Chrysler IIIH User manual

Chrysler IIIH Engine Assembly Manual
Rsϭ
Revision Release Date:
:ƵŶĞ1ϰ, 201ϴ
Engineering Contact:
Jeff Betz
313-363-8093
Fiat Chrysler America
This document is to be used as a supplement to the Chrysler Sequence IIIH Engine Oil
Certification Test, (ASTM Standard Test Method Dϴϭϭϭ), and is used in conjunction with the
Standard Test Method to outline test engine build and assembly instructions.

Section 0
Document Index
0) Document Index
1) Engine Specifications and Fastener Torque
2) Precautionary Statements & Cylinder Head Core Preparation
3) New Engine Disassembly
4) Main Oil Gallery Modifications and Honing
5) Post Honing and Special Parts Cleaning
6) Cylinder Head Pre-Build Cleaning and Assembly
7) Short Block Assembly and General Information
8) Long Block Assembly
9) Final Dress
10) OHT Hardware
11) Reagents and Equipment
12) Document Update Timeline

GeneralInformation
EngineFamily
CompressionRatio
LeadCylinder
FiringOrder
Displacement
BoreandStroke
CylinderBlock
CylinderBoreDiameter(TestTarget)
CylinderBoreOut‐of‐Round(Max.)
CylinderBoreCylindricity
Pistons
PistonDiameter(MetaltoMetal)
ClearanceatSizeLocation(MetaltoMetal)
ClearanceatSizeLocation(MetaltoCoating)
PistonPinOffset
PistonRingGrooveDiameterNo.1
PistonRingGrooveDiameterNo.2
PistonRingGrooveDiameterNo.3
PistonPinDiameter
PistonPinClearanceinPiston
PistonPinClearanceinRod
PistonRings
RingGapTop(TestTarget)
RingGapSecond(TestTarget)
RingGapOilControlRails
PistonRingSideClearance
Top
Second
OilControlAssembly
PistonRingWidth
Top
Second
OilControlRails
Description Specification
60°DOHCV‐624Valve
ChryslerIIIHEngineSpecifications
Revision1
June‐18
Section
Sheet
1
1
10.2:1
#1RightBank
1‐2‐3‐4‐5‐6
Metric Standard
Metric Standard
96.04 3.781
0.009mm 0.00035in.
0.015mm
3.6Liters 220CubicInches
96.0x83.0mm 3.779x3.268in.
Metric Standard
0.8mm 0.031in.
N/A N/A
0.0006in.
N/A N/A
N/A N/A
0.011‐0.024mm 0.0004‐0.0009in.
89.16‐89.36mm 3.510‐3.518in.
21.9985±0.0015mm 0.86608±0.00006in.
0.002‐0.011mm 0.0001‐0.0004in.
88.24‐88.44mm 3.474‐3.482in.
86.54‐86.74mm 3.407‐3.415in.
0.889 0.035
0.15‐0.66mm 0.006‐0.026in.
Metric Standard
Metric Standard
0.635 0.025
Metric Standard
3.00‐3.20mm 0.118‐0.126in.
3.59‐3.85mm 0.141‐0.152in.
0.025‐0.083mm 0.0010‐0.0033in.
0.030‐0.078mm 0.0012‐0.0031in.
0.007‐0.173mm 0.0003‐0.0068in.
1.930‐2.083mm 0.076‐0.082in.

ConnectingRods
BearingClearance(WithCrush)
SideClearance
PistonPinBoreDiameter
BearingBoreOutofRound(Max.)
CrankshaftMainBearingJournals
Diameter
BearingClearance
OutofRound(Max.)
CrankshaftEndPlay
CrankshaftRodBearingJournals
Diameter
BearingClearance
OutofRound(Max.)
CamshaftJournalDia.&Clearance
BoreDia.CamTowerNo.1
BoreDia.CamTowersNo.2,3,4
JournalDia.No1
JournalDia.No.2,3,4
ClearanceNo.1
ClearanceNo.2,3,4
CamshaftEndPlay
CylinderHead
CompressedGasketThickness@FireRing
CylinderHeadDeckFlatness
ValveSeatAngle
IntakeValveSeatWidth
ExhaustValveSeatWidth
ValveGuideBoreDiameter
ValveStemtoGuideClearance(Intake)
ValveStemtoGuideClearance(Exhaust)
6.00‐6.02mm 0.236‐0.237in.
0.023‐0.061mm 0.0009‐0.0024in.
44.75°±0.25°fromthevalveguideaxis
0.030‐0.068mm 0.0012‐0.0027in.
1.0‐1.2mm 0.04‐0.05in.
1.41‐1.61mm 0.055‐0.063in.
Metric Standard
0.48‐0.60mm 0.019‐0.024in.
0.09mm 0.0035in.
0.024‐0.064mm 0.0009‐0.0025in.
0.008mm 0.0003in.
0.075‐0.251mm 0.003‐0.010in.
23.977‐23.996mm 0.9440‐0.9447in.
0.025‐0.065mm 0.001‐0.0026in.
32.020‐32.041mm 1.2606‐1.2615in.
24.020‐24.041mm 0.9457‐0.9465in.
31.976‐31.995mm 1.2589‐1.2596in.
0.023‐0.064mm 0.0009‐0.0025in.
0.005mm 0.0002in.
Metric Standard
Metric Standard
59.0±0.009mm 2.3228±0.0035in.
0.050‐0.290mm 0.002‐0.0114in.
71.996±0.009mm 2.8345±0.0035in.
0.024‐0.050mm 0.0009‐0.0020in.
0.005mm 0.0002in.
0.070‐0.370mm 0.0028‐0.0146in.
22.016±0.005mm 0.8668±0.0002in.
Metric Standard
Description Specification
Metric Standard
0.023‐0.064mm 0.0009‐0.0025in.
ChryslerIIIHEngineSpecifications
RevisionDRAFT Section 1
Mar‐16 Sheet 2

IntakeManifold(Upper)M6Bolt
IntakeManifold(Lower)M6Bolt 12 106
106
10 89
871
10 89
266
15 133
12 106
12 106
18 9
40+105° 30+105°
97
21+90° 16+90°
20+90° 15+90°
11
97
11 97
55 40
80
9.5
CamshaftChainRHGuide(Secondary)M6T30
CamshaftPosition(CMP)SensortoCylinderHeadM6T30
CamshaftBearingCapM6T30
ConnectingRodCapM9Bolt
CoolantPumpPlatetoEngineTimingCoverM6Bolt
12
11
106
12 106
12 106
10612
84
20+90°
CamshaftChainTensioner(Primary)M6T30
CamshaftChainGuide(Primary)M6T30
CamshaftChainIdlerSprocketM8T45
CamshaftChainLHTensioner(Secondary)M6T30
CamshaftChainLHGuide(Secondary)M6T30
CylinderHeadOilGalleryPlug
CylinderHeadOilRestrictorM8Plug
CylinderHeadtoEngineBlockM12inSequence
CoolantCrossoverPlatetoEngineTimingCoverM6Bolt
CoolantPumpPlatetoEngineTimingCoverM10Bolt
CrankshaftTargetWheeltoCounterweightM6T30
CrankshaftOuterMainBearingCapandWindageTrayM8Bolt
CrankshaftInnermainBearingCapM11Bolt
CrankshaftSideMainBearingCap(TieBolt)M8Bolt
CrankshaftVibrationDamperM16Bolt
CrankshaftPosition(CKP)SensortoEngineBlockM6Bolt
CrankshaftRearOilSealRetainerM6T30
CamshaftChainRHTensioner(Secondary)M6T30
9
IgnitionCapacitortoCylinderHeadM6Bolt
IgnitionCoiltoCylinderHeadCoverM6Bolt
CylinderHead/CamshaftCoverM6Bolt
EngineCoolantTemperatureSensor(ECT)
FlywheeltoCrankshaftM10Bolt
FuelRailtoLowerIntakeManifoldM6Bolt
LowerOilPantoUpperOilPanM6Bolt
IdlerPulleytoEngineTimingCoverAccessoryDriveM8Bolt
15+90°
28
12
106
22 16
Revision1ChryslerIIIHTorqueSpecifications
June‐18
N∙m Lb.Ft. Lb.In.
12 106
12 106
25 18
Section 1
Sheet 3
SeeIIIHAssemblyManualSection8
95 70
762
11 93
12

VariableValveTimingSolenoidtoCylinderHeadCoverM5T25
WireHarnessRetainerBrackettoLHCylinderHeadM6T30
435
10 89
UpperIntakeManifoldSupportBrackettoUpperIntakeManifoldM8
B
UpperIntakeManifoldSupportBrackettoUpperIntakeManifoldM6
N
980
EngineTimingCoverM8Bolt
EngineTimingCoverM10Bolt
25 18
55 41
17 177
ThrottleBodyM6Bolt
EngineTimingCoverM6Bolt
TensionertoEngineTimingCoverAccessoryDriveM10Bolt
ThermostatHousingtoCoolantCrossoverM6Bolt
55 41
12 106
980
12 106
SparkPlugtoCylinderHeadM12
StarterMountingM10Bolt
OxygenSensortoExhaustTakeDownPipeM18
PCVValveM5T25
50 37
435
18 13
47 35
OilPumpPickupTubeBrackettoWindageTrayM6Bolt
OilPumpPickupTubetoOilPumpM6Bolt
OilLevelIndicatortoCylinderHeadM6Bolt
OilPumpSprocketM8T45
17 151
25 18
12 106
12 106
OilPumptoEngineBlockM6Bolt
OilLevelIndicatortoEngineBlockM10Bolt
OilFilterHousing/OilCoolertoEngineBlockM6
OilfilterHousingCap
12 106
25 18
12 106
35 26
OilTemperatureSensortoOilFilterHousing
PistonOilCoolerJettoEngineBlockM5
OilPanDrainPlugM14
OilPressureSensortoOilFilterHousing
27 20
20 177
20 177
653
UpperOilPantoRearSealRetainerM6Bolt
OilControlValve‐CamPhaserM8Bolt
UpperOilPantoEngineBlockM8Bolt 17
12 106
10 89
Description
KnockSensortoEngineBlock
OilCoolertoOilFilterHousingScrews
21 16
150 118
23
Revision1ChryslerIIIHTorqueSpecifications
June‐18
N∙m Lb.Ft. Lb.In.
Section 1
Sheet 4

Caution:
Caution:
Warning:
Note:
1.
2.
3.
Notes:
Section 2
PrecautionaryStatements
Revision1
Sheet 1June‐18
The3.6LPentastarEngineisNOTAFREESPINENGINE.Care
mustbeexercisedduringdisassemblynottorotatethe
crankshaftorcamshaftsoncethevalvetrainchain
assemblieshavebeenalteredinanymanner.
Cleanallcylinderheadboltholesintheengineblock.Do
notuseanysealantsoradhesivesonfasteners,MultiLayer
Gaskets,oranysealingsurfacesunlessspecifiedinthis
procedure.Surfacesmustbedebrisfreeandscratchfree
forpropersealing.
NOTAFREESPINENGINE
Multi‐LayerSteelgasketsrequireascratchfreesealing
surface.
ValvetoPistoninterferencewilloccurifnot
properlydisassembled/assembled
Removeallgasketmaterialsfromcylinderheadandblock
usingcarenottogougeorscratchthealuminumsealing
surfaces.
Noncompressibledebrissuchasoil,coolant,orRTV
sealantsnotremovedfromboltholescancausethe
aluminumcylinderblocktofracturewhentightening
fasteners.
Donotlaycylinderheadsongasketsealingsurfaces.The
designoftheMulti‐LayerSteel(MLS)cylinderheadgasket
willnotsealproperlyifthereareanyimperfectionsonthe
cylinderheadorengineblock.Plastictypegasketremoving
toolshavebeenfoundsuitablewhencleaningthese
surfaces.
Multi‐LayerSteel(MLS)headgasketshaveverysharpedges
thatcouldcausepersonalinjuryifnothandledcarefully.

1.
2.
3. Donotremoveoilgalleryplugsorfreezeplugs
4
Topinsertrotates180°depending
whichhead,leftorrightisinbox.
Keepallcamshaftbearingcapsinorder.Replaceafter
valvetrainhardwareremoval.Donotuseimpacttools
totightencamshaftcaps.Useaspeedhandletolightly
snugfastenersandtorqueM6T30fastenersto9.5Nm.
Afterremovingallvalvetraingearandtorqueingall
camshaftcapsintheirproperposition,installthecylinder
headinVCIbagandinserttheassemblyintheIMTS
Packagingwithproperinserts,Securelytapepackageand
shipto:IMTS8460RondaDr.
Canton,MI.48187
2
CylinderHeadCorePreparation
Revision1
Sheet 2June‐18
Removeallvalvetrainhardwarefromcylinderheads;
camshafts,rollerrockers,lashadjusters,valvesprings,
valveseals,andsparkplugs.
Camshaftcapsareidentifiedonthesides,"1E‐>,2E‐>"etc.
forexhaustcamshaftsand"1I‐>,2I‐>"etc.forintake
camshaftcaps.Capsmustbekeptinorder.
NewenginesareorderedthroughChryslerMOPARunder
specialorderpartnumber.Enginesarepreservedunder
longtermpackaging.Oncereceivedatthetestlaboratory,
theyshouldbedisassembledandputintostorageforfuture
build.Cylinderheadsshouldbecompletelydisassembled
andthevalvetraingearstoredforfutureuse.
Barecylinderheads(Cores)shouldbesenttoIMTSforre‐
work.LabsmustusetheIMTSSpecialPackagingto
protectthecoresfromdamage.Packagingcontains
specialcushioningsleevesforbothRightandLeft
cylinderheads.
Section

Section 3
New Engine Disassembly

12
Removeupperintakemanifold(2)fasteners(1)
NewenginesarereceivedfromChryslerasfullassemblies.Upondeliverytothebuildarea,theyshouldbe
disassembledandpreparedfortest.Cylinderheadsshouldbedisassembledandthebareheadsneedtobepackaged
forshipmenttoIMTSforspecialprocessing.Packagingfromthenewcylinderheadstobeusedforthetestshouldbe
usedforreturnofnewcorematerialstoIMTS.
Removetheflywheelanddisengagethe
ignitionandfuelinjectorharnessclipson
theupperintakemanifoldbrackets(1).
Removebothupperintakemanifold
brackets(2).
RemovePCVvacuumtubefromrockercoverto
upperintakemanifold.
1
RevisionDRAFT
Mar‐16 NewEngineDisassembly Section
Sheet
3

Removetheeightlowerintakemanifoldattaching Removethelowerintakemanifold(2)withthefuel
bolts(1). injectorsandfuelrail.
Seal,LowerIntaketoCylinderHead
051844331AC(Sixindividualseals)
Seal,LowerIntaketoUpperIntake
05184562AC(Sixindividualseals)
Disconnectallinjectionharnessandignitionharnessretainerclips.Disconnectcoilpackelectricalconnectors.
Disconnectfuelinjectorelectricalconnectorsfromfuelinjectors.Removeharness.
Thelowerintakemanifoldisaninjectionmoldednyloncompositedesign.Thelowerintakesealstothecylinder
headsusingsixindividualsiliconegaskets.Thesevenupperintakemanifoldfastenersthreaddirectlyintothe
compositelowerintakemanifoldandareself‐tappingdesign.Thefuelrailisalsoacompositedesign.Thefourfuel
railfastenersthreaddirectlyintothelowerintakemanifoldandalsoareself‐tappingdesign.Thefuelrailandfuel
injectorsmustbeinstalledintothelowerintakemanifoldasanassembly.Donotattempttoinstallthefuelrailwhen
theinjectorsareinthemanifold.
RevisionDRAFT NewEngineDisassembly Section 3
Mar‐16 Sheet 2

InstalltheDriverSideEngineLiftingBracket10242‐1
(1)ontheLHcylinderheadwithbolts(2)provided
withtheEngineLiftingBracket.Tightenthebolts
to21N∙m(15ft.lbs.).
InstallthePassengerSideEngineLiftingBracket
10242‐2(1)ontheRHcylinderheadwithbolts(2)
fromtheEngineLiftingBracket.Tightentheboltsto
21N∙m(15ft.lbs.).
Drainthefactoryfillengineoilfromtheoilpanbeforerotatingtheengineontherolloverstand.
Removethefrontbalancer.
Labsmayalsochosetofabricatein‐houseliftingbrackets.Careshouldbetakentoensurethebracketskeepall
chainsandhooksfromcontactingthecamshaftcovers.Ithasbeenfoundthatplatesattachedtotheexhaust
manifoldfastenerareaworkwellwhenmovingfullyassembledengines.
Oncepositionedontherolloverstand,Removetheoilfiltercapandfiltercartridge,therebyallowinganyoilin
thefilterhousingtodraintotheoilpan.
Revision1NewEngineDisassembly Section 3
Jun‐18 Sheet 3

RemoveOilFilterCap&Cartridge
RemovertheRightEngineMountBracket.
Removetheidlerpulley.
Removethecoolant
crossoverandthermostat
housing.
Removethecoolant
pump.
Removetheserpentinebelttensioner. DrainFactoryFillOil
Removethefrontbalancer.
RevisionDRAFT NewEngineDisassembly Section 3
Mar‐16 Sheet 4

Drainallfluidsintheengine,rotatingtheenginetoremoveasmuchoilfromtheoilpanaspossible.
Disconnectallharnessretainerclipsandconnectionsfromtheoilfilterhousingsensorsandcoolanthoseassembly.
Removethefasteners(2)holdingtheoilfilterhousing(1)andoilcoolertotheenginevalley.
Donotremovethescrews(1)and(3)holdingtheoilcoolertotheoilfilterhousing.
OilFilter/CoolerAdapterO‐ringKit
68191356AA
Containsitems(1)&(2)
RevisionDRAFT NewEngineDisassembly Section 3
Mar‐16 Sheet 5

RemovetheCamshaftPositionSensors
RemoveIgnitionCoils RemovePCVHousing
RemoveCamshaftCovers
PartNumbers:
Gasket,RightSideCylinderHeadCover05184595AE
Gasket,LeftSideCylinderHeadCover05184596AE
Seal,O‐ring,CamshaftPhaserControl05184855AB
Seal,CamshaftPositionSensor06509450AA
Seal,Tube,SparkPlugWell05184778AB
Careshouldbeusedtopreventdamagetothecamshaftcoversealsatthejointbetweenthefrontcoverand
cylinderheadbyusingasharpputtyknifetoslicetheRTVsealerintheseareasasthecoverisliftedfromthe
cylinderhead.
RevisionDRAFT NewEngineDisassembly Section 3
Mar‐16 Sheet 6

Removetheloweroilpanfasteners.Asharp,rigidputtyknifehasbeenfoundsuitabletocuttheRTVsealerbetween
the lower andupperoilpans.Removetheloweroilpan.
Removetheupperoilpanfasteners.UsetheprypointstobreaktheRTVbond.Applypressureonthefront
oftheupperoilpanwhiletappingwithaplasticmallettoremovetheassembly.
Note:maincapsideboltshavealsobeenremovedwhileremovingupperoilpanfasteners.
Revision1
NewEngineDisassembly Section 3
Jun‐18 Sheet 7

Removetheenginetimingchainfrontcoverfasteners.
Usinganappropriateprybar,breaktheRTVsealattheprypointsbetweenthefrontcoverandblock.
Removetheenginetimingchainfrontcover.
PartNumbers:
GasketKit,ChainCaseCover,CrossoverWaterOutlet68078604AA
Gasket,Pump,Water68087340AA
Gasket,Crossover,WaterOutlet05184454AE
Seal,CrankshaftOil,Front68079589AA
RevisionDRAFT NewEngineDisassembly Section 3
Mar‐16 Sheet 8
2
4
5
9

Caution:Camshafttimingalignmentisnotperformedduringenginedisassembly.
Oncethetimingchainassembliesareremoved,donotrotatethecrankshaftuntilthecamshaftsareremoved.
Removealltimingchaintensioners,guides,chainsandtheidlershaft.SeeLongBlockAssemblyforPartNumbers.
Removethecamshafts,rollerrockers,lashadjusters,cylinderheadfasteners,andcylinderheads.
Re‐installthecamshaftbushingcaps.Removethevalvesprings,seals,shims,andvalvesandpackage
thecylinderheadsforshippingtoIMTSforprocessing.
RevisionDRAFT NewEngineDisassembly Section 3
Mar‐16 Sheet 9

Removethewindagetrayandmaincapsidebolts.
Markthepositionsontheconnectingrodsandremove
thepistonandrodassemblies.
Removethecrankshaftandpreparetheengineblockforcleaning.
Followprocedureforprestressingandhoningtheblockfortest.
Note:Idlershaftshouldberemoved
RevisionDRAFT NewEngineDisassembly Section 3
Mar‐16 Sheet 10

Section 4
Main Oil Gallery Modifications and Honing