ENGINE - 3.7LTABLE OF CONTENTSpage pageENGINE - 3.7LDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - ENGINEDIAGNOSIS - INTRODUCTION. . . . . . . . . . . . 4DIAGNOSIS AND TESTING - ENGINEDIAGNOSIS - PERFORMANCE. . . . . . . . . . . . 4DIAGNOSIS AND TESTING - ENGINEDIAGNOSIS - MECHANICAL. . . . . . . . . . . . . . 6DIAGNOSIS AND TESTING - ENGINEDIAGNOSIS - LUBRICATION . . . . . . . . . . . . . . 7DIAGNOSIS AND TESTING - CYLINDERCOMPRESSION PRESSURE . . . . . . . . . . . . . . 8DIAGNOSIS AND TESTING - CYLINDERCOMBUSTION PRESSURE LEAKAGE. . . . . . . 8STANDARD PROCEDURESTANDARD PROCEDURE - ENGINEGASKET SURFACE PREPARATION. . . . . . . . . 9STANDARD PROCEDURE - REPAIRDAMAGED OR WORN THREADS. . . . . . . . . . 9STANDARD PROCEDURE - ENGINE COREAND OIL GALLERY PLUGS . . . . . . . . . . . . . . 10REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11SPECIFICATIONSTORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 12SPECIAL TOOLS3.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 15AIR CLEANER ELEMENTREMOVAL - 3.7L . . . . . . . . . . . . . . . . . . . . . . . . 19INSTALLATION - 3.7L . . . . . . . . . . . . . . . . . . . . 19CYLINDER HEAD - LEFTDESCRIPTION - VALVE GUIDES . . . . . . . . . . . 19DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - HYDRAULICLASH ADJUSTER. . . . . . . . . . . . . . . . . . . . . 19DIAGNOSIS AND TESTING - CYLINDERHEAD GASKET. . . . . . . . . . . . . . . . . . . . . . . 19REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22CAMSHAFT(S)DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25CYLINDER HEAD COVER(S)DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26INTAKE/EXHAUST VALVES & SEATSDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26STANDARD PROCEDURE - REFACING . . . . . . 26REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28ROCKER ARMDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29VALVE GUIDE SEALSDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29VALVE SPRINGSDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29CYLINDER HEAD - RIGHTDESCRIPTIONDESCRIPTION - CYLINDER HEAD . . . . . . . . 30DESCRIPTION - VALVE GUIDES . . . . . . . . . . 30DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 30DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - HYDRAULICLASH ADJUSTER. . . . . . . . . . . . . . . . . . . . . 30DIAGNOSIS AND TESTING - CYLINDERHEAD GASKET. . . . . . . . . . . . . . . . . . . . . . . 30REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 32INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32CAMSHAFT(S)DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33CYLINDER HEAD COVER(S)REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34INTAKE/EXHAUST VALVES & SEATSSTANDARD PROCEDURE - REFACING . . . . . . 34REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36ROCKER ARMDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37VALVE GUIDE SEALSDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38VALVE SPRINGSDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38KJ ENGINE - 3. 7L 9 -1ENGINE BLOCKDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39STANDARD PROCEDURE - CYLINDER BOREHONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 40CONNECTING ROD BEARINGSSTANDARD PROCEDURE - CONNECTINGROD BEARING - FITTING . . . . . . . . . . . . . . . 40CRANKSHAFTDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 43INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43CRANKSHAFT MAIN BEARINGSSTANDARD PROCEDUREMAIN BEARING - FITTING . . . . . . . . . . . . . . . 45CRANKSHAFT OIL SEAL - FRONTREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47CRANKSHAFT OIL SEAL - REARREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48FLEX PLATEREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49PISTON & CONNECTING RODDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49STANDARD PROCEDURECONNECTING ROD BEARING - FITTING . . . 49STANDARD PROCEDURE - PISTONFITTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 51INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51PISTON RINGSSTANDARD PROCEDURE - PISTON RINGFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52VIBRATION DAMPERREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55STRUCTURAL COVERDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 55OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 55REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55FRONT MOUNTREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57REAR MOUNTREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57LUBRICATIONDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 57OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 58DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - ENGINE OILLEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60DIAGNOSIS AND TESTING - ENGINE OILPRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 60DIAGNOSIS AND TESTING - REAR SEALAREA LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . 61OILSTANDARD PROCEDURE - ENGINE OIL . . . . . 61OIL FILTERREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63OIL PANDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 63REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 63INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64OIL PRESSURE SENSOR/SWITCHDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 65OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 65REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 65OIL PUMPREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 65INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 66ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67INTAKE MANIFOLDDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 68DIAGNOSIS AND TESTING - INTAKEMANIFOLD LEAKS . . . . . . . . . . . . . . . . . . . . . 68REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69EXHAUST MANIFOLDDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 69REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70VALVE TIMINGDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 71OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 71STANDARD PROCEDUREMEASURING TIMING CHAIN WEAR . . . . . . . 71SERVICE PROCEDURES . . . . . . . . . . . . . . . 72BALANCE SHAFTREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 74TIMING BELT / CHAIN COVER(S)REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 76IDLER SHAFTREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77TIMING BELT/CHAIN AND SPROCKET(SREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 79INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 809 -2 ENGINE - 3. 7L KJENGI NE - 3.7LDESCRIPTIONThe 3.7 l i ter (226 CI D) si x-cyl i nder engi ne i s an90 si ngl e overhead camshaft engi ne. The cast i roncyl i nder bl ock i s made up of two di fferent compo-nents; the fi rst component i s the cyl i nder bore andupper bl ock, the second component i s the bedpl atethat compri sesthel ower porti onofthecyl i nder bl ockand houses the l ower hal f of the crankshaft mai nbeari ngs. The cyl i nders are numbered fromfront torear wi th the l eft bank bei ng numbered 1,3,and 5andtheri ght bank bei ngnumbered2,4, and6. Thefi ri ngorder i s 165432. Theengi neseri al num-ber i s l ocated at the ri ght front si de of the engi nebl ock3.7 L ENGINEKJ ENGINE - 3. 7L 9 -3DI AGNOSI S AND TESTI NGDIAGNOSIS AND TESTING -ENGINEDIAGNOSIS -INTRODUCTIONEngi ne di agnosi s i s hel pful i n determi ni ng thecausesofmal functi onsnotdetectedandremedi edbyrouti nemai ntenance.Thesemal functi onsmaybecl assi fi edasei ther per-formance (e.g., engi ne i dl es rough and stal l s) ormechani cal (e.g., astrangenoi se).(Refer to9- ENGI NE- DI AGNOSI SANDTEST-I NG)PERFORMANCEand(Refer to9-ENGI NE-DI AGNOSI S AND TESTI NG)MECHANI CAL forpossi bl e causes and correcti ons of mal functi ons.(Refer to 14 - FUEL SYSTEM/FUEL DELI VERY-DI AGNOSI S AND TESTI NG) and (Refer to 14 -FUEL SYSTEM/FUEL I NJECTI ON - DI AGNOSI SANDTESTI NG) for thefuel systemdi agnosi s.Addi ti onal tests anddi agnosti cprocedures may benecessary for speci fi c engi ne mal functi ons that cannot be i sol ated wi th the Servi ce Di agnosi s charts.I nformati on concerni ngaddi ti onal tests and di agno-si s i s provi dedwi thi nthefol l owi ngdi agnosi s:Cyl i nder Compressi onPressureTest (Refer to 9-ENGI NE-DI AGNOSI SANDTESTI NG).Cyl i nder Combusti on Pressure Leakage Test(Refer to 9 - ENGI NE - DI AGNOSI S ANDTEST-I NG).Engi neCyl i nder HeadGasketFai l ureDi agnosi s(Refer to 9- ENGI NE/CYLI NDERHEAD- DI AGNO-SI SANDTESTI NG).I ntakeMani fol dLeakageDi agnosi s(Refer to9-ENGI NE/MANI FOLDS/I NTAKE MANI FOLD -DI AGNOSI SANDTESTI NG).DIAGNOSIS AND TESTING -ENGINE DIAGNOSIS -PERFORMANCECONDITION POSSIBLE CAUSE CORRECTIONENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary.2. Corroded or loose batteryconnections.2. Clean and tighten batteryconnections. Apply a coat of lightmineral grease to the terminals.3. Faulty starter. 3. (Refer to 8 - ELECTRICAL/STARTING - DIAGNOSIS ANDTESTING).4. Faulty coil or control unit. 4. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITIONCOIL - REMOVAL).5. Incorrect spark plug gap. 5. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/SPARK PLUG- CLEANING).6. Incorrect right bank cam timing. 6. Refer to engine timing in thissection.7. Dirt or water in fuel system. 7. Clean system and replace fuelfilter.8.Faulty fuel pump, relay or wiring. 8.Repair or replace as necessary.9. Faulty cam or crank sensor 9. Refer to Ignition system.ENGINE STALLS OR ROUGH IDLE 1. Vacuum leak. 1. Inspect intake manifold andvacuum hoses, repair or replace asnecessary.2. Faulty crank position sensor 2. Replace crank position sensor.4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITIONCOIL - REMOVAL).9 -4 ENGINE - 3. 7L KJENGI NE-3.7L(Cont inued)CONDITION POSSIBLE CAUSE CORRECTION5. Incorrect cam timing. 5. (Refer to 9 - ENGINE/VALVETIMING - STANDARDPROCEDURE).1. ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped sparkplugs.1. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/SPARK PLUG- CLEANING).2. Dirt or water in fuel system. 2. Clean system and replace fuelfilter.3. Faulty fuel pump. 3. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP -DIAGNOSIS AND TESTING).4. Blown cylinder head gasket. 4. Replace cylinder head gasket.5. Low compression. 5. (Refer to 9 - ENGINE -DIAGNOSIS AND TESTING), repairas necessary.6. Burned, warped or pitted valves. 6. Replace as necessary.7. Plugged or restricted exhaustsystem.7. Inspect and replace asnecessary.8. Faulty coil. 8. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITIONCOIL - REMOVAL).9. Incorrect cam timing. 9. Refer to Engine TIming in thissection.1. ENGINE MISSES ONACCELERATION1. Spark plugs dirty or incorrectlygapped.1. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/SPARK PLUG- CLEANING).2. Dirt in fuel system. 2. Clean fuel system.3. Burned, warped or pitted valves. 3. Replcae as necessary.4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITIONCOIL - REMOVAL).1. ENGINE MISSES AT HIGHSPEED1. Spark plugs dirty or incorrectlygapped.1. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/SPARK PLUG- CLEANING).2. Faulty coil. 2. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITIONCOIL - REMOVAL).3. Dirt or water in fuel system. 3. Clean system and replace fuelfilter.KJ ENGINE - 3. 7L 9 -5ENGI NE-3.7L(Cont inued)DIAGNOSIS AND TESTING -ENGINE DIAGNOSIS -MECHANICALCONDITION POSSIBLE CAUSES CORRECTIONSNOISY VALVES 1. High or low oil level incrankcase.1. (Refer to LUBRICATION &MAINTENANCE/FLUID TYPES -SPECIFICATIONS).2. Thin or diluted oil. 2. Change oil and filter.3. Low oil pressure. 3. Check oil pump, if Ok, check rodand main bearings for excessivewear.4. Dirt in lash adjusters. 4. Clean or replace as necessary.5. Worn rocker arms. 5. Replace as necessary.7. Worn valve guides. 7. (Refer to 9 - ENGINE/CYLINDERHEAD/INTAKE/EXHAUST VALVES& SEATS - STANDARDPROCEDURE).8. Excessive runout of valve seatson valve faces.8. Service valves and valve seats.(Refer to 9 - ENGINE/CYLINDERHEAD/INTAKE/EXHAUST VALVES& SEATS - STANDARDPROCEDURE).ENGINE VIBRATION 1. Counter Balance Shaft not timedproperly1. Refer to Engine Timing in thissectionCONNECTING ROD NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &MAINTENANCE/FLUID TYPES -SPECIFICATIONS).2. Low oil pressure. 2. Check oil pump, if Ok, check rodand main bearings for excessivewear.3. Thin or diluted oil. 3. Change oil and filter.4. Excessive bearing clearance. 4. Replace as necessary.5. Connecting rod journalout-of-round.5. Service or replace crankshaft.6. Misaligned connecting rods. 6. Replace bent connecting rods.MAIN BEARING NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &MAINTENANCE/FLUID TYPES -SPECIFICATIONS).2. Low oil pressure. 2. Check oil pump, if Ok, check rodand main bearings for excessivewear.3. Thin or diluted oil. 3. Change oil and filter.4. Excessive bearing clearance. 4. Replace as necessary.5. Excessive end play. 5. Check thrust washers for wear.6. Crankshaft journal out-of round. 6. Service or replace crankshaft.7. Loose flywheel or torqueconverter.7. Tighten to correct torque9 -6 ENGINE - 3. 7L KJENGI NE-3.7L(Cont inued)DIAGNOSIS AND TESTING -ENGINE DIAGNOSIS -LUBRICATIONCONDITION POSSIBLE CAUSES CORRECTIONOIL LEAKS 1. Gaskets and O-Rings. 1.(a) Misaligned or damaged. (a) Replace as necessary.(b) Loose fasteners, broken orporous metal parts.(b) Tighten fasteners, Repair orreplace metal parts.2. Crankshaft rear seal 2. Replace as necessary (Refer to 9- ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR -REMOVAL).3. Crankshaft seal flange.Scratched, nicked or grooved.3. Polish or replace crankshaft.4. Oil pan flange cracked. 4. Replace oil pan (Refer to 9 -ENGINE/LUBRICATION/OIL PAN -REMOVAL).5. Timing chain cover sealdamaged.5. Re-seal timing cover.6. Scratched or damaged vibrationdamper hub.6. Polish or replace damper.OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.2. Faulty oil pressure sending unit. 2. Replace sending unit (Refer to 9- ENGINE/LUBRICATION/OILPRESSURE SENSOR/SWITCH -REMOVAL).3. Low oil pressure. 3. Check oil pump and bearingclearance.4. Clogged oil filter. 4. Replace oil filter (Refer to 9 -ENGINE/LUBRICATION/OIL FILTER- REMOVAL).5. Worn oil pump. 5. Replace oil pump (Refer to 9 -ENGINE/LUBRICATION/OIL PUMP- REMOVAL).6. Thin or diluted oil. 6. Change oil and filter.7. Excessive bearing clearance. 7. Replace as necessary.8. Oil pump relief valve stuck. 8. Replace oil pump (Refer to 9 -ENGINE/LUBRICATION/OIL PUMP- REMOVAL).9. Oil pump suction tube loose,damaged or clogged.9. Replace as necessary.KJ ENGINE - 3. 7L 9 -7ENGI NE-3.7L(Cont inued)CONDITION POSSIBLE CAUSES CORRECTIONOIL PUMPING AT RINGS; SPARKPLUGS FOULING1. Worn or damaged rings. 1. Hone cylinder bores and replacerings.2. Carbon in oil ring slots. 2. Replace rings (Refer to 9 -ENGINE/ENGINE BLOCK/PISTONRINGS - STANDARDPROCEDURE).3. Incorrect ring size installed. 3. Replace rings (Refer to 9 -ENGINE/ENGINE BLOCK/PISTONRINGS - STANDARDPROCEDURE).4. Worn valve guides. 4. Ream guides and replace valves(Refer to 9 - ENGINE/CYLINDERHEAD/INTAKE/EXHAUST VALVES& SEATS - STANDARDPROCEDURE).5. Leaking valve guide seals. 5. Replace valve guide seals.DIAGNOSIS AND TESTING -CYLINDERCOMPRESSION PRESSURETheresul tsofacyl i nder compressi onpressuretestcan be uti l i zed todi agnose several engi ne mal func-ti ons.Ensure the battery i s compl etel y chargedandtheengi ne starter motor i s i n good operati ngcondi ti on.Otherwi se the i ndi cated compressi on pressures maynotbeval i dfor di agnosi s purposes.(1) Cl eanthesparkpl ugrecesseswi thcompressedai r.(2) Removethespark pl ugs.(3) Securethethrottl ei nthewi de-openposi ti on.(4) Di sabl e the fuel system(Refer to14 - FUELSYSTEM/FUELDELI VERY-DESCRI PTI ON).(5) RemovetheASDrel ay(Refer to8-ELECTRI -CAL/I GNI TI ON CONTROL/AUTO SHUT DOWNRELAY-REMOVAL).(6) I nsert acompressi onpressuregaugeandrotatethe engi ne wi th the engi ne starter motor for threerevol uti ons.(7) Record the compressi on pressure on the 3rdrevol uti on. Conti nuethetestfor theremai ni ngcyl i n-ders.(8) (Refer to 9-ENGI NE-SPECI FI CATI ONS) forthecorrectengi necompressi onpressures.DIAGNOSIS AND TESTING -CYLINDERCOMBUSTION PRESSURE LEAKAGEThecombusti on pressurel eakagetest provi des anaccuratemeans for determi ni ngengi necondi ti on.Combusti onpressurel eakagetesti ngwi l l detect:Exhaust andi ntakeval vel eaks (i mproper seat-i ng).Leaks between adjacent cyl i nders or i ntowaterjacket.Anycausesfor combusti on/compressi onpressurel oss.(1) Checkthecool ant l evel andfi l l asrequi red. DONOT i nstal l theradi ator cap.(2) Start and operate the engi ne unti l i t attai nsnormal operati ngtemperature, thenturntheengi neOFF.(3) Removethespark pl ugs.(4) Removetheoi l fi l l er cap.(5) Removetheai r cl eaner.(6) Cal i bratethetester accordi ngtothemanufac-turers i nstructi ons. The shop ai r source for testi ngshoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1,379kPa(200psi ) maxi mumand552kPa(80psi ) recom-mended.(7) Performthe test procedures on each cyl i nderaccordi ng tothe tester manufacturers i nstructi ons.Set pi ston of cyl i nder tobetestedat TDCcompres-si on,Whi l etesti ng,l i stenfor pressuri zedai r escapi ngthrough the throttl e body, tai l pi pe and oi l fi l l er capopeni ng. Check for bubbl es i ntheradi ator cool ant.Al l gauge pressure i ndi cati ons shoul d be equal ,wi thnomorethan25%l eakage.FOR EXAMPLE: At 552kPa(80psi )i nput pres-sure, ami ni mumof414kPa(60psi ) shoul dbemai n-tai nedi nthecyl i nder.Refer to CYLI NDER COMBUSTI ON PRESSURELEAKAGEDI AGNOSI SCHART .9 -8 ENGINE - 3. 7L KJENGI NE-3.7L(Cont inued)CYLI NDER COMBUSTI ONPRESSURE LEAKAGE DI AGNOSI S CHARTCONDITION POSSIBLE CAUSE CORRECTIONAIR ESCAPES THROUGHTHROTTLE BODYIntake valve bent, burnt, or notseated properlyInspect valve and valve seat.Reface or replace, as necessary.Inspect valve springs. Replace asnecessary.AIR ESCAPES THROUGHTAILPIPEExhaust valve bent, burnt, or notseated properlyInspect valve and valve seat.Reface or replace, as necessary.Inspect valve springs. Replace asnecessary.AIR ESCAPES THROUGHRADIATORHead gasket leaking or crackedcylinder head or blockRemove cylinder head and inspect.Replace defective partMORE THAN 50% LEAKAGEFROM ADJACENT CYLINDERSHead gasket leaking or crack incylinder head or block betweenadjacent cylindersRemove cylinder head and inspect.Replace gasket, head, or block asnecessaryMORE THAN 25% LEAKAGE ANDAIR ESCAPES THROUGH OILFILLER CAP OPENING ONLYStuck or broken piston rings;cracked piston; worn rings and/orcylinder wallInspect for broken rings or piston.Measure ring gap and cylinderdiameter, taper and out-of-round.Replace defective part as necessarySTANDARD PROCEDURESTANDARD PROCEDURE -ENGINE GASKETSURFACE PREPARATIONTo ensure engi ne gasket seal i ng, proper surfacepreparati on must be performed, especi al l y wi th theuseof al umi numengi necomponents andmul ti -l ayersteel cyl i nder headgaskets.Neverusethefol l owi ngtocl eangasketsurfaces:Metal scraperAbrasi ve pad or paper to cl ean cyl i nder bl ockandheadHi ghspeedpower tool wi thanabrasi vepador awi rebrush(Fi g. 1)NOTE: Multi-Layer Steel (MLS) head gaskets requireascratchfreesealingsurface.Onl yusethefol l owi ng for cl eani ng gasket surfaces:Sol vent or a commerci al l y avai l abl e gasketremoverPl asti cor woodscraper (Fi g. 1)Dri l l motor wi th3MRol oc Bri stl eDi sc(whi teor yel l ow) (Fi g. 1)CAUTION: Excessive pressure or high RPM (beyondtherecommendedspeed), candamagethesealingsurfaces. Themild(white, 120grit) bristlediscisrecommended. If necessary, the medium (yellow, 80grit)bristlediscmaybeusedoncastironsurfaceswithcare.STANDARD PROCEDURE -REPAIR DAMAGEDOR WORN THREADSCAUTION: Besurethat thetappedholesmaintaintheoriginal centerline.Damagedor wornthreads canberepai red. Essen-ti al l y, thi s repai r consi sts of:Dri l l i ngoutwornor damagedthreads.Fig. 1 Proper Tool Usage For Surface Preparation1 - ABRASIVE PAD2 - 3M ROLOC BRISTLE DISC3 - PLASTIC/WOOD SCRAPERKJ ENGINE - 3. 7L 9 -9ENGI NE-3.7L(Cont inued)Tappi ngthehol ewi thaspeci al Hel i -Coi l Tap, orequi val ent.I nstal l i ngani nserti nto thetappedhol eto bri ngthehol eback toi ts ori gi nal threadsi ze.STANDARD PROCEDURE -ENGINE CORE ANDOIL GALLERY PLUGSUsi ngabl unt tool such as adri ft andahammer,stri kethebottomedgeofthecuppl ug.Wi ththecuppl ugrotated, grasp fi rml y wi th pl i ers or other sui t-abl etool andremovepl ug(Fi g. 2).CAUTION: Do not drive cup plug into the casting asrestricted cooling can result and cause seriousengineproblems.Thoroughl y cl ean i nsi deof cuppl ughol ei n cyl i n-der bl ock or head. Be sure to remove ol d seal er.Li ghtl y coat i nsi de of cup pl ug hol e wi th MoparStudandBeari ngMount. Makecertai nthenewpl ugi s cl eaned of al l oi l or grease. Usi ng proper dri vepl ug, dri ve pl ugi ntohol e sothat the sharpedge ofthe pl ug i s at l east 0.5 mm(0.020 i n.) i nsi de thel ead-i nchamfer.I t i snot necessaryto wai t for curi ngof theseal ant.The cool i ng systemcan be refi l l ed and the vehi cl epl acedi nservi cei mmedi atel y.REMOVAL(1) Di sconnectthebatterynegati vecabl e.(2) Remove hood. Mark hood hi nge l ocati on forrei nstal l ati on.(3) Removeai r cl eaner assembl y.(4) Removeradi ator coresupportbracket.(5) Removefanshroudwi thel ectri cfanassembl y.(6) Removemechani cal cool i ngfan.(7) Removedri vebel t.NOTE: It is NOTnecessary todischarge theA/Csystemtoremovetheengine.(8) RemoveA/Ccompressor andsecureaway fromengi newi thl i nes attached.(9) Remove generator and secure away fromengi ne.NOTE: Do NOT remove the phenolic pulley from theP/Spump. ItisnotrequiredforP/Spumpremoval.(10) Remove power steeri ng pump wi th l i nesattachedandsecureawayfromengi ne.(11) Drai ncool i ngsystem.(12) Removecool antbottl e.(13) Di sconnecttheheater hoses fromtheengi ne.(14) Di sconnectheater hoses fromheater coreandremovehoseassembl y.(15) Di sconnectthrottl eandspeedcontrol cabl es.(16) Removeupper radi ator hosefromengi ne.(17) Removel ower radi ator hosefromengi ne.(18) Di sconnect the engi ne tobody ground strapsatthel eftsi deof cowl .(19) Di sconnect the engi ne wi ri ng harness at thefol l owi ngpoi nts:I ntakeai r temperature(I AT) sensorFuel I njectorsThrottl ePosi ti on(TPS) Swi tchI dl eAi r Control (I AC) MotorEngi neOi l PressureSwi tchEngi neCool antTemperature(ECT) SensorMani fol dAbsol utePressureMAP) SensorCamshaftPosi ti on(CMP) SensorCoi l Over Pl ugsCrankshaftPosi ti onSensor(20) Removecoi l over pl ugs.(21) Rel easefuel rai l pressure.(22) Remove fuel rai l and secure away fromengi ne.NOTE:Itisnotnecessarytoreleasethequickcon-nect fitting fromthe fuel supply line for engineremoval.(23) RemovethePCVhose.(24) Removethebreather hoses.(25) Removethevacuumhosefor thepower brakebooster.(26) Di sconnectknock sensors.(27) Removeengi neoi l di psti ck tube.(28) Removei ntakemani fol d.(29) I nstal l engi nel i ftpl ate.Fig. 2 Core Hole Plug Removal1 - CYLINDER BLOCK2 - REMOVE PLUG WITH PLIERS3 - STRIKE HERE WITH HAMMER4 - DRIFT PUNCH5 - CUP PLUG9 -10 ENGINE - 3. 7L KJENGI NE-3.7L(Cont inued)NOTE: Recheck bolt torque for engine lift platebeforeremovingengine.(30) Secure the l eft and ri ght engi ne wi ri ng har-nesses awayfromengi ne.(31) Rai sevehi cl e.(32) Di sconnectoxygensensor wi ri ng.(33) Di sconnectcrankshaftposti onsensor.(34) Di sconnect the engi ne bl ock heater powercabl e, i f equi pped.(35) Di sconnect the front propshaft at the frontdi fferenti al andsecureoutof way.NOTE:Itisnecessarytodisconnectthefrontprop-shaftforaccesstothestarterandleftsideexhaustflange.(36) Removethestarter.(37) Remove the ground straps fromthe l eft andri ghtsi deof thebl ock.(38) Di sconnecttheri ghtandl eftexhaustpi pesatthe mani fol ds and fromthe crossover, and removefromthevehi cl e.NOTE: The exhaust clamps at the manifolds cannotbereused.Newclampsmustbeusedorleaksmayoccur.NOTE: For manual transmission vehicles, the trans-missionmust beremovedfromthevehicle, beforetheenginecanberemoved. Themanual transmis-sion will contact the floorpan before the engineclearsthemotormounts, soitmustberemoved.(39) Removethestructural cover.(40) Remove torque convertor bol ts, and markl ocati onfor reassembl y.(41) Remove transmi ssi on bel l housi ng to engi nebol ts.(42) Loosenl eft andri ght engi nemount thrubol ts.NOTE: It is not necessary to completely removeenginemountthrubolts, forengineremoval.(43) Lower thevehi cl e.(44) Support thetransmi ssi onwi thasui tabl ejack.(45) Connectasui tabl eengi nehoi sttotheengi nel i ftpl ate.(46) Removeengi nefromvehi cl e.INSTALLATION(1) Posi ti ontheengi nei nthevehi cl e.(2) I nstal l both l eft andri ght si de engi ne mountsontoengi ne.(3) Rai sethevehi cl e.(4) I nstal l the transmi ssi on bel l housi ngtoengi nemounti ng bol ts. Ti ghten the bol ts to41 Nm(30ft.l bs.).(5) Ti ghtentheengi nemountthrubol ts.(6) I nstal l thetorqueconvertor bol ts.(7) Connect thegroundstrapsonthel eft andri ghtsi deof theengi ne.(8) I nstal l thestarter.(9) Connectthecrankshaftposi ti onsensor.(10) I nstal l theengi nebl ockheater power cabl e,i fequi pped.CAUTION: Thestructural cover requiresaspecifictorque sequence. Failure to followthis sequencemaycauseseveredamagetothecover.(11) I nstal l thestructural cover.NOTE:Newclampsmustbeusedonexhaustman-ifoldflanges.Failuretousenewclampsmayresultinexhaustleaks.(12) I nstal l thel eftandri ghtexhaustpi pes.(13) Connectthel eftandri ghtoxygensensors.(14) Lower vehi cl e.(15) Removetheengi nel i ftpl ate.(16) Connecttheknock sensors.(17) Connect the engi ne tobody groundstraps atthel eftsi deof thecowl .(18) I nstal l thei ntakemani fol d.(19) I nstal l theengi neoi l di psti ck tube.(20) I nstal l thepower brakebooster vacuumhose.(21) I nstal l thebreather hoses.(22) I nstal l thePCVhose.(23) I nstal l thefuel rai l .(24) I nstal l thecoi l over pl ugs.(25) Connecttheengi newi ri ngharness atthefol -l owi ngpoi nts:I ntakeai r temperature(I AT) sensorFuel I njectorsThrottl ePosi ti on(TPS) Swi tchI dl eAi r Control (I AC) MotorEngi neOi l PressureSwi tchEngi neCool antTemperature(ECT) SensorMani fol dAbsol utePressureMAP) SensorCamshaftPosi ti on(CMP) SensorCoi l Over Pl ugsCrankshaftPosi ti onSensor(26) Connectl ower radi ator hose.(27) Connectupper radi ator hose.(28) Connectthrottl eandspeedcontrol cabl es.(29) I nstal l theheater hoseassembl y.(30) I nstal l cool antrecoverybottl e.(31) I nstal l thepower steeri ngpump.(32) I nstal l thegenerator.(33) I nstal l theA/Ccompressor.(34) I nstal l thedri vebel t.KJ ENGINE - 3. 7L 9 -11ENGI NE-3.7L(Cont inued)(35) I nstal l themechani cal cool i ngfan.(36) I nstal l the fan shroud wi th the el ectri c fanassembl y.(37) I nstal l theradi ator coresupportbracket.(38) I nstal l theai r cl eaner assembl y.(39) Refi l l theengi necool i ngsystem.(40) I nstal l thehood.(41) Check andfi l l engi neoi l .(42) Connectthebatterynegati vecabl e.(43) Starttheengi neandcheck for l eaks.SPECI FI CATI ONSTORQUEDESCRIPTION Nm Ft. In.Lbs. Lbs.CamshaftNon - Oiled Sprocket Bolt 122 90 Bearing Cap Bolts 11 100Timing Chain CoverBolts 54 40 Connecting Rod CapBolts 27 20 PLUS 90TURNBed PlateBolts Refer to ProcedureCrankshaft DamperBolt 175 130 Cylinder HeadBoltsM11 Bolts Refer ToProcedureM8 Bolts - - -Cylinder Head CoverBolts 12 105Exhaust ManifoldBolts 25 18 Exhaust Manifold HeatShieldNuts8 72Then loosen 45FlexplateBolts 60 45 Engine Mount Bracket toBlockBolts61 45 Rear Mount toTransmissionBolts46 34 Generator MountingBoltsM10 Bolts 54 40 M8 Bolts 28 250Intake ManifoldBolts 12 105Refer to ProcedureforTightening SequenceOil PanBolts 15 130DESCRIPTION Nm Ft. In.Lbs. Lbs.Oil PanDrain Plug 34 25 Oil PumpBolts 28 250Oil Pump CoverBolts 12 105Oil Pickup TubeBolt andNut28 250Oil Dipstick Tube to EngineBlockBolt 15 130Oil Fill TubeBolts 12 105Timing Chain GuideBolts 28 250Timing Chain TensionerArmSpecialPin Bolt 17 150Hydraulic TensionerBolts 28 250Timing Chain PrimaryTensionerBolts28 250Timing Drive Idler SprocketBolt34 25 Thermostat HousingBolts 12 105Water PumpBolts 54 40 3. 7L ENGINESPECI FI CATI ONSDESCRIPTION SPECIFICATIONEngine Type 90SOHC V-6 12-ValveDisplacement 3.7 Liters / 3700 cc( Cubic Inches)Bore 93.0 mm (3.66 in.)Stroke 90.8 mm (3.40 in.)Compression Ratio 9.1:1Horsepower 210 BHP @ 5200 RPMTorque 225 LB-FT @ 4200 RPMLead Cylinder #1 Left BankFiring Order 1-6-5-4-3-2CYLINDER BLOCKCylinder Block Cast IronBore Diameter 93.0 .0075 mm(3.6619 0.0003 in.)Out of Round (MAX) 0.076 mm (0.003 in.)Taper (MAX) 0.051 mm (0.002 in.)9 -12 ENGINE - 3. 7L KJENGI NE-3.7L(Cont inued)DESCRIPTION SPECIFICATIONPISTONSMaterial Aluminum AlloyDiameter 92.975 mm (3.6605 in.)Weight 367.5 grams (12.96 oz)Ring Groove DiameterNo. 1 83.73 - 83.97 mm(3.296 - 3.269 in.)No. 2 82.833 - 83.033 mm(3.261 - 3.310 in.)No. 3 83.88 - 84.08 mm(3.302 - 3.310 in.)PISTON PINSType FloatingClearance In Piston 0.010 - 0.019 mm(0.0004 - 0.0008 in.)Diameter 24.013 - 24.016 mm(0.9454 - 0.9456 in.)PISTON RINGSRing GapTop Compression Ring 0.37 - 0.63 mm(0.0146 - 0.0249 in.)Second CompressionRing0.37 - 0.63 mm(0.0146 - 0.0249 in.)Oil Control (Steel Rails) 0.25 - 0.76 mm(0.0099 - 0.30 in.)Side ClearanceTop Compression Ring .051 - .094 mm(0.0020 - 0.0037 in.)Second CompressionRing0.040 - 0.080 mm(0.0016 - 0.0031 in.)Oil Ring (Steel Ring) .019 - .229 mm(.0007 - .0091 in.)Ring WidthTop Compression Ring 1.472 - 1.490 mm(0.057 - 0.058 in.)Second CompressionRing1.472 - 1.490 mm(0.057 - 0.058 in.)Oil Ring (Steel Rails) 0.445 - 0.470 mm(0.017 - 0.018 in.)DESCRIPTION SPECIFICATIONCONNECTING RODSBearing Clearance 0.010 - 0.048 mm(0.0004 - 0.0019 in.)Side Clearance 0.10 - 0.35 mm(0.004 - 0.0138 in.)Piston Pin Clearance .015 - .028 mm(0.0006 - 0.0011 in.)Bearing Bore Out ofRound0.004 mm(MAX) (0.0002 in.)Total Weight (LessBearing)612 grams (21.588ounces)CRANKSHAFTMain BearingJournalDiameter 63.488 - 63.512 mm(2.4996 - 2.5005 in.)Bearing Clearance 0.002 - 0.034 mmOut of Round (MAX) 0.005 mm (0.0002 in.)Taper (MAX) 0.006 mm (0.0004 in.)End Play 0.052 - 0.282 mm(0.0021 - 0.0112 in.)End Play (MAX) 0.282 mm (0.0112 in)Connecting RodJournalDiameter 57.904 - 57.896 mmBearing Clearance 0.010 - 0.048 mmOut of Round (MAX) 0.005 mm (0.0002 in.)Taper (MAX) 0.006 mm (0.0002 in.)CAMSHAFTBore Diameter 26.02 - 26.04 mm(1.0245 - 1.0252 in.)Bearing Journal Diameter 25.975 - 25.995 mm(1.0227 - 1.0235 in.)Bearing Clearance 0.025 - 0.065 mm(0.001 - 0.0026 in.)Bearing Clearance (MAX) 0.065 mm (0.0026 in.)End Play .075 - .200 mm(0.003 - 0.0079 in.)End Play (MAX) .200 mm (0.0079 in.)KJ ENGINE - 3. 7L 9 -13ENGI NE-3.7L(Cont inued)DESCRIPTION SPECIFICATIONVALVE TIMINGIntakeOpens (ATDC) 3.6Closes (ATDC) 247.1Duration 243.5ExhaustOpens (BTDC) 232.5Closes (ATDC) 21.2Duration 253.70Valve Overlap 17.6VALVESFace Angle 45- 45.5Head DiameterIntake 48.52 - 48.78 mm(1.9103 - 1.9205 in.)Exhaust 36.87 - 37.13 mm1.4516 - 1.4618 in.)Length (Overall)Intake 113.45 - 114.21 mm(4.4666 - 4.4965)Exhaust 114.92 - 115.68 mm(4.5244 - 4.5543 in.)Stem DiameterIntake 6.931 - 6.957 mm(0.2729 - 0.2739 in.)Exhaust 6.902 - 6.928 mm(0.2717 - 0.2728 in.)Stem - to - GuideClearanceIntake 0.018 - 0.069 mm(0.0008 - 0.0028 in.)Exhaust 0.047 - 0.098 mm(0.0019 - 0.0039 in.)Max. Allowable Stem -to -Guide Clearance(RockingMethod)Intake 0.069 mm (0.0028 in.)Exhaust 0.098 mm (0.0039 in.)DESCRIPTION SPECIFICATIONValve Lift (Zero Lash)Intake 12.00 mm (0.472 in.)Exhaust 10.90 mm (0.4292 in.)VALVE SPRINGFree Lenght (Approx)Intake and Exhaust 48.92 mm (1.9260 in.)Spring Force (ValveClosed)Intake and Exhaust 361.0 - 399.0 N @ 40.12mm(81.15 - 89.70 lbs. @1.5795 in.)Spring Force (ValveOpen)Intake and Exhaust 984.0 - 1076.0 N @28.12 mm221.2 - 241.9 lbs. @1.107 in.)Number of CoilsIntake and Exhaust 7.30Wire DiameterIntake and Exhaust 4.77 3.80mm(0.1878 - 0.1496 in.)Installed Height (SpringSeat to Bottom ofRetainer)NominalIntake 41.11 mm (1.619 in.)Exhaust 41.13 mm (1.619 in.)CYLINDER HEADGasket Thickness(Compressed) 0.7 mm (0.0276 in.)Valve Seat Angle 44.5- 45.0Valve Seat Runout (MAX) 0.051 mm (0.002 in.)Valve Seat WidthIntake 1.75 - 2.36 mm(0.0698 - 0.0928 in.)Exhaust 1.71 - 2.32 mm(0.0673 - 0.0911 in.)Guide Bore Diameter(Std.)6.975 - 7.00 mm(0.2747 - 0.2756 in.)9 -14 ENGINE - 3. 7L KJENGI NE-3.7L(Cont inued)DESCRIPTION SPECIFICATIONCylinder Head Warpage(Flatness) 0.0508 mm (0.002 in.)OIL PUMPClearance OverRotors/End Face(MAX)0.035 - 0.095 mm(0.0014 - 0.0038 in.)Cover Out - of -Flat(MAX)0.025 mm (0.001 in.)Inner and Outer RotorThickness 12.02 mm (0.4731 in.)Outer Rotor Diameter(MAX).235 mm (.0093 in.)Outer Rotor Diameter(MIN)85.925 mm (0.400 in.)Tip Clearance BetweenRotors(MAX) 0.150 mm (0.006 in.)OIL PRESSUREAt Curb Idle Speed(MIN)*25 kPa (4 psi)@ 3000 rpm 170 - 758 kPa (25 - 110psi)* CAUTION: If pressure is zero at curb idle, DONOT run engine at 3000 rpm.SPECI AL TOOLS3. 7L ENGINESpanner Wrench 6958Adapter Pins 8346Front Crankshaft Seal Remover 8511Front Crankshaft Seal Installer 8348Handle C-4171KJ ENGINE - 3. 7L 9 -15ENGI NE-3.7L(Cont inued)Rear Crankshaft Seal Installer 8349Rear Crankshaft Seal Remover 8506Connecting Rod Guides 8507Crankshaft Damper Installer 8512Puller 1026Crankshaft Damper Removal Insert 8513Chain Tensioner Wedge 8379Chain Tensioner Pins 85149 -16 ENGINE - 3. 7L KJENGI NE-3.7L(Cont inued)VALVE SPRING COMPRESSOR 8426ENGINE LIFTING FIXTURE 8427CAMSHAFT HOLDER 8428HOLDER SECONDARY CAMSHAFT CHAIN 8429Remover, Rocker Arm 8516Idler Shaft Remover 8517Valve Spring Compressor Adapters 8519KJ ENGINE - 3. 7L 9 -17ENGI NE-3.7L(Cont inued)INSTALLER - REMOVER - COUNTER BALANCESHAFT 8641Valve Spring Tester C-647Dial Indicator C-3339Valve Spring Compressor C-3422-BBore Size Indicator C-119Oil Pressure Gauge C-3292Piston Ring Compressor C-385Pressure Tester Kit 7700BlocChekKit C-3685A9 -18 ENGINE - 3. 7L KJENGI NE-3.7L(Cont inued)AI R CLEANER ELEMENTREMOVAL -3. 7LHousi ngremoval i s not necessary for el ement (fi l -ter) repl acement.(1) Pry up 2 spri ng cl i ps (Fi g. 3) from front ofhousi ngcover (spri ngcl i ps retai ncover tohousi ng).(2) Rel ease housi ng cover from 4 l ocati ng tabsl ocatedonrear of housi ng, andremovecover.(3) Removeai r cl eaner el ement (fi l ter)fromhous-i ng.(4) Cl ean i nsi de of housi ng before repl aci ng el e-ment.INSTALLATION -3. 7L(1) I nstal l el ementi ntohousi ng.(2) Posi ti on housi ng cover i nto housi ng l ocati ngtabs.(3) Pryupspri ngcl i ps andl ock cover tohousi ng.I f any ai r fi l ter, ai r resonator, ai r i ntake tubes orai r fi l ter housi ng cl amps had been l oosened orremoved, ti ghtenthemto5Nm(40i n. l bs.) torque.CYLI NDER HEAD - LEFTDESCRIPTION -VALVE GUIDESThe val ve gui des are made of powered metal andare pressed i ntothe cyl i nder head. The gui des arenotrepl aceabl eor servi ceabl e,andval vegui deream-i ng i s not recommended. I f the gui des are wornbeyondacceptabl el i mi ts, repl acethecyl i nder heads.DI AGNOSI S AND TESTI NGDIAGNOSIS AND TESTING -HYDRAULIC LASHADJUSTERAtappet-l i ke noi se may be produced fromseverali tems. Check thefol l owi ngi tems.(1) Engi neoi l l evel toohi gh or tool ow. Thi s maycause aerated oi l to enter the adjusters and causethemtobespongy.(2) I nsuffi ci ent runni ng ti meafter rebui l di ng cyl i n-der head. Lowspeed runni ngup to1hour may berequi red.(3) Turn engi ne off and l et set for a fewmi nutesbefore restarti ng. Repeat thi s several ti mes afterengi nehas reachednormal operati ngtemperature.(4) Lowoi l pressure.(5) Theoi l restri ctor i ncyl i nder headgasket or theoi l passage to the cyl i nder head i s pl ugged wi thdebri s.(6) Ai r i ngestedi ntooi l due tobroken or crackedoi l pumppi ck up.(7) Wornval vegui des.(8) Rocker arm ears contacti ng val ve spri ngretai ner.(9) Rocker arml oose, adjuster stuck or at maxi -mumextensi onandsti l l l eaves l ashi nthesystem.(10) Oi l l eak or excessi vecamborewear i n cyl i n-der head.(11) Faul tyl ashadjuster.Check l ash adjusters for spongi ness whi l ei nstal l ed i n cyl i nder head and camon camshaft atbaseci rcl e.Depresspartofrocker armover adjuster.Normal adjusters shoul d feel very fi rm. Spongyadjusters canbebottomedouteasi l y.Removesuspectedl ashadjusters, andrepl ace.Before i nstal l ati on, make sure adjusters are atl eastparti al l yful l ofoi l . Thi scanbeveri fi edbyl i ttl eor no pl unger travel whenl ashadjuster i sdepressed.DIAGNOSIS AND TESTING -CYLINDER HEADGASKETA cyl i nder headgasket l eakcanbel ocatedbetweenadjacent cyl i nders or between a cyl i nder and theadjacentwater jacket.Fig. 3 AIR CLEANER ELEMENT - 3.7L1 - AIR INTAKE HOSE2 - HOSE CLAMP3 - COVER4 - CLIPS (2)KJ ENGINE - 3. 7L 9 -19Possi bl e i ndi cati ons of the cyl i nder head gasketl eaki ngbetweenadjacentcyl i nders are:Loss of engi nepowerEngi nemi sfi ri ngPoor fuel economyPossi bl e i ndi cati ons of the cyl i nder head gasketl eaki ng between a cyl i nder and an adjacent waterjacketare:Engi neoverheati ngLoss of cool antExcessi ve steam (whi te smoke) emi tti ng fromexhaustCool antfoami ngCYLINDER-TO-CYLINDER LEAKAGE TESTTodetermi nei f an engi necyl i nder headgasket i sl eaki ngbetweenadjacentcyl i nders, fol l owtheproce-dures i n Cyl i nder Compressi on PressureTest (Referto9- ENGI NE - DI AGNOSI SANDTESTI NG). Anengi ne cyl i nder head gasket l eaki ng between adja-centcyl i nderswi l l resul ti napproxi matel ya5070%reducti oni ncompressi onpressure.CYLINDER-TO-WATER JACKET LEAKAGE TESTWARNING: USE EXTREME CAUTION WHEN THEENGINE IS OPERATING WITH COOLANT PRES-SURECAPREMOVED.VISUAL TEST METHODWi th theengi necool , removethecool ant pressurecap. Start theengi neandal l owi t towarmupunti lthermostatopens.I f a l arge combusti on/compressi on pressure l eakexi sts, bubbl es wi l l bevi si bl ei nthecool ant.COOLING SYSTEMTESTER METHODWARNING: WITH COOLING SYSTEM TESTER INPLACE, PRESSUREWILLBUILDUPFAST. EXCES-SIVE PRESSURE BUILT UP, BY CONTINUOUSENGINEOPERATION, MUSTBERELEASEDTOASAFE PRESSURE POINT. NEVER PERMIT PRES-SURETOEXCEED138kPa(20psi).I nstal l Cool i ngSystemTester 7700or equi val ent topressurecapneck. Starttheengi neandobservethetesters pressuregauge.I f gaugepul sates wi theverypower stroke of a cyl i nder a combusti on pressurel eak i s evi dent.CHEMICAL TEST METHODCombusti onl eaks i ntothecool i ngsystemcanal sobe checked by usi ng Bl oc-Chek Ki t C-3685-A orequi val ent. Perform test fol l owi ng the proceduressuppl i edwi ththetool ki t.REMOVAL(1) Di sconnectthenegati vecabl efromthebattery.(2) Rai sethevehi cl eonahoi st.(3) Di sconnect the exhaust pi pe at the l eft si deexhaustmani fol d.(4) Drai n the engi ne cool ant. Refer toCOOLI NGSYSTEM.(5) Lower thevehi cl e.(6) Remove the i ntake mani fol d. Refer to proce-durei nthi s secti on.(7) Removethecyl i nder headcover. Refer to proce-durei nthi s secti on.(8) Removethefanshroudandfanbl adeassembl y.Refer toCOOLI NGSYSTEM.(9) Remove accessory dri ve bel t. Refer toCOOL-I NGSYSTEM.(10) Remove the power steeri ng pump and setasi de.(11) Rotatethecrankshaft unti l thedamper ti mi ngmark i s al i gnedwi thTDCi ndi cator mark (Fi g. 4).(12) Veri fy theV6mark onthecamshaftsprocketi sat the12ocl ockposi ti on(Fi g. 5). Rotatethecrank-shaftoneturni f necessary.(13) Removethecrankshaftdamper. Refer toPro-cedure.(14) Removetheti mi ngchai n cover. Refer topro-cedure.Fig. 4 Engine Top Dead Center1 - TIMING CHAIN COVER2 - CRANKSHAFT TIMING MARKS9 -20 ENGINE - 3. 7L KJCYLI NDERHEAD-LEFT(Cont inued)(15) Lock thesecondaryti mi ngchai ns tothei dl ersprocketusi ngSpeci al Tool 8429Ti mi ngChai nHol d-i ngFi xture(Fi g. 6).NOTE: Mark the secondary timing chain prior toremoval toaidininstallation.(16) Markthesecondaryti mi ngchai n,onel i nkoneachsi deoftheV6markonthecamshaftdri vegear.(17) Remove the l eft si de secondary chai n ten-si oner. Refer toTi mi ngChai nandSprockets.(18) Removethecyl i nder headaccesspl ug(Fi g. 7).(19) Remove the l eft si de secondary chai n gui de.Refer toTi mi ngChai nandSprockets.(20) Remove the retai ni ng bol t and the camshaftdri vegear.CAUTION: Do not allow the engine to rotate. Severedamagetothevalvetraincanoccur.CAUTION: Do not overlook the four smaller bolts atthefront of thecylinder head. Donot attempt toremovethecylinder headwithout removingthesefourbolts.NOTE: The cylinder head is attached to the cylinderblockwithtwelvebolts.Fig. 5 Camshaft Sprocket V6 Marks1 - LEFT CYLINDER HEAD2 - RIGHT CYLINDER HEADFig. 6 Using Special Tool 84291 - SPECIAL TOOL 84292 - CAMSHAFT CHAIN3 - CRANKSHAFT TIMING GEARKJ ENGINE - 3. 7L 9 -21CYLI NDERHEAD-LEFT(Cont inued)(21) Removethecyl i nder headretai ni ngbol ts.(22) Removethecyl i nder headandgasket. Di scardthegasket.CAUTION:Donotlaythecylinderheadonitsgas-ketsealingsurface, duetothedesignofthecylin-derheadgasketanydistortiontothecylinderheadsealingsurfacemayprevent thegasket fromprop-erlysealingresultinginleaks.CLEANINGTo ensure engi ne gasket seal i ng, proper surfacepreparati on must be performed, especi al l y wi th theuse of al umi numengi ne components (Fi g. 8). (Referto9-ENGI NE-STANDARDPROCEDURE)INSTALLATIONNOTE:Thecylinderheadboltsaretightenedusingatorqueplusangleprocedure. Theboltsmust beexaminedBEFOREreuse.Ifthethreadsareneckeddowntheboltsshouldbereplaced. TheM8headbolts, shouldnotbereused. UsenewM8bolts.Necki ngcanbecheckedbyhol di ngastrai ghtedgeagai nstthethreads.I fal l thethreadsdonotcontactthescal e, thebol tshoul dberepl aced(Fi g. 9).CAUTION: Whencleaningcylinder headandcylin-der blocksurfaces, DONOTuseametal scraperbecausethesurfacescouldbecut orground. Useonlyawoodenorplasticscraper.(1) Cl ean the cyl i nder head and cyl i nder bl ockmati ngsurfaces (Fi g. 10).(2) Posi ti on the newcyl i nder head gasket on thel ocati ngdowel s.CAUTION: Wheninstallingcylinder head, usecarenotdamagethetensionerarmortheguidearm.(3) Posi ti on the cyl i nder head onto the cyl i nderbl ock. Make sure the cyl i nder head seats ful l y overthel ocati ngdowel s.NOTE: The four smaller cylinder head mountingboltsrequiresealant tobeaddedtothembeforeinstalling. Failuretodosomaycauseleaks.Fig. 7 Cylinder Head Access Plugs1 - RIGHT CYLINDER HEAD ACCESS PLUG2 - LEFT CYLINDER HEAD ACCESS PLUGFig. 8 Proper Tool Usage For Surface Preparation1 - PLASTIC/WOOD SCRAPERFig. 9 Checking Cylinder Head Bolts for Stretching(Necking)1 - STRETCHED BOLT2 - THREADS ARE NOT STRAIGHT ON LINE3 - THREADS ARE STRAIGHT ON LINE4 - UNSTRETCHED BOLT9 -22 ENGINE - 3. 7L KJCYLI NDERHEAD-LEFT(Cont inued)(4) Lubri cate the cyl i nder head bol t threads wi thcl eanengi neoi l andi nstal l theei ghtM11bol ts.(5) Coat the four M8 cyl i nder head bol ts wi thMopar Lock and Seal Adhesivethen i nstal l thebol ts.NOTE:Thecylinderheadboltsaretightenedusinganangletorqueprocedure, however, theboltsarenotatorque-to-yielddesign.(6) Ti ghtenthebol ts i nsequenceusi ngthefol l ow-i ngsteps andtorqueval ues:Step1: Ti ghtenbol ts 110, 27Nm(20ft. l bs.).Step 2: Veri fy that bol ts 110, al l reached 27Nm(20ft. l bs.), by repeati ngstep-1wi thoutl oosen-i ngthebol ts.Ti ghtenbol ts11thru14to 14Nm(10ft. l bs.).Step3: Ti ghtenbol ts 110, 90degrees (Fi g. 11).Step 4: Ti ghten bol ts 110, 90 degrees, agai n.Ti ghtenbol ts 1114, 26Nm(19ft. l bs.)(7) Posi ti onthesecondarychai nonto thecamshaftdri vegear,maki ngsureonemarkedchai nl i nki sonei ther si de of the V6 mark on the gear then usi ngSpeci al Tool 8428 Camshaft Wrench, posi ti on thegear ontothecamshaft.CAUTION: Remove excess oil from camshaftsprocketretainingboltbeforereinstallingbolt.Fail-ure to do so may cause over-torqueing of boltresultinginboltfailure.(8) I nstal l thecamshaftdri vegear retai ni ngbol t.(9) I nstal l thel eftsi desecondarychai ngui de.(10) I nstal l thecyl i nder headaccess pl ug.(11) Re-set and I nstal l the l eft si de secondarychai ntensi oner.(12) RemoveSpeci al Tool 8429.(13) I nstal l theti mi ngchai ncover.(14) I nstal l the crankshaft damper. Ti ghtendamper bol t175Nm(130Ft. Lbs.).(15) I nstal l thepower steeri ngpump.(16) I nstal l the fan bl ade assembl y and fanshroud.(17) I nstal l thecyl i nder headcover.(18) I nstal l thei ntakemani fol d.(19) Refi l l thecool i ngsystem(20) Rai sethevehi cl e.(21) I nstal l theexhaustpi peontothel eftexhaustmani fol d.(22) Lower thevehi cl e.(23) Connectthenegati vecabl etothebattery.(24) Starttheengi neandcheck for l eaks.CAMSHAFT(S)DESCRIPTIONThe camshafts consi st of powdered metal steell obes whi ch are si nter-bonded toa steel tube. Fourbeari ng journal s are machi ned i nto the camshaft.Camshaftendpl ay i s control l edby twothrustwal l sthatborder thenosepi ecejournal . Engi neoi l entersthehol l owcamshafts at thethi rdjournal andl ubri -cates everyi ntakel oberocker throughadri l l edpas-sagei nthei ntakel obe.Fig. 10 Proper Tool Usage For Surface Preparation1 - PLASTIC/WOOD SCRAPERFig. 11 CYLINDER HEAD TIGHTENING SEQUENCEKJ ENGINE - 3. 7L 9 -23CYLI NDERHEAD-LEFT(Cont inued)REMOVALCAUTION: Whenthetimingchainisremovedandthe cylinder heads are still installed, DO NOT force-fully rotate the camshafts or crankshaft indepen-dently of each other. Severe valve and/or pistondamagecanoccur.CAUTION: When removing the cam sprocket, timingchains or camshaft, Failure to use Special Tool8379will result inhydraulictensioner ratchet overextension, requiringtimingchaincoverremoval toresetthetensionerratchet.(1) Remove cyl i nder head cover. Refer toCYLI N-DERHEADCOVERi nthi s secti on.(2) Set engi ne to TDC cyl i nder #1, camshaftsprocketV6marks atthe12ocl ock posi ti on.(3) Mark one l i nk on the secondary ti mi ngchai non both si des of the V6 mark on the camshaftsprockettoai di ni nstal l ati on.CAUTION: Donot holdorpryonthecamshaft tar-get wheel (Located on the right side camshaftsprocket) for any reason, Severe damage will occurtothetarget wheel resultinginavehiclenostartcondition.(4) Loosen but DO NOT remove the camshaftsprocket retai ni ngbol t. Leavethebol t snugagai nstthesprocket.NOTE: The timing chain tensioners must besecuredpriortoremovingthecamshaft sprockets.Failuretosecuretensionerswill allowthetension-erstoextend,requiringtimingchaincoverremovalinordertoresettensioners.CAUTION: Donot forcewedgepast thenarrowestpoint between the chain strands. Damage to thetensionersmayoccur.(5) Posi ti on Speci al Tool 8379ti mi ngchai n wedgebetween the ti mi ng chai n strands, tap the tool tosecurel y wedge the ti mi ng chai n agai nst the ten-si oner armandgui de(Fi g. 12).(6) Hol dthecamshaft wi thSpeci al Tool 8428Cam-shaftWrench, whi l eremovi ngthecamshaftsprocketbol tandsprocket(Fi g. 13).(7) Usi ng Speci al Tool 8428 Camshaft Wrench,gentl yal l owthecamshaftto rotate5cl ockwi seunti lthe camshaft i s i n the neutral posi ti on (no val vel oad).(8) Starti ngattheoutsi deworki ngi nward, l oosenthecamshaftbeari ngcapretai ni ngbol ts 1/2turnatati me. Repeatunti l al l l oadi s off thebeari ngcaps.CAUTION: DONOTSTAMPORSTRIKETHECAM-SHAFT BEARINGCAPS. SEVERE DAMAGE WILLOCCURTOTHEBEARINGCAPS.Fig. 12 SECURING TIMING CHAIN TENSIONERSUSING TIMING CHAIN WEDGE Typical1 - SPECIAL TOOL 83792 - CAMSHAFT SPROCKET3 - CAMSHAFT SPROCKET BOLTFig. 13 Special Tool 84281 - Camshaft hole2 - Special Tool 84289 -24 ENGINE - 3. 7L KJCAMSHAFT(S) (Cont inued)NOTE: Whenthecamshaft isremovedtherockerarmsmayslidedownward, marktherocker armsbeforeremovingcamshaft.(9) Remove the camshaft beari ng caps and thecamshaft.INSTALLATION(1) Lubri catecamshaft journal s wi th cl ean engi neoi l .NOTE: Positiontheleft sidecamshaft sothat thecamshaft sprocket dowel is near the 1 oclock posi-tion, This will place the camshaft at the neutralposition easing the installation of the camshaftbearingcaps.(2) Posi ti onthecamshafti ntothecyl i nder head.(3) I nstal l thecamshaft beari ngcaps, handti ghtentheretai ni ngbol ts.NOTE: Caps should be installed so that thestamped numbers on the caps are in numericalorder, ( 1thru4) fromthefront totherearof theengine. All caps should be installed so that thestampedarrowsonthecapspointtowardthefrontoftheengine.(4) Worki ng i n turn i ncrements, ti ghten thebeari ngcapretai ni ngbol ts starti ngwi th themi ddl ecapworki ngoutward(Fi g. 14).(5) Torque the camshaft beari ng cap retai ni ngbol ts to11Nm(100i n. l bs.).(6) Posi ti on thecamshaft dri vegear i ntotheti m-i ng chai n al i gni ng the V6 mark between the twomarkedchai nl i nks(Two l i nksmarkedduri ngremov-al ).(7) Usi ng Speci al Tool 8428 Camshaft Wrench,rotate the camshaft unti l the camshaft sprocketdowel i s al i gned wi th the sl ot i n the camshaftsprocket. I nstal l thesprocketontothecamshaft.CAUTION: Remove excess oil from camshaftsprocket bolt. Failure to do so can cause bolt over-torqueresultinginboltfailure.(8) Remove excess oi l frombol t, then i nstal l thecamshaftsprocketretai ni ngbol tandhandti ghten.(9) RemoveSpeci al Tool 8379ti mi ngchai nwedge.(10) Usi ngSpeci al Tool 6958spanner wrenchwi thadapter pi ns 8346, torque the camshaft sprocketretai ni ngbol tto122Nm(90ft. l bs.).(11) I nstal l thecyl i nder headcover.CYLI NDER HEAD COVER(S)DESCRIPTIONThecyl i nder headcovers aremadeof si ngl el ayerstampedsteel ,andarenoti nterchangabl efromsi de-to-si de(Fi g. 15).REMOVAL(1) Di sconnectnegati vecabl efrombattery.(2) Remove the resonator assembl e and ai r i nl ethose.(3) Di sconnect i njector connectors and un-cl i p thei njector harness.(4) Routei njector harnessi nfrontofcyl i nder headcover.(5) Di sconnect the l eft si de breather tube andremovethebreather tube.(6) Removethecyl i nder headcover mounti ngbol ts(Fi g. 16).(7) Removecyl i nder headcover andgasket.NOTE: The gasket may be used again, providing nocuts, tears, ordeformationhasoccurred.Fig. 14 Camshaft Bearing Caps TighteningSequenceKJ ENGINE - 3. 7L 9 -25CAMSHAFT(S) (Cont inued)INSTALLATIONCAUTION: Donot useharshcleanerstocleanthecylinder head covers. Severe damage to coversmayoccur.NOTE:Thegasketmaybeusedagain, providednocuts, tears, ordeformationhasoccurred.(1) Cl eancyl i nder headcover andbothseal i ng sur-faces. I nspectandrepl acegasketas necessary.(2) Ti ghten cyl i nder head cover bol ts and doubl eendedstuds to12Nm(105i n. l bs.).(3) I nstal l l eft si debreather andconnect breathertube.(4) Connecti njector el ectri cal connectorsandi njec-tor harness retai ni ngcl i ps.(5) I nstal l theresonator andai r i nl ethose.(6) Connectnegati vecabl etobattery.I NTAKE/EXHAUSTVALVES &SEATSDESCRIPTIONThe val ves are made of heat resi stant steel andhavechromepl atedstems toprevent scuffi ng. Eachval vei sactuatedbyarol l er rocker armwhi chpi votson a stati onary l ash adjuster. Al l val ves use threebeadl ock keepers toretai nthespri ngs andpromoteval verotati on.STANDARD PROCEDURE -REFACINGNOTE:Valveseatsthatarewornorburnedcanbereworked, provided that correct angle and seatwidtharemaintained. Otherwisethecylinder headmustbereplaced.NOTE: Whenrefacingvalvesandvalveseats, it isimportantthatthecorrectsizevalveguidepilotbeused for reseating stones. A true and complete sur-facemustbeobtained.(1) Usi ng a sui tabl e di al i ndi cator measure thecenter of the val ve seat Total run out must notexceed0.051mm(0.002i n).(2) Appl y a smal l amount of Prussi an bl uetotheval ve seat, i nsert the val ve i ntothe cyl i nder head,whi l eappl yi ngl i ghtpressureontheval verotatetheFig. 15 CYLINDER HEAD COVERS1 - LEFT SIDE CYLINDER HEAD COVER2 - RIGHT SIDE CYLINDER HEAD COVERFig. 16 CYLINDER HEAD COVER -TYPICAL1 - SCREWS2 - CYLINDER HEAD COVER9 -26 ENGINE - 3. 7L KJCYLI NDERHEADCOVER(S) (Cont inued)val ve.Removetheval veandexami netheval veface.I f the bl ue i s transferred bel owthe top edge of theval ve face, l ower the val ve seat usi ng a 15 degreestone. I fthebl uei stransferredto thebottomedgeoftheval veface, rai setheval veseatusi nga65degreestone.(3) Whentheseati sproperl yposi ti onedthewi dthofthei ntakeseatmustbe1.752.36mm(0.06890.0928i n.) andtheexhaustseatmustbe1.712.32mm(0.06730.0911i n.).(4) Check the val ve spri ng i nstal l ed hei ght afterrefaci ngtheval veandseat. Thei nstal l edhei ghtforboth i ntake and exhaust val ve spri ngs must notexceed41.44mm(1.6315i n.).(5) Theval veseatandval vefacemustmai ntai nafaceangl eof 44.545degrees angl e(Fi g. 17).REMOVALNOTE: The cylinder heads must be removed inordertoperformthisprocedure.(1) Removerocker arms andl ash adjusters. Refertoprocedures i nthi s secti on(Fi g. 18).(2) Remove the camshaft beari ng caps and thecamshaft.NOTE: All six valve springs and valves are removedin the same manner; this procedure only coversonevalveandvalvespring.(3) Usi ng Speci al Tool C-3422B or C-3422CVal ve Spri ng Compressor and Speci al tool 8519Adapter, compress theval vespri ng.NOTE: It maybenecessarytotapthetopof thevalve springtoloosenthe springretainers locksenoughtoberemoved.(4) Removethetwospri ngretai ner l ock hal ves.NOTE: thevalvespringisunder tensionusecarewhenreleasingthevalvespringcompressor.(5) Removetheval vespri ngcompressor.(6) Removethespri ngretai ner, andthespri ng.NOTE: Check for sharp edges on the keepergrooves. Remove any burrs fromthe valve stembeforeremovingthevalvefromthecylinderhead.(7) Removetheval vefromthecyl i nder head.NOTE: Thevalvestemsealsarecommonbetweenintakeandexhaust.(8) Removetheval vestemseal . Marktheval veforproper i nstal l ati on.Fig. 17 Valve Assembly Configuration1 - VALVE LOCKS (3BEAD)2 - RETAINER3 - VALVE STEM OIL SEAL4 - INTAKE VALVE5 - EXHAUST VALVE6 - VALVE SPRINGFig. 18 Rocker Arm Removal1 - CAMSHAFT2 - SPECIAL TOOL 8516KJ ENGINE - 3. 7L 9 -27I NTAKE/EXHAUSTVALVES&SEATS(Cont inued)TESTING VALVE SPRINGSNOTE: Whenever thevalvesareremovedfromthecylinder head it is recommended that the valvespringsbeinspectedandtestedforreuse.I nspecttheval vespri ngsfor physi cal si gnsofwearor damage. Turn tabl eof tool C-647unti l surfacei si n l i ne wi th the 40.69 mm(1.602 i n.)mark on thethreadedstudandthezeromark onthefront.Pl acespri ngover thestudon thetabl eandl i ft compress-i ngl ever toset tone devi ce. Pul l on torque wrenchunti l Pi ngi s heard. Take readi ngon torque wrenchat thi s i nstant. Mul ti pl y thi s readi ng by two. Thi swi l l gi ve the spri ng l oad at test l ength. Fracti onalmeasurements are i ndi cated on the tabl e for fi neradjustments. Refer to Speci fi cati onsSecti onto obtai nspeci fi edhei ghtandal l owabl etensi ons. Repl aceanyspri ngs thatdonotmeetspeci fi cati ons (Fi g. 19).INSTALLATION(1) coat the val ve stemwi th cl ean engi ne oi l andi nserti ti ntothecyl i nder head.(2) I nstal l theval vestemseal .makesuretheseali s ful l y seatedandthatthegarter spri ngatthetopof theseal i s i ntact.(3) I nstal l thespri ngandthespri ngretai ner (Fi g.20).(4) Usi ng the val ve spri ng compressor, compressthespri ngandi nstal l thetwoval vespri ngretai nerhal ves.(5) Rel easetheval vespri ngcompressor andmakesure the twospri ng retai ner hal ves and the spri ngretai ner areful l yseated.(6) l ubri cate the camshaft journal wi th cl eanengi ne oi l then Posi ti on the camshaft (wi th thesprocketdowel onthel eftcamshaftat11ocl ockandthe ri ght camshaft at 12 ocl ock), then posi ti on thecamshaftbeari ngcaps.(7) I nstal l the camshaft beari ng cap retai ni ngbol ts. Ti ghtenthebol ts 913Nm(100i n. l bs.) i nturni ncrements i nthesequenceshown(Fi g. 21).(8) Posi ti on the hydraul i c l ash adjusters androcker arms.Fig. 19 Testing Valve Springs1 - SPECIAL TOOL C-647Fig. 20 Valve Assembly Configuration1 - VALVE LOCKS (3BEAD)2 - RETAINER3 - VALVE STEM OIL SEAL4 - INTAKE VALVE5 - EXHAUST VALVE6 - VALVE SPRING9 -28 ENGINE - 3. 7L KJI NTAKE/EXHAUSTVALVES&SEATS(Cont inued)ROCKER ARMDESCRIPTIONTherocker arms aresteel stampi ngs wi thani nte-gral rol l er beari ng. Therocker armsi ncorporatea2.8mm(0.11i nch) oi l hol ei nthel ashadjuster socket forrol l er andcamshaftl ubri cati on.VALVE GUI DE SEALSDESCRIPTIONThe val ve gui de seal s are made of rubber andi ncorporate an i ntegral steel val ve spri ngseat. Thei ntegral garter spri ng mai ntai ns consi stent l ubri ca-ti oncontrol totheval vestems.VALVE SPRI NGSDESCRIPTIONThe val ve spri ngs are made fromhi gh strengthchrome si l i con steel . The spri ngs are common fori ntake and exhaust appl i cati ons. The val ve spri ngseati s i ntegral wi ththeval vestemseal , whi chi s aposi ti vetypeseal tocontrol l ubri cati on.REMOVAL(1) Remove the cyl i nder head cover. Refer toCyl -i nder HeadCover i nthi s Secti on.(2) Usi ngSpeci al Tool 8516Val veSpri ngCompres-sor, remove the rocker arms and the hydraul i cl ashadjusters.(3) Remove the spark pl ug for the cyl i nder theval vespri ngandseal aretoberemovedfrom.(4) Appl y shop ai r to the cyl i nder to hol d theval ves i npl acewhenthespri ngi s removed.NOTE: All sixvalvespringsandsealsareremovedin the same manner; this procedure only coversonevalveseal andvalvespring.(5) Usi ngSpeci al Tool 8387Val veSpri ngCompres-sor, compress theval vespri ng.NOTE: It maybenecessarytotapthetopof thevalve springtoloosenthe springretainers locksenoughtoberemoved.(6) Removethetwospri ngretai ner l ock hal ves.NOTE: thevalvespringisunder tensionusecarewhenreleasingthevalvespringcompressor.(7) Removetheval vespri ngcompressor.(8) Removethespri ngretai ner, andthespri ng.(9) Removetheval vestemseal .NOTE: Thevalvestemsealsarecommonbetweenintakeandexhaust.INSTALLATIONNOTE: All sixvalvespringsandsealsareremovedin the same manner; this procedure only coversonevalveseal andvalvespring.(1) Appl y shop ai r to the cyl i nder to hol d theval ves i npl acewhi l ethespri ngi s i nstal l ed.NOTE: Thevalvestemsealsarecommonbetweenintakeandexhaust.(2) I nstal l theval vestemseal .(3) I nstal l thespri ngretai ner, andthespri ng.(4) Usi ngSpeci al Tool 8387Val veSpri ngCompres-sor, compress theval vespri ng.(5) I nstal l thetwospri ngretai ner l ock hal ves.NOTE: thevalvespringisunder tensionusecarewhenreleasingthevalvespringcompressor.(6) Removetheval vespri ngcompressor.(7) Di sconnecttheshopai r tothecyl i nder.(8) I nstal l thesparkpl ugfor thecyl i nder theval vespri ngandseal was i nstal l edon.Fig. 21 Camshaft Bearing Caps TighteningSequenceKJ ENGINE - 3. 7L 9 -29I NTAKE/EXHAUSTVALVES&SEATS(Cont inued)(9) Usi ngSpeci al Tool 8516Val veSpri ngCompres-sor, i nstal l the rocker arms and the hydraul i c l ashadjusters.(10) I nstal l thecyl i nder headcover. Refer to Cyl i n-der HeadCover i nthi s Secti on.CYLI NDER HEAD - RI GHTDESCRI PTI ONDESCRIPTION -CYLINDER HEADThecyl i nder headsaremadeof anal umi numal l oy.The cyl i nder head features twoval ves per cyl i nderwi th pressed i n powdered metal val ve gui des. Thecyl i nder headsal soprovi deencl osuresfor theti mi ngchai ndrai n, necessi tati nguni quel eft andri ght cyl i n-der heads.DESCRIPTION -VALVE GUIDESThe val ve gui des are made of powered metal andare pressed i ntothe cyl i nder head. The gui des arenotrepl aceabl eor servi ceabl e,andval vegui deream-i ng i s not recommended. I f the gui des are wornbeyondacceptabl el i mi ts, repl acethecyl i nder heads.DESCRIPTIONThe val ves are made of heat resi stant steel andhavechromepl atedstems toprevent scuffi ng. Eachval vei sactuatedbyarol l er rocker armwhi chpi votson a stati onary l ash adjuster. Al l val ves use threebeadl ock keepers toretai nthespri ngs andpromoteval verotati on.DI AGNOSI S AND TESTI NGDIAGNOSIS AND TESTING -HYDRAULIC LASHADJUSTERAtappet-l i ke noi se may be produced fromseverali tems. Check thefol l owi ngi tems.(1) Engi neoi l l evel toohi gh or tool ow. Thi s maycause aerated oi l to enter the adjusters and causethemtobespongy.(2) I nsuffi ci ent runni ng ti meafter rebui l di ng cyl i n-der head. Lowspeed runni ngup to1hour may berequi red.(3) Turn engi ne off and l et set for a fewmi nutesbefore restarti ng. Repeat thi s several ti mes afterengi nehas reachednormal operati ngtemperature.(4) Lowoi l pressure.(5) Theoi l restri ctor i ncyl i nder headgasket or theoi l passage to the cyl i nder head i s pl ugged wi thdebri s.(6) Ai r i ngestedi ntooi l due tobroken or crackedoi l pumppi ck up.(7) Wornval vegui des.(8) Rocker arm ears contacti ng val ve spri ngretai ner.(9) Rocker arml oose, adjuster stuck or at maxi -mumextensi onandsti l l l eaves l ashi nthesystem.(10) Oi l l eak or excessi vecamborewear i n cyl i n-der head.(11) Faul tyl ashadjuster.Check l ash adjusters for spongi ness whi l ei nstal l ed i n cyl i nder head and camon camshaft atbaseci rcl e.Depresspartofrocker armover adjuster.Normal adjusters shoul d feel very fi rm. Spongyadjusters canbebottomedouteasi l y.Removesuspectedl ashadjusters, andrepl ace.Before i nstal l ati on, make sure adjusters are atl eastparti al l yful l ofoi l . Thi scanbeveri fi edbyl i ttl eor no pl unger travel whenl ashadjuster i sdepressed.DIAGNOSIS AND TESTING -CYLINDER HEADGASKETA cyl i nder headgasket l eakcanbel ocatedbetweenadjacent cyl i nders or between a cyl i nder and theadjacentwater jacket.Possi bl e i ndi cati ons of the cyl i nder head gasketl eaki ngbetweenadjacentcyl i nders are:Loss of engi nepowerEngi nemi sfi ri ngPoor fuel economyPossi bl e i ndi cati ons of the cyl i nder head gasketl eaki ng between a cyl i nder and an adjacent waterjacketare:Engi neoverheati ngLoss of cool antExcessi ve steam (whi te smoke) emi tti ng fromexhaustCool antfoami ngCYLINDER-TO-CYLINDER LEAKAGE TESTTodetermi nei f an engi necyl i nder headgasket i sl eaki ngbetweenadjacentcyl i nders, fol l owtheproce-dures i n Cyl i nder Compressi on PressureTest (Referto9- ENGI NE - DI AGNOSI SANDTESTI NG). Anengi ne cyl i nder head gasket l eaki ng between adja-centcyl i nderswi l l resul ti napproxi matel ya5070%reducti oni ncompressi onpressure.CYLINDER-TO-WATER JACKET LEAKAGE TESTWARNING: USE EXTREME CAUTION WHEN THEENGINE IS OPERATING WITH COOLANT PRES-SURECAPREMOVED.9 -30 ENGINE - 3. 7L KJVALVESPRI NGS(Cont inued)VISUAL TEST METHODWi th theengi necool , removethecool ant pressurecap. Start theengi neandal l owi t towarmupunti lthermostatopens.I f a l arge combusti on/compressi on pressure l eakexi sts, bubbl es wi l l bevi si bl ei nthecool ant.COOLING SYSTEMTESTER METHODWARNING: WITH COOLING SYSTEM TESTER INPLACE, PRESSUREWILLBUILDUPFAST. EXCES-SIVE PRESSURE BUILT UP, BY CONTINUOUSENGINEOPERATION, MUSTBERELEASEDTOASAFE PRESSURE POINT. NEVER PERMIT PRES-SURETOEXCEED138kPa(20psi).I nstal l Cool i ngSystemTester 7700or equi val ent topressurecapneck. Starttheengi neandobservethetesters pressuregauge.I f gaugepul sates wi theverypower stroke of a cyl i nder a combusti on pressurel eak i s evi dent.CHEMICAL TEST METHODCombusti onl eaks i ntothecool i ngsystemcanal sobe checked by usi ng Bl oc-Chek Ki t C-3685-A orequi val ent. Perform test fol l owi ng the proceduressuppl i edwi ththetool ki t.REMOVAL(1) Di sconnectbatterynegati vecabl e.(2) Rai sethevehi cl eonahoi st.(3) Di sconnect the exhaust pi pe at the ri ght si deexhaustmani fol d.(4) Drai n the engi ne cool ant. Refer toCOOLI NGSYSTEM.(5) Lower thevehi cl e.(6) Remove the i ntake mani fol d. Refer to proce-dure.(7) Removethecyl i nder headcover. Refer to proce-dure.(8) Remove the fan shroud. Refer to COOLI NGSYSTEM.(9) Removeoi l fi l l housi ngfromcyl i nder head.(10) Removeaccessory dri vebel t. Refer toCOOL-I NGSYSTEM.(11) Rotatethecrankshaft unti l thedamper ti mi ngmark i s al i gnedwi thTDCi ndi cator mark.(12) Veri fy theV6mark onthecamshaftsprocketi s at the 12 ocl ock posi ti on. Rotate the crankshaftoneturni f necessary.(13) Removethecrankshaft damper. Refer topro-cedure.(14) Removetheti mi ngchai n cover. Refer topro-cedure.(15) Lock thesecondaryti mi ngchai ns tothei dl ersprocketusi ngSpeci al Tool 8429Ti mi ngChai nHol d-i ngFi xture.NOTE: Mark the secondary timing chain prior toremoval toaidininstallation.(16) Markthesecondaryti mi ngchai n,onel i nkoneachsi deoftheV6markonthecamshaftdri vegear.(17) Remove the ri ght si de secondary chai n ten-si oner. Refer toTi mi ngChai n andSprockets i n thi ssecti on.(18) Removethecyl i nder headaccess pl ug.(19) Removetheri ghtsi desecondary chai ngui de.Refer toTi mi ngChai nandSprocketsi nthi ssecti on.CAUTION: The nut on the right side camshaftsprocketshouldnotberemovedforanyreason,asthesprocket andcamshaft sensor target wheel isservicedasanassembly. If thenut wasremovedretorquenutto5Nm(44in. lbs.).(20) Remove the retai ni ng bol t and the camshaftdri vegear.CAUTION: Do not allow the engine to rotate. severedamagetothevalvetraincanoccur.CAUTION: Do not overlook the four smaller bolts atthefront of thecylinder head. Donot attempt toremovethecylinder headwithout removingthesefourbolts.CAUTION: Donot holdorpryonthecamshaft tar-get wheel foranyreason. Adamagedtarget wheelcanresultinavehiclenostartcondition.NOTE: The cylinder head is attached to the cylinderblockwithtwelvebolts.(21) Removethecyl i nder headretai ni ngbol ts.(22) Removethecyl i nder headandgasket. Di scardthegasket.CAUTION:Donotlaythecylinderheadonitsgas-ket sealing surface, do to the design of the cylinderhead gasket any distortion to the cylinder headsealingsurfacemayprevent thegasket fromprop-erlysealingresultinginleaks.CLEANINGTo ensure engi ne gasket seal i ng, proper surfacepreparati on must be performed, especi al l y wi th theuseofal umi numengi necomponents(Fi g.22).(Referto9-ENGI NE-STANDARDPROCEDURE)KJ ENGINE - 3. 7L 9 -31CYLI NDERHEAD-RI GHT(Cont inued)INSPECTION(1) I nspect the cyl i nder head for out-of-fl atness,usi ngastrai ghtedgeandafeel er gauge. I f measure-ments exceed0.0508mm(0.002i n.)repl acethecyl -i nder head.(2) I nspecttheval veseatsfor damage.Servi cetheval veseats as necessary.(3) I nspect the val ve gui des for wear, cracks orl ooseness. I f ei ther condi ti onexi st, repl acethecyl i n-der head.INSTALLATIONNOTE:Thecylinderheadboltsaretightenedusingatorqueplusangleprocedure. Theboltsmust beexaminedBEFOREreuse.Ifthethreadsareneckeddowntheboltsshouldbereplaced.Necki ngcanbecheckedbyhol di ngastrai ghtedgeagai nstthethreads.I fal l thethreadsdonotcontactthescal e, thebol tshoul dberepl aced.CAUTION: Whencleaningcylinder headandcylin-der blocksurfaces, DONOTuseametal scraperbecausethesurfacescouldbecut orground. Useonlyawoodenorplasticscraper.(1) Cl ean the cyl i nder head and cyl i nder bl ockmati ngsurfaces.(2) Posi ti on the newcyl i nder head gasket on thel ocati ngdowel s.CAUTION: Wheninstallingcylinder head, usecarenotdamagethetensionerarmortheguidearm.(3) Posi ti on the cyl i nder head onto the cyl i nderbl ock. Make sure the cyl i nder head seats ful l y overthel ocati ngdowel s.NOTE: Thefour M8cylinder headmountingboltsrequiresealant tobeaddedtothembeforeinstall-ing. Failure to do so may cause leaks. Do not reusetheoldM8bolts, usenewM8bolts.(4) Lubri cate the cyl i nder head bol t threads wi thcl eanengi neoi l andi nstal l theei ghtM10bol ts.(5) Coat the four M8 cyl i nder head bol ts wi thMopar Lock and Seal Adhesivethen i nstal l thebol ts.The cyl i nder head bol ts are ti ghtened usi ng anangl etorqueprocedure, however, thebol ts arenotatorque-to-yi el ddesi gn.(6) Ti ghtenthebol ts i nsequenceusi ngthefol l ow-i ngsteps andtorqueval ues:Step1: Ti ghtenbol ts 110, 20Nm(15ft. l bs.).Step2: Ti ghten bol ts 110, 47Nm(35ft. l bs.).Ti ghtenbol ts 1114, 25Nm(18ft. l bs.).Step3: Ti ghten bol ts 110, 90degrees. Ti ghtenbol ts 1114, 30Nm(22ft. l bs.).CAUTION: The nut on the right side camshaftsprocketshouldnotberemovedforanyreason,asthesprocket andcamshaft sensor target wheel isservicedasanassembly. If thenut wasremovedretorquenutto5Nm(44in. lbs.).(7) Posi ti onthesecondarychai nonto thecamshaftdri vegear,maki ngsureonemarkedchai nl i nki sonei ther si de of the V6 mark on the gear then usi ngSpeci al Tool 8428 Camshaft Wrench, posi ti on thegear ontothecamshaft.CAUTION: Remove excess oil from camshaftsprocketretainingboltbeforereinstallingbolt.Fail-ure to do so may cause over-torquing of bolt result-inginboltfailure.(8) I nstal l thecamshaftdri vegear retai ni ngbol t.(9) I nstal l theri ghtsi desecondarychai ngui de.(10) I nstal l thecyl i nder headaccess pl ug.(11) Re-set and i nstal l the ri ght si de secondarychai ntensi oner.(12) RemoveSpeci al Tool 8429.(13) I nstal l theti mi ngchai ncover.(14) I nstal l thecrankshaftdamper.Ti ghtendamperbol t175Nm(130Ft. Lbs.).(15) I nstal l accessorydri vebel t.(16) I nstal l thefanshroud.(17) I nstal l thecyl i nder headcover.(18) I nstal l thei ntakemani fol d.Fig. 22 Proper Tool Usage For Surface Preparation1 - PLASTIC/WOOD SCRAPER9 -32 ENGINE - 3. 7L KJCYLI NDERHEAD-RI GHT(Cont inued)(19) I nstal l oi l fi l l housi ngontocyl i nder head.(20) Refi l l thecool i ngsystem.(21) Rai sethevehi cl e.(22) I nstal l the exhaust pi pe onto the ri ghtexhaustmani fol d.(23) Lower thevehi cl e.(24) Reconnectbatterynegi ti vecabl e.(25) Starttheengi neandcheck for l eaks.CAMSHAFT(S)DESCRIPTIONThe camshafts consi st of powdered metal steell obes whi ch are si nter-bonded toa steel tube. Fourbeari ng journal s are machi ned i nto the camshaft.Camshaftendpl ay i s control l edby twothrustwal l sthatborder thenosepi ecejournal . Engi neoi l entersthehol l owcamshafts at thethi rdjournal andl ubri -cates everyi ntakel oberocker throughadri l l edpas-sagei nthei ntakel obe.REMOVALCAUTION: Whenthetimingchainisremovedandthe cylinder heads are still installed, DO NOT force-fully rotate the camshafts or crankshaft indepen-dently of each other. Severe valve and/or pistondamagecanoccur.CAUTION: When removing the cam sprocket, timingchains or camshaft, Failure to use special tool 8379will result in hydraulic tensioner ratchet over exten-sion, Requiring timing chain cover removal to re-setthetensionerratchet.(1) Removethecyl i nder headcover.Refer toCYL-I NDERHEADCOVERi nthi s secti on.(2) Set engi ne to TDC cyl i nder #1, camshaftsprocketV6marks atthe12ocl ock posi ti on.(3) Mark one l i nk on the secondary ti mi ngchai non both si des of the V6 mark on the camshaftsprockettoai di ni nstal l ati on.CAUTION: Donot holdorpryonthecamshaft tar-get wheel for any reason, Severe damage will occurtothetarget wheel. Adamagedtarget wheel couldcauseavehiclenostartcondition.(4) Loosen but DO NOT remove the camshaftsprocket retai ni ng bol t. Leave bol t snug agai nstsprocket.NOTE: The timing chain tensioners must besecuredpriortoremovingthecamshaft sprockets.Failuretosecuretensionerswill allowthetension-erstoextend,requiringtimingchaincoverremovalinordertoresettensioners.CAUTION: Donot forcewedgepast thenarrowestpoint between the chain strands. Damage to thetensionersmayoccur.(5) Posi ti on Speci al Tool 8379ti mi ngchai n wedgebetween the ti mi ng chai n strands. Tap the tool tosecurel y wedge the ti mi ng chai n agai nst the ten-si oner armandgui de.(6) Removethecamshaftposi ti onsensor.(7) Hol dthecamshaft wi thSpeci al Tool 8428Cam-shaftWrench, whi l eremovi ngthecamshaftsprocketbol tandsprocket.(8) Starti ngattheoutsi deworki ngi nward, l oosenthecamshaftbeari ngcapretai ni ngbol ts 1/2turnatati me. Repeatunti l al l l oadi s off thebeari ngcaps.CAUTION: DONOTSTAMPORSTRIKETHECAM-SHAFT BEARINGCAPS. SEVERE DAMAGE WILLOCCURTOTHEBEARINGCAPS.NOTE: Whenthecamshaft isremovedtherockerarmsmayslidedownward, marktherocker armsbeforeremovingcamshaft.(9) Remove the camshaft beari ng caps and thecamshaft.INSTALLATION(1) Lubri catecamshaft journal s wi th cl ean engi neoi l .NOTE:Positiontherightsidecamshaftsothatthecamshaft sprocket dowel is near the 10 oclockposition,Thiswillplacethecamshaftattheneutralposition easing the installation of the camshaftbearingcaps.(2) Posi ti onthecamshafti ntothecyl i nder head.(3) I nstal l thecamshaft beari ngcaps, handti ghtentheretai ni ngbol ts.NOTE: Caps should be installed so that thestamped numbers on the caps are in numericalorder, ( 1thru4) fromthefront totherearof theengine. All caps should be installed so that thestampedarrowsonthecapspointtowardthefrontoftheengine.(4) Worki ng i n 1/2 turn i ncrements, ti ghten thebeari ngcapretai ni ngbol ts starti ngwi th themi ddl ecapworki ngoutward(Fi g. 23).(5) Torque the camshaft beari ng cap retai ni ngbol ts to11Nm(100i n. l bs.).KJ ENGINE - 3. 7L 9 -33CYLI NDERHEAD-RI GHT(Cont inued)(6) Posi ti on thecamshaft dri vegear i ntotheti m-i ng chai n al i gni ng the V6 mark between the twomarkedchai nl i nks(Two l i nksmarkedduri ngremov-al ).(7) Usi ng Speci al Tool 8428 Camshaft Wrench,rotate the camshaft unti l the camshaft sprocketdowel i s al i gned wi th the sl ot i n the camshaftsprocket. I nstal l thesprocketontothecamshaft.CAUTION: Remove excess oil from camshaftsprocket bolt. Failure to do so can cause bolt over-torqueresultinginboltfailure.(8) Removeexcessoi l fromcamshaftsprocketbol t,theni nstal l thecamshaftsprocketretai ni ngbol tandhandti ghten.(9) Removeti mi ngchai nwedgespeci al tool 8379.(10) Usi ngSpeci al Tool 6958spanner wrenchwi thadapter pi ns 8346, torque the camshaft sprocketretai ni ngbol tto122Nm(90ft. l bs.).(11) I nstal l thecamshaftposi ti onsensor.(12) I nstal l thecyl i nder headcover.CYLI NDER HEAD COVER(S)REMOVAL(1) Di sconnectbatterynegati vecabl e.(2) Removeai r cl eaner assembl y,resonator assem-bl yandai r i nl ethose.(3) Drai n cool i ng system, bel ow the l evel of theheater hoses. Refer toCOOLI NGSYSTEM.(4) Removeaccessorydri vebel t.(5) Remove ai r condi ti oni ng compressor retai ni ngbol ts andmovecompressor tothel eft.(6) Removeheater hoses.(7) Di sconnecti njector andi gni ti oncoi l connectors.(8) Di sconnectandremoveposi ti vecrankcaseven-ti l ati on(PCV) hose.(9) Removeoi l fi l l tube.(10) Un-cl i pi njector andi gni ti on coi l harness andmoveawayfromcyl i nder headcover.(11) Remove ri ght rear breather tube and fi l terassembl y.(12) Removecyl i nder headcover retai ni ngbol ts.(13) Removecyl i nder headcover.INSTALLATIONCAUTION: Donot useharshcleanerstocleanthecylinder head covers. Severe damage to coversmayoccur.NOTE:Thegasketmaybeusedagain, providednocuts, tears, ordeformationhasoccurred.(1) Cl eancyl i nder headcover andbothseal i ng sur-faces. I nspectandrepl acegasketas necessary.(2) Ti ghten cyl i nder head cover bol ts and doubl eendedstuds to12Nm(105i n. l bs).(3) I nstal l ri ght rear breather tube and fi l terassembl y.(4) Connecti njector, i gni ti oncoi l el ectri cal connec-tors andharness retai ni ngcl i ps.(5) I nstal l theoi l fi l l tube.(6) I nstal l PCVhose.(7) I nstal l heater hoses.(8) I nstal l ai r condi ti oni ng compressor retai ni ngbol ts.(9) I nstal l accessorydri vebel t(10) Fi l l Cool i ngsystem(11) I nstal l ai r cl eaner assembl y, resonator assem-bl yandai r i nl ethose.(12) Connectbatterynegati vecabl e.I NTAKE/EXHAUSTVALVES &SEATSSTANDARD PROCEDURE -REFACINGNOTE:Valveseatsthatarewornorburnedcanbereworked, provided that correct angle and seatwidtharemaintained. Otherwisethecylinder headmustbereplaced.Fig. 23 Camshaft Bearing Caps TighteningSequence9 -34 ENGINE - 3. 7L KJCAMSHAFT(S) (Cont inued)NOTE: Whenrefacingvalvesandvalveseats, it isimportantthatthecorrectsizevalveguidepilotbeused for reseating stones. A true and complete sur-facemustbeobtained.(1) Usi ng a sui tabl e di al i ndi cator measure thecenter of the val ve seat Total run out must notexceed0.051mm(0.002i n).(2) Appl y a smal l amount of Prussi an bl uetotheval ve seat, i nsert the val ve i ntothe cyl i nder head,whi l eappl yi ngl i ghtpressureontheval verotatetheval ve.Removetheval veandexami netheval veface.I f the bl ue i s transferred bel owthe top edge of theval ve face, l ower the val ve seat usi ng a 15 degreestone. I fthebl uei stransferredto thebottomedgeoftheval veface, rai setheval veseatusi nga65degreestone.(3) Whentheseati sproperl yposi ti onedthewi dthofthei ntakeseatmustbe1.752.36mm(0.06890.0928i n.) andtheexhaustseatmustbe1.712.32mm(0.06730.0911i n.).(4) Check the val ve spri ng i nstal l ed hei ght afterrefaci ngtheval veandseat. Thei nstal l edhei ghtforboth i ntake and exhaust val ve spri ngs must notexceed41.44mm(1.6315i n.).(5) Theval veseatandval vefacemustmai ntai nafaceangl eof 44.545degrees angl e(Fi g. 24).REMOVALNOTE: The cylinder heads must be removed inordertoperformthisprocedure.(1) Removerocker arms andl ash adjusters. Refertoprocedures i nthi s secti on(Fi g. 25).(2) Remove the camshaft beari ng caps and thecamshaft.NOTE: All six valve springs and valves are removedin the same manner; this procedure only coversonevalveandvalvespring.(3) Usi ng Speci al Tool C-3422B or C-3422CVal ve Spri ng Compressor and Speci al tool 8519Adapter, compress theval vespri ng.NOTE: It maybenecessarytotapthetopof thevalve springtoloosenthe springretainers locksenoughtoberemoved.(4) Removethetwospri ngretai ner l ock hal ves.NOTE: thevalvespringisunder tensionusecarewhenreleasingthevalvespringcompressor.(5) Removetheval vespri ngcompressor.(6) Removethespri ngretai ner, andthespri ng.Fig. 24 Valve Assembly Configuration1 - VALVE LOCKS (3BEAD)2 - RETAINER3 - VALVE STEM OIL SEAL4 - INTAKE VALVE5 - EXHAUST VALVE6 - VALVE SPRINGFig. 25 Rocker Arm Removal1 - CAMSHAFT2 - SPECIAL TOOL 8516KJ ENGINE - 3. 7L 9 -35I NTAKE/EXHAUSTVALVES&SEATS(Cont inued)NOTE: Check for sharp edges on the keepergrooves. Remove any burrs fromthe valve stembeforeremovingthevalvefromthecylinderhead.(7) Removetheval vefromthecyl i nder head.NOTE: Thevalvestemsealsarecommonbetweenintakeandexhaust.(8) Removetheval vestemseal . Marktheval veforproper i nstal l ati on.TESTING VALVE SPRINGSNOTE: Whenever thevalvesareremovedfromthecylinder head it is recommended that the valvespringsbeinspectedandtestedforreuse.I nspecttheval vespri ngsfor physi cal si gnsofwearor damage. Turn tabl eof tool C-647unti l surfacei si n l i ne wi th the 40.69 mm(1.602 i n.)mark on thethreadedstudandthezeromark onthefront.Pl acespri ngover thestudon thetabl eandl i ft compress-i ngl ever toset tone devi ce. Pul l on torque wrenchunti l Pi ngi s heard. Take readi ngon torque wrenchat thi s i nstant. Mul ti pl y thi s readi ng by two. Thi swi l l gi ve the spri ng l oad at test l ength. Fracti onalmeasurements are i ndi cated on the tabl e for fi neradjustments. Refer to Speci fi cati onsSecti onto obtai nspeci fi edhei ghtandal l owabl etensi ons. Repl aceanyspri ngs thatdonotmeetspeci fi cati ons (Fi g. 26).INSTALLATION(1) coat the val ve stemwi th cl ean engi ne oi l andi nserti ti ntothecyl i nder head.(2) I nstal l theval vestemseal .makesuretheseali s ful l y seatedandthatthegarter spri ngatthetopof theseal i s i ntact.(3) I nstal l thespri ngandthespri ngretai ner.(4) Usi ng the val ve spri ng compressor, compressthespri ngandi nstal l thetwoval vespri ngretai nerhal ves (Fi g. 27).(5) Rel easetheval vespri ngcompressor andmakesure the twospri ng retai ner hal ves and the spri ngretai ner areful l yseated.(6) l ubri cate the camshaft journal wi th cl eanengi ne oi l then Posi ti on the camshaft (wi th thesprocketdowel onthel eftcamshaftat11ocl ockandthe ri ght camshaft at 12 ocl ock), then posi ti on thecamshaftbeari ngcaps.(7) I nstal l the camshaft beari ng cap retai ni ngbol ts. Ti ghtenthebol ts 913Nm(100i n. l bs.) i nturni ncrements i nthesequenceshown(Fi g. 28).(8) Posi ti on the hydraul i c l ash adjusters androcker arms.Fig. 26 Testing Valve Springs1 - SPECIAL TOOL C-647Fig. 27 Valve Assembly Configuration1 - VALVE LOCKS (3BEAD)2 - RETAINER3 - VALVE STEM OIL SEAL4 - INTAKE VALVE5 - EXHAUST VALVE6 - VALVE SPRING9 -36 ENGINE - 3. 7L KJI NTAKE/EXHAUSTVALVES&SEATS(Cont inued)ROCKER ARMDESCRIPTIONTherocker arms aresteel stampi ngs wi thani nte-gral rol l er beari ng. Therocker armsi ncorporatea2.8mm(0.11i nch) oi l hol ei nthel ashadjuster socket forrol l er andcamshaftl ubri cati on.REMOVALNOTE: Disconnect the battery negative cable to pre-ventaccidental starterengagement.(1) Remove the cyl i nder head cover (Refer to9 -ENGI NE/CYLI NDER HEAD/CYLI NDER HEADCOVER(S) -REMOVAL).(2) For rocker armremoval oncyl i nder #4, Rotatethe crankshaft unti l cyl i nder #1i s at TDCexhauststroke.(3) For rocker armremoval oncyl i nder #1, Rotatethecrankshaft unti l cyl i nder #1i s at TDCcompres-si onstroke.(4) For rocker armremoval oncyl i nders#2and#3,Rotate the crankshaft unti l cyl i nder #1 i s at BDCcompressi onstroke.(5) For rocker armremoval oncyl i nders#5and#6,Rotate the crankshaft unti l cyl i nder #1 i s at BDCexhauststroke.(6) Usi ngspeci al tool 8516 Rocker ArmRemover,press downward on the val ve spri ng, remove rockerarm(Fi g. 29).INSTALLATIONCAUTION: Makesuretherockerarmsareinstalledwiththe concave pocket over the lashadjusters.Failuretodosomaycauseseveredamagetotherockerarmsand/orlashadjusters.NOTE: Coat therocker armswithcleanengineoilpriortoinstallation.(1) For rocker arm i nstal l ati on on cyl i nders #4,Rotate the crankshaft unti l cyl i nder #1 i s at TDCexhauststroke.(2) For rocker arm i nstal l ati on on cyl i nder #1,Rotate the crankshaft unti l cyl i nder #1 i s at TDCcompressi onstroke.(3) For rocker armi nstal l ati ononcyl i nders#2and#3, Rotatethecrankshaftunti l cyl i nder #1i satBDCcompressi onstroke.(4) For rocker armi nstal l ati ononcyl i nders#5and#6, Rotatethecrankshaftunti l cyl i nder #1i satBDCexhauststroke.(5) Usi ngspeci al tool 8516pressdownwardontheval vespri ng, i nstal l rocker arm(Fi g. 30).(6) I nstal l the cyl i nder head cover (Refer to 9 -ENGI NE/CYLI NDER HEAD/CYLI NDER HEADCOVER(S) -I NSTALLATI ON).Fig. 28 Camshaft Bearing Caps TighteningSequenceFig. 29 Rocker Arm - Removal1 - CAMSHAFT2 - SPECIAL TOOL 8516KJ ENGINE - 3. 7L 9 -37I NTAKE/EXHAUSTVALVES&SEATS(Cont inued)VALVE GUI DE SEALSDESCRIPTIONThe val ve gui de seal s are made of rubber andi ncorporate an i ntegral steel val ve spri ngseat. Thei ntegral garter spri ng mai ntai ns consi stent l ubri ca-ti oncontrol totheval vestems.VALVE SPRI NGSDESCRIPTIONThe val ve spri ngs are made fromhi gh strengthchrome si l i con steel . The spri ngs are common fori ntake and exhaust appl i cati ons. The val ve spri ngseati s i ntegral wi ththeval vestemseal , whi chi s aposi ti vetypeseal tocontrol l ubri cati on.REMOVAL(1) Remove the cyl i nder head cover. Refer toCyl -i nder HeadCover i nthi s Secti on.(2) Usi ngSpeci al Tool 8516Val veSpri ngCompres-sor, remove the rocker arms and the hydraul i cl ashadjusters.(3) Remove the spark pl ug for the cyl i nder theval vespri ngandseal aretoberemovedfrom.(4) Appl y shop ai r to the cyl i nder to hol d theval ves i npl acewhenthespri ngi s removed.NOTE: All sixvalvespringsandsealsareremovedin the same manner; this procedure only coversonevalveseal andvalvespring.(5) Usi ngSpeci al Tool 8387Val veSpri ngCompres-sor, compress theval vespri ng.NOTE: It maybenecessarytotapthetopof thevalve springtoloosenthe springretainers locksenoughtoberemoved.(6) Removethetwospri ngretai ner l ock hal ves.NOTE: thevalvespringisunder tensionusecarewhenreleasingthevalvespringcompressor.(7) Removetheval vespri ngcompressor.(8) Removethespri ngretai ner, andthespri ng.(9) Removetheval vestemseal .NOTE: Thevalvestemsealsarecommonbetweenintakeandexhaust.INSTALLATIONNOTE: All sixvalvespringsandsealsareremovedin the same manner; this procedure only coversonevalveseal andvalvespring.(1) Appl y shop ai r to the cyl i nder to hol d theval ves i npl acewhi l ethespri ngi s i nstal l ed.NOTE: Thevalvestemsealsarecommonbetweenintakeandexhaust.(2) I nstal l theval vestemseal .(3) I nstal l thespri ngretai ner, andthespri ng.(4) Usi ngSpeci al Tool 8387Val veSpri ngCompres-sor, compress theval vespri ng.(5) I nstal l thetwospri ngretai ner l ock hal ves.NOTE: thevalvespringisunder tensionusecarewhenreleasingthevalvespringcompressor.(6) Removetheval vespri ngcompressor.(7) Di sconnecttheshopai r tothecyl i nder.(8) I nstal l thesparkpl ugfor thecyl i nder theval vespri ngandseal was i nstal l edon.(9) Usi ngSpeci al Tool 8516Val veSpri ngCompres-sor, i nstal l the rocker arms and the hydraul i c l ashadjusters.(10) I nstal l thecyl i nder headcover. Refer to Cyl i n-der HeadCover i nthi s Secti on.Fig. 30 Rocker Arm - Installation1 - CAMSHAFT2 - SPECIAL TOOL 85169 -38 ENGINE - 3. 7L KJROCKERARM(Cont inued)ENGI NE BLOCKDESCRIPTIONThecyl i nder bl ock i s madeof casti ron. Thebl ocki sacl oseddeckdesi gnwi ththel eftbankforward. Toprovi de hi gh ri gi di ty and i mproved NVH anenhanced compacted graphi te bedpl ate (Fi g. 31) i sbol ted tothe bl ock. The bl ock desi gn al l ows cool antfl ow between the cyl i nders bores, and an i nternalcool antbypass toasi ngl epoppeti nl etthermostati si ncl udedi nthecastal umi numfrontcover.STANDARD PROCEDURE -CYLINDER BOREHONINGBefore honi ng, stuff pl enty of cl ean shop towel sunder the bores and over the crankshaft to keepabrasi ve materi al s from enteri ng the crankshaftarea.(1) Usedcareful l y, theCyl i nder BoreSi zi ngHoneC-823,equi ppedwi th220gri tstones,i sthebesttoolfor thi s job. I n addi ti on todegl azi ng, i t wi l l reducetaper and out-of-round, as wel l as removi ng l i ghtscuffi ng, scori ng andscratches. Usual l y, afewstrokeswi l l cl ean upaboreandmai ntai n therequi redl i m-i ts.CAUTION:DONOTuserigidtypehonestoremovecylinderwall glaze.(2) Degl azi ngof thecyl i nder wal l s may bedonei fthecyl i nder borei s strai ghtandround. Useacyl i n-der surfaci ng hone, Honi ng Tool C-3501, equi ppedwi th 280 gri t stones (C-3501-3810). about 20-60strokes,dependi ngontheborecondi ti on,wi l l besuf-fi ci ent to provi deasati sfactorysurface. Usi nghoni ngoi l C-3501-3880, or al i ghthoni ngoi l , avai l abl efrommajor oi l di stri butors.CAUTION:DONOTuseengineortransmissionoil,mineral spirits, orkerosene.(3) Honi ngshoul dbedonebymovi ngthehoneupand down fast enough toget a crosshatch pattern.The hone marks shoul d I NTERSECTat 50 to60for proper seati ngof ri ngs (Fi g. 32).(4) A control l edhonemotor speedbetween200and300 RPMi s necessary to obtai n the proper cross-hatchangl e. Thenumber ofupanddownstrokespermi nutecanberegul atedto getthedesi red50to 60angl e. Fasterupanddownstrokesi ncreasethecross-hatchangl e.(5) After honi ng, i t i s necessary that thebl ock becl eanedto removeal l tracesofabrasi ve.Useabrushto washpartswi thasol uti onofhotwater anddeter-gent. Dry parts thoroughl y. Useacl ean, whi te, l i nt-free cl oth to check that the bore i s cl ean. Oi l thebores after cl eani ngtopreventrusti ng.CLEANINGThoroughl ycl eantheoi l panandengi nebl ockgas-ketsurfaces.Usecompressedai r tocl eanout:Thegal l eyattheoi l fi l ter adaptor hol e.Thefrontandrear oi l gal l eyhol es.Thefeedhol esfor thecrankshaftmai nbeari ngs.Fig. 31 CYLINDER BLOCK BEDPLATE1 - Cylinder Block Bedplate2 - Cranksh