Content .. 240 241 242 243 ..

Chrysler 300M, Dodge Interpid. Manual - part 242

(6) Tighten engine mount fastener to 61 N·m (45

ft. lbs.).

(7) Align flex plate to torque converter and install

mounting bolts. Tighten bolts to 75 N·m (55 ft. lbs.).

(8) Install crankshaft position sensor. (Refer to 14 -

FUEL SYSTEM/FUEL INJECTION/CRANKSHAFT
POSITION SENSOR - INSTALLATION)

(9) Install starter. (Refer to 8 - ELECTRICAL/

STARTING/STARTER MOTOR - INSTALLATION)

(10) Install new V-Band clamp at left side exhaust

manifold to catalytic converter. Tighten V-Band
clamp to 11 N·m (100 in. lbs.).

(11) Install left side catalytic converter down pipe

support fastener at transaxle. Tighten fastener to 47
N·m (35 ft. lbs.).

(12) Tighten the left converter down pipe band clamp.
(13) Install

the

transmission

oil

cooler

lines

bracket to engine.

(14) Install structural collar/cover. (Refer to 9 -

ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
INSTALLATION)

(15) Lower vehicle.
(16) Connect all electrical connections.
(17) Install four upper transmission to block bolts

tighten to 102 N·m (75 ft. lbs.).

(18) Install water pipe and retaining fasteners to

the transaxle/cylinder block double-ended bolts.

(19) Install rear throttle body support bracket.
(20) Connect heater hoses.
(21) Install upper intake manifold. (Refer to 9 -

ENGINE/MANIFOLDS/INTAKE

MANIFOLD

INSTALLATION)

(22) Connect ground straps at both cylinder heads.
(23) Connect all vacuum hoses.
(24) Connect coolant hoses at coolant recovery/

pressure container.

(25) Connect throttle and speed control cables to

bracket and throttle arm. (Refer to 14 - FUEL SYS-
TEM/FUEL

INJECTION/THROTTLE

CONTROL

CABLE - INSTALLATION)

(26) Connect fuel line. (Refer to 14 - FUEL SYS-

TEM/FUEL DELIVERY/FUEL LINES - STANDARD
PROCEDURE)

(27) Install new V-Band clamp at right exhaust man-

ifold. Tighten V-Band clamp to 11 N·m (100 in. lbs.).

(28) Install and tighten right side catalytic con-

verter down pipe support bracket fastener at trans-
axle mount.

(29) Install

air

conditioning

compressor

and

tighten fasteners to 28 N·m (250 in. lbs.).

(30) Install power steering pump and tighten fas-

teners to 28 N·m (250 in. lbs.).

(31) Install generator. (Refer to 8 - ELECTRICAL/

CHARGING/GENERATOR - INSTALLATION)

(32) Install radiator. (Refer to 7 - COOLING/EN-

GINE/RADIATOR - INSTALLATION)

(33) Attach air conditioning condenser to radiator.
(34) Install power steering line bracket to radiator.
(35) Connect engine oil and transmission cooler

lines to radiator.

(36) Install lower radiator hose.
(37) Install upper radiator hose.
(38) Install accessory drive belts. (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

INSTALLATION) .

(39) Install radiator fan. (Refer to 7 - COOLING/

ENGINE/RADIATOR FAN - INSTALLATION)

(40) Fill cooling system. (Refer to 7 - COOLING -

STANDARD PROCEDURE)

(41) Fill engine with proper amount of oil.
(42) Connect hood release cable to hood latch and

install upper radiator crossmember. (Refer to 23 -
BODY/EXTERIOR/GRILLE OPENING REINFORCE-
MENT - INSTALLATION)

(43) Install air cleaner and air inlet hose.
(44) Install strut tower brace. (Refer to 23 - BODY/

EXTERIOR/FRONT STRUT TOWER TO TOWER
BRACE - INSTALLATION)

(45) Install both cowl covers. (Refer to 23 - BODY/

EXTERIOR/COWL

GRILLE

AND

SCREEN

INSTALLATION)

(46) Install both wiper arms. (Refer to 8 - ELEC-

TRICAL/WIPERS/WASHERS/WIPER

ARMS

INSTALLATION)

(47) Install hood. (Refer to 23 - BODY/HOOD/

HOOD - INSTALLATION)

(48) Connect negative cable.

SPECIFICATIONS

3.5L ENGINE

DESCRIPTION

SPECIFICATION

Type

60° SOHC V-6 24-Valve

Displacement

3.5 Liters

(214 Cubic Inches)

Bore and Stroke

96.0 x 81.0 mm

(3.780 x 3.189 in.)

Compression Ratio

9.9:1

Lead Cylinder

#1 Right Bank

Firing Order

1-2-3-4-5-6

Cylinder Block

Cylinder Bore Diameter

96.0 mm ±0.0076

(3.780 in. ±0.0003 in.)

Out-of-Round (Max.)

0.076 mm

(0.003 in.)

Taper (Max.)

0.051 mm

(0.002 in.)

ENGINE

9 - 15

ENGINE 3.5L (Continued)

DESCRIPTION

SPECIFICATION

Pistons

Type Material

Aluminum (Full Floating

Pins)

Piston Diameter

95.98 ± 0.019 mm

(3.7788 ± 0.0008 in.)

Clearance at Size
Location

–0.007 to +0.047 mm

(–0.0003 to +0.0018 in.)

Piston Weight

—A Size

438–443 grams

(15.45–15.62 oz.)

—B Size

433–438 grams

(15.27–15.45 oz.)

Piston Ring Groove
Diameter

—No. 1

87.4–87.6 mm

(3.441–3.449 in.)

—No. 2

86.3–86.5 mm

(3.397–3.4055 in.)

—No. 3

85.8–86.0 mm

(3.378–3.385 in.)

Piston Pins

Type

Full Floating

Clearance in Piston

0.005–0.015 mm

(0.0002–0.0006 in.)

Clearance in Rod

0.007–0.018 mm

(0.0003–0.007 in.)

Diameter

23.997–24.000 mm

(0.9448–0.9449 in.)

Piston Rings

Ring Gap—Top
Compression Ring

0.20–0.36 mm

(0.008–0.014 in.)

Ring Gap—2nd
Compression Ring

0.23–0.50 mm

(0.0091–0.0197 in.)

Ring Gap—Oil Control
(Steel Rails)

0.25–0.76 mm

(0.010–0.030 in.)

Ring Side Clearance

Top and Second
Compression Ring

0.04–0.08 mm

(0.0016–0.0031 in.)

Oil Ring (Steel Rails)

0.038–0.184 mm

(0.0015–0.0073 in.)

DESCRIPTION

SPECIFICATION

Ring Width

Top Compression Ring

1.17–1.19 mm

(0.0461–0.0469 in.)

2nd Compression Ring

1.47–1.49 mm

(0.058–0.059 in.)

Oil Ring (Steel Rings)

0.445–0.470 mm

(0.0176–0.0186 in.)

Connecting Rods

Bearing Clearance

0.019–0.081 mm

(0.0007–0.0031 in.)

Piston Pin Bore Diameter

24.0076–24.0153 mm

(0.9452–0.9455 in.)

Side Clearance (Max.)

0.39 mm

(0.0153 in.)

Total Weight (Less
Bearing)

647 grams

(22.8223 oz.)

Crankshaft Main Bearing Journals

Diameter

63.987–64.013 mm

(2.519–2.520 in.)

Main Bearing Diametrical
Clearance

0.011–0.077 mm

(0.0007–0.0030 in.)

—(Max. Allowable)

0.087 mm

(0.0034 in.)

Out-of-Round (Max.)

0.015 mm

(0.0006 in.)

Taper (Max.)

0.015 mm

(0.0006 in)

End Play

0.10–0.30 mm

(0.004–0.012 in.)

—(Max.)

0.43 mm

(0.017 in.)

Connecting Rod Journals

Diameter

57.979–58.005 mm

(2.283–2.284 in.)

Bearing Diametrical
Clearance

0.019–0.087 mm

(0.00075–0.0034 in.)

Out-of-Round (Max.)

0.015 mm

(0.0006 in.)

Taper (Max.)

0.015 mm

(0.0006 in.)

9 - 16

ENGINE

ENGINE 3.5L (Continued)

DESCRIPTION

SPECIFICATION

Camshaft

Bore Diameter

43.038–43.059 mm

(1.6944–1.6952 in.)

Bearing Journal Diameter

42.939–42.960 mm

(1.6905–1.6913 in.)

Diametrical Clearance

0.078–0.12 mm

(0.003–0.0047 in.)

—(Max.)

0.15 mm

(0.0059 in.)

End Play

0.11–0.35 mm

(0.004–0.014 in.)

Valve Timing—Intake Valve

Opens (ATDC)

3°

Closes (ABDC)

61°

Duration

238°

Centerline

122°

Valve Timing—Exhaust Valve

Opens (BBDC)

56°

Closes (ATDC)

16°

Duration

252°

Centerline

112°

Valve Overlap

13°

Cylinder Head

Gasket Thickness
(Compressed)

1.78 mm

(0.070 in.)

Valve Seat Angle

45–45.5°

Valve Seat Runout (Max.)

0.051 mm

(0.002 in.)

Valve Seat Width—Intake

0.75–1.25 mm

(0.0295–0.0492 in.)

Valve Seat Width—
Exhaust

1.25–1.75 mm

(0.0492–0.0689 in.)

Guide Bore Diameter
(Std.)

6.975–7.00 mm

(0.2746–0.2756 in.)

Valve Guide Height*

9.5–10.5 mm

(0.3740–0.4134 in.)

*Measured from cylinder head surface

Valves

Face Angle

44.5–45°

Head Diameter—Intake

36.37–36.63 mm

(1.4319–1.4421 in.)

DESCRIPTION

SPECIFICATION

Head Diameter—Exhaust

28.87–29.13 mm

(1.1366–1.1469 in.)

Length—Intake (Overall)

114.41–114.99 mm

(4.5043–4.5272 in.)

Length—Exhaust
(Overall)

125.67–126.25 mm

(4.9476–4.9705 in.)

Stem Diameter—Intake

6.935–6.953 mm

(0.2730–0.2737 in.)

Stem Diameter—Exhaust

6.906–6.924 mm

(0.2719–0.2726 in.)

Stem-to-Guide
Clearance—Intake

0.022–0.065 mm

(0.0009–0.0026 in.)

—(Max.) Rocking Method

0.29 mm

(0.0114 in.)

Stem-to-Guide
Clearance—Exhaust

0.051–0.094 mm

(0.002–0.0037 in.)

—(Max.) Rocking Method

0.370 mm

(0.0146 in.)

Valve Lift—Intake (Zero
Lash)

8.55 mm

(0.3367 in.)

Valve Lift—Exhaust (Zero
Lash)

6.53 mm

(0.2571 in.)

Valve Margin - Intake:

0.835–1.165 mm

(0.0329–0.0459 in.)

Valve Margin - Exhaust:

1.44–1.77 mm

(0.0567–0.0697 in.)

Valve Stem Tip
Height—Intake

42.366–43.655 mm

(1.6680–1.7187 in.)

Valve Stem Tip
Height—Exhaust

44.705–45.986 mm

(1.760–1.8105 in.)

Valve Springs

Free Length—Intake
(Approx.)

43.675 mm

(1.7195 in.)

Free Length—Exhaust
(Approx.)

44.319 mm

(1.7448 in.)

Spring Force—Intake
(Valve Closed)

309–358 N @ 38.0 mm

(69.5–80.5 lbs. @ 1.4961

in.)

Spring Force—Exhaust
(Valve Closed)

314–354 N @ 38.0 mm

(71–79 lbs. @ 1.4961 in.)

ENGINE

9 - 17

ENGINE 3.5L (Continued)

DESCRIPTION

SPECIFICATION

Spring Force—Intake

(Valve Open)

836–907 N @ 29.85 mm

(188–204 lbs. @ 1.1594

in.)

Spring Force—Exhaust
(Valve Open)

579–640 N @ 31.47 mm

(130–144 lbs. @ 1.239

in.)

Number of Coils—Intake

6.86

Number of Coils—
Exhaust

7.66

Color of Spring (Top of
Coils)

—Intake (Right Hand Coil

Direction)

Orange

—Exhaust (Left Hand

Coil Direction)

Yellow

Wire Diameter—Intake

4.29–4.34 mm

(0.1689–0.1709 in.)

Wire Diameter—Exhaust

4.16–4.22 mm

(0.1638–0.1661 in.)

Spring Installed Height
(Spring Seat to Bottom of
Retainer)—Intake &
Exhaust

38.0 mm

(1.4961 in.)

Oil Pump

Clearance Over Rotors

0.077 mm

(0.003 in.)

Cover Out-of-Flat (Max.)

0.025 mm

(0.001 in.)

Inner & Outer Rotor

Thickness (MIn.)

14.299 mm

(0.563 in.)

Outer Rotor Thickness
(Max.)

0.39 mm

(0.015 in.)

Outer Rotor Diameter
(Min.)

79.997 mm

(3.149 in.)

Tip Clearance Between
Rotors (Max.)

0.20 mm

(0.008 in.)

Oil Pressure

(NOTE: At Normal Operating Temperatures)

Pressure @ Curb Idle
Speed*

34.47 kPa Min.

(5 psi) Min.

Pressure @ 3000 RPM

300–724 kPa

(45–105 psi)

*CAUTION: If pressure is zero at curb idle, DO NOT
run engine at 3000 RPM.

TORQUE

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

A/C Compressor Bracket to
Engine—Bolts

—

A/C Compressor to Bracket

—

250

Camshaft Sprocket Bolt—Right
Side

102

⁄

Turn

⁄

Turn

—

Camshaft Sprocket Bolt—Left Side

115

⁄

Turn

⁄

Turn

—

Camshaft Thrust Plate—Bolts

—

250

Connecting Rod Cap—Nuts

⁄

Turn

⁄

Turn

—

Crankshaft Main Bearing Cap

—Inner Main Cap Bolts

⁄

Turn

⁄

Turn

—

—Outer Main Cap Bolts

⁄

Turn

⁄

Turn

—

—Tie Bolts (Horizontal)

—

250

Crankshaft Damper—Bolt

—

Cylinder Head Bolts*

—Step 1

—

—Step 2

—

—Step 3

—

—Step 4

⁄

Turn

⁄

Turn

—

*Refer to procedure for tightening sequence. (Refer to
9 - ENGINE/CYLINDER HEAD - INSTALLATION)

Cylinder Head Cover—Bolts

—

105

Exhaust Manifold to Cylinder
Head—Bolts

—

200

Exhaust Manifold Heat Shield—
Bolts

—

105

Engine Mount Bracket to
Block—Bolts

—

Engine Mount Isolator—Nuts

—

Generator Bracket—Bolts

—

Intake Manifold

—M6 Bolts

—

105

—M8 Bolts

—

250

9 - 18

ENGINE

ENGINE 3.5L (Continued)

Content .. 240 241 242 243 ..