPLICATION
Assembl i ng parts usi ng a form-i n-pl ace gasket
requi res care.
Mopar Si l i cone Rubber Adhesi ve Seal ant shoul d
be appl i ed i n a conti nuous bead approxi matel y 3 mm
(0.12 i nch) i n di ameter. Al l mounti ng hol es must be
ci rcl ed. For corner seal i ng, a 3 or 6 mm (1/8 or 1/4
i nch) drop i s pl aced i n the center of the gasket con-
tact area. Uncured seal ant may be removed wi th a
shop towel . Components shoul d be torqued i n pl ace
whi l e the seal ant i s sti l l wet to the touch (wi thi n ten
mi nutes). The use of a l ocati ng dowel i s recom-
mended duri ng assembl y to prevent smeari ng the
materi al off l ocati on.
Mopar Gasket Maker shoul d be appl i ed spari ngl y
to one gasket surface. The seal ant di ameter shoul d
be 1.00 mm (0.04 i nch) or l ess. Be certai n the mate-
ri al surrounds each mounti ng hol e. Excess materi al
can be easi l y wi ped off. Components shoul d be
torqued i n pl ace wi thi n 15 mi nutes. The use of a
l ocati ng dowel i s recommended duri ng assembl y to
prevent smeari ng the materi al off l ocati on.
ENGINE PERFORMANCE
I t i s i mportant that the vehi cl e i s operati ng to i ts
opti mum performance l evel to mai ntai n fuel economy
and the l owest emi ssi on l evel s. I f vehi cl e i s not oper-
ati ng to these standards, refer to Engi ne Di agnosi s
outl i ned i n thi s secti on. The fol l owi ng procedures can
assi st i n achi evi ng the proper engi ne di agnosi s.
(1) Test cranki ng amperage draw. Refer to El ectri -
cal Group 8B, Col d Cranki ng Test.
(2) Check i ntake mani fol d bol t torque; Refer to
Group 11, Exhaust System and I ntake Mani fol d.
(3) Perform cyl i nder compressi on test. Refer to
Cyl i nder Compressi on Pressure Test i n the Engi ne
Di agnosi s area of thi s secti on.
(4) Cl ean or repl ace spark pl ugs as necessary and
adjust gap as speci fi ed i n El ectri cal Group 8D.
Ti ghten to speci fi cati ons.
(5) Test resi stance of spark pl ug cabl es. Refer to
El ectri cal Group 8D, Spark Pl ug Cabl es.
(6) I nspect the pri mary wi res. Test coi l output vol t-
age and pri mary resi stance. Repl ace parts as neces-
sary. Refer to El ectri cal Group 8D, for speci fi cati ons.
(7) Test fuel pump for pressure. Refer to Group 14,
Fuel System Speci fi cati ons.
(8) The ai r fi l ter el ements shoul d be repl aced as
speci fi ed i n Lubri cati on and Mai ntenance, Group 0.
(9) I nspect crankcase venti l ati on system as out
l i ned i n Group 0, Lubri cati on and Mai ntenance. For
emi ssi on control s see Group 25, Emi ssi on Control s
for servi ce procedures.
(10) Road test vehi cl e as a fi nal test.
HONING CYLINDER BORES
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores and over the crankshaft to keep
abrasi ve materi al s from enteri ng the crankshaft
area.
(1) Used careful l y, the Cyl i nder Bore Si zi ng Hone
C-823 equi pped wi th 220 gri t stones, i s the best tool
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round as wel l as removi ng l i ght
scuffi ng, scori ng or scratches. Usual l y a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i m-
i ts.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degl azi ng of the cyl i nder wal l s may be done i f
the cyl i nder bore i s strai ght and round. Use a cyl i n-
der surfaci ng hone, Honi ng Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810). 20-60 strokes,
dependi ng on the bore condi ti on, wi l l be suffi ci ent to
provi de a sati sfactory surface. Usi ng honi ng oi l
C-3501-3880 or a l i ght honi ng oi l avai l abl e from
major oi l di stri butors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a crosshatch pattern.
The hone marks shoul d I NTERSECT at 50 to 60
for proper seati ng of ri ngs (Fi g. 1).
(4) A control l ed hone motor speed between 200 and
300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 50 to 60
angl e. Faster up and down strokes i ncrease the cross-
hatch angl e.
Fig. 1 Cylinder Bore Crosshatch Pattern
9 - 2 ENGINE ZJ
GENERAL INFORMATION (Continued)
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned to remove al l traces of abrasi ve. Use a brush
to wash parts wi th a sol uti on of hot water and deter-
gent. Dry parts thoroughl y. Use a cl ean, whi te, l i nt-
free cl oth to check that the bore i s cl ean. Oi l the
bores after cl eani ng to prevent rusti ng.
MEASURING WITH PLASTIGAGE
CRANKSHAFT MAIN BEARING CLEARANCE
Engi ne crankshaft beari ng cl earances can be deter-
mi ned by use of Pl asti gage, or equi val ent. The fol l ow-
i ng i s the recommended procedures for the use of
Pl asti gage:
(1) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
(2) The total cl earance of the mai n beari ngs can
onl y be determi ned by removi ng the wei ght of the
crankshaft. Thi s can be accompl i shed by ei ther of two
methods:
METHOD - 1 (PREFERRED)
Shi m the beari ngs adjacent to the beari ng to be
checked. Thi s wi l l remove the cl earance between
upper beari ng shel l and the crankshaft. Pl ace a mi n-
i mum of 0.254 mm (0.010 i nch) shi m between the
beari ng shel l and the adjacent beari ng cap. Ti ghten
the bol ts to 18 Nm (13 ft. l bs.) torque.
ALL ENGINESWhen checki ng No.1 mai n
beari ng; shi m No.2 mai n beari ng.
beari ng; shi m No.1 and No.3 mai n beari ng.
5.2/5.9L ENGINEWhen checki ng No.5 mai n
beari ng; shi m No.4 mai n beari ng.
4.0L ENGINEWhen checki ng No.5 mai n bear-
i ng; shi m No.4 and No.6 mai n beari ng.
i ng; shi m No.5 and No.7 mai n beari ng.
i ng; shi m No.6 mai n beari ng.
NOTE: Remove all shims before assembling
engine.
METHOD - 2 (ALTERNATIVE)
The wei ght of the crankshaft i s supported by a jack
under the counterwei ght adjacent to the beari ng
bei ng checked.
(1) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng cap shel l (Fi g. 2). Posi ti on the
Pl asti gage approxi matel y 6.35 mm (1/4 i nch) off cen-
ter and away from the oi l hol es. I n addi ti on, suspect
areas can be checked by pl aci ng the Pl asti gage i n
that area. Ti ghten the beari ng cap bol ts of the bear-
i ng bei ng checked to 108 Nm (80 ft. l bs.) torque
(4.0L Engi ne). Ti ghten the beari ng cap bol ts of the
beari ng bei ng checked to 115 Nm (85 ft. l bs.) torque
(5.2/5.9L Engi ne). DO NOT rotate the crankshaft
or the Plastigage may be smeared, giving inac-
curate results.
(2) Remove the beari ng cap and compare the wi dth
of the fl attened Pl asti gage wi th the scal e provi ded on
the package (Fi g. 3). Pl asti gage general l y comes i n 2
scal es (one scal e i s i n i nches and the other i s a met-
ri c scal e). Locate the band cl osest to the same wi dth.
Thi s band shows the amount of cl earance. Di ffer-
ences i n readi ngs between the ends i ndi cate the
amount of taper present. Record al l readi ngs taken
(refer to Engi ne Speci fi cati ons).
(3) Pl asti gage i s avai l abl e i n a vari ety of cl earance
ranges. The 0.025-0.076 mm (0.001-0.003 i nch) range
i s usual l y the most appropri ate for checki ng engi ne
beari ng cl earances.
CONNECTING ROD BEARING CLEARANCE
Engi ne connecti ng rod beari ng cl earances can be
determi ned by use of Pl asti gage, or equi val ent. The
fol l owi ng i s the recommended procedures for the use
of Pl asti gage:
(1) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
Fig. 2 Placement of Plastigage in Bearing Shell
Fig. 3 Clearance Measurement
ZJ ENGINE 9 - 3
(2) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng cap shel l (Fi g. 2). Posi ti on the
Pl asti gage approxi matel y 6.35 mm (1/4 i nch) off cen-
ter and away from the oi l hol es. I n addi ti on, suspect
areas can be checked by pl aci ng the Pl asti gage i n the
suspect area.
(3) The crankshaft must be turned unti l the con-
necti ng rod to be checked starts movi ng toward the
top of the engi ne. Onl y then shoul d the rod cap wi th
Pl asti gage i n pl ace be assembl ed. Ti ghten the 4.0L
rod cap nut to 45 Nm (33 ft. l bs.) torque. Ti ghten the
5.2/5.9L rod cap nut to 61 Nm (45 ft. l bs.) torque.
DO NOT rotate the crankshaft or the Plastigage
may be smeared, giving inaccurate results.
(4) Remove the beari ng cap and compare the wi dth
of the fl attened Pl asti gage wi th the scal e provi ded on
the package (Fi g. 3). Pl asti gage general l y comes i n 2
scal es (one scal e i s i n i nches and the other i s a met-
ri c scal e). Locate the band cl osest to the same wi dth.
Thi s band shows the amount of cl earance. Di ffer-
ences i n readi ngs between the ends i ndi cate the
amount of taper present. Record al l readi ngs taken
(refer to Engi ne Speci fi cati ons).
(5) Pl asti gage i s avai l abl e i n a vari ety of cl earance
ranges. The 0.025-0.076 mm (0.001-0.003 i nch) range
i s usual l y the most appropri ate for checki ng engi ne
beari ng cl earances.
REPAIR DAMAGED OR WORN THREADS
Damaged or worn threads can be repai red. Essen-
ti al l y, thi s repai r consi sts of:
Dri l l i ng out worn or damaged threads.
Tappi ng the hol e wi th a speci al Hel i -Coi l Tap, or
equi val ent.
I nstal l i ng an i nsert i nto the tapped hol e to bri ng
the hol e back to i ts ori gi nal thread si ze.
CAUTION: Be sure that the tapped holes maintain
the original center line.
Hel i -Coi l tool s and i nserts are readi l y avai l abl e
from automoti ve parts jobbers.
SERVICE ENGINE ASSEMBLY (SHORT BLOCK)
A servi ce repl acement engi ne assembl y (short
bl ock) may be i nstal l ed whenever the ori gi nal cyl i n-
der bl ock i s defecti ve or damaged beyond repai r. I t
consi sts of the cyl i nder bl ock, crankshaft, pi ston and
rod assembl i es. I f needed, the camshaft must be pro-
cured separatel y and i nstal l ed before the engi ne i s
i nstal l ed i n the vehi cl e.
A short bl ock i s i denti fi ed wi th the l etter S
stamped on the same machi ned surface where the
bui l d date code i s stamped for compl ete engi ne
assembl i es.
I nstal l ati on i ncl udes the transfer of components
from the defecti ve or damaged ori gi nal engi ne. Fol -
l ow the appropri ate procedures for cl eani ng, i nspec-
ti on and torque ti ghteni ng.
HYDROSTATIC LOCK
When an engi ne i s suspected of hydrostati c l ock
(regardl ess of what caused the probl em), fol l ow the
steps bel ow.
(1) Perform the Fuel Pressure Rel ease Procedure
(refer to Group 14, Fuel System).
(2) Di sconnect the battery negati ve cabl e.
(3) I nspect ai r cl eaner, i nducti on system and
i ntake mani fol d to ensure system i s dry and cl ear of
forei gn materi al .
(4) Pl ace a shop towel around the spark pl ugs to
catch any fl ui d that may possi bl y be under pressure
i n the cyl i nder head. Remove the pl ugs from the
engi ne.
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) Wi th al l spark pl ugs removed, rotate the crank-
shaft usi ng a breaker bar and socket.
(6) I denti fy the fl ui d i n the cyl i nders (i .e. cool ant,
fuel , oi l , etc.).
(7) Make sure al l fl ui d has been removed from the
cyl i nders.
(8) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
(9) Squi rt engi ne oi l i nto the cyl i nders to l ubri cate
the wal l s. Thi s wi l l prevent damage on restart.
(10) I nstal l new spark pl ugs. Ti ghten the 4.0L
engi ne spark pl ugs to 37 Nm (27 ft. l bs.) torque.
Ti ghten the 5.2/5.9L engi ne spark pl ugs to 41 Nm
(30 ft. l bs.) torque.
(11) Drai n engi ne oi l . Remove and di scard the oi l
fi l ter.
(12) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
Nm (25 ft. l bs.) torque.
(13) I nstal l a new oi l fi l ter.
(14) Fi l l engi ne crankcase wi th the speci fi ed
amount and grade of oi l .
(15) Connect the battery negati ve cabl e.
(16) Start the engi ne and check for any l eaks.
9 - 4 ENGINE ZJ
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
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 engi ne oi l that i s API Servi ce Grade Certi -
fi ed or an oi l that conforms to the API Servi ce Grade
SH or SH/CD. MOPAR provi des engi ne oi l s that con-
form to al l of these servi ce grades.
SAE VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . SAE 30 speci fi es a si ngl e vi scos-
i ty engi ne oi l . Engi ne oi l s al so have mul ti pl e
vi scosi ti es. These are speci fi ed wi th a dual SAE vi s-
cosi ty grade whi ch i ndi cates the col d-to-hot tempera-
ture vi scosi ty range. Sel ect an engi ne oi l that i s best
sui ted to your parti cul ar temperature range and vari -
ati on (Fi g. 4).
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. They are desi gnated as ei ther
ENERGY CONSERVI NG or ENERGY CONSERV-
I NG I I .
CONTAINER IDENTIFICATION
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the l abel
of engi ne oi l pl asti c bottl es and the top of engi ne oi l
cans (Fi g. 5).
OIL LEVEL INDICATOR (DIPSTICK)
The engi ne oi l l evel i ndi cator i s l ocated at the ri ght
rear of engi ne on 4.0L engi nes (Fi g. 6) and the ri ght
front of the engi ne on 5.2/5.9L engi nes (Fi g. 7).
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine
oil, oil foaming and oil pressure loss can result.
I nspect engi ne oi l l evel approxi matel y every 800
ki l ometers (500 mi l es). Unl ess the engi ne has exhi b-
i ted l oss of oi l pressure, run the engi ne for about fi ve
mi nutes before checki ng oi l l evel . Checki ng engi ne oi l
l evel on a col d engi ne i s not accurate.
To ensure proper l ubri cati on of an engi ne, the
engi ne oi l must be mai ntai ned at an acceptabl e l evel .
The acceptabl e l evel s are i ndi cated between the ADD
and SAFE marks on the engi ne oi l di psti ck (Fi g. 8).
(1) Posi ti on vehi cl e on l evel surface.
Fig. 4 Temperature/Engine Oil Viscosity
Fig. 5 Engine Oil Container Standard Notations
Fig. 6 Engine Oil Dipstick 4.0L Engine
ZJ ENGINE 9 - 5
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
utes for oi l to settl e to bottom of crankcase, remove
engi ne oi l di psti ck.
(3) Wi pe di psti ck cl ean.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
(5) Remove di psti ck, wi th handl e hel d above the
ti p, take oi l l evel readi ng (Fi g. 8).
(6) Add oi l onl y i f l evel i s bel ow the ADD mark on
di psti ck.
ENGINE OIL CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n Mai ntenance Schedul es.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(2) Hoi st and support vehi cl e on safety stands.
(3) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l descri bed i n thi s sec-
ti on.
(8) I nstal l oi l fi l l cap.
(9) Start engi ne and i nspect for l eaks.
(10) Stop engi ne and i nspect oi l l evel .
ENGINE OIL FILTER CHANGE
FILTER SPECIFICATION
Al l engi nes are equi pped wi th a hi gh qual i ty ful l -
fl ow, di sposabl e type oi l fi l ter. Chrysl er Corporati on
recommends a Mopar or equi val ent oi l fi l ter be used.
OIL FILTER REMOVAL
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se (Fi g. 9) to
remove i t from the cyl i nder bl ock oi l fi l ter boss.
(4) When fi l ter separates from adapter ni ppl e, ti p
gasket end upward to mi ni mi ze oi l spi l l . Remove fi l -
ter from vehi cl e.
(5) Wi th a wi pi ng cl oth, cl ean the gasket seal i ng
surface (Fi g. 10) of oi l and gri me.
OIL FILTER INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l or chassi s grease.
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, (Fi g. 10) hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect for oi l l eaks.
Fig. 7 Engine Oil Dipstick 5.2/5.9L Engine
Fig. 8 Engine Oil Dipstick4.0L Engine
Fig. 9 Oil Filter4.0L Engine
9 - 6 ENGINE ZJ
USED ENGINE OIL DISPOSAL
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne. Refer to the WARNI NG at begi nni ng of thi s
secti on.
Fig. 10 Oil Filter Sealing SurfaceTypical
ZJ ENGINE 9 - 7
ENGINE DIAGNOSIS
INDEX
page page
DIAGNOSIS AND TESTING
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 9
CYLINDER COMPRESSION PRESSURE TEST . . 8
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . . 9
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . 11
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 8
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 10
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 8
SERVICE DIAGNOSISMECHANICAL . . . . . . . . 14
SERVICE DIAGNOSISPERFORMANCE . . . . . . 12
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne mai ntenance.
These mal functi ons may be cl assi fi ed as ei ther per-
formance (e.g., engi ne i dl es rough and stal l s) or
mechani cal (e.g., a strange noi se).
Refer to the Servi ce Di agnosi sPerformance chart
and the Servi ce Di agnosi sMechani cal chart for pos-
si bl e causes and correcti ons of mal functi ons. Refer to
Group 14, Fuel System for the fuel system di agnosi s.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng di agnosi s:
Cyl i nder Compressi on Pressure Test.
Cyl i nder Combusti on Pressure Leakage Test.
Engi ne Cyl i nder Head Gasket Fai l ure Di agnosi s.
I ntake Mani fol d Leakage Di agnosi s.
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engi ne.
(2) Spray a smal l stream of water at the suspected
l eak area.
(3) I f a change i n RPM i s observed the area of the
suspected l eak has been found.
(4) Repai r as requi red.
CYLINDER COMPRESSION PRESSURE TEST
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Cl ean the spark pl ug recesses wi th compressed
ai r.
(2) Remove the spark pl ugs.
(3) Secure the throttl e i n the wi de-open posi ti on.
(4) Di sabl e the fuel system. (Refer to Group 14,
Fuel System for the correct procedure)
(5) Di sconnect the i gni ti on coi l .
(6) I nsert a compressi on pressure gauge and rotate
the engi ne wi th the engi ne starter motor for three
revol uti ons.
(7) Record the compressi on pressure on the 3rd
revol uti on. Conti nue the test for the remai ni ng cyl i n-
ders.
Refer to Engi ne Speci fi cati ons for the correct
engi ne compressi on pressures.
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS
A l eaki ng engi ne cyl i nder head gasket usual l y
resul ts i n l oss of power, l oss of cool ant and engi ne
mi sfi ri ng.
An engi ne cyl i nder head gasket l eak can be l ocated
between adjacent cyl i nders or between a cyl i nder and
the adjacent water jacket.
An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders i s i ndi cated by a l oss of power
and/or engi ne mi sfi re.
An engi ne cyl i nder head gasket l eaki ng between
a cyl i nder and an adjacent water jacket i s i ndi cated
by cool ant foami ng or overheati ng and l oss of cool ant.
9 - 8 ENGINE ZJ
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders; fol l ow the proce-
dures outl i ned i n Cyl i nder Compressi on Pressure
Test. An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders wi l l resul t i n approxi matel y a
50-70% reducti on i n compressi on pressure.
CYLINDER-TO-WATER J ACKET LEAKAGE
TEST
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
Remove the radi ator cap.
Start the engi ne and al l ow i t to warm up unti l the
engi ne thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
I f bubbl es are not vi si bl e, i nstal l a radi ator pres-
sure tester and pressuri ze the cool ant system.
I f a cyl i nder i s l eaki ng combusti on pressure i nto
the water jacket, the tester poi nter wi l l pul sate wi th
every combusti on stroke of the cyl i nder.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
Exhaust and i ntake val ve l eaks (i mproper seat-
i ng).
Leaks between adjacent cyl i nders or i nto water
jacket.
Any causes for combusti on/compressi on pressure
l oss.
(1) Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
(2) Start and operate the engi ne unti l i t attai ns
normal operati ng temperature, then turn the engi ne
OFF.
(4) Remove the oi l fi l l er cap.
(5) Remove the ai r cl eaner.
(6) Cal i brate the tester accordi ng to the manufac-
turers i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1,379
kPa (200 psi ) maxi mum and 552 kPa (80 psi ) recom-
mended.
(7) Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturers i nstructi ons.
Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
Refer to the Cyl i nder Combusti on Pressure Leak-
age Test Di agnosi s chart.
ENGINE OIL LEAK INSPECTION
Begi n wi th a thorough vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24km (15 mi l es), and
repeat i nspecti on.
(5) If the oil leak source is not positively
identified at this time, proceed wi th the ai r l eak
detecti on test method.
Air Leak Detec tion Test Method
(1) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(2) Remove the PCV val ve from the cyl i nder head
cover. Cap or pl ug the PCV val ve grommet.
(3) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce manual
procedures.
(5) I f the l eakage occurs at the rear oi l seal area,
refer to the secti on, I nspecti on for Rear Seal Area
Leak.
(6) I f no l eaks are detected, turn off the ai r suppl y
and remove the ai r hose and al l pl ugs and caps.
I nstal l the PCV val ve and breather cap hose.
ZJ ENGINE 9 - 9
DIAGNOSIS AND TESTING (Continued)
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
INSPECTION FOR REAR SEAL AREA LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(1) Di sconnect the battery.
(2) Rai se the vehi cl e.
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak:
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, di stri butor seal ,
camshaft bore cup pl ugs oi l gal l ey pi pe pl ugs, oi l
fi l ter runoff, and mai n beari ng cap to cyl i nder
bl ock mati ng surfaces.
(4) I f no l eaks are detected, pressuri ze the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed.
HYDRAULIC TAPPETS
Before di sassembl i ng any part of the engi ne to cor-
rect tappet noi se, check the oi l pressure. I f vehi cl e
has no oi l pressure gauge, i nstal l a rel i abl e gauge at
the pressure sendi ng-uni t. The pressure shoul d be
between 207-552 kPa (30-80 psi ) at 3,000 RPM.
Check the oi l l evel after the engi ne reaches normal
operati ng temperature. Al l ow 5 mi nutes to stabi l i ze
oi l l evel , check di psti ck. The oi l l evel i n the pan
shoul d never be above the FULL mark or bel ow the
ADD OI L mark on di psti ck. Ei ther of these two con-
di ti ons coul d be responsi bl e for noi sy tappets.
OIL LEVEL
HIGH
I f oi l l evel i s above the FULL mark, i t i s possi bl e
for the connecti ng rods to di p i nto the oi l . Wi th the
engi ne runni ng, thi s condi ti on coul d create foam i n
the oi l pan. Foam i n oi l pan woul d be fed to the
hydraul i c tappets by the oi l pump causi ng them to
l ose l ength and al l ow val ves to seat noi si l y.
LOW
Low oi l l evel may al l ow oi l pump to take i n ai r.
When ai r i s fed to the tappets, they l ose l ength,
whi ch al l ows val ves to seat noi si l y. Any l eaks on
i ntake si de of oi l pump through whi ch ai r can be
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODY
Intake valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
TAILPIPE
Exhaust valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
RADIATOR
Head gasket leaking or cracked
cylinder head or block
Remove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERS
Head gasket leaking or crack in
cylinder head or block between
adjacent cylinders
Remove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLY
Stuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wall
Inspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
9 - 10 ENGINE ZJ
drawn wi l l create the same tappet acti on. Check the
l ubri cati on system from the i ntake strai ner to the
pump cover, i ncl udi ng the rel i ef val ve retai ner cap.
When tappet noi se i s due to aerati on, i t may be
i ntermi ttent or constant, and usual l y more than one
tappet wi l l be noi sy. When oi l l evel and l eaks have
been corrected, operate the engi ne at fast i dl e. Run
engi ne for a suffi ci ent ti me to al l ow al l of the ai r
i nsi de the tappets to be bl ed out.
TAPPET NOISE DIAGNOSIS
(1) To determi ne source of tappet noi se, operate
engi ne at i dl e wi th cyl i nder head covers removed.
(2) Feel each val ve spri ng or rocker arm to detect
noi sy tappet. The noi sy tappet wi l l cause the affected
spri ng and/or rocker arm to vi brate or feel rough i n
operati on.
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.
(3) Val ve tappet noi se ranges from l i ght noi se to a
heavy cl i ck. A l i ght noi se i s usual l y caused by exces-
si ve l eak-down around the uni t pl unger, or by the
pl unger parti al l y sti cki ng i n the tappet body cyl i nder.
The tappet shoul d be repl aced. A heavy cl i ck i s
caused by a tappet check val ve not seati ng, or by for-
ei gn parti cl es wedged between the pl unger and the
tappet body. Thi s wi l l cause the pl unger to sti ck i n
the down posi ti on. Thi s heavy cl i ck wi l l be accompa-
ni ed by excessi ve cl earance between the val ve stem
and rocker arm as val ve cl oses. I n ei ther case, tappet
assembl y shoul d be removed for i nspecti on and cl ean-
i ng.
(4) The val ve trai n generates a noi se very much
l i ke a l i ght tappet noi se duri ng normal operati on.
Care must be taken to ensure that tappets are mak-
i ng the noi se. I f more than one tappet seems to be
noi sy, i ts probabl y not the tappets.
ENGINE OIL PRESSURE
(1) Di sconnect connector and remove oi l pressure
sendi ng uni t.
(2) I nstal l Oi l Pressure Li ne and Gauge Tool
C-3292 or equi val ent. Start engi ne and record pres-
sure. Refer to Oi l Pressure i n Engi ne Speci fi cati ons
for the correct pressures.
ZJ ENGINE 9 - 11
SERVICE DIAGNOSISPERFORMANCE
ENGINE PERFORMANCE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. Refer to
Group 8A, Battery, for correct
procedures. Check charging system.
Refer to Group 8C, Charging
Systems, for correct procedures.
2. Corroded or loose battery
connections
2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. Refer to
Group 8B, Starting Systems, for
correct diagnostics/procedures
4. Siezed accessory drive
component
4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace siezed
component.
5. Engine internal mechanical
failure or hydro-static lock
5. Refer to Group 9, Engine, for
correct diagnostics/procedures
ENGINE CRANKS BUT WILL NOT
START
1. No spark 1. Check for spark. Refer to Group
8D, Ignition System, for correct
procedures.
2. No fuel 2. Perform fuel pressure test, and if
necessary, inspect fuel injector(s)
and driver circuits. Refer to Group
14, Fuel System, for correct
procedures.
3. Low or no engine compression 3. Perform cylinder compression
pressure test. Refer to Group 9,
Engine, for correct procedures.
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to group 8D, Ignition System
3. Worn or incorrect gapped spark
plugs
3. Clean plugs and set gap. (Refer
to group 8D, Ignition System)
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression
9. Burned, warped, or pitted valves 9. Install/Reface valves as
necessary
10. Plugged or restricted exhaust
system
10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted
cables
12. Faulty ignition coil 12. Test and replace, as necessary
(Refer to Group 8D, ignition system)
9 - 12 ENGINE ZJ
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to Group 14 for
correct procedures)
2. Engine idle speed too low 2. Check Idle Air Control circuit.
(Refer to Group 14, Fuel System)
3. Worn or incorrectly gapped spark
plugs
3. Replace or clean and re-gap
spark plugs (Refer to group 8D,
Ignition System)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or
crossed
5. Check for correct firing order or
replace spark plug cables. (Refer to
Group 8D, Ignition System for
correct procedures.)
6. Faulty coil 6. Test and replace, if necessary
(Refer to group 8D, Ignition System)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket
and vacuum hoses. Replace if
necessary (Refer to Group 11,
Exhaust System & Intake Manifold)
8. EGR valve leaking or stuck open 8. Test and replace, if necessary
(Refer to group 25, Emission
Control Systems)
ENGINE MISSES ON
ACCELERATION
1. Worn or incorrectly gapped spark
plugs
1. Replace spark plugs or clean and
set gap. (Refer to group 8D, Ignition
System)
2. Spark plug cables defective or
crossed
2. Check Idle Air Control circuit.
(Refer to Group 14, Fuel System)
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary
(refer to group 8D, Ignition System)
ZJ ENGINE 9 - 13
SERVICE DIAGNOSISMECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil (Refer to Engine Oil
Service in this group)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic
tappets/lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats
or valve faces
9. Grind valves and seats
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
group 0, Lubrication and
Maintenance)
test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
4. Excessive connecting rod
bearing clearance
Measure bearings for correct
clearance with plasti-gage. Repair
as necessary
5. Connecting rod journal out of
round
5. Replace crankshaft or grind
journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
group 0, Lubrication and
Maintenance)
test/specifications
4. Excessive main bearing
clearance
4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
9 - 14 ENGINE ZJ
MAIN BEARING NOISE (CONTD) 6. Crankshaft main journal out of
round or worn
6. Grind journals or replace
crankshaft
7. Loose flywheel or torque
converter
7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if
necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace worn gears or oil pump
assy
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pump suction tube loose,
broken, bent or clogged
8. Inspect suction tube and clean or
replace if necessary
9. Oil pump cover warped or
cracked
9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated
gaskets
1. Replace gasket
2. Loose fastener, broken or porous
metal part
2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking
3. Replace seal
4. Leaking oil gallery plug or cup
plug
4. Remove and reseal threaded
plug. Replace cup style plug
EXCESSIVE OIL CONSUMPTION
OR SPARK PLUGS OIL FOULED
1. PCV System malfunction 1. Refer to group 25, Emission
Control System for correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves
7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
ZJ ENGINE 9 - 15
4.0L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE DESCRIPTION . . . . . . . . . . . . . . . . . . . 16
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 17
OIL PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . 19
OVERSIZE AND UNDERSIZE COMPONENT
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SERVICE PROCEDURES
FITTING CONNECTING ROD BEARINGS . . . . . . 22
FITTING CRANKSHAFT MAIN BEARINGS . . . . . 24
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . . . 19
PISTON RING FITTING . . . . . . . . . . . . . . . . . . . 20
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL AND INSTALLATION
CAMSHAFT PIN REPLACEMENT . . . . . . . . . . . . 40
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . 42
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 31
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 33
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 29
ENGINE MOUNTSFRONT . . . . . . . . . . . . . . . . 28
ENGINE MOUNTREAR . . . . . . . . . . . . . . . . . . 28
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
PISTONS AND CONNECTING RODS . . . . . . . . . 44
REAR MAIN OIL SEALS . . . . . . . . . . . . . . . . . . . 45
ROCKER ARMS AND PUSH RODS . . . . . . . . . . 32
TIMING CASE COVER OIL SEAL . . . . . . . . . . . . 47
TIMING CASE COVER . . . . . . . . . . . . . . . . . . . . 37
TIMING CHAIN AND SPROCKETS . . . . . . . . . . . 37
VALVE STEM SEAL AND SPRING . . . . . . . . . . . 33
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 35
VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . 36
DISASSEMBLY AND ASSEMBLY
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 49
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 47
CLEANING AND INSPECTION
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 51
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 50
SPECIFICATIONS
4.0L ENGINE SPECIFICATIONS . . . . . . . . . . . . . 52
SPECIAL TOOLS
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ENGINE DESCRIPTION
The 4.0 Li ter (242 CI D) si x-cyl i nder engi ne i s an
I n-l i ne, l i ghtwei ght, overhead val ve engi ne. Thi s
engi ne i s desi gned for unl eaded fuel .
The engi ne cyl i nder head has dual quench-type
combusti on chambers that create turbul ence and fast
burni ng of the ai r/fuel mi xture. Thi s resul ts i n good
fuel economy.
The cyl i nders are numbered 1 through 6 from front
to rear. The fi ri ng order i s 1-5-3-6-2-4 (Fi g. 1).
The crankshaft rotati on i s cl ockwi se, when vi ewed
from the front of the engi ne. The crankshaft rotates
wi thi n seven mai n beari ngs. The camshaft rotates
wi thi n four beari ngs.
BUILD DATE CODE
The engi ne Bui l d Date Code i s l ocated on a
machi ned surface on the ri ght si de of the cyl i nder
bl ock between the No.2 and No.3 cyl i nders (Fi g. 2).
The di gi ts of the code i denti fy:
1st Di gi tThe year (8 = 1998).
2nd & 3rd Di gi tsThe month (01 - 12).
4th & 5th Di gi tsThe engi ne type/fuel system/
compressi on rati o (MX = A 4.0 Li ter (242 CI D) 8.7:1
compressi on rati o engi ne wi th a mul ti -poi nt fuel
i njecti on system).
6th & 7th Di gi tsThe day of engi ne bui l d (01 -
31).
Fig. 1 Engine Firing Order
9 - 16 4. 0L ENGINE ZJ
(1) FOR EXAMPLE: Code * 801MX12 * i denti fi es
a 4.0 Li ter (242 CI D) engi ne wi th a mul ti -poi nt fuel
i njecti on system, 8.7:1 compressi on rati o and bui l t on
January 12, 1998.
LUBRICATION SYSTEM
A geartype posi ti ve di spl acement pump i s
mounted at the undersi de of the bl ock opposi te the
No. 4 mai n beari ng. The pump draws oi l through the
screen and i nl et tube from the sump at the rear of
the oi l pan. The oi l i s dri ven between the dri ve and
i dl er gears and pump body, then forced through the
outl et to the bl ock. An oi l gal l ery i n the bl ock chan-
nel s the oi l to the i nl et si de of the ful l fl ow oi l fi l ter.
After passi ng through the fi l ter el ement, the oi l
passes from the center outl et of the fi l ter through an
oi l gal l ery that channel s the oi l up to the mai n gal -
l ery whi ch extends the enti re l ength of the bl ock.
Gal l eri es extend downward from the mai n oi l gal -
l ery to the upper shel l of each mai n beari ng. The
crankshaft i s dri l l ed i nternal l y to pass oi l from the
mai n beari ng journal s (except number 4 mai n bear-
i ng journal ) to the connecti ng rod journal s. Each con-
necti ng rod beari ng cap has a smal l squi rt hol e, oi l
passes through the squi rt hol e and i s thrown off as
the rod rotates. Thi s oi l throwoff l ubri cates the cam-
shaft l obes, di stri butor dri ve gear, cyl i nder wal l s, and
pi ston pi ns.
The hydraul i c val ve tappets recei ve oi l di rectl y
from the mai n oi l gal l ery. Oi l i s provi ded to the cam-
shaft beari ng through gal l eri es. The front camshaft
beari ng journal passes oi l through the camshaft
sprocket to the ti mi ng chai n. Oi l drai ns back to the
oi l pan under the number one mai n beari ng cap.
The oi l suppl y for the rocker arms and bri dged
pi vot assembl i es i s provi ded by the hydraul i c val ve
tappets whi ch pass oi l through hol l ow push rods to a
hol e i n the correspondi ng rocker arm. Oi l from the
rocker arm l ubri cates the val ve trai n components,
then passes down through the push rod gui de hol es
i n the cyl i nder head past the val ve tappet area, and
returns to the oi l pan.
Fig. 2 Build Date Code Location
ZJ 4. 0L ENGINE 9 - 17
DESCRIPTION AND OPERATION (Continued)
Oil Lubrication System4.0L Engine
OIL PUMP PRESSURE
The MI NI MUM oi l pump pressure i s 89.6 kPa (13
psi ) at 600 rpm. The NORMAL oi l pump pressure i s
517 kPa (75 psi ) at 1600 rpm or more.
OVERSIZE AND UNDERSIZE COMPONENT CODES
Some engi nes may be bui l t wi th oversi ze or under-
si ze components such as:
Oversi ze cyl i nder bores.
Oversi ze camshaft beari ng bores.
Undersi ze crankshaft mai n beari ng journal s.
Undersi ze connecti ng rod journal s.
These engi nes are i denti fi ed by a l etter code (Fi g.
3) stamped on a boss between the i gni ti on coi l and
the di stri butor (Fi g. 4).
SERVICE PROCEDURES
VALVE TIMING
Di sconnect the spark pl ug wi res and remove the
spark pl ugs.
Remove the engi ne cyl i nder head cover.
Remove the capscrews, bri dge and pi vot assembl y,
and rocker arms from above the No.1 cyl i nder.
Al ternatel y l oosen each capscrew, one turn at a
ti me, to avoi d damagi ng the bri dge.
Rotate the crankshaft unti l the No.6 pi ston i s at
top dead center (TDC) on the compressi on stroke.
Rotate the crankshaft countercl ockwi se (vi ewed
from the front of the engi ne) 90.
I nstal l a di al i ndi cator on the end of the No.1 cyl -
i nder i ntake val ve push rod. Use rubber tubi ng to
secure the i ndi cator stem on the push rod.
Set the di al i ndi cator poi nter at zero.
Rotate the crankshaft cl ockwi se (vi ewed from the
front of the engi ne) unti l the di al i ndi cator poi nter
i ndi cates 0.305 mm (0.012 i nch) travel di stance (l i ft).
The ti mi ng notch i ndex on the vi brati on damper
shoul d be al i gned wi th the TDC mark on the ti mi ng
degree scal e.
I f the ti mi ng notch i s more than 13 mm (1/2 i nch)
away from the TDC mark i n ei ther di recti on, the
val ve ti mi ng i s i ncorrect.
I f the val ve ti mi ng i s i ncorrect, the cause may be a
broken camshaft pi n. I t i s not necessary to repl ace
the camshaft because of pi n fai l ure. A spri ng pi n i s
avai l abl e for servi ce repl acement.
PISTON FITTING
BORE GAGE METHOD
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm (
.0001 i n.) I NCREMENTS i s requi red. I f a bore gauge
i s not avai l abl e, do not use an i nsi de mi crometer.
(2) Measure the i nsi de di ameter of the cyl i nder
bore at a poi nt 49.5 mm (1-15/16 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
Fig. 3 Oversize and Undersize Component Codes
Fig. 4 Oversize and Undersize Component Code
Location
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 6).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed. The
coated piston connecting rod assembly can be
used to service previous built engines and
MUST be replaced as complete sets. Ti n coated
pi stons shoul d not be used as repl acements for coated
pi stons.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 5). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
PISTON SIZE CHART
CYLINDER PISTON
BORE LETTER
SIZE SIZE
98.438 to 98.448 mm (3.8755 to 3.8759 i n.) . . . . . . .A
98.448 to 98.458 mm (3.8759 to 3.8763 i n.) . . . . . . .B
98.458 to 98.468 mm (3.8763 to 3.8767 i n.) . . . . . . .C
98.468 to 98.478 mm (3.8767 to 3.8771 i n.) . . . . . . .D
98.478 to 98.488 mm (3.8771 to 3.8775 i n.) . . . . . . .E
98.488 to 98.498 mm (3.8775 to 3.8779 i n.) . . . . . . .F
PISTON RING FITTING
(1) Careful l y cl ean the carbon from al l ri ng
grooves. Oi l drai n openi ngs i n the oi l ri ng groove and
pi n boss must be cl ear. DO NOT remove metal from
the grooves or l ands. Thi s wi l l change ri ng-to-groove
cl earances and wi l l damage the ri ng-to-l and seati ng.
(2) Be sure the pi ston ri ng grooves are free of
ni cks and burrs.
(3) Measure the ri ng si de cl earance wi th a feel er
gauge fi tted snugl y between the ri ng l and and ri ng
(Fi g. 7) (Fi g. 8). Rotate the ri ng i n the groove. I t must
move freel y around ci rcumference of the groove.
Fig. 5 Moly Coated Piston
Fig. 6 Bore Gauge
Fig. 7 Piston Dimensions
SERVICE PROCEDURES (Continued)
Ring Side Clearance Measurement
Top Compressi on Ri ng. . . . . . . . . .0.042 to 0.084 mm
(0.0017 to 0.0033 i n.)
Second Compressi on Ri ng . . . . . . .0.042 to 0.084 mm
(0.0017 to 0.0033 i n.)
Oi l Control Ri ng . . . . . . . . . . . . . . . .0.06 to 0.21 mm
(0.0024 to 0.0083 i n.)
(4) Pl ace ri ng i n the cyl i nder bore and push down
wi th i nverted pi ston to posi ti on near l ower end of the
ri ng travel . Measure ri ng gap wi th a feel er gauge fi t-
ti ng snugl y between ri ng ends (Fi g. 9).
Ring Gap Measurement
Top Compressi on Ri ng . . . . . . . . . 0.229 to 0.610 mm
(0.0090 to 0.0240 i nch)
Second Compressi on Ri ng . . . . . . .0.483 to 0.965 mm
(0.0190 to 0.080 i nch)
Oi l Control Ri ng . . . . . . . . . . . . . .0.254 to 1.500 mm
(0.010 to 0.060 i nch)
(5) The oi l control ri ngs are symmetri cal , and can
be i nstal l ed wi th ei ther si de up. I t i s not necessary to
use a tool to i nstal l the upper and l ower rai l s. I nsert
oi l rai l spacer fi rst, then si de rai l s.
(6) The two compressi on ri ngs are di fferent and can-
not be i nterchanged. The top compressi on ri ng can be
i denti fi ed by the shi ny coati ng on the outer seal i ng sur-
face and can be i nstal l ed wi th ei ther si de up. (Fi g. 10).
(7) The second compressi on ri ng has a sl i ght
chamfer on the bottom of the i nsi de edge and a dot
on the top for correct i nstal l ati on (Fi g. 11).
(8) Usi ng a ri ng i nstal l er, i nstal l the second com-
pressi on ri ng wi th the dot faci ng up (Fi g. 11) (Fi g.
13).
(9) Usi ng a ri ng i nstal l er, i nstal l the top compres-
si on ri ng (ei ther si de up).
Ring Gap Orientation
Posi ti on the gaps on the pi ston as shown (Fi g. 14).
Oi l spacer - Gap on center l i ne of pi ston ski rt.
Fig. 8 Ring Side Clearance Measurement
Fig. 9 Gap Measurement
Fig. 10 Top Compression ring identification
Fig. 11 Second Compression Ring Identification
Oi l rai l s - gap 180 apart on centerl i ne of pi ston
pi n bore.
No. 2 Compressi on ri ng - Gap 180 from top oi l
rai l gap.
No. 1 Compressi on ri ng - Gap 180 from No. 2
compressi on ri ng gap.
FITTING CONNECTING ROD BEARINGS
INSPECTION
BEARINGS
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 15) (Fi g. 16). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 17). Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
CONNECTING RODS
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
BEARING-TO-JOURNAL CLEARANCE
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Use short rubber hose secti ons over rod bol ts
duri ng i nstal l ati on.
Fig. 12 Compression Ring Chamfer Location
Fig. 13 Compression Ring Installation
Fig. 14 Ring Gap Orientation
Fig. 15 Connecting Rod Bearing Inspection
(3) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(4) Use pi ston ri ng compressor to i nstal l the rod
and pi ston assembl i es. The oi l squi rt hol es i n the
rods must face the camshaft. The arrow on the pi ston
crown shoul d poi nt to the front of the engi ne (Fi g.
18). Veri fy that the oi l squi rt hol es i n the rods face
the camshaft and that the arrows on the pi stons face
the front of the engi ne.
(5) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(6) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten nuts to 45 Nm (33 ft. l bs.)
torque. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(7) Remove the beari ng cap and determi ne amount
of beari ng-to- journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 19). Refer to
Engi ne Speci fi cati ons for the proper cl earance. Plas-
tigage should indicate the same clearance
across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(8) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(9) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, i nstal l a pai r of 0.0254 mm (0.001 i nch)
undersi ze beari ng i nserts. Al l the odd si ze i nserts
must be on the bottom. The si zes of the servi ce
repl acement beari ng i nserts are stamped on the
backs of the i nserts. Measure the cl earance as
descri bed i n the previ ous steps.
(10) The cl earance i s measured wi th a pai r of
0.0254 mm (0.001 i nch) undersi ze beari ng i nserts
i nstal l ed. Thi s wi l l determi ne i f two 0.0254 mm
(0.001 i nch) undersi ze i nserts or another combi nati on
i s needed to provi de the correct cl earance (refer to
Connecti ng Rod Beari ng Fi tti ng Chart).
(11) FOR EXAMPLE: I f the i ni ti al cl earance was
0.0762 mm (0.003 i nch), 0.025 mm (0.001 i nch)
undersi ze i nserts woul d reduce the cl earance by
0.025 mm (0.001 i nch). The cl earance woul d be 0.002
Fig. 16 Locking Tab Inspection
Fig. 17 Scoring Caused by Insufficient Lubrication
or by Damaged Crankshaft Pin Journal
Fig. 18 Rod and Piston Assembly Installation
Fig. 19 Measuring Bearing Clearance with
Plastigage
i nch and wi thi n speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze i nsert woul d reduce the i ni ti al cl ear-
ance an addi ti onal 0.013 mm (0.0005 i nch). The
cl earance woul d then be 0.038 mm (0.0015 i nch).
(12) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(13) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
bol ts to 45 Nm (33 ft. l bs.) torque.
SIDE CLEARANCE MEASUREMENT
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 20).
Refer to Engi ne Speci fi cati ons for the proper cl ear-
ance. Repl ace the connecti ng rod i f the si de cl earance
i s not wi thi n speci fi cati on.
FITTING CRANKSHAFT MAIN BEARINGS
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated (Fi g. 21).
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
FITTING BEARINGS (CRANKSHAFT
INSTALLED)
The mai n beari ng caps, numbered (front to rear)
from 1 through 7 have an arrow to i ndi cate the for-
ward posi ti on. The upper mai n beari ng i nserts are
grooved to provi de oi l channel s whi l e the l ower
i nserts are smooth.
Each beari ng i nsert pai r i s sel ecti vel y fi tted to i ts
respecti ve journal to obtai n the speci fi ed operati ng
cl earance. I n producti on, the sel ect fi t i s obtai ned by
usi ng vari ous-si zed col or-coded beari ng i nsert pai rs
as l i sted i n the Mai n Beari ng Fi tti ng Chart. The
beari ng col or code appears on the edge of the i nsert.
The size is not stamped on bearing inserts used
for engine production.
CONNECTING ROD BEARING FITTING CHART
CRANKSHAFT JOURNAL CORRESPONDING ROD BEARING INSERT
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow 53.2257 - 53.2079 mm Yellow - Standard Yellow - Standard
(2.0955 - 2.0948 in.)
Orange 53.2079 - 53.1901 mm Yellow - Standard Blue - Undersize
(2.0948 - 2.0941 in.)
0.0178 mm (0.0007 in.) 0.025 mm (0.001 in.)
Undersize
Blue 53.1901 - 53.1724 mm Blue - Undersize Blue - Undersize
(2.0941 - 2.0934 in.)
0.0356 mm (0.0014 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Undersize
Red 52.9717 - 52.9539 mm Red - Undersize Red - Undersize
(2.0855 - 2.0848 in.)
0.254 mm (0.010 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
Undersize
Fig. 20 Checking Connecting Rod Side Clearance
Typical
The mai n beari ng journal si ze (di ameter) i s i denti -
fi ed by a col or-coded pai nt mark (Fi g. 22) on the
adjacent cheek or counterwei ght towards the rear of
the crankshaft (fl ange end). The rear mai n journal , i s
i denti fi ed by a col or-coded pai nt mark on the crank-
shaft rear fl ange.
When requi red, upper and l ower beari ng i nserts of
di fferent si zes may be used as a pai r. A standard si ze
i nsert i s someti mes used i n combi nati on wi th a 0.025
mm (0.001 i nch) undersi ze i nsert to reduce the cl ear-
ance by 0.013 mm (0.0005 i nch). Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size (Fig. 23).
NOTE: When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block) or
all on the bottom (in main bearing cap).
Once the beari ngs have been properl y fi tted, pro-
ceed to Crankshaft Mai n Beari ngI nstal l ati on.
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When usi ng Pl asti gage, check onl y one beari ng
cl earance at a ti me.
I nstal l the grooved mai n beari ngs i nto the cyl i nder
bl ock and the non-grooved beari ngs i nto the beari ng
caps.
I nstal l the crankshaft i nto the upper beari ngs dry.
Pl ace a stri p of Pl asti gage across ful l wi dth of the
crankshaft journal to be checked.
I nstal l the beari ng cap and ti ghten the bol ts to 108
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the beari ng cap. Determi ne the amount of
cl earance by measuri ng the wi dth of the compressed
Fig. 22 Crankshaft Journal Size Paint I.D. Location
Fig. 21 Main Bearing Wear Patterns
Fig. 23 Bearing Insert Pairs
Pl asti gage wi th the scal e on the Pl asti gage envel ope
(Fi g. 24). Refer to Engi ne Speci fi cati ons for the
proper cl earance.
Pl asti gage shoul d i ndi cate the same cl earance
across the enti re wi dth of the i nsert. I f cl earance var-
i es, i t may i ndi cate a tapered journal or forei gn
materi al trapped behi nd the i nsert.
I f the speci fi ed cl earance i s i ndi cated and there are
no abnormal wear patterns, repl acement of the bear-
i ng i nserts i s not necessary. Remove the Pl asti gage
from the crankshaft journal and beari ng i nsert. Pro-
ceed to Crankshaft Mai n Beari ngI nstal l ati on.
I f the cl earance exceeds speci fi cati on, i nstal l a pai r
of 0.025 mm (0.001 i nch) undersi ze beari ng i nserts
and measure the cl earance as descri bed i n the previ -
ous steps.
The cl earance i ndi cate wi th the 0.025 mm (0.001
i nch) undersi ze i nsert pai r i nstal l ed wi l l determi ne i f
thi s i nsert si ze or some other combi nati on wi l l pro-
vi de the speci fi ed cl earance. FOR EXAMPLE: I f the
cl earance was 0.0762 mm (0.003 i nch) ori gi nal l y, a
pai r of 0.0254 mm (0.001 i nch) undersi ze i nserts
woul d reduce the cl earance by 0.0254 mm (0.001
i nch). The cl earance woul d then be 0.0508 mm (0.002
i nch) and wi thi n the speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze beari ng i nsert and a 0.0254 mm
(0.001 i nch) undersi ze i nsert woul d reduce the ori gi -
nal cl earance an addi ti onal 0.0127 mm (0.0005 i nch).
The cl earance woul d then be 0.0381 mm (0.0015
i nch).
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
FOR EXAMPLE: DO NOT use a standard si ze
upper i nsert and a 0.051 mm (0.002 i nch) undersi ze
l ower i nsert.
I f the cl earance exceeds speci fi cati on usi ng a pai r
of 0.051 mm (0.002 i nch) undersi ze beari ng i nserts,
measure crankshaft journal di ameter wi th a
mi crometer. I f the journal di ameter i s correct, the
crankshaft bore i n the cyl i nder bl ock may be mi s-
al i gned, whi ch requi res cyl i nder bl ock repl acement or
machi ni ng to true bore.
Repl ace the crankshaft or gri nd to accept the
appropri ate undersi ze beari ng i nserts i f:
Journal di ameters 1 through 6 are l ess than
63.4517 mm (2.4981 i nches)
Journal 7 di ameter i s l ess than 63.4365 mm
(2.4975 i nches).
Once the proper cl earances have been obtai ned,
proceed to Crankshaft Mai n Beari ngI nstal l ati on.
MAIN BEARING J OURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cyl i nder bl ock
(refer to Cyl i nder Bl ock - Di sassembl e).
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90
apart at each end of the journal .
The maxi mum al l owabl e taper and out of round i s
0.013 mm (0.0005 i nch). Compare the measured
di ameter wi th the journal di ameter speci fi cati on
(Mai n Beari ng Fi tti ng Chart). Sel ect i nserts requi red
to obtai n the speci fi ed beari ng-to-journal cl earance.
I nstal l the crankshaft i nto the cyl i nder bl ock (refer
to Cyl i nder Bl ock - Assembl e and Crankshaft Mai n
Beari ngs - I nstal l ati on).
Fig. 24 Measuring Bearing Clearance with
Plastigage
MAIN BEARING FITTING CHART
Crankshaft Journals #1-6 Corresponding Crankshaft Bearing Insert
Yellow 63.5025 -63.4898 mm Yellow - Standard Yellow - Standard
(2.5001 - 2.4996 in.)
0.025 mm (0.001 in.)
(2.4996 - 2.4991 in.)
0.0127 mm (0.0015 in.)
Undersize
Blue 63.4771 - 63.4644 mm Blue - Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4991 - 2.4986 in.)
0.0254 mm (0.001 in.)
Undersize
Green 63.4644 - 63.4517 mm Blue - Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4986 - 2.4981 in.)
0.0381 mm (0.0015 in.)
Undersize
Red 63.2485 - 63.2358 mm Red - Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4901 - 2.4896 in.)
0.254 mm (0.010 in.)
Undersize
Crankshaft Journal #7 Only Corresponding Bearing Insert
Yellow 63.4873 - 63.4746 mm Yellow - Standard Yellow - Standard
(2.4995 - 2.4990 in.)
0.025 mm (0.001 in.)
(2.4996 - 2.4991 in.)
0.0127 mm (0.0005 in.)
Undersize
Blue 63.4619 - 63.4492 mm Blue - Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4985 - 2.4980 in.)
0.0254 mm (0.001 in.)
Undersize
Green 63.4492 - 63.4365 mm Blue - Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4980 - 2.4975 in.)
0.0381 mm (0.0015 in.)
Undersize
Red 63.2333 - 63.2206 mm Red - Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4895 - 2.4890 in.)
0.254 mm (0.010 in.)
Undersize
ENGINE MOUNTSFRONT
The front mounts support the engi ne at each si de.
These i nsul ators are made of resi l i ent rubber.
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Support the engi ne.
(4) Remove the i nsul ator assembl y-to-l ower front
si l l bol ts (Fi g. 25) (Fi g. 26).
(5) Rai se the engi ne sl i ghtl y.
(6) Remove the thru-bol t nut and thru-bol t (Fi g.
25) (Fi g. 26). Remove the i nsul ator.
(7) I f requi red, remove the engi ne bracket from the
bl ock (Fi g. 25) (Fi g. 26).
INSTALLATION
(1) I f removed, i nstal l the engi ne bracket to the
bl ock (Fi g. 25) (Fi g. 26). Ti ghten the bol ts to 61 Nm
(2) I nstal l the i nsul ator assembl y to the l ower
front si l l . Ti ghten the bol ts to 65 Nm (48 ft. l bs.)
torque.
(3) Wi th the engi ne i nsul ator assembl y and engi ne
bracket i n posi ti on, i nstal l the thru-bol t and nut (Fi g.
25) (Fi g. 26). Ti ghten the thru- bol t nut to 121 Nm
(4) Lower the vehi cl e.
(5) Remove the engi ne support.
(6) Connect the negati ve cabl e to the battery.
ENGINE MOUNTREAR
A resi l i ent rubber cushi on bracket assembl y sup-
ports the transmi ssi on at the rear. Thi s bracket i s
attached to the crossmember (Fi g. 27) (Fi g. 28).
REMOVAL
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the bol ts hol di ng the mount assy. to
the crossmember.
Fig. 25 Front Engine MountRight Side
Fig. 26 Front Engine MountLeft Side
Fig. 27 Rear Engine Mount(4x2)
(4) Rai se the transmi ssi on SLI GHTLY.
(5) Remove the thru-bol t and nut. Remove the rear
mount assy (Fi g. 27) (Fi g. 28).
(6) I f necessary, remove the bol ts hol di ng the rear
mount bracket to the transmi ssi on. Remove the
bracket from the exhaust pi pe hanger. Remove the
bracket.
INSTALLATION
(1) Posi ti on the rear mount bracket onto the
exhaust hanger (i f previ ousl y removed). Posi ti on the
rear mount bracket assembl y onto the transmi ssi on
and i nstal l the bol ts. Ti ghten the bol ts to 46 Nm (34
ft. l bs.)
(2) Posi ti on mount i nto mount bracket and i nstal l
thru-bol t and nut. DO NOT ti ghten the bol t at thi s
ti me.
(3) Lower the transmi ssi on unti l the mount fasten-
i ng studs are i n posi ti on i n the crossmember.
(4) Remove the transmi ssi on support.
(5) I nstal l the mount fasteni ng nuts and ti ghten
the nuts to 54 Nm (40 ft. l bs.) torque.
(6) Ti ghten the thru-bol t nut to 65 Nm (48 ft. l bs.)
torque.
ENGINE ASSEMBLY
REMOVAL
(2) Mark the hi nge l ocati ons on the hood panel for
al i gnment reference duri ng i nstal l ati on. Remove the
engi ne compartment l amp. Remove the hood.
(3) Remove the radi ator drai n cock and radi ator
cap to drai n the cool ant. DO NOT waste usabl e cool -
ant. I f the sol uti on i s cl ean, drai n the cool ant i nto a
cl ean contai ner for reuse.
(4) Remove the upper radi ator hose and cool ant
recovery hose (Fi g. 29).
(5) Remove the l ower radi ator hose.
(6) Remove upper radi ator support retai ni ng bol ts
and remove radi ator support.
(7) Remove the fan assembl y from the water
pump.
(8) Remove the fan shroud (Fi g. 29).
(9) Di sconnect the transmi ssi on fl ui d cool er l i nes
(automati c transmi ssi on).
(10) Di scharge the A/C system. (Refer to Group 24,
Heati ng and Ai r Condi ti oni ng)
(11) Remove the servi ce val ves and cap the com-
pressor ports.
(12) Remove the radi ator or radi ator/condenser (i f
equi pped wi th A/C).
(13) Di sconnect the heater hoses at the engi ne
thermostat housi ng and water pump (Fi g. 29).
(14) Di sconnect the accel erator cabl e, transmi ssi on
l i ne pressure cabl e and speed control cabl e (i f
equi pped) from the throttl e body (Fi g. 30).
(15) Remove cabl es from the bracket and secure
out of the way.
(16) Di sconnect the body ground at the engi ne.
Fig. 28 Rear Engine Mount(4x4)
Fig. 29 Upper Radiator Hose, Coolant Recovery
Hose, Fan Shroud & Heater hoses
REMOVAL AND INSTALLATION (Continued)
(17) Di sconnect the fol l owi ng connectors and
secure thei r harness out of the way.
Power steeri ng pressure swi tch
Cool ant temperature sensor
Si x (6) fuel i njector connectors
I ntake ai r temperature sensor
Throttl e posi ti on sensor
Map sensor
Crankshaft posi ti on sensor
Oxygen sensor
(18) Di sconnect the di stri butor el ectri cal connec-
ti on and the oi l pressure swi tch connector.
(19) Perform the fuel pressure rel ease procedure.
(Refer to Group 14, Fuel System for correct proce-
dure)
(20) Di sconnect the fuel suppl y l i ne at the i njector
rai l . (Refer to Group 14, Qui ck-Connect Fi tti ngs for
the correct procedure)
(21) Remove the fuel l i ne bracket from the i ntake
mani fol d.
(22) Remove the ai r cl eaner assembl y (Fi g. 31).
(23) Di sconnect the hoses from the fi tti ngs at the
steeri ng gear.
(24) Drai n the pump reservoi r.
(25) Cap the fi tti ngs on the hoses and steeri ng
gear to prevent forei gn objects from enteri ng the sys-
tem.
(26) Rai se and support the vehi cl e.
(27) Di sconnect the wi res from the engi ne starter
motor sol enoi d.
(28) Remove the engi ne starter motor.
(29) Di sconnect the oxygen sensor from the
exhaust pi pe.
(30) Di sconnect the exhaust pi pe from the mani -
fol d. Di scard the seal .
(31) Remove the exhaust pi pe support.
(32) Remove the engi ne fl ywheel /converter housi ng
access cover.
(33) Mark the converter and dri ve pl ate l ocati on.
(34) Remove the converter-to-dri ve pl ate bol ts.
(35) Remove the upper engi ne fl ywheel /converter
housi ng bol ts and l oosen the bottom bol ts.
(36) Remove the engi ne mount cushi on-to-engi ne
compartment bracket bol ts.
(38) Attach a l i fti ng devi ce to the engi ne.
(39) Rai se the engi ne off the front supports.
(40) Pl ace a support or fl oor jack under the con-
verter (or engi ne fl ywheel ) housi ng.
(41) Remove the remai ni ng converter (or engi ne
fl ywheel ) housi ng bol ts.
(42) Li ft the engi ne out of the engi ne compart-
ment.
INSTALLATION
CAUTION: When installing the engine into a vehi-
cle equipped with an automatic transmission, be
careful not to damage the trigger wheel on the
engine flywheel.
(1) Attach a l i fti ng devi ce to the engi ne and l ower
the engi ne i nto the engi ne compartment. For easi er
i nstal l ati on, i t may be necessary to remove the
Fig. 30 Accelerator Cable, Vehicle Speed Control
Cable, Automatic Transmission Control Cable &
Quick-Connect Fuel Lines
Fig. 31 Air Cleaner Assembly & Power Steering
Pump
engi ne mount bracket as an ai d i n al i gnment of the
engi ne to the transmi ssi on.
(2) Al i gn the transmi ssi on torque converter hous-
i ng wi th the engi ne.
(3) Loosel y i nstal l the converter housi ng l ower
bol ts and i nstal l the next hi gher bol t and nut on each
si de.
(4) Ti ghten al l 4 bol ts fi nger ti ght.
(5) I nstal l the engi ne mount brackets (i f removed).
(6) Lower the engi ne and engi ne mount brackets
onto the engi ne compartment cushi ons. I nstal l the
bol ts and fi nger ti ghten the nuts.
(7) Remove the engi ne l i fti ng devi ce.
(8) Rai se and support the vehi cl e.
(9) I nstal l the remai ni ng engi ne fl ywheel /converter
housi ng bol ts. Ti ghten al l bol ts to 38 Nm (28 ft. l bs.)
torque.
(10) I nstal l the converter-to-dri ve pl ate bol ts.
(11) Ensure the i nstal l ati on reference marks are
al i gned.
(12) I nstal l the engi ne fl ywheel /converter housi ng
access cover.
(13) I nstal l the exhaust pi pe support and ti ghten
the screw.
(14) Ti ghten the engi ne mount-to-bracket bol ts.
(15) Connect the vehi cl e speed sensor wi re connec-
ti ons and ti ghten the screws.
(16) Connect the exhaust pi pe to the mani fol d.
(17) I nstal l the engi ne starter motor and connect
the cabl e.
(18) Connect the wi res to the engi ne starter motor
sol enoi d.
(20) Connect al l the vacuum hoses and wi re con-
nectors i denti fi ed duri ng engi ne removal .
(21) Remove protecti ve caps from the power steer-
i ng hoses.
(22) Connect the hoses to the fi tti ngs at the steer-
i ng gear. Ti ghten the nut to 52 Nm (38 ft. l bs.)
torque.
(23) Fi l l the pump reservoi r wi th fl ui d.
(24) I nspect the fuel suppl y l i ne o-ri ng(s) and
repl ace i f necessary. Connect fuel suppl y l i ne to i njec-
ti or rai l and veri fy connecti on by pul l i ng outward on
the l i ne.
(25) I nstal l the fuel l i ne bracket to the i ntake
mani fol d.
(26) Connect the di stri butor el ectri cal connector
and oi l pressure swi tch connector.
(27) Connect the fol l owi ng el ectri cal connectors:
Power steeri ng pressure swi tch
Cool ant temperature sensor
Si x (6) fuel i njector connectors
I ntake ai r temperature sensor
Throttl e posi ti on sensor
Map sensor
Crankshaft posi ti on sensor
Oxygen sensor
(28) Connect al l previ ousl y removed vacuum hoses.
(29) Connect the body ground strap.
(30) I nstal l the throttl e, transmi ssi on l i ne pres-
sure, and speed control cabl es to thei r mounti ng
bracket and connect them to the throttl e body.
(31) Connect the heater hoses at the engi ne ther-
mostat housi ng and water pump.
(32) I nstal l the fan assembl y to the water pump.
(33) Pl ace the fan shroud i n posi ti on over the fan.
(34) I nstal l the radi ator or radi ator/condenser.
(35) Connect the servi ce val ves to the A/C com-
pressor ports, i f equi pped wi th A/C.
(36) Charge the ai r condi ti oner system (refer to
Group 24, Heati ng and Ai r Condi ti oni ng).
(37) Connect the radi ator hoses and automati c
transmi ssi on fl ui d cool er pi pes, i f equi pped.
(38) I nstal l the fan shroud to the radi ator or radi -
ator/condenser (i f equi pped wi th A/C).
(39) I nstal l upper radi ator support.
(40) Connect the upper radi ator hose and ti ghten
the cl amp.
(41) Connect the l ower radi ator hose and ti ghten
the cl amp.
(42) Fi l l crankcase wi th engi ne oi l . (Refer to Group
0, Lubri cati on and Mai ntenance for correct capaci -
ti es.)
(43) Fi l l the cool i ng system wi th reusabl e cool ant
or new cool ant (refer to Group 7, Cool i ng System).
(44) Al i gn the hood to the scri be marks. I nstal l the
hood.
(45) I nstal l the ai r cl eaner assembl y.
(46) I nstal l the battery and connect the battery
cabl e.
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(47) Start the engi ne, i nspect for l eaks and correct
the fl ui d l evel s, as necessary.
CYLINDER HEAD COVER
The cyl i nder head cover i s i sol ated from the cyl i n-
der head vi a grommets and a reusabl e mol ded rubber
gasket. The grommet and l i mi ter are retai ned i n the
cyl i nder head cover.
There are two cyl i nder head bol ts that have a pi n
to l ocate the cyl i nder head cover gasket, they are
l ocated at posi ti on 8 and 9 (Fi g. 33)
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Di sconnect the Crankcase Venti l ati on (CCV)
vacuum hose from engi ne cyl i nder head cover.
(3) Di sconnect the fresh ai r i nl et hose from the
engi ne cyl i nder head cover.
(4) Di sconnect the accel erator, transmi ssi on, and
speed (i f equi pped) control cabl es from the throttl e
body (Fi g. 32).
(5) Remove the three bol ts that fasten the control
cabl e bracket to the i ntake mani fol d.
(6) Remove control cabl es from cyl i nder head cover
cl i p.
(7) Posi ti on control cabl es and bracket away from
cyl i nder head cover secure wi th ti e straps.
(8) Remove the engi ne cyl i nder head cover mount-
i ng bol ts.
(9) Remove the engi ne cyl i nder head cover and
gasket.
INSTALLATION
(1) I f a repl acement cover i s i nstal l ed, transfer the
CCV val ve grommet and oi l fi l l er cap from the ori gi -
nal cover to the repl acement cover.
(2) I nstal l cyl i nder head cover and gasket. Ti ghten
the mounti ng bol ts to 10 Nm (85 i n. l bs.) torque.
(3) Connect the CCV hoses.
(4) I nstal l control cabl es and bracket on i ntake
mani fol d and ti ghten bol ts to 8.7 Nm (77 i n. l bs.)
torque.
(5) Connect control cabl es to throttl e body l i nkage.
(6) Snap control cabl es i nto cyl i nder head cover
cl i p.
(7) Connect negati ve cabl e to battery.
ROCKER ARMS AND PUSH RODS
Thi s procedure can be done wi th the engi ne i n or
out of the vehi cl e.
REMOVAL
(1) Remove the engi ne cyl i nder head cover.
(2) Check for rocker arm bri dges whi ch are caus-
i ng mi sal i gnment of the rocker arm to val ve ti p area.
(3) Remove the capscrews at each bri dge and pi vot
assembl y (Fi g. 34). Al ternatel y l oosen the capscrews
one turn at a ti me to avoi d damagi ng the bri dges.
(4) Remove the bri dges, pi vots and correspondi ng
pai rs of rocker arms (Fi g. 34). Pl ace them on a bench
i n the same order as removed.
(5) Remove the push rods and pl ace them on a
bench i n the same order as removed.
INSTALLATION
(1) Lubri cate the bal l ends of the push rods wi th
Mopar Engi ne Oi l Suppl ement, or equi val ent and
i nstal l push rods i n thei r ori gi nal l ocati ons. Ensure
that the bottom end of each push rod i s centered i n
the tappet pl unger cap seat.
(2) Usi ng Mopar Engi ne Oi l Suppl ement, or equi v-
al ent, l ubri cate the area of the rocker arm that the
Fig. 32 Engine Cylinder Head Cover
Fig. 33 Cylinder Head Cover Gasket Locator Pins at
#8 & #9
Fig. 34 Rocker Arm Assembly
pi vot contacts. I nstal l rocker arms, pi vots and bri dge
above each cyl i nder i n thei r ori gi nal l y posi ti on.
(3) Loosel y i nstal l the capscrews through each
bri dge.
(4) At each bri dge, ti ghten the capscrews al ter-
natel y, one turn at a ti me, to avoi d damagi ng the
bri dge. Ti ghten the capscrews to 28 Nm (21 ft. l bs.)
torque.
(5) I nstal l the engi ne cyl i nder head cover.
VALVE STEM SEAL AND SPRING
Thi s procedure can be done wi th the engi ne cyl i n-
der head i nstal l ed on the bl ock.
REMOVAL
I nspect the val ve stems, especi al l y the grooves. An
Arkansas smooth stone shoul d be used to remove
ni cks and hi gh spots.
Each val ve spri ng i s hel d i n pl ace by a retai ner
and a set of coni cal val ve l ocks. The l ocks can be
removed onl y by compressi ng the val ve spri ng.
(2) Remove capscrews, bri dge and pi vot assembl i es
and rocker arms for access to each val ve spri ng to be
removed.
(3) Remove push rods. Retain the push rods,
bridges, pivots and rocker arms in the same
order and position as removed.
(4) I nspect the spri ngs and retai ner for cracks and
possi bl e si gns of weakeni ng.
(5) Remove the spark pl ug(s) adjacent to the cyl i n-
der(s) bel ow the val ve spri ngs to be removed.
(6) Connect an ai r hose to the adapter and appl y
ai r pressure sl owl y. Mai ntai n at l east 621 kPa (90
psi ) of ai r pressure i n the cyl i nder to hol d the val ves
agai nst thei r seats. For vehi cl es equi pped wi th an ai r
condi ti oner, use a fl exi bl e ai r adaptor when servi ci ng
the No.1 cyl i nder.
(7) Tap the retai ner or ti p wi th a rawhi de hammer
to l oosen the l ock from the retai ner. Use Val ve Spri ng
Compressor Tool MD-998772A to compress the spri ng
and remove the l ocks (Fi g. 35).
(8) Remove val ve spri ng and retai ner (Fi g. 35).
(9) Remove val ve stem oi l seal s (Fi g. 35). Note the
val ve seal s are di fferent for i ntake and exhaust
val ves. The top of each seal i s marked ei ther I NT
(I ntake) or EXH (Exhaust). DO NOT mi x the seal s.
INSTALLATION
CAUTION: Install oil seals carefully to prevent
damage from the sharp edges of the valve spring
lock grove.
(1) Li ghtl y push the val ve seal over the val ve stem
and val ve gui de boss. Be sure the seal i s compl etel y
seated on the val ve gui de boss.
(2) I nstal l val ve spri ng and retai ner.
(3) Compress the val ve spri ng wi th Val ve Spri ng
Compressor Tool MD-998772A and i nsert the val ve
l ocks. Rel ease the spri ng tensi on and remove the
tool . Tap the spri ng from si de-to-si de to ensure that
the spri ng i s seated properl y on the engi ne cyl i nder
head.
(4) Rel ease ai r pressure and di sconnect the ai r
hose. Remove the adaptor from the spark pl ug hol e
and i nstal l the spark pl ug.
(5) Repeat the procedures for each remai ni ng val ve
spri ng to be removed.
(6) I nstal l the push rods. Ensure the bottom end of
each rod i s centered i n the pl unger cap seat of the
hydraul i c val ve tappet.
(7) I nstal l the rocker arms, pi vots and bri dge at
thei r ori gi nal l ocati on.
(8) Ti ghten the bri dge capscrews al ternatel y, one
at a ti me, to avoi d damagi ng the bri dge. Ti ghten the
capscrews to 28 Nm (21 ft. l bs.) torque.
CYLINDER HEAD
Thi s procedure can be done wi th the engi ne i n or
out of the vehi cl e.
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
Fig. 35 Valve and Valve Components
(2) Drai n the cool ant and di sconnect the hoses at
the engi ne thermostat housi ng and the water pump
i nl et. DO NOT waste reusabl e cool ant. I f the sol uti on
i s cl ean and i s bei ng drai ned onl y to servi ce the
engi ne or cool i ng system, drai n the cool ant i nto a
(3) Remove the ai r cl eaner assembl y.
(5) Remove the capscrews, bri dge and pi vot assem-
bl i es and rocker arms.
(6) Remove the push rods. Retain the push rods,
bridges, pivots and rocker arms in the same
order as removed.
(7) Loosen the accessory dri ve bel t at the power
steeri ng pump. (Refer to Group 7, Cool i ng System for
the correct procedure). Sl i p the bel t off of the power
steeri ng pul l ey.
(8) Remove the ai r condi ti oni ng compressor mount-
i ng bol ts and secure the compressor to the si de.
(9) Remove the power steeri ng pump and bracket
from the i ntake mani fol d and water pump. Set the
pump and bracket asi de. DO NOT di sconnect the
hoses.
(10) Perform the Fuel System Pressure Rel ease
procedure. (Refer to Group 14, Fuel System)
(11) Di sconnect the fuel suppl y l i ne at the fuel rai l .
(Refer to Group 14, Qui ck-Connect Fi tti ngs for the
correct procedures)
(12) Remove the i ntake and engi ne exhaust mani -
fol ds from the engi ne cyl i nder head. (Refer to Group
11, Exhaust System and I ntake Mani fol d for the
proper procedures)
(13) Di sconnect the i gni ti on wi res and remove the
spark pl ugs.
(14) Di sconnect the temperature sendi ng uni t wi re
connector.
(15) Remove the i gni ti on coi l and bracket assem-
bl y.
(16) Remove the engi ne cyl i nder head bol ts. Bol t
No.14 cannot be removed unti l the head i s moved for-
ward (Fi g. 36). Pul l bol t No.14 out as far as i t wi l l go
and then suspend the bol t i n thi s posi ti on (tape
around the bol t).
(17) Remove the engi ne cyl i nder head and gasket
(Fi g. 36).
(18) I f thi s was the fi rst ti me the bol ts were
removed, put a pai nt dab on the top of the bol t. I f the
bol ts have a pai nt dab on the top of the bol t or i t
i snt known i f they were used before, di scard the
bol ts.
(19) Stuff cl ean l i nt free shop towel s i nto the cyl -
i nder bores.
INSTALLATION
The engi ne cyl i nder head gasket i s a composi ti on
gasket. The gasket i s to be i nstal l ed DRY. DO NOT
use a gasket sealing compound on the gasket.
I f the engi ne cyl i nder head i s to be repl aced and
the ori gi nal val ves used, measure the val ve stem
di ameter. Onl y standard si ze val ves can be used wi th
a servi ce repl acement engi ne cyl i nder head unl ess
the repl acement head val ve stem gui de bores are
reamed to accommodate oversi ze val ve stems.
Remove al l carbon bui l dup and reface the val ves.
(1) Remove the shop towel s from the cyl i nder
bores. Coat the bores wi th cl ean engi ne oi l .
(2) Posi ti on the engi ne cyl i nder head gasket (wi th
the numbers faci ng up) usi ng the al i gnment dowel s
i n the cyl i nder bl ock, to posi ti on the gasket.
CAUTION: Engine cylinder head bolts should be
reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
(3) Wi th bol t No.14 hel d i n pl ace (tape around
bol t), i nstal l the engi ne cyl i nder head over the same
dowel s used to l ocate the gasket. Remove the tape
from bol t No.14.
(4) Coat the threads of stud bol t No.11 wi th Loc-
ti te 592 seal ant, or equi val ent.
(5) Ti ghten the engi ne cyl i nder head bol ts i n
sequence accordi ng to the fol l owi ng procedure (Fi g.
37).
CAUTION: During the final tightening sequence,
bolt No.11 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt
No.11.
(a) Ti ghten al l bol ts i n sequence (1 through 14)
to 30 Nm (22 ft. l bs.) torque.
(b) Ti ghten al l bol ts i n sequence (1 through 14)
(c) Check al l bol ts to veri fy they are set to 61
Fig. 36 Engine Cylinder Head Assembly
(d) Ti ghten bol ts i n sequence:
Bol ts 1 through 10 to 149 Nm (110 ft. l bs.)
torque.
Bol t 11 to 13 Nm (100 ft. l bs.) torque.
Bol ts 12 through 14 to 149 Nm (110 ft. l bs.)
torque.
(e) Check al l bol ts i n sequence to veri fy the cor-
rect torque.
(f) I f not al ready done, cl ean and mark each bol t
wi th a dab of pai nt after ti ghteni ng. Shoul d you
encounter bol ts whi ch were pai nted i n an earl i er
servi ce operati on, repl ace them.
(6) I nstal l the i gni ti on coi l and bracket assembl y.
(7) Connect the temperature sendi ng uni t wi re
connector.
(8) I nstal l the spark pl ugs and ti ghten to 37 Nm
(27 ft. l bs.) torque. Connect the i gni ti on wi res.
(9) I nstal l the i ntake and engi ne exhaust mani -
fol ds (refer to Group 11, Exhaust System and I ntake
Mani fol d for the proper procedures).
(10) I nstal l the fuel l i nes and the vacuum advance
hose.
(11) I f equi pped, attach the power steeri ng pump
and bracket.
(12) I nstal l the push rods, rocker arms, pi vots and
bri dges i n the order they were removed (refer to
Rocker Arms and Push Rods i n thi s secti on).
(14) Attach the ai r condi ti oner compressor mount-
i ng bracket to the engi ne cyl i nder head and bl ock.
Ti ghten the bol ts to 40 Nm (30 ft. l bs.) torque.
(15) Attach the ai r condi ti oni ng compressor to the
bracket. Ti ghten the bol ts to 27 Nm (20 ft. l bs.)
torque.
CAUTION: The serpentine drive belt must be
routed correctly. Incorrect routing can cause the
water pump to turn in the opposite direction caus-
ing the engine to overheat.
(16) I nstal l the serpenti ne dri ve bel t and correctl y
tensi on the bel t (refer to Group 7, Cool i ng System for
the proper procedure).
(17) I nstal l the ai r cl eaner and ducti ng.
(19) Connect the hoses to the engi ne thermostat
housi ng and fi l l the cool i ng system to the speci fi ed
l evel (refer to Group 7, Cool i ng Systems for the
proper procedure).
(20) The automati c transmi ssi on throttl e l i nkage
and cabl e must be adjusted after compl eti ng the
engi ne cyl i nder head i nstal l ati on (refer to Group 21,
Transmi ssi ons for the proper procedures).
(21) I nstal l the temperature sendi ng uni t and con-
nect the wi re connector.
(22) Connect the fuel l i ne.
(23) I f equi pped wi th ai r condi ti oni ng, i nstal l ai r
compressor and charge A/C system (refer to Group 24
Heati ng and Ai r Condi ti oni ng).
(25) Connect the upper radi ator hose and heater
hose at the engi ne thermostat housi ng.
(26) Fi l l the cool i ng system. Check for l eaks.
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(27) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the engi ne thermostat opens. Add cool ant, i f
requi red.
VALVES AND VALVE SPRINGS
Thi s procedure i s done wi th the engi ne cyl i nder
head removed from the bl ock.
REMOVAL
(1) Remove the engi ne cyl i nder head from the cyl -
i nder bl ock.
(2) Use Val ve Spri ng Compressor Tool
MD-998772A and compress each val ve spri ng.
(3) Remove the val ve l ocks, retai ners, spri ngs and
val ve stem oi l seal s. Di scard the oi l seal s.
CYLINDER HEAD BOLTS
POSITION DESCRIPTION
1,4,5,12,13 1/2 in.-13 BOLT
8,9 1/2 in.-13 BOLT WITH
DOWEL POINT
2,3,6,7,10,11,14 1/2 in.-13 WITH 7/16
in.-14 STUD END
All bolts are 12 point drives for rocker cover clearance
Fig. 37 Engine Cylinder Head Bolt Tightening
Sequence
(4) Use a smooth stone or a jewel ers fi l e to remove
any burrs on the top of the val ve stem, especi al l y
around the groove for the l ocks.
(5) Remove the val ves, and pl ace them i n a rack i n
the same order as removed.
INSTALLATION
(1) Thoroughl y cl ean the val ve stems and the val ve
gui de bores.
(2) Li ghtl y l ubri cate the stem.
(3) I nstal l the val ve i n the ori gi nal val ve gui de
bore.
(4) I nstal l the repl acement val ve stem oi l seal s on
the val ve stems. I f the 0.381 mm (0.015 i nch) over-
si ze val ve stems are used, oversi ze oi l seal s are
requi red.
(5) Posi ti on the val ve spri ng and retai ner on the
engi ne cyl i nder head and compress the val ve spri ng
wi th Val ve Spri ng Compressor Tool MD-998772A.
(6) I nstal l the val ve l ocks and rel ease the tool .
(7) Tap the val ve spri ng from si de to si de wi th a
hammer to ensure that the spri ng i s properl y seated
at the engi ne cyl i nder head. Al so tap the top of the
retai ner to seat the val ve l ocks.
(8) I nstal l the engi ne cyl i nder head.
HYDRAULIC TAPPETS
Retai n al l the components i n the same order as
removed.
REMOVAL
(1) Remove the engi ne cyl i nder head (Refer to cyl -
i nder head r&i i n thi s secti on).
(2) Remove the push rods.
(3) Remove the tappets through the push rod open-
i ngs i n the cyl i nder bl ock wi th a Hydraul i c Val ve
Tappet Removal /I nstal l ati on Tool (Fi g. 38).
INSTALLATION
I t i s not necessary to charge the tappets wi th
engi ne oi l . They wi l l charge themsel ves wi thi n a very
short peri od of engi ne operati on.
(1) Di p each tappet i n Mopar Engi ne Oi l Suppl e-
ment, or equi val ent.
(2) Use Hydraul i c Val ve Tappet Removal /I nstal l a-
ti on Tool to i nstal l each tappet i n the same bore from
where i t was ori gi nal l y removed.
(3) I nstal l the cyl i nder head assy (Refer to cyl i nder
head r&i i n thi s secti on).
(4) I nstal l the push rods i n thei r ori gi nal l ocati ons.
(5) I nstal l the rocker arms and bri dge and pi vot
assembl i es at thei r ori gi nal l ocati ons. Loosel y i nstal l
the capscrews at each bri dge.
(6) Ti ghten the capscrews al ternatel y, one turn at
a ti me, to avoi d damagi ng the bri dges. Ti ghten the
capscrews to 28 Nm (21 ft. l bs.) torque.
(7) Pour the remai ni ng Mopar Engi ne Oi l Suppl e-
ment, or equi val ent over the enti re val ve actuati ng
assembl y. The Mopar Engi ne Oi l Suppl ement, or
equi val ent must remai n wi th the engi ne oi l for at
l east 1 609 km (1,000 mi l es). The oi l suppl ement
need not be drai ned unti l the next schedul ed oi l
change.
VIBRATION DAMPER
REMOVAL
(2) Remove the serpenti ne dri ve bel t and fan
shroud.
(3) Remove the vi brati on damper retai ni ng bol t
and washer.
(4) Use Vi brati on Damper Removal Tool 7697 to
remove the damper from the crankshaft (Fi g. 39).
INSTALLATION
(1) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i n posi ti on, al i gn the keyway on the
vi brati on damper hub wi th the crankshaft key and
tap the damper onto the crankshaft.
Fig. 38 Hydraulic Valve Tappet Removal
Installation Tool
Fig. 39 Vibration Damper Removal Tool 7697
(2) I nstal l the vi brati on damper retai ni ng bol t and
washer.
(3) Ti ghten the damper retai ni ng bol t to 108 Nm
(4) I nstal l the serpenti ne dri ve bel t and ti ghten to
the speci fi ed tensi on (refer to Group 7, Cool i ng Sys-
tems for the proper speci fi cati ons and procedures).
TIMING CASE COVER
REMOVAL
(2) Remove the vi brati on damper.
(3) Remove the fan and hub assembl y and remove
the fan shroud.
(4) Remove the accessory dri ve brackets that are
attached to the ti mi ng case cover.
(5) Remove the A/C compressor (i f equi pped) and
generator bracket assembl y from the engi ne cyl i nder
head and move to one si de.
(6) Remove the oi l pan-to-ti mi ng case cover bol ts
and ti mi ng case cover-to-cyl i nder bl ock bol ts.
(7) Remove the ti mi ng case cover and gasket from
the engi ne. Make sure the tensi on spri ng and thrust
pi n do not fal l out of the prel oad bol t.
(8) Pry the crankshaft oi l seal from the front of the
ti mi ng case cover (Fi g. 40).
INSTALLATION
Cl ean the ti mi ng case cover, oi l pan and cyl i nder
bl ock gasket surfaces.
(1) I nstal l a new crankshaft oi l seal i n the ti mi ng
case cover. The open end of the seal shoul d be toward
the i nsi de of the cover. Support the cover at the seal
area whi l e i nstal l i ng the seal . Force i t i nto posi ti on
wi th Seal I nstal l ati on Tool 6139.
(2) Posi ti on the gasket on the cyl i nder bl ock.
(3) Posi ti on the ti mi ng case cover on the oi l pan
gasket and the cyl i nder bl ock. Make sure the tensi on
spri ng and thrust pi n are i n pl ace i n the camshaft
prel oad bol t.
(4) I nsert Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng i n
the cover (Fi g. 41).
(5) I nstal l the ti mi ng case cover-to-cyl i nder bl ock
and the oi l pan-to-ti mi ng case cover bol ts.
(6) Ti ghten the 1/4 i nch cover-to-bl ock bol ts to 7
Nm (60 i n. l bs.) torque. Ti ghten the 5/16 i nch front
cover-to-bl ock bol ts to 22 Nm (192 i n. l bs.) torque.
Ti ghten the oi l pan-to-cover 1/4 i nch bol ts to 9.5 Nm
(84 i n. l bs.) torque.
(7) Remove the cover al i gnment tool .
(8) Appl y a l i ght fi l m of engi ne oi l on the vi brati on
damper hub contact surface of the seal .
Wi th the key i nserted i n the keyway i n the crank-
shaft, i nstal l the vi brati on damper, washer and bol t.
Lubri cate and ti ghten the bol t to 108 Nm (80 ft. l bs.)
torque.
(10) I nstal l the A/C compressor (i f equi pped) and
generator bracket assembl y.
(11) I nstal l the engi ne fan and hub assembl y and
shroud.
(12) I nstal l the serpenti ne dri ve bel t and ti ghten
to obtai n the speci fi ed tensi on.
TIMING CHAIN AND SPROCKETS
REMOVAL
(2) Remove the fan and shroud.
(3) Remove the serpenti ne dri ve bel t.
(4) Remove the crankshaft vi brati on damper.
(5) Remove the ti mi ng case cover.
Fig. 40 Timing Case Cover Components
Fig. 41 Timing Case Cover Alignment and Seal
Installation Tool 6139
(6) Rotate crankshaft unti l the 0 ti mi ng mark i s
cl osest to and on the center l i ne wi th camshaft
sprocket ti mi ng mark (Fi g. 42).
(7) Remove the oi l sl i nger from the crankshaft.
(8) Remove the tensi on spri ng and thrust pi n from
the prel oad bol t (Fi g. 43). Remove the camshaft
sprocket retai ni ng prel oad bol t and washer.
(9) Remove the crankshaft sprocket, camshaft
sprocket and ti mi ng chai n as an assembl y.
(10) I nstal l ati on of the ti mi ng chai n wi th the ti m-
i ng marks on the crankshaft and camshaft sprockets
properl y al i gned ensures correct val ve ti mi ng. A worn
or stretched ti mi ng chai n wi l l adversel y affect val ve
ti mi ng. I f the ti mi ng chai n defl ects more than 12.7
mm (1/2 i nch) repl ace i t. The correct ti mi ng chai n
has 48 pi ns. A chai n wi th more than 48 pi ns wi l l
cause excessi ve sl ack.
INSTALLATION
Assembl e the ti mi ng chai n, crankshaft sprocket
and camshaft sprocket wi th the ti mi ng marks
al i gned (Fi g. 44).
Wi th the key i n the keyway on the crankshaft, i nstal l
the assembl y on the crankshaft and camshaft.
(2) I nstal l the camshaft sprocket retai ni ng prel oad
bol t and washer (Fi g. 43). Ti ghten the prel oad bol t to
108 Nm (80 ft. l bs.) torque.
(3) To veri fy correct i nstal l ati on of the ti mi ng
chai n, turn the crankshaft to posi ti on the camshaft
sprocket ti mi ng mark as shown i n (Fi g. 44). Count
the number of chai n pi ns between the ti mi ng marks
of both sprockets. There must be 15 pi ns.
(4) I nstal l the crankshaft oi l sl i nger.
(5) Repl ace the oi l seal i n the ti mi ng case cover.
(6) Lubri cate the tensi on spri ng, thrust pi n and
pi n bore i n the prel oad bol t wi th Mopar Engi ne Oi l
Suppl ement, or equi val ent. I nstal l the spri ng and
thrust pi n i n the prel oad bol t head (Fi g. 43).
(7) I nstal l the ti mi ng case cover and gasket.
(8) Wi th the key i nstal l ed i n the crankshaft key-
way, i nstal l the vi brati on damper, washer and bol t.
torque.
(9) I nstal l the serpenti ne dri ve bel t and ti ghten to
the speci fi ed tensi on (refer to Group 7, Cool i ng Sys-
tem for the proper procedure).
(10) I nstal l the fan and hub assembl y. I nstal l the
shroud.
Fig. 42 CrankshaftCamshaft AlignmentTypical
Fig. 43 Camshaft Sprocket Preload Bolt
Fig. 44 Verify SprocketChain InstallationTypical
CAMSHAFT
REMOVAL
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(2) Drai n the cool i ng system. DO NOT waste reus-
abl e cool ant. I f the sol uti on i s cl ean, drai n i t i nto a
(3) Remove the radi ator or radi ator and condenser,
i f equi pped wi th A/C (refer to Group 7, Cool i ng Sys-
tem for the proper procedure).
(4) Remove the di stri butor cap and mark the posi -
ti on of the rotor.
(5) Remove the di stri butor and i gni ti on wi res.
(7) Remove the rocker arms, bri dges and pi vots.
(9) Remove the engi ne cyl i nder head and gasket.
(10) Remove the hydraul i c val ve tappets from the
engi ne cyl i nder bl ock.
(12) Remove the ti mi ng case cover.
(13) Remove the ti mi ng chai n and sprockets.
(14) Remove the front bumper and/or gri l l e, as
requi red.
(15) Remove the camshaft (Fi g. 45).
INSTALLATION
(1) I nspect the cam l obes for wear.
(2) I nspect the beari ng journal s for uneven wear
pattern or fi ni sh.
(3) I nspect the beari ngs for wear.
(4) I nspect the di stri butor dri ve gear for wear.
(5) I f the camshaft appears to have been rubbi ng
agai nst the ti mi ng case cover, exami ne the oi l pres-
sure rel i ef hol es i n the rear cam journal . The oi l
pressure rel i ef hol es must be free of debri s.
(6) Lubri cate the camshaft wi th Mopar Engi ne Oi l
Suppl ement, or equi val ent.
(7) Careful l y i nstal l the camshaft to prevent dam-
age to the camshaft beari ngs (Fi g. 45).
(8) I nstal l the ti mi ng chai n, crankshaft sprocket
and camshaft sprocket wi th the ti mi ng marks
al i gned.
(9) I nstal l the camshaft sprocket retai ni ng prel oad
bol t. Ti ghten the bol t to 108 Nm (80 ft. l bs.) torque.
(10) Lubri cate the tensi on spri ng, the thrust pi n
and the pi n bore i n the prel oad bol t wi th Mopar
Engi ne Oi l Suppl ement, or equi val ent. I nstal l the
spri ng and thrust pi n i n the prel oad bol t head.
(11) I nstal l the ti mi ng case cover wi th a repl ace-
ment oi l seal (Fi g. 46). Refer to Ti mi ng Case Cover
I nstal l ati on.
(12) I nstal l the vi brati on damper (Fi g. 46).
(13) I nstal l the hydraul i c val ve tappets.
(14) I nstal l the cyl i nder head gasket wi th the
numbers faci ng up.
(15) I nstal l the cyl i nder head and head bol ts
(Refer to cyl i nder head R&I i n thi s secti on for torque
val ues and ti ghteni ng sequence).
(16) I nstal l the push rods.
(17) I nstal l the rocker arms and pi vot and bri dge
assembl i es. Ti ghten each of the capscrews for each
bri dge al ternatel y, one turn at a ti me, to avoi d dam-
agi ng the bri dge (Refer to Rocker Arms and Push
Rods i n thi s secti on).
(19) Posi ti on the oi l pump gear. Refer to Di stri bu-
tor i n the Component Removal /I nstal l ati on secti on of
Group 8D, I gni ti on Systems.
(20) I nstal l the di stri butor and i gni ti on wi res.
Refer to Di stri butor i n the Component Removal /I n-
stal l ati on secti on of Group 8D, I gni ti on Systems.
Fig. 45 Camshaft
Fig. 46 Timing Case Cover Components
(21) I nstal l the serpenti ne dri ve bel t and ti ghten
to the speci fi ed tensi on (refer to Group 7, Cool i ng
System for the proper procedure).
NOTE: During installation, lubricate the hydraulic
valve tappets and all valve components with Mopar
Engine Oil Supplement, or equivalent. The Mopar
Engine Oil Supplement, or equivalent must remain
with the engine oil for at least 1609 km (1,000
miles). The oil supplement need not be drained until
the next scheduled oil change.
(22) I nstal l the A/C condenser and recei ver/dri er
assembl y, i f equi pped (refer to Group 24, Heati ng and
Ai r Condi ti oni ng).
CAUTION: Both service valves must be opened
before the air conditioning system is operated.
(23) I nstal l the radi ator, connect the hoses and fi l l
the cool i ng system to the speci fi ed l evel (refer to
Group 7, Cool i ng System for the proper procedure).
(24) Check the i gni ti on ti mi ng and adjust as nec-
essary.
(25) I nstal l the gri l l e and bumper, i f removed.
CAMSHAFT PIN REPLACEMENT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM COOL-
ANT CAN OCCUR.
(2) Drai n the radi ator. DO NOT waste reusabl e
cool ant. Drai n the cool ant i nto a cl ean contai ner.
(3) Remove the fan and shroud.
(4) Di sconnect the radi ator overfl ow tube, radi ator
hoses, automati c transmi ssi on fl ui d cool er pi pes (i f
equi pped).
(5) Remove the radi ator.
(6) I f equi pped wi th ai r condi ti oni ng:
CAUTION: DO NOT loosen or disconnect any air
conditioner system fittings. Move the condenser
and receiver/drier aside as a complete assembly.
(a) Remove the A/C compressor serpenti ne dri ve
bel t i dl er pul l ey.
(b) Di sconnect and remove the generator.
(c) Remove the A/C condenser attachi ng bol ts
and move the condenser and recei ver/dri er assem-
bl y up and out of the way.
(8) Remove the crankshaft vi brati on damper.
(9) Remove the ti mi ng case cover. Cl ean the gasket
materi al from the cover.
(10) Remove the thrust pi n and tensi on spri ng
from the prel oad bol t head.
(11) Rotate crankshaft unti l the crankshaft
sprocket ti mi ng mark i s cl osest to and on the center
l i ne wi th the camshaft sprocket ti mi ng mark (Fi g.
47).
(12) Remove the camshaft sprocket prel oad retai n-
i ng bol t and washer.
(13) Remove the crankshaft oi l sl i nger.
(14) Remove the sprockets and chai n as an assem-
bl y.
CAUTION: The following procedural step must be
accomplished to prevent the camshaft from damag-
ing the rear camshaft plug during pin installation.
(15) I nspect the damaged camshaft pi n.
(16) I f the pi n i s a spri ng-type pi n, remove the bro-
ken pi n by i nserti ng a sel f-tappi ng screw i nto the pi n
and careful l y pul l i ng the pi n from the camshaft.
(17) I f the pi n i s a dowel -type pi n, center-punch i t.
Ensure the exact center i s l ocated when center-
punchi ng the pi n.
CAUTION: Cover the opened oil pan area to pre-
vent metal chips from entering the pan.
(18) Dri l l i nto the pi n center wi th a 4 mm (5/32
i nch) dri l l bi t.
(19) I nsert a sel f-tappi ng screw i nto the dri l l ed pi n
and careful l y pul l the pi n from the camshaft.
CAMSHAFT BEARINGS
The camshaft rotates wi thi n four steel -shel l ed,
babbi tt-l i ned beari ngs that are pressed i nto the cyl -
i nder bl ock and then l i ne reamed. The camshaft
beari ng bores and beari ng di ameters are not the
same si ze. They are stepped down i n 0.254 mm
Fig. 47 Timing Chain AlignmentTypical
(0.010 i nch) i ncrements from the front beari ng (l arg-
est) to the rear beari ng (smal l est). Thi s permi ts eas-
i er removal and i nstal l ati on of the camshaft. The
camshaft beari ngs are pressure l ubri cated.
NOTE: It is not advisable to attempt to replace
camshaft bearings unless special removal and
installation tools are available.
Camshaft end pl ay i s mai ntai ned by the l oad
pl aced on the camshaft by the sprocket prel oad bol t
tensi on spri ng and thrust pi n.
INSTALLATION
(1) Cl ean the camshaft pi n hol e.
(2) Compress the center of the repl acement spri ng
pi n wi th vi se gri ps.
(3) Careful l y dri ve the pi n i nto the camshaft pi n
hol e unti l i t i s seated.
(4) I nstal l the camshaft sprocket, crankshaft
sprocket and ti mi ng chai n wi th the ti mi ng marks
al i gned (Fi g. 47).
(5) To veri fy correct i nstal l ati on of the ti mi ng
chai n, turn the crankshaft to posi ti on the camshaft
sprocket ti mi ng mark as shown i n (Fi g. 48). Count
the number of chai n pi ns between the ti mi ng marks
of both sprockets. There must be 15 pi ns.
(6) I nstal l the crankshaft oi l sl i nger.
(7) Ti ghten the camshaft sprocket prel oad bol t to
(8) Check the val ve ti mi ng.
(9) Lubri cate the tensi on spri ng, the thrust pi n
and the pi n bore i n the prel oad bol t wi th Mopar
Engi ne Oi l Suppl ement, or equi val ent. I nstal l the
spri ng and thrust pi n i n the prel oad bol t head.
(10) Coat both si des of the repl acement ti mi ng
case cover gasket wi th gasket seal er. Appl y a 3 mm
(1/8 i nch) bead of Mopar Si l i cone Rubber Adhesi ve
Seal ant, or equi val ent to the joi nt formed at the oi l
pan and cyl i nder bl ock.
(11) Posi ti on the ti mi ng case cover on the oi l pan
gasket and the cyl i nder bl ock.
(12) Pl ace Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng i n
the cover (Fi g. 49).
(13) I nstal l the ti mi ng case cover-to-cyl i nder bl ock
bol ts. I nstal l the oi l pan-to-ti mi ng case cover bol ts.
(14) Ti ghten the 1/4 i nch cover-to-bl ock bol ts to 7
Nm (60 i n. l bs.) torque. Ti ghten the 5/16 i nch front
cover-to-bl ock bol ts to 22 Nm (192 i n. l bs.) torque.
Ti ghten the oi l pan-to-cover 1/4 i nch bol ts to 14 Nm
(120 i n. l bs.) torque. Ti ghten the oi l pan-to-cover 5/16
i nch bol ts to 18 Nm (156 i n. l bs.) torque.
(15) Remove the cover al i gnment tool and i nstal l a
repl acement oi l seal i nto the cover.
(16) I nstal l the vi brati on damper on the crank-
shaft.
(17) Lubri cate and ti ghten the damper bol t to 108
(18) I f equi pped wi th ai r condi ti oni ng:
(a) I nstal l the A/C compressor serpenti ne dri ve
bel t i dl er pul l ey.
(b) I nstal l the generator.
(c) I nstal l the A/C condenser and recei ver/dri er
assembl y.
(19) I nstal l the serpenti ne dri ve bel t on the pul l eys
and ti ghten (refer to Group 7, Cool i ng System for the
speci fi cati ons and procedures).
Fig. 48 Verify CrankshaftCamshaft Installation
Typical
Fig. 49 Timing Case Cover Alignment and Seal
Installation Tool 6139
(20) I nstal l the radi ator. Connect the radi ator
hoses and automati c transmi ssi on fl ui d cool er pi pes,
i f equi pped. Fi l l the cool i ng system.
(21) I nstal l the fan and shroud.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(4) Remove the oi l pan and oi l pump.
(5) Remove mai n beari ng cap brace (Fi g. 50).
(6) Remove onl y one mai n beari ng cap and l ower
i nsert at a ti me (Fi g. 51).
(7) Remove the l ower i nsert from the beari ng cap.
(8) Remove the upper i nsert by LOOSENI NG (DO
NOT REMOVE) al l of the other beari ng caps. Now
i nsert a smal l cotter pi n tool i n the crankshaft jour-
nal oi l hol e. Bend the cotter pi n as i l l ustrated to fab-
ri cate the tool (Fi g. 52). Wi th the cotter pi n tool i n
pl ace, rotate the crankshaft so that the upper bear-
i ng i nsert wi l l rotate i n the di recti on of i ts l ocki ng
tab. Because there i s no hol e i n the No.3 mai n jour-
nal , use a tongue depressor or si mi l ar soft-faced tool
to remove the beari ng i nsert (Fi g. 52). After movi ng
the i nsert approxi matel y 25 mm (1 i nch), i t can be
removed by appl yi ng pressure under the tab.
(9) Usi ng the same procedure descri bed above,
remove the remai ni ng beari ng i nserts one at a ti me
for i nspecti on.
INSTALLATION
(1) Lubri cate the beari ng surface of each i nsert
wi th engi ne oi l .
(2) Loosen al l the mai n beari ng caps. I nstal l the
mai n beari ng upper i nserts.
(3) I nstal l the l ower beari ng i nserts i nto the mai n
beari ng caps.
(4) I nstal l the mai n beari ng cap(s) and l ower
i nsert(s).
(5) Ti ghten the bol ts of caps 1, 2, 4, 5, 6, and 7 to
54 Nm (40 ft. l bs.) torque. Now ti ghten these bol ts to
Fig. 50 Main Bearing Caps and Brace.
Fig. 51 Removing Main Bearing Caps and Lower
Inserts
Fig. 52 Removing Upper Inserts
95 Nm (70 ft. l bs.) torque. Fi nal l y, ti ghten these
(6) Push the crankshaft forward and backward.
Load the crankshaft front or rear and ti ghten cap
bol t No.3 to 54 Nm (40 ft. l bs.) torque. Then ti ghten
to 95 Nm (70 ft. l bs.) torque and fi nal l y ti ghten to
(7) Rotate the crankshaft after ti ghteni ng each
mai n beari ng cap to ensure the crankshaft rotates
freel y.
(8) Check crankshaft end pl ay. Crankshaft end
pl ay i s control l ed by the thrust beari ng whi ch i s
fl ange and i nstal l ed at the No.2 mai n beari ng posi -
ti on.
(a) Attach a magneti c base di al i ndi cator to the
cyl i nder bl ock at ei ther the front or rear of the
engi ne.
(b) Posi ti on the di al i ndi cator rod so that i t i s
paral l el to the center l i ne of the crankshaft.
(c) Pry the crankshaft forward, posi ti on the di al
i ndi cator to zero.
(d) Pry the crankshaft forward and backward.
Note the di al i ndi cator readi ngs. End pl ay i s the
di fference between the hi gh and l ow measurements
(Fi g. 53). Correct end pl ay i s 0.038-0.165 mm
(0.0015-0.0065 i nch). The desi red speci fi cati ons are
0.051-0.064 mm (0.002-0.0025 i nch).
(e) I f end pl ay i s not wi thi n speci fi cati on, i nspect
crankshaft thrust faces for wear. I f no wear i s
apparent, repl ace the thrust beari ng and measure
end pl ay. I f end pl ay i s sti l l not wi thi n speci fi ca-
ti on, repl ace the crankshaft.
(9) I f the crankshaft was removed, i nstal l the
crankshaft i nto the cyl i nder bl ock (refer to Cyl i nder
Bl ock - Assembl e).
(10) I nstal l mai n beari ng cap brace ti ghten nuts to
(11) I nstal l oi l pump assy. and ti ghten attachi ng
bol ts to 23 Nm (17 ft. l bs.)
(12) I nstal l the oi l pan.
(13) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
(15) I nstal l the spark pl ugs. Ti ghten the pl ugs to
(16) Fi l l the oi l pan wi th engi ne oi l to the ful l
mark on the di psti ck l evel .
OIL PAN
REMOVAL
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l .
(4) Di sconnect the exhaust pi pe at the exhaust
mani fol d.
(5) Di sconnect the exhaust hanger at the catal yti c
converter and l ower the pi pe.
(6) Remove the starter motor.
(7) Remove the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
(8) I f equi pped wi th an oi l l evel sensor, di sconnect
the sensor.
(9) Posi ti on a jack stand di rectl y under the engi ne
vi brati on damper.
(10) Pl ace a pi ece of wood (2 x 2) between the jack
stand and the engi ne vi brati on damper.
(11) Remove the engi ne mount through bol ts.
(12) Usi ng the jack stand, rai se the engi ne unti l
adequate cl earance i s obtai ned to remove the oi l pan.
(13) Remove the oi l pan bol ts. Careful l y sl i de the
oi l pan and gasket to the rear. I f equi pped wi th an oi l
l evel sensor, take care not to damage the sensor.
INSTALLATION
(1) Cl ean the bl ock and pan gasket surfaces.
(2) Fabri cate 4 al i gnment dowel s from 1 1/2 x 1/4
i nch bol ts. Cut the head off the bol ts and cut a sl ot
i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 54).
(3) I nstal l two dowel s i n the ti mi ng case cover.
I nstal l the other two dowel s i n the cyl i nder bl ock
(Fi g. 55).
(4) Sl i de the one-pi ece gasket over the dowel s and
onto the bl ock and ti mi ng case cover.
(5) Posi ti on the oi l pan over the dowel s and onto
the gasket. I f equi pped wi th an oi l l evel sensor, take
care not to damage the sensor.
(6) I nstal l the 1/4 i nch oi l pan bol ts. Ti ghten these
bol ts to 9.5 Nm (84 i n. l bs.) torque. I nstal l the 5/16
i nch oi l pan bol ts (Fi g. 56). Ti ghten these bol ts to 15
Nm (132 i n. l bs.) torque.
Fig. 53 Crankshaft End Play Measurement
(7) Remove the dowel s. I nstal l the remai ni ng 1/4
i nch oi l pan bol ts. Ti ghten these bol ts to 9.5 Nm (84
i n. l bs.) torque.
(8) Lower the engi ne unti l i t i s properl y l ocated on
the engi ne mounts.
(9) I nstal l the through bol ts and ti ghten the nuts.
(10) Lower the jack stand and remove the pi ece of
wood.
(11) I nstal l the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
(12) I nstal l the engi ne starter motor.
(13) Connect the exhaust pi pe to the hanger and to
the engi ne exhaust mani fol d.
(14) I nstal l the oi l pan drai n pl ug (Fi g. 56).
Ti ghten the pl ug to 34 Nm (25 ft. l bs.) torque.
(17) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
(18) Start the engi ne and i nspect for l eaks.
PISTONS AND CONNECTING RODS
REMOVAL
(2) Remove the rocker arms, bri dges and pi vots.
(4) Remove the engi ne cyl i nder head.
(5) Posi ti on the pi stons one at a ti me near the bot-
tom of the stroke. Use a ri dge reamer to remove the
ri dge from the top end of the cyl i nder wal l s. Use a
protecti ve cl oth to col l ect the cutti ngs.
(7) Drai n the engi ne oi l .
(8) Remove the oi l pan and gasket.
(9) Remove the connecti ng rod beari ng caps and
i nserts. Mark the caps and rods wi th the cyl i nder
bore l ocati on. The connecti ng rods and caps are
stamped wi th a two l etter combi nati on (Fi g. 57).
(10) Lower the vehi cl e unti l i t i s about 2 feet from
the fl oor.
Fig. 54 Fabrication of Alignment Dowels
Fig. 55 Position of Dowels in Cylinder Block
Fig. 56 Position of 5/16 inch Oil Pan Bolts
Fig. 57 Stamped Connecting Rods and Caps
CAUTION: Ensure that the connecting rod bolts
DO NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(11) Have an assi stant push the pi ston and con-
necti ng rod assembl i es up and through the top of the
cyl i nder bores (Fi g. 58).
INSTALLATION
(1) Cl ean the cyl i nder bores thoroughl y. Appl y a
l i ght fi l m of cl ean engi ne oi l to the bores wi th a cl ean
l i nt-free cl oth.
(2) I nstal l the pi ston ri ngs on the pi stons i f
removed.
(3) Lubri cate the pi ston and ri ngs wi th cl ean
engi ne oi l .
CAUTION: Ensure that connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose slipped over the
connecting rod bolts will provide protection during
installation.
(4) Use a pi ston ri ng compressor to i nstal l the con-
necti ng rod and pi ston assembl i es through the top of
the cyl i nder bores (Fi g. 59).
(5) Ensure the arrow on the pi ston top poi nts to
the front of the engi ne (Fi g. 59).
(7) Each beari ng i nsert i s fi tted to i ts respecti ve
journal to obtai n the speci fi ed cl earance between the
beari ng and the journal . I n producti on, the sel ect fi t
i s obtai ned by usi ng vari ous-si zed, col or-coded bear-
i ng i nserts as l i sted i n the Connecti ng Rod Beari ng
Fi tti ng Chart. The col or code appears on the edge of
the beari ng i nsert. The si ze i s not stamped on i nserts
used for producti on of engi nes.
(8) The rod journal i s i denti fi ed duri ng the engi ne
producti on by a col or-coded pai nt mark on the adja-
cent cheek or counterwei ght toward the fl ange (rear)
end of the crankshaft. The col or codes used to i ndi -
cate journal si zes are l i sted i n the Connecti ng Rod
Beari ng Fi tti ng Chart.
(9) When requi red, upper and l ower beari ng
i nserts of di fferent si zes may be used as a pai r (refer
to Connecti ng Rod Beari ng Fi tti ng Chart). A stan-
dard si ze i nsert i s someti mes used i n combi nati on
wi th a 0.025 mm (0.001 i nch) undersi ze i nsert to
reduce cl earance 0.013 mm (0.0005 i nch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
(10) I nstal l the connecti ng rod beari ng caps and
i nserts i n the same posi ti ons as removed.
CAUTION: Verify that the oil squirt holes in the
rods face the camshaft and that the arrows on the
pistons face the front of the engine.
(11) I nstal l the oi l pan and gaskets as outl i ned i n
the i nstal l ati on procedure.
(13) I nstal l the engi ne cyl i nder head, push rods,
rocker arms, bri dges, pi vots and engi ne cyl i nder head
cover.
(14) Fi l l the crankcase wi th engi ne oi l .
REAR MAIN OIL SEALS
The crankshaft rear mai n beari ng oi l seal consi sts
of two hal f pi eces of vi ton wi th a si ngl e l i p that effec-
Fig. 58 Removal of Connecting Rod and Piston
Assembly
Fig. 59 Rod and Piston Assembly Installation
ti vel y seal s the rear of the crankshaft. Repl ace the
upper and l ower seal hal ves as a uni t to ensure l eak-
free operati on.
REMOVAL
(1) Remove the transmi ssi on i nspecti on cover.
(2) Remove the oi l pan.
(3) Remove the mai n beari ng cap brace.
(4) Remove the rear mai n beari ng cap (No.7).
(5) Push the upper seal out of the groove. Ensure
that the crankshaft and seal groove are not damaged.
(6) Remove the l ower hal f of the seal from the
beari ng cap.
INSTALLATION
(1) Wi pe the seal surface area of the crankshaft
unti l i t i s cl ean.
(2) Appl y a thi n coat of engi ne oi l .
(3) Coat the l i p of the seal wi th engi ne oi l .
(4) Careful l y posi ti on the upper seal i nto the
groove i n the cyl i nder bl ock. The l i p of the seal faces
toward the front of the engi ne.
(5) Pl ace the l ower hal f of the seal i nto beari ng cap
No.7 (Fi g. 60).
(6) Coat the outer curved surface of the l ower seal
wi th soap and the l i p of the seal wi th engi ne oi l (Fi g.
60).
(7) Posi ti on the l ower seal i nto the beari ng cap
recess and seat i t fi rml y. Be sure the seal i s fl ush
wi th the cyl i nder bl ock pan rai l .
(8) Appl y Locti te 518, or equi val ent on the rear
beari ng cap (Fi g. 61). The bead shoul d be 3 mm
(0.125 i n) thi ck. DO NOT appl y Locti te 518, or equi v-
al ent to the l i p of the seal .
(9) I nstal l the rear mai n beari ng cap. DO NOT
stri ke the cap more than twi ce for proper engage-
ment.
(10) Ti ghten al l mai n beari ng bol ts to 108 Nm (80
ft. l bs.) torque.
(11) I nstal l the mai n beari ng cap brace. Ti ghten
nuts to 47 Nm (35 ft. l bs.).
(12) I nstal l the oi l pan gasket and oi l pan. Ti ghten
1/4 20 screws to 14 Nm (120 i n. l bs.). Ti ghten 5/16
18 screws to 18 Nm (156 i n. l bs.)
(13) I nstal l the engi ne fl ywheel or converter dri ve
pl ate. Ti ghten bol ts to 142 Nm (105 ft. l bs.)
OIL PUMP
A gear-type oi l pump i s mounted at the undersi de
of the cyl i nder bl ock opposi te the No.4 mai n beari ng.
The pump i ncorporates a nonadjustabl e pressure
rel i ef val ve to l i mi t maxi mum pressure to 517 kPa
(75 psi ). I n the rel i ef posi ti on, the val ve permi ts oi l to
bypass through a passage i n the pump body to the
i nl et si de of the pump.
Oi l pump removal or repl acement wi l l not affect
the di stri butor ti mi ng because the di stri butor dri ve
gear remai ns i n mesh wi th the camshaft gear.
REMOVAL
(1) Drai n the engi ne oi l .
(3) Remove the pump-to-cyl i nder bl ock attachi ng
bol ts. Remove the pump assembl y wi th gasket (Fi g.
62).
Fig. 60 Rear Main Bearing Oil Seal
Fig. 61 Location of Loctite 518 (or equivalent)
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.
INSTALLATION
(1) I nstal l the oi l pump on the cyl i nder bl ock usi ng
a repl acement gasket. Ti ghten the bol ts to 23 Nm
(3) Fi l l the oi l pan wi th oi l to the speci fi ed l evel .
TIMING CASE COVER OIL SEAL
Thi s procedure i s done wi th the ti mi ng case cover
i nstal l ed.
REMOVAL
(4) Remove the radi ator shroud.
(5) Careful l y remove the oi l seal . Make sure seal
bore i s cl ean.
INSTALLATION
(1) Posi ti on the repl acement oi l seal on Ti mi ng
Case Cover Al i gnment and Seal I nstal l ati on Tool
6139 wi th seal open end faci ng i nward. Appl y a l i ght
fi l m of Perfect Seal , or equi val ent, on the outsi de
di ameter of the seal . Li ghtl y coat the crankshaft wi th
engi ne oi l .
(2) Posi ti on the tool and seal over the end of the
crankshaft and i nsert a draw screw tool i nto Seal
I nstal l ati on Tool 6139 (Fi g. 63). Ti ghten the nut
agai nst the tool unti l i t contacts the cover.
(3) Remove the tool s. Appl y a l i ght fi l m of engi ne
oi l on the vi brati on damper hub contact surface of
the seal .
Wi th the key i nserted i n the keyway i n the crank-
shaft, i nstal l the vi brati on damper, washer and bol t.
torque.
(5) I nstal l the serpenti ne bel t and ti ghten to the
speci fi ed tensi on (refer to Group 7, Cool i ng Systems
for the proper speci fi cati ons and procedures).
(6) I nstal l the radi ator shroud.
VALVE SERVICE
Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and head.
Cl ean al l gri me and gasket materi al from the
engi ne cyl i nder head machi ned gasket surface.
I nspect for cracks i n the combusti on chambers and
val ve ports.
I nspect for cracks on the exhaust seat.
I nspect for cracks i n the gasket surface at each
cool ant passage.
I nspect val ves for burned, cracked or warped
heads.
I nspect for scuffed or bent val ve stems.
Repl ace val ves di spl ayi ng any damage.
Fig. 62 Oil Pump Assembly
Fig. 63 Timing Case Cover Oil Seal Installation
VALVE REFACING
(1) Use a val ve refaci ng machi ne to reface the
i ntake and exhaust val ves to the speci fi ed angl e.
(2) After refaci ng, a margi n of at l east 0.787 mm
(0.031 i nch) must remai n (Fi g. 64). I f the margi n i s
l ess than 0.787 mm (0.031 i nch), the val ve must be
repl aced.
VALVE SEAT REFACING
(1) I nstal l a pi l ot of the correct si ze i n the val ve
gui de bore. Reface the val ve seat to the speci fi ed
angl e wi th a good dressi ng stone. Remove onl y
enough metal to provi de a smooth fi ni sh.
(2) Use tapered stones to obtai n the speci fi ed seat
wi dth when requi red.
(3) Control val ve seat runout to a maxi mum of
0.0635 mm (0.0025 i n.) (Fi g. 65).
VALVE STEM OIL SEAL REPLACEMENT
Val ve stem oi l seal s are i nstal l ed on each val ve
stem to prevent rocker arm l ubri cati ng oi l from
enteri ng the combusti on chamber through the val ve
gui de bores. One seal i s marked I NT (i ntake val ve)
and the other i s marked EXH (exhaust val ve).
Repl ace the oi l seal s whenever val ve servi ce i s per-
formed or i f the seal s have deteri orated.
VALVE GUIDES
The val ve gui des are an i ntegral part of the engi ne
cyl i nder head and are not repl aceabl e.
When the val ve stem gui de cl earance i s excessi ve,
the val ve gui de bores must be reamed oversi ze. Ser-
vi ce val ves wi th oversi ze stems are avai l abl e i n 0.076
mm (0.003 i nch) and 0.381 mm (0.015 i nch) i ncre-
ments.
Correspondi ng oversi ze val ve stem seal s are al so
avai l abl e and must be used wi th val ves havi ng 0.381
mm (0.015 i nch) oversi ze stems.
NOTE: If the valve guides are reamed oversize, the
valve seats must be ground to ensure that the valve
seat is concentric to the valve guide.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
Val ve stem-to-gui de cl earance may be measured by
ei ther of the fol l owi ng two methods.
PREFERRED METHOD
(1) Remove the val ve from the head.
(2) Cl ean the val ve stem gui de bore wi th sol vent
and a bri stl e brush.
(3) I nsert a tel escopi ng gauge i nto the val ve stem
gui de bore approxi matel y 9.525 mm (.375 i nch) from
the val ve spri ng si de of the head (Fi g. 66).
Fig. 64 Valve Facing Margin
Fig. 65 Measurement of Valve Seat Runout
Fig. 66 Measurement of Valve Guide Bore Diameter
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Remove and measure tel escopi ng gauge wi th a
mi crometer.
(5) Repeat the measurement wi th contacts l ength-
wi se to engi ne cyl i nder head.
(6) Compare the crosswi se to l engthwi se measure-
ments to determi ne out-of-roundness. I f the measure-
ments di ffer by more than 0.0635 mm (0.0025 i n.),
ream the gui de bore to accommodate an oversi ze
val ve stem.
(7) Compare the measured val ve gui de bore di am-
eter wi th speci fi cati ons (7.95-7.97 mm or 0.313-0.314
i nch). I f the measurement di ffers from speci fi cati on
by more than 0.076 mm (0.003 i nch), ream the gui de
bore to accommodate an oversi ze val ve stem.
ALTERNATIVE METHOD
(1) Use a di al i ndi cator to measure the l ateral
movement of the val ve stem (stem-to-gui de cl ear-
ance). Thi s must be done wi th the val ve i nstal l ed i n
i ts gui de and just off the val ve seat (Fi g. 67).
(2) Correct cl earance i s 0.025-0.0762 mm
(0.001-0.003 i nch). I f i ndi cated movement exceeds the
speci fi cati on ream the val ve gui de to accommodate
an oversi ze val ve stem.
NOTE: Valve seats must be ground after reaming
the valve guides to ensure that the valve seat is
concentric to the valve guide.
VALVE SPRING TENSION TEST
Use a uni versal Val ve Spri ng Tester and a torque
wrench to test each val ve spri ng for the speci fi ed ten-
si on val ue (Fi g. 68).
Repl ace val ve spri ngs that are not wi thi n speci fi ca-
ti ons.
CYLINDER BLOCK
DISASSEMBLY
Refer to the appl i cabl e secti ons for detai l ed
i nstructi ons.
(1) Drai n the engi ne oi l . Remove and di scard the
oi l fi l ter.
(2) Remove the water pump from the cyl i nder
bl ock.
(4) Remove the ti mi ng case cover and l ay the cover
upsi de down.
(5) Posi ti on a dri ft punch i nto the sl ot i n the back
of the cover and tap the ol d seal out.
(6) Remove the oi l sl i nger from crankshaft.
(7) Remove the camshaft retai ni ng bol t and
remove the sprockets and chai n as an assembl y.
(8) Remove the camshaft.
(9) Remove the oi l pan and gasket.
(10) Remove the front and rear oi l gal l ey pl ugs.
(11) Remove the oi l pump.
(12) Remove the connecti ng rods and the pi stons.
Remove the connecti ng rod and pi ston assembl i es
through the top of the cyl i nder bores.
(13) Remove the crankshaft.
ASSEMBLY
Refer to the appl i cabl e secti ons for detai l ed
i nstructi ons.
(1) I nstal l the crankshaft.
(2) I nstal l the connecti ng rods and the pi stons
through the top of the cyl i nder bores.
(3) I nstal l the oi l pump.
(4) I nstal l the oi l pan and gasket.
(5) I nstal l the camshaft.
(6) I nstal l the sprockets and chai n as an assembl y.
(7) I nstal l the oi l sl i nger from the crankshaft.
(8) I nstal l the ti mi ng case cover seal .
(9) I nstal l the ti mi ng case cover.
Fig. 67 Measurement of Lateral Movement of Valve
Stem
Fig. 68 Valve Spring Tester
(10) I nstal l the vi brati on damper.
(11) I nstal l the water pump. Ti ghten the mounti ng
(12) Lubri cate the oi l fi l ter seal wi th cl ean engi ne
oi l . Ti ghten oi l fi l ter to 18 Nm (156 i n. l bs.) torque.
(13) I nstal l the engi ne i nto the vehi cl e.
(14) Fi l l the engi ne wi th cl ean l ubri cati on oi l (refer
to Group 0, Lubri cati on and Mai ntenance).
(15) Fi l l the cool i ng system.
CYLINDER HEAD
CLEANING
Thoroughl y cl ean the engi ne cyl i nder head and cyl -
i nder bl ock mati ng surfaces. Cl ean the i ntake and
engi ne exhaust mani fol d and engi ne cyl i nder head
mati ng surfaces. Remove al l gasket materi al and car-
bon.
Check to ensure that no cool ant or forei gn materi al
has fal l en i nto the tappet bore area.
Remove the carbon deposi ts from the combusti on
chambers and top of the pi stons.
INSPECTION
Use a strai ghtedge and feel er gauge to check the
fl atness of the engi ne cyl i nder head and bl ock mati ng
surfaces.
CYLINDER HEAD COVER
CLEANING
Remove any ori gi nal seal er from the cover seal i ng
surface of the engi ne cyl i nder head and cl ean the
surface usi ng a fabri c cl eaner.
Remove al l resi due from the seal i ng surface usi ng
a cl ean, dry cl oth.
INSPECTION
I nspect the engi ne cyl i nder head cover for cracks.
Repl ace the cover, i f cracked.
The ori gi nal dark grey gasket materi al shoul d
NOT be removed. I f secti ons of the gasket materi al
are mi ssi ng or are compressed, repl ace the engi ne
cyl i nder head cover. However, secti ons wi th mi nor
damage such as smal l cracks, cuts or chi ps may be
repai red wi th a hand hel d appl i cator. The new mate-
ri al must be smoothed over to mai ntai n gasket
hei ght. Al l ow the gasket materi al to cure pri or to
engi ne cyl i nder head cover i nstal l ati on.
CLEANING
Cl ean al l the components wi th cl eani ng sol vent.
Use compressed ai r to bl ow out the oi l passages i n
the rocker arms and push rods.
INSPECTION
I nspect the pi vot surface area of each rocker arm.
Repl ace any that are scuffed, pi tted, cracked or
excessi vel y worn.
I nspect the val ve stem ti p contact surface of each
rocker arm and repl ace any rocker arm that i s deepl y
pi tted.
I nspect each push rod end for excessi ve wear and
repl ace as requi red. I f any push rod i s excessi vel y
worn because of l ack of oi l , repl ace i t and i nspect the
correspondi ng hydraul i c tappet for excessi ve wear.
I nspect the push rods for strai ghtness by rol l i ng
them on a fl at surface or by shi ni ng a l i ght between
the push rod and the fl at surface.
A wear pattern al ong the l ength of the push rod i s
not normal . I nspect the engi ne cyl i nder head for
obstructi on i f thi s condi ti on exi sts.
HYDRAULIC TAPPETS
CLEANING
Cl ean each tappet assembl y i n cl eani ng sol vent to
remove al l varni sh, gum and sl udge deposi ts.
INSPECTION
I nspect for i ndi cati ons of scuffi ng on the si de and
base of each tappet body.
I nspect each tappet base for concave wear wi th a
strai ghtedge posi ti oned across the base. I f the base i s
concave, the correspondi ng l obe on the camshaft i s
al so worn. Repl ace the camshaft and defecti ve tap-
pets.
LEAK-DOWN TEST
After cl eani ng and i nspecti on, test each tappet for
speci fi ed l eak-down rate tol erance to ensure zero-l ash
operati on (Fi g. 69).
Swi ng the wei ghted arm of the hydraul i c val ve tap-
pet tester away from the ram of the Leak-Down
Tester.
(1) Pl ace a 7.925-7.950 mm (0.312-0.313 i nch)
di ameter bal l beari ng on the pl unger cap of the tap-
pet.
(2) Li ft the ram and posi ti on the tappet (wi th the
bal l beari ng) i nsi de the tester cup.
(3) Lower the ram, then adjust the nose of the ram
unti l i t contacts the bal l beari ng. DO NOT ti ghten
the hex nut on the ram.
(4) Fi l l the tester cup wi th hydraul i c val ve tappet
test oi l unti l the tappet i s compl etel y submerged.
(5) Swi ng the wei ghted arm onto the push rod and
pump the tappet pl unger up and down to remove ai r.
When the ai r bubbl es cease, swi ng the wei ghted arm
away and al l ow the pl unger to ri se to the normal
posi ti on.
(6) Adjust the nose of the ram to al i gn the poi nter
wi th the SET mark on the scal e of the tester and
ti ghten the hex nut.
(7) Sl owl y swi ng the wei ghted arm onto the push
rod.
(8) Rotate the cup by turni ng the handl e at the
base of the tester cl ockwi se one revol uti on every 2
seconds.
(9) Observe the l eak-down ti me i nterval from the
i nstant the poi nter al i gns wi th the START mark on
the scal e unti l the poi nter al i gns wi th the 0.125
mark. A normal l y functi oni ng tappet wi l l requi re
20-110 seconds to l eak-down. Di scard tappets wi th
l eak-down ti me i nterval not wi thi n thi s speci fi cati on.
CYLINDER BLOCK
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
The gal l ey at the oi l fi l ter adaptor hol e.
The front and rear oi l gal l ey hol es.
The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Locti te PST pi pe seal ant wi th Tefl on 592 to the
threads of the front and rear oi l gal l ey pl ugs. Ti ghten
the pl ugs to 34 Nm (25 ft. l bs.) torque.
INSPECTIONCYLINDER BORE
(1) I t i s mandatory to use a di al bore gauge to
measure each cyl i nder bore di ameter (Fi g. 70). To
correctl y sel ect the proper si ze pi ston, a cyl i nder bore
gauge, capabl e of readi ng i n 0.003 mm (.0001 i n.)
I NCREMENTS i s requi red. I f a bore gauge i s not
avai l abl e, do not use an i nsi de mi crometer.
(2) Measure the i nsi de di ameter of the cyl i nder
bore at three l evel s bel ow top of bore. Start perpen-
di cul ar (across or at 90 degrees) to the axi s of the
crankshaft and then take two addi ti onal readi ng.
(3) Measure the cyl i nder bore di ameter crosswi se
to the cyl i nder bl ock near the top of the bore. Repeat
the measurement near the mi ddl e of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determi ne taper by subtracti ng the smal l er
di ameter from the l arger di ameter.
(5) Rotate measuri ng devi ce 90 and repeat steps
above.
(6) Determi ne out-of-roundness by compari ng the
di fference between each measurement.
(7) I f cyl i nder bore taper does not exceed 0.025
mm (0.001 i nch) and out-of-roundness does not
exceed 0.025 mm (0.001 i nch), the cyl i nder bore can
be honed. I f the cyl i nder bore taper or out- of-round
condi ti on exceeds these maxi mum l i mi ts, the cyl i nder
must be bored and then honed to accept an oversi ze
pi ston. A sl i ght amount of taper al ways exi sts i n the
cyl i nder bore after the engi ne has been i n use for a
peri od of ti me.
HONINGCYLINDER BORE
The honi ng operati on shoul d be cl osel y coordi nated
wi th the fi tti ng of pi stons and ri ngs. Thi s wi l l ensure
speci fi ed cl earances are mai ntai ned.
Refer to Standard Servi ce Procedures i n the begi n-
ni ng of thi s Group for the proper honi ng of cyl i nder
bores.
Fig. 69 Leak-Down Tester
Fig. 70 Cylinder Bore Measurement
CLEANING AND INSPECTION (Continued)
SPECIFICATIONS
4. 0L ENGINE SPECIFICATIONS
4.0L Engine Description
Engi ne Type . . . . . . . . . . . . . . . . . .I n-l i ne 6 Cyl i nder
Bore and Stroke . .98.4 x 86.69 mm (3.88 x 3.413 i n.)
Di spl acement . . . . . . . . . . . . . . . . . .4.0L (242 cu. i n.)
Compressi on Rati o . . . . . . . . . . . . . . . . . . . . . . .8.8:1
Fi ri ng Order . . . . . . . . . . . . . . . . . . . . .153624
Lubri cati on . . . . .Pressure FeedFul l Fl ow Fi l trati on
Cool i ng System . . .Li qui d Cool edForced Ci rcul ati on
Cyl i nder Bl ock . . . . . . . . . . . . . . . . . . . . . . .Cast I ron
Crankshaft . . . . . . . . . . . . . . . . . .Cast Nodul ar I ron
Cyl i nder Head . . . . . . . . . . . . . . . . . . . . . . .Cast I ron
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . .Cast I ron
Pi stons . . . . . . . . . . . . . . .Al umi num Al l oy (w/struts)
Combusti on Chamber . . . . . . . . . . . . . .Dual -Quench
Connecti ng Rods . . . . . . . . . . . . .Cast Mal l eabl e I ron
4.0L Engine Specifications
Camshaft
Hydraul i c Tappet Cl earance . . . . . . . . . .Zero Lash
Beari ng Cl earance . . . . . . . . . . .0.025 to 0.076 mm
(0.001 to 0.003 i n.)
Bearing J ournal Diameter
No. 1 . . . . . .51.54 to 51.56 mm (2.029 to 2.030 i n.)
No. 2 . . . . . .51.28 to 51.31 mm (2.019 to 2.020 i n.)
No. 3 . . . . . .51.03 to 51.05 mm (2.009 to 2.010 i n.)
No. 4 . . . . . .50.78 to 50.80 mm (1.999 to 2.000 i n.)
Base Ci rcl e Runout. . . . . . . . . . . . .0.03 mm - max.
(0.001 i n. - max.)
Val ve Li ft . . . . . . . . . . . . . . . .10.29 mm (0.405 i n.)
Intake Valve Timing
Opens . . . . . . . . . . . . . . . . . . . . . . . . . .12.4 BTDC
Cl oses . . . . . . . . . . . . . . . . . . . . . . . . . .60.9 ABDC
Exhaust Valve Timing
Opens . . . . . . . . . . . . . . . . . . . . . . . . . .49.8 BBDC
Cl oses . . . . . . . . . . . . . . . . . . . . . . . . . .29.2 ATDC
Val ve Overl ap . . . . . . . . . . . . . . . . . . . . . . . . .41.6
I ntake Durati on . . . . . . . . . . . . . . . . . . . . . .253.3
Exhaust Durati on . . . . . . . . . . . . . . . . . . . . . .259.
Crankshaft
End Pl ay . . . . . . . . . . . . . . . . . .0.038 to 0.165 mm
(0.0015 to 0.0065 i n.)
Mai n Beari ng Journal
Di ameter No. 1-6 . . . . . . . . . .63.489 to 63.502 mm
(2.4996 to 2.5001 i n.)
Di ameter No. 7 . . . . . . . . . . .63.449 to 63.487 mm
(2.4980 to 2.4995 i n.)
Wi dth No. 1. . . . . . . . . . . . . . . .27.58 to 27.89 mm
(1.086 to 1.098 i n.)
Wi dth No. 3. . . . . . . . . . . . . . . .32.28 to 32.33 mm
(1.271 to 1.273 i n.)
Wi dth No. 2-4-5-6-7 . . . . . . . . . .30.02 to 30.18 mm
(1.182 to 1.188 i n.)
Mai n Beari ng Cl earance . . . . . . . .0.03 to 0.06 mm
(0.001 to 0.0025 i n.)
Mai n Beari ng Cl earance (Preferred) . . . .0.051 mm
(0.002 i n.)
Connecti ng Rod Journal
Di ameter . . . . . . . . . . . . . . . . . .53.17 to 53.23 mm
(2.0934 to 2.0955 i n.)
Connecti ng Rod Journal Wi dth . . .27.18 to 27.33 mm
(1.070 to 1.076 i n.)
Out-of-Round (Max. Al l Journal s) . . . . . .0.013 mm
(0.0005 i n.)
Taper (Max. Al l Journal s). . . . . . . . . . .0.013 mm
(0.0005 i n.)
Cylinder Block
Deck Hei ght . . . . . . . . . . . . . .240.03 to 240.18 mm
(9.450 to 9.456 i n.)
Deck Cl earance (Bel ow Bl ock). . . . . . . . .0.546 mm
(0.0215 i n.)
Cyl i nder Bore Di ameter
Standard . . . . . . . . . . . . . . . .98.45 to 98.48 mm
(3.8759 to 3.8775 i n.)
Cyl i nder Bore Di ameter
Taper (Max.). . . . . . . . . . . .0.025 mm (0.001 i n.)
Cyl i nder Bore Di ameter Out-of-Round .0.025 mm
(0.001 i n.)
Tappet Bore Di ameter . . . . . .23.000 to 23.025 mm
(0.9055 to 0.9065 i n.)
Fl atness . . . . . . . . . . . . . . . . .0.03 mm per 25 mm
(0.001 i n. per 1 i n.)
Fl atness. . . . . . . . . . . . . . . . .0.05 mm per 152 mm
(0.002 i n. per 6 i n.)
Fl atness Max. . . . . .0.20 mm max. for total l ength
(0.008 i n. max. for total l ength)
Mai n Beari ng Bore
Di ameter . . . . . . . . . . . . . .68.3514 to 68.3768 mm
(2.691 to 2.692 i n.)
Connecting Rods
Total Wei ght (Less Beari ng). . . . .657 to 665 grams
(23.17 to 23.45 oz.)
Length (Center-to-Center) . . .155.52 to 155.62 mm
(6.123 to 6.127 i n.)
Pi ston Pi n Bore Di ameter . . . . .23.59 to 23.62 mm
(0.9288 to 0.9298 i n.)
Bore (Less Beari ngs) . . . . . . . . .56.08 to 56.09 mm
(2.2080 to 2.2085 i n.)
Beari ng Cl earance . . . . . . . . . . .0.025 to 0.076 mm
(0.001 to 0.003 i n.)
Beari ng Cl earance (Preferred) . .0.044 to 0.050 mm
(0.0015 to 0.0020 i n.)
Si de Cl earance. . . . . . . . . . . . . . . .0.25 to 0.48 mm
(0.010 to 0.019 i n.)
Twi st (Max.). . . . . . . . . . . . . . . .0.001 mm per mm
(0.001 i n. per i nch)
Bend (Max.) . . . . . . . . . . . . . . . .0.001 mm per mm
(0.001 i n. per i nch.)
Cylinder Compression Pressure
Rati o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7:1
Pressure Range. . . . . . . . . . . . . . .827 to 1,034 kPa
(120 to 150 psi )
Max. Vari ati on Between Cyl i nders . . . . . . .206 kPa
(30 psi )
Cylinder Head
Combusti on Chamber . . . . . . . . . .52.22 to 58.22 cc
(3.37 to 3.55 cu. i n.)
Val ve Gui de I .D. (I ntegral ) . . . . . .7.95 to 7.97 mm
(0.313 to 0.314 i n.)
Val ve Stem-to-Gui de Cl earance .0.025 to 0.076 mm
(0.001 to 0.003 i n.)
I ntake Val ve Seat Angl e . . . . . . . . . . . . . . . . .44.5
Exhaust Val ve Seat Angl e . . . . . . . . . . . . . . . .44.5
Val ve Seat Wi dth . . . . . . . . . . . . . .1.02 to 1.52 mm
(0.040 to 0.060 i n.)
Val ve Seat Runout . . . . . . . .0.064 mm (0.0025 i n.)
Fl atness . . . . . . . . . . . . . . . . .0.03 mm per 25 mm
(0.001 i n. per 1 i n.)
Fl atness. . . . . . . . . . . . . . . . .0.05 mm per 152 mm
(0.002 i n. per 6 i n.)
Fl atness Max. . . . .0.20 mm - max. for total l ength
(0.008 i n. max. for total l ength)
Rocker Arms, Push Rods & Tappets
Rocker Arm Rati o . . . . . . . . . . . . . . . . . . . . . .1.6:1
Push Rod Length . . . . . . . .244.856 to 245.364 mm
(9.640 to 9.660 i n.)
Push Rod Di ameter . . . . . . . . . . . .7.92 to 8.00 mm
(0.312 to 0.315 i n.)
Hydraul i c Tappet Di ameter . .22.962 to 22.974 mm
(0.904 to 0.9045 i n.)
Tappet-to-Bore Cl earance. . . . . .0.025 to 0.063 mm
(0.001 to 0.0025 i n.)
Valves
Length (Ti p-to-Gauge Di mensi on Li ne)
I ntake. . . . . . . . . . . . . . .122.479 to 122.860 mm
(4.822 to 4.837 i n.)
Length (Ti p-to-Gauge Di mensi on Li ne)
Exhaust . . . . . . . . . . . . .122.860 to 123.241 mm
(4.837 to 4.852 i n.)
Val ve Stem Di ameter . . . . . . . . .7.899 to 7.925 mm
(0.311 to 0.312 i n.)
Stem-to-Gui de Cl earance . . . . . .0.025 to 0.076 mm
(0.001 to 0.003 i n.)
Val ve Head Di ameter
I ntake . . . . . . . . . . . . . . . .48.387 to 48.641 mm
(1.905 to 1.915 i n.)
Val ve Head Di ameter
Exhaust.37.973 to 38.227 mm (1.495 to 1.505 i n.)
Val ve Face Angl eI ntake . . . . . . . . . . . . . . . . .45
Val ve Face Angl eExhaust . . . . . . . . . . . . . . . .45
Ti p Refi ni shi ng (Max. Al l owabl e). . . . . . . .0.25 mm
(0.010 i n.)
Valve Springs
Free Length (Approx.) . . . . . .47.65 mm (1.876 i n.)
Spri ng Tensi onVal ve
Cl osed . . . . . . . . . . . .271 to 307 N @ 41.656 mm
(61 to 69 l bf. @ 1.64 i n.)
Spri ng Tensi onVal ve Open . . .818.5 to 871.9 N @
30.89 mm
(184 to 196 l bf @ 1.216 i n.)
I nsi de Di ameter . . . . . . . . . .21.0 mm to 21.51 mm
(0.827 to 0.847 i n.)
Pistons
Wei ght (Less Pi n). . . . . . . . . . . . .563 to 567 grams
(19.86 to 20.00 oz.)
Pi ston Pi n Bore
(Centerl i ne to Pi ston Top) . . . . .40.61 to 40.72 mm
(1.599 to 1.603 i n.)
Pi ston-to-Bore Cl earance . . . . . .0.033 to 0.053 mm
(0.0013 to 0.0021 i n.)
Pi ston-to-Bore Cl earance
(Preferred). . . . . . . . . . . . . . . . .0.033 to 0.038 mm
(0.0013 to 0.0015 i n.)
Ri ng Gap Cl earance
Top Compressi on Ri ng . . . . . . . .0.229 to 0.610mm
(0.0090 to 0.0240 i n.)
2nd Compressi on Ri ng . . . . . . .0.483 to 0.965 mm
(0.0190 to 0.0380 i n.)
Oi l Control Steel Rai l s . . . . . . .0.254 to 1.500 mm
(0.010 to 0.060 i n.)
Ri ng Si de Cl earance
Compressi on Ri ngs . . . . . . . . . .0.042 to 0.084 mm
(0.0017 to 0.0033 i n.)
Ri ng Si de Cl earance
Oi l Control Ri ngs . . . . . . . . . . . . .0.06 to 0.21 mm
(0.0024 to 0.0083 i n.)
Pi ston Ri ng Groove Hei ght
Compressi on Ri ngs . . . . . . . . . . 1.530 to 1.555 mm
(0.0602 to 0.0612 i n.)
Pi ston Ri ng Groove Hei ght
Oi l Control Ri ng . . . . . . . . . . . .4.035 to 4.060 mm
(0.1589 to 0.1598 i n.)
Pi ston Ri ng Groove Di ameter
Compressi on Ri ngs. . . . . . . . . . . 88.3 to 88.55 mm
(3.476 to 3.486 i n.)
Pi ston Ri ng Groove Di ameter
Oi l Control Ri ng. . . . . . . . . . . . 90.35 to 90.60 mm
(3.557 to 3.566 i n.)
Pi ston Pi n Bore Di ameter . . .23.647 to 23.655 mm
(0.9310 to 0.9313 i n.)
SPECIFICATIONS (Continued)
Pi ston Pi n Di ameter . . . . . . . .23.637 to 23.640 mm
(0.9306 to 0.9307 i n.)
Pi ston-to-Pi n Cl earance . . .0.0076 to 0.0178 mm
Loose (0.0003 to 0.0007 i n. Loose)
Pi ston-to-Pi n Cl earance (Preferred). . . . .0.013 mm
(0.0005 i n.)
Pi ston-to-Pi n Connecti ng Rod (Press Fi t) . . .8.9 kN
(2000 l bf.)
Oil Pump
Gear-to-Body Cl earance
(Radi al ). . . . . . . . . . . . . . . . .0.051 to 0.102 mm
(0.002 to 0.004 i n.)
Gear-to-Body Cl earance
(Radi al ) (Preferred) . . . . . . . .0.051 mm (0.002 i n.)
Gear End Cl earance
Pl asti gage . .0.051 to 0.152 mm (0.002 to 0.006 i n.)
Gear End Cl earance
Pl asti gage (Preferred) . . . . . .0.051 mm (0.002 i n.)
Gear End Cl earance
Feel er Gauge . . . . . . . . . . . . .0.1016 to 0.2032 mm
(0.004 to 0.008 i n.)
Gear End Cl earance
Feel er Gauge (Preferred). . . 0.1778 mm (0.007 i n.)
Oil Pressure
At I dl e Speed (600 rpm) . . . . . . . .89.6 kPa (13 psi )
At 1600 rpm & Hi gher . . . . . . . . . .255 to 517 kPa
(37 to 75 psi )
Oi l Pressure Rel i ef . . . . . . . . . . . .517 kPa (75 psi )
SPECIAL TOOLS
4. 0L ENGINE
Valve Spring Compressor Tool MD-998772A
Timing Case Cover Alignment and Seal installation
Tool 6139
Vibration Damper Removal Tool 7697
Rear Main Seal Installer Tool 6271A
Hydraulic Valve Tappet Removal/Installation Tool
C-4129A
5.2L ENGINE
INDEX
page page
GENERAL INFORMATION
PISTON AND CONNECTING ROD ASSEMBLY . . 55
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . 58
SERVICE PROCEDURES
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 60
FITTING PISTON RINGS . . . . . . . . . . . . . . . . . . 59
FITTING PISTONS . . . . . . . . . . . . . . . . . . . . . . . 59
MEASURING TIMING CHAIN STRETCH . . . . . . . 58
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . 69
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
CRANKSHAFT OIL SEAL FRONT . . . . . . . . . . 74
CRANKSHAFT OIL SEALS REAR . . . . . . . . . . 74
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 73
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 64
DISTRIBUTOR DRIVE SHAFT BUSHING . . . . . . 70
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 62
ENGINE CORE OIL AND CAMSHAFT PLUGS . . 76
ENGINE MOUNTREAR . . . . . . . . . . . . . . . . . . 62
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . . 66
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 68
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE . . . . . . . . . . . . . 64
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 79
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 77
CRANKSHAFT JOURNALS . . . . . . . . . . . . . . . . . 80
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 82
CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . 79
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
SPECIFICATIONS
5.2L ENGINE SPECIFICATIONS . . . . . . . . . . . . . 83
5.2L TORQUE SPECIFICATIONS . . . . . . . . . . . . 85
SPECIAL TOOLS
5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
GENERAL INFORMATION
The val ves are arranged i n-l i ne and i ncl i ned 18.
The rocker pi vot support and the val ve gui des are
cast i ntegral wi th the heads.
OIL PUMP PRESSURE
psi ) at curb i dl e. The MAXI MUM oi l pump pressure
i s 207-552 kPa (30-80 psi ) at 3,000 RPM or more.
CAUTION: If oil pressure is ZERO at curb idle, DO
NOT run engine.
PISTON AND CONNECTING ROD ASSEMBLY
The pi stons are el l i pti cal l y turned so that the
di ameter at the pi n boss i s l ess than i ts di ameter
across the thrust face. Thi s al l ows for expansi on
under normal operati ng condi ti ons. Under operati ng
temperatures, expansi on forces the pi n bosses away
from each other, causi ng the pi ston to assume a more
nearl y round shape.
Al l pi stons are machi ned to the same wei ght,
regardl ess of si ze, to mai ntai n pi ston bal ance.
The pi ston pi n rotates i n the pi ston onl y and i s
retai ned by the press i nterference fi t of the pi ston
pi n i n the connecti ng rod.
ENGINE DESCRIPTION
The 5.2 Li ter (318 CI D) ei ght-cyl i nder engi ne i s a
V-Type l i ghtwei ght, si ngl e cam, overhead val ve
engi ne wi th hydraul i c rol l er tappets.
Thi s engi ne i s desi gned for unl eaded fuel .
Engi ne l ubri cati on system consi sts of a rotor type
oi l pump and a ful l fl ow oi l fi l ter.
The cyl i nders are numbered from front to rear; 1,
3, 5, 7 on the l eft bank and 2, 4, 6, 8 on the ri ght
bank. The fi ri ng order i s 1-8-4-3-6-5-7- 2 (Fi g. 1).
The engi ne seri al number i s stamped i nto a
machi ned pad l ocated on the l eft, front corner of the
cyl i nder bl ock. When component part repl acement i s
necessary, use the engi ne type and seri al number for
reference (Fi g. 2).
LUBRICATION SYSTEM
mounted at the undersi de of the rear mai n beari ng
cap. The pump draws oi l through the screen and
i nl et tube from the sump at the rear of the oi l pan.
The oi l i s dri ven between the dri ve and i dl er gears
and pump body, then forced through the outl et to the
bl ock. An oi l gal l ery i n the bl ock channel s the oi l to
the i nl et si de of the ful l fl ow oi l fi l ter. After passi ng
through the fi l ter el ement, the oi l passes from the
center outl et of the fi l ter through an oi l gal l ery that
channel s the oi l up to the mai n gal l ery whi ch
extends the enti re l ength on the ri ght si de of the
bl ock. The oi l then goes down to the No. 1 mai n bear-
i ng, back up to the l eft si de of the bl ock and i nto the
oi l gal l ery on the l eft si de of the engi ne.
mai n beari ng journal s to the connecti ng rod journal s.
Each connecti ng rod beari ng has hal f a hol e i n i t, oi l
passes through the hol e when the rods rotate and the
hol e l i nes up, oi l i s then thrown off as the rod
rotates. Thi s oi l throw off l ubri cates the camshaft
l obes, di stri butor dri ve gear, cyl i nder wal l s, and pi s-
ton pi ns.
from the mai n oi l gal l ery. The camshaft beari ngs
recei ve oi l from the mai n beari ng gal l eri es. The front
camshaft beari ng journal passes oi l through the cam-
shaft sprocket to the ti mi ng chai n. Oi l drai ns back to
the oi l pan under the number one mai n beari ng cap.
rocker arm l ubri cates the val ve trai n components.
The oi l then passes down through the push rod gui de
hol es, and the oi l drai n back passages i n the cyl i nder
head past the val ve tappet area, and returns to the
oi l pan.
Fig. 1 Firing Order
Fig. 2 Engine Identification Number
F
i
g
.
3
O
i
l
L
u
b
r
i
c
a
t
i
o
n
S
y
s
t
e
m
ENGINE COMPONENTS
CYLINDER HEAD
The al l oy cast i ron cyl i nder heads (Fi g. 4) are hel d
i n pl ace by 10 bol ts. The spark pl ugs are l ocated i n
the peak of the wedge between the val ves.
The 5.2L cyl i nder head i s i denti fi ed by the foundry
mark NH.
PISTONS
SERVICE PROCEDURES
VALVE TIMING
(1) Turn crankshaft unti l the No.6 exhaust val ve i s
cl osi ng and No.6 i ntake val ve i s openi ng.
(2) I nsert a 6.350 mm (1/4 i nch) spacer between
rocker arm pad and stem ti p of No.1 i ntake val ve.
Al l ow spri ng l oad to bl eed tappet down gi vi ng i n
effect a sol i d tappet.
(3) I nstal l a di al i ndi cator so pl unger contacts
val ve spri ng retai ner as nearl y perpendi cul ar as pos-
si bl e. Zero the i ndi cator.
(4) Rotate the crankshaft cl ockwi se (normal run-
ni ng di recti on) unti l the val ve has l i fted 0.863 mm
(0.034 i nch). The ti mi ng of the crankshaft shoul d
now read from 10 before top dead center to 2 after
top dead center. Remove spacer.
CAUTION: DO NOT turn crankshaft any further
clockwise as valve spring might bottom and result
in serious damage.
I f readi ng i s not wi thi n speci fi ed l i mi ts:
Check sprocket i ndex marks.
I nspect ti mi ng chai n for wear.
Check accuracy of DC mark on ti mi ng i ndi cator.
MEASURING TIMING CHAIN STRETCH
NOTE: To access timing chain Refer to Timing
Chain Cover in Removal and Installation Section.
(1) Pl ace a scal e next to the ti mi ng chai n so that
any movement of the chai n may be measured.
(2) Pl ace a torque wrench and socket over cam-
shaft sprocket attachi ng bol t. Appl y torque i n the
di recti on of crankshaft rotati on to take up sl ack; 41
Nm (30 ft. l bs.) torque wi th cyl i nder head i nstal l ed
or 20 Nm (15 ft. l bs.) torque wi th cyl i nder head
removed. Wi th a torque appl i ed to the camshaft
sprocket bol t, crankshaft shoul d not be permi tted to
move. I t may be necessary to bl ock the crankshaft to
prevent rotati on.
(3) Hol d a scal e wi th di mensi onal readi ng even
wi th the edge of a chai n l i nk. Wi th cyl i nder heads
i nstal l ed, appl y 14 Nm (30 ft. l bs.) torque i n the
reverse di recti on. Wi th the cyl i nder heads removed,
appl y 20 Nm (15 ft. l bs.) torque i n the reverse di rec-
ti on. Note the amount of chai n movement (Fi g. 5).
(4) I nstal l a new ti mi ng chai n, i f i ts movement
exceeds 3.175 mm (1/8 i nch).
(5) I f chai n i s not sati sfactory, remove camshaft
sprocket attachi ng bol t and remove ti mi ng chai n wi th
crankshaft and camshaft sprockets.
(6) Pl ace both camshaft sprocket and crankshaft
sprocket on the bench wi th ti mi ng marks on exact
i magi nary center l i ne through both camshaft and
crankshaft bores.
(7) Pl ace ti mi ng chai n around both sprockets.
Fig. 4 Cylinder Head Assembly
Fig. 5 Measuring Timing Chain Wear and Stretch
(8) Turn crankshaft and camshaft to l i ne up wi th
keyway l ocati on i n crankshaft sprocket and i n cam-
shaft sprocket.
(9) Li ft sprockets and chai n (keep sprockets ti ght
agai nst the chai n i n posi ti on as descri bed).
(10) Sl i de both sprockets evenl y over thei r respec-
ti ve shafts and use a strai ghtedge to check al i gnment
of ti mi ng marks (Fi g. 6).
(11) I nstal l the camshaft bol t. Ti ghten the bol t to
(12) Check camshaft end pl ay. The end pl ay shoul d
be 0.051-0.152 mm (0.002-0.006 i nch) wi th a new
thrust pl ate and up to 0.254 mm (0.010 i nch) wi th a
used thrust pl ate. I f not wi thi n these l i mi ts i nstal l a
new thrust pl ate.
FITTING PISTONS
Pi ston and cyl i nder wal l must be cl ean and dry.
Speci fi ed cl earance between the pi ston and the cyl i n-
der wal l i s 0.013-0.038 mm (0.0005-0.0015 i nch) at
21C (70F).
Pi ston di ameter shoul d be measured at the top of
ski rt, 90 to pi ston pi n axi s l ocati on A i n (Fi g. 7). Cyl -
i nder bores shoul d be measured hal fway down the
cyl i nder bore and transverse to the engi ne crankshaft
center l i ne.
Pi stons and cyl i nder bores shoul d be measured at
normal room temperature, 21C (70F).
FITTING PISTON RINGS
(1) Measurement of end gaps:
(a) Measure pi ston ri ng gap 2 i nches from bot-
tom of cyl i nder bore. An i nverted pi ston can be
used to push the ri ngs down to ensure posi ti oni ng
ri ngs squarel y i n the cyl i nder bore before measur-
i ng.
(b) I nsert feel er gauge i n the gap. The top com-
pressi on ri ng gap shoul d be between 0.254-0.508
mm (0.010-0.020 i nch). The second compressi on
ri ng gap shoul d be between 0.508-0.762 mm (0.020-
0.030 i nch). The oi l ri ng gap shoul d be 0.254-1.270
mm (0.010-0.050 i nch).
(c) Ri ngs wi th i nsuffi ci ent end gap may be prop-
erl y fi l ed to the correct di mensi on. Ri ngs wi th
excess gaps shoul d not be used.
(2) I nstal l ri ngs and confi rm ri ng si de cl earance:
(a) I nstal l oi l ri ngs bei ng careful not to ni ck or
scratch the pi ston. I nstal l the oi l control ri ngs
accordi ng to i nstructi ons i n the package. I t i s not
necessary to use a tool to i nstal l the upper and
l ower rai l s. I nsert oi l rai l spacer fi rst, then si de
rai l s.
(b) I nstal l the second compressi on ri ngs usi ng
I nstal l ati on Tool C-4184. The compressi on ri ngs
must be i nstal l ed wi th the i denti fi cati on mark face
up (toward top of pi ston) and chamfer faci ng down.
An i denti fi cati on mark on the ri ng i s a dri l l poi nt,
a stamped l etter O, an oval depressi on or the
word TOP (Fi g. 8) (Fi g. 10).
(c) Usi ng a ri ng i nstal l er, i nstal l the top com-
pressi on ri ng wi th the chamfer faci ng up (Fi g. 9)
(Fi g. 10). An i denti fi cati on mark on the ri ng i s a
dri l l poi nt, a stamped l etter O, an oval depressi on
or the word TOP faci ng up.
(d) Measure si de cl earance between pi ston ri ng
and ri ng l and. Cl earance shoul d be 0.074-0.097 mm
(0.0029-0.0038 i nch) for the compressi on ri ngs. The
steel rai l oi l ri ng shoul d be free i n groove, but
Fig. 6 Alignment of Timing Marks
Fig. 7 Piston Measurements
shoul d not exceed 0.246 mm (0.0097 i nch) si de
cl earance.
(e) Pi stons wi th i nsuffi ci ent or excessi ve si de
cl earance shoul d be repl aced.
Fi t al l rods on a bank unti l compl eted. DO NOT
al ternate from one bank to another, because connect-
i ng rods and pi stons are not i nterchangeabl e from
one bank to another.
The beari ng caps are not i nterchangeabl e and
shoul d be marked at removal to ensure correct
assembl y.
Each beari ng cap has a smal l V-groove across the
parti ng face. When i nstal l i ng the l ower beari ng shel l ,
make certai n that the V-groove i n the shel l i s i n l i ne
wi th the V-groove i n the cap. Thi s provi des l ubri ca-
ti on of the cyl i nder wal l i n the opposi te bank.
The beari ng shel l s must be i nstal l ed so that the
tangs are i n the machi ned grooves i n the rods and
caps.
Li mi ts of taper or out-of-round on any crankshaft
journal s shoul d be hel d to 0.025 mm (0.001 i nch).
Beari ngs are avai l abl e i n 0.025 mm (0.001 i nch),
0.051 mm (0.002 i nch), 0.076 mm (0.003 i nch), 0.254
mm (0.010 i nch) and 0.305 mm (0.012 i nch) under-
si ze. 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.
Beari ng caps are not i nterchangeabl e and shoul d
be marked at removal to ensure correct assembl y.
Upper and l ower beari ng hal ves are NOT i nter-
changeabl e. Lower mai n beari ng hal ves of No.2 and 4
are i nterchangeabl e.
Upper and l ower No.3 beari ng hal ves are fl anged
to carry the crankshaft thrust l oads. They are NOT
i nterchangeabl e wi th any other beari ng hal ves i n the
engi ne (Fi g. 12). Beari ng shel l s are avai l abl e i n stan-
dard and the fol l owi ng undersi zes: 0.25 mm (0.001
i nch), 0.051 mm (0.002 i nch), 0.076 mm (0.003 i nch),
0.254 mm (0.010 i nch) and 0.305 mm (0.012 i nch).
Never i nstal l an undersi ze beari ng that wi l l reduce
cl earance bel ow speci fi cati ons.
CRANKSHAFT
A crankshaft whi ch has undersi ze journal s wi l l be
stamped wi th 1/4 i nch l etters on the mi l l ed fl at on
the No.8 crankshaft counterwei ght (Fi g. 13).
FOR EXAMPLE: R2 stamped on the No.8 crank-
shaft counterwei ght i ndi cates that the No.2 rod jour-
(Typical)
Fig. 9 Top Compression Ring Identification (Typical)
(Typical)
Fig. 11 Proper Ring Installation
nal i s 0.025 mm (0.001 i n) undersi ze. M4 i ndi cates
that the No.4 mai n journal i s 0.025 mm (0.001 i n)
undersi ze. R3 M2 i ndi cates that the No.3 rod journal
and the No.2 mai n journal are 0.025 mm (0.001 i n)
undersi ze.
When a crankshaft i s repl aced, al l mai n and con-
necti ng rod beari ngs shoul d be repl aced wi th new
beari ngs. Therefore, sel ecti ve fi tti ng of the beari ngs
i s not requi red when a crankshaft and beari ngs are
repl aced.
ENGINE MOUNTSFRONT
REMOVAL
(2) Posi ti on fan to assure cl earance for radi ator top
tank and hose.
CAUTION: DO NOT lift the engine by the intake
manifold.
(3) I nstal l engi ne l i fti ng fi xture.
(4) Rai se vehi cl e on hoi st.
(5) Remove the engi ne support i nsul ator thru-bol ts
and nuts (Fi g. 14) (Fi g. 15).
(6) Rai se engi ne SLI GHTLY. Remove the engi ne
support i nsul ator bol ts. Remove the engi ne support
i nsul ator assembl y.
(7) I f requi red, remove the si l l bracket assembl y.
INSTALLATION
(1) I f the si l l bracket assembl y was removed,
i nstal l the bracket to the si l l assembl y.
Fig. 12 Main Bearing Identification
Fig. 13 Location of Crankshaft Identification
(a) RI GHT SI DEI nstal l the si l l bracket assem-
bl y onto the si l l assembl y (Fi g. 14). I nstal l and
ti ghten the bol ts to 65 Nm (48 ft. l bs.) torque.
(b) LEFT SI DEI nstal l the si l l bracket assem-
ti ghten the 2 top bol ts to 65 Nm (48 ft. l bs.)
torque. I nstal l and ti ghten the 2 si de bol ts to 95
Nm (70 ft. l bs.) torque. I nstal l and ti ghten the 2
bottom bol ts to 121 Nm (89 ft. l bs.) torque.
(2) Wi th the engi ne rai sed SLI GHTLY, posi ti on
engi ne support i nsul ator assembl y onto the engi ne
bl ock (Fi g. 14) (Fi g. 15). I nstal l bol ts and ti ghten to
(3) Lower engi ne wi th l i fti ng fi xture whi l e al i gni ng
engi ne support i nsul ator assembl y i nto si l l bracket
assembl y.
(4) I nstal l the thru-bol t and nut. Ti ghten the
RI GHT SI DE nut to 81 Nm (60 ft. l bs.) torque.
Ti ghten the LEFT SI DE nut to 81 Nm (60 ft. l bs.)
torque.
(6) Remove l i fti ng fi xture.
ENGINE MOUNTREAR
REMOVAL
(2) Rai se the vehi cl e on a hoi st.
(3) Support the transmi ssi on wi th a jack.
(4) Remove stud nuts attachi ng engi ne mount to
crossmember (Fi g. 16). Remove mount.
(5) Rai se the transmi ssi on and engi ne SLI GHTLY.
(6) Remove engi ne mount bracket thru-bol t (Fi g.
16).
(7) Remove the engi ne mount assembl y from the
adaptor (Fi g. 16).
(8) I f requi red, remove the transmi ssi on support
bracket adaptor.
INSTALLATION
ft. l bs.).
(2) Posi ti on mount i nto mount bracket and i nstal l
thru-bol t and nut. DO NOT ti ghten the bol t at thi s
ti me.
(4) Remove transmi ssi on jack.
torque.
ENGINE ASSEMBLY
REMOVAL
(1) Scri be hood hi nge outl i nes on hood and remove
the hood.
(2) Remove the battery.
(3) Drai n cool i ng system.
(4) Remove the ai r cl eaner and tube.
(5) Set fan shroud asi de.
(6) Remove radi ator and heater hoses. Remove the
radi ator (refer to Group 7, Cool i ng System).
(7) Remove the vacuum l i nes.
(8) Remove the di stri butor cap and wi ri ng.
(9) Di sconnect the accel erator l i nkage.
procedure (refer to Group 14, Fuel System).
(11) Remove throttl e body.
(12) Remove the starter wi res.
(13) Remove the oi l pressure wi re.
(14) Di scharge the ai r condi ti oni ng system, i f
equi pped (refer to Group 24, Heati ng and Ai r Condi -
ti oni ng for servi ce procedures).
(15) Remove ai r condi ti oni ng hoses.
(16) Di sconnect the power steeri ng hoses, i f
equi pped.
(17) Remove starter motor (refer to Group 8B, Bat-
tery/Starter Servi ce).
(18) Remove the generator (refer to Group 8C,
Generator Servi ce).
(19) Rai se and support the vehi cl e on a hoi st.
(20) Di sconnect exhaust pi pe at mani fol d.
Fig. 16 Rear Engine MountV-8
(21) Support automati c transmi ssi on wi th a trans-
mi ssi on stand. Thi s wi l l assure that the torque con-
verter wi l l remai n i n proper posi ti on i n the
transmi ssi on housi ng.
(22) Remove bel l housi ng bol ts and i nspecti on
pl ate. Attach C-cl amp on front bottom of transmi s-
si on torque converter housi ng to prevent torque con-
verter from comi ng out.
(23) Remove torque converter dri ve pl ate bol ts
from torque converter dri ve pl ate. Mark converter
and dri ve pl ate to ai d i n assembl y.
(24) Di sconnect the engi ne from the torque con-
verter dri ve pl ate.
manifold.
(25) I nstal l an engi ne l i fti ng fi xture.
(26) Remove the engi ne front mount thru-bol ts.
(28) Remove engi ne from engi ne compartment.
(29) I nstal l on engi ne repai r stand.
INSTALLATION
(1) Remove engi ne from the repai r stand and posi -
ti on i n the engi ne compartment.
(2) I nstal l engi ne support fi xture.
(4) Posi ti on the torque converter and dri ve pl ate.
I nstal l torque converter dri ve pl ate bol ts. Ti ghten the
bol ts to 31 Nm (270 i n. l bs.) torque.
(5) I nstal l the engi ne front mount thru-bol ts.
(6) I nstal l bel l housi ng bol ts. Ti ghten the bol ts to
(7) Remove C-cl amp and i nstal l i nspecti on pl ate.
(8) Remove stand from transmi ssi on.
(9) I nstal l exhaust pi pe to mani fol d.
(11) Remove engi ne l i fti ng fi xture.
(12) I nstal l the generator (refer to Group 8C, Gen-
erator Servi ce).
(13) I nstal l starter motor (refer to Group 8B, Bat-
(14) I nstal l power steeri ng hoses, i f equi pped.
(15) I nstal l ai r condi ti oni ng hoses.
(16) Charge the ai r condi ti oner, i f equi pped (refer
to Group 24, Heater and Ai r Condi ti oni ng for servi ce
procedures).
(17) Usi ng a new gasket, i nstal l throttl e body.
Ti ghten the throttl e body bol ts to 23 Nm (200 i n.
l bs.) torque.
(18) Connect the accel erator l i nkage.
(19) Connect the starter wi res.
(20) Connect the oi l pressure wi re.
(21) I nstal l the di stri butor cap and wi ri ng.
(22) I nstal l vacuum l i nes.
(23) I nstal l radi ator, radi ator hoses and heater
hoses (refer to Group 7, Cool i ng System).
(24) I nstal l fan shroud i n posi ti on.
(25) I nstal l the battery
(26) Fi l l cool i ng system (refer to Group 7, Cool i ng
(27) I nstal l the ai r cl eaner.
(28) Warm engi ne and adjust.
(29) I nstal l hood and l i ne up.
(30) Road test vehi cl e.
CYLINDER HEAD COVER
A steel backed si l i con gasket i s used wi th the cyl -
i nder head cover (Fi g. 17). Thi s gasket can be used
agai n.
REMOVAL
(2) Di sconnect cl osed venti l ati on system and evap-
orati on control system from cyl i nder head cover.
(3) On the l eft cover, remove the cool ant tube
bracket.
(4) Remove the i gni ti on wi res from the hol ders.
(5) Remove cyl i nder head cover and gasket. The
gasket may be used agai n.
(6) Cl ean cyl i nder head cover gasket surface.
(7) Cl ean head rai l , i f necessary.
INSTALLATION
(1) I nspect cover for di storti on and strai ghten, i f
necessary.
(2) Check the gasket for use i n head cover i nstal -
l ati on. I f damaged, use a new gasket.
(3) The cyl i nder head cover gasket can be used
agai n. I nstal l the gasket onto the head rai l .
(4) Posi ti on the cyl i nder head cover onto the gas-
ket. On the l eft cover, i nstal l the cool ant tube bracket
(refer to Group 7, Cool i ng System). Ti ghten the bol ts
to 11 Nm (95 i n. l bs.) torque.
(5) I nstal l the i gni ti on wi res onto the hol ders.
(6) I nstal l cl osed crankcase venti l ati on system and
evaporati on control system.
Fig. 17 Cylinder Head Cover Gasket
REMOVAL
(1) Di sconnect spark pl ug wi res by pul l i ng on the
boot strai ght out i n l i ne wi th pl ug.
(2) Remove cyl i nder head cover and gasket.
(3) Remove the rocker arm bol ts and pi vots (Fi g.
18). Pl ace them on a bench i n the same order as
removed.
INSTALLATION
(1) Rotate the crankshaft unti l the V8 mark l i nes
up wi th the TDC mark on the ti mi ng chai n case
cover. Thi s mark i s l ocated 147 ATDC from the No.1
fi ri ng posi ti on.
(2) I nstal l the push rods i n the same order as
removed.
(3) I nstal l rocker arm and pi vot assembl i es i n the
same order as removed. Ti ghten the rocker arm bol ts
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(4) I nstal l cyl i nder head cover.
(5) Connect spark pl ug wi res.
VALVE SPRING AND STEM SEAL REPLACEMENT-
IN VEHICLE
(1) Set engi ne basi c ti mi ng to Top Dead Center
(TDC).
(3) Remove cyl i nder head covers and spark pl ugs.
(4) Remove coi l wi re from di stri butor and secure to
good ground to prevent engi ne from starti ng.
(5) Usi ng sui tabl e socket and fl ex handl e at crank-
shaft retai ni ng bol t, turn engi ne so the No.1 pi ston i s
at TDC on the compressi on stroke.
(6) Remove rocker arms.
(7) Wi th ai r hose attached to an adapter i nstal l ed
i n No.1 spark pl ug hol e, appl y 620-689 kPa (90-100
psi ) ai r pressure.
(8) Usi ng Val ve Spri ng Compressor Tool
MD-998772A wi th adaptor 6716A, compress val ve
spri ng and remove retai ner val ve l ocks and val ve
spri ng.
(9) I nstal l seal s on the exhaust val ve stem and
posi ti on down agai nst val ve gui des.
(10) The i ntake val ve stem seal s shoul d be pushed
fi rml y and squarel y over the val ve gui de usi ng the
val ve stem as a gui de. DO NOT force seal agai nst top
of gui de. When i nstal l i ng the val ve retai ner l ocks,
compress the spri ng onl y enough to i nstal l the l ocks.
(11) Fol l ow the same procedure on the remai ni ng 7
cyl i nders usi ng the fi ri ng sequence 1-8-4-3-6-5-7-2.
Make sure pi ston i n cyl i nder i s at TDC on the val ve
spri ng that i s bei ng removed.
(12) Remove adapter from the No.1 spark pl ug
hol e.
(13) I nstal l rocker arms.
(14) I nstal l covers and coi l wi re to di stri butor.
(15) I nstal l ai r cl eaner.
CYLINDER HEAD
REMOVAL
(2) Drai n cool i ng system (refer to Group 7, Cool i ng
System for the proper procedures).
(3) Remove the generator.
(4) Remove cl osed crankcase venti l ati on system.
(5) Di sconnect the evaporati on control system.
(7) Perform the Fuel System Pressure Rel ease pro-
cedure (refer to Group 14, Fuel System). Di sconnect
the fuel suppl y l i ne.
(8) Di sconnect accel erator l i nkage and i f so
equi pped, the speed control and transmi ssi on ki ck-
down cabl es.
(9) Remove di stri butor cap and wi res.
(10) Di sconnect the coi l wi res.
(11) Di sconnect heat i ndi cator sendi ng uni t wi re.
(12) Di sconnect heater hoses and bypass hose.
(13) Remove cyl i nder head covers and gaskets.
(14) Remove i ntake mani fol d and throttl e body as
an assembl y. Di scard the fl ange si de gaskets and the
front and rear cross-over gaskets.
(15) Remove exhaust mani fol ds.
(16) Remove rocker arm assembl i es and push rods.
I denti fy to ensure i nstal l ati on i n ori gi nal l ocati ons.
(17) Remove the head bol ts from each cyl i nder
head and remove cyl i nder heads. Di scard the cyl i n-
der head gasket.
(18) Remove spark pl ugs.
Fig. 18 Rocker Arms
INSTALLATION
(1) Posi ti on the new cyl i nder head gaskets onto
the cyl i nder bl ock.
(2) Posi ti on the cyl i nder heads onto head gaskets
and cyl i nder bl ock.
(3) Starti ng at top center, ti ghten al l cyl i nder head
bol ts, i n sequence, to 68 Nm (50 ft. l bs.) torque (Fi g.
19). Repeat procedure, ti ghten al l cyl i nder head bol ts
to 143 Nm (105 ft. l bs.) torque. Repeat procedure to
confi rm that al l bol ts are at 143 Nm (105 ft. l bs.)
torque.
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(4) I nstal l push rods and rocker arm assembl i es i n
thei r ori gi nal posi ti on. Ti ghten the bol ts to 28 Nm
(5) I nstal l the i ntake mani fol d and throttl e body
assembl y (refer to Group 11, Exhaust System and
I ntake Mani fol d).
(6) I nstal l exhaust mani fol ds. Ti ghten the bol ts
and nuts to 34 Nm (25 ft. l bs.) torque.
(7) Adjust spark pl ugs to speci fi cati ons (refer to
Group 8D, I gni ti on System). I nstal l the pl ugs and
ti ghten to 41 Nm (30 ft. l bs.) torque.
(8) I nstal l coi l wi res.
(9) Connect heat i ndi cator sendi ng uni t wi re.
(10) Connect the heater hoses and bypass hose.
(11) I nstal l di stri butor cap and wi res.
(12) Connect the accel erator l i nkage and i f so
down cabl es.
(13) I nstal l the fuel suppl y l i ne.
(14) I nstal l the generator and dri ve bel t. Ti ghten
generator mounti ng bol t to 41 Nm (30 ft. l bs.)
torque. Ti ghten the adjusti ng strap bol t to 23 Nm
(200 i n. l bs.) torque. Refer to Group 7, Cool i ng Sys-
tem for adjusti ng the bel t tensi on.
(15) I nstal l the i ntake mani fol d-to-generator
bracket support rod. Ti ghten the bol ts.
(16) Pl ace the cyl i nder head cover gaskets i n posi -
ti on and i nstal l cyl i nder head covers. Ti ghten the
(17) I nstal l cl osed crankcase venti l ati on system.
(18) Connect the evaporati on control system.
System for proper procedure).
REMOVAL
(1) Remove the cyl i nder head.
(2) Compress val ve spri ngs usi ng Val ve Spri ng
Compressor Tool MD- 998772A and adapter 6716A.
(3) Remove val ve retai ni ng l ocks, val ve spri ng
retai ners, val ve stem seal s and val ve spri ngs.
(4) Before removi ng val ves, remove any burrs from
val ve stem l ock grooves to prevent damage to the
val ve gui des. I denti fy val ves to ensure i nstal l ati on i n
ori gi nal l ocati on.
INSTALLATION
(1) Cl ean val ves thoroughl y. Di scard burned,
warped and cracked val ves.
(2) Remove carbon and varni sh deposi ts from
i nsi de of val ve gui des wi th a rel i abl e gui de cl eaner.
(3) Measure val ve stems for wear. I f wear exceeds
0.051 mm (0.002 i nch), repl ace the val ve.
(4) Coat val ve stems wi th l ubri cati on oi l and i nsert
them i n cyl i nder head.
(5) I f val ves or seats are reground, check val ve
stem hei ght. I f val ve i s too l ong, repl ace cyl i nder
head.
(6) I nstal l new seal s on al l val ve gui des. I nstal l
val ve spri ngs and val ve retai ners.
(7) Compress val ve spri ngs wi th Val ve Spri ng
Compressor Tool MD-998772A and adapter 6716A,
i nstal l l ocks and rel ease tool . I f val ves and/or seats
are ground, measure the i nstal l ed hei ght of spri ngs.
Make sure the measurement i s taken from bottom of
spri ng seat i n cyl i nder head to the bottom surface of
spri ng retai ner. I f spacers are i nstal l ed, measure
from the top of spacer. I f hei ght i s greater than 42.86
mm (1-11/16 i nches), i nstal l a 1.587 mm (1/16 i nch)
spacer i n head counterbore. Thi s shoul d bri ng spri ng
hei ght back to normal 41.27 to 42.86 mm (1-5/8 to
1-11/16 i nch).
Fig. 19 Cylinder Head Bolt Tightening Sequence
HYDRAULIC TAPPETS
REMOVAL
(2) Remove cyl i nder head cover, rocker assembl y
and push rods. I denti fy push rods to ensure i nstal l a-
ti on i n ori gi nal l ocati on.
(3) Remove i ntake mani fol d, yoke retai ner and
al i gni ng yokes.
(4) Sl i de Hydraul i c Tappet Remover/I nstal l er Tool
C-4129-A through openi ng i n cyl i nder head and seat
tool fi rml y i n the head of tappet.
(5) Pul l tappet out of bore wi th a twi sti ng moti on.
I f al l tappets are to be removed, i denti fy tappets to
ensure i nstal l ati on i n ori gi nal l ocati on.
INSTALLATION
(1) I f the tappet or bore i n cyl i nder bl ock i s
scored, scuffed, or shows si gns of sti cki ng, ream the
bore to next oversi ze. Repl ace wi th oversi ze tappet.
(2) Lubri cate tappets.
(3) I nstal l tappets and push rods i n thei r ori gi nal
posi ti ons. Ensure that the oi l feed hol e i n the si de of
the tappet body faces up (away from the crankshaft).
(4) I nstal l al i gni ng yokes wi th ARROW toward
camshaft.
(5) I nstal l yoke retai ner. Ti ghten the bol ts to 23
Nm (200 i n. l bs.) torque. I nstal l i ntake mani fol d.
(6) I nstal l push rods i n ori gi nal posi ti ons.
(7) I nstal l rocker arm.
(9) Start and operate engi ne. Warm up to normal
operati ng temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
VIBRATION DAMPER
REMOVAL
(2) Remove fan shroud retai ner bol ts and set
shroud back over engi ne.
(3) Remove the cool i ng system fan.
(4) Remove the serpenti ne bel t (refer to Group 7,
Cool i ng System).
(5) Remove the vi brati on damper pul l ey.
(6) Remove vi brati on damper bol t and washer from
end of crankshaft.
(7) I nstal l bar and screw from Pul l er Tool Set
C-3688. I nstal l 2 bol ts wi th washers through the
pul l er tool and i nto the vi brati on damper (Fi g. 20).
(8) Pul l vi brati on damper off of the crankshaft.
INSTALLATION
(1) Posi ti on the vi brati on damper onto the crank-
shaft.
(2) Pl ace i nstal l i ng tool , part of Pul l er Tool Set
C-3688 i n posi ti on and press the vi brati on damper
onto the crankshaft (Fi g. 21).
(3) I nstal l the crankshaft bol t and washer. Ti ghten
the bol t to 183 Nm (135 ft. l bs.) torque.
(4) I nstal l the crankshaft pul l ey. Ti ghten the pul -
l ey bol ts to 23 Nm (200 i n. l bs.) torque.
(5) I nstal l the serpenti ne bel t (refer to Group 7,
Cool i ng System).
(6) I nstal l the cool i ng system fan. Ti ghten the
(7) Posi ti on the fan shroud and i nstal l the bol ts.
Ti ghten the retai ner bol ts to 11 Nm (95 i n. l bs.)
torque.
TIMING CHAIN COVER
REMOVAL
System).
Cool i ng System).
(4) Remove water pump (refer to Group 7, Cool i ng
System).
Fig. 20 Vibration Damper Assembly
Fig. 21 Installing Vibration Damper
(5) Remove power steeri ng pump (refer to Group
19, Steeri ng).
(6) Remove vi brati on damper.
(7) Loosen oi l pan bol ts and remove the front bol t
at each si de.
(8) Remove the cover bol ts.
(9) Remove chai n case cover and gasket usi ng
extreme cauti on to avoi d damagi ng oi l pan gasket.
(10) Pl ace a sui tabl e tool behi nd the l i ps of the oi l
seal to pry the oi l seal outward. Be careful not to
damage the crankshaft seal surface of cover (Fi g. 22).
INSTALLATION
(1) Usi ng a new cover gasket, careful l y i nstal l
chai n case cover to avoi d damagi ng oi l pan gasket.
Use a smal l amount of Mopar Si l i cone Rubber Adhe-
si ve Seal ant, or equi val ent, at the joi nt between ti m-
i ng chai n cover gasket and the oi l pan gasket. Fi nger
ti ghten the ti mi ng chai n cover bol ts at thi s ti me.
(2) Pl ace the smal l er di ameter of the oi l seal over
Front Oi l Seal I nstal l ati on Tool 6635 (Fi g. 23). Seat
the oi l seal i n the groove of the tool .
(3) Posi ti on the seal and tool onto the crankshaft
(Fi g. 24).
(4) Ti ghten the 4 l ower chai n case cover bol ts to
13Nm (10 ft.l bs.) to prevent the cover from ti ppi ng
duri ng seal i nstal l ati on.
(5) Usi ng the vi brati on damper bol t, ti ghten the
bol t to draw the seal i nto posi ti on on the crankshaft
(Fi g. 25).
(6) Loosen the 4 bol ts ti ghtened i n step 4 to al l ow
real i gnment of front cover assembl y.
(7) Ti ghten chai n case cover bol ts to 41 Nm (30 ft.
l bs.) torque. Ti ghten oi l pan bol ts to 24 Nm (215 i n.
l bs.) torque.
(8) Remove the vi brati on damper bol t and seal
i nstal l ati on tool .
Fig. 22 Removal of Front Crankshaft Oil Seal
Fig. 23 Placing Oil Seal on Installation Tool 6635
Fig. 24 Position Tool and Seal onto Crankshaft
Fig. 25 Installing Oil Seal
(9) I nstal l vi brati on damper.
(10) I nstal l water pump and housi ng assembl y
usi ng new gaskets (refer to Group 7, Cool i ng Sys-
tem). Ti ghten bol ts to 41 Nm (30 ft. l bs.) torque.
(11) I nstal l power steeri ng pump (refer to Group
19, Steeri ng).
Cool i ng System).
Ti ghten the bol ts to 11 Nm (95 i n. l bs.) torque.
TIMING CHAIN
REMOVAL
(1) Remove Ti mi ng Chai n Cover Refer to proce-
dure i n thi s secti on.
(2) Remove camshaft sprocket attachi ng bol t and
remove ti mi ng chai n wi th crankshaft and camshaft
sprockets.
INSTALLATION
crankshaft bores.
shaft sprocket.
(6) I nstal l the camshaft bol t. Ti ghten the bol t to 68
new thrust pl ate.
CAMSHAFT
NOTE: The camshaft has an integral oil pump and
distributor drive gear (Fig. 27).
REMOVAL
(1) Remove i ntake mani fol d.
(2) Remove cyl i nder head covers.
(3) Remove ti mi ng case cover and ti mi ng chai n.
(5) Remove push rods and tappets. I denti fy each
part so i t can be i nstal l ed i n i ts ori gi nal l ocati on.
(6) Remove di stri butor and l i ft out the oi l pump
and di stri butor dri ve shaft.
(7) Remove camshaft thrust pl ate, note l ocati on of
oi l tab (Fi g. 28).
(8) I nstal l a l ong bol t i nto front of camshaft to
faci l i tate removal of the camshaft. Remove camshaft,
Fig. 27 Camshaft and Sprocket Assembly
Fig. 28 Timing Chain Oil Tab Installation
bei ng careful not to damage cam beari ngs wi th the
cam l obes.
INSTALLATION
(1) Lubri cate camshaft l obes and camshaft beari ng
journal s and i nsert the camshaft to wi thi n 51 mm (2
i nches) of i ts fi nal posi ti on i n cyl i nder bl ock.
NOTE: Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1 pint of
Mopar Crankcase Conditioner, or equivalent. The oil
mixture should be left in engine for a minimum of
805 km (500 miles). Drain at the next normal oil
change.
(2) I nstal l Camshaft Gear I nstal l er Tool C-3509
wi th tongue back of di stri butor dri ve gear (Fi g. 29).
(3) Hol d tool i n posi ti on wi th a di stri butor l ock-
pl ate bol t. Thi s tool wi l l restri ct camshaft from bei ng
pushed i n too far and prevent knocki ng out the wel ch
pl ug i n rear of cyl i nder bl ock. Tool should remain
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) I nstal l camshaft thrust pl ate and chai n oi l tab.
Make sure tang enters lower right hole in
thrust plate. Ti ghten bol ts to 24 Nm (210 i n. l bs.)
torque. Top edge of tab shoul d be fl at agai nst thrust
pl ate i n order to catch oi l for chai n l ubri cati on.
crankshaft bores.
shaft sprocket.
(10) I nstal l the camshaft bol t/cup washer. Ti ghten
bol t to 68 Nm (50 ft. l bs.) torque.
(11) Measure camshaft end pl ay. Refer to Speci fi ca-
ti ons for proper cl earance. I f not wi thi n l i mi ts i nstal l
a new thrust pl ate.
(12) Each tappet reused must be i nstal l ed i n the
same posi ti on from whi ch i t was removed. When
camshaft is replaced, all of the tappets must be
replaced.
CAMSHAFT BEARINGS
REMOVAL
NOTE: This procedure requires that the engine is
removed from the vehicle.
(1) Wi th engi ne compl etel y di sassembl ed, dri ve out
rear cam beari ng core hol e pl ug.
(2) I nstal l proper si ze adapters and horseshoe
washers (part of Camshaft Beari ng Remover/I nstal l er
Tool C-3132-A) at back of each beari ng shel l . Dri ve
out beari ng shel l s (Fi g. 31).
INSTALLATION
(1) I nstal l new camshaft beari ngs wi th Camshaft
Beari ng Remover/I nstal l er Tool C-3132-A by sl i di ng
the new camshaft beari ng shel l over proper adapter.
Fig. 29 Camshaft Holding Tool C-3509 (Installed
Position)
Fig. 31 Camshaft Bearings Removal/Installation with
Tool C-3132-A
(2) Posi ti on rear beari ng i n the tool . I nstal l horse-
shoe l ock and by reversi ng removal procedure, care-
ful l y dri ve beari ng shel l i nto pl ace.
(3) I nstal l remai ni ng beari ngs i n the same man-
ner. Beari ngs must be careful l y al i gned to bri ng oi l
hol es i nto ful l regi ster wi th oi l passages from the
mai n beari ng. I f the camshaft beari ng shel l oi l hol es
are not i n exact al i gnment, remove and i nstal l them
correctl y. I nstal l a new core hol e pl ug at the rear of
camshaft. Be sure this plug does not leak.
REMOVAL
(2) Remove the oi l pump from the rear mai n bear-
i ng cap.
(3) I denti fy beari ng caps before removal . Remove
beari ng caps one at a ti me.
(4) Remove upper hal f of beari ng by i nserti ng
Crankshaft Mai n Beari ng Remover/I nstal l er Tool
C-3059 i nto the oi l hol e of crankshaft (Fi g. 32).
(5) Sl owl y rotate crankshaft cl ockwi se, forci ng out
upper hal f of beari ng shel l .
INSTALLATION
Onl y one mai n beari ng shoul d be sel ecti vel y fi tted
whi l e al l other mai n beari ng caps are properl y ti ght-
ened. Al l beari ng capbol ts removed duri ng servi ce
procedures are to be cl eaned and oi l ed before i nstal -
l ati on.
When i nstal l i ng a new upper beari ng shel l , sl i ghtl y
chamfer the sharp edges from the pl ai n si de.
(1) Start beari ng i n pl ace, and i nsert Crankshaft
Mai n Beari ng Remover/I nstal l er Tool C-3059 i nto oi l
hol e of crankshaft (Fi g. 32).
(2) Sl owl y rotate crankshaft countercl ockwi se sl i d-
i ng the beari ng i nto posi ti on. Remove Tool C-3059.
(3) I nstal l the beari ng caps. Cl ean and oi l the
bol ts. Ti ghten the capbol ts to 115 Nm (85 ft. l bs.)
torque.
DISTRIBUTOR DRIVE SHAFT BUSHING
REMOVAL
(1) Remove di stri butor, refer to Group 8D, I gni ti on
Systems for the proper procedure.
(2) Remove the i ntake mani fol d (refer to Group 11,
Exhaust System and I ntake Mani fol d).
(3) I nsert Di stri butor Dri ve Shaft Bushi ng Pul l er
Tool C-3052 i nto ol d bushi ng and thread down unti l a
ti ght fi t i s obtai ned (Fi g. 33).
(4) Hol d pul l er screw and ti ghten pul l er nut unti l
bushi ng i s removed.
INSTALLATION
(1) Sl i de new bushi ng over burni shi ng end of Di s-
tri butor Dri ve Shaft Bushi ng Dri ver/Burni sher Tool
C-3053. I nsert the tool and bushi ng i nto the bore.
(2) Dri ve bushi ng and tool i nto posi ti on, usi ng a
hammer (Fi g. 34).
(3) As the burni sher i s pul l ed through the bushi ng,
the bushi ng i s expanded ti ght i n the bl ock and bur-
ni shed to correct si ze (Fi g. 35). DO NOT ream this
bushing.
Fig. 32 Upper Main Bearing Removal and
Installation with Tool C-3059
Fig. 33 Distributor Driveshaft Bushing Removal
Fig. 34 Distributor Driveshaft Bushing Installation
CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may
occur.
(4) I nstal l the i ntake mani fol d (refer to Group 11,
DISTRIBUTOR INSTALLATION
NOTE: Before installing the distributor, the oil
pump drive shaft must be aligned to number one
cylinder.
(1) Rotate crankshaft unti l No.1 cyl i nder i s at top
dead center on the fi ri ng stroke.
(2) When i n thi s posi ti on, the ti mi ng mark of
vi brati on damper shoul d be under 0 on the ti mi ng
i ndi cator.
(3) I nstal l the shaft so that after the gear spi ral s
i nto pl ace, i t wi l l i ndex wi th the oi l pump shaft. The
sl ot on top of oi l pump shaft shoul d be al i gned
towards the l eft front i ntake mani fol d attachi ng bol t
hol e (Fi g. 36).
(4) I nstal l di stri butor, refer to Group 8D, I gni ti on
After the di stri butor has been i nstal l ed, i ts rota-
ti onal posi ti on must be set usi ng the SET SYNC
mode of the DRB scan tool . Refer to Checki ng Di s-
tri butor Posi ti on fol l owi ng the Di stri butor I nstal l a-
ti on secti on i n Group 8D, I gni ti on system.
Do not attempt to adjust ignition timing by
rotating the distributor. It has no effect on igni-
tion timing. Adjusting distributor position will
effect fuel synchronization only.
OIL PAN
REMOVAL
engi ne oi l .
(4) Remove the oi l fi l ter.
(5) Remove the starter (refer to Group 8B, Battery/
Starter/Generator Servi ce).
the sensor.
(7) Posi ti on the cool er l i nes out of the way.
(8) Di sconnect the oxygen sensor.
(9) Remove exhaust pi pe.
INSTALLATION
(1) Fabri cate 4 al i gnment dowel s from 5/16 x 1 1/2
(2) I nstal l the dowel s i n the cyl i nder bl ock (Fi g.
38).
(3) Appl y smal l amount of Mopar Si l i cone Rubber
Adhesi ve Seal ant, or equi val ent i n the corner of the
cap and the cyl i nder bl ock.
onto the bl ock.
(6) I nstal l the oi l pan bol ts. Ti ghten the bol ts to 24
(7) Remove the dowel s. I nstal l the remai ni ng oi l
pan bol ts. Ti ghten these bol ts to 24 Nm (215 i n. l bs.)
torque.
Fig. 35 Burnishing Distributor Driveshaft Bushing
Fig. 36 Position of Oil Pump Shaft Slot
(8) I nstal l the drai n pl ug. Ti ghten drai n pl ug to 34
(9) I nstal l exhaust pi pe.
(10) Connect the oxygen sensor.
(11) I nstal l the oi l fi l ter.
(12) I f equi pped wi th an oi l l evel sensor, connect
the sensor.
(13) I nstal l the starter (refer to Group 8B, Battery/
(14) Move the cool er l i nes back i nto posi ti on.
(15) Lower vehi cl e.
l evel .
REMOVAL
(1) Remove the engi ne from the vehi cl e.
(4) Remove top ri dge of cyl i nder bores wi th a rel i -
abl e ri dge reamer before removi ng pi stons from cyl -
i nder bl ock. Be sure to keep tops of pi stons covered
duri ng thi s operati on.
(5) Be sure the connecti ng rod and connecti ng rod
cap are i denti fi ed wi th the cyl i nder number. Remove
connecti ng rod cap. I nstal l connecti ng rod bol t gui de
set on connecti ng rod bol ts.
(6) Pi stons and connecti ng rods must be removed
from top of cyl i nder bl ock. When removi ng pi ston and
connecti ng rod assembl i es, rotate crankshaft to cen-
ter the connecti ng rod i n the cyl i nder bore and at
BDC. Be careful not to nick crankshaft journals.
(7) After removal , i nstal l beari ng cap on the mat-
i ng rod.
INSTALLATION
(1) Be sure that compressi on ri ng gaps are stag-
gered so that nei ther i s i n-l i ne wi th oi l ri ng rai l gap.
(2) Before i nstal l i ng the ri ng compressor, make
sure the oi l ri ng expander ends are butted and the
rai l gaps l ocated properl y (Fi g. 39).
(3) I mmerse the pi ston head and ri ngs i n cl ean
engi ne oi l . Sl i de Pi ston Ri ng Compressor Tool C-385
over the pi ston and ti ghten wi th the speci al wrench
(part of Tool C-385). Be sure position of rings
does not change during this operation.
(4) I nstal l connecti ng rod bol t protectors on rod
bol ts, the l ong protector shoul d be i nstal l ed on the
numbered si de of the connecti ng rod.
(5) Rotate crankshaft so that the connecti ng rod
journal i s on the center of the cyl i nder bore. Be sure
connecti ng rod and cyl i nder bore number are the
same. I nsert rod and pi ston i nto cyl i nder bore and
gui de rod over the crankshaft journal .
(6) Tap the pi ston down i n cyl i nder bore, usi ng a
hammer handl e. At the same ti me, gui de connecti ng
rod i nto posi ti on on crankshaft journal .
(7) The notch or groove on top of pi ston must be
poi nti ng toward front of engi ne. The l arger chamfer
of the connecti ng rod bore must be i nstal l ed toward
crankshaft journal fi l l et.
(8) I nstal l rod caps. Be sure connecti ng rod, con-
necti ng rod cap and cyl i nder bore number are the
same. I nstal l nuts on cl eaned and oi l ed rod bol ts and
ti ghten nuts to 61 Nm (45 ft. l bs.) torque.
(10) I nstal l the cyl i nder head.
CRANKSHAFT
REMOVAL
i ng cap.
(4) Remove the ti mi ng chai n cover.
beari ng caps and beari ngs one at a ti me.
(6) Li ft the crankshaft out of the bl ock.
(7) Remove and di scard the crankshaft rear oi l
seal s.
(8) Remove and di scard the front crankshaft oi l
seal .
INSTALLATION
(1) Cl ean Locti te 518 resi due and seal ant from the
cyl i nder bl ock and rear cap mati ng surface. Do thi s
before appl yi ng the Locti te drop and the i nstal l ati on
of rear cap.
(2) Li ghtl y oi l the new upper seal l i ps wi th engi ne
oi l .
(3) I nstal l the new upper rear beari ng oi l seal wi th
the whi te pai nt faci ng towards the rear of the engi ne.
(4) Posi ti on the crankshaft i nto the cyl i nder bl ock.
(5) Li ghtl y oi l the new l ower seal l i ps wi th engi ne
oi l .
(6) I nstal l the new l ower rear beari ng oi l seal i nto
the beari ng cap wi th the whi te pai nt faci ng towards
the rear of the engi ne.
(7) Appl y 5 mm (0.20 i n) drop of Locti te 518, or
equi val ent, on each si de of the rear mai n beari ng cap
(Fi g. 40). DO NOT over appl y seal ant or al l ow the
seal ant to contact the rubber seal . Assembl e beari ng
cap to cyl i nder bl ock i mmedi atel y after seal ant appl i -
cati on.
(8) To al i gn the beari ng cap, use cap sl ot, al i gn-
ment dowel and cap bol ts. DO NOT remove excess
materi al after assembl y. DO NOT stri ke rear cap
more than 2 ti mes for proper engagement.
(9) Cl ean and oi l al l cap bol ts. I nstal l al l mai n
beari ng caps. I nstal l al l cap bol ts and al ternatel y
(10) I nstal l oi l pump.
(11) I nstal l the ti mi ng chai n cover.
(13) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant, or equi val ent, at beari ng cap to bl ock joi nt to
provi de cap to bl ock and oi l pan seal i ng (Fi g. 41).
Appl y enough seal ant unti l a smal l amount i s
squeezed out. Wi thdraw nozzl e and wi pe excess seal -
ant off the oi l pan seal groove.
(14) I nstal l new front crankshaft oi l seal .
(15) I mmedi atel y i nstal l the oi l pan.
OIL PUMP
REMOVAL
(2) Remove the oi l pump from rear mai n beari ng
cap.
INSTALLATION
(1) I nstal l oi l pump. Duri ng i nstal l ati on sl owl y
rotate pump body to ensure dri veshaft-to-pump rotor
shaft engagement.
(2) Hol d the oi l pump base fl ush agai nst mati ng
surface on No.5 mai n beari ng cap. Fi nger ti ghten
pump attachi ng bol ts. Ti ghten attachi ng bol ts to 41
Fig. 40 Sealant Application to Bearing Cap
Fig. 41 Apply Sealant to Bearing Cap to Block Joint
CRANKSHAFT OIL SEAL FRONT
The oi l seal can be repl aced wi thout removi ng the
ti mi ng chai n cover provi ded the cover i s not mi s-
al i gned.
(3) I f front seal i s suspected of l eaki ng, check front
oi l seal al i gnment to crankshaft. The seal i nstal l a-
ti on/al i gnment tool 6635, shoul d fi t wi th mi ni mum
i nterference. I f tool does not fi t, the cover must be
removed and i nstal l ed properl y.
damage the crankshaft seal bore of cover.
(Fi g. 43).
(Fi g. 44).
(9) I nspect the seal fl ange on the vi brati on
damper.
CRANKSHAFT OIL SEALS REAR
The servi ce seal i s a 2 pi ece, vi ton seal . The upper
seal hal f can be i nstal l ed wi th crankshaft removed
from engi ne or wi th crankshaft i nstal l ed. When a
new upper seal i s i nstal l ed, i nstal l a new l ower seal .
The l ower seal hal f can onl y be i nstal l ed wi th the
rear mai n beari ng cap removed.
UPPER SEAL CRANKSHAFT REMOVED
REMOVAL
(1) Remove the crankshaft. Di scard the ol d upper
seal .
INSTALLATION
(1) Cl ean the cyl i nder bl ock rear cap mati ng sur-
face. Make sure the seal groove i s free of debri s.
oi l .
oi l .
cati on.
UPPER SEAL CRANKSHAFT INSTALLED
REMOVAL
i ng cap.
(3) Remove the rear mai n beari ng cap. Remove
and di scard the ol d l ower oi l seal .
(4) Careful l y remove and di scard the ol d upper oi l
seal .
INSTALLATION
(1) Cl ean the cyl i nder bl ock mati ng surfaces before
oi l seal i nstal l ati on. Check for burr at the oi l hol e on
the cyl i nder bl ock mati ng surface to rear cap.
oi l . To al l ow ease of i nstal l ati on of the seal , l oosen at
l east the 2 mai n beari ng caps forward of the rear
beari ng cap.
(3) Rotate the new upper seal i nto the cyl i nder
bl ock bei ng careful not to shave or cut the outer sur-
face of the seal . To assure proper i nstal l ati on, use the
i nstal l ati on tool provi ded wi th the ki t. I nstal l the
new seal wi th the whi te pai nt faci ng towards the
rear of the engi ne.
cati on. Be sure the whi te pai nt faces toward the rear
of the engi ne.
(7) I nstal l the rear mai n beari ng cap wi th cl eaned
and oi l ed cap bol ts. Al ternatel y ti ghten ALL cap bol ts
(9) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant,
or equi val ent, at beari ng cap to bl ock joi nt to provi de
cap to bl ock and oi l pan seal i ng (Fi g. 46). Appl y
enough seal ant unti l a smal l amount i s squeezed out.
Wi thdraw nozzl e and wi pe excess seal ant off the oi l
pan seal groove.
LOWER SEAL
REMOVAL
i ng cap.
(3) Remove the rear mai n beari ng cap and di scard
the ol d l ower seal .
INSTALLATION
(1) Cl ean the rear mai n cap mati ng surfaces
i ncl udi ng the oi l pan gasket groove.
(2) Careful l y i nstal l a new upper seal (refer to
Upper Seal Repl acement - Crankshaft I nstal l ed pro-
cedure above).
oi l .
(4) I nstal l a new l ower seal i n beari ng cap wi th
the whi te pai nt faci ng the rear of engi ne.
cati on.
and oi l ed cap bol ts. Al ternatel y ti ghten the cap bol ts
pan seal groove.
ENGINE CORE OIL AND CAMSHAFT PLUGS
Engi ne core pl ugs have been pressed i nto the oi l
gal l eri es behi nd the camshaft thrust pl ate (Fi g. 47).
Thi s wi l l reduce i nternal l eakage and hel p mai ntai n
hi gher oi l pressure at i dl e.
REMOVAL
(1) Usi ng a bl unt tool such as a dri ft or a screw-
dri ver and a hammer, stri ke the bottom edge of the
cup pl ug (Fi g. 48).
(2) Wi th the cup pl ug rotated, grasp fi rml y wi th
pl i ers or other sui tabl e tool and remove pl ug (Fi g.
48).
INSTALLATION
Thoroughl y cl ean i nsi de of cup pl ug hol e i n cyl i n-
der bl ock or head. Be sure to remove ol d seal er.
Be certai n the new pl ug i s cl eaned of al l oi l or
grease.
(1) Coat edges of pl ug and core hol e wi th Mopar
Gasket Maker, or equi val ent.
CAUTION: DO NOT drive cup plug into the casting,
as restricted coolant flow can result and cause seri-
ous engine problems.
(2) Usi ng proper pl ug dri ve, dri ve cup pl ug i nto
hol e. The sharp edge of the pl ug shoul d be at l east
0.50 mm (0.020 i n.) i nsi de the l ead-i n chamfer.
Fig. 47 Location of Cup Plugs in Oil Galleries
Fig. 48 Core Hole Plug Removal
(3) I t i s not necessary to wai t for curi ng of the
seal ant. The cool i ng system can be fi l l ed and the
vehi cl e pl aced i n servi ce i mmedi atel y.
HYDRAULIC TAPPETS
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable
to work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. DO NOT dis-
assemble a tappet on a dirty work bench.
DISASSEMBLE
(1) Pry out pl unger retai ner spri ng cl i p (Fi g. 49).
(2) Cl ean varni sh deposi ts from i nsi de of tappet
body above pl unger cap.
(3) I nvert tappet body and remove pl unger cap,
pl unger, check val ve, check val ve spri ng, check val ve
retai ner and pl unger spri ng (Fi g. 49). Check val ve
coul d be fl at or bal l .
ASSEMBLE
(1) Cl ean al l tappet parts i n a sol vent that wi l l
remove al l varni sh and carbon.
(2) Repl ace tappets that are unfi t for further ser-
vi ce wi th new assembl i es.
(3) I f pl unger shows si gns of scori ng or wear,
i nstal l a new tappet assembl y. I f val ve i s pi tted, or
val ve seat on end of pl unger i s prevented from seat-
i ng, i nstal l a new tappet assembl y.
(4) Assembl e tappets (Fi g. 49).
VALVE SERVICE
VALVE GUIDES
Measure val ve stem gui de cl earance as fol l ows:
(1) I nstal l Val ve Gui de Sl eeve Tool C-3973 over
val ve stem and i nstal l val ve (Fi g. 50). The speci al
sl eeve pl aces the val ve at the correct hei ght for
checki ng wi th a di al i ndi cator.
(2) Attach Di al I ndi cator Tool C-3339 to cyl i nder
head and set i t at ri ght angl e of val ve stem bei ng
measured (Fi g. 51).
(3) Move val ve to and from the i ndi cator. The total
di al i ndi cator readi ng shoul d not exceed 0.432 mm
(0.017 i nch). Ream the gui des for val ves wi th over-
si ze stems i f di al i ndi cator readi ng i s excessi ve or i f
the stems are scuffed or scored.
(4) Servi ce val ves wi th oversi ze stems are avai l -
abl e (Fi g. 52).
(5) Sl owl y turn reamer by hand and cl ean gui de
thoroughl y before i nstal l i ng new val ve. Ream the
Fig. 49 Hydraulic Tappet Assembly
Fig. 50 Positioning Valve with Tool C-3973
Fig. 51 Measuring Valve Guide Wear
Fig. 52 Reamer Sizes
valve guides from standard to 0.381 mm (0.015
inch). Use a 2 step procedure so the valve
guides are reamed true in relation to the valve
seat:
Step 1Ream to 0.0763 mm (0.003 i nch).
REFACING VALVES AND VALVE SEATS
The i ntake and exhaust val ves have a 43-1/4 to
43-3/4 face angl e and a 44-1/4 to 44-3/4 seat angl e
(Fi g. 53).
VALVES
I nspect the remai ni ng margi n after the val ves are
refaced (Fi g. 54). Val ves wi th l ess than 1.190 mm
(0.047 i nch) margi n shoul d be di scarded.
VALVE SEATS
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 55).
(1) When refaci ng val ve seats, i t i s i mportant that
the correct si ze val ve gui de pi l ot be used for reseat-
i ng stones. A true and compl ete surface must be
obtai ned.
(2) Measure the concentri ci ty of val ve seat usi ng a
di al i ndi cator. Total runout shoul d not exceed 0.051
mm (0.002 i nch) total i ndi cator readi ng.
(3) I nspect the val ve seat wi th Prussi an bl ue to
determi ne where the val ve contacts the seat. To do
thi s, coat val ve seat LI GHTLY wi th Prussi an bl ue
then set val ve i n pl ace. Rotate the val ve wi th l i ght
pressure. I f the bl ue i s transferred to the center of
val ve face, contact i s sati sfactory. I f the bl ue i s trans-
ferred to the top edge of val ve face, l ower val ve seat
wi th a 15 stone. I f the bl ue i s transferred to bottom
edge of val ve face rai se val ve seat wi th a 60 stone.
(4) When seat i s properl y posi ti oned the wi dth of
i ntake seats shoul d be 1.016-1.524 mm (0.040-0.060
i nch). The wi dth of the exhaust seats shoul d be
1.524-2.032 mm (0.060-0.080 i nch).
VALVE SPRING INSPECTION
Whenever val ves have been removed for i nspecti on,
recondi ti oni ng or repl acement, val ve spri ngs shoul d
be tested. As an exampl e the compressi on l ength of
the spri ng to be tested i s 1-5/16 i nch. Turn tabl e of
Uni versal s Val ve Spri ng Tester Tool unti l surface i s
i n l i ne wi th the 1-5/16 i nch mark on the threaded
stud. Be sure the zero mark i s to the front (Fi g. 56).
Pl ace spri ng over stud on the tabl e and l i ft compress-
i ng l ever to set tone devi ce. Pul l on torque wrench
unti l pi ng i s heard. Take readi ng on torque wrench
Fig. 53 Valve Face and Seat Angles
Fig. 54 Intake and Exhaust Valves
Fig. 55 Refacing Valve Seats
at thi s i nstant. Mul ti pl y thi s readi ng by 2. Thi s wi l l
gi ve the spri ng l oad at test l ength. Fracti onal mea-
surements are i ndi cated on the tabl e for fi ner adjust-
ments. Refer to speci fi cati ons to obtai n speci fi ed
hei ght and al l owabl e tensi ons. Di scard the spri ngs
that do not meet speci fi cati ons.
OIL PUMP
DISASSEMBLE
(1) Remove the rel i ef val ve as fol l ows:
(a) Remove cotter pi n. Dri l l a 3.175 mm (1/8
i nch) hol e i nto the rel i ef val ve retai ner cap and
i nsert a sel f-threadi ng sheet metal screw.
(b) Cl amp screw i nto a vi se and whi l e support-
i ng oi l pump, remove cap by tappi ng pump body
usi ng a soft hammer. Di scard retai ner cap and
remove spri ng and rel i ef val ve (Fi g. 57).
(2) Remove oi l pump cover (Fi g. 58).
(3) Remove pump outer rotor and i nner rotor wi th
shaft (Fi g. 58).
(4) Wash al l parts i n a sui tabl e sol vent and i nspect
careful l y for damage or wear.
ASSEMBLE
(1) I nstal l pump rotors and shaft, usi ng new parts
as requi red.
(2) Posi ti on the oi l pump cover onto the pump
body. Ti ghten cover bol ts to 11 Nm (95 i n. l bs.)
torque.
(3) I nstal l the rel i ef val ve and spri ng. I nsert the
cotter pi n.
(4) Tap on a new retai ner cap.
(5) Pri me oi l pump before i nstal l ati on by fi l l i ng
rotor cavi ty wi th engi ne oi l .
CYLINDER BLOCK
DISASSEMBLE
Engi ne assembl y removed from vehi cl e:
(3) Remove the pi ston and connecti ng rod assem-
bl i es.
ASSEMBLE
(1) I nstal l the pi ston and connecti ng rod assembl y.
CYLINDER HEADS
CLEANING
Cl ean al l surfaces of cyl i nder bl ock and cyl i nder
heads.
Cl ean cyl i nder bl ock front and rear gasket surfaces
usi ng a sui tabl e sol vent.
INSPECTION
I nspect al l surfaces wi th a strai ghtedge i f there i s
any reason to suspect l eakage. I f out-of-fl atness
Fig. 56 Testing Valve Spring for Compressed
Length
Fig. 57 Oil Pressure Relief Valve
Fig. 58 Oil Pump
exceeds 0.00075 mm/mm (0.00075 i nch/i nch) ti mes
the span l ength i n i nches i n any di recti on, ei ther
repl ace head or l i ghtl y machi ne the head surface.
FOR EXAMPLE: A 305 mm (12 i nch) span i s
0.102 mm (0.004 i nch) out-of-fl at. The al l owabl e out-
of-fl at i s 305 x 0.00075 (12 x 0.00075) equal s 0.23
mm (0.009 i nch). Thi s amount of out-of-fl at i s accept-
abl e.
The cyl i nder head surface fi ni sh shoul d be
1.78-3.00 mi crons (70-125 mi cro i nches).
I nspect push rods. Repl ace worn or bent rods.
INSPECTION
Check the crankshaft connecti ng rod journal for
excessi ve wear, taper and scori ng.
Check the cyl i nder bl ock bore for out-of-round,
taper, scori ng and scuffi ng.
Check the pi stons for taper and el l i pti cal shape
before they are fi tted i nto the cyl i nder bore (Fi g. 59).
CRANKSHAFT JOURNALS
The crankshaft connecti ng rod and mai n journal s
shoul d be checked for excessi ve wear, taper and scor-
i ng. The maxi mum taper or out-of-round on any
crankshaft journal i s 0.025 mm (0.001 i nch).
Journal gri ndi ng shoul d not exceed 0.305 mm
(0.012 i nch) under the standard journal di ameter. DO
NOT gri nd thrust faces of No.3 mai n beari ng. DO
NOT ni ck crank pi n or beari ng fi l l ets. After gri ndi ng,
remove rough edges from crankshaft oi l hol es and
cl ean out al l oi l passages.
CAUTION: After any journal grind, it is important
that the final paper or cloth polish be in the same
direction as the engine rotates.
OIL PAN
CLEANING
Cl ean the bl ock and pan gasket surfaces.
Tri m or remove excess seal ant fi l m i n the rear
mai n cap oi l pan gasket groove. DO NOT remove
the sealant inside the rear main cap slots.
I f present, tri m excess seal ant from i nsi de the
engi ne.
Cl ean oi l pan i n sol vent and wi pe dry wi th a cl ean
cl oth.
Cl ean oi l screen and pi pe thoroughl y i n cl ean sol -
vent. I nspect condi ti on of screen.
INSPECTION
I nspect oi l drai n pl ug and pl ug hol e for stri pped or
damaged threads. Repai r as necessary.
I nspect oi l pan mounti ng fl ange for bends or di stor-
ti on. Strai ghten fl ange, i f necessary.
OIL PUMP
INSPECTION
Mati ng surface of the oi l pump cover shoul d be
smooth. Repl ace pump assembl y i f cover i s scratched
or grooved.
Lay a strai ghtedge across the pump cover surface
(Fi g. 60). I f a 0.038 mm (0.0015 i nch) feel er gauge
can be i nserted between cover and strai ghtedge,
pump assembl y shoul d be repl aced.
Measure thi ckness and di ameter of OUTER rotor.
I f outer rotor thi ckness measures 20.9 mm (0.825
i nch) or l ess or i f the di ameter i s 62.7 mm (2.469
i nches) or l ess, repl ace outer rotor (Fi g. 61).
I f i nner rotor measures 20.9 mm (0.825 i nch) or
l ess, repl ace i nner rotor and shaft assembl y (Fi g. 62).
Sl i de outer rotor i nto pump body. Press rotor to the
si de wi th your fi ngers and measure cl earance
between rotor and pump body (Fi g. 63). I f cl earance
i s 0.356 mm (0.014 i nch) or more, repl ace oi l pump
assembl y.
I nstal l i nner rotor and shaft i nto pump body. I f
cl earance between i nner and outer rotors i s 0.203
mm (0.008 i nch) or more, repl ace shaft and both
rotors (Fi g. 64).
Pl ace a strai ghtedge across the face of the pump,
between bol t hol es. I f a feel er gauge of 0.102 mm
(0.004 i nch) or more can be i nserted between rotors
and the strai ghtedge, repl ace pump assembl y (Fi g.
65).
I nspect oi l pressure rel i ef val ve pl unger for scori ng
and free operati on i n i ts bore. Smal l marks may be
removed wi th 400-gri t wet or dry sandpaper.
The rel i ef val ve spri ng has a free l ength of approx-
i matel y 49.5 mm (1.95 i nches). The spri ng shoul d
test between 19.5 and 20.5 pounds when compressed
Fig. 60 Checking Oil Pump Cover Flatness
Fig. 61 Measuring Outer Rotor Thickness
Fig. 62 Measuring Inner Rotor Thickness
Fig. 63 Measuring Outer Rotor Clearance in
Housing
Fig. 64 Measuring Clearance Between Rotors
Fig. 65 Measuring Clearance Over Rotors
to 34 mm (1-11/32 i nches). Repl ace spri ng that fai l s
to meet these speci fi cati ons (Fi g. 66).
I f oi l pressure was l ow and pump i s wi thi n speci fi -
cati ons, i nspect for worn engi ne beari ngs or other
reasons for oi l pressure l oss.
CYLINDER BLOCK
CLEANING
Cl ean cyl i nder bl ock thoroughl y and check al l core
hol e pl ugs for evi dence of l eaki ng.
INSPECTION
Exami ne bl ock for cracks or fractures.
The cyl i nder wal l s shoul d be checked for out-of-
round and taper wi th Cyl i nder Bore I ndi cator Tool
C-119. The cyl i nder bl ock shoul d be bored and honed
wi th new pi stons and ri ngs fi tted i f:
The cyl i nder bores show more than 0.127 mm
(0.005 i n.) out-of-round.
The cyl i nder bores show a taper of more than
0.254 mm (0.010 i n.).
The cyl i nder wal l s are badl y scuffed or scored.
Bori ng and honi ng operati on shoul d be cl osel y coor-
di nated wi th the fi tti ng of pi stons and ri ngs, so that
speci fi ed cl earances can be mai ntai ned.
OIL LINE PLUG
The oi l l i ne pl ug i s l ocated i n the verti cal passage
at the rear of the bl ock between the oi l -to-fi l ter and
oi l -from-fi l ter passages (Fi g. 67). I mproper i nstal l a-
ti on or pl ug mi ssi ng coul d cause errati c, l ow, or no oi l
pressure.
The oi l pl ug must come out the bottom. Use fl at
dowel , down the oi l pressure sendi ng uni t hol e from
the top, to remove oi l pl ug.
(1) Remove oi l pressure sendi ng uni t from back of
bl ock.
(2) I nsert a 3.175 mm (1/8 i n.) fi ni sh wi re, or
equi val ent, i nto passage.
(3) Pl ug shoul d be 190.0 to 195.2 mm (7-1/2 to
7-11/16 i n.) from machi ned surface of bl ock (Fi g. 67).
I f pl ug i s too hi gh, use a sui tabl e fl at dowel to posi -
ti on properl y.
(4) I f pl ug i s too l ow, remove oi l pan and No. 4
mai n beari ng cap. Use sui tabl e fl at dowel to posi ti on
properl y. Coat outsi de di ameter of pl ug wi th Mopar
Stud and Beari ng Mount Adhesi ve, or equi val ent.
Pl ug shoul d be 54.0 to 57.7 mm (2-1/8 to 2-5/16 i n.)
from bottom of the bl ock.
Fig. 66 Proper Installation of Retainer Cap
Fig. 67 Oil Line Plug
SPECIFICATIONS
GENERAL INFORMATION
Engi ne Type . . . . . . . . . . . . . . . . . . . . . .90 V-8 OHV
Bore and Stroke . . . .99.3 x 84.0 mm (3.91 x 3.31 i n.)
Di spl acement . . . . . . . . . . . . . . . . . . . .5.2L (318 c.i .)
Fi ri ng Order . . . . . . . . . . . . . . . . . .18436572
Lubri cati on . . . .Pressure FeedFul l Fl ow Fi l trati on
Cool i ng System. . .Li qui d Cool edForced Ci rcul ati on
Crankshaft. . . . . . . . . . . . . . . . . . . . . . .Nodul ar I ron
Combusti on Chambers . . . . .Wedge-Hi gh Swi rl Val ve
shroudi ng
Camshaft . . . . . . . . . . . . . . . . . . . .Nodul ar Cast I ron
Pi stons . . . . . . . . . . . . . . . . .Al umi num Al l oy w/strut
Connecti ng Rods . . . . . . . . . . . . . . . . . . .Forged Steel
CAMSHAFT
Bearing Diameter
No. 1 . . . . . . .50.800 50.825 mm (2.000 2.001 i n.)
No. 2 . . . . . . .50.394 50.419 mm (1.984 1.985 i n.)
No. 3 . . . . . . .50.013 50.038 mm (1.969 1.970 i n.)
No. 4 . . . . . . .49.606 49.632 mm (1.953 1.954 i n.)
No. 5 . . . . .39.688 39.713 mm (1.5625 1.5635 i n.)
No. 1 . . . . . . .50.749 50.775 mm (1.998 1.999 i n.)
No. 2 . . . . . . .50.343 50.368 mm (1.982 1.983 i n.)
No. 3 . . . . . . .49.962 49.987 mm (1.967 1.968 i n.)
No. 4 . . . . . . .49.555 49.581 mm (1.951 1.952 i n.)
No. 5 . . . . .39.637 39.662 mm (1.5605 1.5615 i n.)
Bearing to J ournal Clearance
Standard . . . .0.0254 0.0762 mm (0.001 0.003 i n.)
Servi ce Li mi t . . . . . . . . . . . . .0.127 mm (0.005 i n.)
Camshaft End Play
End Pl ay . . . . . .0.051 0.254 mm (0.002 0.010 i n.)
CONNECTING RODS
Pi ston Pi n bore Di ameter . . . . . .24.966 24.978 mm
(0.9829 0.9834 i n.)
Si de Cl earance . . . . . . . . . . . . . . . .0.152 0.356 mm
(0.006 0.014 i n.)
CRANKSHAFT
Rod J ournal
Di ameter . . . .53.950 53.975 mm (2.124 2.125 i n.)
Out of Round (Max.). . . . . . . . .0.0254 mm (0.001 i n.)
Rod J ournal
Taper (Max.). . . . . . . . . . . . . . .0.0254 mm (0.001 i n.)
Beari ng Cl earance . . . . . . . . . . . . .0.013 0.056 mm
(0.0005 0.0022 i n.)
Servi ce Li mi t . . . . . . . . . . . .0.0762 mm (0.003 i n.)
Main Bearing J ournal
Di ameter . . .63.487 63.513 mm (2.4995 2.5005i n.)
Out of Round (Max.) . . . . . . . . .0.127 mm (0.001 i n.)
Taper (Max.). . . . . . . . . . . . . . .0.0254 mm (0.001 i n.)
Beari ng Cl earance (#1 Journal ) . . .0.013 0.038 mm
(0.0005 0.0015 i n.)
Servi ce Li mi t (#1 Journal ). . . . . . . . . . .0.0381 mm
(0.0015 i n.)
Beari ng Cl earance
(#2-5 Journal s) . . . . . . . . . . . . . .0.013 0.051 mm
(0.0005 0.002 i n.)
Servi ce Li mi t (#2-5 Journal s) . . . . . . . . .0.064 mm
(0.0025 i n.)
Crankshaft End Play
End Pl ay . . . . . .0.051 0.178 mm (0.002 0.007 i n.)
CYLINDER BLOCK
Cylinder Bore
Di ameter . . . .99.314 99.365 mm (3.910 3.912 i n.)
Taper (Max.) . . . . . . . . . . . . . . .0.254 mm (0.010 i n.)
Oversi ze Li mi t . . . . . . . . . . . . . .1.016 mm (0.040 i n.)
Lifter Bore
Di ameter . . . . . . . . . . . . . . . . . . . .22.99 23.01 mm
(0.9051 0.9059 i n.)
Distributor Drive Bushing (Press Fit)
Bushi ng to Bore I nterference . . .0.0127 0.3556 mm
(0.0005 0.0140 i n.)
Shaft to Bushi ng Cl earance . . . .0.0178 0.0686 mm
(0.0007 0.0027 i n.)
CYLINDER HEAD AND VALVES
Valve Seat
Angl e . . . . . . . . . . . . . . . . . . . . . . . . .44.25 44.75
Runout (Max.) . . . . . . . . . . . . .0.0762 mm (0.003 i n.)
Wi dth (Fi ni sh) I ntake . . . . . . . . .1.016 1.524 mm
(0.040 0.060 i n.)
Wi dth (Fi ni sh) Exhaust . . . . . . . .1.524 2.032 mm
(0.060 0.080 i n.)
Valves
Face Angl e . . . . . . . . . . . . . . . . . . . . .43.25 43.75
Head Di ameter I ntake . . . . .48.666 mm (1.916 i n.)
Head Di ameter Exhaust. . . . . . . .41.250 (1.624 i n.)
Length (Overal l ) I ntake . . . . . .124.28 125.92 mm
(4.893 4.918 i n.)
Length (Overal l ) Exhaust . . . .124.64 125.27 mm
(4.907 4.932 i n.)
Li ft (@ zero l ash) . . . . . . . . . . .10.973 mm (0.432 i n.)
Stem Di ameter . . .7.899 7.925 mm (0.311 0.312 i n.)
Valve Seat
Gui de Bore . . . . . . . . . . . . . . . . . . .7.950 7.976 mm
(0.313 0.314 on.)
Stem to Gui de Cl earance . . . . . .0.0254 0.0762 mm
(0.001 0.003 i n.)
Servi ce Li mi t (rocki ng method) . .0.4318 (0.017 i n.)
Valve Springs
Free Length . . . . . . . . . . . . . . .49.962 mm (1.967 i n.)
Spri ng Tensi on (val ve cl osed) . .378 N @ 41.66 mm
(85 l bs. @ 1.64 i n.)
Spri ng Tensi on (val ve open). . . .890 N @ 30.89 mm
(200 l bs. @ 1.212 i n.)
Number of Coi l s. . . . . . . . . . . . . . . . . . . . . . . . . . .6.5
I nstal l ed Hei ght. . . . . . . . . . . . . .41.66 mm (1.64 i n.)
Wi re Di ameter . . . . . . . . . . . . . . .4.50 mm (0.177 i n.)
HYDRAULIC TAPPETS
Body Di ameter . . . . . . . . . . . . . .22.949 22.962 mm
(0.9035 0.9040 i n.)
Cl earance (to bore) . . . . . . . . . . .0.0279 0.0610 mm
(0.0011 0.0024 i n.)
Dry Lash . . . . . .1.524 5.334 mm (0.060 0.210 i n.)
Push Rod Length . . . . . . . . . . . .175.64 176.15 mm
(6.915 6.935 i n.)
OIL PRESSURE
Curb I dl e (Mi n.*). . . . . . . . . . . . . . . .41.4 kPa (6 psi )
3000 rpm. . . . . . . . . . . . .207 552 kPa (30 80 psi )
Oi l Pressure Bypass Val ve Setti ng. . . . .62 103 kPa
(9 15 psi )
Swi tch Actuati ng Pressure . . . . . . . . .34.5 48.3 kPa
(5 7 psi )
CAUTION: If oil pressure is zero at curb idle, DO
NOT RUN ENGINE.
OIL PUMP
Cl earance over Rotors (Max.). .0.1016 mm (0.004 i n.)
Cover Out of Fl at (Max.) . . . .0.0381 mm (0.0015 i n.)
I nner Rotor Thi ckness (Mi n.) . . . .20.955 mm (0.825 i n.)
Outer Rotor Cl earance (Max.) . . .0.3556 mm (0.014 i n.)
Outer Rotor Di ameter (Mi n.) . . .62.7126 mm (2.469 i n.)
Outer Rotor Thi ckness (Mi n.). . . .20.955 mm (0.825 i n.)
Ti p Cl earance between Rotors (Max.) . . . .0.2032 mm
(0.008 i n.)
PISTON PINS
Cl earance at Top of Ski rt . . . . . . . .0.013 0.038 mm
(0.0005 0.0015 i n.)
Land Cl earance (Di am.) . . . . . . . . .0.635 1.016 mm
(0.025 0.040 i n.)
(0.0005 0.0015 i n.)
Pi ston Length . . . . . . . . . . . . . .86.360 mm (3.40 i n.)
Pi ston Ri ng Groove
Depth #1&2 . . . . . . . . . . . . . . .4.572 4.826 mm
(0.180 0.190 i n.)
Pi ston Ri ng Groove Depth #3 . . .3.810 4.064 mm
(0.150 0.160 i n.)
Wei ght. . . . . .592.6 596.6 grams (20.90 21.04 oz.)
PISTON RINGS
Cl earance i n Pi ston . . . . . . . . .0.00635 0.01905 mm
(0.00025 0.00075 i n.)
Di ameter . . . . . . . . . . . . . . . . . . .24.996 25.001 mm
(0.9841 0.9843 i n.)
End Pl ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NONE
Length . . . . . .75.946 76.454 mm (2.990 3.010 i n.)
PISTON RINGS
Ring Gap
Compressi on Ri ngs . . . . . . . . . . . . .0.254 0.508 mm
(0.010 0.020 i n.)
Oi l Control (Steel Rai l s) . . . . . . . . .0.254 1.270 mm
(0.010 0.050 i n.)
Ring Side Clearance
(0.0015 0.0030 i n.)
Oi l Ri ng (Steel Rai l s) . . . . . . . . . . . . .0.06 0.21 mm
(0.002 0.008 i n.)
Ring Width
Compressi on ri ngs . . . . . . . . . . . . .1.971 1.989 mm
(0.0776 0.0783 i n.)
Oi l Ri ng (Steel Rai l s) Max. . . . . .3.848 3.975 mm
(0.1515 0.1565 i n.)
VALVE TIMING
Exhaust Valve
Cl oses (ATDC). . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Opens (BBDC). . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
Intake Valve
Cl oses (ATDC). . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Opens (BBDC). . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
Val ve Overl ap . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
5. 2L TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Camshaft Sprocket
Bol t . . . . . . . . . . . . . . . . . . . . . .68 Nm (50 ft. l bs.)
Camshaft Thrust Plate
Bol ts . . . . . . . . . . . . . . . . . . . . .24 Nm (18 ft. l bs.)
Chain Case Cover
Bol ts . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Connecting Rod Cap
Bol ts . . . . . . . . . . . . . . . . . . . . .61 Nm (45 ft. l bs.)
Crankshaft Main Bearing Cap
Bol ts . . . . . . . . . . . . . . . . . . . .115 Nm (85 ft. l bs.)
Crankshaft Pulley
Bol ts . . . . . . . . . . . . . . . . . . . .24 Nm (210 i n. l bs.)
Cylinder Head Bolts
Step 1 I ni ti al . . . . . . . . . . . . .68 Nm (50 ft. l bs.)
Step 2 Fi nal . . . . . . . . . . . .143 Nm (105 ft. l bs.)
Cylinder Head Cover
Bol ts . . . . . . . . . . . . . . . . . . . . .11 Nm (95 i n. l bs.)
Exhaust Manifold to Cylinder Head
Bol ts/Nuts . . . . . . . . . . . . . . . . .34 Nm (25 ft. l bs.)
Flywheel
Bol ts . . . . . . . . . . . . . . . . . . . . .75 Nm (55 ft. l bs.)
Front Engine Mount Bracket to Block
Bol ts . . . . . . . . . . . . . . . . . . . . .81 Nm (60 ft. l bs.)
Front Engine Mount
Through Bol t/Nut . . . . . . . . . . .68 Nm (50 ft. l bs.)
Generator Mounting
Bol ts . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Intake Manifold
Bol ts . . . . . . . . . .Refer to procedure i n thi s secti on
Oil Pan
Bol ts . . . . . . . . . . . . . . . . . . . .24 Nm (215 i n. l bs.)
DESCRIPTION TORQUE
Oil Pan Drain Plug
Pl ug. . . . . . . . . . . . . . . . . . . . . .34 Nm (25 ft. l bs.)
Oil Pump
Bol ts . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Oil Pump Cover
Bol ts . . . . . . . . . . . . . . . . . . . . .11 Nm (95 i n. l bs.)
Rear Mount Insulator to Support Bracket
Nuts . . . . . . . . . . . . . . . . . . . . .47 Nm (35 ft. l bs.)
Rear Mount Insulator to Crossmember
Nut . . . . . . . . . . . . . . . . . . . . . .47 Nm (35 ft. l bs.)
Rear Support Bracket to Transmission
Bol ts . . . . . . . . . . . . . . . . . . . .102 Nm (75 ft. l bs.)
Rocker Arm
Bol ts . . . . . . . . . . . . . . . . . . . . .28 Nm (21 ft. l bs.)
Spark Plugs
Pl ugs . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Starter Mounting
Bol ts . . . . . . . . . . . . . . . . . . . . .68 Nm (50 ft. l bs.)
Thermostat Housing
Bol ts . . . . . . . . . . . . . . . . . . . .25 Nm (225 i n. l bs.)
Throttle Body
Bol ts . . . . . . . . . . . . . . . . . . . .23 Nm (200 i n. l bs.)
Torque Converter Drive Plate
Bol ts . . . . . . . . . . . . . . . . . . . .31 Nm (270 i n. l bs.)
Transmission Support Bracket
Bol ts . . . . . . . . . . . . . . . . . . . .102 Nm (75 ft. l bs.)
Transmission Support Spacer to
Insulator Mounting Plate (4wd)
Nuts. . . . . . . . . . . . . . . . . . . .204 Nm (150 ft. l bs.)
Vibration Damper
Bol t . . . . . . . . . . . . . . . . . . . .183 Nm (135 ft. l bs.)
Water Pump to Chain Case Cover
Bol t . . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
SPECIAL TOOLS
5. 2L ENGINE
Oil Pressure Gauge C-3292
Engine Support Fixture C-3487A
Valve Spring Compressor MD-998772A
Adapter 6633
Adapter 6716A
Valve Guide Sleeve C-3973
Dial Indicator C-3339
Puller C-3688
Front Oil Seal Installer 6635
Cam Bearing Remover/Installer C-3132A
Camshaft Holder C-3509
Distributor Bushing Puller C-3052
Distributor Bushing Driver/Burnisher C-3053
Piston Ring Compressor C-385
Crankshaft Main Bearing Remover C-3059
Cylinder Bore Gauge C-119
SPECIAL TOOLS (Continued)
5.9L ENGINE
INDEX
page page
GENERAL INFORMATION
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . 91
SERVICE PROCEDURES
CRANKSHAFT SERVICE . . . . . . . . . . . . . . . . . . 94
FITTING CRANKSHAFT MAIN BEARINGS . . . . . 93
FITTING PISTON RINGS . . . . . . . . . . . . . . . . . . 92
FITTING PISTONS . . . . . . . . . . . . . . . . . . . . . . . 92
MEASURING TIMING CHAIN STRETCH . . . . . . . 91
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . 91
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . 102
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . 103
CRANKSHAFT OIL SEAL FRONT . . . . . . . . . 107
CRANKSHAFT OIL SEALS REAR . . . . . . . . . 108
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 106
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 97
DISTRIBUTOR DRIVE SHAFT BUSHING . . . . . 103
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 96
ENGINE CORE OIL AND CAMSHAFT PLUGS . . 109
ENGINE MOUNTSREAR . . . . . . . . . . . . . . . . . 95
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
PISTON AND CONNECTING ROD ASSEMBLY . 105
TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . 100
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . 101
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE . . . . . . . . . . . . . 97
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . 112
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 110
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 110
CRANKSHAFT JOURNALS . . . . . . . . . . . . . . . . 113
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . 115
CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . 113
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
PISTON AND CONNECTING ROD ASSEMBLY . 113
SPECIFICATIONS
5.9L ENGINE SPECIFICATIONS . . . . . . . . . . . . 116
5.9L TORQUE SPECIFICATIONS . . . . . . . . . . . 118
SPECIAL TOOLS
5.9L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 119
GENERAL INFORMATION
OIL PUMP PRESSURE
psi ) at curb i dl e. The MAXI MUM oi l pump pressure
i s 207-552 kPa (30-80 psi ) at 3,000 RPM or more.
CAUTION: If oil pressure is ZERO at curb idle, DO
NOT run engine.
ENGINE DESCRIPTION
The 5.9 Li ter (360 CI D) ei ght-cyl i nder engi ne i s a
V-Type l i ghtwei ght, si ngl e cam, overhead val ve
engi ne wi th hydraul i c rol l er tappets.
Thi s engi ne i s desi gned for unl eaded fuel .
Engi ne l ubri cati on system consi sts of a rotor type
oi l pump and a ful l fl ow oi l fi l ter.
The cyl i nders are numbered from front to rear; 1,
3, 5, 7 on the l eft bank and 2, 4, 6, 8 on the ri ght
bank. The fi ri ng order i s 1-8-4-3-6-5-7-2 (Fi g. 1).
The engi ne seri al number i s stamped i nto a
machi ned pad l ocated on the l eft, front corner of the
cyl i nder bl ock. When component part repl acement i s
necessary, use the engi ne type and seri al number for
reference (Fi g. 2).
LUBRICATION SYSTEM
mounted at the undersi de of the rear mai n beari ng
cap. The pump draws oi l through the screen and
i nl et tube from the sump at the rear of the oi l pan.
The oi l i s dri ven between the dri ve and i dl er gears
and pump body, then forced through the outl et to the
bl ock. An oi l gal l ery i n the bl ock channel s the oi l to
the i nl et si de of the ful l fl ow oi l fi l ter. After passi ng
through the fi l ter el ement, the oi l passes from the
center outl et of the fi l ter through an oi l gal l ery that
channel s the oi l up to the mai n gal l ery whi ch
extends the enti re l ength on the ri ght si de of the
bl ock. The oi l then goes down to the No. 1 mai n bear-
i ng, back up to the l eft si de of the bl ock and i nto the
oi l gal l ery on the l eft si de of the engi ne.
mai n beari ng journal s to the connecti ng rod journal s.
Each connecti ng rod beari ng has hal f a hol e i n i t, oi l
passes through the hol e when the rods rotate and the
hol e l i nes up, oi l i s then thrown off as the rod
rotates. Thi s oi l throw off l ubri cates the camshaft
l obes, di stri butor dri ve gear, cyl i nder wal l s, and pi s-
ton pi ns.
from the mai n oi l gal l ery. The camshaft beari ngs
recei ve oi l from the mai n beari ng gal l eri es. The front
camshaft beari ng journal passes oi l through the cam-
shaft sprocket to the ti mi ng chai n. Oi l drai ns back to
the oi l pan under the number one mai n beari ng cap.
rocker arm l ubri cates the val ve trai n components.
The oi l then passes down through the push rod gui de
hol es, and the oi l drai n back passages i n the cyl i nder
head past the val ve tappet area, and returns to the
oi l pan.
Fig. 1 Firing Order
Fig. 2 Engine Identification Number
F
i
g
.
3
O
i
l
L
u
b
r
i
c
a
t
i
o
n
S
y
s
t
e
m
ENGINE COMPONENTS
CYLINDER HEADS
The al l oy cast i ron cyl i nder heads (Fi g. 4) are hel d
i n pl ace by 10 bol ts. The spark pl ugs are l ocated i n
the peak of the wedge between the val ves.
The 5.9L cyl i nder head i s i denti fi ed by the foundry
mark CF.
PISTONS
The val ves are arranged i n-l i ne and i ncl i ned 18.
The rocker pi vot support and the val ve gui des are
cast i ntegral wi th the heads.
SERVICE PROCEDURES
VALVE TIMING
(1) Turn crankshaft unti l the No.6 exhaust val ve i s
cl osi ng and No.6 i ntake val ve i s openi ng.
(2) I nsert a 6.350 mm (1/4 i nch) spacer between
rocker arm pad and stem ti p of No.1 i ntake val ve.
Al l ow spri ng l oad to bl eed tappet down gi vi ng i n
effect a sol i d tappet.
(3) I nstal l a di al i ndi cator so pl unger contacts
val ve spri ng retai ner as nearl y perpendi cul ar as pos-
si bl e. Zero the i ndi cator.
(4) Rotate the crankshaft cl ockwi se (normal run-
ni ng di recti on) unti l the val ve has l i fted 0.863 mm
(0.034 i nch). The ti mi ng of the crankshaft shoul d
now read from 10 before top dead center to 2 after
top dead center. Remove spacer.
CAUTION: DO NOT turn crankshaft any further
clockwise as valve spring might bottom and result
in serious damage.
I f readi ng i s not wi thi n speci fi ed l i mi ts:
Check sprocket i ndex marks.
I nspect ti mi ng chai n for wear.
Check accuracy of DC mark on ti mi ng i ndi cator.
MEASURING TIMING CHAIN STRETCH
NOTE: To access timing chain Refer to Timing
Chain Cover in Removal and Installation Section.
(1) Pl ace a scal e next to the ti mi ng chai n so that
any movement of the chai n may be measured.
(2) Pl ace a torque wrench and socket over cam-
shaft sprocket attachi ng bol t. Appl y torque i n the
di recti on of crankshaft rotati on to take up sl ack; 41
Nm (30 ft. l bs.) torque wi th cyl i nder head i nstal l ed
or 20 Nm (15 ft. l bs.) torque wi th cyl i nder head
removed. Wi th a torque appl i ed to the camshaft
sprocket bol t, crankshaft shoul d not be permi tted to
move. I t may be necessary to bl ock the crankshaft to
prevent rotati on.
(3) Hol d a scal e wi th di mensi onal readi ng even
wi th the edge of a chai n l i nk. Wi th cyl i nder heads
i nstal l ed, appl y 14 Nm (30 ft. l bs.) torque i n the
reverse di recti on. Wi th the cyl i nder heads removed,
appl y 20 Nm (15 ft. l bs.) torque i n the reverse di rec-
ti on. Note the amount of chai n movement (Fi g. 5).
(4) I nstal l a new ti mi ng chai n, i f i ts movement
exceeds 3.175 mm (1/8 i nch).
(5) I f chai n i s not sati sfactory, remove camshaft
sprocket attachi ng bol t and remove ti mi ng chai n wi th
crankshaft and camshaft sprockets.
Fig. 4 Cylinder Head Assembly
Fig. 5 Measuring Timing Chain Wear and Stretch
crankshaft bores.
shaft sprocket.
(11) I nstal l the camshaft bol t. Ti ghten the bol t to
new thrust pl ate.
FITTING PISTONS
Pi ston and cyl i nder wal l must be cl ean and dry.
Speci fi ed cl earance between the pi ston and the cyl i n-
der wal l i s 0.013-0.038 mm (0.0005-0.0015 i nch) at
21C (70F).
Pi ston di ameter shoul d be measured at the top of
ski rt, 90 to pi ston pi n axi s. Cyl i nder bores shoul d be
measured hal fway down the cyl i nder bore and trans-
verse to the engi ne crankshaft center l i ne.
Pi stons and cyl i nder bores shoul d be measured at
normal room temperature, 21C (70F).
FITTING PISTON RINGS
(1) Measurement of end gaps:
(a) Measure pi ston ri ng gap 2 i nches from bot-
tom of cyl i nder bore. An i nverted pi ston can be
used to push the ri ngs down to ensure posi ti oni ng
ri ngs squarel y i n the cyl i nder bore before measur-
i ng.
(b) I nsert feel er gauge i n the gap. The top com-
pressi on ri ng gap shoul d be between 0.254-0.508
mm (0.010-0.020 i nch). The second compressi on
ri ng gap shoul d be between 0.508-0.762 mm (0.020-
0.030 i nch). The oi l ri ng gap shoul d be 0.254-1.270
mm (0.010-0.050 i nch).
(c) Ri ngs wi th i nsuffi ci ent end gap may be prop-
erl y fi l ed to the correct di mensi on. Ri ngs wi th
excess gaps shoul d not be used.
(2) I nstal l ri ngs and confi rm ri ng si de cl earance:
(a) I nstal l oi l ri ngs bei ng careful not to ni ck or
scratch the pi ston. I nstal l the oi l control ri ngs
accordi ng to i nstructi ons i n the package. I t i s not
necessary to use a tool to i nstal l the upper and
l ower rai l s. I nsert oi l rai l spacer fi rst, then si de
rai l s.
(b) I nstal l the second compressi on ri ngs usi ng
I nstal l ati on Tool C-4184. The compressi on ri ngs
must be i nstal l ed wi th the i denti fi cati on mark face
up (toward top of pi ston) and chamfer faci ng down.
An i denti fi cati on mark on the ri ng i s a dri l l poi nt,
a stamped l etter O, an oval depressi on or the
word TOP (Fi g. 8) (Fi g. 10).
(c) Usi ng a ri ng i nstal l er, i nstal l the top com-
pressi on ri ng wi th the chamfer faci ng up (Fi g. 9)
(Fi g. 10). An i denti fi cati on mark on the ri ng i s a
dri l l poi nt, a stamped l etter O, an oval depressi on
or the word TOP faci ng up.
(d) Measure si de cl earance between pi ston ri ng
and ri ng l and. Cl earance shoul d be 0.074-0.097 mm
(0.0029-0.0038 i nch) for the compressi on ri ngs. The
steel rai l oi l ri ng shoul d be free i n groove, but
shoul d not exceed 0.246 mm (0.0097 i nch) si de
cl earance.
(e) Pi stons wi th i nsuffi ci ent or excessi ve si de
cl earance shoul d be repl aced.
Fi t al l rods on a bank unti l compl eted. DO NOT
al ternate from one bank to another, because connect-
i ng rods and pi stons are not i nterchangeabl e from
one bank to another.
The beari ng caps are not i nterchangeabl e and
shoul d be marked at removal to ensure correct
assembl y.
Each beari ng cap has a smal l V-groove across the
parti ng face. When i nstal l i ng the l ower beari ng shel l ,
make certai n that the V-groove i n the shel l i s i n l i ne
wi th the V-groove i n the cap. Thi s provi des l ubri ca-
ti on of the cyl i nder wal l i n the opposi te bank.
The beari ng shel l s must be i nstal l ed so that the
tangs are i n the machi ned grooves i n the rods and
caps.
Li mi ts of taper or out-of-round on any crankshaft
journal s shoul d be hel d to 0.025 mm (0.001 i nch).
Beari ngs are avai l abl e i n 0.025 mm (0.001 i nch),
0.051 mm (0.002 i nch), 0.076 mm (0.003 i nch), 0.254
mm (0.010 i nch) and 0.305 mm (0.012 i nch) under-
si ze. 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.
FITTING CRANKSHAFT MAIN BEARINGS
Beari ng caps are not i nterchangeabl e and shoul d
be marked at removal to ensure correct assembl y.
Upper and l ower beari ng hal ves are NOT i nter-
changeabl e. Lower mai n beari ng hal ves of No.2 and 4
are i nterchangeabl e.
Upper and l ower No.3 beari ng hal ves are fl anged
to carry the crankshaft thrust l oads. They are NOT
i nterchangeabl e wi th any other beari ng hal ves i n the
engi ne (Fi g. 12). Beari ng shel l s are avai l abl e i n stan-
dard and the fol l owi ng undersi zes: 0.25 mm (0.001
i nch), 0.051 mm (0.002 i nch), 0.076 mm (0.003 i nch),
0.254 mm (0.010 i nch) and 0.305 mm (0.012 i nch).
Never i nstal l an undersi ze beari ng that wi l l reduce
cl earance bel ow speci fi cati ons.
(Typical)
Fig. 9 Top Compression Ring Identification (Typical)
(Typical)
CRANKSHAFT SERVICE
A crankshaft whi ch has undersi ze journal s wi l l be
stamped wi th 1/4 i nch l etters on the mi l l ed fl at on
the No.3 crankshaft counterwei ght (Fi g. 13).
FOR EXAMPLE: R2 stamped on the No.3 crank-
shaft counterwei ght i ndi cates that the No.2 rod jour-
nal i s 0.025 mm (0.001 i n) undersi ze. M4 i ndi cates
that the No.4 mai n journal i s 0.025 mm (0.001 i n)
undersi ze. R3 M2 i ndi cates that the No.3 rod journal
and the No.2 mai n journal are 0.025 mm (0.001 i n)
undersi ze.
When a crankshaft i s repl aced, al l mai n and con-
necti ng rod beari ngs shoul d be repl aced wi th new
beari ngs. Therefore, sel ecti ve fi tti ng of the beari ngs
i s not requi red when a crankshaft and beari ngs are
repl aced.
INSPECTION OF J OURNALS
ENGINE MOUNTSFRONT
REMOVAL
(2) Posi ti on fan to assure cl earance for radi ator top
tank and hose.
manifold.
(3) I nstal l engi ne l i fti ng fi xture.
(4) Rai se vehi cl e on hoi st.
(5) Remove the engi ne support i nsul ator thru-bol ts
and nuts (Fi g. 14) (Fi g. 15).
(6) Rai se engi ne SLI GHTLY. Remove the engi ne
support i nsul ator bol ts. Remove the engi ne support
i nsul ator assembl y.
(7) I f requi red, remove the si l l bracket assembl y.
INSTALLATION
(1) I f the si l l bracket assembl y was removed,
i nstal l the bracket to the si l l assembl y.
Fig. 12 Main Bearing Identification
Fig. 13 Location of Crankshaft Identification
(a) RI GHT SI DEI nstal l the si l l bracket assem-
ti ghten the bol ts to 65 Nm (48 ft. l bs.) torque.
(b) LEFT SI DEI nstal l the si l l bracket assem-
ti ghten the 2 top bol ts to 65 Nm (48 ft. l bs.)
torque. I nstal l and ti ghten the 2 si de bol ts to 95
Nm (70 ft. l bs.) torque. I nstal l and ti ghten the 2
bottom bol ts to 121 Nm (89 ft. l bs.) torque.
(2) Wi th the engi ne rai sed SLI GHTLY, posi ti on
engi ne support i nsul ator assembl y onto the engi ne
bl ock (Fi g. 14) (Fi g. 15). I nstal l bol ts and ti ghten to
(3) Lower engi ne wi th l i fti ng fi xture whi l e al i gni ng
engi ne support i nsul ator assembl y i nto si l l bracket
assembl y.
(4) I nstal l the thru-bol t and nut. Ti ghten the
RI GHT SI DE nut to 81 Nm (60 ft. l bs.) torque.
Ti ghten the LEFT SI DE nut to 81 Nm (60 ft. l bs.)
torque.
(6) Remove l i fti ng fi xture.
ENGINE MOUNTSREAR
REMOVAL
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the bol ts hol di ng the mount assy. to
the crossmember.
(4) Rai se the transmi ssi on and engi ne SLI GHTLY.
(5) Remove engi ne mount bracket thru-bol t and
nut (Fi g. 16).
(6) Remove the rear mount assy.
(7) I f necessary, remove the bol ts hol di ng the rear
mount bracket to the transmi ssi on. Remove the
bracket from the exhaust pi pe hanger. Remove the
bracket.
INSTALLATION
ft. l bs.).
(2) Posi ti on the mount i nto the mount bracket and
i nstal l the thru-bol t and nut. DO NOT ti ghten the
bol t at thi s ti me.
(3) I nstal l the engi ne mount bracket assembl y to
the adaptor. I nstal l the bol ts and ti ghten to 75 Nm
(5) Remove the transmi ssi on support.
torque.
Fig. 16 Engine Rear Support Assembly
ENGINE ASSEMBLY
REMOVAL
(1) Scri be hood hi nge outl i nes on hood and remove
the hood.
(2) Remove the battery.
(3) Drai n cool i ng system.
(4) Remove the ai r cl eaner and tube.
(5) Set fan shroud asi de.
(6) Remove radi ator and heater hoses. Remove the
radi ator (refer to Group 7, Cool i ng System).
(7) Remove the vacuum l i nes.
(8) Remove the di stri butor cap and wi ri ng.
(9) Di sconnect the accel erator l i nkage.
procedure. Refer to Group 14, Fuel Systems for the
correct procedure.
(11) Di sconnect the fuel suppl y l i ne from the i njec-
tor rai l . Refer to Group 14, Fuel Systems for the cor-
rect procedure.
(12) Remove throttl e body.
(13) Remove the starter wi res.
(14) Remove the oi l pressure wi re.
(15) Di scharge the ai r condi ti oni ng system, i f
equi pped (refer to Group 24, Heati ng and Ai r Condi -
ti oni ng for servi ce procedures).
(16) Remove ai r condi ti oni ng hoses.
(17) Di sconnect the power steeri ng hoses, i f
equi pped.
(18) Remove starter motor (refer to Group 8B, Bat-
(19) Remove the generator (refer to Group 8C,
Generator Servi ce).
(21) Di sconnect exhaust pi pe at mani fol d.
(22) Support automati c transmi ssi on wi th a trans-
mi ssi on stand. Thi s wi l l assure that the torque con-
verter wi l l remai n i n proper posi ti on i n the
transmi ssi on housi ng.
(23) Remove bel l housi ng bol ts and i nspecti on
pl ate. Attach C-cl amp on front bottom of transmi s-
si on torque converter housi ng to prevent torque con-
verter from comi ng out.
(24) Remove torque converter dri ve pl ate bol ts
from torque converter dri ve pl ate. Mark converter
and dri ve pl ate to ai d i n assembl y.
(25) Di sconnect the engi ne from the torque con-
verter dri ve pl ate.
manifold.
(26) I nstal l an engi ne l i fti ng fi xture.
(27) Remove the engi ne front mount thru-bol ts.
(29) Remove engi ne from engi ne compartment.
(30) I nstal l on engi ne repai r stand.
INSTALLATION
(1) Remove engi ne from the repai r stand and posi -
ti on i n the engi ne compartment.
(2) I nstal l engi ne support fi xture.
(4) Posi ti on the torque converter and dri ve pl ate.
I nstal l torque converter dri ve pl ate bol ts. Ti ghten the
(5) I nstal l the engi ne front mount thru-bol ts.
(6) I nstal l bel l housi ng bol ts. Ti ghten the bol ts to
(7) Remove C-cl amp and i nstal l i nspecti on pl ate.
(8) Remove stand from transmi ssi on.
(9) I nstal l exhaust pi pe to mani fol d.
(11) Remove engi ne l i fti ng fi xture.
(12) I nstal l the generator (refer to Group 8C, Gen-
erator Servi ce).
(13) I nstal l starter motor (refer to Group 8B, Bat-
(14) I nstal l power steeri ng hoses, i f equi pped.
(15) I nstal l ai r condi ti oni ng hoses.
(16) Charge the ai r condi ti oner, i f equi pped (refer
to Group 24, Heater and Ai r Condi ti oni ng for servi ce
procedures).
(17) Usi ng a new gasket, i nstal l throttl e body.
Ti ghten the throttl e body bol ts to 23 Nm (200 i n.
l bs.) torque.
(18) Connect the accel erator l i nkage.
(19) Connect the starter wi res.
(20) Connect the oi l pressure wi re.
(21) I nstal l the di stri butor cap and wi ri ng.
(22) I nstal l vacuum l i nes.
(23) I nstal l radi ator, radi ator hoses and heater
hoses (refer to Group 7, Cool i ng System).
(24) I nstal l fan shroud i n posi ti on.
(25) I nstal l the battery
(28) Warm engi ne and adjust.
(29) I nstal l hood and l i ne up.
CYLINDER HEAD COVER
A steel backed si l i con gasket i s used wi th the cyl -
i nder head cover (Fi g. 17). Thi s gasket can be used
agai n.
REMOVAL
(2) Di sconnect cl osed venti l ati on system and evap-
orati on control system from cyl i nder head cover.
(3) Remove cyl i nder head cover and gasket. The
gasket may be used agai n.
INSTALLATION
(1) Cl ean cyl i nder head cover gasket surface.
(2) Cl ean head rai l , i f necessary.
(3) I nspect cover for di storti on and strai ghten, i f
necessary.
(4) Check the gasket for use i n head cover i nstal -
l ati on. I f damaged, use a new gasket.
(5) Posi ti on the cyl i nder head cover onto the gas-
ket. Ti ghten the bol ts to 11 Nm (95 i n. l bs.) torque.
(6) I nstal l cl osed crankcase venti l ati on system and
evaporati on control system.
REMOVAL
(1) Di sconnect spark pl ug wi res by pul l i ng on the
boot strai ght out i n l i ne wi th pl ug.
(2) Remove cyl i nder head cover and gasket.
(3) Remove the rocker arm bol ts and pi vots (Fi g.
18). Pl ace them on a bench i n the same order as
removed.
INSTALLATION
(1) Rotate the crankshaft unti l the V8 mark l i nes
up wi th the TDC mark on the ti mi ng chai n case
cover. Thi s mark i s l ocated 147 ATDC from the No.1
fi ri ng posi ti on.
(2) I nstal l the push rods i n the same order as
removed.
(3) I nstal l rocker arm and pi vot assembl i es i n the
same order as removed. Ti ghten the rocker arm bol ts
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(5) Connect spark pl ug wi res.
VALVE SPRING AND STEM SEAL REPLACEMENT-
IN VEHICLE
(1) Set engi ne basi c ti mi ng to Top Dead Center
(TDC).
(3) Remove cyl i nder head covers and spark pl ugs.
(4) Remove coi l wi re from di stri butor and secure to
good ground to prevent engi ne from starti ng.
(5) Usi ng sui tabl e socket and fl ex handl e at crank-
shaft retai ni ng bol t, turn engi ne so the No.1 pi ston i s
at TDC on the compressi on stroke.
(7) Wi th ai r hose attached to an adapter i nstal l ed
i n No.1 spark pl ug hol e, appl y 620-689 kPa (90-100
psi ) ai r pressure.
(8) Usi ng Val ve Spri ng Compressor Tool
MD-998772A wi th adaptor 6716A, compress val ve
spri ng and remove retai ner val ve l ocks and val ve
spri ng.
(9) I nstal l seal s on the exhaust val ve stem and
posi ti on down agai nst val ve gui des.
(10) The i ntake val ve stem seal s shoul d be pushed
fi rml y and squarel y over the val ve gui de usi ng the
val ve stem as a gui de. DO NOT force seal agai nst top
of gui de. When i nstal l i ng the val ve retai ner l ocks,
compress the spri ng onl y enough to i nstal l the l ocks.
(11) Fol l ow the same procedure on the remai ni ng 7
cyl i nders usi ng the fi ri ng sequence 1-8-4-3-6-5-7-2.
Make sure pi ston i n cyl i nder i s at TDC on the val ve
spri ng that i s bei ng removed.
(12) Remove adapter from the No.1 spark pl ug
hol e.
(13) I nstal l rocker arms.
(14) I nstal l covers and coi l wi re to di stri butor.
(15) I nstal l ai r cl eaner.
CYLINDER HEAD
REMOVAL
System for the proper procedures).
(3) Remove the generator.
(4) Remove cl osed crankcase venti l ati on system.
Fig. 17 Cylinder Head Cover Gasket
Fig. 18 Rocker Arms
(5) Di sconnect the evaporati on control system.
(7) Perform the Fuel System Pressure Rel ease pro-
cedure (refer to Group 14, Fuel System). Di sconnect
the fuel suppl y l i ne.
(8) Di sconnect accel erator l i nkage and i f so
down cabl es.
(9) Remove di stri butor cap and wi res.
(10) Di sconnect the coi l wi res.
(11) Di sconnect heat i ndi cator sendi ng uni t wi re.
(12) Di sconnect heater hoses and bypass hose.
(13) Remove cyl i nder head covers and gaskets.
(14) Remove i ntake mani fol d and throttl e body as
an assembl y. Di scard the fl ange si de gaskets and the
front and rear cross-over gaskets.
(15) Remove exhaust mani fol ds.
(16) Remove rocker arm assembl i es and push rods.
I denti fy to ensure i nstal l ati on i n ori gi nal l ocati ons.
(17) Remove the head bol ts from each cyl i nder
head and remove cyl i nder heads. Di scard the cyl i n-
der head gasket.
(18) Remove spark pl ugs.
INSTALLATION
(1) Posi ti on the new cyl i nder head gaskets onto
the cyl i nder bl ock.
(2) Posi ti on the cyl i nder heads onto head gaskets
and cyl i nder bl ock.
(3) Starti ng at top center, ti ghten al l cyl i nder head
bol ts, i n sequence, to 68 Nm (50 ft. l bs.) torque (Fi g.
19). Repeat procedure, ti ghten al l cyl i nder head bol ts
to 143 Nm (105 ft. l bs.) torque. Repeat procedure to
confi rm that al l bol ts are at 143 Nm (105 ft. l bs.)
torque.
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(4) I nstal l push rods and rocker arm assembl i es i n
thei r ori gi nal posi ti on. Ti ghten the bol ts to 28 Nm
(5) I nstal l the i ntake mani fol d and throttl e body
assembl y (refer to Group 11, Exhaust System and
I ntake Mani fol d).
(6) I nstal l exhaust mani fol ds. Ti ghten the bol ts
and nuts to 34 Nm (25 ft. l bs.) torque.
(7) Adjust spark pl ugs to speci fi cati ons (refer to
Group 8D, I gni ti on System). I nstal l the pl ugs and
(8) I nstal l coi l wi res.
(9) Connect heat i ndi cator sendi ng uni t wi re.
(10) Connect the heater hoses and bypass hose.
(11) I nstal l di stri butor cap and wi res.
(12) Connect the accel erator l i nkage and i f so
down cabl es.
(13) I nstal l the fuel suppl y l i ne.
(14) I nstal l the generator and dri ve bel t. Ti ghten
generator mounti ng bol t to 41 Nm (30 ft. l bs.)
torque. Ti ghten the adjusti ng strap bol t to 23 Nm
(200 i n. l bs.) torque. Refer to Group 7, Cool i ng Sys-
tem for adjusti ng the bel t tensi on.
(15) I nstal l the i ntake mani fol d-to-generator
bracket support rod. Ti ghten the bol ts.
(16) Pl ace the cyl i nder head cover gaskets i n posi -
ti on and i nstal l cyl i nder head covers. Ti ghten the
(17) I nstal l cl osed crankcase venti l ati on system.
(18) Connect the evaporati on control system.
System for proper procedure).
REMOVAL
(2) Compress val ve spri ngs usi ng Val ve Spri ng
Compressor Tool MD- 998772A and adapter 6716A.
(3) Remove val ve retai ni ng l ocks, val ve spri ng
retai ners, val ve stem seal s and val ve spri ngs.
(4) Before removi ng val ves, remove any burrs from
val ve stem l ock grooves to prevent damage to the
val ve gui des. I denti fy val ves to ensure i nstal l ati on i n
ori gi nal l ocati on.
INSTALLATION
(1) Cl ean val ves thoroughl y. Di scard burned,
warped and cracked val ves.
(2) Remove carbon and varni sh deposi ts from
i nsi de of val ve gui des wi th a rel i abl e gui de cl eaner.
(3) Measure val ve stems for wear. I f wear exceeds
0.051 mm (0.002 i nch), repl ace the val ve.
Fig. 19 Cylinder Head Bolt Tightening Sequence
(4) Coat val ve stems wi th l ubri cati on oi l and i nsert
them i n cyl i nder head.
(5) I f val ves or seats are reground, check val ve
stem hei ght. I f val ve i s too l ong, repl ace cyl i nder
head.
(6) I nstal l new seal s on al l val ve gui des. I nstal l
val ve spri ngs and val ve retai ners.
(7) Compress val ve spri ngs wi th Val ve Spri ng
Compressor Tool MD-998772A and adapter 6716A,
i nstal l l ocks and rel ease tool . I f val ves and/or seats
are ground, measure the i nstal l ed hei ght of spri ngs.
Make sure the measurement i s taken from bottom of
spri ng seat i n cyl i nder head to the bottom surface of
spri ng retai ner. I f spacers are i nstal l ed, measure
from the top of spacer. I f hei ght i s greater than 42.86
mm (1-11/16 i nches), i nstal l a 1.587 mm (1/16 i nch)
spacer i n head counterbore. Thi s shoul d bri ng spri ng
hei ght back to normal 41.27 to 42.86 mm (1-5/8 to
1-11/16 i nch).
HYDRAULIC TAPPETS
REMOVAL
(2) Remove cyl i nder head cover, rocker assembl y
and push rods. I denti fy push rods to ensure i nstal l a-
ti on i n ori gi nal l ocati on.
(3) Remove i ntake mani fol d, yoke retai ner and
al i gni ng yokes.
(4) Sl i de Hydraul i c Tappet Remover/I nstal l er Tool
C-4129-A through openi ng i n cyl i nder head and seat
tool fi rml y i n the head of tappet.
(5) Pul l tappet out of bore wi th a twi sti ng moti on.
I f al l tappets are to be removed, i denti fy tappets to
ensure i nstal l ati on i n ori gi nal l ocati on.
INSTALLATION
(1) I f the tappet or bore i n cyl i nder bl ock i s
scored, scuffed, or shows si gns of sti cki ng, ream the
bore to next oversi ze. Repl ace wi th oversi ze tappet.
(2) Lubri cate tappets.
(3) I nstal l tappets and push rods i n thei r ori gi nal
posi ti ons. Ensure that the oi l feed hol e i n the si de of
the tappet body faces up (away from the crankshaft).
(4) I nstal l al i gni ng yokes wi th ARROW toward
camshaft.
(5) I nstal l yoke retai ner. Ti ghten the bol ts to 23
Nm (200 i n. l bs.) torque. I nstal l i ntake mani fol d.
(6) I nstal l push rods i n ori gi nal posi ti ons.
(7) I nstal l rocker arm.
(9) Start and operate engi ne. Warm up to normal
operati ng temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
VIBRATION DAMPER
REMOVAL
(2) Remove fan shroud retai ner bol ts and set
shroud back over engi ne.
(3) Remove the cool i ng system fan.
Cool i ng System).
(5) Remove the vi brati on damper pul l ey.
(6) Remove vi brati on damper bol t and washer from
end of crankshaft.
(7) I nstal l bar and screw from Pul l er Tool Set
C-3688. I nstal l 2 bol ts wi th washers through the
pul l er tool and i nto the vi brati on damper (Fi g. 20).
(8) Pul l vi brati on damper off of the crankshaft.
INSTALLATION
(1) Posi ti on the vi brati on damper onto the crank-
shaft.
(2) Pl ace i nstal l i ng tool , part of Pul l er Tool Set
C-3688 i n posi ti on and press the vi brati on damper
onto the crankshaft (Fi g. 21).
(3) I nstal l the crankshaft bol t and washer. Ti ghten
the bol t to 183 Nm (135 ft. l bs.) torque.
Fig. 20 Vibration Damper Assembly
Fig. 21 Installing Vibration Damper
(4) I nstal l the crankshaft pul l ey. Ti ghten the pul -
l ey bol ts to 23 Nm (200 i n. l bs.) torque.
Cool i ng System).
Ti ghten the retai ner bol ts to 11 Nm (95 i n. l bs.)
torque.
TIMING CHAIN COVER
REMOVAL
System).
Cool i ng System).
(4) Remove water pump (refer to Group 7, Cool i ng
System).
(5) Remove power steeri ng pump (refer to Group
19, Steeri ng).
(7) Loosen oi l pan bol ts and remove the front bol t
at each si de.
(8) Remove the cover bol ts.
(9) Remove chai n case cover and gasket usi ng
extreme cauti on to avoi d damagi ng oi l pan gasket.
damage the crankshaft seal surface of cover (Fi g. 22).
INSTALLATION
(1) Usi ng a new cover gasket, careful l y i nstal l
chai n case cover to avoi d damagi ng oi l pan gasket.
Use a smal l amount of Mopar Si l i cone Rubber Adhe-
si ve Seal ant, or equi val ent, at the joi nt between ti m-
i ng chai n cover gasket and the oi l pan gasket. Fi nger
ti ghten the ti mi ng chai n cover bol ts at thi s ti me.
(Fi g. 24).
(4) Ti ghten the 4 l ower chai n case cover bol ts to
13Nm (10 ft.l bs.) to prevent the cover from ti ppi ng
duri ng seal i nstal l ati on.
(Fi g. 25).
(6) Loosen the 4 bol ts ti ghtened i n step 4 to al l ow
real i gnment of front cover assembl y.
(7) Ti ghten chai n case cover bol ts to 41 Nm (30 ft.
l bs.) torque. Ti ghten oi l pan bol ts to 24 Nm (215 i n.
l bs.) torque.
(9) I nstal l vi brati on damper.
Fig. 22 Removal of Front Crankshaft Oil Seal
9 - 100 5. 9L ENGINE ZJ
(10) I nstal l water pump and housi ng assembl y
usi ng new gaskets (refer to Group 7, Cool i ng Sys-
tem). Ti ghten bol ts to 41 Nm (30 ft. l bs.) torque.
(11) I nstal l power steeri ng pump (refer to Group
19, Steeri ng).
Cool i ng System).
Ti ghten the bol ts to 11 Nm (95 i n. l bs.) torque.
TIMING CHAIN
REMOVAL
(1) Remove Ti mi ng Chai n Cover Refer to proce-
dure i n thi s secti on.
(2) Remove camshaft sprocket attachi ng bol t and
remove ti mi ng chai n wi th crankshaft and camshaft
sprockets.
INSTALLATION
crankshaft bores.
shaft sprocket.
(6) I nstal l the camshaft bol t. Ti ghten the bol t to 68
new thrust pl ate.
CAMSHAFT
NOTE: The camshaft has an integral oil pump and
distributor drive gear (Fig. 27).
REMOVAL
(1) Remove i ntake mani fol d.
(2) Remove cyl i nder head covers.
(3) Remove ti mi ng case cover and ti mi ng chai n.
(5) Remove push rods and tappets. I denti fy each
part so i t can be i nstal l ed i n i ts ori gi nal l ocati on.
(6) Remove di stri butor and l i ft out the oi l pump
and di stri butor dri ve shaft.
(7) Remove camshaft thrust pl ate, note l ocati on of
oi l tab (Fi g. 28).
(8) I nstal l a l ong bol t i nto front of camshaft to
faci l i tate removal of the camshaft. Remove camshaft,
Fig. 27 Camshaft and Sprocket Assembly
ZJ 5. 9L ENGINE 9 - 101
bei ng careful not to damage cam beari ngs wi th the
cam l obes.
INSTALLATION
(1) Lubri cate camshaft l obes and camshaft beari ng
journal s and i nsert the camshaft to wi thi n 51 mm (2
i nches) of i ts fi nal posi ti on i n cyl i nder bl ock.
NOTE: Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1 pint of
Mopar Crankcase Conditioner, or equivalent. The oil
mixture should be left in engine for a minimum of
805 km (500 miles). Drain at the next normal oil
change.
(2) I nstal l Camshaft Gear I nstal l er Tool C-3509
wi th tongue back of di stri butor dri ve gear (Fi g. 29).
(3) Hol d tool i n posi ti on wi th a di stri butor l ock-
pl ate bol t. Thi s tool wi l l restri ct camshaft from bei ng
pushed i n too far and prevent knocki ng out the wel ch
pl ug i n rear of cyl i nder bl ock. Tool should remain
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) I nstal l camshaft thrust pl ate and chai n oi l tab.
Make sure tang enters lower right hole in
thrust plate. Ti ghten bol ts to 24 Nm (210 i n. l bs.)
torque. Top edge of tab shoul d be fl at agai nst thrust
pl ate i n order to catch oi l for chai n l ubri cati on.
crankshaft bores.
shaft sprocket.
(10) I nstal l the camshaft bol t/cup washer. Ti ghten
bol t to 68 Nm (50 ft. l bs.) torque.
(11) Measure camshaft end pl ay. Refer to Speci fi ca-
ti ons for proper cl earance. I f not wi thi n l i mi ts i nstal l
a new thrust pl ate.
(12) Each tappet reused must be i nstal l ed i n the
same posi ti on from whi ch i t was removed. When
camshaft is replaced, all of the tappets must be
replaced.
CAMSHAFT BEARINGS
REMOVAL
NOTE: This procedure requires that the engine is
removed from the vehicle.
(1) Wi th engi ne compl etel y di sassembl ed, dri ve out
rear cam beari ng core hol e pl ug.
(2) I nstal l proper si ze adapters and horseshoe
washers (part of Camshaft Beari ng Remover/I nstal l er
Fig. 28 Timing Chain Oil Tab Installation
Fig. 29 Camshaft Holding Tool C-3509 (Installed
Position)
9 - 102 5. 9L ENGINE ZJ
Tool C-3132-A) at back of each beari ng shel l . Dri ve
out beari ng shel l s (Fi g. 31).
INSTALLATION
(1) I nstal l new camshaft beari ngs wi th Camshaft
Beari ng Remover/I nstal l er Tool C-3132-A by sl i di ng
the new camshaft beari ng shel l over proper adapter.
(2) Posi ti on rear beari ng i n the tool . I nstal l horse-
shoe l ock and by reversi ng removal procedure, care-
ful l y dri ve beari ng shel l i nto pl ace.
(3) I nstal l remai ni ng beari ngs i n the same man-
ner. Beari ngs must be careful l y al i gned to bri ng oi l
hol es i nto ful l regi ster wi th oi l passages from the
mai n beari ng. I f the camshaft beari ng shel l oi l hol es
are not i n exact al i gnment, remove and i nstal l them
correctl y. I nstal l a new core hol e pl ug at the rear of
camshaft. Be sure this plug does not leak.
REMOVAL
i ng cap.
beari ng caps one at a ti me.
(4) Remove upper hal f of beari ng by i nserti ng
Crankshaft Mai n Beari ng Remover/I nstal l er Tool
C-3059 i nto the oi l hol e of crankshaft (Fi g. 32).
(5) Sl owl y rotate crankshaft cl ockwi se, forci ng out
upper hal f of beari ng shel l .
INSTALLATION
Onl y one mai n beari ng shoul d be sel ecti vel y fi tted
whi l e al l other mai n beari ng caps are properl y ti ght-
ened. Al l beari ng capbol ts removed duri ng servi ce
procedures are to be cl eaned and oi l ed before i nstal -
l ati on.
When i nstal l i ng a new upper beari ng shel l , sl i ghtl y
chamfer the sharp edges from the pl ai n si de.
(1) Start beari ng i n pl ace, and i nsert Crankshaft
Mai n Beari ng Remover/I nstal l er Tool C-3059 i nto oi l
hol e of crankshaft (Fi g. 32).
(2) Sl owl y rotate crankshaft countercl ockwi se sl i d-
i ng the beari ng i nto posi ti on. Remove Tool C-3059.
(3) I nstal l the beari ng caps. Cl ean and oi l the
bol ts. Ti ghten the capbol ts to 115 Nm (85 ft. l bs.)
torque.
DISTRIBUTOR DRIVE SHAFT BUSHING
REMOVAL
(1) Remove di stri butor, refer to Group 8D, I gni ti on
(2) Remove the i ntake mani fol d (refer to Group 11,
(3) I nsert Di stri butor Dri ve Shaft Bushi ng Pul l er
Tool C-3052 i nto ol d bushi ng and thread down unti l a
ti ght fi t i s obtai ned (Fi g. 33).
(4) Hol d pul l er screw and ti ghten pul l er nut unti l
bushi ng i s removed.
INSTALLATION
(1) Sl i de new bushi ng over burni shi ng end of Di s-
tri butor Dri ve Shaft Bushi ng Dri ver/Burni sher Tool
C-3053. I nsert the tool and bushi ng i nto the bore.
Fig. 31 Camshaft Bearings Removal/Installation with
Tool C-3132-A
Fig. 32 Upper Main Bearing Removal and
Installation with Tool C-3059
Fig. 33 Distributor Driveshaft Bushing Removal
ZJ 5. 9L ENGINE 9 - 103
(2) Dri ve bushi ng and tool i nto posi ti on, usi ng a
hammer (Fi g. 34).
(3) As the burni sher i s pul l ed through the bushi ng,
the bushi ng i s expanded ti ght i n the bl ock and bur-
ni shed to correct si ze (Fi g. 35). DO NOT ream this
bushing.
CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may
occur.
(4) I nstal l the i ntake mani fol d (refer to Group 11,
DISTRIBUTOR INSTALLATION
NOTE: Before installing the distributor, the oil
pump drive shaft must be aligned to number one
cylinder.
(1) Rotate crankshaft unti l No.1 cyl i nder i s at top
dead center on the fi ri ng stroke.
(2) When i n thi s posi ti on, the ti mi ng mark of
vi brati on damper shoul d be under 0 on the ti mi ng
i ndi cator.
(3) I nstal l the shaft so that after the gear spi ral s
i nto pl ace, i t wi l l i ndex wi th the oi l pump shaft. The
sl ot on top of oi l pump shaft shoul d be al i gned
towards the l eft front i ntake mani fol d attachi ng bol t
hol e (Fi g. 36).
(4) I nstal l di stri butor, refer to Group 8D, I gni ti on
After the di stri butor has been i nstal l ed, i ts rota-
ti onal posi ti on must be set usi ng the SET SYNC
mode of the DRB scan tool . Refer to Checki ng Di s-
tri butor Posi ti on fol l owi ng the Di stri butor I nstal l a-
ti on secti on i n Group 8D, I gni ti on system.
Do not attempt to adjust ignition timing by
rotating the distributor. It has no effect on igni-
tion timing. Adjusting distributor position will
effect fuel synchronization only.
OIL PAN
REMOVAL
engi ne oi l .
(4) Remove the oi l fi l ter.
(5) Remove the starter (refer to Group 8B, Battery/
the sensor.
(7) Posi ti on the cool er l i nes out of the way.
(8) Di sconnect the oxygen sensor.
(9) Remove exhaust pi pe.
INSTALLATION
(1) Fabri cate 4 al i gnment dowel s from 5/16 x 1 1/2
(2) I nstal l the dowel s i n the cyl i nder bl ock (Fi g.
38).
(3) Appl y smal l amount of Mopar Si l i cone Rubber
Adhesi ve Seal ant, or equi val ent i n the corner of the
cap and the cyl i nder bl ock.
onto the bl ock.
Fig. 34 Distributor Driveshaft Bushing Installation
Fig. 35 Burnishing Distributor Driveshaft Bushing
Fig. 36 Position of Oil Pump Shaft Slot
9 - 104 5. 9L ENGINE ZJ
(6) I nstal l the oi l pan bol ts. Ti ghten the bol ts to 24
(7) Remove the dowel s. I nstal l the remai ni ng oi l
pan bol ts. Ti ghten these bol ts to 24 Nm (215 i n. l bs.)
torque.
(8) I nstal l the drai n pl ug. Ti ghten drai n pl ug to 34
(9) I nstal l exhaust pi pe.
(10) Connect the oxygen sensor.
(11) I nstal l the oi l fi l ter.
(12) I f equi pped wi th an oi l l evel sensor, connect
the sensor.
(13) I nstal l the starter (refer to Group 8B, Battery/
(14) Move the cool er l i nes back i nto posi ti on.
(15) Lower vehi cl e.
l evel .
REMOVAL
(1) Remove the engi ne from the vehi cl e.
(4) Remove top ri dge of cyl i nder bores wi th a rel i -
abl e ri dge reamer before removi ng pi stons from cyl -
i nder bl ock. Be sure to keep tops of pi stons covered
duri ng thi s operati on.
(5) Be sure the connecti ng rod and connecti ng rod
cap are i denti fi ed wi th the cyl i nder number. Remove
connecti ng rod cap. I nstal l connecti ng rod bol t gui de
set on connecti ng rod bol ts.
(6) Pi stons and connecti ng rods must be removed
from top of cyl i nder bl ock. When removi ng pi ston and
connecti ng rod assembl i es, rotate crankshaft to cen-
ter the connecti ng rod i n the cyl i nder bore and at
BDC. Be careful not to nick crankshaft journals.
(7) After removal , i nstal l beari ng cap on the mat-
i ng rod.
INSTALLATION
(1) Be sure that compressi on ri ng gaps are stag-
gered so that nei ther i s i n-l i ne wi th oi l ri ng rai l gap.
(2) Before i nstal l i ng the ri ng compressor, make
sure the oi l ri ng expander ends are butted and the
rai l gaps l ocated properl y (Fi g. 39).
ZJ 5. 9L ENGINE 9 - 105
(3) I mmerse the pi ston head and ri ngs i n cl ean
engi ne oi l . Sl i de Pi ston Ri ng Compressor Tool C-385
over the pi ston and ti ghten wi th the speci al wrench
(part of Tool C-385). Be sure position of rings
does not change during this operation.
(4) I nstal l connecti ng rod bol t protectors on rod
bol ts, the l ong protector shoul d be i nstal l ed on the
numbered si de of the connecti ng rod.
(5) Rotate crankshaft so that the connecti ng rod
journal i s on the center of the cyl i nder bore. Be sure
connecti ng rod and cyl i nder bore number are the
same. I nsert rod and pi ston i nto cyl i nder bore and
gui de rod over the crankshaft journal .
(6) Tap the pi ston down i n cyl i nder bore, usi ng a
hammer handl e. At the same ti me, gui de connecti ng
rod i nto posi ti on on crankshaft journal .
(7) The notch or groove on top of pi ston must be
poi nti ng toward front of engi ne. The l arger chamfer
of the connecti ng rod bore must be i nstal l ed toward
crankshaft journal fi l l et.
(8) I nstal l rod caps. Be sure connecti ng rod, con-
necti ng rod cap and cyl i nder bore number are the
same. I nstal l nuts on cl eaned and oi l ed rod bol ts and
ti ghten nuts to 61 Nm (45 ft. l bs.) torque.
CRANKSHAFT
REMOVAL
i ng cap.
(4) Remove the ti mi ng chai n cover.
beari ng caps and beari ngs one at a ti me.
(6) Li ft the crankshaft out of the bl ock.
(7) Remove and di scard the crankshaft rear oi l
seal s.
(8) Remove and di scard the front crankshaft oi l
seal .
INSTALLATION
(1) Cl ean Locti te 518 resi due and seal ant from the
cyl i nder bl ock and rear cap mati ng surface. Do thi s
before appl yi ng the Locti te drop and the i nstal l ati on
of rear cap.
oi l .
oi l .
cati on.
(11) I nstal l the ti mi ng chai n cover.
OIL PUMP
REMOVAL
(2) Remove the oi l pump from rear mai n beari ng
cap.
INSTALLATION
(1) I nstal l oi l pump. Duri ng i nstal l ati on sl owl y
rotate pump body to ensure dri veshaft-to-pump rotor
shaft engagement.
9 - 106 5. 9L ENGINE ZJ
(2) Hol d the oi l pump base fl ush agai nst mati ng
surface on No.5 mai n beari ng cap. Fi nger ti ghten
pump attachi ng bol ts. Ti ghten attachi ng bol ts to 41
CRANKSHAFT OIL SEAL FRONT
The oi l seal can be repl aced wi thout removi ng the
ti mi ng chai n cover provi ded the cover i s not mi s-
al i gned.
(3) I f front seal i s suspected of l eaki ng, check front
oi l seal al i gnment to crankshaft. The seal i nstal l a-
ti on/al i gnment tool 6635, shoul d fi t wi th mi ni mum
i nterference. I f tool does not fi t, the cover must be
removed and i nstal l ed properl y.
damage the crankshaft seal bore of cover.
(Fi g. 43).
(Fi g. 44).
(9) I nspect the seal fl ange on the vi brati on
damper.
ZJ 5. 9L ENGINE 9 - 107
CRANKSHAFT OIL SEALS REAR
The servi ce seal i s a 2 pi ece, vi ton seal . The upper
seal hal f can be i nstal l ed wi th crankshaft removed
from engi ne or wi th crankshaft i nstal l ed. When a
new upper seal i s i nstal l ed, i nstal l a new l ower seal .
The l ower seal hal f can onl y be i nstal l ed wi th the
rear mai n beari ng cap removed.
UPPER SEAL CRANKSHAFT REMOVED
REMOVAL
(1) Remove the crankshaft. Di scard the ol d upper
seal .
INSTALLATION
(1) Cl ean the cyl i nder bl ock rear cap mati ng sur-
face. Make sure the seal groove i s free of debri s.
oi l .
oi l .
cati on.
UPPER SEAL CRANKSHAFT INSTALLED
REMOVAL
i ng cap.
(3) Remove the rear mai n beari ng cap. Remove
and di scard the ol d l ower oi l seal .
(4) Careful l y remove and di scard the ol d upper oi l
seal .
INSTALLATION
(1) Cl ean the cyl i nder bl ock mati ng surfaces before
oi l seal i nstal l ati on. Check for burr at the oi l hol e on
the cyl i nder bl ock mati ng surface to rear cap.
oi l . To al l ow ease of i nstal l ati on of the seal , l oosen at
l east the 2 mai n beari ng caps forward of the rear
beari ng cap.
(3) Rotate the new upper seal i nto the cyl i nder
bl ock bei ng careful not to shave or cut the outer sur-
face of the seal . To assure proper i nstal l ati on, use the
i nstal l ati on tool provi ded wi th the ki t. I nstal l the
new seal wi th the whi te pai nt faci ng towards the
rear of the engi ne.
9 - 108 5. 9L ENGINE ZJ
cati on. Be sure the whi te pai nt faces toward the rear
of the engi ne.
and oi l ed cap bol ts. Al ternatel y ti ghten ALL cap bol ts
pan seal groove.
LOWER SEAL
REMOVAL
i ng cap.
(3) Remove the rear mai n beari ng cap and di scard
the ol d l ower seal .
INSTALLATION
(1) Cl ean the rear mai n cap mati ng surfaces
i ncl udi ng the oi l pan gasket groove.
(2) Careful l y i nstal l a new upper seal (refer to
Upper Seal Repl acement - Crankshaft I nstal l ed pro-
cedure above).
oi l .
(4) I nstal l a new l ower seal i n beari ng cap wi th
the whi te pai nt faci ng the rear of engi ne.
cati on.
and oi l ed cap bol ts. Al ternatel y ti ghten the cap bol ts
pan seal groove.
ENGINE CORE OIL AND CAMSHAFT PLUGS
Engi ne core pl ugs have been pressed i nto the oi l
gal l eri es behi nd the camshaft thrust pl ate (Fi g. 47).
Thi s wi l l reduce i nternal l eakage and hel p mai ntai n
hi gher oi l pressure at i dl e.
REMOVAL
(1) Usi ng a bl unt tool such as a dri ft or a screw-
dri ver and a hammer, stri ke the bottom edge of the
cup pl ug (Fi g. 48).
(2) Wi th the cup pl ug rotated, grasp fi rml y wi th
pl i ers or other sui tabl e tool and remove pl ug (Fi g.
48).
INSTALLATION
Thoroughl y cl ean i nsi de of cup pl ug hol e i n cyl i n-
der bl ock or head. Be sure to remove ol d seal er.
Be certai n the new pl ug i s cl eaned of al l oi l or
grease.
(1) Coat edges of pl ug and core hol e wi th Mopar
Gasket Maker, or equi val ent.
CAUTION: DO NOT drive cup plug into the casting,
as restricted coolant flow can result and cause seri-
ous engine problems.
Fig. 47 Location of Cup Plugs in Oil Galleries
ZJ 5. 9L ENGINE 9 - 109
(2) Usi ng proper pl ug dri ve, dri ve cup pl ug i nto
hol e. The sharp edge of the pl ug shoul d be at l east
0.50 mm (0.020 i n.) i nsi de the l ead-i n chamfer.
(3) I t i s not necessary to wai t for curi ng of the
seal ant. The cool i ng system can be fi l l ed and the
vehi cl e pl aced i n servi ce i mmedi atel y.
HYDRAULIC TAPPETS
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable
to work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. DO NOT dis-
assemble a tappet on a dirty work bench.
DISASSEMBLE
(1) Pry out pl unger retai ner spri ng cl i p (Fi g. 49).
(2) Cl ean varni sh deposi ts from i nsi de of tappet
body above pl unger cap.
(3) I nvert tappet body and remove pl unger cap,
pl unger, check val ve, check val ve spri ng, check val ve
retai ner and pl unger spri ng (Fi g. 49). Check val ve
coul d be fl at or bal l .
ASSEMBLE
(1) Cl ean al l tappet parts i n a sol vent that wi l l
remove al l varni sh and carbon.
(2) Repl ace tappets that are unfi t for further ser-
vi ce wi th new assembl i es.
(3) I f pl unger shows si gns of scori ng or wear,
i nstal l a new tappet assembl y. I f val ve i s pi tted, or
val ve seat on end of pl unger i s prevented from seat-
i ng, i nstal l a new tappet assembl y.
(4) Assembl e tappets (Fi g. 49).
VALVE SERVICE
VALVE GUIDES
Measure val ve stem gui de cl earance as fol l ows:
(1) I nstal l Val ve Gui de Sl eeve Tool C-3973 over
val ve stem and i nstal l val ve (Fi g. 50). The speci al
sl eeve pl aces the val ve at the correct hei ght for
checki ng wi th a di al i ndi cator.
(2) Attach Di al I ndi cator Tool C-3339 to cyl i nder
head and set i t at ri ght angl e of val ve stem bei ng
measured (Fi g. 51).
(3) Move val ve to and from the i ndi cator. The total
di al i ndi cator readi ng shoul d not exceed 0.432 mm
(0.017 i nch). Ream the gui des for val ves wi th over-
Fig. 48 Core Hole Plug Removal
Fig. 49 Hydraulic Tappet Assembly
Fig. 50 Positioning Valve with Tool C-3973
Fig. 51 Measuring Valve Guide Wear
9 - 110 5. 9L ENGINE ZJ
si ze stems i f di al i ndi cator readi ng i s excessi ve or i f
the stems are scuffed or scored.
(4) Servi ce val ves wi th oversi ze stems are avai l -
abl e (Fi g. 52).
(5) Sl owl y turn reamer by hand and cl ean gui de
thoroughl y before i nstal l i ng new val ve. Ream the
valve guides from standard to 0.381 mm (0.015
inch). Use a 2 step procedure so the valve
guides are reamed true in relation to the valve
seat:
REFACING VALVES AND VALVE SEATS
The i ntake and exhaust val ves have a 43-1/4 to
43-3/4 face angl e and a 44-1/4 to 44-3/4 seat angl e
(Fi g. 53).
VALVES
I nspect the remai ni ng margi n after the val ves are
refaced (Fi g. 54). Val ves wi th l ess than 1.190 mm
(0.047 i nch) margi n shoul d be di scarded.
VALVE SEATS
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 55).
(1) When refaci ng val ve seats, i t i s i mportant that
the correct si ze val ve gui de pi l ot be used for reseat-
i ng stones. A true and compl ete surface must be
obtai ned.
(2) Measure the concentri ci ty of val ve seat usi ng a
di al i ndi cator. Total runout shoul d not exceed 0.051
mm (0.002 i nch) total i ndi cator readi ng.
(3) I nspect the val ve seat wi th Prussi an bl ue to
determi ne where the val ve contacts the seat. To do
thi s, coat val ve seat LI GHTLY wi th Prussi an bl ue
then set val ve i n pl ace. Rotate the val ve wi th l i ght
Fig. 52 Reamer Sizes
Fig. 53 Valve Face and Seat Angles
Fig. 54 Intake and Exhaust Valves
Fig. 55 Refacing Valve Seats
ZJ 5. 9L ENGINE 9 - 111
pressure. I f the bl ue i s transferred to the center of
val ve face, contact i s sati sfactory. I f the bl ue i s trans-
ferred to the top edge of val ve face, l ower val ve seat
wi th a 15 stone. I f the bl ue i s transferred to bottom
edge of val ve face rai se val ve seat wi th a 60 stone.
(4) When seat i s properl y posi ti oned the wi dth of
i ntake seats shoul d be 1.016-1.524 mm (0.040-0.060
i nch). The wi dth of the exhaust seats shoul d be
1.524-2.032 mm (0.060-0.080 i nch).
VALVE SPRING INSPECTION
Whenever val ves have been removed for i nspecti on,
recondi ti oni ng or repl acement, val ve spri ngs shoul d
be tested. As an exampl e the compressi on l ength of
the spri ng to be tested i s 1-5/16 i nch. Turn tabl e of
Uni versal s Val ve Spri ng Tester Tool unti l surface i s
i n l i ne wi th the 1-5/16 i nch mark on the threaded
stud. Be sure the zero mark i s to the front (Fi g. 56).
Pl ace spri ng over stud on the tabl e and l i ft compress-
i ng l ever to set tone devi ce. Pul l on torque wrench
unti l pi ng i s heard. Take readi ng on torque wrench
at thi s i nstant. Mul ti pl y thi s readi ng by 2. Thi s wi l l
gi ve the spri ng l oad at test l ength. Fracti onal mea-
surements are i ndi cated on the tabl e for fi ner adjust-
ments. Refer to speci fi cati ons to obtai n speci fi ed
hei ght and al l owabl e tensi ons. Di scard the spri ngs
that do not meet speci fi cati ons.
OIL PUMP
DISASSEMBLE
(1) Remove the rel i ef val ve as fol l ows:
(a) Remove cotter pi n. Dri l l a 3.175 mm (1/8
i nch) hol e i nto the rel i ef val ve retai ner cap and
i nsert a sel f-threadi ng sheet metal screw.
(b) Cl amp screw i nto a vi se and whi l e support-
i ng oi l pump, remove cap by tappi ng pump body
usi ng a soft hammer. Di scard retai ner cap and
remove spri ng and rel i ef val ve (Fi g. 57).
(2) Remove oi l pump cover (Fi g. 58).
(3) Remove pump outer rotor and i nner rotor wi th
shaft (Fi g. 58).
(4) Wash al l parts i n a sui tabl e sol vent and i nspect
careful l y for damage or wear.
ASSEMBLE
(1) I nstal l pump rotors and shaft, usi ng new parts
as requi red.
(2) Posi ti on the oi l pump cover onto the pump
body. Ti ghten cover bol ts to 11 Nm (95 i n. l bs.)
torque.
(3) I nstal l the rel i ef val ve and spri ng. I nsert the
cotter pi n.
(4) Tap on a new retai ner cap.
(5) Pri me oi l pump before i nstal l ati on by fi l l i ng
rotor cavi ty wi th engi ne oi l .
CYLINDER BLOCK
DISASSEMBLE
Engi ne assembl y removed from vehi cl e:
Fig. 56 Testing Valve Spring for Compressed
Length
Fig. 57 Oil Pressure Relief Valve
Fig. 58 Oil Pump
9 - 112 5. 9L ENGINE ZJ
(3) Remove the pi ston and connecti ng rod assem-
bl i es.
ASSEMBLE
(1) I nstal l the pi ston and connecti ng rod assembl y.
CYLINDER HEADS
CLEANING
Cl ean al l surfaces of cyl i nder bl ock and cyl i nder
heads.
Cl ean cyl i nder bl ock front and rear gasket surfaces
usi ng a sui tabl e sol vent.
INSPECTION
I nspect al l surfaces wi th a strai ghtedge i f there i s
any reason to suspect l eakage. I f out-of-fl atness
exceeds 0.00075 mm/mm (0.00075 i nch/i nch) ti mes
the span l ength i n i nches i n any di recti on, ei ther
repl ace head or l i ghtl y machi ne the head surface.
FOR EXAMPLE: A 305 mm (12 i nch) span i s
0.102 mm (0.004 i nch) out-of-fl at. The al l owabl e out-
of-fl at i s 305 x 0.00075 (12 x 0.00075) equal s 0.23
mm (0.009 i nch). Thi s amount of out-of-fl at i s accept-
abl e.
The cyl i nder head surface fi ni sh shoul d be
1.78-3.00 mi crons (70-125 mi cro i nches).
I nspect push rods. Repl ace worn or bent rods.
INSPECTION
Check the crankshaft connecti ng rod journal for
excessi ve wear, taper and scori ng.
Check the cyl i nder bl ock bore for out-of-round,
taper, scori ng and scuffi ng.
CRANKSHAFT JOURNALS
OIL PAN
CLEANING
Cl ean the bl ock and pan gasket surfaces.
Tri m or remove excess seal ant fi l m i n the rear
mai n cap oi l pan gasket groove. DO NOT remove
the sealant inside the rear main cap slots.
I f present, tri m excess seal ant from i nsi de the
engi ne.
Cl ean oi l pan i n sol vent and wi pe dry wi th a cl ean
cl oth.
Cl ean oi l screen and pi pe thoroughl y i n cl ean sol -
vent. I nspect condi ti on of screen.
INSPECTION
I nspect oi l drai n pl ug and pl ug hol e for stri pped or
damaged threads. Repai r as necessary.
I nspect oi l pan mounti ng fl ange for bends or di stor-
ti on. Strai ghten fl ange, i f necessary.
Fig. 59 Piston Measurements5.9L
ZJ 5. 9L ENGINE 9 - 113
OIL PUMP
INSPECTION
Mati ng surface of the oi l pump cover shoul d be
smooth. Repl ace pump assembl y i f cover i s scratched
or grooved.
Lay a strai ghtedge across the pump cover surface
(Fi g. 60). I f a 0.038 mm (0.0015 i nch) feel er gauge
can be i nserted between cover and strai ghtedge,
pump assembl y shoul d be repl aced.
Measure thi ckness and di ameter of OUTER rotor.
I f outer rotor thi ckness measures 20.9 mm (0.825
i nch) or l ess or i f the di ameter i s 62.7 mm (2.469
i nches) or l ess, repl ace outer rotor (Fi g. 61).
I f i nner rotor measures 20.9 mm (0.825 i nch) or
l ess, repl ace i nner rotor and shaft assembl y (Fi g. 62).
Sl i de outer rotor i nto pump body. Press rotor to the
si de wi th your fi ngers and measure cl earance
between rotor and pump body (Fi g. 63). I f cl earance
i s 0.356 mm (0.014 i nch) or more, repl ace oi l pump
assembl y.
I nstal l i nner rotor and shaft i nto pump body. I f
cl earance between i nner and outer rotors i s 0.203
mm (0.008 i nch) or more, repl ace shaft and both
rotors (Fi g. 64).
Pl ace a strai ghtedge across the face of the pump,
between bol t hol es. I f a feel er gauge of 0.102 mm (0.004
i nch) or more can be i nserted between rotors and the
strai ghtedge, repl ace pump assembl y (Fi g. 65).
Fig. 64 Measuring Clearance Between Rotors
Fig. 60 Checking Oil Pump Cover Flatness
Fig. 61 Measuring Outer Rotor Thickness
Fig. 62 Measuring Inner Rotor Thickness
Fig. 63 Measuring Outer Rotor Clearance in
Housing
9 - 114 5. 9L ENGINE ZJ
I nspect oi l pressure rel i ef val ve pl unger for scori ng
and free operati on i n i ts bore. Smal l marks may be
removed wi th 400-gri t wet or dry sandpaper.
The rel i ef val ve spri ng has a free l ength of approx-
i matel y 49.5 mm (1.95 i nches). The spri ng shoul d
test between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 i nches). Repl ace spri ng that fai l s
to meet these speci fi cati ons (Fi g. 66).
I f oi l pressure was l ow and pump i s wi thi n speci fi -
cati ons, i nspect for worn engi ne beari ngs or other
reasons for oi l pressure l oss.
CYLINDER BLOCK
CLEANING
Cl ean cyl i nder bl ock thoroughl y and check al l core
hol e pl ugs for evi dence of l eaki ng.
INSPECTION
Exami ne bl ock for cracks or fractures.
The cyl i nder wal l s shoul d be checked for out-of-
round and taper wi th Cyl i nder Bore I ndi cator Tool
C-119. The cyl i nder bl ock shoul d be bored and honed
wi th new pi stons and ri ngs fi tted i f:
The cyl i nder bores show more than 0.127 mm
(0.005 i n.) out-of-round.
The cyl i nder bores show a taper of more than
0.254 mm (0.010 i n.).
The cyl i nder wal l s are badl y scuffed or scored.
Bori ng and honi ng operati on shoul d be cl osel y coor-
di nated wi th the fi tti ng of pi stons and ri ngs, so that
speci fi ed cl earances can be mai ntai ned.
OIL LINE PLUG
The oi l l i ne pl ug i s l ocated i n the verti cal passage
at the rear of the bl ock between the oi l -to-fi l ter and
oi l -from-fi l ter passages (Fi g. 67). I mproper i nstal l a-
ti on or pl ug mi ssi ng coul d cause errati c, l ow, or no oi l
pressure.
The oi l pl ug must come out the bottom. Use fl at
dowel , down the oi l pressure sendi ng uni t hol e from
the top, to remove oi l pl ug.
(1) Remove oi l pressure sendi ng uni t from back of
bl ock.
(2) I nsert a 3.175 mm (1/8 i n.) fi ni sh wi re, or
equi val ent, i nto passage.
(3) Pl ug shoul d be 190.0 to 195.2 mm (7-1/2 to
7-11/16 i n.) from machi ned surface of bl ock (Fi g. 67).
I f pl ug i s too hi gh, use a sui tabl e fl at dowel to posi -
ti on properl y.
(4) I f pl ug i s too l ow, remove oi l pan and No. 4
mai n beari ng cap. Use sui tabl e fl at dowel to posi ti on
properl y. Coat outsi de di ameter of pl ug wi th Mopar
Stud and Beari ng Mount Adhesi ve, or equi val ent.
Pl ug shoul d be 54.0 to 57.7 mm (2-1/8 to 2-5/16 i n.)
from bottom of the bl ock.
Fig. 65 Measuring Clearance Over Rotors
Fig. 66 Proper Installation of Retainer Cap
Fig. 67 Oil Line Plug
ZJ 5. 9L ENGINE 9 - 115
SPECIFICATIONS
GENERAL INFORMATION
Engi ne Type . . . . . . . . . . . . . . . . . . . . . .90 V-8 OHV
Bore and Stroke . . .101.6 x 90.9 mm (4.00 x 3.58 i n.)
Di spl acement . . . . . . . . . . . . . . . . . . . .5.9L (360 c.i .)
Fi ri ng Order . . . . . . . . . . . . . . . . . .18436572
Lubri cati on . . . .Pressure Feed Ful l Fl ow Fi l trati on
Cool i ng System . .Li qui d Cool ed Forced Ci rcul ati on
Crankshaft. . . . . . . . . . . . . . . . . . . . . . .Nodul ar I ron
Camshaft . . . . . . . . . . . . . . . . . . . .Nodul ar Cast I ron
Combusti on Chambers . . . .Wedge - Hi gh Swi rl Val ve
Shroudi ng
Pi stons . . . . . . . . . . . . . . . . .Al umi num Al l oy w/strut
Connecti ng Rods . . . . . . . . . . . . . . . . . . .Forged Steel
Compressi on Pressure . . . .689.5 kPa (100 psi ) (Mi n.)
CAMSHAFT
Bearing Diameter
No. 1 . . . . . . .50.800 50.825 mm (2.000 2.001 i n.)
No. 2 . . . . . . .50.394 50.419 mm (1.984 1.985 i n.)
No. 3 . . . . . . .50.013 50.038 mm (1.969 1.970 i n.)
No. 4 . . . . . . .49.606 49.632 mm (1.953 1.954 i n.)
No. 5 . . . . .39.688 39.713 mm (1.5625 1.5635 i n.)
No. 1 . . . . . . .50.749 50.775 mm (1.998 1.999 i n.)
No. 2 . . . . . . .50.343 50.368 mm (1.982 1.983 i n.)
No. 3 . . . . . . .49.962 49.987 mm (1.967 1.968 i n.)
No. 4 . . . . . . .49.555 49.581 mm (1.951 1.952 i n.)
No. 5 . . . . .39.637 39.662 mm (1.5605 1.5615 i n.)
Bearing to J ournal Clearance
Standard . . . .0.0254 0.0762 mm (0.001 0.003 i n.)
Camshaft End Play
End Pl ay . . . . . .0.051 0.254 mm (0.002 0.010 i n.)
CONNECTING RODS
Pi ston Pi n bore Di ameter . . . . . .24.966 24.978 mm
(0.9829 0.9834 i n.)
Si de Cl earance . . . . . . . . . . . . . . . .0.152 0.356 mm
(0.006 0.014 i n.)
CRANKSHAFT
Rod J ournal
Di ameter . . . .53.950 53.975 mm (2.124 2.125 i n.)
Out of Round (Max.). . . . . . . . .0.0254 mm (0.001 i n.)
Taper (Max.). . . . . . . . . . . . . . .0.0254 mm (0.001 i n.)
Rod J ournal
Beari ng Cl earance . . . . . . . . . . . . .0.013 0.056 mm
(0.0005 0.0022 i n.)
Servi ce Li mi t . . . . . . . . . . . .0.0762 mm (0.003 i n.)
Main Bearing J ournal
Di ameter . .71.361 71.387 mm (2.8095 2.8105 i n.)
Taper (Max.). . . . . . . . . . . . . . .0.0254 mm (0.001 i n.)
Beari ng Cl earance (#1 Journal ) . . .0.013 0.038 mm
(0.0005 0.0015 i n.)
Servi ce Li mi t (#1 Journal ). . . . . . . . . . .0.0381 mm
(0.0015 i n.)
Beari ng Cl earance (#2-5 Journal s) . . .0.013 0.051 mm
(0.0005 0.002 i n.)
Servi ce Li mi t (#2-5 Journal s) . . . . . . . . .0.064 mm
(0.0025 i n.)
Crankshaft End Play
End Pl ay . . . . . .0.051 0.178 mm (0.002 0.007 i n.)
CYLINDER BLOCK
Cylinder Bore
Di ameter . . . .101.60 101.65 mm (4.000 4.002 i n.)
Taper (Max.) . . . . . . . . . . . . . . .0.254 mm (0.010 i n.)
Lifter Bore
Di ameter . . . .22.99 23.01 mm (0.9051 0.9059 i n.)
Distributor Drive Bushing (Press Fit)
Bushi ng to Bore I nterference . . .0.0127 0.3556 mm
(0.0005 0.0140 i n.)
Shaft to Bushi ng Cl earance . . . .0.0178 0.0686 mm
(0.0007 0.0027 i n.)
CYLINDER HEAD AND VALVES
Valve Seat
Angl e . . . . . . . . . . . . . . . . . . . . . . . . .44.25 44.75
Runout (Max.) . . . . . . . . . . . . .0.0762 mm (0.003 i n.)
Wi dth (Fi ni sh) I ntake . . . . . . . . .1.016 1.524 mm
(0.040 0.060 i n.)
Wi dth (Fi ni sh) Exhaust . . . . . . . .1.524 2.032 mm
(0.060 0.080 i n.)
Valves
Face Angl e . . . . . . . . . . . . . . . . . . . . .43.25 43.75
Head Di ameter I ntake . . . . . .47.752 mm (1.88 i n.)
Head Di ameter Exhaust. . . . . . . .41.072 (1.617 i n.)
Length (Overal l ) I ntake . . . . . .126.21 126.85 mm
(4.969 4.994 i n.)
Length (Overal l ) Exhaust . . . .126.44 127.30 mm
(4.978 5.012 i n.)
9 - 116 5. 9L ENGINE ZJ
Valve Seat
Li ft (@ zero l ash) I ntake . . . .10.414 mm (0.410 i n.)
Li ft (@ zero l ash) Exhaust . . .10.592 mm (0.417 i n.)
Stem Di ameter I ntake. . . . . . . . .9.449 9.474 mm
(0.372 0.373 i n.)
Stem Di ameter Exhaust . . . . . . .9.423 9.449 mm
(0.371 0.372 i n.)
Gui de Bore . . . .9.500 9.525 mm (0.374 0.375 on.)
Stem to Gui de Cl earance
I ntake. . . .0.0254 0.0762 mm (0.001 0..003 i n.)
Stem to Gui de Cl earance
Exhaust . . .0.0508 0.1016 mm (0.002 0.004 i n.)
Servi ce Li mi t . . . . . . . . . . . . . . . .0.4318 (0.017 i n.)
Valve Springs
Free Length . . . . . . . . . . . . . . .49.962 mm (1.967 i n.)
Spri ng Tensi on (val ve cl osed) . .378 N @ 41.66 mm
(85 l bs. @ 1.64 i n.)
Spri ng Tensi on (val ve open). . . .890 N @ 30.89 mm
(200 l bs. @ 1.212 i n.)
Number of Coi l s. . . . . . . . . . . . . . . . . . . . . . . . . . .6.8
I nstal l ed Hei ght. . . . . . . . . . . . . .41.66 mm (1.64 i n.)
Wi re Di ameter . . . . . . . . . . . . . . .4.50 mm (0.177 i n.)
HYDRAULIC TAPPETS
Body Di ameter . . . . . . . . . . . . . .22.949 22.962 mm
(0.9035 0.9040 i n.)
Cl earance (to bore) . . . . . . . . . . .0.0279 0.0610 mm
(0.0011 0.0024 i n.)
Dry Lash . . . . . .1.524 5.334 mm (0.060 0.210 i n.)
Push Rod Length . . . . . . . . . . . .175.64 176.15 mm
(6.915 6.935 i n.)
OIL PRESSURE
Curb I dl e (Mi n.*). . . . . . . . . . . . . . . .41.4 kPa (6 psi )
3000 rpm. . . . . . . . . . . . .207 552 kPa (30 80 psi )
Oi l Pressure Bypass Val ve Setti ng. . . . .62 103 kPa
(9 15 psi )
Swi tch Actuati ng Pressure . . . . . . . . .34.5 48.3 kPa
(5 7 psi )
CAUTION: If oil pressure is zero at curb idle, DO
NOT RUN ENGINE.
OIL PUMP
Cl earance over Rotors (Max.). .0.1016 mm (0.004 i n.)
Cover Out of Fl at (Max.) . . . .0.0381 mm (0.0015 i n.)
I nner Rotor Thi ckness (Mi n.) . . . .20.955 mm (0.825 i n.)
Outer Rotor Cl earance (Max.) . . .0.3556 mm (0.014 i n.)
Outer Rotor Di ameter (Mi n.) . . .62.7126 mm (2.469 i n.)
Outer Rotor Thi ckness (Mi n.). . . .20.955 mm (0.825 i n.)
Ti p Cl earance between Rotors (Max.) . . . .0.2032 mm
(0.008 i n.)
PISTONS
(0.0005 0.0015 i n.)
Land Cl earance (Di am.) . . . . . . . . .0.508 0.660 mm
(0.020 0.026 i n.)
Pi ston Length . . . . . . . . . . . . . . .81.03 mm (3.19 i n.)
Pi ston Ri ng Groove Depth #1&2 . . .4.761 4.912 mm
(0.187 0.193 i n.)
Pi ston Ri ng Groove Depth #3 . . .3.996 4.177 mm
(0.157 0.164 i n.)
Wei ght . . . . . . . .582 586 grams (20.53 20.67 oz.)
PISTON PINS
Cl earance i n Pi ston . . . . . . . . . . . .0.006 0.019 mm
(0.00023 0.00074 i n.)
Di ameter . . . .25.007 25.015 mm (0.9845 0.9848 i n.)
End Pl ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NONE
Length . . . . . . . . . . .67.8 68.3 mm (2.67 2.69 i n.)
PISTON RINGS
Ring Gap
Compressi on Ri ng (Top) . . . . . . . . . . .0.30 0.55 mm
(0.012 0.022 i n.)
Compressi on Ri ng (2nd). . . . . . . . . . .0.55 0.80 mm
(0.022 0.031 i n.)
Oi l Control (Steel Rai l s) . . . . . . . . .0.381 1.397 mm
(0.015 0.055 i n.)
Ring Side Clearance
(0.0016 0.0033 i n.)
Oi l Ri ng (Steel Rai l s) . . . . . . . . . . . . .0.05 0.21 mm
(0.002 0.008 i n.)
Ring Width
Compressi on ri ngs . . . . . . . . . . . . .1.530 1.555 mm
(0.060 0.061 i n.)
Oi l Ri ng (Steel Rai l s) Max. . . . . . .0.447 0.473 mm
(0.018 0.019 i n.)
VALVE TINING
Exhaust Valve
Cl oses (ATDC). . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Opens (BBDC). . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
Intake Valve
Cl oses (ATDC). . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Opens (BBDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
Val ve Overl ap . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
ZJ 5. 9L ENGINE 9 - 117
OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
5. 9L TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Camshaft Sprocket
Bol t . . . . . . . . . . . . . . . . . . . . . .68 Nm (50 ft. l bs.)
Camshaft Thrust Plate
Bol ts . . . . . . . . . . . . . . . . . . . . .24 Nm (18 ft. l bs.)
Chain Case Cover
Bol ts . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Connecting Rod Cap
Bol ts . . . . . . . . . . . . . . . . . . . . .61 Nm (45 ft. l bs.)
Crankshaft Main Bearing Cap
Bol ts . . . . . . . . . . . . . . . . . . . .115 Nm (85 ft. l bs.)
Crankshaft Pulley
Bol ts . . . . . . . . . . . . . . . . . . . .24 Nm (210 i n. l bs.)
Cylinder Head Bolts
Step 1 I ni ti al . . . . . . . . . . . . .68 Nm (50 ft. l bs.)
Step 2 Fi nal . . . . . . . . . . . .143 Nm (105 ft. l bs.)
Cylinder Head Cover
Bol ts . . . . . . . . . . . . . . . . . . . . .11 Nm (95 i n. l bs.)
Exhaust Manifold to Cylinder Head
Bol ts/Nuts . . . . . . . . . . . . . . . . .34 Nm (25 ft. l bs.)
Flywheel
Bol ts . . . . . . . . . . . . . . . . . . . . .75 Nm (55 ft. l bs.)
Front Engine Mount Bracket to Block
Bol ts . . . . . . . . . . . . . . . . . . . . .81 Nm (60 ft. l bs.)
Front Engine Mount
Through Bol t/Nut . . . . . . . . . . .68 Nm (50 ft. l bs.)
Generator Mounting
Bol ts . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Intake Manifold
Bol ts . . . . . . . . . .Refer to procedure i n thi s secti on
DESCRIPTION TORQUE
Oil Pan
Bol ts . . . . . . . . . . . . . . . . . . . .24 Nm (215 i n. l bs.)
Oil Pan Drain Plug
Pl ug. . . . . . . . . . . . . . . . . . . . . .34 Nm (25 ft. l bs.)
Oil Pump
Bol ts . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Oil Pump Cover
Bol ts . . . . . . . . . . . . . . . . . . . . .11 Nm (95 i n. l bs.)
Rear Mount Insulator to Support Bracket
Nuts . . . . . . . . . . . . . . . . . . . . .47 Nm (35 ft. l bs.)
Rear Mount Insulator to Crossmember
Nut . . . . . . . . . . . . . . . . . . . . . .47 Nm (35 ft. l bs.)
Rear Support Bracket to Transmission
Bol ts . . . . . . . . . . . . . . . . . . . .102 Nm (75 ft. l bs.)
Rocker Arm
Bol ts . . . . . . . . . . . . . . . . . . . . .28 Nm (21 ft. l bs.)
Spark Plugs
Pl ugs . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Starter Mounting
Bol ts . . . . . . . . . . . . . . . . . . . . .68 Nm (50 ft. l bs.)
Thermostat Housing
Bol ts . . . . . . . . . . . . . . . . . . . .25 Nm (225 i n. l bs.)
Throttle Body
Bol ts . . . . . . . . . . . . . . . . . . . .23 Nm (200 i n. l bs.)
Torque Converter Drive Plate
Bol ts . . . . . . . . . . . . . . . . . . . .31 Nm (270 i n. l bs.)
Transmission Support Bracket
Bol ts . . . . . . . . . . . . . . . . . . . .102 Nm (75 ft. l bs.)
Transmission Support Spacer to
Insulator Mounting Plate (4wd)
Nuts. . . . . . . . . . . . . . . . . . . .204 Nm (150 ft. l bs.)
9 - 118 5. 9L ENGINE ZJ
DESCRIPTION TORQUE
Vibration Damper
Bol t . . . . . . . . . . . . . . . . . . . .183 Nm (135 ft. l bs.)
Water Pump to Chain Case Cover
Bol t . . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
SPECIAL TOOLS
5. 9L ENGINE
Oil Pressure Gauge C-3292
Engine Support Fixture C-3487A
Valve Spring Compressor MD-998772A
Adaptor 6633
Adaptor 6716A
Valve Guide Sleeve C-3973
Dial Indicator C-3339
ZJ 5. 9L ENGINE 9 - 119
Puller C-3688
Front Oil Seal Installer 6635
Cam Bearing Remover/Installer C-3132A
Camshaft Holder C-3509
Distributor Bushing Puller C-3052
Distributor Bushing Driver/Burnisher C-3053
Piston Ring Compressor C-385
Crankshaft Main Bearing Remover C-3059
Cylinder Bore Gauge C-119
9 - 120 5. 9L ENGINE ZJ
SPECIAL TOOLS (Continued)

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