Page 209 of 2103
ENGINE OVERHAUL
SPECIFICATIONS
SERVICE SPECIFICATIONS,
Ignition coil system
Standard valueLimit
Spark plug cable
Ignition coil
Camshaft and cam follower
Cam wear amount mm (in.)
Camshaft bearing bore diameter mm (in.) Primary
Secondary
12000
0 . 0 2 5 40.254
Camshaft diameter bearing clearance mm (in.)
Camshaft end play mm (in.)
Camshaft bearing journal diameter mm (in.)
0.15
Camshaft lift mm (in.)
Hydraulic lash adjuster mm (in.)
head and valve
Intake
Exhaust
Body diameter
Plunger travel
minimum (dry)8.22.
7.00
2 2 . 9 4 9 - 2 2 . 9 6 2
4.24
of gasket surface mm (in.)
seat angle
seat (max) mm (in.)
seat width (Finish) mm (in.)
seat guide bore diameter mm (in.)
valve seat diameter mm (in.)
valve diameter mm (in.)
face angle
head diameter mm (in.) Intake
Exhaust
0.1
44.5” -45”
0.050
.
34.50 (1.358)
29.50 (1.161)
34.67-34.93
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Page 210 of 2103
ENGINE OVERHAUL . . . . .------- ----
ItemsStandard value
Valve margin mm (in.)
,
Exhaust
Valve length (Overall) mm (in.)Intake
Exhaust
(4.314-4.334)
Valve stem tip height mm (in.)
Intake48.04 (1.891)
Exhaust47.99 (1.889)
Valve stem diameter mm (in.)Intake5.934-5.952 ,
Exhaust
Valve stem to guide clearance mm (in.) Intake
Exhaust
guide inner diameter mm (in.)
spring free length mm (in.)
spring tension (valve closed) N/mm
0 . 0 7 6
0.101
46 (1.811)
spring tension (valve open) N/mm
spring number of coils mm (in.)
spring wire diameter mm (in.)
installed spring height mm (in.)
pump
pump clearance over rotors mm (in.)
pump cover out of flat mm (in.)
pump inner rotor thickness mm (in.)
pump outer rotor clearance mm (in.)
pump outer rotor diameter mm (in.)
pump outer rotor thickness mm (in.)
pump tip clearance between rotors mm (in.)
pressure at curb idle speed (psi)
7.35.
3.76
38.00 (1.496)
0.102
0 . 0 7 6
7.64
79.95 (3.148)
7.64
0.02
25 (4).
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Page 211 of 2103

ENGINE OVERHAUL Specifications
Items
Piston, connecting rod and cylinder block
Piston standard piston size mm (in.)
Standard valueLimit
,
87.463-87.481
Piston to bore clearance mm (in.)
From bottom of skirt mm (in.)
.
Land clearance (Diametrical) mm (in.)
Piston length mm (in.)
Piston ring groove Top upper compression ring
depth mm (in.)
Intermediate compression ring
Oil control (Steel ring) ring
Piston pin clearance in piston mm (in.)
Piston pin in rod (interference) mm (in.)
63.82
.
,
,
pin diameter mm (in.)
pin length mm (in.)74.75-75.25
ring gap mmTop upper compression ring0 . 8
‘in.)
Intermediate compression ring1
Oil control (Steel ring) ring1
ring sideTop upper and intermediate compression ring
mm (in.)
Oil control (Pack) ring
ring width mmTop upper and intermediate compression ring 1
. ,
Oil control (Pack) ring
Cylinder block cylinder bore diameter mm (in.)
Cylinder block cylinder bore out-of-round mm (in.)
Cylinder block cylinder bore taper mm (in.) 87.5 (3.445)
0.051 .
Revision
Page 212 of 2103

ENGINE OVERHAUL Specifications
Items
Connecting rod bearing oil clearance mm (in.)Standard value
Limit
Connecting rod piston pin bore diameter mm (in.)
Connecting rod large end bore diameter mm (in.)
Connecting rod side clearance mm (in.)
Main bearing journal diameter mm (in.)0.37
.
Main bearing journal out-of-round mm (in.)
Main bearing journal taper mm (in.)
Crankshaft
0.0035.
0.0038
Crankshaft connecting rod journal diameter mm (in.)
Crankshaft out-of-round mm (in.)
Crankshaft tape mm (in.)
Crankshaft main bearing diameter clearance mm (in.)0.0035
0.0038
.
Crankshaft end play mm (in.)
TORQUE SPECIFICATIONS
Items
Generator
Pivot
Lock nut61
Ignition system
Spark plug28 20
Camshaft position sensor3
Timing belt
Crankshaft damper bolt62 45
Engine mount bracket4130
Timing belt inspection cover
Tensioner pulley28 20
Timing belt tensioner3122
Tensioner arm bracket3122
Camshaft sprocket10173
Rear timing belt cover 9.6
Cooling system components
Water pump
Thermostat housing2216
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Page 213 of 2103

ENGINE OVERHAUL
Items
Engine coolant temperature sensor
Fuel and emission control parts
EGR tube
EGR valve
Intake manifold
11 8
Intake manifold air temperature sensor
Manifold absolute pressure sensor
Intake manifold
Exhaust manifold
Exhaust manifold
Camshaft and cam follower
Cvlinder head cover
Bearing head cover
No.5 12
No.1, 628 20
Cvlinder head and
valve.
7
21 . 4
231 7 :
23 17
Cylinder head bolt
Oil pan and oil pump
Oil filter
Adapter
Oil
Oil pick-up tube
Oil pump
Oil pump
Relief valve retaining cap
Long bolt87
Short bolt2820
21,
12
2 8
23
54
Oil pump cover
Piston, connecting rod and cylinder block
Connecting rod cap bolt
1 2
2720
Knock sensor 10I
SEALANTS
Engine coolant temperature sensor
switch
Camshaft bearing cap
Oil pump
Bed plate to oil pan gasket
Oil pressure switch Bed plate to cylinder block Specified sealant
Loctite 24200 or equivalent
Loctite 24200 or equivalent
Loctite 51817 or equivalent
Loctite 51817 or equivalent
Loctite 18718 or equivalent
Loctite 24200 or equivalent
Loctite 19614 or equivalent
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Page 214 of 2103

ENGINE OVERHAUL
FORM-IN-PLACE GASKETS
There are numerous places where form-in-place gaskets are used on the engine. Care must be
when applying form-in-place gaskets to assure obtaining the desired results. size, continuity, ‘and
location are of great importance. Too thin a bead can result in leakage
too much can result’ in
spill-over which can break off and obstruct fluid f eed lines.
A continuous bead of the proper width
essential to obtain a leak-free joint.
GASKET DISASSEMBLY
Parts assembled with form-in-place gaskets may be d isassembled without unusual effort’
it may be necessary to lightly tap the part with a mallet or other suitable tool to break the seal between
the mating surfaces.A flat gasket scraper may also be lightly tapped in to the joint but care be
taken not to damage the mating surfaces.
SURFACE PREPARATION
Scrape clean or wire brush all gasketsurfaces removing all loose material. Inspect
assure gasket rails are flat.
Flatten rails with a hammer on a flat plate if
must be free of oil and dirt. Make sure old gasket material is removed from blind
FORM-IN-PLACE GASKET APPLICATION
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gaskets.
Gasket material should be applied sparingly 1 mm
inch.) diameter or less to one
surface, Be certain the material surrounds each mou nting hole.
Excess material can easily be
‘off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommen ded
during assembly, to prevent smearing the material off location.
Loctite 18718 gasket material or equivalent should be applied in a continuous bead
3
mm
inch.) in diameter. All mounting holes must be circled.
For corner sealing, 3.17 or 6.35
mm
or inch.) drop is placed in the center of the gasket contact area. Uncured may
be removed with a shop towels. Components should be torqued in place while the sea lant
wet
to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to
prevent smearing of material off location.
MOPAR TORQUE CURE GASKET MAKER
Mopar torque cure gasket maker is a unique anaerobi c type gasket material to be used ONLY
the and engine block. The material cures in the absenc e of air when. two
metallic surfaces. It will not cure if left in the uncovered tube. This anaerobic material
specially made
to seal the area between the
and cylinder block without disturbing the bearing’ or
alignment of these components.. .
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Page 215 of 2103
ENGINE OVERHAUL
SPECIAL TOOLS
ToolTool number and nameApplication
Removal
Removaland
crankshaft
damper/sprocket
8995057
1026Removal of damper.
Removal
puller damper
Installer
damper/sprocket
Installation of crankshaft damper
‘and crankshaft
End yoke holder
Holding camshaft sprocket when
loosening or
9
Pin (2)
6792 Installation of crankshaft
Installer sprocket.
crankshaft
sprocket
6793
3Installation of crankshaft seal.
Installer
camshaft oil
seal
Installer
crankshaft seal
1
Revision
Page 216 of 2103
ENGINE OVERHAUL Special
crankshaft seal
Installation of crankshaft oil seal
6926-2
8995060
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