2004 CHRYSLER CONCORDE Service and 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

2004 CHRYSLER CONCORDE Service and Repair Manual

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