Service Training

Self-Study Program 821803

Routan Engines
3.8L and 4.0L
Volkswagen of America, Inc.
Volkswagen Academy
Printed in U.S.A.
Printed 06-2008
Course Number 821803

©2008 Volkswagen of America, Inc.

All rights reserved. All information contained in this manual is

based on the latest information available at the time of printing
and is subject to the copyright and other intellectual property
rights of Volkswagen of America, Inc., its affiliated companies and
its licensors. All rights are reserved to make changes at any time
without notice. No part of this document may be reproduced,
stored in a retrieval system, or transmitted in any form or by
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other sites without the prior expressed written permission of
the publisher.

All requests for permission to copy and redistribute information

should be referred to Volkswagen of America, Inc.

Always check Technical Bulletins and the latest electronic repair

information for information that may supersede any information
included in this booklet.

Trademarks: All brand names and product names used in

this manual are trade names, service marks, trademarks, or
registered trademarks; and are the property of their respective
owners.
 Contents

Introduction........................................................................................................1
Objectives; Acronyms;

3.8L Engine.........................................................................................................2
Features; Specifications; Engine Oil; Timing System; Upper Engine; Lower Engine;
Cooling System; Lubrication System

4.0L Engine.......................................................................................................23
Features; Specifications; Timing System; Upper Engine; Lower Engine; Engine
Lubrication; Cooling System

Knowledge Assessment...................................................................................49

Note Important!

This Self-Study Program covers information on For testing, adjustment and repair
the Routan Engine Systems. procedures, always refer to the latest
This Self-Study Program is not a Repair Manual. electronic service information.
This information will not be updated.


Page intentionally left blank
 Introduction

Introduction Objectives
This SSP covers Engine Specifications, Engine Timing, At the end of this self-study program you will be able
Upper and Lower Engine Components, and the to:
Lubrication and Cooling Systems for the 3.8L and
4.0L engines used in the Routan. • Identify the features of the 3.8L and 4.0L engines
• Locate components of the 3.8L and 4.0L engines
The information provided in this publication should be • Understand the engine timing systems
used with ElsaWEB when performing repairs. This
• Identify upper engine and lower engine
publication only provides the information necessary to
components for the 3.8L and 4.0L engines
become familiar with these engines.
• Describe cooling system operation and coolant
flow for 3.8L and 4.0L engines
Caution: The 3.8L and 4.0L engines
are non-freewheeling. In addition to • Describe oil flow through the 3.8L and 4.0L
piston-to-valve interference, these engines
engines have the potential for intake
and exhaust valve-to-valve interference
if the camshafts are not properly timed.
Timing belt or chain service procedures
must be followed carefully to ensure
proper valve timing.


Introduction

Acronyms
The acronyms listed here are used throughout this course.

BHP Brake Horsepower

COP Coil On Plug

CRS Coolant Recovery System

HOAT Hybrid Organic Additive Technology

MAP Manifold Absolute Pressure

MLS Multi Layer Steel

NVH Noise, Vibration and Harshness

PCV Positive Crankcase Ventilation

SOHC Single Overhead Camshaft

SRV Short Runner Valve

TDC Top Dead Center

WOT Wide Open Throttle


 3.8L Engine

Overview
The 3.8L Engine is a 6-cylinder, 60 degree, V-type.
It was introduced for use in passenger vehicles in
1991. In 2001, second generation 3.8L engine was
developed to provide increased power.

The 3.8L engine is NOT free-wheeling; which means

if a timing chain fails, the pistons may contact and
damage the valves.

• The oil pump is built into the timing chain cover.

To service the oil pump, the oil pan and front case
cover must be removed.
• To service the hydraulic lifters, the cylinder heads
must be removed. Be careful when handling the
lower intake manifold gasket - it is very sharp.
• Do not damage the rocker shaft retainers when
servicing the rocker arm/shaft assemblies.
• The coolant used in the 3.8L egnine is extended-
life, Hybrid Organic Additive Technology (HOAT) Specifications
coolant with a normal service life of five years or
100,000 miles. Engine Displacement 230 cu in (3778cc) 3.8L
Type V6 (60° V-block, 6-
Features cylinder)
Fuel System Sequential Multipoint
• 100,000-mile platinum spark plugs Fuel Injection
• Cast iron deep skirted cylinder block with cross Maximum Power 197 bhp @ 5200 rpm
bolted mains (147 kW @ 5200 rpm)
• Aluminum cylinder head - common left and right Peak Torque 230 lb-ft @ 4000 rpm
(312 Nm @ 4000 rpm)
• Fracture split forged steel connecting rods
Compression Ratio 9.7:1
• Cast aluminum piston with low friction skirt coating
Bore X Stroke 3.8 x 3.4 inch (96 x 87
• Thermoplastic isolated valve covers
mm)
• High silicon nodular iron exhaust manifolds with
Bore Spacing 4.5 in. (113.3 mm)
tubular crossover pipe
Firing Order 1-2-3-4-5-6
• Hybrid oil pan consisting of cast aluminum
Valve Configuration OHV
structural upper pan and collar for improved Two Valves per Cylinder
powerplant bending with stamped steel sump for
Intake Valve Dimensions 1.9 in. (48 mm)
impact resistance
Exhaust Valve 1.4 in. (35.5 mm)
• Composite upper intake manifold and aluminum Dimensions
lower intake manifold
Oil Capacity 5 qt (4.7 L)
• Front end accessory drive with automatic self
Coolant Capacity 13.4 qt (12.6 L)
tensioning single belt drive system, allowing direct
mounting of accessories


3.8L Engine

Engine Identification Number Engine Oil

Proper identification of an engine is important to The recommended engine oil for the 3.8L engine is
diagnosing or repairing them with minimal difficulty 5W-20.
or complication. When component part replacement
is necessary, use the engine identification number for
reference.

The engine identification number is on the left

cylinder head cover. The VIN is on the rear of the
cylinder block, just below the left cylinder head.

1 Engine Identification Number


 3.8L Engine

Timing System
Timing Chain Cover
The cast aluminum timing chain cover provides
several functions:

• Camshaft drive chain housing

• Crankshaft driven oil pump
• Water pump housing
• Integrally cast coolant distribution passages
• Front crankshaft seal retainer
• Accessory drive mounting
• Camshaft position sensor (CMP) mounting
• Oil pick-up tube attachment

If the engine is not equipped with an oil cooler, the

heater hose is connected to a port on the timing chain
1 Rocker Arm cover. If an oil cooler is present, this hose is routed
2 Rocker Arm Lube Feed Hole to the water pump inlet tube. Also, with the use of a
3 Valve Spring single gasket, there are no O-rings at the coolant and
4 Rocker Arm Shaft
oil feed passages.
5 Pushrod
6 Hydraulic Lifter
7 Camshaft
The camshaft timing system in the 3.8L engines is a
chain-driven pushrod system. The valve train includes
the following features:

• Roller hydraulic lifters

• Nodular iron (a gray iron that produces stronger
and more ductile castings, also called ductile iron).
camshaft, hardened after machining
• “Silent” camshaft drive chain
• Short, hardened-end, tubular pushrods
• “Beehive” valve spring design with lightweight
retainers
• Rocker arm and shaft assembly
• Powdered metal valve guides and seat inserts
• Spring “spider” and “dog bone” lifter anti-rotation
mechanism


3.8L Engine

Timing Chain Camshaft Position Sensor

There are two ways to set timing when performing
timing chain installation procedures.
1. Align the arrows on the sprockets with each other,
then check their alignment with a straightedge.
2. An alternate method, which is used when the
engine is assembled at the plant, calls for lining up
the dots on the sprockets with the plated links of
the timing chain.
When servicing the camshaft position sensor,
properly set the gap between the sensor tip and the
tone ring to prevent a no-start condition or damage
to the sensor. Thoroughly clean the tip of the sensor
and install a new spacer before reinstalling the
sensor.

1 Plated Links
2 Cranshaft Sprocket Timing Mark
3 Arrows 1 Camshaft Sensor
4 Camshaft Sprocket Timing Mark


 3.8L Engine

Upper Engine
PCV Valve
The PCV system routes filtered air into the crankcase through the air cleaner hose. The filtered air, along with
crankcase vapors, is drawn through the PCV valve and into the intake manifold.

The PCV valve is mounted in the right cylinder head cover. The valve contains a spring loaded plunger that meters
the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. The
vapors are consumed during combustion. When the engine is operating and an engine backfire occurs, the PCV
valve prevents vapors from flowing back into the crankcase.

1 Make-Up Air
2 PCV Valve
3 Baffle


3.8L Engine

Intake Manifolds
The intake system is made up of an upper and lower
intake manifold. The upper intake manifold is made
of a composite material. The lower intake manifold
is made of aluminum, provides coolant crossover
between cylinder heads and houses the coolant
thermostat.

Upper Intake Manifold

1 Lower Intake Manifold

2 Intake Manifold Gasket


 3.8L Engine

Cylinder Head Covers

The cylinder head covers are made of thermoplastic.
The covers are sealed with a press-in-place poly-
acrylic gasket. The PCV valve snaps into a molded-in
feature at the base of the nipple. Applying a light
layer of grease to the PCV valve grommet helps
during assembly. Push the valve into place by
applying pressure to the top surface of the valve.

1 PCV Valve
2 Right Cylinder Head Cover


3.8L Engine

Rocker Arms and Rocker Shaft

The rocker arms are made of stamped steel. The
rocker arms are installed on the rocker arm shaft. The
rocker arms and shaft assembly is mounted on the
cylinder head with fasteners and retainers.

1 Rocker Arms and Shaft Assembly

2 Rocker Shaft Bolts

10
 3.8L Engine

Pushrods Anti-Rotation Mechanism

The passages in the pushrods are used to supply
oil to the junction between the pushrod and the
rocker arm. The pushrod socket in the rocker arm is
lubricated by oil fed up through the pushrod from the
roller hydraulic lifter.
There is a spring metal device resembling a spider,
used to hold the lifter anti-rotation yokes, or “dog
bones,” in place. It has three mounting points and
holds the “dog bones” in place through spring
pressure.

1 “Spider” Device 2 Lifter Anti-Roation Yokes (“Dog Bones”)

11
 3.8L Engine

Hydraulic Lifters
To allow proper oil flow to the roller hydraulic lifters,
the lifters should be installed with the lubrication hole
facing up and toward the middle of the engine block.

1 Oil Hole

Valves
The valves have chrome-plated valve stems with four
lock grooves that mate with the three bead keepers.
The valve stem seals are made of Viton rubber.

Valve Springs
To reduce effective valve spring oscillations in this
engine, a “beehive” spring design is used. The
reduction of oscillations is achieved through its shape.
The upper portion of the valve spring is rounded and
allows the use of a smaller, lighter valve spring retainer.
The beehive shape gives the spring a variable rate,
which dampens spring surge or resonance. The lighter 1 Spring Retainer
weight retainer and variable rate spring combine to 2 Spring
allow lower spring forces, and result in less engine 3 Valve
friction than with a cylindrical, constant-rate spring. 4 Three Bead Keepers

12
 3.8L Engine

Cylinder Heads
The 3.8L aluminum cylinder head is designed to
create high flow combustion chambers to improve
performance. The cylinder head is designed to
provide better cooling to the exhaust ports. The
exhaust ports are separated from each another which
allows them to be cooled on all sides by the cooling
system.

1 Valve Locks 5 Spring Seats

2 Retainers 6 Cylinder Head
3 Valve Springs 7 Exhaust Valve
4 Valve Stem Seals 8 Intake Valve

13
3.8L Engine

Cylinder Head Gaskets

The 3.8L engines uses a Multi-Layer Steel (MLS)
gasket. Caution: For this engine, the cylinder
head bolts can be reused if they are not
The left bank gasket is identified with an “L8” stretched or necked. Refer to ELSAWeb
stamped in the exposed area of the gasket located for the proper procedure.
at the front of the engine. The right bank gasket is
identified with an “R8” stamped in the exposed area
of the gasket located at the rear of the engine.

1 Cylinder Head Gasket 2 Location Indicator (L8 = Left Bank)

14
 3.8L Engine

Lower Engine
Cylinder Block
This V-6 engine has a conventional deep skirt cast-iron cylinder block. This means that the sealing surface for the
oil pan extends down past the level of the crankshaft. This design has several benefits.

First, the crankshaft exits the front and rear of the engine through the block itself, rather than at the split between
the block and the oil pan. This eliminates the elliptical seal at the front and rear of the oil pan, and allows a flat
gasket to be used around the entire perimeter of the bottom of the engine. In addition, the deep skirt design adds
structural rigidity to the block, and reduces noise, vibration, and harshness.

1 Sealing Surface
2 Crankshaft
3 Main Seal
4 Cylinder Block

15
3.8L Engine

Camshaft
The nodular iron camshaft is mounted in the engine block and supported with four steel-backed aluminum
bearings. The camshaft bearings are line bored and cannot be serviced. A thrust plate in front of the first bearing
is bolted to the block and controls the camshaft end play.

Crankshaft
The crankshaft has the following features:

• Nodular Iron
• Four Main Journals
• Cross-drilled Main Journals
• Rolled Fillets
On the 3.8L engine, the two center main bearing caps
have cross (horizontal) bolts to add increased rigidity
to the lower engine block. These cross bolts and
washers are not reusable. The torsional vibration
damper is mounted to the nose of the crankshaft.

1 Lower Thrust Bearing

2 Upper Main Bearing Shell
3 Upper Thrust Bearing
4 Cylinder Block
5 Crankshaft
6 Lower Main Bearing Shell

16
 3.8L Engine

Pistons and Connecting Rods

The piston and connecting rod transmit the
combustion force from the combustion chamber to
the crankshaft. A piston pin connects the aluminum
piston to the connecting rod. The piston pin is press
fit into the rod.

The connecting rods are made of powdered metal

and are a fractured cap design.

Even though the piston and connecting rod are

separate components, they are only serviced as an
assembly.

Pistons
The pistons are a strutless, short-skirt design
that reduces cylinder temperatures and piston
weight. The pistons are made of a high-silicon, cast
aluminum for added strength and contributes to their
lightweight and high-wear resistance. An anti-friction
coating provides NVH benefits. Each piston has two
compression rings and a three-piece oil ring.

Connecting Rods

The 3.8L engine connecting rods are made from

powdered metal and are a cracked cap design. They
have a side weight pad on the small end for balancing
instead of the normal pad at the top of the small end.
Relocating the pad on the side allows for clearance
between the connecting rod and piston. In addition
to the side weight pad, the rod assemblies also have
the normal weight pad on the bottom of the bearing
cap.

1 Piston
2 Piston Pin
3 Weight Pads

17
3.8L Engine

Cooling System
Water Pump
The water pump has a die-cast aluminum body and
a plastic impeller. It bolts directly to the timing chain
case cover and has a rubber seal. The rubber seal
is not reusable. The accessory drive belt drives the
water pump.

The water pump has a weep hole and reservoir. A

weepage stain around this area that is black, brown or
gray is considered normal if it is dry. If the weep area
appears wet, perform a pressure test on the cooling
system to determine if the water pump should be
replaced.
Water Pump Weep Reservoir

To access the water pump mounting bolts, remove

the water pump pulley bolts, rotate the pulley until
the slots in the the pulley line up with the pump
mounting bolts, and move the pulley inward between
the pump housing and drive hub.

Thermostat
The thermostat controls the flow of engine coolant
from the engine to the radiator. It is positioned
between the coolant outlet connector and the lower
intake manifold, at the rear of the engine.

1 Coolant Outlelt Connector

2 Bolt
3 Thermostat
4 Gasket

18
 3.8L Engine

Oil Cooler
An optional oil cooler is available on vehicles with
towing packages. The oil cooler is located between
the oil filter and the oil filter adapter. With an oil
cooler, coolant is routed from the heater core through
the oil cooler, back to the water pump inlet tube.

1 Oil Filter Adapter 4 Fitting

2 Connector 5 Oil Filter
3 Oil Cooler

19
3.8L Engine

Coolant Flow
The 3.8L engine cooling system is a forced-circulation, water-cooled type. The purpose of the cooling system is
to maintain engine temperature in a range that provides satisfactory engine performance and emission levels
under all expected driving conditions. It also provides hot water for heater performance and cooling for automatic
transmission oil.

1 Rear Heater Core 6 Water Pump

2 Front Heater Core 7 Radiator
3 Engine 8 Coolant Recovery/Reserve Container
4 Thermostat 9 Coolant Flow - Pressure Cap Vacuum
5 Engine Oil Cooler (Optional) 10 Coolant Flow - Pressure Cap Relief

The coolant flow for the 3.8L engines is as follows:

• When the engine is cold and the thermostat is closed, coolant enters the water pump.
• Then it is routed through the engine block and into the cylinder head.
• Next, the coolant is routed from the cylinder head to the lower intake manifold and through the heater core,
back to the water pump, where the cycle starts over again.
• When the engine is hot, the thermostat opens. Coolant enters the water pump.
• Then it is routed through the engine block and into the cylinder head and through the lower intake manifold.
• Next, the coolant is routed from the lower intake manifold to both the heater core and the radiator and back to
the water pump, where the cycle starts over again.

If an engine is equipped with an oil cooler, coolant is routed from the heater core through the oil cooler and back
to the water pump inlet tube. In this case, a plug blocks the inlet port on the timing chain cover.

20
 3.8L Engine

Lubrication System
Oil Pump
The oil pump is located in the timing chain case
cover. It is driven by the crankshaft and has four basic
components: a pump cover, an inner and outer pump
rotor and the timing chain cover.

The inner pump rotor is attached to the crankshaft by

lugs (flats) machined onto the crankshaft. It rotates
at crankshaft speed. The outer pump rotor fits into a
bore in the timing chain cover and engages the inner
rotor there. The outer rotor spins in the bore in the
timing chain cover. It is lubricated through circuits
machined into the chain case cover. The outer rotor
is held in place in the timing chain cover by a retainer 1 Oil Pump Cover 5
that fixes to the inside of the cover. 2 Inner Oil Pump Rotor
3 Outer Oil Pump Rotor
An oil pressure relief valve is located inside the cover 4 Timing Cover
and, along with the spring, can be serviced separately 5 Pressure Reliefe Valve
from the cover.

21
3.8L Engine

Oil Pan
The oil pan is made of stamped steel. The oil pan-to-
engine block joint is sealed with a gasket.

Block

Gasket
Crankshaft

Upper Oil Pan

Lower Oil Pan

22
 3.8L Engine

Oil Flow

1 Oil Supply for Ball Socket through Pushrod 6 Crankshaft

2 Oil Supply Passage from Shaft to Rocker Arm 7 Outer Rotor
3 Rocker Shaft 8 Inner Rotor
4 Oil Flows to Only One Pedestal on Each Head, 9 Relief Valve
Third from Rear on Right Head, Third from Front 10 Oil Pan
on Left Head 11 Oil Pump Pick-Up Tube
5 Rocker Shaft Tower 12 Oil Pump Case

The 3.8L engine has a full flow filtration, pressure feed type lubrication system. An internal gear-type oil pump is
directly coupled to the crankshaft and pumps oil from the oil pan. A relief valve located in the timing chain cover,
regulates the pressure.

• The oil is pumped through an oil filter and feeds the main oil gallery.
• This oil gallery feeds oil under pressure to the main, rod and camshaft bearings.
• Oil from the camshaft bearings travels through passages in the block to the hydraulic lifters and to one pedestal
in each cylinder head.
• The rocker arm shafts carry oil from the pedestals to each rocker arm.
• Splash oil drains to the oil pan through cast and drilled passages in the cylinder heads and engine block.

23
Notes

24
 4.0L Engine

Features
• Single Overhead Cam
• 3,952 cc (241 cu.in.) Displacement
• 91mm (3.6 in) Stroke
• 24 Valves, Four Valves Per Cylinder
• 69mm Main Journal Diameter
• Cast-In Iron Cylinder Liners
• Cast Aluminum Lower Intake Manifold
• Composite Upper Intake Plenum
• Two-Piece Outer Timing Belt Cover
• Thermostat and Plastic Housing Assembly located
on the outlet side
• Thermoplastic Valve Cover Assemblies
• Direct Mount Oil Pan to Transmission Bell Housing

The 4.0L engine is a cast aluminum, 6-cylinder, 60

degree, V-type.

• The 4.0L engine is NOT free-wheeling; which

means if a timing belt fails, the pistons may
contact and damage the valves.
• The 4.0L engine has a Coil-On-Plug (COP) ignition
system.
• The 4.0L engine uses 100,000-mile platinum spark
plugs.
• The coolant used in the 4.0L engine is extended-
life, Hybrid Organic Additive Technology (HOAT)
coolant with a normal service life of five years or
100,000 miles. 1 Left Cylinder Head
• Crankshaft main bearing clearance tolerance is 2 Engine Identification Number
critical to aluminum block engines. A unique main
bearing procedure has been developed for this
The engine identification number is located on the
engine.
rear of the engine block, just below the left cylinder
head.

25
4.0L Engine

Specifications Engine Oil

• The 4.0L engine is rated at 251 BHP (187 KW) The recommended oil viscosity for the 4.0L engines
@ 6000 RPM. is 10W-30.
• The 4.0L engine torque is rated at 259 Lb. Ft.
(351 Nm) at 4200 RPM.

Displacement 3952cm3
Type V6 (60° V-Block, 6-
Cylinder)
Maximum Power 251 BHP (187 KW)
@ 6000 RPM
Peak Torque 259 Lb. Ft.
(351 N•m) at 4200 RPM.
Bore 96mm
Stroke 91mm
Bore/Stroke Ratio 1.055
Leading Cylinder No. 1 (Right Bank)
Firing Order 1-2-3-4-5-6
Block Length 409.6 mm
Block Deck Height 229.28mm
Bank Angle 60 degrees
Bank Offset 43mm
Connecting Rod Length 151mm
Head Gasket Thickness 1.5 (Compressed)
Piston Comp. Height 33.14mm
Compression Ratio 10.2:1

26
 4.0L Engine

Timing System
Crankshaft Vibration Damper
The engine crankshaft vibration damper is a press
fit (0.003 in. interference), but is not keyed to the
crankshaft. Special Tools are required for removal and
Installation.

1 Crankshaft Damper 5 Special Tool 9020-R Insert

2 Special Tool 9365 6 Special Tool C-4685-C1
3 Center Bolt 7 Special Tool 6792-1
4 Special Tool 1023

27
4.0L Engine

Front Timing Belt Cover

The 4.0L front cover is a stamped steel and aluminum
two-piece design.

900130046

Rear Timing Belt Cover

The rear timing belt cover encloses the timing belt,
water pump mounting and coolant manifold. Be
sure the O-rings are properly placed into the grooves
before installing the rear timing belt cover.

1 O-Rings
2 Rear Timing Belt Cover

28
 4.0L Engine

Timing Drive System

The timing drive system consists of a single notched
timing belt (driven by the crankshaft sprocket) that
drives the left and right camshaft sprockets and the
water pump. A tensioner and pulley maintain tension
on the belt.

Timing Procedure
Installation of the timing belt is critical for proper
operation of the engine. If the belt is installed off
by one tooth, the engine may not start. If the belt is
installed off more than two teeth, valve and/or piston
damage will occur.

1 Right Camshaft Sprocket Alignment Mark 7 Left Camshaft Sprocket

2 Right Camshaft Sprocket 8 Left Camshaft Sprocket Alignment Mark
3 Upper Cylinder Head to Inner Timing Belt Cover 9 Crankshaft Sprocket Alignment Mark
Bolts 10 Crankshaft Sprocket
4 Timing Belt 11 Timing Belt Tensioner Pulley
5 Water Pump Pulley 12 Timing Belt Tensioner
6 Left Cylinder Head to Inner Timing Belt Cover
Bolts

29
4.0L Engine

Upper Engine
Intake Manifolds Short Runner Valve

The upper intake manifold (plenum) is made of a

glass-filled nylon material. The lower intake manifold
is made of cast aluminum. The thermostat is located
at the rear of the lower manifold. Refer to ElsaWEB
for proper torque specifications and tightening
sequence.

Upper Intake Manifold

Lower Intake Manifold

Short Runner Valve

The Short Runner Valve (SRV) is electrically actuated.
The 4.0L aluminum lower and composite upper intake
manifold is a cross flow design with long runners to
improve air charge inertia. The 4.0L has an electric
SRV that opens under Wide Open Throttle (WOT)
conditions above 5,000 RPM to maximize engine
performance. When actuated by the PCM, the SRV
solenoid is energized and activates a mechanical
linkage that redirects the intake airfow to six short
runners.

30
 4.0L Engine

Cylinder Head Covers

The 4.0L cylinder head cover is made of a
thermoplastic material and has a provisions for a
molded-in wiring harness attachment, make-up air
hose, PCV hose assembly and ignition coil.

4
1
2
5

G I N E O IL
EN

SA
E1 0W-30
6

3 900130044

1 Make-Up Hose Assembly 4 Oil Fill Neck

2 Make-Up Air Cap 5 Wiring Harness Attachment
3 Oil Fill Neck Assembly 6 Cap Bores
7 PCV Valve Bore

31
4.0L Engine

Rocker Arm and Shaft Assemblies

The rocker arm shafts are supported by several forged
aluminum alloy pedestals that are fastened to the
cylinder head. Four shafts are used, one for each
intake and exhaust bank on each cylinder head.
The shafts are hollow to provide a path for oil to flow
from the cylinder head to the valve mechanisms.
Each pedestal has a dowel that positions the pedestal
to the cylinder head, orients the rocker shaft to the
pedestal, and is an oil feed passage for the bearings.

1 Intake Rocker Arms 3 Notches Facing Up

2 Exhaust Rocker Arms

32
 4.0L Engine

Camshafts
A single overhead camshaft per cylinder head
provides valve actuation on the 4.0L engine.

• Left camshaft has a pickup wheel, and is longer

than the right camshaft.
• 9mm Intake/7mm Exhaust lift profile.
• Camshafts are identified with Date Code.

Left Camshaft Right Camshaft

33
4.0L Engine

Valve Springs
The exhaust valve and intake valve springs are
different colors. Yellow and white exhaust springs can
be mixed in an engine, but both exhaust springs must
be the same color for each cylinder. That is, the No. 1
cylinder exhaust springs must be either both white or
both yellow.

Valve Stem Seals

he 4.0L engine has a two-piece assembly valve stem
seal. No Special Tool is required to remove and install
the seal, although a universal valve seal tool aids in
removal. With the integrated valve spring seat, the
valve spring holds the seal in place.

Valves
The 4.0L engine uses four valves per cylinder
operated by a single camshaft on each bank. The
valves are made of heat-resistant steel and are
chrome-plated to prevent scuffing.

1 Spring Retainer 5 Valve Stem Seal

2 Valve Keeper 6 Valve Stem
3 Garter Spring 7 Valve Spring
4 Valve Spring Seat Top

34
 4.0L Engine

Exhaust Manifold
The exhaust manifold and catalytic converter are
one assembly called a “maniverter.” The assembly
is stamped stainless steel with a two layer graphite
gasket.

Exhaust Maniverter Exhaust Pipe Routed Under Engine

35
4.0L Engine

Cylinder Head
The aluminum alloy cylinder heads have cross flow-
type intake and exhaust ports. The chambers are a
compact spherical design to improve combustion
speed. The chambers have a squish area of
approximately 30% of the piston top area. The Caution: For this engine, the cylinder
cylinder heads are common to either cylinder bank by head bolts can be reused if they are not
reversing the direction of installation. stretched or necked. Refer to ELSAWeb
for the proper procedure.
The engine uses a 1.5mm thick Multi-Layer Steel
(MLS) cylinder head gasket.

Valve Guides
The valve guides are made from powdered metal
and are pressed into the cylinder head. The guides
are not replaceable and there are no oversized
valves available, therefore reaming the guides is not
recommended.

1 Spark Plug Tube 4 Left Cylinder Head Gasket

2 Rocker Arm Assembly 5 Camshaft
3 Right Cylinder Head Gasket 6 Seal

36
 4.0L Engine

Lower Engine
Cylinder Block
The engine cylinder block is made of heat-treated
aluminum with cast-in-place, non-serviceable, iron
cylinder liners. The block is a closed-deck design
with the right bank forward. The block is designed so
coolant flows completely around the cylinder bores.

37
4.0L Engine

Crankshaft
The engine crankshaft is made of forged steel and
is internally balanced. It is supported by four main
bearings.

The No. 2 main bearing is the thrust washer location.

38
 4.0L Engine

Crankshaft Front Seal

The crankshaft front seal is a one-piece design. The
oil pump housing, not the front cover, retains the
crankshaft front seal. Since a timing belt is used
instead of a chain, the front cover area must be kept
free of oil.

Oil Pump Housing

Front Seal

Crankshaft Rear Seal

The engine crankshaft rear seal one-piece assembly
is retained in a stamped steel housing attached to the
cylinder block.

Rear Seal Assembly

39
4.0L Engine

Piston and Connecting Rods

The pistons are made of an aluminum alloy with an
anodized top ring groove. Piston skirts are coated
with a solid lubricant for scuff resistance. The
connecting rods are a conventional design using
forged steel. There is an oil squirt hole for lubricating
the major thrust side of the piston.

The connecting rod attaches to the piston with a

full-floating pin retained by lock rings. The pistons
and rods are serviced as an assembly. The 4.0L
connecting rods are made of steel but with a
fractured cap design. Rod bearings are available in
three sizes.

40
 4.0L Engine

Oil Pan
The engine oil pan is a single plane design and is
made of cast aluminum to stiffen the lower end of the
engine. The oil pan uses an aluminum plate gasket
with a rubber seal.

Windage Tray
A stamped steel windage tray is mounted to the main
bearing caps to keep oil off the connecting rods when
Caution: Pay close attention to the
the crankshaft is rotating. The crankshaft rotates
tightening sequence. If not tightened
more easily and foaming is reduced when oil is kept
correctly, the oil pan may crack.
off the rods.

41
4.0L Engine

Engine Lubrication
Engine Oil Flow

1 Crankshaft 9 Oil Flow to Pedestal

2 Outer Rotor 10 Pedestal Drilled Passage
3 Inner Rotor 11 Exhaust Rocker Shaft
4 Relief Valve 12 Shaft/Pedestal Dowel Passage
5 Oil Pan 13 Camshaft Bearing Bore
6 Oil Screen 14 Cylinder Block Oil Gallery
7 Oil Pump Case 15 Cylinder Head Gasket
8 Intake Rocker Shaft 16 Head Bolt Hole

FROM TO
Oil Pump Oil Filter Mounting (Inlet)
Oil Filter Mounting (Inlet) Oil Filter
Oil Filter Oil Filter Mounting (Outlet)
Oil Filter Mounting (Outlet) Main Oil Gallery
Main Oil Gallery - Center of Block 1. Crankshaft Main Bearing
2. Left Cylinder Head*
3. Right Cylinder Head*
Crankshaft Main Bearings Connecting Rod Bearings
Left Cylinder Head
Right Cylinder Head

* The cylinder head gaskets have an oil restrictor to control oil flow to the cylinder heads.

42
 4.0L Engine

Positive Crankcase Ventilation System

• Filtered fresh air (makeup air) is drawn into the
engine through the cylinder head cover and enters
the crankcase where it scavenges the blow by
gases created during combustion.
• Crankcase gasses are drawn back into the top of
the engine where they enter a baffling device in
the cylinder head cover. The baffle is designed to
separate the oil droplets in the blow by gases.
• The oil droplets return to the crankcase and gases
are routed to the PCV valve located at the rear
of the rightt valve cover, and then to the intake
manifold where they are re-circulated into the
combustion chambers and burned.

1 4

EN
G I N E O IL
2
SAE
1 0W-30

2 900130043
900130044

3 PCV Valve Hand Hose

1 Make-Up Air Hose 4 To Intake Manifold
2 Oil Fill Neck Assembly

43
4.0L Engine

Oil Pump
A six-lobed gerotor oil pump provides lubrication
for the 4.0L engine. The oil pump body is part of
the front cover assembly (lower inside portion) and
retains the crankshaft front seal. The pump is driven
directly off the nose of the crankshaft.

Viewed from Front

44
 4.0L Engine

Oil Cooler
The engine oil cooler is an oil-to-coolant type and
is mounted between the oil filter and the oil pan.
Engine oil travels from the oil cooler and into the oil
filter. Engine oil then exits the filter into the main
gallery. Engine coolant flows into the cooler from the
heater return tube and exits into the water inlet tube.

45
4.0L Engine

Cooling System
Water Pump
The 4.0L water pump has a die-cast aluminum body
and plastic swept vane impeller. It bolts directly to
the inner front cover and cylinder block, behind the
outer front cover. The water pump is driven by the
back-side of the timing belt.

Internal Coolant Bypass

The 4.0L engines are equipped with an internal
coolant bypass that allows hot coolant from the
cylinder head to return to the engine inlet area of the
block.

46
 4.0L Engine

Thermostat
The thermostat is located on the outlet side of the
engine. The thermostat housing is attached to the left
side of the lower intake manifold.

The thermostat housing is equipped with a check

valve that allows air that might be trapped by the
thermostat during a coolant service fill, to pass
through the thermostat. The check valve should
seat and seal during normal operating conditions
as a result of the differential pressure across the
thermostat.

Radiator and Cooling Fans

The radiator is a cross-flow type (horizontal tubes)
that keeps the engine cooled under all operating
conditions.

47
4.0L Engine

Engine Block Heater

An optional engine block heater is mounted on the
right side of the cylinder block near the rear transaxle
attachment flange. The block heater is a cylinder-type
design that transfers heat through the aluminum
engine block without penetrating the cooling system.

1 Engine Block Heater

Coolant Reservoir and Cap

The cooling system builds pressure as coolant
expands while it is heated. This increase in pressure
raises the boiling point of the coolant.

The reservoir provides some room within the cooling

system for the coolant to expand, allowing pressure
to build. The system pressure develops when the
coolant expands (depending on the volume of coolant
in the system). The system pressure is optimized
when the coolant volume indicated by cold coolant
levels is between the MIN and MAX lines on the
reservoir.
1 Pressure Cap
The pressurized coolant bottle has a cap that releases 2 Inlet
at a nominally rated pressure that may vary by 3 Outlet
application. A spring-loaded valve in the center of the
cap allows the system to pressurize the cap to the
rated pressure. A gasket seals the pressure cap to
the top of the bottle. Air or coolant from the reservoir
escapes the pressurized area through an overflow
hose.

48
 4.0L Engine

Coolant
The coolant draws heat from engine metal in the
cylinder head area near the exhaust valve and engine
block and carries the heat to the radiator where the
tube/fin radiator transfers the heat to the air.

The coolant used in this engine is extended-life

coolant with a normal service life of five years or
100,000 miles.

Aluminum cylinder blocks, cylinder heads and water

pumps require special corrosion protection. Mopar®
Antifreeze/Coolant Five-Year/100,000-Mile Formula or
equivalent ethylene glycol based coolant with Hybrid
Organic Additive Technology (HOAT) is recommended.
This coolant offers the best engine cooling without
corrosion when mixed with 50% ethylene glycol and
50% distilled water to obtain a freeze point of -37°C
(-35°F).

49
Notes

50
 Knowledge Assessment
Knowledge Assessment

An on-line Knowledge Assessment (exam) is available for this Self-Study Program.

The Knowledge Assessment may or may not be required for Certification.

You can find this Knowledge Assessment at:

www.vwwebsource.com

For Assistance, please call:

Volkswagen Academy

Certification Program Headquarters

1 – 877 – VW – CERT – 5

(1 – 877 – 892 – 3785)

(8:00 a.m. to 8:00 p.m. EST)

Or, E-mail:

vwlms@convergent.com

51
Notes

52
Notes

53
 821803

Volkswagen of America, Inc.

3800 Hamlin Road
Auburn Hill, MI 48326
Printed in the U.S.A.
June, 2008