Chrysler New Yorker. Manual — part 237
INSTALLATION
(1) Clean cylinder head and cover mating surfaces.
Inspect and replace gasket and seals as necessary
(Fig. 35).
(2) To replace spark plug tube seals:
a. Using a pry tool, carefully remove tube seals.
b. Position new seal with the part number on seal
facing cylinder head cover.
c. Install seals with Special Tool MB-998306 (Fig.
36).
(3) Install cylinder head cover bolts and tighten to
12 N·m (105 in. lbs.) (Fig. 34).
(4) Install ignition coils and connect all electrical
connectors.
(5) Install upper intake plenum and air cleaner
assembly.
SPARK PLUG TUBES
REMOVAL
(1) Remove cylinder head cover. Refer to procedure
outlined in this section.
(2) Using locking pliers remove the tube from the
cylinder head (Fig. 37). Discard old tube.
(3) Clean area around spark plug with Mopar
t
Parts Cleaner or equivalent.
INSTALLATION
(1) Apply Mopar
t Stud and Bearing Mount to a
new tube approximately 1 mm (0.039 in.) from the
end of tube, in a 3 mm (0.118 in.) wide area.
(2) Install sealer end of tube into the cylinder
head. Then carefully install the tube using a hard-
wood block and mallet. Install the tube until it is
seated into the bottom of the bore.
(3) Install cylinder head cover. Refer to procedure
outlined in this section.
CYLINDER HEAD
REMOVAL
(1) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(2) Remove crankshaft damper.
(3) Remove timing belt covers.
(4) Remove camshaft sprockets. Refer to Camshaft
Sprocket and Engine Timing Procedure in this sec-
tion.
(5) Remove intake manifold assembly. Refer to Group
11, Intake and Exhaust Manifolds, for procedure.
Fig. 36 Spark Plug Tube Seal Installation
Fig. 37 Servicing Spark Plug Tubes
Cylinder Head, Camshaft, and Rocker Arms
300M
3.5L ENGINE
9 - 31
REMOVAL AND INSTALLATION (Continued)
(6) Remove rear timing belt cover to cylinder head
fasteners (Fig. 38). Remove the rear covers.
(7) The right side rear timing belt cover has
O-rings to seal the water pump passages to cylinder
block (Fig. 39). Do not reuse O-rings.
(8) Remove cylinder head bolts and remove cylin-
der head.
INSTALLATION
The cylinder head bolts are tightened using a
torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are
necked down the bolts should be replaced (Fig.
40).
Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
Fig. 38 Rear Timing Belt Cover Attaching Bolts
Fig. 39 Right Side Timing Belt Cover Water Pump
O-Rings
Fig. 40 Checking Bolts for Stretching (Necking)
Fig. 41 Cylinder Head Gasket Identification
9 - 32
3.5L ENGINE
300M
REMOVAL AND INSTALLATION (Continued)
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
ONLY a wooden or plastic scraper.
(1) Clean sealing surfaces of cylinder head and
block.
CAUTION: Ensure that the correct head gaskets are
used and are oriented correctly on cylinder block.
The 3.5L engine head gaskets have perfectly round
combustion sealing rings. The 3.2L engine does
NOT
have
perfectly
round
combustion
sealing
rings.
(2) Install
head
gasket
over
locating
dowels.
Ensure the gasket is installed on the correct side of
engine (Fig. 41).
(3) Install cylinder head over locating dowels.
(4) Before
installing
the
bolts,
lubricate
the
threads with engine oil.
(5) ighten the cylinder head bolts in the sequence
shown in (Fig. 42). Using the 4 step torque-turn
method, tighten according to the following torque val-
ues:
• Step 1: All to 61 N·m (45 ft. lbs.)
• Step 2: All to 88 N·m (65 ft. lbs.)
• Step 3: All (again) to 88 N·m (65 ft. lbs.)
• Step 4: + 90° Turn Do not use a torque
wrench for this step.
(6) Bolt torque after 90° turn should be over 122
N·m (90 ft. lbs.) in the tightening direction. If not,
replace the bolt.
(7) Clean right rear timing belt cover O-ring seal-
ing surfaces and grooves. Lubricate new O-rings with
synthetic grease to facilitate assembly.
(8) Install rear timing belt covers (Fig. 38). (Fig.
39). Tighten bolts to specified torque:
• M10—54 N·m (40 ft. lbs.)
• M8—28 N·m (20 ft. lbs.)
• M6—12 N·m (105 in. lbs.)
(9) Install camshaft sprockets and timing belt.
Refer to procedure in this section.
(10) Install timing belt covers. Refer to procedure
in this section.
(11) Install intake and exhaust manifolds. Refer to
Group 11, Intake and Exhaust Manifolds for procedures.
(12) Install crankshaft damper.
(13) Fill cooling system. Refer to Group 7, Cooling
System for procedure.
CRANKSHAFT
REMOVAL
(1) Remove engine from vehicle. Refer to Engine
Assembly Removal and Installation in this section.
(2) Remove oil pan.
(3) Remove oil pick-up tube.
(4) Remove idler pulley for accessory drive belt.
(5) Remove front lower timing belt cover.
(6) Remove front main timing belt cover.
(7) Remove front left side timing belt cover.
(8) Remove crankshaft damper. Refer to procedure
in this section.
(9) Remove timing belt tensioner and timing belt.
(10) Remove crankshaft sprocket. Refer to Front
Crankshaft Oil Seal Removal and Installation for
procedure.
(11) Tap dowel pin out of crankshaft. Refer to
Front Crankshaft Oil Seal Removal and Installation
for procedure.
(12) Remove oil pump assembly.
(13) Remove rear crankshaft oil seal retainer.
(14) Remove connecting rod bearing caps. Connect-
ing rod bearing caps are not interchangeable and
should be marked before removal to insure correct
assembly (Fig. 43).
(15) Remove main bearing caps. Main bearing caps
are not interchangeable and are marked to insure
correct assembly (Fig. 44).
(16) Remove Crankshaft.
NOTE: Before installing Crankshaft refer to Fitting
Main Bearings and Installation of Connecting Rod
Bearings in this section.
Fig. 42 Cylinder Head Bolt Tightening Sequence
Fig. 43 Connecting Rod to Cylinder Identification
300M
3.5L ENGINE
9 - 33
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
CAUTION: Main bearings are select fit. Refer to
Crankshaft Main Bearing Fitting in this section for
proper bearing selection.
(1) Install Crankshaft.
(2) Move crankshaft forward to limit of travel.
Lubricate and install the front thrust washer by roll-
ing the washer onto the machined shelf between the
No. 2 upper main bulk head and crankshaft thrust
surface (Fig. 46).
(3) Move crankshaft rearward to limit of travel.
Lubricate and install the rear thrust washer by rolling
the washer onto the machined shelf between the No. 2
upper main bulk head and crankshaft thrust surface.
(4) Lubricate lower main bearings with clean
engine oil.
NOTE: Lubricate
main
bearing
cap
bolts
with
engine oil before installation.
(5) Install each main cap and tighten bolts finger
tight.
The main bearing cap bolts must be tightened in
the proper sequence. First the inner main cap bolts,
secondly the windage tray bolts, lastly the main cap
tie (horizontal) bolts.
(6) Install the inside main bearing cap bolts and
tighten to 20 N·m + 1/4 turn (15 ft. lbs. + 1/4 turn).
(7) Measure crankshaft end play. Refer to Service
Procedures in this section.
(8) Install connecting rods and measure side clear-
ance. Refer to Service Procedures in this section.
(9) Install windage tray. Lubricate bolts with
engine oil and tighten to 27 N·m + 1/4 turn (20 ft.
lbs. + 1/4 turn).
(10) Install the main cap tie (horizontal) bolts and
tighten to 28 N·m (250 in. lbs.).
(11) Install rear crankshaft oil seal retainer and oil
seal. Refer to procedure in this section.
(12) Install oil pump assembly. Refer to Oil Pump
Removal and Installation in this section.
(13) Install dowel pin in crankshaft. Refer to Front
Crankshaft Oil Seal Removal and Installation for
procedure.
(14) Install crankshaft sprocket. Refer to Front
Crankshaft Oil Seal Removal and Installation for
procedure.
(15) Install
Timing
Belt.
Refer
to
Camshaft
Sprockets and Timing Procedure in this section.
(16) Install (3) timing belt covers.
(17) Install crankshaft damper. Refer to procedure
in this section.
(18) Install idler pulley for accessory drive belt.
(19) Install oil pick-up tube and tighten bolt to 28
N·m (250 in. lbs.).
(20) Install oil pan. Refer to procedures outlined in
this section.
(21) Install engine assembly.
(22) Fill engine crankcase with proper amount of oil.
Fig. 44 Main Bearing Cap Identification
Fig. 45 Main Bearing Identification
Fig. 46 Thrust Washer Installation
9 - 34
3.5L ENGINE
300M
REMOVAL AND INSTALLATION (Continued)
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