1999-2001 Chrysler 300M Service & Repair Manual

ENGINE page page page page DESCRIPTION AND OPERATION 2.7L ENGINE ............................. 2 CYLINDER BLOCK......................... 3 CRANKSHAFT ............................ 5 PISTONS AND CONNECTING RODS ........... 5 CYLINDER HEAD.......................... 5 VALVES ................................. 5 VALVE SPRINGS .......................... 6 TIMING DRIVE SYSTEM .................... 6 CAMSHAFT .............................. 7 ROCKER ARMS ........................... 8 INTAKE MANIFOLD ........................ 9 EXHAUST MANIFOLD ...................... 9 ENGINE LUBRICATION ..................... 9 DIAGNOSIS AND TESTING ENGINE DIAGNOSIS—INTRODUCTION........ 13 ENGINE DIAGNOSIS—PERFORMANCE ....... 13 ENGINE DIAGNOSIS—MECHANICAL ......... 15 CHECKING ENGINE OIL PRESSURE.......... 16 INTAKE MANIFOLD LEAKAGE DIAGNOSIS ..... 16 CYLINDER COMPRESSION PRESSURE TEST . . 17 CYLINDER COMBUSTION PRESSURE LEAKAGE TEST ........................ 17 CYLINDER HEAD GASKET FAILURE DIAGNOSIS ........................... 17 LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS ........................... 18 ENGINE OIL LEAK INSPECTION ............. 19 SERVICE PROCEDURES ENGINE OIL LEVEL—CHECKING ............ 20 ENGINE OIL SERVICE ..................... 20 FORM-IN-PLACE GASKETS & SEALERS ....... 21 ENGINE GASKET SURFACE PREPARATION .... 22 REPAIR OF DAMAGED OR WORN THREADS . . . 22 CYLINDER BORE—HONING ................ 23 HYDROSTATIC LOCKED ENGINE ............ 23 PISTONS ............................... 23 PISTON RING—FITTING ................... 24 CONNECTING ROD BEARING— INSTALLATION ......................... 25 CRANKSHAFT MAIN BEARING—FITTING ...... 26 CRANKSHAFT END PLAY—CHECKING ........ 27 VALVE AND VALVE SEAT—REFACING ........ 27 ENGINE TIMING—VERIFICATION ............ 29 INTAKE MANIFOLD VACUUM PORT REPAIR— 2.7L ................................. 30 REMOVAL AND INSTALLATION ENGINE MOUNTS—LEFT AND RIGHT ......... 31 ENGINE MOUNT—REAR ................... 31 STRUCTURAL COLLAR .................... 32 ENGINE ASSEMBLY....................... 32 CRANKSHAFT DAMPER ................... 35 INTAKE MANIFOLD—UPPER ................ 36 INTAKE MANIFOLD—LOWER ............... 37 EXHAUST MANIFOLD ..................... 38 CYLINDER HEAD COVERS ................. 39 CAMSHAFT ............................. 40 ROCKER ARMS .......................... 41 HYDRAULIC LASH ADJUSTER .............. 42 VALVE STEM SEALS OR VALVE SPRINGS—IN VEHICLE.............................. 42 CYLINDER HEAD......................... 43 VALVE AND VALVE SPRINGS ............... 44 TIMING CHAIN COVER .................... 45 TIMING CHAIN AND SPROCKETS ............ 46 CRANKSHAFT SPROCKET ................. 51 CRANKSHAFT OIL SEAL—FRONT............ 52 CRANKSHAFT OIL SEAL—REAR ............. 52 CRANKSHAFT OIL SEAL RETAINER—REAR .... 53 OIL PAN ................................ 54 CRANKSHAFT ........................... 55 OIL FILTER ............................. 57 OIL PUMP .............................. 57 PISTON AND CONNECTING ROD ............ 58

ENGINE CORE AND OIL PLUGS ............. 61 DISASSEMBLY AND ASSEMBLY OIL PUMP .............................. 62 CLEANING AND INSPECTION INTAKE MANIFOLD ....................... 63 EXHAUST MANIFOLD ..................... 63 CAMSHAFT ............................. 63 CYLINDER HEAD......................... 63 CAMSHAFT FOLLOWER ................... 63 VALVE INSPECTION ...................... 63 OIL PUMP .............................. 64 CYLINDER BLOCK AND BORE .............. 66 ENGINE HYDRO-MOUNT ISOLATOR .......... 66 TIMING DRIVE SYSTEM ................... 66 SPECIFICATIONS 2.7L ENGINE ............................ 67 TORQUE ............................... 69 SPECIAL TOOLS 2.7L ENGINE ............................ 70 Fig. 1 2.7 Liter Engine

Fig. 2 Cylinder Numbering and Firing Order X MODEL YEAR X MANUFACTURING PLANT XXXXX COMPONENT CODE/ USAGE XXXX MONTH/ DAY XXXXX SERIAL CODE LAST DIGIT OF MODEL YEAR KENOSHA 9 ENGINE 2.7L USAGE PASS CAR PC Fig. 3 Engine Identification

Fig. 4 Cylinder Block and Crankshaft 1 – MAIN CAP BOLT—VERTICAL 2 – MAIN CAP 3 – MAIN BEARING—LOWER 4 – MAIN BEARING—UPPER 5 – MAIN CAP BOLT—HORIZONTAL 6 – CYLINDER BLOCK 7 – CRANKSHAFT

Fig. 5 Piston and Connecting Rod 1 – “F” TOWARD FRONT OF ENGINE 2 – RING COMPRESSOR 3 – SPECIAL TOOL 8189 4 – OIL SQUIRT HOLE

Fig. 6 Cylinder Head, Valves, and Springs 1 – VALVE KEEPER 2 – SPRING RETAINER 3 – VALVE KEEPER 4 – VALVE SPRING-EXHAUST 5 – SPRING RETAINER 6 – VALVE STEM SEAL 7 – VALVE-EXHAUST 8 – VALVE-INTAKE 9 – CYLINDER HEAD 10 – VALVE STEM SEAL 11 – VALVE SPRING-INTAKE

Fig. 7 Timing Drive System 1 – CAMSHAFT DAMPER 2 – CHAIN GUIDE 3 – ACCESS PLUG 4 – CAMSHAFT POSITION SENSOR 5 – PRIMARY TIMING CHAIN 6 – CRANKSHAFT SPROCKET 7 – CHAIN GUIDE 8 – CHAIN TENSIONER ARM 9 – CHAIN TENSIONER 10 – CAMSHAFT SPROCKETS 11 – CHAIN GUIDE

Fig. 8 Valvetrain Components 1 – CAMSHAFT BEARING CAP-INTAKE 2 – CAMSHAFT BEARING CAP-EXHAUST 3 – CAMSHAFT-EXHAUST 4 – ROCKER ARM 5 – HYDRAULIC LIFTER 6 – CYLINDER HEAD 7 – CAMSHAFT (SECONDARY) CHAIN TENSIONER 8 – CYLINDER BLOCK 9 – CYLINDER HEAD 10 – CAMSHAFT-INTAKE 11 – CAMSHAFT (SECONDARY) TIMING CHAIN Fig. 9 Rocker Arm 1 – LASH ADJUSTER POCKET 2 – OIL SQUIRT HOLE 3 – ROLLER

Fig. 10 Exhaust Manifold 1 – HEAT SHIELD 2 – BOLT 3 – GASKET 4 – BOLT 5 – EXHAUST MANIFOLD 6 – HEAT SHIELD

Fig. 11 Cylinder Block Oil Lubrication System 1 – TO RIGHT CYLINDER HEAD 2 – TO LEFT CYLINDER HEAD 3 – OIL PUMP 4 – OIL PICKUP TUBE 5 – OIL FILTER 6 – TO CRANKSHAFT MAIN JOURNALS 7 – MAIN OIL GALLERY FROM: TO: FROM: TO: Oil Pump Oil Filter Mounting (inlet) Main Oil Gallery – Center of Block 1. Crankshaft Main Bearings Oil Filter Mounting (inlet) Oil Filter 2. Left Cylinder Head* Oil Filter Oil Filter Mounting (outlet) 3. Right Cylinder Head* Oil Filter Mounting (outlet) Oil Gallery – Right side of Block Crankshaft Main Bearings Connecting Rod Bearings Oil Gallery – Right side of Block Oil Gallery – Rear of Block and to Oil Cooler (some models) Left Cylinder Head Refer to (Fig. 12) Oil Gallery – Rear of Block Main Oil Gallery – Center of Block Right Cylinder Head Refer to (Fig. 13) * The cylinder head gaskets have an oil restrictor to control oil flow to the cylinder heads.

1999-2001 Chrysler 300M Service & Repair Manual

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