Chrysler IIIH Engine Assembly Manual

Rs͘ϭ
Revision Release Date:

:ƵŶĞ1ϰ, 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
 Revision 1 Section 1
June‐18 Chrysler IIIH Engine Specifications Sheet 1
Description Specification
General Information
Engine Family 60° DOHC V‐6 24 Valve
Compression Ratio 10.2 : 1
Lead Cylinder #1 Right Bank
Firing Order 1‐2‐3‐4‐5‐6
Metric Standard
Displacement 3.6 Liters 220 Cubic Inches
Bore and Stroke 96.0 x 83.0 mm 3.779 x 3.268 in.

Cylinder Block Metric Standard

Cylinder Bore Diameter (Test Target) 96.04 3.781
Cylinder Bore Out‐of‐Round (Max.) 0.009 mm 0.00035 in.
Cylinder Bore Cylindricity 0.015 mm 0.0006 in.

Pistons Metric Standard

Piston Diameter (Metal to Metal) N/A N/A
Clearance at Size Location (Metal to Metal) N/A N/A
Clearance at Size Location (Metal to Coating) N/A N/A
Piston Pin Offset 0.8 mm 0.031 in.
Piston Ring Groove Diameter No. 1 88.24 ‐ 88.44 mm 3.474 ‐ 3.482 in.
Piston Ring Groove Diameter No. 2 86.54 ‐ 86.74 mm 3.407 ‐ 3.415 in.
Piston Ring Groove Diameter No. 3 89.16 ‐ 89.36 mm 3.510 ‐ 3.518 in.
Piston Pin Diameter 21.9985 ± 0.0015 mm 0.86608 ± 0.00006 in.
Piston Pin Clearance in Piston 0.002 ‐ 0.011 mm 0.0001 ‐ 0.0004 in.
Piston Pin Clearance in Rod 0.011 ‐ 0.024 mm 0.0004 ‐ 0.0009 in.

Piston Rings Metric Standard

Ring Gap Top (Test Target) 0.635 0.025
Ring Gap Second (Test Target) 0.889 0.035
Ring Gap Oil Control Rails 0.15 ‐ 0.66 mm 0.006 ‐ 0.026 in.

Piston Ring Side Clearance Metric Standard

Top 0.025 ‐ 0.083 mm 0.0010 ‐ 0.0033 in.
Second 0.030 ‐ 0.078 mm 0.0012 ‐ 0.0031 in.
Oil Control Assembly 0.007 ‐ 0.173 mm 0.0003 ‐ 0.0068 in.

Piston Ring Width Metric Standard

Top 3.00 ‐ 3.20 mm 0.118 ‐ 0.126 in.
Second 3.59 ‐ 3.85 mm 0.141 ‐ 0.152 in.
Oil Control Rails 1.930 ‐ 2.083 mm 0.076 ‐ 0.082 in.
 Revision DRAFT Section 1
Mar‐16 Chrysler IIIH Engine Specifications Sheet 2
Description Specification
Connecting Rods Metric Standard
Bearing Clearance (With Crush) 0.023 ‐ 0.064 mm 0.0009 ‐ 0.0025 in.
Side Clearance 0.070 ‐ 0.370 mm 0.0028 ‐ 0.0146 in.
Piston Pin Bore Diameter 22.016 ± 0.005 mm 0.8668 ± 0.0002 in.
Bearing Bore Out of Round (Max.) 0.008 mm 0.0003 in.

Crankshaft Main Bearing Journals Metric Standard

Diameter 71.996 ± 0.009 mm 2.8345 ± 0.0035 in.
Bearing Clearance 0.024 ‐ 0.050 mm 0.0009 ‐ 0.0020 in.
Out of Round (Max.) 0.005 mm 0.0002 in.
Crankshaft End Play 0.050 ‐ 0.290 mm 0.002 ‐ 0.0114 in.

Crankshaft Rod Bearing Journals Metric Standard

Diameter 59.0 ± 0.009 mm 2.3228 ± 0.0035 in.
Bearing Clearance 0.023 ‐ 0.064 mm 0.0009 ‐ 0.0025 in.
Out of Round (Max.) 0.005 mm 0.0002 in.

Camshaft Journal Dia. & Clearance Metric Standard

Bore Dia. Cam Tower No. 1 32.020 ‐ 32.041 mm 1.2606 ‐ 1.2615 in.
Bore Dia. Cam Towers No. 2, 3, 4 24.020 ‐ 24.041 mm 0.9457 ‐ 0.9465 in.
Journal Dia. No 1 31.976 ‐ 31.995 mm 1.2589 ‐ 1.2596 in.
Journal Dia. No. 2, 3, 4 23.977 ‐ 23.996 mm 0.9440 ‐ 0.9447 in.
Clearance No. 1 0.025 ‐ 0.065 mm 0.001 ‐ 0.0026 in.
Clearance No. 2, 3, 4 0.024 ‐ 0.064 mm 0.0009 ‐ 0.0025 in.
Camshaft End Play 0.075 ‐ 0.251 mm 0.003 ‐ 0.010 in.

Cylinder Head Metric Standard

Compressed Gasket Thickness @ Fire Ring 0.48 ‐ 0.60 mm 0.019 ‐ 0.024 in.
Cylinder Head Deck Flatness 0.09 mm 0.0035 in.
Valve Seat Angle 44.75° ± 0.25° from the valve guide axis
Intake Valve Seat Width 1.0 ‐ 1.2 mm 0.04 ‐ 0.05 in.
Exhaust Valve Seat Width 1.41 ‐ 1.61 mm 0.055 ‐ 0.063 in.
Valve Guide Bore Diameter 6.00 ‐ 6.02 mm 0.236 ‐ 0.237 in.
Valve Stem to Guide Clearance (Intake) 0.023 ‐ 0.061 mm 0.0009 ‐ 0.0024 in.
Valve Stem to Guide Clearance (Exhaust) 0.030 ‐ 0.068 mm 0.0012 ‐ 0.0027 in.
 Revision 1 Section 1
June‐18 Chrysler IIIH Torque Specifications Sheet 3
N∙m Lb. Ft. Lb. In.
Camshaft Chain Tensioner (Primary) M6 T30 12 106
Camshaft Chain Guide (Primary) M6 T30 12 106
Camshaft Chain Idler Sprocket M8 T45 25 18
Camshaft Chain LH Tensioner (Secondary) M6 T30 12 106
Camshaft Chain LH Guide (Secondary) M6 T30 12 106
Camshaft Chain RH Tensioner (Secondary) M6 T30 12 106
Camshaft Chain RH Guide (Secondary) M6 T30 12 106
Camshaft Position (CMP) Sensor to Cylinder Head M6 T30 9 80
Camshaft Bearing Cap M6 T30 9.5 84
Connecting Rod Cap M9 Bolt 20 + 90° 15 + 90°
Coolant Pump Plate to Engine Timing Cover M6 Bolt 11 97
Coolant Crossover Plate to Engine Timing Cover M6 Bolt 11 97
Coolant Pump Plate to Engine Timing Cover M10 Bolt 55 40
Crankshaft Target Wheel to Counterweight M6 T30 11 97
Crankshaft Outer Main Bearing Cap and Windage Tray M8 Bolt 21 + 90° 16 + 90°
Crankshaft Inner main Bearing Cap M11 Bolt 20 + 90° 15 + 90°
Crankshaft Side Main Bearing Cap (Tie Bolt) M8 Bolt 28 266
Crankshaft Vibration Damper M16 Bolt 40 + 105° 30 + 105°
Crankshaft Position (CKP) Sensor to Engine Block M6 Bolt 12 106
Crankshaft Rear Oil Seal Retainer M6 T30 12 106
Cylinder Head Oil Gallery Plug 18 9
Cylinder Head Oil Restrictor M8 Plug 15 133
Cylinder Head to Engine Block M12 in Sequence See IIIH Assembly Manual Section 8
Cylinder Head / Camshaft Cover M6 Bolt 12 106
Engine Coolant Temperature Sensor (ECT) 22 16
Flywheel to Crankshaft M10 Bolt 95 70
Fuel Rail to Lower Intake Manifold M6 Bolt 7 62
Lower Oil Pan to Upper Oil Pan M6 Bolt 11 93
Idler Pulley to Engine Timing Cover Accessory Drive M8 Bolt 12 106
Ignition Capacitor to Cylinder Head M6 Bolt 10 89

Ignition Coil to Cylinder Head Cover M6 Bolt 8 71

Intake Manifold (Upper) M6 Bolt 10 89

Intake Manifold (Lower) M6 Bolt 12 106

 Revision 1 Section 1
June‐18 Chrysler IIIH Torque Specifications Sheet 4
Description N∙m Lb. Ft. Lb. In.
Knock Sensor to Engine Block 21 16
Oil Control Valve ‐ Cam Phaser M8 Bolt 150 118
Upper Oil Pan to Engine Block M8 Bolt 23 17
Oil Cooler to Oil Filter Housing Screws 12 106
Upper Oil Pan to Rear Seal Retainer M6 Bolt 10 89
Oil Pan Drain Plug M14 27 20
Oil Pressure Sensor to Oil Filter Housing 20 177
Oil Temperature Sensor to Oil Filter Housing 20 177
Piston Oil Cooler Jet to Engine Block M5 6 53
Oil Filter Housing / Oil Cooler to Engine Block M6 12 106
Oil filter Housing Cap 25 18
Oil Pump to Engine Block M6 Bolt 12 106
Oil Level Indicator to Engine Block M10 Bolt 35 26
Oil Level Indicator to Cylinder Head M6 Bolt 17 151
Oil Pump Sprocket M8 T45 25 18
Oil Pump Pickup Tube Bracket to Windage Tray M6 Bolt 12 106
Oil Pump Pickup Tube to Oil Pump M6 Bolt 12 106
Oxygen Sensor to Exhaust Take Down Pipe M18 50 37
PCV Valve M5 T25 4 35
Spark Plug to Cylinder Head M12 18 13
Starter Mounting M10 Bolt 47 35
Tensioner to Engine Timing Cover Accessory Drive M10 Bolt 55 41
Thermostat Housing to Coolant Crossover M6 Bolt 12 106
Throttle Body M6 Bolt 9 80
Engine Timing Cover M6 Bolt 12 106
Engine Timing Cover M8 Bolt 25 18
Engine Timing Cover M10 Bolt 55 41
Upper Intake Manifold Support Bracket to Upper Intake Manifold M8 B 17 177
Upper Intake Manifold Support Bracket to Upper Intake Manifold M6 N 9 80
Variable Valve Timing Solenoid to Cylinder Head Cover M5 T25 4 35
Wire Harness Retainer Bracket to LH Cylinder Head M6 T30 10 89
 Revision 1 Section 2
June‐18 Precautionary Statements Sheet 1
Caution:
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.

Caution:
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.
NOT A FREE SPIN ENGINE
Warning: Valve to Piston interference will occur if not
Multi‐Layer Steel (MLS) head gaskets have very sharp edges properly disassembled / assembled
that could cause personal injury if not handled carefully.

Note:
Multi‐Layer Steel gaskets require a scratch free sealing
surface.
1. Remove all gasket materials from cylinder head and block
using care not to gouge or scratch the aluminum sealing
surfaces.
2. 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.

3. 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.

Notes:
 Revision 1 Section 2
June‐18 Cylinder Head Core Preparation Sheet 2
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.

1. 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.
2. Remove all valvetrain hardware from cylinder heads;
camshafts, roller rockers, lash adjusters, valve springs,
valve seals, and spark plugs.
3. Keep all camshaft bearing caps in order. Replace after Do not remove oil gallery plugs or freeze plugs
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.

4 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

Top insert rotates 180° depending

which head, left or right is in box.
 Section 3
New Engine Disassembly
 Revision DRAFT Section 3
Mar‐16 New Engine Disassembly Sheet 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.

1 2

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 Remove upper intake manifold (2) fasteners (1)
upper intake manifold.
 Revision DRAFT Section 3
Mar‐16 New Engine Disassembly Sheet 2
Disconnect all injection harness and ignition harness retainer clips. Disconnect coil pack electrical connectors.
Disconnect fuel injector electrical connectors from fuel injectors. Remove harness.

Remove the eight lower intake manifold attaching Remove the lower intake manifold (2) with the fuel
bolts (1). injectors and fuel rail.

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.

Seal, Lower Intake to Cylinder Head

051844331AC (Six individual seals)

Seal, Lower Intake to Upper Intake

05184562AC (Six individual seals)
 Revision 1 Section 3
Jun‐18 New Engine Disassembly Sheet 3

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.).

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.

Drain the factory fill engine oil from the oil pan before rotating the engine on the roll over stand.

Remove the front balancer.

 Revision DRAFT Section 3
Mar‐16 New Engine Disassembly Sheet 4

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 Section 3
Mar‐16 New Engine Disassembly Sheet 5

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 Section 3
Mar‐16 New Engine Disassembly Sheet 6

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 1 Section 3
Jun‐18 New Engine Disassembly Sheet 7

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 DRAFT Section 3
Mar‐16 New Engine Disassembly Sheet 8

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:
2 Gasket Kit, Chain Case Cover, Crossover Water Outlet 68078604AA
4 Gasket, Pump, Water 68087340AA
5 Gasket, Crossover, Water Outlet 05184454AE
9 Seal, Crankshaft Oil, Front 68079589AA
 Revision DRAFT Section 3
Mar‐16 New Engine Disassembly Sheet 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 Section 3
Mar‐16 New Engine Disassembly Sheet 10

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

 Section 4
Main Oil Gallery Modifications and Honing
 Revision DRAFT Cylinder Block Main Oil Gallery Section 4
Mar‐16 Thermocouple Installation Tools Sheet 1

The rear main oil gallery is modified to adapt an 1/8 thermocouple just below the mixing point where the oil cooler flow
and the oil cooler by‐pass flow intermix as it enters the main oil gallery. Special modifications are required to perform
these operations and are outlined in this section of the cleaning and pre‐hone preparations section of the manual.

Special tooling fixtures and tools to perform this operation are required and provided through IMTS
IMTS Chrysler 3.6L Thermocouple Tapping Fixture Assembly 151132‐F001
1. Thermocouple Tapping Fixture 151132‐F001 (Main Plate Less Total Assembly Components)

2. Thermocouple Tapping Jig 151132‐J001 3. Thermocouple Setting Fixture 151132‐F002

4. Thermocouple Tapping Jig Tools and Fasteners

d
a. Clearance Drill 151132‐T001 a
b. Aircraft Drill Special 151132‐T002 e
c. NPTF Tap Special 151132‐T003
d. Oil Gallery Clean Plug 151132‐P003
e. Fixture Fasteners
b

c
 Revision DRAFT Cylinder Block Main Oil Gallery Section 4
Mar‐16 Thermocouple Modification Sheet 2

1. Remove the main oil gallery access plug from the right
side of the engine. Remove the Crankshaft Sensor
from the right side of the engine.

Coolant Jacket Plug

2. Remove the main oil gallery access plug from the left
side of the engine.

Coolant Jacket Plug

3. Caution: Due to potential oil leakage.

Do not remove front main oil gallery cup plug

Remove the timing chain idler gear shaft

4. Remove the rear main oil gallery plug.

5. Remove all three piston cooling jet assemblies from

the main oil gallery.
 Revision DRAFT Cylinder Block Main Oil Gallery Section 4
Mar‐16 Thermocouple Modification Sheet 3

6. Attach the main tooling fixture plate to the rear of the

engine aligning the plate over the transmission dowel
pins with five allen hex fasteners.

7. Install the oil gallery Clean Plug Assembly 151132‐P003

using EF‐411 or an assembly type grease on the
leather seal to aid in preventing machining debris
from entering the lower main oil gallery. Gently rock
the plug assembly back and forth installing the tool
until it bottoms in the oil gallery.

8. Using a 1/2 inch Drill Motor with the Clearance Drill

151132‐T001, drill a clearance hole through the rear
China Wall of the engine block using the hardened
bushing to guide the drill bit through the China Wall.
 Revision DRAFT Cylinder Block Main Oil Gallery Section 4
Mar‐16 Thermocouple Modification Sheet 4

9. Install the main oil gallery thermocouple drilling and tapping

fixture 151132‐J001 to the rear of the engine. Note the round
and triangular alignment pin combination on the fixture for
ease of installation alignment. Secure the 151132‐J001 fixture
using the toggle clamps and allen hex head fasteners.

Fasteners
(Snug Only)

Alignment pins

Toggle Clamps

10. Using a 1/2" drill motor with the Special Tip Aircraft Drill
151132‐T002, drill through the main oil gallery until the
tip of the drill breaks through the inside.

Note special cut tip on tool 151132‐T002

11. Using an appropriately sized Tee Handle with the special

length tapping tool 151132‐T003 1/16" NPTF Tap, thread
the drilled hole in the main oil gallery until the Yellow Ring
on 151132‐T003 meets the hardened bushing guide on the
tapping fixture 151132‐J001.

Note, the use of a tapping lubricant or grease to hold

machining debris is recommended.

12. After threading the main oil gallery, carefully remove all fixture
tooling, leaving the Clean Plug Assembly in the main gallery.

Using preferred laboratory cleaning practice, clean the threads

and any machining debris from the main oil gallery. Carefully
remove the Clean Plug Assembly and inspect the threaded hole
for any burrs or sharp edges on the inside of the main oil gallery.
 Revision DRAFT Cylinder Block Cleaning Section 4
Mar‐16 Pre Hone Prep Sheet 5

1. After disassembly and modification of the main oil gallery, technicians should carefully clean all RTV from mating
surfaces using care to avoid scratching or gouging any mating surfaces. Spray degreasing solvent through all
oil gallery passages from the underside through the piston cooling jet access holes to clean any debris from galleries.
Caution:
Technicians should exercise extreme caution while cleaning mating surfaces of the engine block. Use only
plastic type non marring scrapers for removal of RTV and other debris from mating surfaces. Visual
imperfections on the cylinder deck and other gasket sealing areas may remain even after removing RTV.

2. If desired, chase all threaded bolt holes for the cylinder head bolt holes and the main cap bolt holes using cleaning
thread chase taps. Avoid using thread cutting type taps to clean threads. Thread cleaning taps are
available through sources such as ARP, Snap‐on, or Mac Tools for SAE and Metric thread sizes.
Caution:
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.

3. Clean the engine block prior to honing using either of the following methods;
a. Clean in the spray booth using degreasing solvent followed by a 50/50 solution of EF‐411 and Degreasing Solvent
followed by air dry using clean dry compressed shop air.
b. Clean using the Ultra Sonic Cleaner following the manufacturers recommendations followed by a water rinse
and spray with a 50/50 solution of EF‐411 and Degreasing Solvent followed by air dry using clean compressed air.
Note:
If cleaning the block in the Ultra Sonic Cleaner, install M12 x 1.5 50mm long bolts with M12 nylon oil drain plug type
washers snugly into the cylinder head bores to prevent the Ultra Sonic Cleaner solution from leaching out the
lubricant on the threads in the block to prevent bolt chatter during the cylinder head fastener torquing procedure.

4. Clean and inspect the cylinder head fasteners from the New Engine Disassembly.

5. Lightly oil the cylinder head fasteners with EF‐411 and allow to drain all excess oil from the threads using clean
Teri towels before installation of cylinder torque plates.

6. Clean and lightly oil the main cap fasteners and side bolts using EF‐411 allowing all excess oil to drain from the
threads using clean Teri towels.

7. Cylinder head gaskets are Multi‐Layer Steel gaskets. The cylinder head gaskets removed during the New Engine
disassembly can be re‐used with the BHJ Torque Plates and spacers used to position the fasteners at the correct
bolt drop in the cylinder block.

8. A good practice for build technicians is to ensure there is no oil or debris in the blind threaded bolt holes before
assembling the main caps or cylinder block torque plates using compressed air or blotting with absorbent materials.

Note:
Technicians should prep the cylinder head fasteners and the main cap fasteners prior to installation by wiping the
threads between folded sections of an EF‐411 saturated "Lint Free" rag during fastener installation.

See the materials section of the IIIH Engine Assembly Manual for suggested supplier information on Lint Free Rags
that have been found suitable for use by the test labs.
 Revision DRAFT Cylinder Block Honing Prep Section 4
Mar‐16 Main Cap Installation Sheet 6

1. After performing all pre hone cleaning requirements, with the engine block upside down on an engine build stand,
install the main caps in their proper orientation. (Instruction line items 1 ‐ 6 Reference View A)

2. Clean all bolts and lubricate their threads with EF‐411 using a lint free rag soaked with EF‐411 to assure a light coating
of lubricant on the threads by twisting the threads between folded sections of the rag.
(See Materials Section of the IIIH Engine Assembly Manual for suggested suppliers)
3. Lightly seat each fastener by hand using a criss cross pattern with a speed handle to seat the main caps.

4. Starting with the Inner Main Cap Fasteners, torque the inner fasteners to 20 N∙m in sequence 1 through 8 followed
by additional tightening of Plus 90° on each fastener in sequence 1 through 8.

5. Tighten all Cross Bolts (outer side main cap tie bolts, not the windage tray fasteners) in sequence to 28 N∙m.

6. Tighten all Windage Tray Main Cap Fasteners (Less the Windage Tray) to 21 N∙m in sequence 9 through 16 followed
by additional tightening of Plus 90° on each fastener in sequence 9 through 16.

View A
 Revision DRAFT Cylinder Block Honing Prep Section 4
Mar‐16 Torque Plate Installation Sheet 7

7. With the engine right‐side‐up on the engine stand, inspect the deck of the block and threaded bores for the cylinder
head fasteners for any debris. Place the cylinder head gasket removed from the New Engine Tear Down on the
cylinder deck.

8. Clean and inspect the left & right side BHJ Cylinder Head Torque Plates MP‐3.6PSV6‐R‐AL‐T‐DID and place on the
engine block.

9. Clean and lubricate the cylinder head fasteners removed from the New Engine Tear Down using a lint free rag soaked
in EF‐411 to assure a light coating on the threads, by twisting the threads between folded sections of the rag.
(See Materials Section of the IIIH Engine Assembly Manual for suggested suppliers)
10. Install each fastener with the Special BHJ Hardened Spacer Type Washer in the Torque Plate and lightly engage the
threads by hand into the block.

11. Lightly seat each bolt following the proper sequence as outlined for each bank in View B.

12. Torque the fasteners as outlined in View B following the proper sequence for each bank in the following order;
a. All fasteners to 30 N∙m
b. All fasteners to 45 N∙m
c. All fasteners plus 70° (First Pass)
d. All fasteners plus 70° (Second Pass)

View B

13. Carefully lift the engine block and install into the Sunnen SV‐10 Hone taking care to clean the tilting table and tie bar
when setting the block in the hone. Carefully snug the tightening fixture while making sure the block is properly
aligned horizontally along the fixture inside the hone.

14. Insure the hone is properly set for the IIIH Honing Operations according to Section 4 Sheet 8.
 Revision DRAFT Sunnen SV‐10 Section 4
Mar‐16 IIIH Hone Settings Sheet 8

All operators should become familiar with the Sunnen SV‐10 Hone Operator Manual, safety precautions,
set up procedures, and operations of the SV‐10 Hone before honing engine blocks.

Required Parts and Equipment

1. Sunnen SV‐10 Hone Machine
2. Sunnen Honing Oil SHO965055 (55 gal.) / SHO965005 (5 gal.)
3. Course Diamond Stones: Sunnen DHH6GMH85
4. Plateau Brush: Sunnen DHHB6534 (DHHB7534 is an adequate substitute)
5 Sunnen Bore Gauge;
GAM‐2121 12" depth, 0.002mm resolution indicator dial bore gauge.
GRM‐2121 12" depth, 0.002mm resolution, with retractable indicator dial bore gauge.
GAM‐2121E 12" depth, 0.002mm resolution indicator bore gauge with digital readout.
GRM‐2121E 12" depth, 0.002mm resolution retractable indicator bore gauge with digital readout.

Machine Setup
Place the block in the SV‐10 honing machine with the front of the block facing left.
Set the stroke length to 3.0 " on the inch scale or 75 mm on the metric scale.
Set the Ratchet Feed setting to 1.
Manually set the tilting table height to 3/8" or 9.65mm.

Using the automated setup screens input the following parameters;

Screen 1 Bore Diameter 95.90mm
Bore Length 131.76mm
Stone Length 76.20mm
Over stroke Top 9.65mm
Over stroke Bottom 9.65mm
Screen 2 Roughing Spindle Speed RPM 200
Roughing Stroke Speed 80
Finishing Spindle Speed RPM 200
Finishing Stroke Speed 80
Auto Dwell Beginning Strokes 10
Settings Strokes Between Dwells 10
Threshold 20%
Dwells 2

These user input values should yield an average X‐hatch angle of 36° and a stroke length of 74.9 mm.
 Revision 1 Cylinder Block Honing Section 4
Jun‐18 IIIH Honing Operations Sheet 9

15. Measure all cylinder bore dimensions using the proper bore gauge specified in section 4 sheet 8 of the
IIIH Engine Assembly Manual for both transverse and longitudinal dimensions at;
Top
Middle
Bottom

16. Install the diamond stones in the Sunnen SV‐10 Hone Head.

17. Set Zero Cut Off Mode to “ON” with the Auto Finish “OFF”.
Note: The Auto Finish is set to “OFF” during these first operations to keep the honer from running an extra
“Six Cycles” during the bore straightening process if the machine were to dwell just before the Zero Cut Off.

18. Insert the hone head into the first cylinder on the right bank. Cylinder #1

19. Using the Crown Wheel on the Hone, tighten the hone head until the diamond stones lightly contact the
cylinder wall using a rocking motion to ensure the stones are fully contacting the cylinder.
Note: Each Technician must acquire the feel for when the stones are fully engaged without putting Too Much
Pressure on the stones as to simulate a high unit loading.

20. With the instruction in line item 19 complete, set the Lower Crown Ring on the Hone Head to Zero Cut Off.

21. Set the lower ring to three divisions from Zero Cut Off.

22. Start the hone and flood the cylinder with honing fluid.
Note: The honing fluid flow should be set at 7L/min.

23. Engage the hone and rapidly put 30 units load on the stones.

24. Immediately set the lower ring to 1 division (or slightly less) before Zero Cut Off.
Note: Line item instruction 21 is set to three divisions to keep the hone from shutting off while putting the
load on the hone head. Operators should immediately perform line item instruction 24, after setting the
initial load head to 1 division before Zero Cut Off, to prevent the hone from removing too much material on
the hone during the cylinder straightening process.

25. Allow the hone to run to the shut off position without adjusting the hone head pressure.
Note: The hone will drop off on the load and dwell as necessary throughout this operation at Top, Middle, and
Bottom positions to auto straighten the cylinder bore and shut off automatically at the zero shut off point.

26. Repeat steps 21 through 25 for each cylinder following the proper sequence (Cylinder 1 – 5 – 4 – 3 – 2 – 6).

27. Upon completion of the first pass through all six cylinders, let the block cool for a minimum time period of 15
minutes.
 Revision 1 Cylinder Block Honing Section 4
Jun‐18 IIIH Honing Operations Sheet 10

28. Set the Auto Finish to “ON”.

29. Measure all cylinders bore transverse and longitudinal dimensions.

30. Repeat the same process as needed based on the cylinder bore dimensions, for each cylinder in sequence while
setting the lower ring to one half of a division before the Zero Cut Off.
Note: This time the machine will run an additional six cycles if it dwells just prior to Zero Cut Off which will
keep the cross hatch pattern.

Note: The Technician must put their trust in the SV‐10 to straighten the bore!

At this point the bores will be ~ 10 to 15 micron (0.010mm to 0.015mm) undersize after the block cools down.

31. Set the honer to Timed Cycles, and ensure the Auto Dwell and Auto Finish are set to “OFF” on both controls.

32. Hone each cylinder in proper sequence ~ 8 to 10 strokes with the Diamond Stones at 30 to 40 units load.

Note: Each Technician needs to acquire the feel for the amount of material removed during this process and
adjust the time to target mid spec. on the bore diameter. This may take more or less strokes to reach mid spec.

Each Technician needs to understand how much load on the hone head is required to meet the surface finish
specifications based on their hone and fluid interaction, i.e., this means they may require more or less load.

33. Once the Technician is satisfied the bore is at mid spec, the technician should switch the Diamond Stones out
replacing them with the Plateau Brushes.

34. Following the cylinder sequencing, cycle the Plateau Brushes for six to ten strokes in each cylinder at 10 to 15
units load.

Note: Each Technician needs to acquire the feel for their hone and fluid condition which will establish the
required stroke and unit loading to meet the final surface finish specifications.

Measurements
Bore Size:
Record bore measurements in the transverse and longitudinal directions at 0.5, 2.0, and 3.5 inch positions below
the cylinder block deck surface. Maximum out‐of‐round specification is 0.009mm and maximum taper is 0.015mm.
 Revision 1 Surface Finish Measurement Section 4
Jun‐18 Mitutoyo Surf Analyzer SJ‐410 Sheet 11

All operators should become familiar with the Mitutoyo Surf Analyzer Model SJ‐410 Operator Manual,
set up procedures, proper settings, and operations of the SJ‐410 Surf Analyzer before use.

Setup and measurement procedure

1. Stylus selection 12AAB409 with a 5 micron tip. Skid Yes
Skid Nose Piece ‐ 12AAC755
Extension Rod 50mm 12AAG202

2. Evaluation conditions:
Standard: ISO1997
Profile: R
Filter: Gaussian
lf: 2.5
lc: 0.8 mm
ls: 2.5μm
M‐Speed: 0.5
Range: 800
N: 5
pre/post: on
del. Wave: off
prof.comp.: off
mean line: off
3. Parameters to set for recording are: Ra, Rz, Rv, Rk, Rpk, Rvk, Mr1, Mr2

4. Using the Mitutoyo Surf analyzer leveled with the cylinder, record the surface finish parameters at 2.0 inches and
1.0 inches below the cylinder block deck surface. Average the readings between each cylinder and record the
values for each cylinder.
Target Specifications
Rk 0.51 to 2.03 μm
Rpk 0.12 to 0.74 μm
Rvk 0.43 to 1.34 μm
Rz 1.71 to 5.17 μm
Mr2 70% Minimum

Upon completion of all surface finish measurements, record the data in the appropriate forms and proceed
to Section 4 Sheet 11 to measure and record the piston ring gaps.
 Revision 1 Piston Ring Gap Measurements Section 4
Jun‐18 Sheet 12

Piston Ring gaps are measured with the BHJ Torque Plates installed on the block.
After the honing process is complete, the block should be set aside to cool to room temperature. Lab
technicians should use a piston ring positioning tool to properly locate each top and second piston ring in each
respective bore ~1.0 inch from the deck of the block as indicated in Section 7 Sheet 4. (See Excerpt Below)
Record the piston ring gaps on the appropriate engine build data form and keep the rings in their respective
order for final engine assembly.

Wipe the cylinder bores and piston rings with solvent prior to performing ring gaps. Ensure the piston rings
are clean and all paint marks are removed.

Excerpt from Section 7 Sheet 4

Upon completion of all piston ring gap measurements, record the data in the appropriate forms and follow
standard laboratory cleaning procedures for cleaning the block using the Ultra Sonic Cleaner following
the manufacturer recommendations followed by a water rinse and spray with a 50/50 solution of degreasing
solvent and air drying.

Piston ring gap tolerence target ± 0.002 inch, the piston ring gap average for the block can be no more
than target ± 0.0015 inch.
 Revision DRAFT Section 4
Mar‐16 Sunnen Hone Maintenance Sheet 13

Perform the required maintenance accordingly;

Use the honing machine Engineering Screen to monitor the run time on the honing fluid, filters, and mats.
Replace the hone filters and mats every 15 hours of operation.
Top off the hone fluid as necessary.
Replace the hone fluid and clean the reservoir every 60 hours of hone operation.

Follow all additional recommended routine maintenance as outlined in the Sunnen SV‐10 Installation, Setup,
and Operations Instruction Manual.
 Section 5
Post Honing and Special Parts Cleaning
 Revision 1 Post Honing and Special Section 5
Jun‐18 Parts Cleaning Sheet 1

Cleaning Reagents

1. Ultra Sonic Cleaning Solution (50/50 volume concentration):

a. Brulin 815 GD
b. Brulin 815 QR‐DF

2. Engine Degreasing Solvent;

Use only mineral spirits meeting the specifications for volume fraction of aromatics 0 % to 2 %, flash point
61 °C minimum, and color not darker than +25 on Saybolt Scale or 25 on Pt‐Co Scale from Specification D235 for
the Type II, Class C mineral spirits. (Warning – Combustible. Health hazard.)

3. 50/50 Engine Degreasing Solvent and Engine Assembly Fluid EF‐411

a. 50% Engine Degreasing Solvent (See Item #2. Above)
b. 50% Engine Assembly Fluid, EF‐411 (A non‐metals additized assembly fluid)

Description

Ultra Sonic Cleaner:

The Ultra Sonic Cleaner must be operated according to the recommended cleaning procedures and guidelines
provided from the manufacturer. The bath should be changed and the unit cleaned after every 25 hours of use.
Operating Guidelines:
a. Solution Temperature of 150°F ± 10°F.
b. Parts should be cleaned for 60 minutes ± 15 minutes depending on level of cleanliness.
c. Upon removal of the engine block, the cylinders must be wiped with an EF‐411 Oil Soaked Lint Free Rag
to reduce the possibility of oxidation flash‐over of the cylinder bores.
d. After wiping the cylinders, rinse the entire block using hot water at a temperature which does not promote
oxidation flash‐over on the surface of the parts being cleaned.
e. After water rising, all parts must be sprayed using a 50/50 solution of Engine Degreasing Solvent and EF‐411.

Note: After performing the aforementioned cleaning process, before assembling the engine, all cylinder bores
should be cleaned using EF‐411 and Teri Towels until all traces of residue are gone.

Engine Degreasing Solvent:

Solvent must be single pass, used in a well ventilated area meeting Occupational Safety and Health Administration
(OSHA) Safety Guidelines.

50/50 Engine Degreasing Solvent and Engine Assembly Fluid EF‐411:

Solvent and EF‐411 must be single pass, used in a well ventilated area meeting OSHA Safety Guidelines.
Parts should be air dried using clean dry shop air to remove excess solution after application.

If additional cleaning reagents are used for any reason, the part must be cleaned using Engine Degreasing Solvent
followed by a 50/50 mix of Engine Degreasing Solvent and EF‐411 following the aforementioned guidelines before
installation on a IIIH Test Engine.