1998 - 2004 Dodge Intrepid 2.7L Engine Torque Specs

2002 Dodge Intrepid 2.7L Complete Torque Specs List

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Dodge Intrepid 2.7L DOHC Repair Information

Dodge Intrepid 2.7L DOHC Engine Repair Information

Here you can find information regarding the assembly of the Dodge 2.7L DOHC engine. In this guide we will start from the inside of the engine including the crankshaft, connecting rods, and piston ring installation and then move outwards all the way to the pulley belt system. Along the way correct procedures and torque specs will be given to aid in the assembly of the engine. Feel free to start from the beggining and work your way outwards or skip ahead to your current position in the engine for what you may need.

Crankshaft Main Caps Installation

Dodge 2.7L engine block
The 2.7L engine block main bearing caps should be inspected for any defects or flaws before installation. Be sure to lubricate the bearing surfaces prior to installation. Once prepared you can place the caps onto the crankshaft and begin tightening the bolts down in a multi stage process. For the inner bolts you can start by torqueing them down to 15 ft-lbs and then follow it up with a 90 degree turn by going through each bolt during each step. The outer bolts can be tightened down to 20 ft-lbs and then a 90 degree turn. Be sure to go through each bolt during each step and work your way from the inside or middle caps to the outside or outwards bearing caps. Once finished you should be good to continue with the rest of the engine.

Dodge Intrepid 2.7L Main Cap Inner Bolts Torque Specs : 15 ft-lbs + 90°

Dodge Intrepid 2.7L Main Cap Outer Bolts Torque Specs : 20 ft-lbs + 90°

 

Piston and Connecting Rod Installation

Dodge 2.7L DOHC piston ring installation
To install the pistons and connecting rods you must first install the piston rings into each piston. Be careful not to stretch the rings or break them during installation. Make sure to put the correct rings in the correct positions, this can be determined by looking at the instructions given with the new rings. Each ring manufacturer is different so be sure to check for your specific rings. Once the rings have been installed you can now fit the connecting rod bearings into the end caps and lube them up with oil or lithium grease. The piston can now be lowered into the cylinder, make sure the dot or mark is facing the front of the engine and that you don't scratch the cylinder. Once installed you can match the connecting rod caps with the correct rods and start to torque the connecting rod bolts to 10 ft-lbs and then to 20 ft-lbs followed by an additional 90 degree turn. After all are done rotate the crank to ensure all pistons move smoothly in and out of their cylinders and nothing binds.

Dodge Intrepid 2.7L DOHC Connecting Rod Torque Specs : 20 ft-lbs + 90°

 

Oil Pump Installation

Dodge 2.7L DOHC oil pump installation
When installing the oil pump be sure to use the proper sealant around the pump base if neccessary to ensure that oil pressure doesn't drop due to leakage. Both surfaces should be cleaned and preped prior to installing. After preparing the contact surfaces carefully install the oil pump onto the engine and torque down the pump mounting bolts to 20 ft-lbs. Be sure to tighten down the bolts in a cross pattern to ensure that even torque is applied to the pump. From here we can install the oil pump cover and torque down its bolts to 8 ft-lbs. The oil pump pickup tube can be installed and torqued down to 20 ft-lbs.

Dodge Intrepid 2.7L Oil Pump Mounting Bolt Torque Specs : 20 ft-lbs

Dodge Intrepid 2.7L Oil Pump Cover Bolts Torque Specs : 8 ft-lbs

Dodge Intrepid 2.7L Oil Pump Pickup Tube Torque Specs : 20 ft-lbs

 

Cylinder Head Installation

Dodge 2.7L DOHC cylinder head installation
The first thing you must do when installing cylinder heads is to ensure both the block and head surfaces are completely clean from dust, oil, and any debris. The next thing you must to is to set the camshafts to their correct positions to prevent any valves from hitting pistons during installation and torquing of the head bolts. Much the same you have to set the pistons to their correct locations, typically this means putting the #1 piston to TDC or Top Dead Center. Once everything is ready you can install the head gasket onto the engine block by aligning the alignment dowels. Something I usually do is spray down the head gasket with some engine copper spray from permatex which you can find here, this ensures that any gaps that could be present between the 2 surfaces gets filled with the spray. It also helps to transfer heat between the 2 metals. With the gasket in place you can set the cylinder head onto the gasket and block, if needed have someone assist with this process as the head can be heavy and you don't want to scratch anything or drop it! Once the head has been placed you will want to start installing the head bolts to make sure it doesn't move. Be sure to buy new head bolts as many manufacturers use TTY or Torque to Yield head bolts meaning they stretch during torqueing and cannot be used twice. Also make sure to lubricate the bolts in clean engine oil before installing them into the head. Once all the head bolts have been installed and finger tightened you can start the torqueing process, almost all head bolts have a multi-step process for torqueing. The 2.7L DOHC engine uses two different sizes of cylinder head bolts with a total of 11 bolts being installed into the cylinder head. The 8 main bolts located on the sides of the cylinder heads should be torqued down to 35 ft-lbs and then 55 ft-lbs followed by an additional 90 degree turn. The 3 small head bolts per each cylinder head can be torqued down to 20 ft-lbs. Make sure to not overturn or underturn any bolt as this can cause an unbalance of surface pressure between the gasket and head.

Dodge Intrepid 2.7L Cylinder Head Main Bolt Torque Specs : 35 ft-lbs + 55 ft-lbs + 90°
Dodge Intrepid 2.7L Cylinder Head Small Bolts Torque Specs : 20 ft-lbs

 

Timing Chain and Camshaft Installation

Dodge 2.7L Timing chain installation
On the Dodge 2.7 DOHC engine the timing system is ran by the use of a single timing chain. This chain system consists of a sprocket on each camshaft located at the top of each cylinder head followed by a single idler sprocket located in the center of the engine, and a crankshaft sprocket. The timing chain system uses 4 guides in total being 2 main guides which hand the tensioning of the chain and 2 smaller guides that go between the camshaft sprockets and the idler sprocket. When installing new timing chains be sure that the engine is turned so that the number 1 cylinder is set to TDC or top dead center. From here simply install the camshafts into the cylinder heads and torque down the camshaft bearing cap bolts to 8 ft-lbs in a cross pattern. From here we can hold the camshafts with a large wrench or tool and install the camshaft timing sprockets and torque them down to 20 ft-lbs per bolt. The crankshaft timing sprocket can then be installed onto the crankshaft by aligning the woodruff key with the slot on the sprocket. The idler sprocket can be installed and torqued down to 20 ft-lbs. From here the chain can be set in place by running from the crankshaft to each camshaft sprocket and then looping down to the idler sprocket as shown in the picture. Be sure to align the timing chain marks with the dots on each sprocket to ensure that the timing is set correctly. Next we can install each chain guide and torque them down to 20 ft-lbs. The timing chain tensioner gets tightened down from the outside of the engine block. Once all guides have been installed and torqued down and the timing chain marks are all aligned you can install the timing chain tensioner and torque it down to 40 ft-lbs. Be sure to double check all of the timing marks prior to releasing the tensioners tension. With the tension released you should check for extra slack in the timing chain system and lightly turn the engine clockwise with a wrench to take up any existing slack. From here we can move onto the next part of the engine.

Dodge Dakota 2.7L Camshaft Sprocket Bolts Torque Spec: 20 ft-lbs

Dodge Dakota 2.7L Camshaft Bearing Cap Bolts Torque Spec : 8 ft-lbs

Dodge Dakota 2.7L Timing Chain Guide Bolts Torque Spec : 20 ft-lbs

Dodge Dakota 2.7L Timing Chain Tensioner Guide Bolts Torque Spec : 20 ft-lbs

Dodge Dakota 2.7L Timing Chain Tensioner Torque Spec : 40 ft-lbs

Dodge Dakota 2.7L Timing Chain Idler Sprocket Torque Spec : 25 ft-lbs

Dodge Dakota 2.7L Crankshaft Position Sensor Torque Spec: 8 ft-lbs

Timing Cover Installation

Dodge 2.7L Timing cover installation
The timing cover on the 2.7L is used to cover up the internals of the engine and hold in massive amounts of oil. For this reason I recommend using some silicon sealant along with a new gasket during installation. Be sure to clean all of the metal surfaces prior to installation and placing the silicon onto the metal. With everything ready to install be sure to double check your timing and engine internals before placing the cover in place. Another tip is to lube up the crankshaft seal with some oil so it seats better. If everything is good to go then place the cover onto the engine block and begin to tighten down the bolts hand tight. Once all of the bolts have been set in place be sure to follow your sealants instructions by waiting the recommended time. Once ready you can torque down the larger timing cover bolts to 40 ft-lbs and the smaller bolts to 8 ft-lbs by going in a cross pattern.

Dodge Intrepid 2.7L Timing Cover Bolts Torque Specs (M6): 8 ft-lbs

Dodge Intrepid 2.7L Timing Cover Bolts Torque Specs (M10): 40 ft-lbs

 

Oil Pan Installation

Dodge 2.7L Oil Pan installation
Much like the timing cover on the 2.7L the oil pan plays an important role in keeping the engine oil inside the engine. For this reason I recommend using a new gasket as well as some silicone sealant during installation. Using the same technique as before with the cover you clean the surfaces of both the oil pan and the engine block and then install the new gasket onto the block and then follow it up with some silicone sealant. Be sure to follow your sealants instructions to ensure you get the best seal from your application. The oil pan bolts can be torqued down to 18 ft-lbs following a cross pattern. Along with the pan is the oil pan drain plug, this gets removed and reinstalled quite frequently and can be torqued down to 20 ft-lbs.

Dodge Intrepid 2.7L Oil Pan Torque Specs : 18 ft-lbs

Dodge Intrepid 2.7L Oil Drain Plug Torque Specs : 20 ft-lbs

 

Valve Covers Installation

Dodge 2.7L Valve Cover installation
The valve cover installation is rather simple, there are rubber seals for each bolt hole and a silicone gasket that prevents oil from leaking out of the engine. It is recommended to replace both the seals and the gaskets although if they are in good condition you can reuse them. If you do choose to reuse them I would use some silicone sealant along with the silicon gasket to ensure it does not leak. The valve cover bolts torque down to 106 in-lbs or about 8 ft-lbs in a criss cross order. Be sure not to miss any bolts to avoid having oil leak out onto the exhaust pipes and cause a lot of smoking.

Dodge Intrepid 2.7L Valve Cover Torque Specs : 8 ft-lbs

 

Intake Manifold and Fuel Rail Installation

Dodge 2.7L Intake Manifold installation
When installing the intake manifold you want to make sure you have all the surfaces as well as intake holes cleaned out before placing the manifold into position. Once cleaned you can then place the intake manifold gaskets onto the alignment pins. If you want you can also use a little bit of sealant on the gaskets to help ensure there are no leaks. With the gaskets in place you can now put the manifold down onto the gaskets and begin to install the bolts. The intake manifold bolts torque to 8 ft-lbs and can be tightened in a cross pattern. The ignition coil assembly can be torque down to 8 ft-lbs and the spark plugs themselves can be torqued down to 13 ft-lbs, be careful not to overtorque these as they can snap and cause big problems. When installing the throttle body make sure that all of the gaskets are in good condition and will hold a seal as you do not want to be leaking gas fumes around the engine. If everything looks good you can tighten the throttle body bolts down to 8 ft-lbs.

Dodge Intrepid 2.7L Intake Manifold Torque Specs : 8 ft-lbs

Dodge Intrepid 2.7L Ignition Coil Assembly Torque Spec : 8 ft-lbs

Dodge Intrepid 2.7L Spark Plug Torque Specs : 13 ft-lbs

Dodge Intrepid 2.7L Throttle Body Torque Specs : 8 ft-lbs

 

Exhaust Manifold Installation

Dodge 2.7L Exhaust Manifold installation
The exhaust manifold can be installed by cleaning the surface areas on both the head an the manifold itself and then by using the exhaust manifold gasket and putting it in place. Once the gasket is in its location you can put the manifold onto the heads and begin to torque them down to 18 ft-lbs. I always use some copper spray from permatex on the exhaust manifold gaskets to ensure I do not end up with any exhaust leaks once done. When you go to install the engine into the vehicle or if it is already in the vehicle the torque specs for the exhaust manifold to the exhaust pipes or catalytic converter is 30 ft-lbs.

Dodge Intrepid 2.7L Exhaust Manifold Torque Spec : 18 ft-lbs

Dodge Intrepid 2.7L Exhaust Pipe Torque Specs : 30 ft-lbs

 

Water Pump and Thermostat Installation

Dodge 2.7L Water Pump installation
The water pump on the Dodge 2.7L engine gets tightened down to the engine block on the inside and is ran off of the timing chain. When removing the old water pump be sure that you drain out the coolant prior to removal otherwise the coolant will spill all over. Once drained you can remove the water pump mounting bolts and remove the old pump from the vehicle. From here we can clean up the engine blocks mating surface and prepare the new water pump for installation. Be sure to use a new gasket and some silicon sealant to ensure that no coolant ends up leaking and causes further engine damage down the road. Once prepared you can install the pump onto the engine and hand tighten the bolts down. Once all of the bolts have been installed you can then torque down the bolts to 8 ft-lbs. Make sure to follow your sealants instructions as they often require you to wait an extended amount of time before torqueing down the bolts. Be sure to check out the timing chain section for more information regarding installing it.

Dodge Intrepid 2.7L Water Pump to Case Torque Specs : 8 ft-lbs

 

Front Dress and Pulley belt Installation

Dodge 2.7L Pulley and Belt installation
Most of what is left on the engine is just place and tighten objects such as the belt pulleys, belt tensioner, throttle body, oil filter neck, crankshaft pulley, and motor mounts. If the items have a gasket and hold either oil or coolant inside the engine then feel free to add some sealant along with the gasket. Always be sure to inspect your gaskets and replace them if there is any deteriation or flaws with them. For the belt system the crankshaft pulley gets tightened down to the crankshaft at 125 ft-lbs. The drive belt tensioner can be tightened to 33 ft-lbs and the idler pulley can be torqued down to 16 ft-lbs. When installing be sure they both turn smoothly and if they do not then replace them with new ones as the bearings can go bad. The engine motor mount can be installed onto the engine block if it hasn't been already, the torques for the mount to the block is 45 ft-lbs and then when installing the mount to the vehicle or frame it can be torqued to 45 ft-lbs. Finally the throttle body can be installed on top of the intake manifold with a good gasket and some added sealant using 7 ft-lbs in a criss cross pattern. For installing the belt you can use a tool to move the tensioner into its springed state and install the belt as shown in the picture. The generator or alternator can be tightened down to the engine block using 30 ft-lbs of force. The power steering pump can be installed and torqued down to 18 ft-lbs and finally the A/C compressor can be torqued down to 15 ft-lbs of force.

Dodge Intrepid 2.7L Crankshaft Pulley Torque Specs : 125 ft-lbs

Dodge Intrepid 2.7L Idler Pulley Bolt Torque Spec : 16 ft-lbs

Dodge Intrepid 2.7L Drive Belt Tensioner Torque Specs : 33 ft-lbs

Dodge Intrepid 2.7L Motor Mount to Engine Torque Specs : 45 ft-lbs

Dodge Intrepid 2.7L Motor Mount to Frame Torque Specs : 45 ft-lbs

Dodge Intrepid 2.7L Alternator to Block Torque Specs : 30 ft-lbs
Dodge Intrepid 2.7L Power Steering Pulley Torque Specs : 18 ft-lbs
Dodge Intrepid 2.7L A/C Compressor to Block Torque Specs : 15 ft-lbs

 


Timing Torque Specs
Timing Cover Bolts Torque spec (M6) 8 ft-lbs
Timing Cover Bolts Torque spec (M10) 40 ft-lbs
Camshaft Timing Sprocket Bolts Torque Specs 20 ft-lbs
Camshaft Bearing Cap Bolts Torque specs 8 ft-lbs
Timing Chain Guide Bolts Torque spec 20 ft-lbs
Timing Chain Tensioner Torque spec 40 ft-lbs
Crankshaft Position Sensor Torque spec 8 ft-lbs
Cylinder Head Torque Specs
Cylinder Head Bolts Torque Specs 35 ft-lbs + 55 ft-lbs + 90°
Valve Cover Torque specs 8 ft-lbs
Exhaust Manifold Bolts Torque specs 18 ft-lbs
Exhaust Manifold to Pipe Torque 30 ft-lbs
Bottom End Torque's
Main Bearing Cap Inner Bolts Torque Spec 15 ft-lbs + 90°
Main Bearing Cap Outer Bolts Torque Spec 20 ft-lbs + 90°
Connecting Rod Bolts Torque Spec 20 ft-lbs + 90°
Oil Pump Mounting Bolts Torque Spec 20 ft-lbs
Oil Pump Cover Bolts Torque Spec 8 ft-lbs
Oil Pump Pickup Tube Torque Spec 20 ft-lbs
Oil Pan Bolts Torque Spec 18 ft-lbs
Oil Pan Drain Plug Torque Spec 25 ft-lbs
Intake Manifold and Fuel Rail Torque Spec
Intake Manifold 8 ft-lbs
Fuel Rail Torque Specs 5 ft-lbs
Spark Plugs Torque Specs 13 ft-lbs
Throttle Body Torque Specs 8 ft-lbs
Ignition Coil Assembly Torque Spec 8 ft-lbs
Water Pump & Pulley Torque Specs
Water Pump to Block Torque Specs 8 ft-lbs
Crankshaft Pulley Bolt Torque Spec 125 ft-lbs
Drive Belt Tensioner Bolt Torque Spec 33 ft-lbs
Belt Idler Pulley Bolt Torque Spec 16 ft-lbs
Motor Mount (Engine Side) Torque 45 ft-lbs
Motor Mount (Frame Side) Torque 45 ft-lbs
Alternator to Block Bolts Torque Spec 30 ft-lbs
Power Steering Pump Bolts Torque Spec 18 ft-lbs
A/C Compressor to Block Torque Spec 15 ft-lbs