Chrysler 300/300 Touring/300C, Dodge Magnum. Manual — part 1607

ENGINE - 6.1L SERVICE INFORMATION

TABLE OF CONTENTS

page

page

ENGINE - 6.1L SERVICE INFORMATION

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2454
DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - ENGINE

DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . . 2455

DIAGNOSIS AND TESTING - ENGINE

DIAGNOSIS - LUBRICATION. . . . . . . . . . . . . . 2457

DIAGNOSIS AND TESTING - CYLINDER

COMBUSTION PRESSURE LEAKAGE . . . . . 2458

DIAGNOSIS AND TESTING - CYLINDER

COMPRESSION PRESSURE . . . . . . . . . . . . . 2459

DIAGNOSIS AND TESTING - ENGINE

DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . . 2459

DIAGNOSIS AND TESTING - ENGINE

DIAGNOSIS - PERFORMANCE . . . . . . . . . . . 2460

DIAGNOSIS AND TESTING - ENGINE

DIAGNOSIS - INTRODUCTION. . . . . . . . . . . . 2461

STANDARD PROCEDURE

STANDARD PROCEDURE - REPAIR

DAMAGED OR WORN THREADS . . . . . . . . . 2461

STANDARD PROCEDURE - HYDROSTATIC

LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2461

REMOVAL - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 2462
INSTALLATION - ENGINE . . . . . . . . . . . . . . . . . . . 2468
SPECIFICATIONS

6.1L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2473
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2478

SPECIAL TOOLS

6.1L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2480

AIR INTAKE SYSTEM

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2483
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2485

CYLINDER HEAD

OPERATION—CYLINDER HEAD . . . . . . . . . . . . . 2487
DIAGNOSIS AND TESTING - CYLINDER HEAD

GASKET FAILURE

. . . . . . . . . . . . . . . . . . . . . . . 2487

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2488
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2491
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2491
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2492

COVER-CYLINDER HEAD

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2497
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500

VALVES & SEATS - INTAKE/EXHAUST

DESCRIPTION

DESCRIPTION - VALVE GUIDES . . . . . . . . . . . 2503
DESCRIPTION - VALVES . . . . . . . . . . . . . . . . . . 2503

STANDARD PROCEDURE - REFACING . . . . . . . 2503
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2504
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2504

ROCKER ARM

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2505
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2507

SEALS-VALVE GUIDE

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2510

SPRINGS-VALVE

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2511
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2517

ENGINE BLOCK

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2522
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2522

CAMSHAFT

REMOVAL

REMOVAL - CAMSHAFT CORE HOLE PLUG . . 2523
REMOVAL - CAMSHAFT . . . . . . . . . . . . . . . . . . . 2523

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2527
INSTALLATION

INSTALLATION - CAMSHAFT CORE HOLE

PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2527

INSTALLATION - CAMSHAFT . . . . . . . . . . . . . . 2528

CRANKSHAFT

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2533
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2537

BEARINGS-CRANKSHAFT MAIN

STANDARD PROCEDURE - CRANKSHAFT

MAIN BEARING - FITTING

. . . . . . . . . . . . . . . . 2542

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2542

SEAL-CRANKSHAFT OIL-FRONT

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2543
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2544

SEAL-CRANKSHAFT OIL-REAR

DIAGNOSIS AND TESTING - REAR SEAL

AREA LEAKS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2545

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2545
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2546

RETAINER-CRANK REAR OIL - SEAL

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2547
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2547

FLEX PLATE

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2548
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2548

TAPPETS-HYDRAULIC ROLLER

DIAGNOSIS AND TESTING - HYDRAULIC

TAPPETS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2549

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2549
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2551

PISTON & CONNECTING ROD

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2552
STANDARD PROCEDURE - PISTON FITTING . 2552
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2553
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2554

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ENGINE - 6.1L SERVICE INFORMATION

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INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2554
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2555

RINGS-PISTON

STANDARD PROCEDURE - PISTON RING

FITTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2557

DAMPER-CRANKSHAFT

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2560
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2560

COVER-STRUCTURAL

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2562
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2562

ENGINE MOUNTING-FRONT

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2563
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2565

MOUNTING-ENGINE REAR

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2569
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2570

LUBRICATION

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2572
DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - CHECKING

ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . 2572

DIAGNOSIS AND TESTING - ENGINE OIL

LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2572

OIL

STANDARD PROCEDURE - ENGINE OIL

SERVICE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2574

FILTER-ENGINE OIL

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2575
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2575

PAN-OIL

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2576

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2578

PUMP-ENGINE OIL

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2582
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2582
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2583
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2584

MANIFOLD - INTAKE

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2585
DIAGNOSIS AND TESTING - INTAKE

MANIFOLD LEAKAGE

. . . . . . . . . . . . . . . . . . . . 2585

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2585
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2585
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2586
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2586

MANIFOLD - EXHAUST

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2587
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2587
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2587
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2588
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2588
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2589

COVER-TIMING

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2591
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2593

TIMING CHAIN & SPROCKETS

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2595
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2598

TENSIONER - TIMING CHAIN

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2601
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2601

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ENGINE - 6.1L SERVICE INFORMATION

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ENGINE - 6.1L SERVICE INFORMATION

DESCRIPTION

The 6.1L engine (370 CID) eight-cylinder engine is a 90° V-Type lightweight, deep skirt cast iron block, aluminum
heads, single cam, overhead valve engine with hydraulic roller tappets. The heads incorporate splayed valves with
a hemispherical style combustion chamber and dual spark plugs. The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2.

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DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL

ENGINE MECHANICAL DIAGNOSIS CHART

CONDITION

POSSIBLE CAUSES

CORRECTION

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 9 -
ENGINE/LUBRICATION/OIL -
STANDARD PROCEDURE)

3. Low oil pressure

3. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) 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.

2. Low oil pressure

2. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) engine
oil pressure test/specifications

3. Thin or diluted oil

3. Change oil to correct viscosity.
(Refer to 9 - ENGINE/
LUBRICATION/OIL - STANDARD
PROCEDURE) for correct
procedure/engine oil specifications

4. Excessive connecting rod
bearing clearance

4. 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

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ENGINE - 6.1L SERVICE INFORMATION

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