Chrysler 300M, Dodge Interpid. Manual — part 238
(4) Remove left knee blocker.
(5) Remove under column ducts.
(6) Remove Junction Block/BCM four mounting
screws.
(7) Remove wire harness connectors from Junction
Block/BCM.
(8) Remove Junction Block/BCM.
(9) Disconnect BCM wire connectors and RKE
antenna connector.
(10) Remove Junction Block/BCM from vehicle.
INSTALLATION
(1) Install Junction Block/BCM to vehicle.
(2) Connect
BCM
wire
connectors
and
RKE
antenna connector.
(3) Install Junction Block/BCM.
(4) Install wire harness connectors to Junction
Block/BCM.
(5) Install four mounting screws.
(6) Install under column ducts.
(7) Install left knee blocker.
(8) Connect cable to hood release, decklid release
switch wiring, and install two screws to lower instru-
ment panel.
(9) Install left end cap.
(10) Connect the negative battery cable remote ter-
minal to the remote battery post.
POWER DISTRIBUTION
CENTER
DESCRIPTION
All of the electrical current distributed throughout
this vehicle is directed through the standard equip-
ment Power Distribution Center (PDC) (Fig. 5). The
molded plastic PDC housing is located in the left
front corner of the engine compartment, just in front
of the coolant reservoir bottle. The PDC housing has
a molded plastic cover. The PDC cover is easily
removed for service access and has a convenient fuse
and relay layout label affixed to the inside surface of
the cover to ensure proper component identification.
The PDC housing is secured in the engine compart-
ment by one screw to the rear of the PDC and two
clips on the front side. A small molded plastic protec-
tive cover on the front right side of the engine com-
partment
is
unsnapped
to
access
the
battery/
generator cable input connection studs.
OPERATION
All of the PDC outputs are through the integral
engine compartment wire harness, which exits from
the front of the PDC housing.
All of the current from the battery/generator cable
connection enters the PDC that is secured with nuts
just inside the left end of the PDC housing. The PDC
houses up to fourteen maxi-fuse cartridges, which
replace all in-line fusible links. The PDC also houses
up to six blade-type fuses, up to four full Interna-
tional Standards Organization (ISO) relays, and up
to seven ISO micro-relays. Internal connection of all
the PDC circuits is accomplished by an intricate net-
work of hard wiring and bus bars. Refer to the appro-
priate wiring information. The wiring information
includes wiring diagrams, proper wire and connector
repair procedures, details of wire harness routing
and retention, connector pin-out information and
location views for the various wire harness connec-
tors, splices and grounds.
The fusible link, fuse cartridges, fuses and relays
are available for service replacement. The PDC unit
cannot be repaired and is only serviced as a unit
with the engine compartment wire harness. If the
PDC is faulty or damaged, the engine compartment
wire harness assembly must be replaced.
REMOVAL
The Power Distribution Center (PDC) is serviced
as a unit with the engine compartment wire harness.
If any internal circuit of the PDC or the PDC hous-
ing is faulty or damaged, the entire PDC and engine
compartment wire harness unit must be replaced.
(1) Disconnect and isolate the battery negative
remote cable.
(2) Disconnect each of the engine compartment
wire harness connectors. (Refer to 8 - ELECTRICAL/
WIRING DIAGRAM INFORMATION - DIAGNOSIS
Fig. 5 Power Distribution Center Location
1 - POWER DISTRIBUTION CENTER
2 - LEFT FRONT FENDER
3 - LEFT FRONT HEADLAMP
LH
8W-97 POWER DISTRIBUTION
8W - 97 - 5
JUNCTION BLOCK (Continued)
AND TESTING) for more information on the loca-
tions of the affected connectors.
(3) Remove the fasteners that secure each of the
engine compartment wire harness ground eyelets to
the vehicle body and chassis components. (Refer to 8
- ELECTRICAL/WIRING DIAGRAM INFORMATION
- DIAGNOSIS AND TESTING) for more information
on the ground eyelet locations.
(4) Disengage each of the retainers that secure the
engine compartment wire harness to the vehicle body
and chassis components. (Refer to 8 - ELECTRICAL/
WIRING DIAGRAM INFORMATION - DIAGNOSIS
AND TESTING) for more information on the retainer
locations.
(5) Remove one PDC mounting screw and disen-
gage the PDC housing by pushing the locking tabs in
on the PDC base. The mounting bracket blades are
retained by a snap fit in the PDC mounting slots.
(6) Remove the PDC and the engine compartment
wire harness from the engine compartment as a unit.
INSTALLATION
The Power Distribution Center (PDC) is serviced
as a unit with the engine compartment wire harness.
If any internal circuit of the PDC or the PDC hous-
ing is faulty or damaged, the entire PDC and engine
compartment wire harness unit must be replaced.
NOTE: If the power distribution center (PDC) is
being replaced with a new unit, be certain to trans-
fer each of the fuses, fuse cartridges, fusible links
and relays from the old power distribution center to
the proper cavities of the new power distribution
center. Refer to Electrical, Wiring Diagram Informa-
tion for the proper power distribution center cavity
assignments.
(1) Position the PDC over the mounting bracket in
the engine compartment.
(2) Align the PDC mounting slots with the blades
on the PDC mounting bracket.
(3) Push down firmly and evenly on the PDC hous-
ing until it snaps into place on the PDC mounting
bracket.
(4) Route the engine compartment wire harness
from the PDC through the engine compartment,
engaging each of the harness retainers to the mount-
ing provisions in the vehicle body and chassis compo-
nents. Make sure to make clip attachment into the
rail located behind the PDC. (Refer to 8 - ELECTRI-
CAL/WIRING DIAGRAM INFORMATION - DIAG-
NOSIS AND TESTING) for more information on the
harness routing and retainer locations.
(5) Install and tighten the fasteners that secure
each of the engine compartment wire harness ground
eyelets to the vehicle body and chassis components.
(Refer to 8 - ELECTRICAL/WIRING DIAGRAM
INFORMATION - DIAGNOSIS AND TESTING) for
more information on the ground eyelet locations.
(6) Reconnect each of the engine compartment
wire harness connectors. (Refer to 8 - ELECTRICAL/
WIRING DIAGRAM INFORMATION - DIAGNOSIS
AND TESTING) for more information on the loca-
tions of the affected connectors.
(7) Torque nut retaining positive battery cable at
PDC to 96 - 141 N·m (85 - 130 in. lbs.).
(8) Reconnect the battery negative remote cable.
8W - 97 - 6
8W-97 POWER DISTRIBUTION
LH
POWER DISTRIBUTION CENTER (Continued)
ENGINE
TABLE OF CONTENTS
page
page
ENGINE 3.5L
. . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST . . . . . . . . 10
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PLACE GASKETS AND SEALERS . . . . . . . . . 10
GASKET SURFACE PREPARATION . . . . . . . . 11
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS . . . . . . . . . 11
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE . . . . . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION - ENGINE ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . 19
AIR CLEANER ELEMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . 22
CYLINDER HEAD
. . . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSIS AND TESTING—CYLINDER HEAD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . 24
CAMSHAFT OIL SEAL(S)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . 26
CAMSHAFT(S)
. . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
STANDARD PROCEDURE - MEASURING
. . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . 27
CYLINDER HEAD COVER(S)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . 28
INTAKE/EXHAUST VALVES & SEATS
. . . . . . . . . . . . . . . . . . . . . . . . . 29
STANDARD PROCEDURE - VALVE AND
. . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . . . . . . 31
ROCKER ARM / ADJUSTER ASSEMBLY
DESCRIPTION - ROCKER ARM SHAFTS
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 32
STANDARD PROCEDURE - HYDRAULIC LASH
. . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . 36
SPARK PLUG TUBE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . 37
VALVE STEM SEALS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . 37
VALVE SPRINGS
. . . . . . . . . . . . . . . . . . . . . . . . . 38
. . . . . . . . . . . . . . . . . . . . . . . . . . 39
LH
ENGINE
9 - 1
INSTALLATION - CYLINDER HEAD OFF
INSTALLATION - CYLINDER HEAD ON
ENGINE BLOCK
. . . . . . . . . . . . . . . . . . . . . . . . . 40
STANDARD PROCEDURE - CYLINDER BORE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
. . . . . . . . . . . . . . . . . . . . . . . . . . 41
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
. . . . . . . . . . . . . . . . . 42
CRANKSHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . 42
STANDARD PROCEDURE - CRANKSHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
. . . . . . . . . . . . . . . . . . . . . . . . . . 43
. . . . . . . . . . . . . . . . . . . . . . . . . 44
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - CRANKSHAFT
. . . . . . . . . . . . . . . . 45
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
. . . . . . . . . . . . . . . . . . . . . . . . . 47
CRANKSHAFT OIL SEAL - FRONT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
. . . . . . . . . . . . . . . . . . . . . . . . . 49
CRANKSHAFT OIL SEAL - REAR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
. . . . . . . . . . . . . . . . . . . . . . . . . 49
CRANKSHAFT REAR OIL SEAL RETAINER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
. . . . . . . . . . . . . . . . . . . . . . . . . 50
FLEX PLATE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
. . . . . . . . . . . . . . . . . . . . . . . . . 51
PISTON & CONNECTING ROD
. . . . . . . . . . . . . . . . . . . . . . . . . 51
STANDARD PROCEDURE - FITTING PISTONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
. . . . . . . . . . . . . . . . . . . . . . . . . 52
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . . . . . . . . . . . 55
STRUCTURAL COLLAR / COVER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . . . . . . . . . . 56
VIBRATION DAMPER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . . . . . . . . . . 57
ENGINE MOUNTING
. . . . . . . . . . . . . . . . . . . . . . . . . 57
. . . . . . . . . . . . . . . . . . . . . . . . . . 58
LEFT MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . . . . . . . . . . 58
REAR MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
. . . . . . . . . . . . . . . . . . . . . . . . . 59
RIGHT MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
. . . . . . . . . . . . . . . . . . . . . . . . . 59
LUBRICATION
. . . . . . . . . . . . . . . . . . . . . . . . . 60
. . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION . . . . . . . . . . . . . . . . . . . . 60
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . 61
OIL
. . . . . . . . . . . . . . . . . . . . . . . . . 62
STANDARD PROCEDURE - ENGINE OIL
LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . 62
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE . . . . . . . . . . . . . . . . . . 62
OIL COOLER & LINES
. . . . . . . . . . . . . . . . . . . . . . . . . 62
. . . . . . . . . . . . . . . . . . . . . . . . . . . 62
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
. . . . . . . . . . . . . . . . . . . . . . . . . 63
OIL FILTER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
. . . . . . . . . . . . . . . . . . . . . . . . . 64
OIL PAN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
. . . . . . . . . . . . . . . . . . . . . . . . . 65
OIL PRESSURE RELIEF VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
. . . . . . . . . . . . . . . . . . . . . . . . . . 66
. . . . . . . . . . . . . . . . . . . . . . . . . 66
OIL PRESSURE SWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . 66
. . . . . . . . . . . . . . . . . . . . . . . . . . . 66
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
. . . . . . . . . . . . . . . . . . . . . . . . . 66
OIL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
. . . . . . . . . . . . . . . . . . . . . . . . . 67
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
. . . . . . . . . . . . . . . . . . . . . . . . . 70
INTAKE MANIFOLD
. . . . . . . . . . . . . . . . . . . . . . . . . 70
DIAGNOSIS AND TESTING - INTAKE
. . . . . . . . . . . . . . . . . . . . . 71
9 - 2
ENGINE
LH
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