Chrysler New Yorker. Manual — part 209
NOTE: Do not reuse V-Band clamps.
(22) Install new V-Band clamps at exhaust mani-
folds and tighten to 11 N·m (100 in. lbs.).
(23) Install catalytic converter down pipe front and
rear supports.
(24) Install
air
conditioning
compressor
and
tighten fasteners to 28 N·m (250 in. lbs.)
(25) Install power steering pump and tighten fas-
teners to 28 N·m (250 in. lbs.).
(26) Install radiator.
(27) Connect transaxle cooler lines to radiator.
(28) Attach A/C condenser to radiator.
(29) Install lower radiator hose.
(30) Install upper radiator hose.
(31) Install A/C and accessory drive belts. Refer to
Group 07, Cooling System for procedure.
(32) Install cooling fan module.
(33) Refill cooling system. Refer to Group 07, Cool-
ing System for procedure.
(34) Fill engine with proper amount of oil.
(35) Connect hood release cable to hood latch and
install upper radiator crossmember.
(36) Install air cleaner and air inlet hose.
(37) Install cowl support.
(38) Install right and left cowl covers.
(39) Install both wiper arms.
(40) Install hood.
(41) Connect negative cable to remote jumper ter-
minal at right strut tower.
CRANKSHAFT DAMPER
REMOVAL
(1) Remove upper radiator crossmember. Refer to
Group 23, Body for procedure.
(2) Remove fan module. Refer to Group 07, Cooling
System for procedure.
(3) Remove accessory drive belt and air condition-
ing belt. Refer to Group 07, Cooling System for pro-
cedure.
(4) Remove damper center bolt while holding the
damper with Special Tool 8191 (Fig. 30).
CAUTION: Before removing damper, verify that A/C
belt tensioner is not contacting the damper, as
damage could occur to tensioner, timing chain
cover, and/or damper.
(5) Remove damper by using Special Tools 8194
Insert and 1023 Three Jaw Puller (Fig. 31).
INSTALLATION
(1) Install damper using Special Tools 8179 Screw,
with Nut and Thrust Bearing from 6792, and 6792-1
Installer (Fig. 32).
(2) Install damper center bolt. Tighten center bolt
while holding the damper with Special Tool 8191 to
170 N·m (125 ft. lbs.) (Fig. 30).
(3) Install air conditioning and accessory drive
belts. Refer to Group 07, Cooling System for proce-
dures.
(4) Install cooling fan module and connect electri-
cal connector.
(5) Install upper radiator crossmember.
Fig. 30 Crankshaft Damper Center Bolt—Removal
and Installation
Fig. 31 Crankshaft Damper—Removal
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2.7L ENGINE
9 - 31
REMOVAL AND INSTALLATION (Continued)
CYLINDER HEAD COVERS
REMOVAL
(1) Remove upper intake manifold. Refer to Group
11, Exhaust System and Intake Manifold
(2) Remove
electrical
connectors
from
ignition
coils.
(3) Remove ground strap from right cylinder head.
(4) Disconnect
electrical
and
vacuum
harness
retaining clips from cylinder head cover studs.
(5) Remove fasteners attaching ignition coil capac-
itors.
(6) Remove fastener attaching right and left side
support brackets for upper intake manifold (Fig. 33).
(7) Loosen all cylinder head cover attaching bolts
(Fig. 34).
NOTE: Cylinder head cover attaching bolts are cap-
tured to the cover.
(8) Remove cylinder head covers.
INSTALLATION
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gaskets as necessary (Fig.
35).
(2) Install cylinder head covers and hand start all
fasteners. Verify that all double-ended studs are in
the correct locations as shown in (Fig. 34).
(3) Tighten cylinder head cover attaching bolts and
double-ended studs to 12 N·m (105 in. lbs.).
(4) Connect all electrical connectors and harness
clips.
(5) Install ignition coil capacitors and fasteners.
(6) Install right and left side support brackets for
the upper intake manifold (Fig. 33). Tighten fasten-
ers only finger tight at this time.
(7) Install upper intake manifold. Refer to Group
11, Exhaust System and Intake Manifold for proce-
dure.
CAMSHAFTS
REMOVAL
(1) Remove the primary timing chain. Refer to pro-
cedure outlined in this section.
(2) Remove secondary chain tensioner mounting
bolts.
NOTE: Camshaft bearing caps have been marked
during engine manufacturing. For example, number
one exhaust camshaft bearing is marked “1E”
Fig. 32 Crankshaft Damper—Installation
Fig. 33 Intake Manifold Side Support Brackets—Left
Side
Fig. 34 Cylinder Head Covers
9 - 32
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
(3) Slowly loosen camshaft bearing cap bolts in
reverse order of installation (Fig. 36).
(4) Remove camshaft bearing caps.
(5) Remove camshafts, secondary chain, and ten-
sioner together as an assembly.
(6) Remove tensioner and camshaft chain from
camshafts.
(7) Inspect
camshafts.
Refer
to
Cleaning
and
Inspection in the Section.
INSTALLATION
CAUTION: When the timing chain is removed and
the cylinder heads are installed, DO NOT rotate the
camshafts or crankshaft without first locating the
proper crankshaft position. Failure to do so will
result in valve and/or piston damage.
(1) Assemble camshaft chain on the cams. Ensure
that plated links are facing toward the front. Align
the plated links to the dot on the camshaft sprockets
(Fig. 40).
NOTE: Two styles of camshaft (Secondary) chain
tensioners will be used; the Early Build tensioners
will separate into subcomponents, the Later Build
tensioners will not.
(2) If camshaft chain tensioner is already in the
compressed and locked position, proceed to step (4).
(3) When the camshaft chain tensioner is removed,
it is necessary to compress and lock the tensioner
using the following procedures:
EARLY BUILD
• Separate the tensioner cylinder from tensioner
housing (Fig. 37).
• Carefully drain oil from housing using care not
to remove the internal tensioner components.
• Assemble plunger to housing (Fig. 37).
• Using hand pressure, compress tensioner and
lock using a fabricated lock pin or the equivalent
(Fig. 38).
LATE BUILD
• Place tensioner into a soft jaw vise (Fig. 39).
• SLOWLY compress tensioner until fabricated
lock pin or the equivalent can be inserted into the
locking holes.
Fig. 35 Cylinder Head Cover Gasket and Spark Plug
Seals
Fig. 36 Camshaft Bearing Cap Tightening Sequence
Fig. 37 Camshaft (Secondary) Chain Tensioner
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2.7L ENGINE
9 - 33
REMOVAL AND INSTALLATION (Continued)
• Remove compressed and locked tensioner from
the vise.
(4) Insert the compressed and locked camshaft
chain tensioner in-between the camshafts and chain.
(5) Rotate the cams so that the plated links and
dots are facing the 12:00 O’clock position (Fig. 40).
(6) Install cams to cylinder head. Ensure that
rocker arms are correctly seated and in proper posi-
tions.
(7) Install camshaft bearing caps. Ensure that
bearing caps are installed in same position as
removed.
(8) Tighten cam bearing cap bolts gradually in
sequence shown in (Fig. 36) to 12 N·m (105 in. lbs.).
(9) Install secondary chain tensioner bolts and
tighten to 12 N·m (105 in. lbs.).
(10) Remove locking pin from secondary tension-
ers.
(11) Measure camshafts end play by mounting a
dial indicator to a stationary point on cylinder head.
Locate the probe perpendicular against the end of
camshaft being checked. Move camshaft all the way
to the rear of its travel. Zero the dial indicator. Move
camshaft forward to limits of travel and read the dial
indicator (Fig. 41).
(12) Install primary timing chain. Refer to proce-
dure outlined in this section.
Fig. 38 Locking Camshaft (Secondary) Chain
Tensioner—Early Build
Fig. 39 Locking Camshaft (Secondary) Chain
Tensioner—Late Build
Fig. 40 Camshaft Chain Timing
Fig. 41 Camshaft End Play Measuring
9 - 34
2.7L ENGINE
LH
REMOVAL AND INSTALLATION (Continued)
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