2.4L ENGINE - SERVICE INFORMATION

• HEADINGS
  • DESCRIPTION
    • DESCRIPTION
  • DIAGNOSIS AND TESTING
    • ENGINE DIAGNOSIS - INTRODUCTION
    • PERFORMANCE
    • ENGINE MECHANICAL DIAGNOSTIC TABLE
    • CYLINDER COMPRESSION PRESSURE LEAKAGE
    • CYLINDER COMBUSTION PRESSURE LEAKAGE
    • OIL CONSUMPTION TEST AND DIAGNOSIS
      • OIL CONSUMPTION TEST
      • OIL CONSUMPTION DIAGNOSIS
      • TOP 19 REASONS THAT MAY LEAD TO ENGINE OIL CONSUMPTION
    • ENGINE LUBRICATION DIAGNOSTIC TABLE
  • STANDARD PROCEDURE
    • DUST COVERS AND CAPS
    • ENGINE GASKET SURFACE PREPARATION
    • FORM-IN-PLACE GASKETS AND SEALERS
      • SEALER APPLICATION
    • MEASURING BEARING CLEARANCE USING PLASTIGAGE
  • SPECIFICATIONS
    • ENGINE SPECIFICATIONS
    • TORQUE SPECIFICATIONS
  • REMOVAL
    • REMOVAL
  • INSTALLATION
    • INSTALLATION
  • SPECIAL TOOLS
    • SPECIAL TOOLS
  • AIR INTAKE SYSTEM
    • AIR CLEANER
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • BODY, AIR CLEANER
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • RESONATOR, AIR CLEANER
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
  • CYLINDER HEAD
    • DESCRIPTION
      • DESCRIPTION
    • DIAGNOSIS AND TESTING
      • CYLINDER HEAD GASKET
        • CYLINDER-TO-CYLINDER LEAKAGE TEST
        • CYLINDER-TO-WATER JACKET LEAKAGE TEST
          • VISUAL TEST METHOD
          • COOLING SYSTEM TESTER METHOD
          • CHEMICAL TEST METHOD
      • HYDRAULIC LASH ADJUSTER
    • REMOVAL
      • REMOVAL
    • CLEANING
      • CLEANING
    • INSPECTION
      • INSPECTION
    • INSTALLATION
      • INSTALLATION
    • CAMSHAFT, ENGINE
      • DESCRIPTION
        • DESCRIPTION
      • OPERATION
        • OPERATION
      • STANDARD PROCEDURE
        • STANDARD PROCEDURE - CAMSHAFT END PLAY
          • STANDARD PROCEDURE - CAMSHAFT ENDPLAY
      • REMOVAL
        • REMOVAL
      • INSPECTION
        • INSPECTION
      • INSTALLATION
        • INSTALLATION
    • COVER(S), CYLINDER HEAD
      • DESCRIPTION
        • DESCRIPTION
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • LIFTER(S), HYDRAULIC
      • DIAGNOSIS AND TESTING
        • DIAGNOSIS AND TESTING - LASH ADJUSTER (TAPPET) NOISE
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • ROCKER ARM, VALVE
      • DESCRIPTION
        • DESCRIPTION
      • REMOVAL
        • REMOVAL
      • INSPECTION
        • INSPECTION
      • INSTALLATION
        • INSTALLATION
    • SEAL(S), VALVE GUIDE
      • DESCRIPTION
        • DESCRIPTION
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • SPRING(S), VALVE
      • DESCRIPTION
        • DESCRIPTION
      • REMOVAL
        • ON VEHICLE
        • OFF VEHICLE
      • INSPECTION
        • INSPECTION
      • INSTALLATION
        • ON VEHICLE
        • OFF VEHICLE
    • VALVES, INTAKE AND EXHAUST
      • DESCRIPTION
        • DESCRIPTION
      • STANDARD PROCEDURE
        • STANDARD PROCEDURE - REFACING - INTAKE AND EXHAUST VALVES
          • VALVES
          • VALVE SEATS
          • VALVE AND SPRING INSTALLED HEIGHT
      • REMOVAL
        • REMOVAL
      • INSPECTION
        • INSPECTION
          • VALVES
          • VALVE GUIDES
      • INSTALLATION
        • INSTALLATION
    • PUMP, VACUUM
      • DESCRIPTION
        • DESCRIPTION
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • ASSEMBLY, VARIABLE VALVE ACTUATION
      • DESCRIPTION
        • DESCRIPTION
      • OPERATION
        • OPERATION
      • REMOVAL
        • REMOVAL
      • INSPECTION
        • INSPECTION
      • INSTALLATION
        • INSTALLATION
  • ENGINE BLOCK
    • DESCRIPTION
      • DESCRIPTION
    • STANDARD PROCEDURE
      • CYLINDER BORE DEGLAZING
      • MEASURING BEARING CLEARANCE USING PLASTIGAGE
    • INSPECTION
      • INSPECTION
    • BEARING(S), CONNECTING ROD
      • STANDARD PROCEDURE
        • STANDARD PROCEDURE - CONNECTING ROD - FITTING
        • CONNECTING ROD BEARING REPLACEMENT
    • BEARING(S), CRANKSHAFT, MAIN
      • STANDARD PROCEDURE
        • STANDARD PROCEDURE - CONNECTING ROD - FITTING
        • CONNECTING ROD BEARING REPLACEMENT
    • CRANKSHAFT
      • DESCRIPTION
        • DESCRIPTION
      • STANDARD PROCEDURE
        • STANDARD PROCEDURE - MEASURING CRANKSHAFT END PLAY
      • REMOVAL
        • REMOVAL
      • INSPECTION
        • INSPECTION
      • INSTALLATION
        • INSTALLATION
    • DAMPER, VIBRATION
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • FLEX PLATE
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • FRAME, LADDER
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • RING(S), PISTON
      • STANDARD PROCEDURE
        • STANDARD PROCEDURE - PISTON RING FITTING
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • ROD, PISTON AND CONNECTING
      • DESCRIPTION
        • DESCRIPTION
      • STANDARD PROCEDURE
        • PISTON FITTING
        • CONNECTING ROD SIDE CLEARANCE
          • DIAL INDICATOR
          • FEELER GAUGE
      • REMOVAL
        • REMOVAL
      • CLEANING
        • CLEANING
      • INSPECTION
        • INSPECTION
      • INSTALLATION
        • INSTALLATION
    • SEAL, CRANKSHAFT OIL, FRONT
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • SEAL, CRANKSHAFT OIL, REAR
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
  • ENGINE MOUNTING
    • INSULATOR, ENGINE MOUNT, LEFT
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • INSULATOR, ENGINE MOUNT, REAR
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • INSULATOR, ENGINE MOUNT, RIGHT
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
  • MANIFOLDS
    • MANIFOLD, EXHAUST
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • MANIFOLD, INTAKE
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
  • LUBRICATION
    • DESCRIPTION
      • DESCRIPTION
    • OPERATION
      • OPERATION
    • DIAGNOSIS AND TESTING
      • ENGINE OIL LEAK
        • AIR LEAK DETECTION TEST METHOD
      • CHECKING ENGINE OIL PRESSURE
      • CHECKING VVT OIL PRESSURE
    • COOLER, OIL
      • DESCRIPTION
        • DESCRIPTION
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • FILTER, ENGINE OIL
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • OIL
      • STANDARD PROCEDURE
        • ENGINE OIL LEVEL CHECK
        • ENGINE OIL AND FILTER CHANGE
          • OIL FILTER SPECIFICATION
          • USED ENGINE OIL DISPOSAL
    • PAN, OIL
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • PLUG, OIL
      • DESCRIPTION
        • DESCRIPTION
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • PUMP, ENGINE OIL
      • DESCRIPTION
        • DESCRIPTION
      • REMOVAL
        • REMOVAL
      • INSPECTION
        • INSPECTION
      • INSTALLATION
        • INSTALLATION
    • SENSOR, OIL TEMPERATURE
      • DESCRIPTION
        • DESCRIPTION
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • SENSOR, OIL PRESSURE
      • DESCRIPTION
        • DESCRIPTION
      • OPERATION
        • OPERATION
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • VALVE, OIL PRESSURE RELIEF
      • REMOVAL
        • REMOVAL
      • INSPECTION
        • INSPECTION
      • INSTALLATION
        • INSTALLATION
  • VALVE TIMING
    • STANDARD PROCEDURE
      • STANDARD PROCEDURE - VALVE TIMING VERIFICATION
    • CHAIN AND SPROCKETS, TIMING
      • REMOVAL
        • TIMING CHAIN
        • CAMSHAFT SPROCKET
        • CRANKSHAFT SPROCKET
      • INSPECTION
        • INSPECTION
      • INSTALLATION
        • TIMING CHAIN
        • CAMSHAFT SPROCKET(S)
        • CRANKSHAFT SPROCKET
    • COVER(S), ENGINE TIMING
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
    • TENSIONER, ENGINE TIMING
      • REMOVAL
        • REMOVAL
      • INSTALLATION
        • INSTALLATION
• FIGURES
  • Fig. 1: 2.4 Liter (146 Cu. In.) Engine
  • Fig. 2: Covers/Caps
  • Fig. 3: Opening Cover
  • Fig. 4: Proper Tool Usage For Surface Preparation
  • Fig. 5: Proper Tool Usage For Surface Preparation
  • Fig. 6: Plastigage Placed In Lower Shell-Typical
  • Fig. 7: Engine Cover & Pins
  • Fig. 8: Lower Coupling Bolt
  • Fig. 9: Battery Cover
  • Fig. 10: Battery & Cables
  • Fig. 11: Powertrain Control Module Electrical Connectors & Nuts
  • Fig. 12: Battery Tray, PCM Mount & Bolts
  • Fig. 13: Removing/Installing Inlet Assembly
  • Fig. 14: Upper Close Out Panel Cover Components
  • Fig. 15: Front Fascia Assembly
  • Fig. 16: Removing/Installing Generator
  • Fig. 17: Air Conditioning Compressor Electrical Connectors
  • Fig. 18: Air Conditioning Compressor & Bolts
  • Fig. 19: Resonator, Clamp & Connector
  • Fig. 20: Resonator, Bolt & Clamp
  • Fig. 21: Foam Insulator, Fuel Line & Purge Line
  • Fig. 22: Hose Assembly & Hot Bottle Return Pipe Bolts
  • Fig. 23: Crossmember To Fascia Support Beams Bracket Retaining Bolts
  • Fig. 24: Lower Bumper Reinforcements & Fasteners
  • Fig. 25: Front Fascia Support Beams
  • Fig. 26: Rear Engine Isolator To Engine Mount Bracket Bolt
  • Fig. 27: Transaxle & Ground Cable
  • Fig. 28: Adapter, Engine Support Cradle, Power Train Dolly & Safety Straps
  • Fig. 29: Removing/Installing Bell-Housing
  • Fig. 30: Removing/Installing Bell-Housing
  • Fig. 31: Flexplate-To-Torque Converter Bolts
  • Fig. 32: Access Door In Splash Shield
  • Fig. 33: Transaxle & Ground Cable
  • Fig. 34: Front Fascia Support Beams
  • Fig. 35: Lower Bumper Reinforcements & Fasteners
  • Fig. 36: Windshield Washer Reservoir-To-Battery Tray Bolt
  • Fig. 37: Hose Assembly & Hot Bottle Return Pipe Bolts
  • Fig. 38: Foam Insulator, Fuel Line & Purge Line
  • Fig. 39: Resonator, Bolt & Clamp
  • Fig. 40: Resonator, Clamp & Connector
  • Fig. 41: Air Conditioning Compressor & Bolts
  • Fig. 42: Air Conditioning Compressor Electrical Connectors
  • Fig. 43: Generator, Bolts & Bracket
  • Fig. 44: Removing/Installing Generator
  • Fig. 45: Front Fascia Assembly
  • Fig. 46: Upper Close Out Panel Cover Components
  • Fig. 47: Removing/Installing Inlet Assembly
  • Fig. 48: Battery Tray, PCM Mount & Bolts
  • Fig. 49: Battery & Cables
  • Fig. 50: Battery Cover
  • Fig. 51: Lower Coupling Bolt
  • Fig. 52: Engine Cover & Pins
  • Fig. 53: Air Cleaner Housing Cover Screws
  • Fig. 54: Air Cleaner Housing Cover & Air Filter
  • Fig. 55: Air Cleaner Housing Cover & Air Filter
  • Fig. 56: Air Cleaner Housing Cover Screws
  • Fig. 57: Resonator, Bolt & Clamp
  • Fig. 58: Removing/Installing Air Cleaner Body
  • Fig. 59: Removing/Installing Air Cleaner Body
  • Fig. 60: Resonator, Bolt & Clamp
  • Fig. 61: Resonator, Clamp & Connector
  • Fig. 62: Resonator, Bolt & Clamp
  • Fig. 63: Resonator, Bolt & Clamp
  • Fig. 64: Resonator, Clamp & Connector
  • Fig. 65: Cylinder Head, Valves & Springs
  • Fig. 66: Cooling System Pressure Tester - 7700-A
  • Fig. 67: Bloc-Chek-Kit - C-3685-A
  • Fig. 68: Resonator, Bolt & Clamp
  • Fig. 69: Cylinder Head Cover Bolts
  • Fig. 70: Exhaust Manifold Bolts
  • Fig. 71: Timing Cover Mark & Notch
  • Fig. 72: Intake Manifold Lower Bracket, Nuts & Bolts
  • Fig. 73: Timing Chain Cover Removal/Installation
  • Fig. 74: Timing Chain, Sprockets, Tensioner & Guides
  • Fig. 75: Foam Insulator, Fuel Line & Purge Line
  • Fig. 76: Score Line
  • Fig. 77: MAP Sensor Connector & Fittings
  • Fig. 78: Front Head Bolt Washers
  • Fig. 79: Fuel Injectors & Rail
  • Fig. 80: Intake Manifold Upper Support Bracket, Bolts & Nuts
  • Fig. 81: Intake Manifold Silencer Pad Screws
  • Fig. 82: MAP Sensor Connector & Fittings
  • Fig. 83: Intake Manifold Retaining Bolts & Nuts
  • Fig. 84: Checking Cylinder Head Flatness
  • Fig. 85: Checking Cylinder Head Bolts For Stretching (Necking)
  • Fig. 86: Intake Manifold Bolts Tightening Sequence
  • Fig. 87: Intake Manifold Upper Support Bracket, Bolts & Nuts
  • Fig. 88: Intake Manifold Silencer Pad Screws
  • Fig. 89: Engine Sealant RTV Location
  • Fig. 90: Washers Must Be Installed With Bevel Edge Up Towards Bolt Head
  • Fig. 91: Front Head Bolt Washers
  • Fig. 92: Cylinder Head Bolt Tightening Sequence
  • Fig. 93: Cylinder Head Cover Bolts
  • Fig. 94: Exhaust Manifold Bolts Tightening Sequence
  • Fig. 95: Foam Insulator, Fuel Line & Purge Line
  • Fig. 96: Intake Manifold Lower Bracket, Nuts & Bolts
  • Fig. 97: Foam Insulator, Fuel Line & Purge Line
  • Fig. 98: Air Cleaner Body, Clamp, Make Up Air Hose, Retainer & Bolt
  • Fig. 99: Engine Cover & Air Resonator Clamp
  • Fig. 100: Engine Camshaft
  • Fig. 101: Measuring Camshaft End Play
  • Fig. 102: Vertical Center Line Of Camshaft, Dowel & Cylinder Head
  • Fig. 103: Timing Cover Mark & Notch
  • Fig. 104: Vertical Center Line Of Camshaft, Dowel & Cylinder Head
  • Fig. 105: Sprocket Mark & Painted Link
  • Fig. 106: Special Tool, Spring Compressor & Indicators
  • Fig. 107: Bearing Cap Bolts
  • Fig. 108: Chain Removal
  • Fig. 109: Inspecting Camshaft Wear Areas
  • Fig. 110: Camshaft Bearing Cap Tightening Sequence
  • Fig. 111: Special Tool, Spring Compressor & Indicators
  • Fig. 112: Camshaft Seal
  • Fig. 113: Cylinder Head Cover
  • Fig. 114: Cylinder Head Cover Bolts
  • Fig. 115: Cylinder Head Cover Gaskets
  • Fig. 116: Sealant Application Areas
  • Fig. 117: Cylinder Head Cover Gaskets
  • Fig. 118: Sealant Application Areas
  • Fig. 119: Cylinder Head Cover Bolts
  • Fig. 120: Cylinder Head Cover Bolts
  • Fig. 121: Special Tool, Spring Compressor & Indicators
  • Fig. 122: Special Tool, Spring Compressor & Indicators
  • Fig. 123: Valve Rocker Arm
  • Fig. 124: Valve Rocker Arm
  • Fig. 125: Valve Stem Oil Seal, Valve Spring & Valve Guide
  • Fig. 126: Valve Spring & Retainer
  • Fig. 127: Valve Guide Seal & Valve Seal Tool
  • Fig. 128: Valve Spring Seat
  • Fig. 129: Valve Spring Seat
  • Fig. 130: Driver, Garter Spring & Valve Guide Seal
  • Fig. 131: Valve Spring & Retainer
  • Fig. 132: Valve Springs Assembly
  • Fig. 133: Valve Spring Compressor & Air Hose
  • Fig. 134: Compressing Valve Spring
  • Fig. 135: Valve Spring & Retainer
  • Fig. 136: Valve Spring Compressor & Adapter
  • Fig. 137: Valve Spring Compressor
  • Fig. 138: Compressing Valve Spring
  • Fig. 139: Valve Spring & Retainer
  • Fig. 140: Testing Valve Spring
  • Fig. 141: Checking Valve Spring Installed Height
  • Fig. 142: Valve Guide Seal & Valve
  • Fig. 143: Valve Spring & Retainer
  • Fig. 144: Compressing Valve Spring
  • Fig. 145: Valve Spring Component Measurements
  • Fig. 146: Valve Guide Seal & Valve
  • Fig. 147: Valve Spring & Retainer
  • Fig. 148: Valve Spring Compressor & Adapter
  • Fig. 149: Valve Spring Compressor
  • Fig. 150: Compressing Valve Spring
  • Fig. 151: Valve Spring Component Measurements
  • Fig. 152: Cylinder Head, Valves & Springs
  • Fig. 153: Valve Face & Seat
  • Fig. 154: Inspecting Valve Margin
  • Fig. 155: Valve Face & Seat
  • Fig. 156: Checking Valve Spring Installed Height
  • Fig. 157: Garter Spring, Valve Guide Seal & Spring Seat
  • Fig. 158: Valve Spring & Retainer
  • Fig. 159: Valve Spring Adapter, Valve Spring Compressor, Retaining Locks & Valve Springs
  • Fig. 160: Checking Valve Spring Installed Height
  • Fig. 161: Valve Spring & Retainer
  • Fig. 162: Inspecting Valve Margin
  • Fig. 163: Garter Spring, Valve Guide Seal & Spring Seat
  • Fig. 164: Inspecting Valve Margin
  • Fig. 165: Measuring Valve Guide Wear
  • Fig. 166: Checking Valve Spring Installed Height
  • Fig. 167: Garter Spring, Valve Guide Seal & Spring Seat
  • Fig. 168: Valve Spring & Retainer
  • Fig. 169: Vacuum Pump
  • Fig. 170: Vacuum Pump & Bolts
  • Fig. 171: Vacuum Pump Gasket
  • Fig. 172: Vacuum Fitting & Screw
  • Fig. 173: Vacuum Fitting O-Ring Seal
  • Fig. 174: Vacuum Fitting O-Ring Seal
  • Fig. 175: Vacuum Fitting & Screw
  • Fig. 176: Intake Valve Tips
  • Fig. 177: Solenoid Valve, Hydraulic Brake Pumping Element/Hydraulic Lash Adjusters, Upper Pumping Element & Oil Accumulator
  • Fig. 178: Variable Valve Actuation Assembly Operating Description
  • Fig. 179: Full Lift
  • Fig. 180: Early Intake Valve Closing (EIVC)
  • Fig. 181: Late Intake Valve Opening (LIVO)
  • Fig. 182: Multi-Lift
  • Fig. 183: Closed
  • Fig. 184: Cylinder Head Cover Bolts
  • Fig. 185: VVAA Block Removal Sequence (1 Of 2)
  • Fig. 186: Special Tool, Spring Compressor & Indicators
  • Fig. 187: VVAA Block Removal Sequence (2 Of 2)
  • Fig. 188: VVAA Assembly On Blocks Of Wood
  • Fig. 189: Rocker Arms
  • Fig. 190: Valve Rocker Arms, Oil Supply O-Ring & Oil Temperature Sensor
  • Fig. 191: Locating Pins
  • Fig. 192: Rocker Arms
  • Fig. 193: Special Tool, Spring Compressor & Indicators
  • Fig. 194: Improperly Aligned VVAA
  • Fig. 195: Properly Aligned VVAA
  • Fig. 196: Six VVAA Retaining Bolts Hand Tightening Sequence
  • Fig. 197: Variable Valve Actuation Assembly Tightening Sequence
  • Fig. 198: Cylinder Head Cover
  • Fig. 199: Service Port & Bleed Port
  • Fig. 200: Serial Number Location
  • Fig. 201: Cylinder Bore Crosshatch Pattern
  • Fig. 202: Plastigage Placed In Lower Shell
  • Fig. 203: Measuring Bearing Clearance With Plastigage
  • Fig. 204: Checking Connecting Rod Bearing Clearance With Plastigage
  • Fig. 205: Main Bearing Inserts
  • Fig. 206: Measuring Cylinder Bore Diameter
  • Fig. 207: Bearing Selection
  • Fig. 208: Connecting Rod Bearing Clearance - Typical
  • Fig. 209: Connecting Rod Side Clearance
  • Fig. 210: Connecting Rod Bearing Shells & Bearing Size
  • Fig. 211: Main Bearing Cap Bolts From Windage Tray Removal Sequence
  • Fig. 212: Connecting Rod To Cylinder Identification
  • Fig. 213: Piston, Connecting Rod Cap, Bolts, Plastic Guide Plates & Guide Pins
  • Fig. 214: Checking Cylinder Head Bolts For Stretching (Necking)
  • Fig. 215: Windage Tray With Main Bearing Cap Bolts Installation Sequence
  • Fig. 216: Bearing Selection
  • Fig. 217: Connecting Rod Bearing Clearance - Typical
  • Fig. 218: Connecting Rod Side Clearance
  • Fig. 219: Connecting Rod Bearing Shells & Bearing Size
  • Fig. 220: Main Bearing Cap Bolts From Windage Tray Removal Sequence
  • Fig. 221: Connecting Rod To Cylinder Identification
  • Fig. 222: Piston, Connecting Rod Cap, Bolts, Plastic Guide Plates & Guide Pins
  • Fig. 223: Checking Cylinder Head Bolts For Stretching (Necking)
  • Fig. 224: Windage Tray With Main Bearing Cap Bolts Installation Sequence
  • Fig. 225: Crankshaft
  • Fig. 226: Checking Crankshaft End Play
  • Fig. 227: Flex Plate
  • Fig. 228: Oil Drain Plug & Oil Pan
  • Fig. 229: Oil Filter
  • Fig. 230: Using Putty Knife To Loosen Seal Around Oil Pan
  • Fig. 231: Crankshaft Sprocket
  • Fig. 232: Crankshaft Position Sensor & Bolt
  • Fig. 233: Identify Connecting Rod To Cylinder-Typical
  • Fig. 234: Main Bearing Cap Removal/Installation Sequence
  • Fig. 235: Measuring Crankshaft Journal
  • Fig. 236: Bearing Identification
  • Fig. 237: Target Wheel
  • Fig. 238: Installing Thrust Bearing
  • Fig. 239: Bearing Identification
  • Fig. 240: Main Bolt Identification
  • Fig. 241: Main Bearing Cap Removal/Installation Sequence
  • Fig. 242: Crankshaft Position Sensor & Bolt
  • Fig. 243: Crankshaft Sprocket
  • Fig. 244: Oil Filter
  • Fig. 245: Removing/Installing Crankshaft Damper Bolt
  • Fig. 246: Removing/Installing Crankshaft Damper Bolt
  • Fig. 247: Flex Plate
  • Fig. 248: Flex Plate
  • Fig. 249: Pry Point 1
  • Fig. 250: Pry Point 2
  • Fig. 251: Sealing Ladder Frame
  • Fig. 252: Ladder Frame Bolts Tightening Sequence
  • Fig. 253: Measuring Piston Ring End Gap
  • Fig. 254: Checking Piston Ring Grooves Clearances
  • Fig. 255: Piston Ring Removal/Installation Sequence
  • Fig. 256: Removing/Installing Upper & Intermediate Rings
  • Fig. 257: Removing/Installing Piston Ring Side Rail
  • Fig. 258: Piston Ring Removal/Installation Sequence
  • Fig. 259: Removing/Installing Piston Ring Side Rail
  • Fig. 260: Dot Marks On Piston Rings
  • Fig. 261: Removing/Installing Upper & Intermediate Rings
  • Fig. 262: Piston Ring End Gap Position
  • Fig. 263: Piston & Connecting Rod
  • Fig. 264: Piston Components
  • Fig. 265: Engine Block Cylinder Bore Diameter Grade Markings
  • Fig. 266: Piston Size Mark
  • Fig. 267: Coating Material On Piston
  • Fig. 268: Measuring Connecting Rod Side Clearance
  • Fig. 269: Connecting Rod Side Clearance
  • Fig. 270: Main Bearing Cap Bolts From Windage Tray Removal Sequence
  • Fig. 271: Connecting Rod To Cylinder Identification
  • Fig. 272: Piston, Connecting Rod Cap, Bolts, Plastic Guide Plates & Guide Pins
  • Fig. 273: Inserts
  • Fig. 274: Connecting Rod To Cylinder Identification
  • Fig. 275: Coating Material On Piston
  • Fig. 276: Vacuum Fitting O-Ring Seal
  • Fig. 277: Vacuum Fitting & Screw
  • Fig. 278: Removing/Installing Crankshaft Damper
  • Fig. 279: Removing Front Crankshaft Oil Seal By Prying Out With Screwdriver
  • Fig. 280: Crankshaft Oil Seal & Seal Installer 9506
  • Fig. 281: Installing New Seal By Using Seal Installer 9506 & Crankshaft Damper Bolt
  • Fig. 282: Pressing Seal Into Front Cover Until Seal Installer
  • Fig. 283: Installing Damper Holder 9707
  • Fig. 284: Flex Plate
  • Fig. 285: Rear Crankshaft Oil Seal - Removal
  • Fig. 286: Rear Main Seal Installation
  • Fig. 287: Flex Plate
  • Fig. 288: Removing/Installing Left Engine Mount Insulator
  • Fig. 289: Strut Tower, Trans Mount & Bolt
  • Fig. 290: Removing/Installing Left Engine Mount Insulator
  • Fig. 291: Strut Tower, Trans Mount & Bolt
  • Fig. 292: Removing/Installing Left Engine Mount Insulator
  • Fig. 293: Rear Mount Bracket Nuts
  • Fig. 294: Rear Mount & Bolts
  • Fig. 295: Removing/Installing Rear Engine Mount Insulator
  • Fig. 296: Rear Mount & Bolts
  • Fig. 297: Removing/Installing Rear Engine Mount Insulator
  • Fig. 298: Rear Mount Bracket Nuts
  • Fig. 299: Removing/Installing Rear Engine Mount Insulator
  • Fig. 300: Removing/Installing Right Engine Mount Insulator
  • Fig. 301: Removing/Installing Right Engine Mount Insulator
  • Fig. 302: Strut Tower, Mount & Bolt
  • Fig. 303: Removing/Installing Right Engine Mount Insulator
  • Fig. 304: Removing/Installing Right Engine Mount Insulator
  • Fig. 305: Converter Outlet Studs
  • Fig. 306: Exhaust Manifold Heat Shields
  • Fig. 307: Exhaust Manifold Bolt
  • Fig. 308: Exhaust Manifold Bolts Tightening Sequence
  • Fig. 309: Exhaust Manifold Heat Shields
  • Fig. 310: Intake Manifold Lower Bracket, Nuts & Bolts
  • Fig. 311: Removing/Installing Air Cleaner Body
  • Fig. 312: Resonator, Clamp & Connector
  • Fig. 313: Resonator, Bolt & Clamp
  • Fig. 314: Removing/Installing Airbox Bracket
  • Fig. 315: Removing/Installing Right Engine Mount Insulator
  • Fig. 316: Measuring Three Inches
  • Fig. 317: Intake Manifold Upper Support Bracket, Bolts & Nuts
  • Fig. 318: Throttle Body Support Bracket, Nut & Bolt
  • Fig. 319: Throttle Body, Gasket & Bolts
  • Fig. 320: Score Line
  • Fig. 321: Intake Manifold Silencer Pad Screws
  • Fig. 322: MAP Sensor Connector & Fittings
  • Fig. 323: Intake Manifold Retaining Bolts & Nuts
  • Fig. 324: Intake Manifold Retaining Bolts & Nuts
  • Fig. 325: Intake Manifold Silencer Pad Screws
  • Fig. 326: Intake Manifold Lower Bracket, Nuts & Bolts
  • Fig. 327: Foam Insulator, Fuel Line & Purge Line
  • Fig. 328: MAP Sensor Connector & Fittings
  • Fig. 329: Throttle Body, Gasket & Bolts
  • Fig. 330: Throttle Body Support Bracket, Nut & Bolt
  • Fig. 331: Intake Manifold Upper Support Bracket, Bolts & Nuts
  • Fig. 332: Removing/Installing Right Engine Mount Insulator
  • Fig. 333: Removing/Installing Airbox Bracket
  • Fig. 334: Resonator, Bolt & Clamp
  • Fig. 335: Resonator, Clamp & Connector
  • Fig. 336: Removing/Installing Air Cleaner Body
  • Fig. 337: Oil Flow Diagram
  • Fig. 338: Oil Hole
  • Fig. 339: Oil Temperature Sensor
  • Fig. 340: Oil Pressure Adapter 9879
  • Fig. 341: Oil PSI Gauge
  • Fig. 342: Oil Pressure Adapter 9879
  • Fig. 343: Oil Temperature Sensor
  • Fig. 344: Oil Sender
  • Fig. 345: Oil Pressure Gauge
  • Fig. 346: Oil Pressure Gauge
  • Fig. 347: Oil Sender
  • Fig. 348: Identifying Oil Cooler
  • Fig. 349: Oil Cooler Mounting
  • Fig. 350: Oil Cooler Mounting
  • Fig. 351: Identifying Oil Cooler
  • Fig. 352: Oil Filter
  • Fig. 353: Oil Filter
  • Fig. 354: Oil Level Indicator
  • Fig. 355: Dip Stick
  • Fig. 356: Oil Drain Plug & Oil Pan
  • Fig. 357: Oil Filter
  • Fig. 358: Oil Drain Plug & Oil Pan
  • Fig. 359: Oil Filter
  • Fig. 360: Oil Drain Plug & Oil Pan
  • Fig. 361: Locating A/C Compressor
  • Fig. 362: Using Putty Knife To Loosen Seal Around Oil Pan
  • Fig. 363: Sealer Location
  • Fig. 364: Sealing Oil Pan
  • Fig. 365: Oil Drain Plug & Oil Pan
  • Fig. 366: Tapered Plugs
  • Fig. 367: Gallery Plug
  • Fig. 368: Gallery Plug
  • Fig. 369: Balance Shaft Module & End Caps
  • Fig. 370: Aligning Balance Shaft/Oil Pump Drive Gear And Housing Indicator
  • Fig. 371: Oil Pump Chain And Sprocket To Module Body Marks
  • Fig. 372: Positioning Plastic Tie Strap
  • Fig. 373: Measuring Distance Between Tensioner Body & Guide Shoe
  • Fig. 374: Checking Cylinder Head Bolts For Stretching (Necking)
  • Fig. 375: Aligning Balance Shaft/Oil Pump Drive Gear And Housing Indicator
  • Fig. 376: BSM Mounting Bolts Tightening Sequence
  • Fig. 377: Oil Pump Chain And Sprocket To Module Body Marks
  • Fig. 378: Positioning Plastic Tie Strap
  • Fig. 379: Oil Temperature Sensor
  • Fig. 380: Engine Cover
  • Fig. 381: Resonator, Bolt & Clamp
  • Fig. 382: Oil Temperature Sensor Location
  • Fig. 383: Oil Temperature Sensor Location
  • Fig. 384: Resonator, Bolt & Clamp
  • Fig. 385: Engine Cover
  • Fig. 386: Oil Temperature Sensor & Connector
  • Fig. 387: Oil Temperature Sensor & Connector
  • Fig. 388: Oil Pressure Relief Valve
  • Fig. 389: Oil Pressure Relief Valve
  • Fig. 390: Oil Pressure Relief Valve
  • Fig. 391: Timing Cover Mark & Notch
  • Fig. 392: Vertical Center Line Of Camshaft, Dowel & Cylinder Head
  • Fig. 393: Chain Link & Crankshaft Timing Mark
  • Fig. 394: Vertical Center Line Of Camshaft, Dowel & Cylinder Head
  • Fig. 395: Timing Chain, Sprockets, Tensioner & Guides
  • Fig. 396: Wrench Flats
  • Fig. 397: Camshaft Center Bolt & Sprocket
  • Fig. 398: BSM Timing Chain Marks
  • Fig. 399: Crankshaft Sprocket
  • Fig. 400: Measuring Distance From Tensioner Body To Edge Of Chain Guide
  • Fig. 401: Chain Link & Crankshaft Timing Mark
  • Fig. 402: Sprocket Mark & Painted Link
  • Fig. 403: Piston, Ratchet Arm & Drill Bit
  • Fig. 404: Timing Chain, Sprockets, Tensioner & Guides
  • Fig. 405: Camshaft Center Bolt & Sprocket
  • Fig. 406: Wrench Flats
  • Fig. 407: Crankshaft Sprocket
  • Fig. 408: BSM Timing Chain Marks
  • Fig. 409: Pushing Tensioner Piston Back Into Tensioner Body
  • Fig. 410: BSM Timing Chain Marks
  • Fig. 411: Identifying Six Stud Bolts
  • Fig. 412: Timing Cover Mark & Notch
  • Fig. 413: Accessory Drive Components & Belt Routing
  • Fig. 414: A/C Compressor & Bracket
  • Fig. 415: Timing Chain Cover Pry Points
  • Fig. 416: Timing Chain Cover Removal/Installation
  • Fig. 417: Applying Engine Sealant RTV (Or Equivalent) At Cylinder Head To Block Parting Line
  • Fig. 418: Applying Engine Sealant RTV (Or Equivalent) At Ladder Frame To Block Parting Line
  • Fig. 419: Engine Block And Cylinder Head To Timing Cover Sealant Application Points
  • Fig. 420: Timing Chain Cover Removal/Installation
  • Fig. 421: Accessory Drive Components & Belt Routing
  • Fig. 422: Cylinder Head Cover Bolts
  • Fig. 423: Engine Cover & Air Resonator Clamp
  • Fig. 424: Timing Chain Tensioner Retaining Bolts
  • Fig. 425: Piston, Ratchet Arm & Drill Bit
  • Fig. 426: Timing Chain, Sprockets, Tensioner & Guides
• TABLES
  • CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
  • GENERAL SPECIFICATIONS
  • CYLINDER BLOCK
  • PISTONS
  • PISTON RINGS
  • CONNECTING ROD
  • CRANKSHAFT
  • CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER
  • CAMSHAFT
  • CYLINDER HEAD
  • VALVE SEAT
  • VALVE GUIDE
  • VALVES
  • VALVE MARGIN
  • VALVE STEM TIP
  • VALVE STEM TO GUIDE CLEARANCE
  • VALVE SPRINGS
  • OIL PRESSURE
  • LASH ADJUSTER (TAPPET) NOISE CHART
  • CONNECTING ROD BEARING SELECTION
  • CONNECTING ROD BEARING SELECTION

2014 ENGINE

2.4L - Service Information - Cherokee

DESCRIPTION

DESCRIPTION

The 2.4 Liter (146 cu. in.) Tigershark in-line four cylinder engine is a single over head camshaft with mechanical lash adjusters and four valves per cylinder design. This engine is NOT free-wheeling; meaning that the pistons will contact the valves in the event of a timing chain failure.

The cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2.

Fig. 1: 2.4 Liter (146 Cu. In.) Engine
Courtesy of CHRYSLER GROUP, LLC

The cylinder head is designed with a variable valve actuator assembly (VVAA) that takes the place of a conventional intake camshaft assembly. The cylinder block and cylinder head are cast aluminum. The engine is mounted in the vehicle transversely.

DIAGNOSIS AND TESTING

ENGINE DIAGNOSIS - INTRODUCTION

Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance.

These malfunctions may be classified as either performance (e.g., engine idles rough and stalls) or mechanical (e.g., a strange noise).

Refer to the Engine Mechanical and the Engine Performance diagnostic charts, for possible causes and corrections of malfunctions. Refer to PERFORMANCE and ENGINE MECHANICAL DIAGNOSTIC TABLE for possible causes and corrections of malfunctions. . Refer to FUEL SYSTEM article for the fuel system diagnosis.

Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the following diagnosis:

• Cylinder Compression Pressure Test. Refer to CYLINDER COMPRESSION PRESSURE LEAKAGE .
• Cylinder Combustion Pressure Leakage Test. Refer to CYLINDER COMBUSTION PRESSURE LEAKAGE .
• Engine Cylinder Head Gasket Failure Diagnosis. Refer to CYLINDER HEAD GASKET - DIAGNOSIS AND TESTING .
• Intake Manifold Leakage Diagnosis. Refer to MANIFOLD, INTAKE, DIAGNOSIS AND TESTING .

PERFORMANCE

CONDITION	POSSIBLE CAUSE	CORRECTION
ENGINE WILL NOT START	1. Weak battery.	1. Test battery. Charge or replace as necessary. Refer to DIAGNOSIS AND TESTING .
	2. Corroded or loose battery connections.	2. Clean and tighten battery connections. Apply a coat of light mineral grease to terminals.
	3. Faulty starter.	3. Test starting system. Check for codes. (Refer to DIAGNOSIS AND TESTING )
	4. Faulty coil(s) or control unit.	4. Test and replace as needed. (Refer to Appropriate Diagnostic Information)
	5. Incorrect spark plug gap.	5. Set gap. Refer to SPECIFICATIONS .
	6. Contamination in fuel system.	6. Clean system and replace fuel filter.
	7. Faulty fuel pump.	7. Test fuel pump and replace as needed. (Refer to Appropriate Diagnostic Information)
	8. Incorrect engine timing.	8. Check for a skipped timing belt/chain.
ENGINE STALLS OR IDLES ROUGH	1. Idle speed too low.	1. Test minimum air flow. (Refer to Appropriate Diagnostic Information)
	2. Incorrect fuel mixture.	2. (Refer to Appropriate Diagnostic Information)
	3. Intake manifold leakage.	3. Inspect intake manifold, manifold gasket, and vacuum hoses.
	4. Faulty ignition coil(s).	4. Test and replace as necessary. (Refer to Appropriate Diagnostic Information)
	5. Contamination in Oil Control Valve (OCV). ECK Only	5. Remove OCV and inspect for contamination. Replace OCV if contaminated. ECK Only
ENGINE LOSS OF POWER	1. Dirty or incorrectly gapped plugs.	1. Clean plugs and set gap.
	2. Contamination in fuel system.	2. Clean system and replace fuel filter.
	3. Faulty fuel pump.	3. Test and replace as necessary. (Refer to Appropriate Diagnostic Information)
	4. Incorrect valve timing.	4. Correct valve timing.
	5. Leaking cylinder head gasket.	5. Replace cylinder head gasket.
	6. Low compression.	6. Test compression of each cylinder.
	7. Burned, warped, or pitted valves.	7. Replace valves.
	8. Plugged or restricted exhaust system.	8. Perform exhaust restriction test. Install new parts, as necessary. Refer to DIAGNOSIS AND TESTING .
	9. Faulty ignition coil(s).	9. Test and replace as necessary. (Refer to Appropriate Diagnostic Information)
ENGINE MISSES ON ACCELERATION	1. Dirty or incorrectly gapped spark plugs.	1. Clean spark plugs and set gap.
	2. Contamination in Fuel System.	2. Clean fuel system and replace fuel filter.
	3. Burned, warped, or pitted valves.	3. Replace valves.
	4. Faulty ignition coil(s).	4. Test and replace as necessary. (Refer to Appropriate Diagnostic Information)
ENGINE MISSES AT HIGH SPEED	1. Dirty or incorrect spark plug gap.	1. Clean spark plugs and set gap.
	2. Faulty ignition coil(s).	2. Test and replace as necessary. (Refer to Appropriate Diagnostic Information)
	3. Dirty fuel injector(s).	3. Test and replace as necessary. (Refer to Appropriate Diagnostic Information)
	4. Contamination in fuel system.	4. Clean system and replace fuel filter.

ENGINE MECHANICAL DIAGNOSTIC TABLE

CONDITION	POSSIBLE CAUSES	CORRECTIONS
NOISY VALVES	1. High or low oil level in crankcase.	1. Refer to OIL - STANDARD PROCEDURE .
	2. Thin or diluted oil.	2. Change oil and filter.
	3. Low oil pressure.	3. Check oil pump, if Ok, check rod and main bearings for excessive wear.
	4. Dirt in lash adjusters.	4. Replace as necessary.
	5. Worn rocker arms.	5. Replace as necessary.
	6. Worn lash adjusters	6. Replace as necessary.
	7. Worn valve guides.	7. Inspect the valve guides for wear, cracks or looseness. If either condition exists, replace the cylinder head. Refer to CYLINDER HEAD, REMOVAL .
	8. Excessive runout of valve seats on valve faces.	8. Refer to VALVES, INTAKE AND EXHAUST - STANDARD PROCEDURE .
CONNECTING ROD NOISE	1. Insufficient oil supply.	1. Refer to OIL - STANDARD PROCEDURE .
	2. Low oil pressure.	2. Check oil pump, if OK, check rod and main bearings for excessive wear.
	3. Thin or diluted oil.	3. Change oil and filter.
	4. Excessive bearing clearance.	4. Replace as necessary.
	5. Connecting rod journal out-of-round.	5. Service or replace crankshaft.
	6. Misaligned connecting rods.	6. Replace bent connecting rods.
MAIN BEARING NOISE	1. Insufficient oil supply.	1. Refer to OIL - STANDARD PROCEDURE .
	2. Low oil pressure.	2. Check oil pump, if OK, check rod and main bearings for excessive wear.
	3. Thin or diluted oil.	3. Change oil and filter.
	4. Excessive bearing clearance.	4. Replace as necessary.
	5. Excessive end play.	5. Check thrust washers for wear.
	6. Crankshaft journal out-of round.	6. Service or replace crankshaft.
	7. Loose flywheel or torque converter.	7. Tighten to correct torque

CYLINDER COMPRESSION PRESSURE LEAKAGE

NOTE:

To perform a compression test on a MULTI-AIR equipped engine, the ignition MUST remain in the "key on" position. If the ignition is in the "off" position, the intake valves will not actuate and the result will be no compression.

NOTE:

The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.

NOTE:

Be certain the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.

1. Clean the spark plug recesses with compressed air.
2. Remove the spark plugs and record the cylinder number of each spark plug for future reference.
3. Inspect the spark plug electrodes for abnormal firing indicators such as fouled, hot, oily, etc.
4. Disable the fuel system and perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders.

   NOTE:

   The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present.

7. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder.
8. If one or more cylinders have abnormally low compression pressures, repeat the compression test.

   NOTE:

   If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question.

9. If one or more cylinders continue to have abnormally low compression pressures, perform the cylinder combustion pressure leakage test. Refer to CYLINDER COMBUSTION PRESSURE LEAKAGE .

CYLINDER COMBUSTION PRESSURE LEAKAGE

The combustion pressure leakage test provides an accurate means for determining engine condition.

Combustion pressure leakage testing will detect:

• Exhaust and intake valve leaks (improper seating).
• Leaks between adjacent cylinders or into water jacket.
• Any causes for combustion/compression pressure loss.

1. Check the coolant level and fill as required. DO NOT install the radiator cap.
2. Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.
3. Remove the spark plugs.
4. Remove the oil filler cap.
5. Remove the air cleaner hose.
6. Calibrate the tester according to the manufacturer's instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1, 379 kPa (200 psi) maximum and 552 kPa (80 psi) recommended.
7. Perform the test procedures on each cylinder according to the tester manufacturer's instructions. Set piston of cylinder to be tested at TDC compression. While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the radiator coolant.

All gauge pressure indications should be equal, with no more than 25% leakage.

FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the cylinder.

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART

CONDITION	POSSIBLE CAUSE	CORRECTION
AIR ESCAPES THROUGH THROTTLE BODY	Intake valve bent, burnt, or not seated properly	Inspect valve and valve seat. Reface or replace, as necessary. Inspect valve springs. Replace as necessary.
AIR ESCAPES THROUGH TAILPIPE	Exhaust valve bent, burnt, or not seated properly	Inspect valve and valve seat. Reface or replace, as necessary. Inspect valve springs. Replace as necessary.
AIR ESCAPES THROUGH RADIATOR	Head gasket leaking or cracked cylinder head or block	Remove cylinder head and inspect. Replace defective part
MORE THAN 50% LEAKAGE FROM ADJACENT CYLINDERS	Head gasket leaking or crack in cylinder head or block between adjacent cylinders	Remove cylinder head and inspect. Replace gasket, head, or block as necessary
MORE THAN 25% LEAKAGE AND AIR ESCAPES THROUGH OIL FILLER CAP OPENING ONLY	Stuck or broken piston rings; cracked piston; worn rings and/or cylinder wall	Inspect for broken rings or piston. Measure ring gap and cylinder diameter, taper and out-of-round. Replace defective part as necessary

OIL CONSUMPTION TEST AND DIAGNOSIS

The following diagnostic procedures are used to determine the source of excessive internal oil Consumption, these procedures and tests apply to vehicles with 50, 000 miles or less.

NOTE:

Engine oil consumption may be greater than normal during engine break-in. Repairs should be delayed until vehicle has been driven at least 7, 500 miles.

Severe service (high ambient temperature, short trips, heavy loading, trailer towing, taxi, off-road, or law enforcement use) may result in greater oil consumption than normal.

Sustained high speed driving and high engine RPM operation may result in increased oil consumption.

Failure to comply with the recommended oil type and viscosity rating, as outlined in the Owner's Manual, may impact oil economy as well as fuel economy.

Oil consumption may increase with vehicle age and mileage due to normal engine wear.

NOTE:

Because a few drops of external oil leakage per mile can quickly account for the loss of one quart of oil in a few hundred miles, ensure no external engine oil leaks are present.

• Oil leakage is not the same as oil consumption and all external leakage must be eliminated before any action can be taken to verify and/or correct oil consumption complaints.
• Verify that the engine has the correct oil level dipstick and dipstick tube installed.
• Verify that the engine is not being run in an overfilled condition. Check the oil level 15 minutes after a hot shutdown with the vehicle parked on a level surface. In no case should the level be above MAX or the FULL mark on the dipstick.

OIL CONSUMPTION TEST

1. Check the oil level at least 15 minutes after a hot shutdown.
2. If the oil level is low, top off with the proper viscosity and API service level engine oil. Add one bottle of MOPAR® 4-In-1 Leak Detection Dye into the engine oil.
3. Tamper proof the oil pan drain plug, oil filter, dipstick and oil fill cap.
4. Record the vehicle mileage.
5. Instruct the customer to drive the vehicle as usual.
6. Ask the customer to return to the servicing dealer after accumulating 500 miles, Check the oil level at least 15 minutes after a hot shutdown. If the oil level is half way between the "FULL" and "ADD" mark continue with the next step.
7. Using a black light, re-check for any external engine oil leaks, repair as necessary, if no external engine oil leaks are present, continue with oil consumption diagnosis.

OIL CONSUMPTION DIAGNOSIS

1. Check the positive crankcase ventilation (PCV) system. Make sure the system is not restricted and the PCV valve has the correct part number and correct vacuum source (18-20 in. Hg at idle below 3000 ft. above sea level is considered normal).
2. Perform a cylinder compression test and cylinder leak down test using the standard leak down gauge following manufacturers suggested best practices.

   NOTE:

   Verify the spark plugs are not oil saturated. If the spark plugs are oil saturated and compression is good it can be assumed the valve seals or valve guides are at fault.

3. If one or more cylinders have more than 15% leak down further engine tear down and inspection will be required.

TOP 19 REASONS THAT MAY LEAD TO ENGINE OIL CONSUMPTION

1. Tapered and Out-of-Round Cylinders

   The increased piston clearances permit the pistons to rock in the worn cylinders. While tilted momentarily, an abnormally large volume of oil is permitted to enter on one side of the piston. The rings, also tilted in the cylinder, permit oil to enter on one side. Upon reversal of the piston on each stroke, some of this oil is passed into the combustion chamber.

2. Distorted Cylinders

   This may be caused by unequal heat distribution or unequal tightening of cylinder head bolts. This condition presents a surface which the rings may not be able to follow completely. In this case, there may be areas where the rings will not remove all of the excess oil. When combustion takes place, this oil will be burned and cause high oil consumption.

3. Improper operation of "PCV" system

   The main purpose of the Positive Crankcase Ventilation (PCV) valve is to recirculate blow-by gases back from the crankcase area through the engine to consume unburned hydrocarbons. The PCV system usually has a one way check valve and a make up air source. The system uses rubber hoses that route crankcase blow by gases to the intake manifold. Vacuum within the engine intake manifold pulls the blow by gases out of the crankcase into the combustion chamber along with the regular intake air and fuel mixture.

   The PCV system can become clogged with sludge and varnish deposits and trap blow by gases in the crankcase. This degrades the oil, promoting additional formation of deposit material. If left uncorrected, the result is plugged oil rings, oil consumption, rapid ring wear due to sludge buildup, ruptured gaskets and seals due to crankcase pressurization.

   If equipped with an engine driven vacuum pump, high oil consumption can be caused by unchecked airflow into the pump. This can be caused by anything that opens the vacuum pump intake port up to the atmosphere such as a faulty vacuum pump, hose fitting, hose and brake booster. If there is not a restriction (normally caused by the pump pulling vacuum on the brake booster), then the vacuum pump will pump a high volume of air. This high volume of air will pressurize the crankcase and cause excessive oil burning and oil flow through the PCV system.

4. Worn Piston Ring Grooves

   For piston rings to form a good seal, the sides of the ring grooves must be true and flat - not flared or shouldered. Piston rings in tapered or irregular grooves will not seal properly and, consequently, oil will pass around behind the rings into the combustion chamber.

5. Worn, Broken or Stuck Piston Rings

   When piston rings are broken, worn or stuck to such an extent that the correct tension and clearances are not maintained, this will allow oil to be drawn into the combustion chamber on the intake stroke and hot gases of combustion to be blown down the cylinder past the piston on the power stroke. All of these conditions will result in burning and carbon build up of the oil on the cylinders, pistons and rings.

6. Cracked or Broken Ring Lands

   Cracked or broken ring lands prevent the rings from seating completely on their sides and cause oil pumping. This condition will lead to serious damage to the cylinders as well as complete destruction of the pistons and rings. Cracked or broken ring lands cannot be corrected by any means other than piston replacement.

7. Worn Valve Stems and Guides

   When wear has taken place on valve stems and valve guides, the vacuum in the intake manifold will draw oil and oil vapor between the intake valve stems and guides into the intake manifold and then into the cylinder where it will be burned.

8. Bent or Misaligned Connecting Rods

   Bent or misaligned connecting rods will not allow the pistons to ride straight in the cylinders. This will prevent the pistons and rings from forming a proper seal with the cylinder walls and promote oil consumption. In addition, it is possible that a bearing in a bent connect rod will not have uniform clearance on the connecting rod wrist pin. Under these conditions, the bearing will wear rapidly and throw off an excessive amount of oil into the cylinder.

9. Fuel Dilution

   If raw fuel is allowed to enter the lubrication system, the oil will become thinner and more volatile and will result in higher oil consumption. The following conditions will lead to higher oil consumption;

   • Excess fuel can enter and mix with the oil via a leaking fuel injector
   • Gasoline contaminated with diesel fuel
   • Restricted air intake
   • Excessive idling
10. Contaminated Cooling Systems

    Corrosion, rust, scale, sediment or other formations in the water jacket and radiator will prevent a cooling system from extracting heat efficiently. This is likely to cause cylinder distortion thus leading to higher oil consumption.

11. Oil Viscosity

    The use of oil with a viscosity that is too light may result in high oil consumption. Refer to the vehicle Owner's Manual for the proper oil viscosity to be used under specific driving conditions and/or ambient temperatures.

12. Dirty Engine Oil

    Failure to change the oil and filter at proper intervals may cause the oil to be so dirty that it will promote accumulation of sludge and varnish and restrict oil passages in the piston rings and pistons. This will increase oil consumption; dirty oil by nature is also consumed at a higher rate than clean oil.

13. Crankcase Overfull

    Due to an error in inserting the oil dip stick so that it does not come to a seat on its shoulder, a low reading may be obtained. Additional oil may be added to make the reading appear normal with the stick in this incorrect position which will actually make the oil level too high. If the oil level is so high that the lower ends of the connecting rods touch the oil in the oil pan excessive quantities of oil will be thrown on the cylinder walls and some of it will work its way up into the combustion chamber.

14. Excessively High Oil Pressure

    A faulty oil pressure relief valve may cause the oil pressure to be too high. The result will be that the engine will be flooded with an abnormally large amount of oil in a manner similar to that which occurs with worn bearings. This condition may also cause the oil filter to burst.

15. Aftermarket Performance Chips and Modification

    Increasing performance through the use of performance/power enhancement products to a stock or factory engine will increase the chance of excessive oil consumption.

16. Lugging Engine

    Lugging is running the engine at a lower RPM in a condition where a higher RPM (more power/torque) should be implemented. Especially susceptible on vehicles equipped with a manual transmission. This driving habit causes more stress loading on the piston and can lead to increases in engine oil consumption.

17. Turbocharged Engines

    There is a possibility for PCV "push-over" due to higher crankcase pressure (as compared to naturally aspirated engines) which is normal for turbocharged engines. This condition causes varying amounts of engine oil to enter the intake manifold, charge air cooler and associated plumbing to and from the charge air cooler, also a leaking turbocharger seal will draw oil into the combustion chamber where it will burn (blue smoke from tail pipe may be present) and form carbon deposits which contribute to further oil consumption as they interfere with proper engine function.

18. Restricted Air Intake

    Excessive restriction in the air intake system will increase engine vacuum and can increase oil consumption, an extremely dirty air filter would be one example of this situation.

19. Intake Manifold port seals

    Engines that have a "V" configuration and a "wet valley" (3.3/3.8L) could draw oil into the intake ports due to improper sealing between the intake manifold ports and cylinder head. Causes may include improper torque of intake manifold bolts, corrosion (aluminum intake manifold) and or warped sealing surface.

ENGINE LUBRICATION DIAGNOSTIC TABLE

CONDITION	POSSIBLE CAUSES	CORRECTION
OIL LEAKS	1. Gaskets and O-rings. Misaligned or damaged.	1. Replace as necessary.
	(a) Loose fasteners, broken or porous metal parts.	(a) Tighten fasteners, Repair or replace metal parts.
	2. Crankshaft rear oil seal.	2. Replace rear crankshaft oil seal. Refer to SEAL, CRANKSHAFT OIL, REAR, REMOVAL .
	3. Crankshaft rear oil seal surface. Scratched, nicked or grooved.	3. Polish or replace crankshaft.
	4. Oil pan flange cracked.	4. Replace oil pan. Refer to PAN, OIL, REMOVAL .
	5. Crankshaft front oil seal.	5. Replace front crankshaft oil seal. Refer to SEAL, CRANKSHAFT OIL, FRONT, REMOVAL .
	6. Crankshaft front oil seal surface. Scratched, nicked or grooved.	6. Polish or replace crankshaft.
OIL PRESSURE DROP	1. Low oil level.	1. Check and correct oil level.
	2. Faulty oil pressure switch.	2. Replace switch (Refer to SENSOR, OIL PRESSURE ).
	3. Low oil pressure.	3. Check main bearing clearance. Refer to BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE . 3. Check rod bearing clearance. Refer to BEARING(S), CONNECTING ROD - STANDARD PROCEDURE .
	4. Clogged oil filter.	4. Replace oil filter. Refer to FILTER, ENGINE OIL, REMOVAL .
	5. Worn oil pump.	5. Replace oil pump. Refer to PUMP, ENGINE OIL, REMOVAL .
	6. Thin or diluted oil.	6. Change oil and filter. Refer to OIL - STANDARD PROCEDURE .
	7. Excessive bearing clearance.	7. Replace crankshaft bearings. Refer to BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE . 7. Replace rod bearings. Refer to BEARING(S), CONNECTING ROD - STANDARD PROCEDURE .
	8. Oil pump relief valve stuck.	8. Replace oil pump. Refer to PUMP, ENGINE OIL, REMOVAL .
	9. Oil pump pick-up tube loose, damaged or clogged.	9. Replace oil pump pick-up. .
OIL PUMPING AT RINGS; SPARK PLUGS FOULING	1. Worn or damaged rings.	1. Hone cylinder bores and replace rings. Refer to RING(S), PISTON - STANDARD PROCEDURE .
	2. Carbon in oil ring slots.	2. Replace rings. Refer to ROD, PISTON AND CONNECTING, REMOVAL .
	3. Worn valve guides.	3. Replace cylinder heads. Refer to CYLINDER HEAD, REMOVAL .
	4. Leaking valve guide seals.	4. Replace valve guide seals. Refer to SEAL(S), VALVE GUIDE, REMOVAL .

STANDARD PROCEDURE

DUST COVERS AND CAPS

Fig. 2: Covers/Caps
Courtesy of CHRYSLER GROUP, LLC

Due to the high amounts of failures caused by dust, dirt, moisture and other foreign debris being introduced to the engine during service. Covers or caps are needed to reduce the possible damage that can be caused or created.

Fig. 3: Opening Cover
Courtesy of CHRYSLER GROUP, LLC

Covers over openings will reduce any possibilities for foreign materials to enter the engine systems. Using miller tool (special tool #10368, Set, Universal Protective Cap), Select the appropriated cover needed to the procedure.

ENGINE GASKET SURFACE PREPARATION

Fig. 4: Proper Tool Usage For Surface Preparation
Courtesy of CHRYSLER GROUP, LLC

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.

Never use the following to clean gasket surfaces:

• Metal scraper (1).
• Abrasive pad or paper to clean cylinder block and head.
• High speed power tool with an abrasive pad or a wire brush (2).

Fig. 5: Proper Tool Usage For Surface Preparation
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Only use the following for cleaning gasket surfaces:

• Solvent or a commercially available gasket remover
• Plastic or wood scraper (4).
• High speed power tool with a plastic bristle brush style disc (3).

Sealing surfaces must be free of grease or oil residue. Clean surfaces with Mopar® brake parts cleaner (or equivalent).

FORM-IN-PLACE GASKETS AND SEALERS

NOTE:

All of the sealants mentioned below are not used on every engine, they are listed as general reference guide. See appropriate Service Information for specific sealer usage.

There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results.Do not use form-in-place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket. All sealing surfaces that use form-in-place gaskets and sealers must free of grease or oil. Surfaces should be cleaned with Mopar® brake parts cleaner prior to sealer application. After the sealer is applied, the parts should be assembled in no more than 10 minutes.

There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Engine RTV GEN II, Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties and can not be used in place of the other.

MOPAR® ENGINE RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® GASKET MAKER is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.

MOPAR® BED PLATE SEALANT is a unique (green-in-color) anaerobic type gasket material that is specially made to seal the area between the bed plate and cylinder block without disturbing the bearing clearance or alignment of these components. The material cures slowly in the absence of air when torqued between two metallic surfaces, and will rapidly cure when heat is applied.

MOPAR® GASKET SEALANT is a slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.

SEALER APPLICATION

Mopar® Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing material off the location.

Mopar® Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing and "T" joint locations, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location.

Mopar® Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces.

MEASURING BEARING CLEARANCE USING PLASTIGAGE

Fig. 6: Plastigage Placed In Lower Shell-Typical
Courtesy of CHRYSLER GROUP, LLC

Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage:

1. Remove oil film from surface to be checked. Plastigage is soluble in oil.
2. Place a piece of Plastigage (1) across the entire width of the journal. (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to the proper specifications.
3. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Compare clearance measurements to specs found in engine specifications. Refer to ENGINE SPECIFICATIONS . Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale.

   NOTE:

   Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking.

4. Install the proper crankshaft bearings to achieve the specified bearing clearances.

SPECIFICATIONS

ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

DESCRIPTION	SPECIFICATION
	Metric	Standard
Type	In-Line OHV, SOHC
Number of Cylinders	4
Firing Order	1-3-4-2
Compression Ratio	10.0:1
Displacement	2.4 L	146 cu. in.
Bore	88 mm	3.465 in.
Stroke	97 mm	3.819 in.
Compression Pressure	1172 - 1551 kPa	170 - 225 psi
Max. Variation Between Cylinders	25%

CYLINDER BLOCK

DESCRIPTION	SPECIFICATION
	Metric	Standard
Material	Cast Aluminum
Cylinder Bore Diameter
A	88.000 - 88.010 mm	3.4645 - 3.4649 in.
B	88.010 - 88.020 mm	3.4649 - 3.4653 in.
C	88.020 - 88.030 mm	3.4653 - 3.4657 in.
Cylinder Bore Out-of-Round (Max.)	0.020 mm	0.0008 in.
Cylinder Bore Taper (Max.)	0.028 mm	0.001 in.
Deck Surface Flatness (Max.)	0.0254 mm	.001 in.
Main Bearing Bore Diameter
1	56.000 - 56.006 mm	2.2047 - 2.2049 in.
2	56.006 - 56.012 mm	2.2049 - 2.2051 in.
3	56.012 - 56.018 mm	2.2051 - 2.2054 in.
Main Bearing Bore Diameter Taper (Max.)	0.0082 mm	0.0003 in.

PISTONS

DESCRIPTION	SPECIFICATION
	Metric	Standard
Piston Diameter
A	87.995 - 88.015 mm	3.4644 - 3.4652 in.
B	88.005 - 88.025 mm	3.4648 - 3.4656 in.
C	88.015 - 88.035 mm	3.4652 - 3.4659 in.
Clearance to Bore	(-0.015) - 0.015 mm	(-0.0006) - 0.0006 in.
Weight	345 - 355 grams	12.17 - 12.52 oz.
Land Clearance (Diametrical)	0.60 - 0.73 mm	0.0236 - 0.0287 in.
Piston Length	51.5 mm	2.028 in.
Piston Ring Groove Depth No. 1	3.51 - 3.68 mm	0.1382 - 0.0256 in.
Piston Ring Groove Depth No. 2	4.05 - 4.25 mm	0.1594 - 0.1673 in.
Piston Ring Groove Depth No. 3	2.70 - 2.90 mm	0.1063 - 0.1142 in.

PISTON RINGS

DESCRIPTION	SPECIFICATION
	Metric	Standard
Ring Gap-Top Compression Ring	0.15 - 0.30 mm	0.0059 - 0.0118 in.
Wear Limit	0.8 mm	0.031 in.
Ring Gap-2nd Compression Ring	0.30 - 0.45 mm	0.0118 - 0.0177 in.
Wear Limit	0.8 mm	0.031 in.
Ring Gap-Oil Control Steel Rails	0.20 - 0.70 mm	0.0079 - 0.0276 in.
Wear Limit	1.0 mm	0.039 in.
Ring Side Clearance-Compression Rings	0.03 - 0.07 mm	0.1182 - 0.0028 in.
Wear Limit	0.10 mm	0.004 in.
Ring Side Clearance-Oil Ring Pack	0.06 - 0.15 mm	0.0024 - 0.0059 in.
Ring Width-Top Compression Ring	2.95 - 3.25 mm	0.1161 - 0.1280 in.
Ring Width-2nd Compression Ring	3.45 - 3.75 mm	0.1358 - 0.1476 in.
Ring Width-Oil Ring Pack	2.30 - 2.60 mm	0.0906 - 0.1024 in.
Ring Thickness-Top Compression Ring	1.17 - 1.19 mm	0.0461 - 0.0469 in.
Ring Thickness-2nd Compression Ring	1.17 - 1.19 mm	0.0461 - 0.0469 in.
Ring Thickness-Oil Ring Pack	1.88 - 1.95 mm	0.0740 - 0.0768 in.

CONNECTING ROD

DESCRIPTION	SPECIFICATION
	Metric	Standard
Bearing Clearance	0.032 - 0.060 mm	0.001 - 0.002 in.
Wear Limit	0.070 mm	0.0027 in.
Bore Diameter-Piston Pin	20.974 - 20.985 mm	0.8257 - 0.8261 in.
Bore Diameter-Crankshaft End	51 - 51.015 mm	2.0078 - 2.0084 in.
Side Clearance	0.1 - 0.25 mm	0.0039 - 0.00098 in.
Wear Limit	0.27 mm	0.0106 in.
Weight-Total (Less Bearing)	484 grams	17.07 oz.

CRANKSHAFT

DESCRIPTION	SPECIFICATION
	Metric	Standard
Connecting Rod Journal Diameter
Journal Grade
1	47.966 - 47.972 mm	1.8884 - 1.8886 in.
2	47.960 - 47.966 mm	1.8884 - 1.8881 in.
3	47.954 - 47.960 mm	1.8879 - 1.8881 in.
Rod Journal- Taper (Max)	0.005 mm	0.0001 in.
Main Bearing Journal Diameter
Journal Grade
0	51.985 - 51.988 mm	2.0466 - 2.0467 in.
1	51.982 - 51.985 mm	2.0465 - 2.0466 in.
2	51.979 - 51.982 mm	2.0464 - 2.0465 in.
3	51.976 - 51.979 mm	2.0462 - 2.0464 in.
4	51.973 - 51.976 mm	2.0461 - 2.0462 in.
Journal Out-of-Round (Max.)	0.005 mm	0.0001 in.
Journal Taper (Max.)	0.006 mm	0.0002 in.
End Play	0.05 - 0.25 mm	0.0019 - 0.0098 in.
Wear Limit	0.30 mm	0.0118 in.
Main Bearing Diametrical Clearance	0.028 - 0.048 mm	0.0011 - 0.0018 in.
Main Bearing Diametrical Clearance (Max)	0.058 mm	0.0022 in.

CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER

DESCRIPTION	SPECIFICATION
	Metric	Standard
Cam Bearing Bore
Cam Bearing Bore	24.000 - 24.021 mm	0.9448 - 0.9457 in.

CAMSHAFT

DESCRIPTION	SPECIFICATION
	Metric	Standard
Cam Journal Diameter
Cam Journal Diameter	23.954 - 23.970 mm	0.943 - 0.944 in.
Bearing Clearance - Diametrical
Cam Journal Clearance	0.020 - 0.067 mm	0.0008 - 0.0026 in.
End Play	0.11 - 0.25 mm	0.004 - 0.009 in.
Max Lift @ 0.2mm (0.007 in.) lash
Intake	9.2 mm	0.362 in.
Max Lift @ 0.28mm (0.011 in.) lash
Exhaust	8.42 mm	0.331 in.
Intake Valve Timing
Closes (ABDC)	Control By VVAA
Opens (ATDC)	Control By VVAA
Duration	Control By VVAA
Exhaust Valve Timing
Closes (BTDC)	8.45°
Opens (BBDC)	45°
Duration	216.55°
Valve Overlap @ 0.5mm (0.019 in.) w/ VVT in lock-pin position	18.75°
* All reading in crankshaft degrees at 0.5 mm (0.019 in.) valve lift.

CYLINDER HEAD

DESCRIPTION	SPECIFICATION
	Metric	Standard
Material	Cast Aluminum - Heat treated
Gasket Thickness (Compressed)	0.54 mm	0.021 in.
Valve Tappet Bore I.D.	32.000 - 32.025 mm	1.2598 - 1.2608 in.
Valve Tappet O.D	31.964 - 31.980 mm	1.2584 - 1.2590 in.
Flatness (Head Gasket Surface)	.05 mm	.002 in.

VALVE SEAT

DESCRIPTION	SPECIFICATION
	Metric	Standard
Angle	44.75° - 45.10°
Seat Outer Diameter - Intake	34.45 - 34.61 mm	1.3562 - 1.3625 in.
Seat Outer Diameter - Exhaust	28.04 - 28.20 mm	1.1039 - 1.1102 in.
Runout (Max.)	0.05 mm	0.002 in.
Valve Seat Width
Intake	1.16 - 1.46 mm	0.0456 - 0.0574 in.
Service Limit	2.0 mm	0.079 in.
Exhaust	1.35 - 1.65 mm	0.0531 - 0.0649 in.
Service Limit	2.5 mm	0.098 in.

VALVE GUIDE

DESCRIPTION	SPECIFICATION
	Metric	Standard
Diameter I.D.	5.500 - 5.518 mm	0.2165 - 0.2172 in.
Guide Bore Diameter	10.983 - 11.001 mm	0.432 - 0.4331 in.
Guide Height (spring seat to guide tip)	14.6 - 15.2 mm	0.5748 - 0.5984 in.

VALVES

DESCRIPTION	SPECIFICATION
	Metric	Standard
Face Angle - Intake and Exhaust	45.25° - 45.75°
Head Diameter - Intake	34.9 - 35.1 mm	1.374 - 1.3818 in.
Head Diameter - Exhaust	28.9 - 29.1 mm	1.1377 - 1.1456 in.
Valve Lash
Intake	0.17 - 0.23 mm	0.006 - 0.009 in.
Exhaust	0.27 - 0.33 mm	0.010 - 0.012 in.
Valve Length (Overall)
Intake	113.18 mm	4.455 in.
Exhaust	105.887 mm	4.168 in.
Valve Stem Diameter
Intake	5.465 - 5.480 mm	0.2151 - 0.2157 in.
Exhaust	5.458 - 5.470 mm	0.2148 - 0.2153 in.

VALVE MARGIN

DESCRIPTION	SPECIFICATION
	Metric	Standard
Intake	0.672 mm	0.0264 in.
Exhaust	0.744 mm	0.02929 in.

VALVE STEM TIP

DESCRIPTION	SPECIFICATION
	Metric	Standard
Intake	48.04 mm	1.891 in.
Exhaust	47.99 mm	1.889 in.

VALVE STEM TO GUIDE CLEARANCE

DESCRIPTION	SPECIFICATION
	Metric	Standard
Intake	0.020 - 0.053 mm	0.0008 - 0.0021 in.
Max. Allowable	0.076 mm	0.003 in.
Exhaust	0.030 - 0.060 mm	0.0012 - 0.0024 in.
Max. Allowable	0.101 mm	0.004 in.

VALVE SPRINGS

DESCRIPTION	SPECIFICATION
	Metric	Standard
Free Length (Approx.)	47.0 mm	1.850 in.
Nominal Force (Valve Closed)	179.5 N ± 9 @ 35.0 mm	40.35 lbs. @ 1.38 in.
Nominal Force (Valve Open)	364.8 N ± 17 N @ 29.25 mm	82.01 lbs. ± 3.82 lbs. @ 1.152 in.
Installed Height	35.00 mm	1.378 in.
Number of Coils	8.5 ± 0.1
Wire Diameter	2.90 mm ± 0.03	0.114 in ± 0.001 in.

OIL PRESSURE

DESCRIPTION	SPECIFICATION
	Metric	Standard
At Curb Idle Speed*	25 kPa	4 psi. min.
At 3000 RPM	170 - 550 kPa	25 - 80 psi.
CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 RPM.

TORQUE SPECIFICATIONS

DESCRIPTION	N.m	Ft. Lbs.	In. Lbs.
AIR BOX LID TO LOWER A/BOX	4		35
ALTERNATOR TO ALTERNATOR BRACKET & ENGINE BLOCK	23	17
BALANCE SHAFT MODULE	Refer to PUMP, ENGINE OIL - INSTALLATION Procedure
BALANCE SHAFT CHAIN GUIDE TO LADDER	12	-	106
BATTERY POSITIVE TO TERMINAL POST	9	-	80
B+ CABLE TO STARTER	10	-	89
Camshaft Bearing Cap-Bolts CAMSHAFT BEARING CAPS
FRONT EXHAUST CAMSHAFT CAP	15	11	-
REMAINING EXHAUST CAMSHAFT CAPS	9.5	-	85
CAMSHAFT SPROCKET	59	44	-
CONNECTING ROD CAPS	20 + 90°	15 + 90°	-
COOLANT TEMPERATURE SENSOR	50	36	-
CRANKSHAFT MAIN BEARING CAPS	Refer to CRANKSHAFT - INSTALLATION Procedure
CRANKSHAFT POSITION SENSOR TO CYLINDER BLOCK	9		80
CRANKSHAFT DAMPER	210	155	-
CYLINDER HEAD	Refer to CYLINDER HEAD - INSTALLATION Procedure
DUCT TO FEM	4		35
ENGINE COVER BALL STUD TO VALVE COVER	3	-	27
ENGINE OIL COOLER SHIELD TO COOLER	8		71
ENGINE OIL COOLER TO ADAPTOR	49	36	-
ENGINE OIL COOLER TUBE TO CYLINDER BLOCK	25	18	-
ENGINE SUPPORT BRACKET	Refer to ENGINE - INSTALLATION Procedure
ENGINE TO TRANSMISSION	50	37	-
EXHAUST MANIVERTER TO CYLINDER HEAD	34	25	-
EXHAUST MANIFOLD HEAT SHIELD	12		105
EXHAUST PIPE TO OIL PAN	25	18
FLEX PLATE TO CRANKSHAFT	95	70	-
HEATER RETURN TO LEFT (TRANS) MOUNT BRACKET	8		71
IGNITION COILS	8	-	71
INTAKE MANIFOLD TO CYLINDER HEAD	12	9	-
INTAKE MANIFOLD SILENCER COVER	2.5	-	22
INTAKE MANIFOLD SUPPORT TO PTU BRACKET	12	-	106
INTERMEDIATE SHAFT BRACKET TO ENGINE BLOCK	55	41
KNOCK SENSOR TO ENGINE BLOCK	28	21
LADDER FRAME TO BLOCK	Refer to FRAME, LADDER - INSTALLATION Procedure
LEFT ENGINE MOUNT TO FRAME RAIL	105	77	-
LEFT ENGINE MOUNT TO STRUT TOWER	64	47	-
LEFT ENGINE MOUNT TO ADAPTER BRACKET	157	115	-
MANIVERTER TO SUPPORT BRACKET	20	15
MASS AIRFLOW SENSOR TO AIRBOX LID	4		35
MULTIAIR FILL PORT PLUG TO CYLINDER HEAD COVER	21	15	-
OIL COOLER TO ADAPTOR	49	36	-
OIL COOLER TO BLOCK	49	36	-
OIL FILTER	14	10	-
OIL JET FASTENER	12	-	105
OIL LEVEL INDICATOR TUBE TO CYLINDER BLOCK	22	16
OIL PAN TO BLOCK
M6 BOLTS	12	-	105
M8 BOLTS	22	-	195
OIL PAN DRAIN PLUG	40	30	-
OIL PRESSURE SENSOR	48	35	-
OIL TEMPERATURE SENSOR	48	35	-
OXYGEN SENSOR	50	37	-
PCV VALVE	135	100	-
RIGHT ENGINE MOUNT TO FRAME RAIL	70	52	-
RIGHT ENGINE MOUNT TO STRUT TOWER	65	48	-
RIGHT ENGINE MOUNT TO TIMING COVER	75	55	-
SPARK PLUGS	27	20	-
STARTER MOTOR TO BLOCK	36	27	-
TENSIONER TO ACCESSORY DRIVE BRACKET	26	19
THROTTLE BODY BRACKET TO THROTTLE BODY	12		106
THROTTLE BODY BRACKET TO THERMOSTAT HOUSING	9		80
THROTTLE BODY SUPPORT TO CYLINDER HEAD	24	18
THROTTLE BODY TO INTAKE MANIFOLD	5.4		48
TIMING CHAIN COVER
M10 BOLTS	65	48	-
M6 BOLTS	9	-	80
M8 BOLTS	26	19	-
TIMING CHAIN TENSIONER ASSEMBLY	12	-	105
TIMING CHAIN GUIDE	12	-	106
TORQUE STRUT (REAR ENGINE MOUNT) TO CRADLE *See Note	150	111	-
TORQUE STRUT (REAR ENGINE MOUNT) TO PIVOT BRACKET	220	162	-
TORQUE STRUT BRACKET TO CRADLE	73	54	-
TRANSMISSION TO ENGINE	50	37	-
VACUUM PUMP TO CYLINDER HEAD	23	17
VALVE COVER TO CYLINDER HEAD	10	-	89
WATER INLET TUBE TO CYLINDER BLOCK	24	18

NOTE:

* READ THE TORQUE VALUE AT THE NUT ONLY.

REMOVAL

REMOVAL

CAUTION:

If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.

1. Release the fuel pressure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .

   Fig. 7: Engine Cover & Pins
   Courtesy of CHRYSLER GROUP, LLC

2. Remove the engine cover (1) from the ball studs (2).
3. Secure the steering wheel.

   Fig. 8: Lower Coupling Bolt
   Courtesy of CHRYSLER GROUP, LLC

4. Remove the steering coupler bolt (3). Position the shaft out of the way.
5. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
6. Drain the coolant.
7. Lower the vehicle.

   Fig. 9: Battery Cover
   Courtesy of CHRYSLER GROUP, LLC

8. Remove the battery cover (1)

   .

   Fig. 10: Battery & Cables
   Courtesy of CHRYSLER GROUP, LLC

9. Disconnect the battery connectors (1 & 3).
10. Remove the battery (2). Refer to BATTERY, REMOVAL .

    Fig. 11: Powertrain Control Module Electrical Connectors & Nuts
    Courtesy of CHRYSLER GROUP, LLC

11. Remove the PCM. Refer to MODULE, POWERTRAIN CONTROL, REMOVAL .

    Fig. 12: Battery Tray, PCM Mount & Bolts
    Courtesy of CHRYSLER GROUP, LLC

12. Remove the PCM mount bracket bolts (2 & 4). Remove the bracket (3) from the battery tray (1).
13. Disconnect the heater core supply and return hoses at the fittings nearest the thermostat housing.
14. Remove the bolt securing the heater supply pipe at the left engine mount bracket.
15. Disconnect the heater hose at the thermostat outlet connector.
16. Separate the wire harness retainers at the transmission bell housing.
17. Loosen the upper starter bolt completely.

    NOTE:

    The upper bolt will not back out completely due to lack of clearance. Leave the bolt in the bell housing.

18. Release the two harness retainers that are secured to the PDC bracket.
19. Remove the PDC. Refer to CENTER, POWER DISTRIBUTION (PDC), REMOVAL .
20. Unlock and separate engine harness connectors at the front of the battery tray.
21. Release the connectors from the battery tray.

    Fig. 13: Removing/Installing Inlet Assembly
    Courtesy of CHRYSLER GROUP, LLC

22. Remove the fresh air hose from valve cover.
23. Remove the air cleaner inlet snorkel push pins (3). Remove the inlet assembly (1).

    Fig. 14: Upper Close Out Panel Cover Components
    Courtesy of CHRYSLER GROUP, LLC

24. Remove the radiator upper closeout panel push pins (2).
25. Remove the radiator upper closeout panel bolts (4).
26. Remove the radiator upper closeout panel bolts (3).

    Fig. 15: Front Fascia Assembly
    Courtesy of CHRYSLER GROUP, LLC

27. Remove the front fascia assembly (1). Refer to FASCIA, FRONT, REMOVAL .
28. Remove the radiator inlet hose clamp.
29. Remove the radiator outlet hose clamp.
30. Remove the oil cooler inlet and outlet hose clamps at the tubes.
31. Remove the serpentine belt.

    Fig. 16: Removing/Installing Generator
    Courtesy of CHRYSLER GROUP, LLC

32. Open the 12 volt protective cover (3).
33. Remove the generator 12 volt connector nut (1).
34. Disconnect the generator fielding connector (4).
35. Reposition the harness (2) aside.
36. Remove the generator bolts.
37. Remove the generator (5).

    Fig. 17: Air Conditioning Compressor Electrical Connectors
    Courtesy of CHRYSLER GROUP, LLC

38. Disconnect the air conditioning compressor electrical connectors (1).

    Fig. 18: Air Conditioning Compressor & Bolts
    Courtesy of CHRYSLER GROUP, LLC

39. Remove the air conditioning compressor bolts (1). Position the compressor (2) aside and secure with a strap.

    NOTE:

    The is no need to separate the lines from the compressor.

    Fig. 19: Resonator, Clamp & Connector
    Courtesy of CHRYSLER GROUP, LLC

40. Loosen the snorkel to throttle body clamp (2).
41. Disconnect the IAT sensor (3).

    Fig. 20: Resonator, Bolt & Clamp
    Courtesy of CHRYSLER GROUP, LLC

42. Loosen the snorkel clamp (1).
43. Remove the air intake snorkel bolt (2) and remove the snorkel (3).

    Fig. 21: Foam Insulator, Fuel Line & Purge Line
    Courtesy of CHRYSLER GROUP, LLC

44. Disconnect the fuel line (1) and the purge line (2) quick connects.
45. Disconnect the MAP sensor connector.
46. Disconnect the oil temperature sensor connector.

    Fig. 22: Hose Assembly & Hot Bottle Return Pipe Bolts
    Courtesy of CHRYSLER GROUP, LLC

47. Remove the coolant reservoir return hose bolts (1). Disconnect both ends of the pipe. Remove the hose assembly (2).
48. Release the engine wire harness retainers.
49. Disconnect the transmission cooler hoses at the transmission fittings. Install plugs to limit the fluid loss.
50. Raise and support the vehicle.
51. Remove the forward skid plate fasteners (if equipped).
52. Remove the rearward skid plate fasteners (if equipped)
53. Remove both skid plates (if equipped)
54. Remove the front wheels.
55. Remove the left wheel well liner.
56. Remove the bolt holding the windshield washer reservoir to the battery tray.
57. Release the retainer from the harness at the bottom of the battery tray.
58. Remove the battery tray. Refer to TRAY, BATTERY, REMOVAL .
59. Raise and support the vehicle.
60. Remove the left and right axle shafts. Refer to REMOVAL .
61. Remove the left and right wheel well liners.
62. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
63. Remove the upper radiator hose.
64. Remove the lower radiator hose.
65. Remove the front tow hooks. Refer to HOOK(S), TOW, FRONT, REMOVAL .
66. Remove the radiator fan assembly. Refer to FAN, COOLING, REMOVAL .

    Fig. 23: Crossmember To Fascia Support Beams Bracket Retaining Bolts
    Courtesy of CHRYSLER GROUP, LLC

67. Remove the four bracket retaining bolts (1) from the cross member to fascia support beams bracket, then remove the bracket.

    Fig. 24: Lower Bumper Reinforcements & Fasteners
    Courtesy of CHRYSLER GROUP, LLC

68. Remove the fasteners (2) securing the lower bumper reinforcement (1) and front fascia support beams to the frame/front end module.

    Fig. 25: Front Fascia Support Beams
    Courtesy of CHRYSLER GROUP, LLC

69. Remove the front fascia support beams (1).

    Fig. 26: Rear Engine Isolator To Engine Mount Bracket Bolt
    Courtesy of CHRYSLER GROUP, LLC

70. Remove the rear engine mount to bracket through bolt (4) and nut (2)

    .

71. Remove the rear engine mount to crossmember through bolt (1).
72. Reposition the engine forward to allow the mount to be removed from the pocket past the engine bracket (3).
73. Remove the front suspension crossmember. Refer to CROSSMEMBER, FRONT SUSPENSION, REMOVAL .
74. Remove the exhaust cross-under pipe assembly. Refer to PIPE, EXHAUST CROSSUNDER, REMOVAL .

    Fig. 27: Transaxle & Ground Cable
    Courtesy of CHRYSLER GROUP, LLC

75. Remove the bolt holding the ground cable (2) to transaxle and separate cable from transaxle (1).
76. Remove the bolt holding the ground strap to left frame rail.
77. Disconnect the shifter cables from the transmission. Refer to CABLE, GEARSHIFT CONTROL, REMOVAL .
78. Reposition the main wire harness away from the engine.

    Fig. 28: Adapter, Engine Support Cradle, Power Train Dolly & Safety Straps
    Courtesy of CHRYSLER GROUP, LLC

79. Raise and position the vehicle height to allow Power Train Dolly (special tool #6135, Dolly, Power Train) (3) and Engine Support Cradle (special tool #6710A, Cradle, Engine Support) (2) to be installed under the engine/transaxle assembly.
80. Loosen the cradle engine mounts to allow movement for positioning onto the engine locating holes on the engine block and oil pan rail. Place Adapter (special tool #6848-3, Adapter) (1) on the front post and align to the oil pan mounting stud. Lower the vehicle and position cradle until the engine is resting on the posts. Tighten the post mounts to the cradle frame. Secure the engine/transaxle assembly to the dolly/cradle with safety straps (4).
81. Remove the left engine mount. Refer to INSULATOR, ENGINE MOUNT, LEFT, REMOVAL .
82. Remove the right engine mount. Refer to INSULATOR, ENGINE MOUNT, RIGHT .
83. Slowly raise the vehicle to allow the it to clear the powertrain assembly.

    CAUTION:

    Make sure that all components are clear of obstructions while raising the vehicle off of the powertrain assembly.

84. On vehicles equipped with an automatic transaxle, remove torque converter bolts.

    Fig. 29: Removing/Installing Bell-Housing
    Courtesy of CHRYSLER GROUP, LLC

85. Affix a chain to the transmission mount bracket to be used as a lifting point.
86. Using an engine hoist, remove the slack from the lifting chain.
87. Remove the bell-housing bolts (2).
88. Separate engine (1) and transmission (2).

INSTALLATION

INSTALLATION

Fig. 30: Removing/Installing Bell-Housing
Courtesy of CHRYSLER GROUP, LLC

1. Push the bell housing against the engine block until the guide pins engage.
2. Install transmission bolts (2). Refer to SPECIFICATIONS .
3. On vehicles equipped with an automatic transaxle, install torque converter bolts.

   Fig. 31: Flexplate-To-Torque Converter Bolts
   Courtesy of CHRYSLER GROUP, LLC

4. Through the access door opening, Install the bolts (1) to hold the flexplate to the torque converter. Refer to SPECIFICATIONS . Apply Mopar® Lock & Seal Adhesive or replace the bolts on the threads. Rotate the crankshaft to bring each set of bolts into view through the access door.

   Fig. 32: Access Door In Splash Shield
   Courtesy of CHRYSLER GROUP, LLC

5. Install the access door in the splash shield on the bellhousing.
6. Slowly lower the vehicle to allow it to clear the powertrain assembly.

   CAUTION:

   Make sure that all components are clear of obstructions while raising the vehicle off of the powertrain assembly.

7. Install the left engine mount. Refer to INSULATOR, ENGINE MOUNT, LEFT, INSTALLATION .
8. Install the right engine mount. Refer to INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION .
9. Remove the Power Train Dolly.
10. Connect the shifter cables from the transmission.

    Fig. 33: Transaxle & Ground Cable
    Courtesy of CHRYSLER GROUP, LLC

11. Install the bolt holding the ground cable (2) to transaxle (1). Refer to SPECIFICATIONS .
12. Install the exhaust cross-under pipe assembly. Refer to PIPE, EXHAUST CROSSUNDER, INSTALLATION .
13. Install the front suspension crossmember. Refer to CROSSMEMBER, FRONT SUSPENSION, INSTALLATION .
14. Install the rear engine mount. Refer to INSULATOR, ENGINE MOUNT, REAR, INSTALLATION .

    Fig. 34: Front Fascia Support Beams
    Courtesy of CHRYSLER GROUP, LLC

15. Install the front fascia support beams (1). Refer to FRAME, SPECIFICATIONS .

Fig. 35: Lower Bumper Reinforcements & Fasteners
Courtesy of CHRYSLER GROUP, LLC

17. Install the fasteners (2) securing the lower bumper reinforcement (1) and front fascia support beams to the frame/front end module. Refer to FRAME, SPECIFICATIONS .

    .

18. Install the radiator fan assembly. Refer to FAN, COOLING, INSTALLATION .

    .

19. Install the front tow hooks. Refer to HOOK(S), TOW, FRONT, INSTALLATION .
20. Install the upper radiator hose.
21. Install the lower radiator hose.
22. Install the belly pan. Refer to BELLY PAN .
23. Install the left and right axle shafts. Refer to INSTALLATION .

    Fig. 36: Windshield Washer Reservoir-To-Battery Tray Bolt
    Courtesy of CHRYSLER GROUP, LLC

24. Install the bolt (2) holding the windshield washer reservoir to the battery tray.
25. Insert the harness retainer to the battery tray.
26. Install the left wheel well liner.
27. Install both skid plates (if equipped).
28. Install the forward skid plate fasteners (if equipped).
29. Install the rearward skid plate fasteners (if equipped).
30. Install the front wheels.
31. Install the engine wire harness retainers.
32. Connect the transmission cooler hoses at the transmission fittings.

    Fig. 37: Hose Assembly & Hot Bottle Return Pipe Bolts
    Courtesy of CHRYSLER GROUP, LLC

33. Install the coolant reservoir return hose assembly (2) Install the hose bolts (1). Connect both ends of the pipe.
34. Connect the MAP sensor connector.
35. Connect the oil temperature sensor connector.

    Fig. 38: Foam Insulator, Fuel Line & Purge Line
    Courtesy of CHRYSLER GROUP, LLC

36. Install the fuel injector insulator (3).
37. Connect the fuel line (1) and the purge line (2) quick connects.

    Fig. 39: Resonator, Bolt & Clamp
    Courtesy of CHRYSLER GROUP, LLC

38. Install the air intake snorkel (3) and snorkel bolt (2). Refer to ENGINE SPECIFICATIONS .
39. Tighten the snorkel clamp (1).

    Fig. 40: Resonator, Clamp & Connector
    Courtesy of CHRYSLER GROUP, LLC

40. Connect the IAT sensor (3).
41. Tighten the snorkel to throttle body clamp (2).

    Fig. 41: Air Conditioning Compressor & Bolts
    Courtesy of CHRYSLER GROUP, LLC

42. Install the air conditioning compressor (2).
43. Install the compressor bolts (1). Refer to SPECIFICATIONS .

    Fig. 42: Air Conditioning Compressor Electrical Connectors
    Courtesy of CHRYSLER GROUP, LLC

44. Disconnect the air conditioning compressor electrical connectors (1).

    Fig. 43: Generator, Bolts & Bracket
    Courtesy of CHRYSLER GROUP, LLC

45. Install the generator (2) to the bracket (3).
46. Install the generator bolts (1). Refer to ENGINE SPECIFICATIONS .

    Fig. 44: Removing/Installing Generator
    Courtesy of CHRYSLER GROUP, LLC

47. Install the generator electrical connectors (1 & 2).
48. Install the nut (1). Tighten to 12 N.m (106 in. lbs.).
49. Close the 12 volt protective cover (3).
50. Install the serpentine belt.
51. Install the radiator inlet hose clamp.
52. Install the radiator outlet hose clamp.
53. Install the oil cooler inlet and outlet hose clamps at the tubes.

    Fig. 45: Front Fascia Assembly
    Courtesy of CHRYSLER GROUP, LLC

54. Install the front fascia. Refer to FASCIA, FRONT, INSTALLATION .

    Fig. 46: Upper Close Out Panel Cover Components
    Courtesy of CHRYSLER GROUP, LLC

55. Install the radiator upper closeout panel push pins (2).
56. Install the radiator upper closeout panel bolts (4).
57. Install the radiator upper closeout panel bolts (3).

    Fig. 47: Removing/Installing Inlet Assembly
    Courtesy of CHRYSLER GROUP, LLC

58. Install the fresh air hose to the valve cover.
59. Install the air cleaner inlet assembly (1). Install the inlet snorkel push pins (3).
60. Install the inline connectors at the front of the battery tray.
61. Lock the engine harness connectors at the front of the battery tray.
62. Install the PDC. Refer to CENTER, POWER DISTRIBUTION (PDC), INSTALLATION .

    .

63. Install the two harness retainers that are secured to the PDC bracket.
64. Separate the wire harness retainers at the transmission bell housing.
65. Connect the heater core supply and return hoses at the fittings nearest the thermostat housing.

    Fig. 48: Battery Tray, PCM Mount & Bolts
    Courtesy of CHRYSLER GROUP, LLC

66. Install the PCM bracket (3) to the battery tray (1). Install the PCM mount bracket bolts (2 & 4).
67. Install the PCM. Refer to MODULE, POWERTRAIN CONTROL, INSTALLATION .

    .

    Fig. 49: Battery & Cables
    Courtesy of CHRYSLER GROUP, LLC

68. Install the battery (2).
69. Connect the battery connectors (1 & 3).

    Fig. 50: Battery Cover
    Courtesy of CHRYSLER GROUP, LLC

70. Install the battery cover (1)
71. Fill the cooling system.

    Fig. 51: Lower Coupling Bolt
    Courtesy of CHRYSLER GROUP, LLC

72. Install the steering coupler bolt (3). Refer to SPECIFICATIONS .

    Fig. 52: Engine Cover & Pins
    Courtesy of CHRYSLER GROUP, LLC

73. Install the engine cover (1) to the ball studs (2).
74. Add engine oil and transmission fluid as necessary.
75. Start engine, check for leaks.
76. Bleed the cooling system. Refer to STANDARD PROCEDURE .

SPECIAL TOOLS

SPECIAL TOOLS

click to open the image	10224 - Adapter, Valve Spring (Originally Shipped In Kit Number(s) 10223.)
click to open the image	10368 - Set, Universal Protective Cap
click to open the image	7700-A - Tester, Cooling System
click to open the image	8189 - Guide Pins (Originally Shipped In Kit Number(s) 8180, 8180CC, 8263, 8263CC.)
click to open the image	9506 - Installer, Oil Seal (Originally Shipped In Kit Number(s) 9610, 9970.)
click to open the image	9509 - Installer, Oil Seal (Originally Shipped In Kit Number(s) 9610, 9970.)
click to open the image	9703 - Pin, Tensioner (Originally Shipped In Kit Number(s) 9610, 9970.)
click to open the image	9706 - Installer, Crankshaft Rear Oil Seal (Originally Shipped In Kit Number(s) 9610, 9970.)
click to open the image	9707 - Holder, Vibration Damper (Originally Shipped In Kit Number(s) 9610, 9970.)
click to open the image	9879 - Adapter, Oil Pressure Test (Originally Shipped In Kit Number(s) 9998.)
click to open the image	C-119 - Cylinder Indicator
click to open the image	C-3339A - Set, Dial Indicator (Originally Shipped In Kit Number(s) 9202.)
click to open the image	C-3685-A - Bloc-Chek Kit
click to open the image	C-385 - Compressor, Piston
click to open the image	C-4171 - Driver Handle, Universal (Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC, 9300A-CAN.)
click to open the image	C-4597 - Socket, Oil Pressure
click to open the image	MD998772A - Compressor, Valve Spring (Originally Shipped In Kit Number(s) 8678, 8853, 8854.)
click to open the image	10288 - Pliers, Hose Clamp
click to open the image	10259B - Compressor, MultiAir® Spring
click to open the image	8534B - Fixture, Driveline Support (Originally Shipped In Kit Number(s) 8534, 8534B, 8849, 9565.)

AIR INTAKE SYSTEM

AIR CLEANER

REMOVAL

REMOVAL

Fig. 53: Air Cleaner Housing Cover Screws
Courtesy of CHRYSLER GROUP, LLC

1. Remove two screws (1) from the air cleaner housing cover.

   Fig. 54: Air Cleaner Housing Cover & Air Filter
   Courtesy of CHRYSLER GROUP, LLC

2. Lift the air cleaner housing cover (1).
3. Pull the cover to disengage the rear tabs.
4. Remove the air filter element (2).

INSTALLATION

INSTALLATION

Fig. 55: Air Cleaner Housing Cover & Air Filter
Courtesy of CHRYSLER GROUP, LLC

1. Install the air filter element (2) into the air cleaner housing.
2. Install the cover (1) so that the rear tabs insert into the lower air box.

   Fig. 56: Air Cleaner Housing Cover Screws
   Courtesy of CHRYSLER GROUP, LLC

3. Seat the cover onto the housing and tighten the two housing cover screws (1).

BODY, AIR CLEANER

REMOVAL

REMOVAL

Fig. 57: Resonator, Bolt & Clamp
Courtesy of CHRYSLER GROUP, LLC

1. Loosen the clamp (1) and disengage the hose from the resonator (3).
2. Remove the make up air hose from the air cleaner body.

   Fig. 58: Removing/Installing Air Cleaner Body
   Courtesy of CHRYSLER GROUP, LLC

3. Lift the air cleaner body (1) straight up off of the locating pins at frame rail (2).

INSTALLATION

INSTALLATION

Fig. 59: Removing/Installing Air Cleaner Body
Courtesy of CHRYSLER GROUP, LLC

1. Install the air cleaner body (1) straight down on the locating pins.

   Fig. 60: Resonator, Bolt & Clamp
   Courtesy of CHRYSLER GROUP, LLC

2. Install the hose to the resonator and tighten the clamp (1) to 4 N.m (35 in. lbs.).
3. Install the make up air hose.

RESONATOR, AIR CLEANER

REMOVAL

REMOVAL

1. Remove the engine cover.

   Fig. 61: Resonator, Clamp & Connector
   Courtesy of CHRYSLER GROUP, LLC

2. Disconnect the electrical connector (2) from the Inlet Air Temperature (IAT) sensor.
3. Loosen the clamp (2) that secures the resonator (1) to the throttle body inlet.

   Fig. 62: Resonator, Bolt & Clamp
   Courtesy of CHRYSLER GROUP, LLC

4. Loosen the clamp (1) and remove the air inlet hose from the resonator (3).
5. Remove the bolt (2) that secures the resonator to the cylinder head cover.
6. Pull the resonator (3) up while tipping the top edge of the resonator slightly forward and remove from the vehicle.

INSTALLATION

INSTALLATION

Fig. 63: Resonator, Bolt & Clamp
Courtesy of CHRYSLER GROUP, LLC

1. Position the resonator (3) between the forward edge of the cowl and the cylinder head cover. Align the openings with the throttle body intake and the airbox flex hose.
2. Install the bolt. Tighten the bolt to 9 N.m (81 in. lbs.).
3. Tighten the hose clamp (1).

   Fig. 64: Resonator, Clamp & Connector
   Courtesy of CHRYSLER GROUP, LLC

4. Tighten the clamp (2) at the resonator outlet (1).
5. Connect the IAT connector (3).
6. Install the engine cover. Push downward to make sure all four rubber mounts are secure.

CYLINDER HEAD

DESCRIPTION

DESCRIPTION

Fig. 65: Cylinder Head, Valves & Springs
Courtesy of CHRYSLER GROUP, LLC

The MultiAir, aluminum cylinder head (7) contains an exhaust camshaft and a variable valve actuator assembly (VVAA) with four valves per cylinder. The valves are arranged in two in-line banks. The exhaust valves (6) face toward the front of the vehicle. The intake valves face the dash panel (5). The valvetrain uses roller rocker arms with hydraulic lifters. The cylinder head incorporates pressed in powdered metal valve guides. The valve guides are not serviceable. The cylinder head is sealed to the block using a multi-layer steel head gasket and retaining bolts. The valves contain a stem seal (4), spring (3), spring retainer (2) and three groove keepers (1).

Integral oil galleries provide lubrication passages to the VVAA, camshaft, and valve mechanisms.

DIAGNOSIS AND TESTING

CYLINDER HEAD GASKET

A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket.

Possible indications of the cylinder head gasket leaking between adjacent cylinders are:

• Loss of engine power
• Engine misfiring
• Poor fuel economy

Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:

• Engine overheating
• Loss of coolant
• Excessive steam (white smoke) emitting from exhaust
• Coolant foaming

CYLINDER-TO-CYLINDER LEAKAGE TEST

To determine if an engine cylinder head gasket is leaking between the cylinders located next to each other, follow the procedures in Cylinder Compression Pressure Test. Refer to CYLINDER COMPRESSION PRESSURE LEAKAGE . An engine cylinder head gasket leaking between the cylinders will result in approximately a 50 - 70% reduction in compression pressure.

CYLINDER-TO-WATER JACKET LEAKAGE TEST

WARNING:

USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRESSURE CAP REMOVED.

VISUAL TEST METHOD

With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens.

If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.

COOLING SYSTEM TESTER METHOD

Fig. 66: Cooling System Pressure Tester - 7700-A
Courtesy of CHRYSLER GROUP, LLC

WARNING:

WITH THE COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP BY CONTINUOUS ENGINE OPERATION MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT THE PRESSURE TO EXCEED 138 kPa (20 psi).

Install Cooling System Tester (special tool #7700-A, Tester, Cooling System) or equivalent to pressure cap neck. Start the engine and observe the tester's pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.

CHEMICAL TEST METHOD

Fig. 67: Bloc-Chek-Kit - C-3685-A
Courtesy of CHRYSLER GROUP, LLC

Combustion leaks into the cooling system can also be checked by using a (special tool #C-3685-A, Bloc-Chek Kit) or equivalent. Perform the test following the procedures supplied with the tool kit.

HYDRAULIC LASH ADJUSTER

A tappet-like noise may be produced from several items. Check the following items.

1. Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy.
2. Insufficient running time after rebuilding the cylinder head. Low speed running up to one hour may be required.
3. Turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature.
4. Low oil pressure.
5. The oil screen in cylinder head or the oil passage to the cylinder head is plugged with debris.
6. Air ingested into oil due to broken or cracked oil pump pick-up.
7. Worn valve guides.
8. Rocker arm ears contacting valve spring retainer.
9. Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system.
10. Oil leak or excessive cam bore wear in the cylinder head.
11. Faulty lash adjuster.

• Check lash adjusters for "sponginess" while installed in the cylinder head and cam lobe at base circle. Depress part of rocker arm over the adjuster. Normal adjusters should feel firm when pressed quickly. When pressed very slowly, lash adjusters should collapse.
• Remove suspected lash adjusters, and replace.
• Before installation, make sure adjusters are full of oil. This can be verified by little plunger travel when lash adjuster is depressed quickly.

REMOVAL

REMOVAL

1. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
2. Disconnect and isolate the battery negative cable.
3. Remove the engine cover.

   Fig. 68: Resonator, Bolt & Clamp
   Courtesy of CHRYSLER GROUP, LLC

4. Remove the resonator (3). Refer to RESONATOR, AIR CLEANER, REMOVAL .
5. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL .
6. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
7. Drain the cooling system. Refer to STANDARD PROCEDURE .

   Fig. 69: Cylinder Head Cover Bolts
   Courtesy of CHRYSLER GROUP, LLC

8. Remove the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL .

   Fig. 70: Exhaust Manifold Bolts
   Courtesy of CHRYSLER GROUP, LLC

9. Remove the maniverter. Refer to MANIFOLD, EXHAUST, REMOVAL.

   Fig. 71: Timing Cover Mark & Notch
   Courtesy of CHRYSLER GROUP, LLC

10. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .

    Fig. 72: Intake Manifold Lower Bracket, Nuts & Bolts
    Courtesy of CHRYSLER GROUP, LLC

11. Drain the coolant.
12. Remove the two nuts (1), the bolt (2) and the intake manifold lower bracket (3).
13. Remove the frame cover portion of the right splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL .

    CAUTION:

    When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.

14. Rotate the crankshaft clockwise (as viewed from the front) to align the timing cover mark (1) with the damper notch (2) to place the number one cylinder piston at top-dead-center on the compression stroke.

    Fig. 73: Timing Chain Cover Removal/Installation
    Courtesy of CHRYSLER GROUP, LLC

15. Remove the engine timing cover (1). Refer to COVER(S), ENGINE TIMING, REMOVAL .

    Fig. 74: Timing Chain, Sprockets, Tensioner & Guides
    Courtesy of CHRYSLER GROUP, LLC

16. Remove the tensioner (6) and timing chain (7). Refer to CHAIN AND SPROCKETS, TIMING, REMOVAL .
17. Remove the timing chain guides (3).

    Fig. 75: Foam Insulator, Fuel Line & Purge Line
    Courtesy of CHRYSLER GROUP, LLC

18. Disconnect the vapor line (2) at the purge vapor solenoid end of the line.
19. Remove the NVH foam pad (3) prior to disconnecting the fuel line (1).

    Fig. 76: Score Line
    Courtesy of CHRYSLER GROUP, LLC

20. To remove the foam pad, cut the pad along the score line (1). Make sure care is taken to not make contact with any other components while cutting the pad. Do not cut beyond the line . Remove the pad from the fuel rail once split.
21. Disconnect the fuel line from the fuel rail. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
22. Unplug the Electronic Throttle Control (ETC) connector.
23. Disconnect the VVAA solenoids.
24. Unplug the purge solenoid.

    Fig. 77: MAP Sensor Connector & Fittings
    Courtesy of CHRYSLER GROUP, LLC

25. Disconnect the three hoses from the intake manifold fittings (3).
26. Using a permanent ink or paint marker, identify the location and position on each camshaft bearing cap.

    CAUTION:

    DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS.

27. Loosen the camshaft bearing cap bolts and remove the camshaft bearing caps.
28. Remove the camshafts.

    NOTE:

    If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.

29. Remove the rocker arm(s).

    NOTE:

    If the hydraulic lifters are to be reused, identify their positions so that they can be reassembled into their original locations.

30. Remove the hydraulic lifter(s).

    Fig. 78: Front Head Bolt Washers
    Courtesy of CHRYSLER GROUP, LLC

    NOTE:

    All of the cylinder head bolts have captured washers EXCEPT the front two (1).

31. Remove the cylinder head bolts and two uncaptured washers (1).
32. Remove the cylinder head from the engine block.

    NOTE:

    There is a foam insulator that is sandwiched between the intake manifold and the engine black that may fall off when the cylinder head is removed. The foam pad must be reinstalled during assembly. Fig. 79: Fuel Injectors & Rail Courtesy of CHRYSLER GROUP, LLC

33. Disconnect the fuel injector electrical connectors (1). Remove the two bolts at the fuel rail (2).

    Fig. 80: Intake Manifold Upper Support Bracket, Bolts & Nuts
    Courtesy of CHRYSLER GROUP, LLC

34. Remove the throttle body bracket bolts (3), loosen the nuts (2). Allow the throttle body bracket bolts to remain with the intake manifold.

    Fig. 81: Intake Manifold Silencer Pad Screws
    Courtesy of CHRYSLER GROUP, LLC

35. Remove the four screws that secure the intake manifold silencer to the manifold (1).

    Fig. 82: MAP Sensor Connector & Fittings
    Courtesy of CHRYSLER GROUP, LLC

36. Remove wiring harness retainer from the intake manifold eyelets (1)
37. Unplug the MAP sensor connector (2).

    Fig. 83: Intake Manifold Retaining Bolts & Nuts
    Courtesy of CHRYSLER GROUP, LLC

38. Remove intake manifold retaining bolts (2) and nuts (1).
39. Remove the intake manifold from the cylinder head.
40. Inspect the cylinder head and cylinder head components. Refer to CYLINDER HEAD - INSPECTION .

NOTE:

Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.

CLEANING

CLEANING

CAUTION:

When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper.

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.

NOTE:

Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

1. Remove all gasket material from cylinder head and block. Refer to ENGINE - STANDARD PROCEDURE . Be careful not to gouge or scratch the aluminum head sealing surface.
2. Clean all engine oil passages.
3. Clean out the cylinder head bolt holes in the engine block.

INSPECTION

INSPECTION

Fig. 84: Checking Cylinder Head Flatness
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Typical Cylinder Head shown in illustration.

1. Check for cylinder head warping with a straight edge (2) and feeler gauge (1).
2. Cylinder head must be flat within specification. Refer to ENGINE SPECIFICATIONS .
3. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
4. Inspect the following components and verify that they are within specification. Refer to ENGINE SPECIFICATIONS .
   • Springs
   • Valve Seats
   • Valve Guides
   • Valves

INSTALLATION

INSTALLATION

Fig. 85: Checking Cylinder Head Bolts For Stretching (Necking)
Courtesy of CHRYSLER GROUP, LLC

CAUTION:

The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

1. Check the cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.

   NOTE:

   Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.

   NOTE:

   Prior to installing the cylinder head to the block, the intake manifold must installed onto the cylinder head.

2. Replace the variable valve timing filter screen (3).
3. Clean all gasket surfaces.
4. Replace intake manifold gasket seals.
5. Position the foam pad over the coolant transfer tube.
6. Apply 3-5 dabs of RTV to the foam pad where it makes contact with the coolant transfer tube prior to setting the foam pad in position. This will aid in holding the pad in the proper position while setting the head on the block.

   Fig. 86: Intake Manifold Bolts Tightening Sequence
   Courtesy of CHRYSLER GROUP, LLC

7. Position the intake manifold onto the cylinder head.
8. Install the three bolts and two nuts. Using the torque sequence pattern as a guide, tighten the bolts and nuts to 25 N.m (18 ft. lbs.).

   Fig. 87: Intake Manifold Upper Support Bracket, Bolts & Nuts
   Courtesy of CHRYSLER GROUP, LLC

9. Install the manifold to head bracket (1). Tighten the nuts (2) and bolts to 9 N.m (81 in. lbs.)
10. Install the fuel rail assembly. Refer to RAIL, FUEL, INSTALLATION .

    Fig. 88: Intake Manifold Silencer Pad Screws
    Courtesy of CHRYSLER GROUP, LLC

11. Install the intake manifold silencer pad and screws. Tighten the screws to 2.5 N.m (22 in. lbs.).

NOTE:

When using RTV, components should be assembled within 10 minutes and tighten to specification within 45 minutes.

Fig. 89: Engine Sealant RTV Location
Courtesy of CHRYSLER GROUP, LLC

12. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on the cylinder block as shown in illustration.
13. Position the new cylinder head gasket on the engine block with the part number facing up. Ensure gasket is seated over the locating dowels in the block.
14. Route the knock sensor wiring harness between the coolant transfer tube and the engine block. Insert the harness retainer into the holder.
15. Position the cylinder head onto the engine block.

    NOTE:

    Make sure the foam pad is not out of position. Inspect the positioning of the pad from below to make sure that no part of the pad is between the cylinder head and the engine block surface.

    Fig. 90: Washers Must Be Installed With Bevel Edge Up Towards Bolt Head
    Courtesy of CHRYSLER GROUP, LLC

    NOTE:

    The front two cylinder head bolts do not have captured washers. The washers must be installed with the bevel edge (1) up towards the bolt head.

    Fig. 91: Front Head Bolt Washers
    Courtesy of CHRYSLER GROUP, LLC

16. Install washers (1) for the front two cylinder head bolts with the beveled edge facing up.

    Fig. 92: Cylinder Head Bolt Tightening Sequence
    Courtesy of CHRYSLER GROUP, LLC

    NOTE:

    DOHC shown in illustration, SOHC same sequence.

    NOTE:

    Before installing the cylinder head bolts, lubricate the threads with clean engine oil.

17. Install the ten cylinder head bolts finger tight.
18. Tighten the cylinder head bolts in the sequence shown in illustration, following this 4 step torque plus angle method. Tighten according to the following torque values:
    • Step 1: All to 30 N.m (22 ft. lbs.)
    • Step 2: All to 73 N.m (54 ft. lbs.)
    • Step 3: All again to 73 N.m (54 ft. lbs.)
    • Step 4: All an additional 90° Turn. Do not use a torque wrench for this step.
19. If the hydraulic lifters are being reused, reassemble them into their original locations.
20. Install the exhaust hydraulic lifters.

    NOTE:

    If the rocker arms are being reused, reassemble them into their original locations.

21. Install the exhaust rocker arms.
22. Oil all of the camshaft journals with clean engine oil.
23. Install the camshaft. Refer to CAMSHAFT, ENGINE, INSTALLATION .
24. Install the VVAA. Refer to ASSEMBLY, VARIABLE VALVE ACTUATION, INSTALLATION.
25. Install timing chain and tensioner. Refer to CHAIN AND SPROCKETS, TIMING, INSTALLATION .
26. Install timing chain cover, engine mount, pulleys and accessory drive belt. Refer to COVER(S), ENGINE TIMING, INSTALLATION .

    Fig. 93: Cylinder Head Cover Bolts
    Courtesy of CHRYSLER GROUP, LLC

27. Install the cylinder head cover and ignition coils. Refer to COVER(S), CYLINDER HEAD, INSTALLATION .

    Fig. 94: Exhaust Manifold Bolts Tightening Sequence
    Courtesy of CHRYSLER GROUP, LLC

28. Install the exhaust manifold. Refer to MANIFOLD, EXHAUST, INSTALLATION.
29. Connect the electrical connectors to the ignition coils and fuel injectors.

    Fig. 95: Foam Insulator, Fuel Line & Purge Line
    Courtesy of CHRYSLER GROUP, LLC

30. Insert the foam insulator (3) over the fuel rail.
31. Connect fuel line (1).
32. Connect the purge vapor line (2). Remove wiring harness retainer from the intake manifold eyelets (1).
33. Connect the three hose connectors (3).
34. Connect the knock sensor connector.

    Fig. 96: Intake Manifold Lower Bracket, Nuts & Bolts
    Courtesy of CHRYSLER GROUP, LLC

35. Install the intake manifold lower bracket (3). Install the nuts (1) and bolt (2). Tighten to 9 N.m (81 in. lbs.)
36. Connect the VVAA solenoids.
37. Connect the MAP sensor connector (2).

    Fig. 97: Foam Insulator, Fuel Line & Purge Line
    Courtesy of CHRYSLER GROUP, LLC

38. Inspect quick connect fittings for damage, replace if necessary. Refer to FITTING, QUICK CONNECT .

    Fig. 98: Air Cleaner Body, Clamp, Make Up Air Hose, Retainer & Bolt
    Courtesy of CHRYSLER GROUP, LLC

39. Install the air cleaner body (1). Refer to BODY, AIR CLEANER, INSTALLATION .

    Fig. 99: Engine Cover & Air Resonator Clamp
    Courtesy of CHRYSLER GROUP, LLC

40. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to OIL - STANDARD PROCEDURE .
41. Fill the cooling system. Refer to STANDARD PROCEDURE .
42. Recharge the air conditioning system. Refer to PLUMBING, STANDARD PROCEDURE .
43. Install the resonator. Refer to RESONATOR, AIR CLEANER, INSTALLATION .
44. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
45. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
46. The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. .

CAMSHAFT, ENGINE

DESCRIPTION

DESCRIPTION

Fig. 100: Engine Camshaft
Courtesy of CHRYSLER GROUP, LLC

The 2.4L engine uses a Single Over Head Camshaft (SOHC) to provide valve actuation but the camshaft is in the standard position of an exhaust camshaft in a Dual Over Head Camshaft (DOHC) engine. The camshaft has five bearing journal surfaces and three cam lobes per cylinder. The camshaft is built up on a hollow tube with cam lobes, bearing journals and end caps pressed into position. The front end cap includes the camshaft sprocket mounting. The middle (number three) bearing surface has thrust walls machined into it to control end play. The rear has a camshaft position sensor pick-up wheel and also drives the vacuum pump.

OPERATION

OPERATION

The camshaft is driven by the crankshaft via a drive sprocket and a chain. The camshaft has precisely machined lobes to provide accurate valve timing and duration.

STANDARD PROCEDURE

STANDARD PROCEDURE - CAMSHAFT END PLAY

Fig. 101: Measuring Camshaft End Play
Courtesy of CHRYSLER GROUP, LLC

STANDARD PROCEDURE - CAMSHAFT ENDPLAY

1. Remove the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL .
2. Mount Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) (1) to a stationary point at the front of the engine. Locate the probe perpendicular against the nose of the camshaft.
3. Move the camshaft all the way to the rear of its travel.
4. Zero the dial indicator.
5. Move the camshaft forward to the limit of travel and read the dial indicator. Compare the measured end play to the specification. Refer to ENGINE SPECIFICATIONS .

REMOVAL

REMOVAL

1. Disconnect and isolate the battery negative cable.
2. Remove the cylinder head cover . Refer to COVER(S), CYLINDER HEAD, REMOVAL .
3. Remove the spark plugs. Refer to SPARK PLUG, REMOVAL .
4. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .

   Fig. 102: Vertical Center Line Of Camshaft, Dowel & Cylinder Head
   Courtesy of CHRYSLER GROUP, LLC

5. Remove the frame cover portion of the right splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL .

   Fig. 103: Timing Cover Mark & Notch
   Courtesy of CHRYSLER GROUP, LLC

6. Rotate the crankshaft clockwise (as viewed from the front) to align the timing cover mark (1) with the damper notch (2) to place the number one cylinder piston at top-dead-center on the compression stroke.

   Fig. 104: Vertical Center Line Of Camshaft, Dowel & Cylinder Head
   Courtesy of CHRYSLER GROUP, LLC

7. Verify that the camshaft timing is correct as viewed above. The vertical center line of the camshaft (1) and the horizontal surface of the top of the cylinder head (3)

   MUST be

   90° from each other.

   NOTE:

   The camshaft dowel (2) is slightly visible above the camshaft center bolt and should be at 12 o'clock when set.

8. Lower the vehicle and support the engine with a jack stand.

   Fig. 105: Sprocket Mark & Painted Link
   Courtesy of CHRYSLER GROUP, LLC

9. Using a paint pen or equivalent, mark both camshaft sprockets and corresponding chain links (1 and 2) to aid in reassembly.

   NOTE:

   Camshaft bearing caps should have been marked during engine manufacturing. For example, number one exhaust camshaft bearing is marked "E1>".

   CAUTION:

   DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS.

10. Remove the vacuum pump.
11. Remove the right engine mount. Refer to INSULATOR, ENGINE MOUNT, RIGHT, REMOVAL .
12. Remove the timing cover. Refer to COVER(S), ENGINE TIMING, REMOVAL .
13. Using a permanent ink or paint marker, identify the location and position on each camshaft bearing cap.

    Fig. 106: Special Tool, Spring Compressor & Indicators
    Courtesy of CHRYSLER GROUP, LLC

14. Using special tool 10259A (1), loosen the spring compressors (2) to fit over the valve and spring assemblies. Adjust the tool to align with the 2.4L indicators (3).
15. Install the (special tool #10259B, Compressor, MultiAir® Spring) spring compressor
16. Rotate the spring compressors counterclockwise until the springs are fully seated.

    Fig. 107: Bearing Cap Bolts
    Courtesy of CHRYSLER GROUP, LLC

17. Slowly remove the exhaust camshaft bearing cap bolts (1) one turn at a time. Remove the camshaft bearing caps.

    Fig. 108: Chain Removal
    Courtesy of CHRYSLER GROUP, LLC

18. Lift the timing chain (2) off of the sprocket (1).
19. Remove the camshaft.
20. Remove the sprocket from the camshaft.

INSPECTION

INSPECTION

Fig. 109: Inspecting Camshaft Wear Areas
Courtesy of CHRYSLER GROUP, LLC

1. Inspect the camshaft bearing journals (4) for damage and binding. If the journals are binding, check the camshaft bearing housing for damage. Also check the oil supply holes for clogging.
2. Check the surface of the cam lobes (5) for abnormal wear (1). Measure and compare the unworn area (3) to the worn area (2). Replace the camshaft if it is not within specification. Refer to ENGINE SPECIFICATIONS .

INSTALLATION

INSTALLATION

NOTE:

Camshaft bearing caps are marked during engine manufacturing. For example, the front camshaft bearing cap is marked 1, the read cap is marked with a 5. The markings on the caps must be read while looking from the left bank of the engine (closest to the front of the vehicle).

NOTE:

Following the installation of each camshaft bearing cap, visually verify that the camshaft has some endplay.

1. Lubricate camshaft journals with clean engine oil.
2. Apply a seam of Anaerobic Loctite® 518 Sealant on the camshaft housing in the contact area of the front and rear camshaft caps.

   Fig. 110: Camshaft Bearing Cap Tightening Sequence
   Courtesy of CHRYSLER GROUP, LLC

   Torque Sequence

   NOTE:

   VVAA removed for clarity

3. Install the camshaft and camshaft bearing caps. Tighten the twelve bolts in two steps following the sequence shown in illustration:
   • Step 1: All to 5 N.m (44 in. lbs.).
   • Step 2: All to 10 N.m (89 in. lbs.).

   Fig. 111: Special Tool, Spring Compressor & Indicators
   Courtesy of CHRYSLER GROUP, LLC

4. Loosen the spring compressors (2), remove the tool (special tool #10259B, Compressor, MultiAir® Spring) (1).

   Fig. 112: Camshaft Seal
   Courtesy of CHRYSLER GROUP, LLC

5. If required, install a new camshaft seal (1). Refer to SEAL(S), CAMSHAFT, INSTALLATION .
6. Install the camshaft sprocket and timing chain. Refer to CHAIN AND SPROCKETS, TIMING, INSTALLATION .
7. Install the timing cover. Refer to COVER(S), ENGINE TIMING, INSTALLATION .
8. Install the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, INSTALLATION .

NOTE:

The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.

COVER(S), CYLINDER HEAD

DESCRIPTION

DESCRIPTION

Fig. 113: Cylinder Head Cover
Courtesy of CHRYSLER GROUP, LLC

The cylinder head cover is made of die cast aluminum. The cylinder head cover is sealed with press-in-place gaskets at the cylinder head and spark plug ports. RTV is used to seal the T-joint at the cylinder head cover, front timing cover and cylinder head. RTV is also used to seal the cylinder head cover to the rear camshaft bearing cap at the vacuum pump.

REMOVAL

REMOVAL

1. Remove the engine cover assembly.
2. Disconnect and isolate the battery negative cable.
3. Remove the make up air hose from the cylinder head cover fitting.
4. Remove the positive crankcase ventilation (PCV) hose.
5. Disconnect and remove the ignition coils. Refer to COIL, IGNITION, REMOVAL .

   Fig. 114: Cylinder Head Cover Bolts
   Courtesy of CHRYSLER GROUP, LLC

6. Use compressed air to blow dirt and debris off of the cylinder head cover prior to removal.
7. Remove the push pins that secure the coil harness to the cover.

   NOTE:

   If any of the push pins break off in the cover, use a pick to rotate the lodged portion counterclockwise to back the portion out of the hole.

8. Loosen twelve cylinder head cover mounting bolts and six stud bolts (1).
9. Remove the cylinder head cover from the cylinder head.

   NOTE:

   With the help of an assistant, hold the coil harness up and spread open as the cover is removed through the area between the left and right harness runs.

   Fig. 115: Cylinder Head Cover Gaskets
   Courtesy of CHRYSLER GROUP, LLC

10. Remove and discard the cylinder head cover gaskets (1 and 2).

    Fig. 116: Sealant Application Areas
    Courtesy of CHRYSLER GROUP, LLC

11. Remove all residual sealant (1) from the cylinder head, timing chain cover, rear exhaust camshaft bearing cap and cylinder head cover mating surfaces. Refer to ENGINE - STANDARD PROCEDURE .

INSTALLATION

INSTALLATION

Fig. 117: Cylinder Head Cover Gaskets
Courtesy of CHRYSLER GROUP, LLC

1. Install new cylinder head cover gaskets (1 and 2).

   Fig. 118: Sealant Application Areas
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   When using RTV, the sealing surfaces must be clean and free from grease and oil.

   NOTE:

   When using RTV, components should be assembled within 10 minutes and tighten to specification within 45 minutes.

2. Apply a 2 to 3 mm wide bead of Mopar® engine sealant RTV or equivalent to the cylinder head/front cover T-joint (1) and the rear exhaust camshaft bearing cap/cylinder head T-joint (1).

   Fig. 119: Cylinder Head Cover Bolts
   Courtesy of CHRYSLER GROUP, LLC

3. Install the cylinder head cover to the cylinder head with twelve bolts and six stud bolts (1). Tighten all eighteen fasteners to 10 N.m (90 in. lbs.).
4. Install the cylinder cover ground strap and nut. Tighten the nut to 10 N.m (90 in. lbs.)
5. Install and connect the ignition coils. Refer to COIL, IGNITION, INSTALLATION .
6. If removed, install the positive crankcase ventilation (PCV) valve and tighten to 4 N.m (37 in. lbs.).

   NOTE:

   Make sure the O-ring is seated on the shoulder of the opening prior to reading the torque.

7. Connect the PCV hose to the PCV valve.
8. Connect the make up air hose.
9. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
10. Install the engine cover assembly.

LIFTER(S), HYDRAULIC

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - LASH ADJUSTER (TAPPET) NOISE

Proper noise diagnosis is essential in locating the source of an NVH complaint. Locating a lash adjuster (tappet) type noise can sometimes be difficult. As a result, an initial misdiagnosis may occur.

Refer to the following chart for possible causes and correction of a lash adjuster (tappet) type noise:

LASH ADJUSTER (TAPPET) NOISE CHART

POSSIBLE CAUSES	CORRECTION
1. Engine oil level-too high or too low. This may allow aerated oil to enter the adjusters and cause them to be spongy.	1. Check and correct the engine oil level.
2. Insufficient running time after rebuilding a cylinder head.	2. Low speed running of up to 1 hour may be required to fully evacuate trapped air from the valve train system. During this time, turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature.
3. Air trapped in the lash adjuster (after 1 hour of run time).	3. See below:
	(a) Check lash adjusters for sponginess while installed in the cylinder head. Depress the lash adjuster. Normal adjusters should feel very firm. Very spongy adjusters can be bottomed out easily.
	(b) If the lash adjuster(s) are still spongy, replace the lash adjuster(s). Refer to LIFTER(S), HYDRAULIC, REMOVAL .
4. Low oil pressure.	4. See below:
	(a) Check and correct the engine oil level.
	(b) Check the engine oil pressure. Refer to LUBRICATION - DIAGNOSIS AND TESTING .
	(c) Check for excessive main bearing clearance and correct. Refer to BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE .
	(d) Check for a worn oil pump.
5. Oil passage to the cylinder head(s) plugged with debris.	5. Check cylinder head oil passages for blockage. Clean or replace as necessary.
6. Worn valve guide(s).	6. Measure valve stem-to-guide clearance. Refer to VALVES, INTAKE AND EXHAUST - STANDARD PROCEDURE .
7. Air ingested into oil due to broken or cracked oil pump pickup tube.	7. Inspect pickup tube and replace as necessary.
8. Collapsed lash adjuster due to debris ingestion.	8. Clean debris from engine and replace lash adjuster(s). Refer to LIFTER(S), HYDRAULIC, REMOVAL .

REMOVAL

REMOVAL

1. Disconnect and isolate the negative battery cable.

   Fig. 120: Cylinder Head Cover Bolts
   Courtesy of CHRYSLER GROUP, LLC

2. Remove the cylinder head cover assembly bolts (1) and remove the cover from the cylinder head.

   Fig. 121: Special Tool, Spring Compressor & Indicators
   Courtesy of CHRYSLER GROUP, LLC

3. Install special (1) tool to the cylinder head. With the spring compressors lined up in the 2.4L position of the bridge (3), rotate the screw jacks counterclockwise to compress the springs enough to allow slight movement of the rockers.
4. Remove the camshaft(s). Refer to CAMSHAFT, ENGINE, REMOVAL .

   NOTE:

   If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.

5. Remove the rocker arm(s). Refer to ROCKER ARM, VALVE, REMOVAL .

   NOTE:

   If the hydraulic lifters are to be reused, identify their positions so that they can be reassembled into their original locations.

6. Remove the hydraulic lifter(s).

INSTALLATION

INSTALLATION

1. Verify that the hydraulic lifters are at least partially full of oil. There should be little or no plunger travel when the hydraulic lifter is depressed.

   NOTE:

   If the hydraulic lifters are being reused, reassemble them into their original locations.

2. Install the hydraulic lifter(s)

   NOTE:

   If the rocker arms are being reused, reassemble them into their original locations.

3. Install the rocker arm(s). Refer to ROCKER ARM, VALVE, INSTALLATION .
4. Install the camshaft. Refer to CAMSHAFT, ENGINE, INSTALLATION .

   Fig. 122: Special Tool, Spring Compressor & Indicators
   Courtesy of CHRYSLER GROUP, LLC

5. Install the VVAA. Refer to ASSEMBLY, VARIABLE VALVE ACTUATION, INSTALLATION.
6. Install the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, INSTALLATION .
7. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).

ROCKER ARM, VALVE

DESCRIPTION

DESCRIPTION

Fig. 123: Valve Rocker Arm
Courtesy of CHRYSLER GROUP, LLC

The valve rocker arms are steel stampings with an integral roller bearing. A spring clip helps to hold the rocker arm in position on the ball socket when removing or installing the variable valve actuation assembly. The rocker arm ball socket also incorporates a 0.5 mm oil hole for roller and camshaft lubrication.

REMOVAL

REMOVAL

1. Disconnect and isolate the battery negative cable.
2. If the exhaust rockers are to be serviced, remove the exhaust camshaft. Refer to CAMSHAFT, ENGINE, REMOVAL .

   NOTE:

   If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.

3. If the intake rockers are to be serviced, remove the Variable Valve Actuator Assembly (VVAA). Refer to ASSEMBLY, VARIABLE VALVE ACTUATION, REMOVAL.
4. Remove the rocker arm(s).

INSPECTION

INSPECTION

Fig. 124: Valve Rocker Arm
Courtesy of CHRYSLER GROUP, LLC

Inspect the valve rocker arm for wear or damage. Replace as necessary.

INSTALLATION

INSTALLATION

1. Lubricate the rocker arms with clean engine oil before installation.

   NOTE:

   If the rocker arms are being reused, reassemble them into their original locations.

2. Install the rocker arm(s).
3. If the intake rockers were serviced, install the VVAA. Refer to ASSEMBLY, VARIABLE VALVE ACTUATION, INSTALLATION.
4. If the exhaust rockers were serviced, Install the camshaft and cylinder head cover. Refer to CAMSHAFT, ENGINE, INSTALLATION .
5. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).

SEAL(S), VALVE GUIDE

DESCRIPTION

DESCRIPTION

Fig. 125: Valve Stem Oil Seal, Valve Spring & Valve Guide
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Typical valve configuration shown in illustration.

The valve stem oil seals (1) are made of elastomer over-molded steel in a non-integrated type guide mounted configuration. The seal is not held in place by the valve spring (2). The valve stem seals are not reusable if removed from the valve guides (3), they must be replaced. Always coat the valve seals with clean engine oil before installing the valves.

REMOVAL

REMOVAL

Fig. 126: Valve Spring & Retainer
Courtesy of CHRYSLER GROUP, LLC

NOTE:

If the springs are to be reused, identify their positions so that they can be reassembled into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valve springs similar.

1. Remove the valve spring(s) (2). Refer to SPRING(S), VALVE, REMOVAL .

   Fig. 127: Valve Guide Seal & Valve Seal Tool
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Number 2 cylinder exhaust valve guide seal shown in illustration, all other valve guide seals similar.

2. Remove the valve guide seal (1) using a valve seal tool (2). Discard the removed seal.

   Fig. 128: Valve Spring Seat
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Number 2 cylinder exhaust valve spring seat shown in illustration. Exhaust valve spring seats are marked with the letter "S" and have a thickness of 0.8 mm (0.031 in.). Intake valve spring seats are marked with the letter "A" and have a thickness of 3.2 mm (0.126 in.).

3. If required, remove the valve spring seat (1).
4. If required, remove the valve(s). Refer to VALVES, INTAKE AND EXHAUST, REMOVAL .

INSTALLATION

INSTALLATION

Fig. 129: Valve Spring Seat
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Reassemble the valves into their original locations. If the valves or valve seats have been refinished, verify that the valve stem tip height is within specification. Refer to ENGINE SPECIFICATIONS .

1. If removed, install the valve(s). Refer to VALVES, INTAKE AND EXHAUST, INSTALLATION .

   NOTE:

   Number 2 cylinder exhaust valve spring seat shown in illustration. Exhaust valve spring seats are marked with the letter "S" and have a thickness of 0.8 mm (0.031 in.). Intake valve spring seats are marked with the letter "A" and have a thickness of 3.2 mm (0.126 in.).

2. If removed, install the spring seat (1) over the valve guide.

   Fig. 130: Driver, Garter Spring & Valve Guide Seal
   Courtesy of CHRYSLER GROUP, LLC

3. Apply engine oil to the lip of the valve guide seal (3). Install the valve guide seal (3) over the valve stem. Using an appropriate driver (1), push the seal firmly and squarely over the valve guide. Do Not Force the seal against the top of guide.

   NOTE:

   Make sure that the garter spring (2) is intact around the top of the valve guide seal (3). Number 2 cylinder exhaust valve guide seal shown in illustration, all other valves similar.

   Fig. 131: Valve Spring & Retainer
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   If the valve springs are being reused, reassemble them into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valves similar.

4. Install the valve spring(s) (2). Refer to SPRING(S), VALVE, INSTALLATION .

SPRING(S), VALVE

DESCRIPTION

DESCRIPTION

Fig. 132: Valve Springs Assembly
Courtesy of CHRYSLER GROUP, LLC

The valve springs are a beehive design and made from high strength chrome silicon steel. The springs are common for intake and exhaust applications. Valve guide seals are rubber overmolded on a steel support cylinder with a garter spring at the seal lip. The seals are not integrated with the valve spring seat. The steel valve spring retainers are designed for use with beehive springs and the valve spring retainer locks are a three bead Butt type design to promote valve rotation.

REMOVAL

ON VEHICLE

NOTE:

The intake and exhaust springs are NOT interchangeable. Make sure the springs are marked if reused. If they are being replaced, correctly identify the part numbers prior to installation.

1. Remove the variable valve actuator assembly. Refer to ASSEMBLY, VARIABLE VALVE ACTUATION, REMOVAL.
2. Remove the exhaust camshaft. Refer to CAMSHAFT, ENGINE, REMOVAL .

   NOTE:

   If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.

3. Remove the rocker arm(s). Refer to ROCKER ARM, VALVE, REMOVAL .
4. Install the (special tool #10224, Adapter, Valve Spring) (2) on the (special tool #MD998772A, Compressor, Valve Spring) (1).

   Fig. 133: Valve Spring Compressor & Air Hose
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.

5. Remove the spark plug. Refer to SPARK PLUG, REMOVAL .
6. Install the (special tool #MD998772A, Compressor, Valve Spring) (1) onto the cylinder head.
7. Install a spark plug adapter attached to a regulated shop air supply (2). Pressurize the cylinder being serviced to 620.5 - 689 kPa (90 - 100 psi) to hold the valves in place.

   Fig. 134: Compressing Valve Spring
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.

   CAUTION:

   Air pressure must be maintained as long as the valve springs are removed to prevent the valves from dropping into the cylinders.

8. Using the (special tool #10224, Adapter, Valve Spring) (2), compress valve spring (4) and remove valve retaining locks (3).

   Fig. 135: Valve Spring & Retainer
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   The intake and exhaust springs are NOT interchangeable. Make sure the springs are marked if reused. If they are being replaced, correctly identify the part numbers prior to installation.

   NOTE:

   If the springs are to be reused, identify their positions so that they can be reassembled into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valve springs similar.

9. Release the valve spring compression and remove the valve spring retainer (1) and valve spring (2).
10. If required, remove the valve guide seal. Refer to SEAL(S), VALVE GUIDE, REMOVAL .

OFF VEHICLE

NOTE:

The intake and exhaust springs are NOT interchangeable. Make sure the springs are marked if reused. If they are being replaced, correctly identify the part numbers prior to installation.

Fig. 136: Valve Spring Compressor & Adapter
Courtesy of CHRYSLER GROUP, LLC

1. Remove the variable valve actuator assembly. Refer to ASSEMBLY, VARIABLE VALVE ACTUATION, REMOVAL.
2. Install the (special tool #10224, Adapter, Valve Spring) (2) on the (special tool #MD998772A, Compressor, Valve Spring) (1).

   Fig. 137: Valve Spring Compressor
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Number 3 intake valve spring compression shown in illustration, all other valves similar.

3. Install the (special tool #MD998772A, Compressor, Valve Spring) (1) onto the cylinder head.
4. Place a cushion of foam padding or a ball of rags in the dome area of the cylinder head to hold the valves in place during the retaining lock removal process.

   Fig. 138: Compressing Valve Spring
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.

5. Using the (special tool #10224, Adapter, Valve Spring) (2), compress valve spring (4) and remove valve retaining locks (3).

   Fig. 139: Valve Spring & Retainer
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   The intake and exhaust springs are NOT interchangeable. Make sure the springs are marked if being reused. If they are being replaced, correctly identify the part numbers prior to installation.

   NOTE:

   If the springs are to be reused, identify their positions so that they can be reassembled into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valve springs similar.

6. Release the valve spring compression and remove the valve spring retainer (1) and valve spring (2).
7. If required, remove the valve guide seal. Refer to SEAL(S), VALVE GUIDE, REMOVAL .

INSPECTION

INSPECTION

Fig. 140: Testing Valve Spring
Courtesy of CHRYSLER GROUP, LLC

When valves have been removed for inspection, reconditioning or replacement, valve springs should be checked against specifications for free-length, spring force and spring installed height. Refer to ENGINE SPECIFICATIONS .

Spring force can be measured with a test fixture (2). Follow the tool manufactures instructions. Replace any springs that do not meet specifications.

Fig. 141: Checking Valve Spring Installed Height
Courtesy of CHRYSLER GROUP, LLC

Installed height of the valve spring must be checked with the valve assembled into the cylinder head. Refer to SPRING(S), VALVE, INSTALLATION .

If the valves or valve seats have been refinished, check the installed height of the valve springs (4). Make sure the measurement is taken from the top of spring seat (6) to the bottom surface of spring retainer (1). Refer to ENGINE SPECIFICATIONS .

INSTALLATION

ON VEHICLE

NOTE:

The intake and exhaust springs are NOT interchangeable. Make sure the springs are marked if reused. If they are being replaced, correctly identify the part numbers prior to installation.

Fig. 142: Valve Guide Seal & Valve
Courtesy of CHRYSLER GROUP, LLC

1. If removed, install the valve guide seal (2) over the valve guide (3). Refer to SEAL(S), VALVE GUIDE, INSTALLATION .

   NOTE:

   Make sure that the garter spring (1) is intact around the top of the valve guide seal (2). Number 2 cylinder exhaust valve guide seal shown in illustration, all other valves similar.

   Fig. 143: Valve Spring & Retainer
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   The intake and exhaust springs are NOT interchangeable. Make sure the springs are marked if reused. If they are being replaced, correctly identify the part numbers prior to installation.

   NOTE:

   If the valve springs are being reused, reassemble them into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valves similar.

2. Install the valve spring (2) and valve spring retainer (1).

   Fig. 144: Compressing Valve Spring
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.

3. Using the (special tool #10224, Adapter, Valve Spring) (2) with the (special tool #MD998772A, Compressor, Valve Spring) (1), compress the valve spring (4) only enough to install the valve retaining locks (3).
4. Relieve the air pressure and remove the spark plug adapter.
5. Install the spark plug and tighten to 19 N.m (14 ft. lbs.). Refer to SPARK PLUG, INSTALLATION .

   NOTE:

   If the rocker arms are being reused, reassemble them into their original locations.

6. Install the rocker arm(s). Refer to ROCKER ARM, VALVE, INSTALLATION .
7. Install the camshaft. Refer to CAMSHAFT, ENGINE, INSTALLATION .
8. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).

OFF VEHICLE

NOTE:

The intake and exhaust springs are NOT interchangeable. Make sure the springs are marked if reused. If they are being replaced, correctly identify the part numbers prior to installation.

Fig. 145: Valve Spring Component Measurements
Courtesy of CHRYSLER GROUP, LLC

1. If removed, install the valve(s). Refer to VALVES, INTAKE AND EXHAUST, INSTALLATION .

   NOTE:

   Reassemble the valves into their original locations. If the valves or valve seats have been refinished, verify that the valve stem tip height (5) is within specification. Refer to ENGINE SPECIFICATIONS .

   Fig. 146: Valve Guide Seal & Valve
   Courtesy of CHRYSLER GROUP, LLC

2. If removed, install the valve guide seal (2) over the valve guide (3). Refer to SEAL(S), VALVE GUIDE, INSTALLATION .

   NOTE:

   Make sure that the garter spring (1) is intact around the top of the valve guide seal (2). Number 2 cylinder exhaust valve guide seal shown in illustration, all other valves similar.

   Fig. 147: Valve Spring & Retainer
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   The intake and exhaust springs are NOT interchangeable. Make sure the springs are marked if reused. If they are being replaced, correctly identify the part numbers prior to installation.

   NOTE:

   If the valve springs are being reused, reassemble them into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valves similar.

3. Install the valve spring (2) and valve spring retainer (1).

   Fig. 148: Valve Spring Compressor & Adapter
   Courtesy of CHRYSLER GROUP, LLC

4. Install the (special tool #10224, Adapter, Valve Spring) (2) on the (special tool #MD998772A, Compressor, Valve Spring) (1).

   Fig. 149: Valve Spring Compressor
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Number 3 intake valve spring compression shown in illustration, all other valves similar.

5. Install the (special tool #MD998772A, Compressor, Valve Spring) (1) onto the cylinder head.
6. Place a ball of rags in the combustion chamber to hold the valves in place.

   Fig. 150: Compressing Valve Spring
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.

7. Using the (special tool #10224, Adapter, Valve Spring) (2) with the (special tool #MD998772A, Compressor, Valve Spring) (1), compress the valve spring (4) only enough to install the valve retaining locks (3).

   Fig. 151: Valve Spring Component Measurements
   Courtesy of CHRYSLER GROUP, LLC

8. If the valves or valve seats have been refinished, verify that the installed height of the valve springs (4) are within specification. Make sure the measurement is taken from the top of spring seat (6) to the bottom surface of spring retainer (1). Refer to ENGINE SPECIFICATIONS .
9. Install the cylinder head. Refer to CYLINDER HEAD, INSTALLATION .

VALVES, INTAKE AND EXHAUST

DESCRIPTION

DESCRIPTION

Fig. 152: Cylinder Head, Valves & Springs
Courtesy of CHRYSLER GROUP, LLC

Each of the four combustion chambers contains four valves, two intake and two exhaust, for a total of 16 valves. The valves are made of heat resistant steel. They have nitrided stems to prevent scuffing. Viton rubber valve stem seals are integral with the spring seats. All valves use three bead lock keepers (1) to retain springs (3) and to promote valve rotation.

STANDARD PROCEDURE

STANDARD PROCEDURE - REFACING - INTAKE AND EXHAUST VALVES

Fig. 153: Valve Face & Seat
Courtesy of CHRYSLER GROUP, LLC

1 - SEAT WIDTH

2 - FACE ANGLE

3 - SEAT ANGLE

4 - SEAT CONTACT AREA

The intake and exhaust valves have a 44.5 to 45 degree face angle (1). The valve seats (2) have a 45 to 45.5 degree face angle.

VALVES

Fig. 154: Inspecting Valve Margin
Courtesy of CHRYSLER GROUP, LLC

Inspect the remaining margin (5) after the valves are refaced. Refer to ENGINE SPECIFICATIONS .

VALVE SEATS

Fig. 155: Valve Face & Seat
Courtesy of CHRYSLER GROUP, LLC

1 - SEAT WIDTH

2 - FACE ANGLE

3 - SEAT ANGLE

4 - SEAT CONTACT AREA

NOTE:

When refacing the valve seats, it is important that the correct size valve guide pilot be used for the reseating stones. A true and complete surface must be obtained.

1. Measure the concentricity of the valve seat using a dial indicator. Refer to ENGINE SPECIFICATIONS .
2. Inspect the valve seat (3) with Prussian blue to determine where the valve contacts the seat. To do this, coat the valve seat (3) LIGHTLY with Prussian blue then set the valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of the valve face (4), contact is satisfactory. If the blue is transferred to the top edge of the valve face, then lower the valve seat with a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, then raise the valve seat with a 65 degree stone.

   NOTE:

   Valve seats which are worn or burned can be reworked, provided that the correct angle and seat width are maintained. Otherwise the cylinder head must be replaced.

3. When the seat is properly positioned the width of the intake and exhaust seats should be within specification. Refer to ENGINE SPECIFICATIONS .

VALVE AND SPRING INSTALLED HEIGHT

Fig. 156: Checking Valve Spring Installed Height
Courtesy of CHRYSLER GROUP, LLC

1. Coat the valve stems (2) with clean engine oil and install the valves into the cylinder head.

   NOTE:

   If the valves are being reused, reassemble them into their original locations.

2. If the valves or valve seats have been refinished, check the valve tip height (5). If the valve tip height (5) exceeds the specification, grind the valve tip until it is within specification. Refer to ENGINE SPECIFICATIONS . Make sure the measurement is taken from the cylinder head surface (7) to the top of the valve stem (2).

   Fig. 157: Garter Spring, Valve Guide Seal & Spring Seat
   Courtesy of CHRYSLER GROUP, LLC

3. If removed, install the spring seat (3) and valve guide seal (2) over the valve guide. Refer to SEAL(S), VALVE GUIDE, INSTALLATION .

   NOTE:

   Ensure that the garter spring (1) is intact around the top of the valve guide seal (2). Number 2 cylinder exhaust valve guide seal shown in illustration, all other valves similar.

   Fig. 158: Valve Spring & Retainer
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   If the valve springs are being reused, reassemble them into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valves similar.

4. Install the valve spring (2) and valve spring retainer (1).

   Fig. 159: Valve Spring Adapter, Valve Spring Compressor, Retaining Locks & Valve Springs
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.

5. Compress valve springs (4) with the Valve Spring Compressor Adapter (special tool #10224, Adapter, Valve Spring) (1) mounted in the Valve Spring Compressor (special tool #C-3422-D, Compressor, Valve Spring) (2). Install the retaining locks (3) and release the valve spring compression.

   Fig. 160: Checking Valve Spring Installed Height
   Courtesy of CHRYSLER GROUP, LLC

6. If the valves or valve seats have been refinished, check the installed height of the valve springs (4). Make sure the measurement is taken from the top of spring seat (6) to the bottom surface of spring retainer (1). Refer to ENGINE SPECIFICATIONS .

REMOVAL

REMOVAL

Fig. 161: Valve Spring & Retainer
Courtesy of CHRYSLER GROUP, LLC

1. Remove the cylinder head. Refer to CYLINDER HEAD, REMOVAL .

   NOTE:

   If the springs are to be reused, identify their positions so that they can be reassembled into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valve springs similar.

2. Remove the valve spring(s) (2). Refer to SPRING(S), VALVE, REMOVAL .

   Fig. 162: Inspecting Valve Margin
   Courtesy of CHRYSLER GROUP, LLC

   CAUTION:

   Before removing the valves, remove any burrs from the valve stem retainer lock grooves (2) and stem tip (1) to prevent damage to the valve guides.

3. Remove the valve(s). Identify each valve to ensure installation in the original location.

   Fig. 163: Garter Spring, Valve Guide Seal & Spring Seat
   Courtesy of CHRYSLER GROUP, LLC

4. If required, remove the valve guide seal (2) and spring seat (3). Refer to SEAL(S), VALVE GUIDE, REMOVAL .

INSPECTION

INSPECTION

VALVES

Fig. 164: Inspecting Valve Margin
Courtesy of CHRYSLER GROUP, LLC

1. Clean and inspect the valves thoroughly. Replace burned, warped and cracked valves.
2. Inspect the retainer lock grooves for wear or damage (2).
3. Inspect the valve face (4) for wear and pitting.
4. Measure the valve stems (3) and margins (5) for wear. Refer to ENGINE SPECIFICATIONS .

VALVE GUIDES

Fig. 165: Measuring Valve Guide Wear
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Typical cylinder head shown in illustration.

1. Remove carbon and varnish deposits from inside of the valve guides with a reliable guide cleaner.
2. Measure valve stem-to-guide clearance as follows:
3. Install the valve (2) into the cylinder head so that it is 15 mm (0.590 inch.) off of the valve seat. A small piece of hose may be used to hold the valve in place.
4. Attach the Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) (1) to the cylinder head and set it at a right angle to the valve stem being measured.
5. Move the valve to and from the indicator. Compare this reading to the specification. Refer to ENGINE SPECIFICATIONS .

NOTE:

If stem-to-guide clearance exceeds specifications, you must measure the valve stem. If the valve stem is within specification or if the valve guide is loose in the cylinder head, replace the cylinder head.

INSTALLATION

INSTALLATION

Fig. 166: Checking Valve Spring Installed Height
Courtesy of CHRYSLER GROUP, LLC

1. Coat the valve stems (2) with clean engine oil and install the valves into the cylinder head.

   NOTE:

   If the valves are being reused, reassemble them into their original locations.

2. If the valves or valve seats have been refinished, check the valve tip height (5). If the valve tip height (5) exceeds the specification, grind the valve tip until it is within specification. Refer to ENGINE SPECIFICATIONS . Make sure the measurement is taken from the cylinder head surface (7) to the top of the valve stem (2).

   Fig. 167: Garter Spring, Valve Guide Seal & Spring Seat
   Courtesy of CHRYSLER GROUP, LLC

3. If removed, install the spring seat (3) and valve guide seal (2) over the valve guide. Refer to SEAL(S), VALVE GUIDE, INSTALLATION .

   NOTE:

   Make sure that the garter spring (1) is intact around the top of the valve guide seal (2). Number 2 cylinder exhaust valve guide seal shown in illustration, all other valves similar.

   Fig. 168: Valve Spring & Retainer
   Courtesy of CHRYSLER GROUP, LLC

4. Install the valve spring(s) (2). Refer to SPRING(S), VALVE, INSTALLATION .

   NOTE:

   Reassemble the valves springs into their original locations. If the valves or valve seats have been refinished, verify that the valve spring installed height is within specification. Refer to ENGINE SPECIFICATIONS . Number 2 cylinder exhaust valve spring shown in illustration, all other valves springs similar.

5. Install the cylinder head. Refer to CYLINDER HEAD, INSTALLATION .

PUMP, VACUUM

DESCRIPTION

DESCRIPTION

Fig. 169: Vacuum Pump
Courtesy of CHRYSLER GROUP, LLC

The vane-type vacuum pump is mounted to the rear of the cylinder head and is driven by the camshaft. The vacuum pump supplies vacuum to the brake booster.

REMOVAL

REMOVAL

1. Remove the engine cover. Refer to RESONATOR, AIR CLEANER, REMOVAL .
2. Remove the battery. Refer to BATTERY, REMOVAL .

   NOTE:

   Oil may leak from the vacuum pump drive when the pump is removed. Place a shop towel under the pump to prevent oil leakage onto the engine or transmission assembly.

   Fig. 170: Vacuum Pump & Bolts
   Courtesy of CHRYSLER GROUP, LLC

3. Disconnect the vacuum line at the pump (1).
4. Remove the vacuum pump mounting bolts (2) and the vacuum pump.

   Fig. 171: Vacuum Pump Gasket
   Courtesy of CHRYSLER GROUP, LLC

5. Remove and discard the vacuum pump gasket (1). Note the location of the pump drive tab.

   Fig. 172: Vacuum Fitting & Screw
   Courtesy of CHRYSLER GROUP, LLC

6. If required, remove the screw (1) and the vacuum fitting (2).

   Fig. 173: Vacuum Fitting O-Ring Seal
   Courtesy of CHRYSLER GROUP, LLC

7. The vacuum fitting O-ring seal (1) can be reused if not damaged.

INSTALLATION

INSTALLATION

Fig. 174: Vacuum Fitting O-Ring Seal
Courtesy of CHRYSLER GROUP, LLC

1. The vacuum fitting O-ring seal (1) can be reused if not damaged. If removed, lightly lubricate the O-ring seal (1) with clean engine oil and install on the vacuum fitting.

   Fig. 175: Vacuum Fitting & Screw
   Courtesy of CHRYSLER GROUP, LLC

2. If removed, install the vacuum fitting (2) to the vacuum pump with the screw (1) tightened to 8 N.m (71 in. lbs.).
3. Clean the mating surfaces of the cylinder head and the vacuum pump. Install a new vacuum pump gasket.
4. Align the pump drive tab with the pump drive slot located on the cam shaft.
5. Install the vacuum pump mounting bolts. Tighten the bolts to 20 N.m (15 ft. lbs.).
6. Connect the vacuum supply line to the pump.

   CAUTION:

   When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.

7. Install the battery (4). Refer to BATTERY, INSTALLATION .
8. Install the engine cover. Refer to RESONATOR, AIR CLEANER, INSTALLATION .
9. Run the engine a check the vacuum pump for proper operation.

ASSEMBLY, VARIABLE VALVE ACTUATION

DESCRIPTION

DESCRIPTION

Fig. 176: Intake Valve Tips
Courtesy of CHRYSLER GROUP, LLC

The primary component of variable valve actuation is the variable valve actuation module. The variable valve actuation module is bolted to the top of the camshaft bearing housing above the intake valves, next to the camshaft. The intake lobes on the camshaft operate hydraulic pumping elements instead of directly acting on the valves. The pumping elements provide high-pressure oil to open the intake valves. The relationship between the camshaft lobe and the intake valves is controlled by a solenoid operated hydraulic port. By varying the solenoid operation, the Powertrain Control Module (PCM) is able to control intake valve lift and duration. The actuators sit directly on top of the intake valve tips (circled).

OPERATION

OPERATION

Fig. 177: Solenoid Valve, Hydraulic Brake Pumping Element/Hydraulic Lash Adjusters, Upper Pumping Element & Oil Accumulator
Courtesy of CHRYSLER GROUP, LLC

Variable valve actuation controls the operation of the intake valves. By using a hydraulic link between the camshaft and the intake valves, the valve lift and timing can be adjusted infinitely.

The main components of variable valve actuation are the Powertrain Control Module (PCM) programming and the variable valve actuation module. The variable valve actuation module contains one set of the following components for each cylinder:

• Upper Pumping Element (3)
• Solenoid Valve (1)
• Hydraulic Brake Pumping Element/Hydraulic Lash Adjusters (2)
• Oil Accumulator (4)

Fig. 178: Variable Valve Actuation Assembly Operating Description
Courtesy of CHRYSLER GROUP, LLC

The upper pumping elements (1) in the variable valve actuator are filled with oil from the engine lubrication system. The upper pumping elements (1) are driven by the rocker arms through camshaft motion (9) to create high-pressure oil inside the oil chamber (2). As the camshaft continues to rotate and the camshaft lobe ramps down, a spring in the upper pumping element returns the piston and the rocker arm to their home positions.

The high-pressure oil in the oil chamber passageway is delivered to the solenoid valve (8) from the upper pumping element. The solenoid valve (8) is a normally open hydraulic control valve. Therefore, the high-pressure oil is vented from the oil chamber to the accumulator (7) unless the solenoid valve is powered. When the solenoid valve is supplied 12 volts, the valve closes and high pressure oil instead acts upon the hydraulic brake pumping elements (6) to operate the intake valves (5).

The hydraulic brake pumping element (6) is essentially a piston that is operated by the high-pressure oil to open the intake valves (5). It also functions as a brake to stop the movement of the pumping element and intake valves. The braking function is the result of vent holes around the perimeter of the element's cylinder. When the piston approaches full stroke, the lower perimeter vent holes bleed off oil. This stops the piston from moving any farther. When the pressure from the solenoid is taken away, the upper supply holes in the cylinder become bleed holes that allow the piston to return to the home position. The piston is pushed back to the home position by the force of the intake valve springs. As the piston approaches the home position, some of the bleed holes are covered and the speed of the piston is regulated as it approaches the final resting position. This also controls the valve speed as it seats in the cylinder head. The hydraulic brake pumping element also functions as a hydraulic lash adjuster (3) because the valve stem clearance is hydraulically taken up by the piston. This occurs because the hydraulic brake pumping element/hydraulic lash adjuster is always under some oil pressure from the engine oil lubrication system. This creates enough pressure to take up valve clearance.

The variable valve actuator features three areas that function together as an oil reservoir so that the actuator always has a ready supply of engine oil. The engine lubrication system provides oil to the lower reservoir area and keeps it full of oil. To flow from the lower reservoir to the upper reservoir, the oil must pass through very small holes. This helps to purge air from the lower reservoir and to maintain engine oil pressure in the lower reservoir. The third reservoir area, the oil accumulator (7), is filled by oil vented from the oil chamber by the solenoid valve (8). The oil accumulator is a spring loaded accumulator that absorbs the hydraulic shock that would otherwise be created when the solenoid valves are opened. This helps to increase the durability of the system, maintains higher pressure in the lower pressure side of the system and lowers the overall load on the engine oil pump.

Variable valve actuation provides five possible phases of operation. Each phase offers unique advantages compared to normal camshaft operation. The five phases are:

Fig. 179: Full Lift
Courtesy of CHRYSLER GROUP, LLC

• Full Lift. When variable valve actuation functions in the full lift phase, all of the camshaft lobe lift is transferred to the intake valves. The intake camshaft lobe is designed with a very aggressive lift and duration profile. This results in good power in the upper RPM ranges with high loads. This profile would rarely be used in everyday driving.

Fig. 180: Early Intake Valve Closing (EIVC)
Courtesy of CHRYSLER GROUP, LLC

• Early intake valve closing (EIVC). When variable valve actuation functions in the EIVC phase, the camshaft lobe lift is transferred to the intake valves at the beginning of the lift duration cycle. However, the hydraulic connection between the camshaft lobe and the valves is taken away before the lobe reaches full lift. The exact timing and lift can be infinitely varied to meet driver requirements. EIVC provides smooth engine performance and more torque at lower engine speeds.

Fig. 181: Late Intake Valve Opening (LIVO)
Courtesy of CHRYSLER GROUP, LLC

• Late intake valve opening (LIVO). When variable valve actuation functions in the LIVO phase, the camshaft lobe lift is NOT transferred to the intake valves at the beginning of the lift duration cycle. The hydraulic connection between the camshaft lobe and the valves is completed after the rocker arm has already begun riding the ramp of the camshaft lobe. When the hydraulic connection is completed, the intake valves will begin to open. The valve lift timing can be varied infinitely within the full profile of the camshaft lobe. Therefore, as long as the hydraulic connection is completed before the camshaft lobe reaches its maximum lift, some valve lift will result. The lift profile will follow the camshaft lobe profile for the time that the hydraulic link is complete. Like EIVC, the exact timing and lift can be infinitely varied to meet driver requirements. LIVO provides lower emissions and a higher efficiency at lower loads or idle conditions.

Fig. 182: Multi-Lift
Courtesy of CHRYSLER GROUP, LLC

• Multi-Lift. Multi-Lift is a combination of EIVC and LIVO because the hydraulic connection between the camshaft lobe and the intake valves is closed early and then re-opened later in the cycle. This creates a longer duration valve lift with a smaller amount of lift. The result is a higher velocity of air flow into the cylinder over a longer period of time. Multi-Lift may be used in mixed driving of acceleration and deceleration with moderate engine speeds.

Fig. 183: Closed
Courtesy of CHRYSLER GROUP, LLC

• Closed. The closed phase simply leaves the intake valves closed by not utilizing the camshaft lobe to lift the intake valves.

REMOVAL

REMOVAL

Fig. 184: Cylinder Head Cover Bolts
Courtesy of CHRYSLER GROUP, LLC

1. Remove the cylinder head cover bolts (1). Remove the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL .
2. Unlock and disconnect the four variable valve timing actuator electrical connectors.

   Fig. 185: VVAA Block Removal Sequence (1 Of 2)
   Courtesy of CHRYSLER GROUP, LLC

3. Remove four bolts from the VVAA block.

   NOTE:

   The bolts need to be removed prior to the installation of the compressor tool due to the tool obstructs access to these bolts once the tool is installed.

   NOTE:

   Be sure to follow the sequence shown in illustration above when removing the bolts.

   Fig. 186: Special Tool, Spring Compressor & Indicators
   Courtesy of CHRYSLER GROUP, LLC

4. Using special tool 10259A (1), loosen the spring compressors (2) to fit over the valve and spring assemblies. Adjust the tool to align with the 2.4L indicators (3).
5. Install the (special tool #10259B, Compressor, MultiAir® Spring) spring compressor.
6. Rotate the spring compressors counterclockwise until the springs are fully seated.

   Fig. 187: VVAA Block Removal Sequence (2 Of 2)
   Courtesy of CHRYSLER GROUP, LLC

   CAUTION:

   Do not invert the variable valve actuation assembly when it is removed from the engine. Oil will drain from the assembly and excessive engine cranking will be required to refill the assembly and start the engine.

7. Remove the remaining five bolts from the VVAA.

   NOTE:

   Be sure to follow the sequence shown in illustration above when removing the bolts.

8. Remove the variable valve timing actuation assembly, with the spring compressor attached, from the camshaft bearing housing.

   Fig. 188: VVAA Assembly On Blocks Of Wood
   Courtesy of CHRYSLER GROUP, LLC

9. Set the assembly (1) onto two blocks of wood (2) to store during repairs.

   NOTE:

   Be sure to store the assembly in the upright position AT ALL TIMES to prevent oil related issues within the assembly.

   NOTE:

   There are two locating pins/dowels that properly position the VVAA. Be careful that both dowels remain installed in cylinder head after removing the VVAA. If a dowel comes loose, locate the missing dowel and discard it A new dowel will need to be used upon installation. DO NOT REUSE A DOWEL THAT HAS BEEN REMOVED FROM THE CYLINDER HEAD.

10. Remove and discard the variable valve actuation assembly gasket.

    Fig. 189: Rocker Arms
    Courtesy of CHRYSLER GROUP, LLC

11. If required, remove the rocker arms. Refer to ROCKER ARM, VALVE, REMOVAL .

INSPECTION

INSPECTION

Fig. 190: Valve Rocker Arms, Oil Supply O-Ring & Oil Temperature Sensor
Courtesy of CHRYSLER GROUP, LLC

Because variable valve actuation is so closely monitored, the diagnostics of the system are strongly Diagnostic Trouble Code (DTC) driven. If the system does not perform according to design, many DTC's may be produced from a condition in the variable valve actuation system.

The variable valve actuation module includes very few serviceable components. The module has no internal components that are serviceable. The following components are serviceable:

• Valve rocker arms (1)
• Oil supply O-ring (2)
• Oil temperature sensor (3)

INSTALLATION

INSTALLATION

click to open the image

A multimedia supplement to the instructions contained in this article is available. To view the multimedia example of the condition described go to; http://www.youtube.com/user/Mitchell1Tips then type "A00641417.vid1" into the "Search Channel" box.

Fig. 191: Locating Pins
Courtesy of CHRYSLER GROUP, LLC

1. If the dowel/locating pins were removed, install two NEW variable valve actuation assembly locating pins (1).

   Fig. 192: Rocker Arms
   Courtesy of CHRYSLER GROUP, LLC

2. If removed, install the rocker arms (1). Refer to ROCKER ARM, VALVE, INSTALLATION .

   Fig. 193: Special Tool, Spring Compressor & Indicators
   Courtesy of CHRYSLER GROUP, LLC

   CAUTION:

   Do not invert the variable valve actuation assembly when it is removed from the engine. Oil will drain from the assembly and excessive engine cranking will be required to refill the assembly and start the engine.

3. Rotate the spring compressors (2) counterclockwise until fully seated.
4. Install a new gasket.

   NOTE:

   To assist in the proper placement of the assembly, it is recommended to apply NEW/CLEAN MS-272 white grease or similar like Vaseline® onto the tips of the plungers to hold them in the retracted position. This will help to locate the assembly correctly while preventing the plunger tips from interfering with the valve stem tips. Use just enough to hold the plungers retracted.

5. Set the VVAA into position onto the two dowels.

   NOTE:

   It is very important that the plungers of the VVAA are centered over the valve stem tips. When properly aligned, the VVAA will set down onto the cylinder head evenly and will not have a tendency to wobble when set onto the head.

   NOTE:

   The VVAA should sit relatively flush to cylinder head with no more then a 1 to 2 mm gap between the mating surfaces. An excessive gap indicates the VVAA is not seated properly.

6. Visually inspect the alignment of the VVAA plungers.

   Fig. 194: Improperly Aligned VVAA
   Courtesy of CHRYSLER GROUP, LLC

7. This is a visual indication of an IMPROPERLY aligned VVAA. The centerline of the plunger (1) and the centerline of the valve stem (2) are misaligned.

   Fig. 195: Properly Aligned VVAA
   Courtesy of CHRYSLER GROUP, LLC

8. This is a visual indication of a PROPERLY aligned VVAA. The centerline (1) of both the plunger and the valve stem are aligned.

   Fig. 196: Six VVAA Retaining Bolts Hand Tightening Sequence
   Courtesy of CHRYSLER GROUP, LLC

9. Install the six accessible bolts. Hand tighten the VVAA retaining bolts.

   Fig. 197: Variable Valve Actuation Assembly Tightening Sequence
   Courtesy of CHRYSLER GROUP, LLC

10. Remove the spring compressor and tighten the ten bolts in three steps following the sequence shown in illustration:
    • Step 1: All to 10 N.m (89 in. lbs.).
    • Step 2: All to 22 N.m (16 ft. lbs.).
    • Step 3: All again to 22 N.m (16 ft. lbs.).
11. Connect and lock the four variable valve timing actuator electrical connectors.
12. Connect and lock the oil temperature sensor electrical connector.
13. Engage the oil temperature electrical connector to the bracket.

    Fig. 198: Cylinder Head Cover
    Courtesy of CHRYSLER GROUP, LLC

14. Install the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, INSTALLATION .

    NOTE:

    If the VVAA is being replaced (new part), it is recommended that the VVAA be primed with NEW/CLEAN oil after installation. This will limit the amount of time it takes for the assembly to fill while cranking the engine. If the cylinder head cover is installed the service port can be accessed through the opening at the rear of the cover (1).

    Fig. 199: Service Port & Bleed Port
    Courtesy of CHRYSLER GROUP, LLC

15. Using an oil can with a CLEAN soft tip or similar tool like a NEW plastic syringe, force CLEAN, UNUSED oil into the service port (1). Continue to inject oil until oil flows continuously from the bleed port (2) or until a maximum of 200 mL has been injected.
16. The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. .

ENGINE BLOCK

DESCRIPTION

DESCRIPTION

The die cast aluminum cylinder block is a two-piece assembly, consisting of the cylinder block and ladder frame. The block is an open deck design with cast in place cast iron cylinder liners. The cast iron cylinder liners are recessed below the aluminum deck surface. The ladder frame bolts to the cylinder block and does not incorporate the main bearing caps. This design offers a much stronger lower end and increased cylinder block and transaxle rigidity. The rear oil seal retainer is integral with the block and ladder frame. The ladder frame and block are serviced as an assembly.

Fig. 200: Serial Number Location
Courtesy of CHRYSLER GROUP, LLC

The engine serial number is located on the bottom of the ladder frame just behind the oil pan. The date can be seen with the oil pan in place.

STANDARD PROCEDURE

CYLINDER BORE DEGLAZING

Fig. 201: Cylinder Bore Crosshatch Pattern
Courtesy of CHRYSLER GROUP, LLC

Before deglazing, mask the crankcase area to keep abrasive materials from entering the engine lower end. Tape off any openings to prevent abrasive material from entering the coolant and oil circuits.

CAUTION:

DO NOT use rigid type hones to remove cylinder wall glaze.

1. Select an appropriate size flexible ball hone.
2. Deglazing of the cylinder walls may be done if the cylinder bore is straight and round. About 20-60 strokes, depending on the condition of the cylinder bore, will be sufficient to provide a satisfactory surface. Use a light honing oil, available from major oil distributors.

   CAUTION:

   DO NOT use engine or transmission oil, mineral spirits, or kerosene.

3. Deglazing should be done by moving the hone up and down fast enough to get a crosshatch pattern. The hone marks should intersect at 30° to 60° inclusive angle for proper seating of rings.
4. A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper crosshatch angle (1). The number of up and down strokes per minute can be regulated to get the desired 30° to 60° inclusive angle (2). Faster up and down strokes increase the crosshatch angle.
5. After deglazing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash parts with a solution of hot water and detergent. Dry parts thoroughly. Use a clean, white, lint-free cloth to check that the bore is clean. Oil the bores after cleaning to prevent rusting. Upon completion, perform a visual inspection of the cylinder block passages to inspect for abrasive debris. If any debris is found, repeat the cleaning process.

   NOTE:

   Cylinder bore diameter should not increase more than 20 microns during deglazing process from original nominal bore diameter, if the maximum of 20 microns is exceeded, the cylinder block must be replaced. If deglazing the cylinder bore cannot remove the light scratches and scuffs the cylinder block should be replaced.

MEASURING BEARING CLEARANCE USING PLASTIGAGE

Fig. 202: Plastigage Placed In Lower Shell
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Typical crankshaft journal shown in illustration.

Engine crankshaft and connecting rod bearing clearances can be determined by the use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage:

1. Remove the oil film from surface to be checked. Plastigage is soluble in oil.
2. Place a piece of Plastigage (1) across the entire width of the journal (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Plastigage must not crumble in use. If brittle, obtain fresh stock.
3. Torque the bearing cap bolts of the bearing being checked to the proper specification. Refer to TORQUE SPECIFICATIONS .

   NOTE:

   DO NOT rotate the crankshaft. Plastigage will smear, causing inaccurate results.

   Fig. 203: Measuring Bearing Clearance With Plastigage
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Typical connecting rod cap shown in illustration.

4. Remove the bearing cap and compare the width of the flattened Plastigage (2) with the scale provided on the package (1). Locate the band closest to the same width. This band shows the amount of clearance. Differences in readings between the ends indicate the amount of taper present or the possibility of foreign material trapped under the bearing insert.
5. Record all readings taken. Compare clearance measurements to. Refer to ENGINE SPECIFICATIONS .

   Fig. 204: Checking Connecting Rod Bearing Clearance With Plastigage
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Typical connecting rod journal shown in illustration.

   NOTE:

   Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale.

6. Install the proper bearings to achieve the specified bearing clearances.
7. Repeat the Plastigage measurement to verify your bearing selection prior to final assembly.

INSPECTION

INSPECTION

Fig. 205: Main Bearing Inserts
Courtesy of CHRYSLER GROUP, LLC

1. Wipe the bearing inserts (1, 2) clean.
2. Inspect the inserts for abnormal wear patterns, scoring, grooving, fatigue, pitting and for metal or other foreign material imbedded in the lining.
3. Inspect the back of the inserts for fractures, scrapes, or irregular wear patterns.
4. Inspect the insert locking tabs for damage.
5. Inspect the crankshaft thrust washers for scoring, scratches, wear or blueing.
6. Replace any bearing that shows abnormal wear. Refer to BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE .
7. Inspect the main bearing bores for signs of scoring, nicks and burrs.
8. If the cylinder block main bearing bores show damage the engine block must be replaced.

   Fig. 206: Measuring Cylinder Bore Diameter
   Courtesy of CHRYSLER GROUP, LLC

9. Use the Cylinder Indicator (special tool #C-119, Cylinder Indicator) (2) to correctly measure the inside diameter of the cylinder bore (3). A cylinder bore gauge capable of reading in 0.003 mm (0.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer.
10. Measure the inside diameter of the cylinder bore at three levels below the top of the bore (4). Start at the top of the bore, perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A (1).
11. Repeat the measurement near the middle of the bore, then repeat the measurement near the bottom of the bore.
12. Determine taper by subtracting the smaller diameter from the larger diameter.
13. Rotate the Cylinder Indicator 90° to point B (1) and repeat the three measurements. Verify that the maximum taper is within specification. Refer to ENGINE SPECIFICATIONS .
14. Determine out-of-roundness by comparing the difference between A and B at each of the three levels. Verify that the maximum out of round is within specification. Refer to ENGINE SPECIFICATIONS .
15. If cylinder bore taper and out-of-roundness are within specification, the cylinder bore can be honed. Refer to ENGINE BLOCK - STANDARD PROCEDURE . If the cylinder bore taper or out-of-round condition exceeds the maximum limits, the cylinder block must be replaced.

NOTE:

A slight amount of taper always exists in the cylinder bore after the engine has been in use for a period of time.

BEARING(S), CONNECTING ROD

STANDARD PROCEDURE

STANDARD PROCEDURE - CONNECTING ROD - FITTING

Fig. 207: Bearing Selection
Courtesy of CHRYSLER GROUP, LLC

There are three different sizes of rod bearings available. Connecting rod bearing identification (4) can be found on the nose of the crankshaft (3). Use the table below for proper bearing selection:

CONNECTING ROD BEARING SELECTION

CRANKSHAFT PIN DIAMETER GRADE	DIMENSION	CONNECTING ROD BEARING CLASSIFICATION	CONNECTING ROD BEARING DIMENSION
1	48 mm	1 (Black)	1.5 mm
2	48 mm	2 (No Color)	1.5 mm
3	48 mm	3 (Green)	1.5 mm

Fig. 208: Connecting Rod Bearing Clearance - Typical
Courtesy of CHRYSLER GROUP, LLC

1. For measuring connecting rod bearing clearance procedure and use of Plastigage, refer to ENGINE - STANDARD PROCEDURE . For bearing clearance, refer to ENGINE SPECIFICATIONS .

   NOTE:

   The rod bolts should not be reused.

2. Before installing the NEW rod bolts the threads and under the bolt head should be oiled with clean engine oil.
3. Install each bolt finger tight then alternately tighten each bolt to assemble the cap properly.
4. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values:

   CAUTION:

   Do not use a torque wrench for the second step.

   • Tighten the bolts to 20 N.m (15 ft. lbs.).
   • Tighten the connecting rod bolts an additional 90°.

   Fig. 209: Connecting Rod Side Clearance
   Courtesy of CHRYSLER GROUP, LLC

5. Using a feeler gauge, check connecting rod side clearance. For clearance specifications, refer to ENGINE SPECIFICATIONS .

CONNECTING ROD BEARING REPLACEMENT

Fig. 210: Connecting Rod Bearing Shells & Bearing Size
Courtesy of CHRYSLER GROUP, LLC

The connecting rod bearings (1) are serviced in-vehicle. They must be replaced one-at-a-time in order to prevent the pistons from contacting the valves. The connecting rod bearings are "select fit" to achieve proper oil clearances. Refer to BEARING(S), CONNECTING ROD - STANDARD PROCEDURE .

Fig. 211: Main Bearing Cap Bolts From Windage Tray Removal Sequence
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect and isolate the battery negative cable.
2. Remove the spark plugs. Refer to SPARK PLUG, REMOVAL .
3. Remove the oil pan, oil pump pick-up and engine oil pump. Refer to PUMP, ENGINE OIL, REMOVAL .
4. Remove the eight main bearing cap bolts in the sequence shown.

   Fig. 212: Connecting Rod To Cylinder Identification
   Courtesy of CHRYSLER GROUP, LLC

   CAUTION:

   DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur

   NOTE:

   Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.

5. Mark connecting rod and bearing cap positions (1) using a permanent ink marker or scribe tool.

   Fig. 213: Piston, Connecting Rod Cap, Bolts, Plastic Guide Plates & Guide Pins
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Typical V6 engine configuration shown.

   CAUTION:

   Replace only one connecting rod bearing at a time while all other connecting rod bearing caps remain properly tightened. If all connecting rod bearing caps are removed, crankshaft rotation will result in valve and/or piston damage.

   CAUTION:

   Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.

6. Remove the connecting rod cap bolts (5) and the connecting rod cap (4). Discard the cap bolts.
7. Remove the plastic guide plates (3) from the Guide Pins (special tool #8189, Guide Pins) (7) and install the Guide Pins to the connecting rod being removed.

   CAUTION:

   Care must be taken not to nick crankshaft journals, as engine damage may occur.

8. Rotate the crankshaft away from the connecting rod and remove the bearing shell.
9. If required, select and fit new bearings to the connecting rod. Refer to BEARING(S), CONNECTING ROD - STANDARD PROCEDURE .
10. Install the bearing shell (8) on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
11. Rotate the crankshaft while guiding the connecting rod into position over the rod journal.

    CAUTION:

    The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.

12. Install the bearing shell (6) on the connecting rod cap (4) with the tang inserted into the machined groove in the cap. Lubricate the bearing surface with clean engine oil.

    NOTE:

    Do not lubricate the threads of the connecting rod cap bolts (5).

13. Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten the NEW connecting rod cap bolts (5) to 20 N.m (15 ft. lbs.) plus 90°.
14. If required, check the connecting rod side clearance. Refer to ROD, PISTON AND CONNECTING - STANDARD PROCEDURE .
15. Repeat the previous steps for each connecting rod bearing being replaced.

    Fig. 214: Checking Cylinder Head Bolts For Stretching (Necking)
    Courtesy of CHRYSLER GROUP, LLC

    CAUTION:

    The main bearing cap bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

16. Check the main bearing cap bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.

    Fig. 215: Windage Tray With Main Bearing Cap Bolts Installation Sequence
    Courtesy of CHRYSLER GROUP, LLC

17. Install the eight main bearing cap bolts. Tighten the bolts in the sequence shown to 21 N.m (16 ft. lbs.) plus 90°.
18. Install the engine oil pump, oil pump pick-up and oil pan. Refer to PUMP, ENGINE OIL, INSTALLATION .
19. Install the spark plugs and ignition coils. Refer to SPARK PLUG, INSTALLATION .
20. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to OIL - STANDARD PROCEDURE .
21. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
22. Operate the engine until it reaches normal operating temperature.

BEARING(S), CRANKSHAFT, MAIN

STANDARD PROCEDURE

STANDARD PROCEDURE - CONNECTING ROD - FITTING

Fig. 216: Bearing Selection
Courtesy of CHRYSLER GROUP, LLC

There are three different sizes of rod bearings available. Connecting rod bearing identification (4) can be found on the nose of the crankshaft (3). Use the table below for proper bearing selection:

CONNECTING ROD BEARING SELECTION

CRANKSHAFT PIN DIAMETER GRADE	DIMENSION	CONNECTING ROD BEARING CLASSIFICATION	CONNECTING ROD BEARING DIMENSION
1	48 mm	1 (Black)	1.5 mm
2	48 mm	2 (No Color)	1.5 mm
3	48 mm	3 (Green)	1.5 mm

Fig. 217: Connecting Rod Bearing Clearance - Typical
Courtesy of CHRYSLER GROUP, LLC

1. For measuring connecting rod bearing clearance procedure and use of Plastigage, refer to ENGINE - STANDARD PROCEDURE . For bearing clearance, refer to ENGINE SPECIFICATIONS .

   NOTE:

   The rod bolts should not be reused.

2. Before installing the NEW rod bolts the threads and under the bolt head should be oiled with clean engine oil.
3. Install each bolt finger tight then alternately tighten each bolt to assemble the cap properly.
4. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values:

   CAUTION:

   Do not use a torque wrench for the second step.

   • Tighten the bolts to 20 N.m (15 ft. lbs.).
   • Tighten the connecting rod bolts an additional 90°.

   Fig. 218: Connecting Rod Side Clearance
   Courtesy of CHRYSLER GROUP, LLC

5. Using a feeler gauge, check connecting rod side clearance. For clearance specifications, refer to ENGINE SPECIFICATIONS .

CONNECTING ROD BEARING REPLACEMENT

Fig. 219: Connecting Rod Bearing Shells & Bearing Size
Courtesy of CHRYSLER GROUP, LLC

The connecting rod bearings (1) are serviced in-vehicle. They must be replaced one-at-a-time in order to prevent the pistons from contacting the valves. The connecting rod bearings are "select fit" to achieve proper oil clearances. Refer to BEARING(S), CONNECTING ROD - STANDARD PROCEDURE .

Fig. 220: Main Bearing Cap Bolts From Windage Tray Removal Sequence
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect and isolate the battery negative cable.
2. Remove the spark plugs. Refer to SPARK PLUG, REMOVAL .
3. Remove the oil pan, oil pump pick-up and engine oil pump. Refer to PUMP, ENGINE OIL, REMOVAL .
4. Remove the eight main bearing cap bolts in the sequence shown.

   Fig. 221: Connecting Rod To Cylinder Identification
   Courtesy of CHRYSLER GROUP, LLC

   CAUTION:

   DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur

   NOTE:

   Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.

5. Mark connecting rod and bearing cap positions (1) using a permanent ink marker or scribe tool.

   Fig. 222: Piston, Connecting Rod Cap, Bolts, Plastic Guide Plates & Guide Pins
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Typical V6 engine configuration shown.

   CAUTION:

   Replace only one connecting rod bearing at a time while all other connecting rod bearing caps remain properly tightened. If all connecting rod bearing caps are removed, crankshaft rotation will result in valve and/or piston damage.

   CAUTION:

   Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.

6. Remove the connecting rod cap bolts (5) and the connecting rod cap (4). Discard the cap bolts.
7. Remove the plastic guide plates (3) from the Guide Pins (special tool #8189, Guide Pins) (7) and install the Guide Pins to the connecting rod being removed.

   CAUTION:

   Care must be taken not to nick crankshaft journals, as engine damage may occur.

8. Rotate the crankshaft away from the connecting rod and remove the bearing shell.
9. If required, select and fit new bearings to the connecting rod. Refer to BEARING(S), CONNECTING ROD - STANDARD PROCEDURE .
10. Install the bearing shell (8) on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
11. Rotate the crankshaft while guiding the connecting rod into position over the rod journal.

    CAUTION:

    The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.

12. Install the bearing shell (6) on the connecting rod cap (4) with the tang inserted into the machined groove in the cap. Lubricate the bearing surface with clean engine oil.

    NOTE:

    Do not lubricate the threads of the connecting rod cap bolts (5).

13. Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten the NEW connecting rod cap bolts (5) to 20 N.m (15 ft. lbs.) plus 90°.
14. If required, check the connecting rod side clearance. Refer to ROD, PISTON AND CONNECTING - STANDARD PROCEDURE .
15. Repeat the previous steps for each connecting rod bearing being replaced.

    Fig. 223: Checking Cylinder Head Bolts For Stretching (Necking)
    Courtesy of CHRYSLER GROUP, LLC

    CAUTION:

    The main bearing cap bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

16. Check the main bearing cap bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.

    Fig. 224: Windage Tray With Main Bearing Cap Bolts Installation Sequence
    Courtesy of CHRYSLER GROUP, LLC

17. Install the eight main bearing cap bolts. Tighten the bolts in the sequence shown to 21 N.m (16 ft. lbs.) plus 90°.
18. Install the engine oil pump, oil pump pick-up and oil pan. Refer to PUMP, ENGINE OIL, INSTALLATION .
19. Install the spark plugs and ignition coils. Refer to SPARK PLUG, INSTALLATION .
20. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to OIL - STANDARD PROCEDURE .
21. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
22. Operate the engine until it reaches normal operating temperature.

CRANKSHAFT

DESCRIPTION

DESCRIPTION

Fig. 225: Crankshaft
Courtesy of CHRYSLER GROUP, LLC

The crankshaft is made from induction hardened forged steel. Eight counterweights at 180° balance the crankshaft rotary mass. The main journals are crossed drilled for rod bearing lubrication. The crankshaft is supported by five select fit main bearings with the center bearing serving as the thrust washer location. Both the front and rear seals are a single piece design and are mounted to the oil pump and cylinder block.

STANDARD PROCEDURE

STANDARD PROCEDURE - MEASURING CRANKSHAFT END PLAY

Fig. 226: Checking Crankshaft End Play
Courtesy of CHRYSLER GROUP, LLC

1 - Crankshaft

2 - DIAL INDICATOR

1. Mount a dial indicator (2) to front of engine with the locating probe on nose of crankshaft (1).
2. Move crankshaft all the way to the rear of its travel.
3. Zero the dial indicator.
4. Move crankshaft all the way to the front and read the dial indicator. for end play specification. Refer to ENGINE SPECIFICATIONS .

REMOVAL

REMOVAL

Fig. 227: Flex Plate
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Crankshaft can not be removed when engine is in vehicle.

1. Remove engine assembly from vehicle. Refer to REMOVAL .
2. Remove flex plate/flywheel (1).
3. Remove crankshaft rear oil seal. Refer to SEAL, CRANKSHAFT OIL, REAR, REMOVAL .

   Fig. 228: Oil Drain Plug & Oil Pan
   Courtesy of CHRYSLER GROUP, LLC

4. Install engine on suitable stand.
5. Drain engine oil (2).

   Fig. 229: Oil Filter
   Courtesy of CHRYSLER GROUP, LLC

6. Remove oil filter (1).
7. Remove crankshaft vibration damper. Refer to DAMPER, VIBRATION, REMOVAL .
8. Remove water pump pulley.

   Fig. 230: Using Putty Knife To Loosen Seal Around Oil Pan
   Courtesy of CHRYSLER GROUP, LLC

9. Remove the oil pan (2). Refer to PAN, OIL, REMOVAL .
10. Remove timing chain cover. Refer to COVER(S), ENGINE TIMING, REMOVAL .
11. Remove the timing chain. Refer to CHAIN AND SPROCKETS, TIMING, REMOVAL .
12. Remove balance shaft module.

    Fig. 231: Crankshaft Sprocket
    Courtesy of CHRYSLER GROUP, LLC

13. Remove the crankshaft sprocket (1).

    Fig. 232: Crankshaft Position Sensor & Bolt
    Courtesy of CHRYSLER GROUP, LLC

14. Remove crankshaft position sensor retaining bolt (1) and remove sensor (2).
15. Remove ladder frame. Refer to FRAME, LADDER, REMOVAL.

    Fig. 233: Identify Connecting Rod To Cylinder-Typical
    Courtesy of CHRYSLER GROUP, LLC

    NOTE:

    If piston/connecting rod replacement is necessary, remove cylinder head. Refer to CYLINDER HEAD, REMOVAL .

    CAUTION:

    DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.

16. Using a permanent ink or paint marker, identify cylinder number on each connecting rod and cap.
17. Remove all connecting rod bolts and caps. Care should be taken not to damage the fracture rod and cap surfaces.

    Fig. 234: Main Bearing Cap Removal/Installation Sequence
    Courtesy of CHRYSLER GROUP, LLC

    NOTE:

    Do not reuse connecting rod bolts.

18. Remove main bearing caps.

    CAUTION:

    Use extreme care when handling crankshaft. Tone wheel damage can occur if crankshaft is mis-handled.

19. Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the crankshaft.

INSPECTION

INSPECTION

Fig. 235: Measuring Crankshaft Journal
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Typical crankshaft journal measurements shown.

1. Clean the oil off the bearing journals.
2. Determine the maximum diameter of the journals with a micrometer. Measure at two locations 90° apart at each end of the journals.
3. Compare the measured rod journal diameter to the crankshaft connecting rod bearing journal diameter grade marking chart. Refer to BEARING(S), CONNECTING ROD - STANDARD PROCEDURE . Select the bearing size that corresponds to the crankshaft markings for each rod bearing journal that will provide the proper oil clearance.
4. Compare the measured main bearing journal diameter to the crankshaft main bearing journal diameter grade marking chart. Refer to BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE . Obtain the main bearing journal grade identification marks from the engine block and select the upper and lower main bearing sizes that will provide the proper oil clearance.
5. For connecting rod journals, verify that the maximum taper and maximum out of round are within specifications. Refer to ENGINE SPECIFICATIONS .
6. For main bearing journals, verify that the maximum taper and maximum out of round are within specifications. Refer to ENGINE SPECIFICATIONS .

INSTALLATION

INSTALLATION

Fig. 236: Bearing Identification
Courtesy of CHRYSLER GROUP, LLC

The crankshaft is supported in five main bearings. All upper bearing shells (2) in the crankcase have oil grooves and holes. All lower bearing shells (1) are smooth. Crankshaft end play is controlled by a two piece thrust bearing (3) on the number three main bearing journal.

1. Clean main bearing cap bolt holes with Mopar® brake parts cleaner or equivalent and blow out with compressed air.
2. Install the main bearing upper (2) shells with the lubrication groove and oil hole in the engine block.
3. Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots.

   Fig. 237: Target Wheel
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   If the crankshaft is sent out for machine work, it must be balanced as an assembly with the target ring installed.

4. Clean crankshaft and target ring with Mopar® brake parts cleaner or equivalent and dry with compressed air to ensure that the crankshaft mating surface and target ring mounting holes are free from oil and lock patch debris.

   NOTE:

   Always use NEW mounting screws whether installing original or new target ring.

5. Install NEW mounting screws finger tight starting with the #1 location. Make sure engagement occurs with the shoulder of the screws and mounting hole before starting all other screws.
6. Tighten all mounting screws to 13 N.m (110 in. lbs.) in the sequence shown.

   Fig. 238: Installing Thrust Bearing
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Lightly apply trans gel to thrust bearings to hold bearings in block.

   NOTE:

   The thrust bearings must be installed with the notches facing the crankshaft.

7. Install thrust bearings (2) in block (1).

   CAUTION:

   Do not get oil on the ladder frame mating surface. It will affect the ability of the RTV to seal the ladder frame to cylinder block.

   NOTE:

   Ensure main bearing cap bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.

8. Oil the bearings and journals. Install crankshaft in engine block.

   Fig. 239: Bearing Identification
   Courtesy of CHRYSLER GROUP, LLC

9. Install lower main bearings (1) into main bearing cap. Make certain the bearing tabs are seated into the bearing cap slots.

   NOTE:

   Main bearing caps are stamped 1 - 5 front to rear. Arrows on the caps must point towards the front of the engine.

10. Install main bearing caps to engine block.
11. Before installing the bolts the threads should be clean and dry.
12. Loosely install main bearing cap bolts.
13. To ensure correct thrust bearing alignment, perform the following steps:
    • Step 1: Rotate crankshaft until number 4 piston is at TDC.
    • Step 2: Move crankshaft rearward to limits of travel.
    • Step 3: Then, move crankshaft forward to limits of travel.
    • Step 4: Wedge an appropriate tool between the rear of the cylinder block and the rear crankshaft counterweight. This will hold the crankshaft in its furthest forward position.

    CAUTION:

    There are different sets main bolts supplied with this engine. Each bolt set has a different torque value and engine damage could result if bolts are not torqued correctly. The bolts are not interchangeable.

    Fig. 240: Main Bolt Identification
    Courtesy of CHRYSLER GROUP, LLC

14. If your bolt heads are marked with b (1) or 6 (2), go to step 15. If your bolt heads are marked with M (3) or any other marking, go to step 16.

    Fig. 241: Main Bearing Cap Removal/Installation Sequence
    Courtesy of CHRYSLER GROUP, LLC

    CAUTION:

    Before tightening bolts, you must identify the bolt head to obtain the correct torque value. Failure to identify the bolts correctly, could result in improperly tightened bolts which could result in engine damage.

15. Tighten bolts marked with b or 6 using the following three step method, in the sequence shown in illustration:
    • Tighten all bolts to 15 N.m (11 ft. lbs.)
    • Tighten all bolts to 27 N.m (20 ft. lbs.)
    • Tighten all bolts an additional 45°.
16. Tighten bolts marked with M using the following three step method, in the sequence shown in illustration:
    • Tighten all bolts to 15 N.m (11 ft. lbs.)
    • Tighten all bolts to 45 N.m (33 ft. lbs.)
    • Tighten all bolts an additional 45°.
17. Remove wedge tool used to hold crankshaft.
18. Check the crankshaft turning torque, it should not exceed 5.6 N.m (50 in. lbs.).
19. Check crankshaft end play. Refer to CRANKSHAFT - STANDARD PROCEDURE .
20. Install connecting rod bearings and caps. Do Not Reuse Connecting Rod Bolts. Tighten connecting rod bolts to 20 N.m + 90° (15 ft. lbs.) + 90°. Refer to ROD, PISTON AND CONNECTING, INSTALLATION .
21. Install the ladder frame assembly. Refer to FRAME, LADDER, INSTALLATION.
22. Install the balance shaft module. Refer to PUMP, ENGINE OIL, INSTALLATION .

    Fig. 242: Crankshaft Position Sensor & Bolt
    Courtesy of CHRYSLER GROUP, LLC

23. Install crankshaft position sensor (2) and bolt (1). Tighten the bolt to 9 N.m (80 in. lbs.)
24. Install cylinder head if it was removed. Refer to CYLINDER HEAD, INSTALLATION .

    Fig. 243: Crankshaft Sprocket
    Courtesy of CHRYSLER GROUP, LLC

25. Install front crankshaft sprocket (1).
26. Install the timing chain. Refer to CHAIN AND SPROCKETS, TIMING, INSTALLATION .
27. Install the timing chain front cover . Refer to COVER(S), ENGINE TIMING, INSTALLATION .
28. Install the oil pan. Refer to PAN, OIL, INSTALLATION .
29. Install rear crankshaft oil seal. Refer to SEAL, CRANKSHAFT OIL, REAR, INSTALLATION .
30. Install front crankshaft oil seal. Refer to SEAL, CRANKSHAFT OIL, FRONT, INSTALLATION .
31. Install crankshaft vibration damper. Refer to DAMPER, VIBRATION, INSTALLATION .
32. Install water pump pulley. Refer to PUMP, WATER, INSTALLATION .
33. Install crankshaft rear oil seal. Refer to SEAL, CRANKSHAFT OIL, REAR, INSTALLATION .
34. Install drive plate/flex plate using new bolts. Tighten bolts to 95 N.m (70 ft. lbs.).
35. Attach transaxle to engine. Tighten bellhousing bolts to 101 N.m (75 ft. lbs.).
36. Install the engine assembly into the vehicle. Refer to INSTALLATION .

    Fig. 244: Oil Filter
    Courtesy of CHRYSLER GROUP, LLC

37. Install new oil filter (1) and fill with oil.
38. Fill with coolant. Refer to STANDARD PROCEDURE .
39. Start engine and check for leaks.
40. Install engine cover.

DAMPER, VIBRATION

REMOVAL

REMOVAL

Fig. 245: Removing/Installing Crankshaft Damper Bolt
Courtesy of CHRYSLER GROUP, LLC

1. Remove accessory drive belts. Refer to BELT, SERPENTINE, REMOVAL .
2. Install Damper holder (special tool #9707, Holder, Vibration Damper) (1).
3. Remove crankshaft damper bolt.
4. Pull damper off crankshaft.

INSTALLATION

INSTALLATION

Fig. 246: Removing/Installing Crankshaft Damper Bolt
Courtesy of CHRYSLER GROUP, LLC

1. Install crankshaft damper.
2. Apply clean engine oil crankshaft damper bolt threads and between bolt head and washer. Tighten bolt to 210 N.m (155 ft. lbs.).
3. Install accessory drive belts. Refer to BELT, SERPENTINE, INSTALLATION .

FLEX PLATE

REMOVAL

REMOVAL

Fig. 247: Flex Plate
Courtesy of CHRYSLER GROUP, LLC

1. Remove transmission.
2. Remove flex plate bolts (3) and discard.
3. Remove washer (2).
4. Remove flex plate (1).

INSTALLATION

INSTALLATION

Fig. 248: Flex Plate
Courtesy of CHRYSLER GROUP, LLC

1. Install flex plate (1).
2. Install washer (2).
3. Install new flex plate bolts (3) and tighten in a criss-cross pattern to 95 N.m (70 ft. lbs.).
4. Install transaxle.

FRAME, LADDER

REMOVAL

REMOVAL

Fig. 249: Pry Point 1
Courtesy of CHRYSLER GROUP, LLC

1. Remove oil pan. Refer to PAN, OIL, REMOVAL .
2. Remove balance shaft assembly. Refer to PUMP, ENGINE OIL, REMOVAL .
3. Remove ladder frame retaining bolts.
4. Remove ladder frame using pry point cast in the rear of the block (1).

   Fig. 250: Pry Point 2
   Courtesy of CHRYSLER GROUP, LLC

5. To assist in removing the ladder frame another (1) pry point cast in the right side of the block.

INSTALLATION

INSTALLATION

Fig. 251: Sealing Ladder Frame
Courtesy of CHRYSLER GROUP, LLC

NOTE:

When using RTV, the sealing surfaces must be clean and free from grease and oil.

NOTE:

When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes.

1. Apply a 2 mm bead of Mopar® engine sealant RTV or equivalent as shown in illustration.

   Fig. 252: Ladder Frame Bolts Tightening Sequence
   Courtesy of CHRYSLER GROUP, LLC

2. Install bolts and tighten as shown in illustration following a two step method.
   • First: All to 10 N.m (89 in. lbs.).
   • Second: All to 26 N.m (19 ft. lbs.).
3. Install balance shaft module. Refer to PUMP, ENGINE OIL, INSTALLATION .
4. Install oil pan. Refer to PAN, OIL, INSTALLATION .

RING(S), PISTON

STANDARD PROCEDURE

STANDARD PROCEDURE - PISTON RING FITTING

Fig. 253: Measuring Piston Ring End Gap
Courtesy of CHRYSLER GROUP, LLC

1. Wipe the cylinder bore clean.
2. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder to a position 12 mm (0.50 in.) from the bottom of the cylinder bore.
3. Using a feeler gauge (1), check the ring end gap. Replace any rings not within specification.

   Ring Position	Ring End Gap
   No. 1 (top) Ring	0.25 - 0.40 mm (0.010 - 0.016 in.)
   No. 2 (center) Ring	0.30 - 0.45 mm (0.012 - 0.018 in.)
   Oil Control Ring (Steel Rail)	0.15 - 0.66 mm (0.006- 0.26 in.)

   Fig. 254: Checking Piston Ring Grooves Clearances
   Courtesy of CHRYSLER GROUP, LLC

4. Clean the piston ring grooves. Remove any nicks or burrs.
5. Measure the ring side clearance as shown in illustration. Make sure the feeler gauge (1) fits snugly between the ring land and the ring. Replace any ring not within specification.

Ring Position	Ring Side Clearance
No. 1 (top) Ring	0.025 - 0.033 mm (0.0010 - 0.0013 in.)
No. 2 (center) Ring	0.030 - 0.078 mm (0.0012 - 0.0031 in.)
Oil Control Ring (Steel Rails)	0.007 - 0.173 mm (.0003 - 0.0068 in.)

REMOVAL

REMOVAL

Fig. 255: Piston Ring Removal/Installation Sequence
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Typical piston shown in illustration.

1. Remove the piston and connecting rod(s). Refer to ROD, PISTON AND CONNECTING, REMOVAL .

   CAUTION:

   To avoid damage to the piston rings, they must be removed in the following order: No. 1 (upper) piston ring (1) No. 2 (intermediate) piston ring (2) Oil ring upper side rail (3) Oil ring lower side rail (4) Oil ring expander (5)

   Fig. 256: Removing/Installing Upper & Intermediate Rings
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Typical piston shown in illustration.

2. Remove the No. 1 (upper) piston ring using a ring expander tool.
3. Remove the No. 2 (intermediate) piston ring using a ring expander tool.

   Fig. 257: Removing/Installing Piston Ring Side Rail
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Typical piston shown in illustration. Do not use a piston ring expander to remove the oil ring side rails.

4. Remove the oil ring upper side rail.
5. Remove the oil ring lower side rail.
6. Remove the oil ring expander (1).

INSTALLATION

INSTALLATION

Fig. 258: Piston Ring Removal/Installation Sequence
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Typical piston shown in illustration.

1. If required, fit new rings to the piston. Refer to RING(S), PISTON - STANDARD PROCEDURE .

   CAUTION:

   To avoid damage to the piston rings, they must be installed in the following order: Oil ring expander (5) Oil ring lower side rail (4) Oil ring upper side rail (3) No. 2 (intermediate) piston ring (2) No. 1 (upper) piston ring (1)

   Fig. 259: Removing/Installing Piston Ring Side Rail
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Typical piston shown in illustration. Do not use a piston ring expander to install the oil ring side rails.

2. Install the oil ring expander (1).
3. Install the oil ring lower side rail by placing one end between the piston ring groove and the oil ring expander. Hold this end firmly and press down the portion to be installed until the side rail is in position.
4. Install the oil ring upper side rail in the same manner as the lower side rail.

   Fig. 260: Dot Marks On Piston Rings
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   The No. 1 (upper) piston ring (1) and No. 2 (intermediate) piston ring (3) have a different cross section. Install the rings with manufacturers I.D. mark (dot) (2) facing up, towards the top of the piston.

   Fig. 261: Removing/Installing Upper & Intermediate Rings
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Typical piston shown in illustration.

5. Install the No. 2 (intermediate) piston ring using a ring expander tool.
6. Install the No. 1 (upper) piston ring using a ring expander tool.
7. Rotate the rings around the piston, the rings must rotate in the grooves with out binding.

   Fig. 262: Piston Ring End Gap Position
   Courtesy of CHRYSLER GROUP, LLC

8. Position the piston ring end gaps as follows:
   • Oil ring expander gap (5)
   • Oil ring lower side rail end gap (4)
   • Oil ring upper side rail end gap (1)
   • No. 2 (intermediate) ring end gap (5)
   • No. 1 (upper) ring end gap (2)
9. Install the piston and connecting rod(s). Refer to ROD, PISTON AND CONNECTING, INSTALLATION .

ROD, PISTON AND CONNECTING

DESCRIPTION

DESCRIPTION

Fig. 263: Piston & Connecting Rod
Courtesy of CHRYSLER GROUP, LLC

CAUTION:

Do not use a metal stamp to mark connecting rods as damage may result, instead use ink or a scratch awl.

The pistons are a lightweight design with ultra low tension piston rings for improved fuel economy. The pistons are made of a high strength aluminum alloy and the piston skirt has a Moly® coating. The top piston ring land has an anodized coating for improved wear. The piston is connected to the rod using a full floating pin with two locking clips. The connecting rod is forged steel with a bolted cracked cap design. The connecting rod bolts are not reusable. Pistons are available in two different diameters with grade markings for each bore indicated on the side of the cylinder block. The upper compression ring is a 1.2 mm steel ring with a spray coating. The intermediate compression ring is 1.2 mm micro napier design. Both compression rings have a dot or a mark on the piston ring. The marked side of the ring must face the top of the piston. The 2 mm three piece oil control ring is very thin. These are chrome plated rings and have a stainless steel expander.

Fig. 264: Piston Components
Courtesy of CHRYSLER GROUP, LLC

• 1 - Head
• 2 - Valve Relief
• 3 - Upper or Top Land
• 4 - Second Land
• 5 - Third Land
• 6 - Moly® Coating
• 7 - Wrist Pin
• 8 - Locking Ring
• 9 - Skirt
• 10 - Oil Ring
• 11 - Secondary Compression Ring
• 12 - Top Compressor Ring

STANDARD PROCEDURE

PISTON FITTING

Fig. 265: Engine Block Cylinder Bore Diameter Grade Markings
Courtesy of CHRYSLER GROUP, LLC

The pistons are "select fit" to achieve proper oil clearance. Engine block cylinder bore diameter grade markings are stamped into the right side of the engine block. These marks are read from front to rear, corresponding with cylinder number 1, 2, 3, 4.

Engine block cylinder bore diameter grade markings correspond to specific cylinder bore diameters. The chart below identifies the three engine block grade markings and their associated cylinder bore diameters.

Engine Block Marking	Cylinder Bore Size mm (in.)
	Metric	Standard
A	72.000 - 72.010 mm	2.8346 - 2.8350 in.
B	72.010 - 72.020 mm	2.8350 - 2.8354 in.
C	72.020 - 72.030 mm	2.8354 - 2.8358 in.

Fig. 266: Piston Size Mark
Courtesy of CHRYSLER GROUP, LLC

The piston is marked with the piston size (1) on the piston crown. The pistons are available in three different sizes in order to achieve the desired oil clearance. Select the piston size that corresponds to the engine block cylinder bore diameter grade markings for each cylinder.

Pistons are available in three sizes. The chart below identifies the three piston sizes.

Piston Marking	Piston Size mm (in.)
	Metric	Standard
A	71.960 - 71.970 mm	2.8331 - 2.8835 in.
B	71.970 - 71.980 mm	2.8835 - 2.8339 in.
C	71.980 - 71.990 mm	2.8339 - 2.8342 in.

Fig. 267: Coating Material On Piston
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Typical coated piston shown in illustration.

The coated pistons are serviced with the piston pin and connecting rod pre-assembled. The coating material (1 and 2) is applied to the piston after the final piston machining process. Piston installation into the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.

CONNECTING ROD SIDE CLEARANCE

DIAL INDICATOR

Fig. 268: Measuring Connecting Rod Side Clearance
Courtesy of CHRYSLER GROUP, LLC

1. Mount Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) to a stationary point on the engine. Locate the probe perpendicular to and resting against the connecting rod cap being checked.
2. Move the connecting rod all the way to the rear of its travel.
3. Zero the dial indicator.
4. Move the connecting rod forward to the limit of travel and read the dial indicator. Compare the measured side clearance to the specification. Refer to ENGINE SPECIFICATIONS .
5. Repeat this procedure for each connecting rod. Rotate the crankshaft for connecting rod accessibility.

FEELER GAUGE

Fig. 269: Connecting Rod Side Clearance
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Typical four cylinder engine shown in illustration.

1. Slide a snug-fitting feeler gauge between the connecting rod and crankshaft journal flange. Compare the measured side clearance to the specification. Refer to ENGINE SPECIFICATIONS .
2. Repeat this procedure for each connecting rod. Rotate the crankshaft for connecting rod accessibility.

REMOVAL

REMOVAL

Fig. 270: Main Bearing Cap Bolts From Windage Tray Removal Sequence
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect and isolate the negative battery cable.
2. Remove the oil pans, engine timing cover and cylinder heads. Refer to CYLINDER HEAD, REMOVAL .
3. Remove the engine oil pump. Refer to PUMP, ENGINE OIL, REMOVAL .
4. Remove the eight main bearing cap bolts from the windage tray in the sequence shown in illustration and remove the windage tray (1).

   Fig. 271: Connecting Rod To Cylinder Identification
   Courtesy of CHRYSLER GROUP, LLC

5. If necessary, remove the top ridge of the cylinder bores with a reliable ridge reamer before removing the pistons from the engine block. Be sure to keep the tops of pistons covered during this operation. Pistons and connecting rods must be removed from the top of the engine block. When removing piston and connecting rod assemblies from the engine, rotate the crankshaft CW so that each connecting rod is centered in the cylinder bore.

   CAUTION:

   DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur

   NOTE:

   Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.

6. Mark connecting rod and bearing cap positions (1) using a permanent ink marker or scribe tool.

   Fig. 272: Piston, Connecting Rod Cap, Bolts, Plastic Guide Plates & Guide Pins
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Typical V6 engine configuration shown in illustration.

   CAUTION:

   Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.

7. Remove the connecting rod cap bolts (5) and the connecting rod cap (4). Discard the cap bolts.

   CAUTION:

   Care must be taken not to nick crankshaft journals, as engine damage may occur.

8. Remove the plastic guide plates (3) from the Guide Pins (special tool #8189, Guide Pins) (7) and install the Guide Pins to the connecting rod being removed.

   CAUTION:

   Avoid contact with the piston oil cooler jet(s). Positioning of the oil cooler jet(s) is critical for proper engine operation.

9. Remove the piston and connecting rod (1) from cylinder bore.
10. Repeat the previous steps for each piston being removed.
11. Immediately after piston and connecting rod removal, reinstall the bearing cap (4) on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
12. If required, remove the piston rings. Refer to RING(S), PISTON, REMOVAL .
13. Repeat the previous steps for each piston being removed.

CLEANING

CLEANING

CAUTION:

DO NOT use a wire wheel or other abrasive cleaning devise to clean the pistons or connecting rods. The pistons have a Moly coating, this coating must not be damaged.

CAUTION:

Do not remove the piston pin from the piston and connecting rod assembly.

1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry.
2. Use a wood or plastic scraper to clean the ring land grooves.

INSPECTION

INSPECTION

Fig. 273: Inserts
Courtesy of CHRYSLER GROUP, LLC

1. Wipe the inserts (1) clean.
2. Inspect the inserts for abnormal wear patterns, scoring, grooving, fatigue, pitting and for metal or other foreign material imbedded in the lining.
3. Inspect the back of the inserts for fractures, scrapes, or irregular wear patterns.
4. Inspect the insert locking tabs for damage.
5. Replace any bearing that shows abnormal wear. Refer to BEARING(S), CONNECTING ROD - STANDARD PROCEDURE .

   Fig. 274: Connecting Rod To Cylinder Identification
   Courtesy of CHRYSLER GROUP, LLC

6. Inspect the connecting rod bearing bores for signs of scoring, nicks and burrs.

   NOTE:

   Misaligned or bent connecting rods can cause abnormal wear on pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft connecting rod journals. If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod, inspect it for correct rod alignment.

7. Replace misaligned, bent or twisted connecting rods.

   NOTE:

   Connecting rods are serviced with the piston pre-assembled. The pistons are "select fit" to achieve proper oil clearance. Refer to ROD, PISTON AND CONNECTING - STANDARD PROCEDURE .

   Fig. 275: Coating Material On Piston
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Typical coated piston shown in illustration.

8. Inspect the piston for scoring or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration.

   NOTE:

   The coating material (1 and 2) is applied to the piston after the final piston machining process. This coating may affect the outside diameter measurement of a coated piston may not provide accurate results.

9. Check the piston for taper and out of round shape.

NOTE:

Piston installation into the cylinder bore may require slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.

NOTE:

The coated pistons will be serviced with the piston pin and connecting rod pre-assembled.

INSTALLATION

INSTALLATION

Fig. 276: Vacuum Fitting O-Ring Seal
Courtesy of CHRYSLER GROUP, LLC

1. The vacuum fitting O-ring seal (1) can be reused if not damaged. If removed, lightly lubricate the O-ring seal (1) with clean engine oil and install on the vacuum fitting.

   Fig. 277: Vacuum Fitting & Screw
   Courtesy of CHRYSLER GROUP, LLC

2. If removed, install the vacuum fitting (2) to the vacuum pump with the screw (1) tightened to 8 N.m (71 in. lbs.).
3. Clean the mating surfaces of the cylinder head and the vacuum pump. Install a new vacuum pump gasket.
4. Align the pump drive tab with the pump drive slot located on the cam shaft.
5. Install the vacuum pump mounting bolts. Tighten the bolts to 20 N.m (15 ft. lbs.).
6. Connect the vacuum supply line to the pump.

   CAUTION:

   When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.

7. Install the battery (4). Refer to BATTERY, INSTALLATION .
8. Install the engine cover. Refer to RESONATOR, AIR CLEANER, INSTALLATION .
9. Run the engine a check the vacuum pump for proper operation.

SEAL, CRANKSHAFT OIL, FRONT

REMOVAL

REMOVAL

Fig. 278: Removing/Installing Crankshaft Damper
Courtesy of CHRYSLER GROUP, LLC

1. Remove accessory drive belt.
2. Install Damper Holder (special tool #9707, Holder, Vibration Damper) (1) and remove damper retaining bolt.
3. Pull damper off crankshaft.

   Fig. 279: Removing Front Crankshaft Oil Seal By Prying Out With Screwdriver
   Courtesy of CHRYSLER GROUP, LLC

4. Remove front crankshaft oil seal (1) by prying out with a screw driver (2). Be careful not to damage the cover seal surface.

INSTALLATION

INSTALLATION

Fig. 280: Crankshaft Oil Seal & Seal Installer 9506
Courtesy of CHRYSLER GROUP, LLC

1. Place seal (1) onto Front Crankshaft Seal Installer (special tool #9506, Installer, Oil Seal) (2) with seal spring towards the inside of engine.

   Fig. 281: Installing New Seal By Using Seal Installer 9506 & Crankshaft Damper Bolt
   Courtesy of CHRYSLER GROUP, LLC

2. Install new seal (1) by using Front Crankshaft Seal Installer (special tool #9506, Installer, Oil Seal) (2) and crankshaft damper bolt (3).

   Fig. 282: Pressing Seal Into Front Cover Until Seal Installer
   Courtesy of CHRYSLER GROUP, LLC

3. Press seal into front cover until Front Crankshaft Seal Installer (special tool #9506, Installer, Oil Seal) (1) seats against timing chain cover (3).
4. Remove Front Crankshaft Seal Installer (special tool #9506, Installer, Oil Seal) (1).

   Fig. 283: Installing Damper Holder 9707
   Courtesy of CHRYSLER GROUP, LLC

5. Install crankshaft vibration damper.
6. Oil the bolt threads and between the bolt head and washer.
7. Install damper retaining bolt and Damper Holder (special tool #9707, Holder, Vibration Damper) (1). Tighten bolt to 210 N.m (155 ft. lbs.).

SEAL, CRANKSHAFT OIL, REAR

REMOVAL

REMOVAL

Fig. 284: Flex Plate
Courtesy of CHRYSLER GROUP, LLC

1. Remove transmission and flexplate (1). Refer to FLEXPLATE, REMOVAL .

   Fig. 285: Rear Crankshaft Oil Seal - Removal
   Courtesy of CHRYSLER GROUP, LLC

2. Insert a 3/16 flat bladed screwdriver (7) between the dust lip (8) and the metal case (4) of the crankshaft seal (1). Angle the screwdriver through the dust lip against metal case of the seal. Pry out seal.

   CAUTION:

   Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of the screwdriver blade against crankshaft edge (chamfer) is permitted.

3. Check to make sure the seals garter spring is not on the crankshaft.

INSTALLATION

INSTALLATION

Fig. 286: Rear Main Seal Installation
Courtesy of CHRYSLER GROUP, LLC

CAUTION:

If a burr or scratch is present on the crankshaft edge (chamfer), cleanup with 800 emery cloth to prevent seal damage during installation of new seal. If emery cloth is used, the crankshaft must be cleaned off Mopar® brake parts cleaner.

NOTE:

When installing seal, lubricate Seal Guide (special tool #9509, Installer, Oil Seal) with clean engine oil.

1. Place Seal Guide (special tool #9509, Installer, Oil Seal) (3) on crankshaft.
2. Position seal (2) over guide tool. Guide tool should remain on crankshaft during installation of seal. Ensure that the lip of the seal is facing towards the crankcase during installation.
3. Drive the seal into the block using Seal Driver (special tool #9706, Installer, Crankshaft Rear Oil Seal) (1) and Driver Handle (special tool #C-4171, Driver Handle, Universal) (4) until Seal Driver (special tool #9706, Installer, Crankshaft Rear Oil Seal) bottoms out against the block.

   Fig. 287: Flex Plate
   Courtesy of CHRYSLER GROUP, LLC

4. Install the flexplate (1) and transmission. Refer to FLEXPLATE, INSTALLATION .

ENGINE MOUNTING

INSULATOR, ENGINE MOUNT, LEFT

REMOVAL

REMOVAL

1. Raise and support the vehicle

2. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
3. Lower the vehicle.
4. Remove the engine cover to prevent contact with the cowl.
5. Remove the battery and tray. Refer to TRAY, BATTERY, REMOVAL .
6. Support transaxle with a suitable jack.

   Fig. 288: Removing/Installing Left Engine Mount Insulator
   Courtesy of CHRYSLER GROUP, LLC

7. Remove the two mount to frame rail bolts (3).
8. Remove the three mount to transaxle bracket bolts (5).

   Fig. 289: Strut Tower, Trans Mount & Bolt
   Courtesy of CHRYSLER GROUP, LLC

9. Loosen, but do not remove the bolt (2) for the trans mount (3) to strut tower (1) attachment.
10. Remove the mount (4).

INSTALLATION

INSTALLATION

Fig. 290: Removing/Installing Left Engine Mount Insulator
Courtesy of CHRYSLER GROUP, LLC

1. Set the mount (4) into position between the engine block (6) and the frame rail (1).

   Fig. 291: Strut Tower, Trans Mount & Bolt
   Courtesy of CHRYSLER GROUP, LLC

2. Tighten the left mount to strut tower bolt (2) finger tight.

   Fig. 292: Removing/Installing Left Engine Mount Insulator
   Courtesy of CHRYSLER GROUP, LLC

3. Install the left mount to frame rail bolts (3). Finger tighten the bolts.
4. Install the left mount to transmission bracket bolts (5). Finger tighten the bolts.
5. Tighten the left mount to strut tower bolt (2) to 64 N.m (47 ft. lbs.).
6. Tighten the left mount to transmission bracket bolts (5) to 157 N.m (115 ft. lbs.).
7. Tighten the left mount to frame rail bolts to 70 N.m (52 ft. lbs.).
8. Remove the jack.
9. Install the battery tray. Refer to TRAY, BATTERY, INSTALLATION .
10. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
11. Install the engine cover assembly.

INSULATOR, ENGINE MOUNT, REAR

REMOVAL

REMOVAL

1. Raise and support the vehicle.
2. If equipped, remove the front skid plate

   Fig. 293: Rear Mount Bracket Nuts
   Courtesy of CHRYSLER GROUP, LLC

3. Remove the mount to bracket through bolt nut (2).

   Fig. 294: Rear Mount & Bolts
   Courtesy of CHRYSLER GROUP, LLC

4. Remove the mount to through bolt (2).

   Fig. 295: Removing/Installing Rear Engine Mount Insulator
   Courtesy of CHRYSLER GROUP, LLC

5. Remove the mount to bracket through bolt and nut (4).
6. Reposition the engine forward to allow the mount to be removed from the pocket past the mount bracket (5).

   NOTE:

   The exhaust system can remain intact. Carefully pry the engine forward enough to clear the bracket but not to overextend the exhaust hangers.

7. Remove rear mount (3).

INSTALLATION

INSTALLATION

Fig. 296: Rear Mount & Bolts
Courtesy of CHRYSLER GROUP, LLC

1. Position rear mount (3) into the crossmember pocket (4).
2. Install the through bolt (2) into the cradle portion of the mount.

   Fig. 297: Removing/Installing Rear Engine Mount Insulator
   Courtesy of CHRYSLER GROUP, LLC

3. Position the front arm of the mount around the bracket and install the through bolt and nut (4).

   Fig. 298: Rear Mount Bracket Nuts
   Courtesy of CHRYSLER GROUP, LLC

4. Tighten the nut (2) to 150 N.m (111 ft. lbs.).

   Fig. 299: Removing/Installing Rear Engine Mount Insulator
   Courtesy of CHRYSLER GROUP, LLC

5. Tighten the rear mount to engine bracket through bolt and nut (4) to 220 N.m (162 ft. lbs.).
6. If equipped, install the front skid plate.

INSULATOR, ENGINE MOUNT, RIGHT

REMOVAL

REMOVAL

1. Remove the engine cover.
2. Remove the air cleaner assembly. Refer to BODY, AIR CLEANER, REMOVAL .
3. Remove the coolant reservoir bolts. Set the reservoir aside.
4. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
5. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
6. Support the powertrain with a suitable jack.

   Fig. 300: Removing/Installing Right Engine Mount Insulator
   Courtesy of CHRYSLER GROUP, LLC

7. Remove the three mount to timing cover bolts (1).
8. Remove the two mount to frame bolts (2).
9. Loosen, but do not remove the mount to strut tower bolt (4).
10. Lift the mount off of the frame rail (5).
11. Remove the engine mount (3).

INSTALLATION

INSTALLATION

Fig. 301: Removing/Installing Right Engine Mount Insulator
Courtesy of CHRYSLER GROUP, LLC

1. Set the mount into position.
2. Tighten the right mount to strut tower bolt (4) finger tight.
3. Install engine mount to frame retaining bolts (2). Finger tighten the bolts.
4. Install the right mount to timing cover bolts (1). Finger tighten the bolts.

   Fig. 302: Strut Tower, Mount & Bolt
   Courtesy of CHRYSLER GROUP, LLC

5. Tighten the right mount to strut tower bolt to 65 N.m (48 ft. lbs.).

   Fig. 303: Removing/Installing Right Engine Mount Insulator
   Courtesy of CHRYSLER GROUP, LLC

6. Tighten the right mount to frame rail bolts (2) to 70 N.m (52 ft. lbs.).

   Fig. 304: Removing/Installing Right Engine Mount Insulator
   Courtesy of CHRYSLER GROUP, LLC

7. Tighten the engine mount to timing cover bolts (1). Tighten to 63 N.m (46 ft. lbs.).
8. Remove the jack stand.
9. Install the coolant reservoir bottle. Tighten bolt to 9 N.m (80 in. lbs.).
10. Install the air cleaner assembly. Refer to BODY, AIR CLEANER, REMOVAL .
11. Install the engine cover.
12. Refer to BELLY PAN, INSTALLATION .

MANIFOLDS

MANIFOLD, EXHAUST

REMOVAL

REMOVAL

1. Remove engine cover.
2. Disconnect battery negative cable.
3. Disconnect the upstream and downstream oxygen sensors.
4. Raise and support the vehicle.
5. Remove the belly pan.

   Fig. 305: Converter Outlet Studs
   Courtesy of CHRYSLER GROUP, LLC

6. Remove the two nuts from the converter outlet. Discard the gasket

   .

7. Lower the vehicle.

   Fig. 306: Exhaust Manifold Heat Shields
   Courtesy of CHRYSLER GROUP, LLC

8. Remove the four bolts from the upper shield (2)

   .

9. Remove the upper shield (2).

   Fig. 307: Exhaust Manifold Bolt
   Courtesy of CHRYSLER GROUP, LLC

10. Remove the exhaust manifold bolts (1).
11. Remove the manifold out the top of the vehicle.
12. Remove and discard manifold gasket.

INSTALLATION

INSTALLATION

1. Install a new exhaust manifold gasket. DO NOT APPLY SEALER .
2. Set the manifold into position. Install the manifold bolts.

   Fig. 308: Exhaust Manifold Bolts Tightening Sequence
   Courtesy of CHRYSLER GROUP, LLC

3. Following the torque sequence, tighten the exhaust manifold bolts to 34 N.m (25 ft. lbs.).

   Fig. 309: Exhaust Manifold Heat Shields
   Courtesy of CHRYSLER GROUP, LLC

4. Install the four shields in the proper sequence. Tighten bolts to 12 N.m (105 in. lbs.).
5. Install a new manifold lower gasket.
6. Install flange nuts. Tighten nuts to 28 N.m (21 ft. lbs.)
7. Install exhaust pipe to manifold (1). Tighten fasteners to (250 in. lbs.).
8. Install the oxygen sensors. Tighten to 50 N.m (37 ft. lbs.).
9. Connect the oxygen sensor connectors.
10. Install belly pan.
11. Lower vehicle.
12. Connect oxygen sensor electrical connector (3).
13. Connect negative cable to battery.
14. Install the engine cover.

MANIFOLD, INTAKE

REMOVAL

REMOVAL

1. Remove the engine cover.
2. Perform the fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
3. Disconnect the battery negative cable.
4. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
5. If equipped: remove the skid plates

   .

   Fig. 310: Intake Manifold Lower Bracket, Nuts & Bolts
   Courtesy of CHRYSLER GROUP, LLC

6. Remove the intake manifold lower bracket nuts (1).
7. Remove the intake manifold lower bracket bolt (2).
8. Remove the intake manifold lower bracket (3).
9. Lower the vehicle.

   Fig. 311: Removing/Installing Air Cleaner Body
   Courtesy of CHRYSLER GROUP, LLC

10. Remove the airbox assembly

    Fig. 312: Resonator, Clamp & Connector
    Courtesy of CHRYSLER GROUP, LLC

    .

11. Loosen the snorkel clamp (2).
12. Disconnect the intake temperature sensor (IAT) connector (3).

    Fig. 313: Resonator, Bolt & Clamp
    Courtesy of CHRYSLER GROUP, LLC

13. Remove the snorkel bolt (2) and the snorkel clamp (1).
14. Remove the snorkel (3).
15. Remove the coolant reservoir bottle bolts. Position the bottle aside.

    Fig. 314: Removing/Installing Airbox Bracket
    Courtesy of CHRYSLER GROUP, LLC

16. Remove the airbox bracket nuts (2) from the right frame rail (3). Remove the bracket (1).

    Fig. 315: Removing/Installing Right Engine Mount Insulator
    Courtesy of CHRYSLER GROUP, LLC

17. Remove the 2 frame rail bolts from the right engine mount (2).
18. Remove the right engine mount to strut tower bolt (4).
19. Position a floor lack under the air conditioning compressor bracket.

    NOTE:

    Use a block of wood or similar between the jack pad and the bracket.

20. Raise the engine enough to remove the load from the right engine mount

    Fig. 316: Measuring Three Inches
    Courtesy of CHRYSLER GROUP, LLC

21. With the help of an assistant, pull the engine forward until 3 inches are between the strut tower bolt ear and the strut tower (1).

    Fig. 317: Intake Manifold Upper Support Bracket, Bolts & Nuts
    Courtesy of CHRYSLER GROUP, LLC

22. Remove the intake manifold upper support bracket bolts (3) and loosen the nuts to allow for ample movement.

    Fig. 318: Throttle Body Support Bracket, Nut & Bolt
    Courtesy of CHRYSLER GROUP, LLC

23. Remove the throttle body bracket (2).

    Fig. 319: Throttle Body, Gasket & Bolts
    Courtesy of CHRYSLER GROUP, LLC

24. Remove the throttle body fasteners (1 & 2). Remove the throttle body (3).

    Fig. 320: Score Line
    Courtesy of CHRYSLER GROUP, LLC

25. Cut the injector silencer pad at the score line (1).
26. Remove the injector silencer pad.
27. Disconnect the VVAA solenoids.

    Fig. 321: Intake Manifold Silencer Pad Screws
    Courtesy of CHRYSLER GROUP, LLC

28. Remove the intake silencer cover screws (1). Remove the cover.
29. Disconnect the fuel injectors.

    Fig. 322: MAP Sensor Connector & Fittings
    Courtesy of CHRYSLER GROUP, LLC

30. Disconnect the vacuum hoses at the intake manifold (3).
31. Disconnect the MAP sensor (2).
32. Release the harness from the manifold eyelets (1).

Fig. 323: Intake Manifold Retaining Bolts & Nuts
Courtesy of CHRYSLER GROUP, LLC

34. Remove the intake manifold nuts (1).
35. Remove the intake manifold bolts (2).
36. Remove the intake manifold by lifting upward and out of the engine bay.

INSTALLATION

INSTALLATION

Fig. 324: Intake Manifold Retaining Bolts & Nuts
Courtesy of CHRYSLER GROUP, LLC

1. Clean all gasket surfaces.
2. Replace intake manifold gasket seals.
3. Position the foam pad over the coolant transfer tube.
4. Position the manifold onto the two studs.
5. Install intake manifold, tighten the fasteners (1 & 2) to 12 N.m (9 ft. lbs.).

   Fig. 325: Intake Manifold Silencer Pad Screws
   Courtesy of CHRYSLER GROUP, LLC

6. Install the intake manifold silencer cover and screws. Tighten the screws to 2.5 N.m (22 in. lbs.).

   Fig. 326: Intake Manifold Lower Bracket, Nuts & Bolts
   Courtesy of CHRYSLER GROUP, LLC

7. Install the intake manifold lower bracket (3). Install the two nuts (1) and one bolt (2). Tighten to 9 N.m (80 in. lbs.).
8. Connect fuel injector electrical connectors.
9. Inspect quick connect fittings for damage, replace if necessary. Refer to FITTING, QUICK CONNECT .
10. Connect the purge solenoid electrical connector.

    Fig. 327: Foam Insulator, Fuel Line & Purge Line
    Courtesy of CHRYSLER GROUP, LLC

11. Insert the foam insulator over the fuel rail (3).
12. Connect fuel line (1).
13. Connect the purge vapor line (2).

    Fig. 328: MAP Sensor Connector & Fittings
    Courtesy of CHRYSLER GROUP, LLC

14. Insert the harness retainers to the intake manifold eyelets (1).
15. Connect the three hose connectors (3).
16. Connect the MAP sensor connector (2).

    Fig. 329: Throttle Body, Gasket & Bolts
    Courtesy of CHRYSLER GROUP, LLC

17. Install throttle body (3) onto the intake manifold.
18. Install the three throttle body screws (1) and one throttle body bolt (2). Tighten to 8 N.m (71 in. lbs.).

    Fig. 330: Throttle Body Support Bracket, Nut & Bolt
    Courtesy of CHRYSLER GROUP, LLC

19. Install the throttle body upper support (2). Tighten the fasteners to 8 N.m (71 in. lbs.).

    Fig. 331: Intake Manifold Upper Support Bracket, Bolts & Nuts
    Courtesy of CHRYSLER GROUP, LLC

20. Install the intake manifold upper bracket (1). Install bolts (3) and nuts (2). Tighten to 9 N.m (80 in. lbs.).
21. Connect the PCV valve hose.
22. With assistance, slide the engine rearward back into its proper position. Make sure the mount is not against the frame while being moved.

    Fig. 332: Removing/Installing Right Engine Mount Insulator
    Courtesy of CHRYSLER GROUP, LLC

23. Lower the floor jack once the mount is in proper alignment.
24. Install the 2 engine mount to frame rail bolts (2).
25. Install the right engine mount to strut tower bolt (4).
26. Tighten the mount to strut tower bolt to 65 N.m (48 ft. lbs.).
27. Tighten the mount to frame rail bolts to 105 N.m (77 ft. lbs.)

    Fig. 333: Removing/Installing Airbox Bracket
    Courtesy of CHRYSLER GROUP, LLC

28. Install the air cleaner bracket (1). Install the nuts (2).
29. Tighten the nuts to 8 N.m (71 in. lbs.).

    Fig. 334: Resonator, Bolt & Clamp
    Courtesy of CHRYSLER GROUP, LLC

30. Install the intake snorkel (3).
31. Install the snorkel fastener (2). Tighten to 8 N.m (71 in lbs.).

    Fig. 335: Resonator, Clamp & Connector
    Courtesy of CHRYSLER GROUP, LLC

32. Connect the IAT sensor (3).
33. Tighten the clamp (2) to 4 N.m (35 in. lbs.).
34. Install the engine cover.

    Fig. 336: Removing/Installing Air Cleaner Body
    Courtesy of CHRYSLER GROUP, LLC

35. Install the air cleaner assembly (1). Refer to BODY, AIR CLEANER, INSTALLATION .
36. Connect negative cable to battery.

LUBRICATION

DESCRIPTION

DESCRIPTION

Fig. 337: Oil Flow Diagram
Courtesy of CHRYSLER GROUP, LLC

The lubrication system is a full-flow filtration, pressure feed type. The balance shaft module (BSM) is mounted below the ladder frame and chain driven by the crankshaft. The BSM consists of a non-serviceable pump, oil pressure relief valve, and a non-serviceable balance assembly.

Fig. 338: Oil Hole
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Not all blocks have the bolt on timing chain oil squirter. Engine blocks either have a bolt-on oil squirter or a 1.0 mm hole (1) drilled into the oil gallery passage. Engine blocks with the 1.0 mm hole no longer use an oil squirter even though the threaded mounting hole may still be present.

OPERATION

OPERATION

Engine oil is drawn up through the pickup tube and is pressurized by the oil pump and routed through the full-flow filter to the main oil gallery running the length of the cylinder block. A diagonal hole in each bulkhead feeds oil to each main bearing. Drilled passages within the crankshaft route oil from main bearing journals to connecting rod journals. Balance shaft lubrication is provided through an internal oil passage at the #3 bearing location around the balance shaft module (BSM) mounting bolt. A vertical hole at the number one bulkhead routes pressurized oil through a filter screen and head gasket up to the cylinder head. The oil then divides into two passages; one to the variable valve actuator assembly (VVAA) and one to the exhaust camshaft. The passage to the camshaft feeds the hollow exhaust camshaft at the second cam journal. The rest of the cam journals are feed oil through the hollow camshaft. Oil returning to the pan from pressurized components supplies lubrication to the valve stems, cam lobes, and tappets. Cylinder bores and wrist pins are splash lubricated from directed slots on the connecting rod thrust collars.

DIAGNOSIS AND TESTING

ENGINE OIL LEAK

Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed:

1. Do not clean or de-grease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak.
2. Add an oil soluble dye (use as recommended by the manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light.
3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of the oil leak. If the oil leak is found and identified, repair per Service Information instructions.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat the inspection.

   If the oil leak source is not positively identified at this time, proceed with the AIR LEAK DETECTION TEST METHOD.

AIR LEAK DETECTION TEST METHOD

1. Disconnect the fresh air make-up hose from the oil filler neck. Cap or plug the make-up air hose nipple.
2. Remove the PCV hose from the PCV valve. Cap or plug the PCV valve nipple.
3. Attach an air hose with a pressure gauge and regulator to the dipstick tube.

   CAUTION:

   Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.

4. Gradually increase air pressure from 7 kPa (1 psi) to 17 kPa (2.5 psi) maximum while applying soapy water at the suspected leak source. Adjust the regulator to a suitable test pressure within this range that provides the best bubble generation which will pinpoint the leak source. If the oil leak is detected and identified, repair per Service Information procedures.
5. If the leakage occurs at the rear crankshaft oil seal area, follow the procedures for rear seal area leaks. Refer to LUBRICATION - DIAGNOSIS AND TESTING .
6. If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve and make-up air hoses.
7. Clean the oil off of the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.

CHECKING ENGINE OIL PRESSURE

Fig. 339: Oil Temperature Sensor
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Anytime the oil temperature sensor is removed, it should be replaced with a new sensor.

1. Disconnect and remove oil temperature sensor (1).

   Fig. 340: Oil Pressure Adapter 9879
   Courtesy of CHRYSLER GROUP, LLC

   CAUTION:

   Threads in cylinder head are British Standard Pipe (BSP). Do not install a NPT threaded adapter, this could crack the cylinder block.

2. Install threaded adapter (special tool #9879, Adapter, Oil Pressure Test) (1).
3. Install oil pressure gauge (2).

   Fig. 341: Oil PSI Gauge
   Courtesy of CHRYSLER GROUP, LLC

4. Start engine and record reading on oil pressure gauge (1).

   CAUTION:

   If oil pressure is 0 at idle, do not perform the 3000 RPM test

5. If oil pressure is 0 at idle, shut off engine. Check for pressure relief valve stuck open or a clogged oil pick-up screen.
6. Remove oil pan and inspect for debris. Refer to PAN, OIL, REMOVAL .
7. Remove oil pressure relief valve. Refer to VALVE, OIL PRESSURE RELIEF, REMOVAL. and
8. Inspect oil pressure relief valve if damaged replace. Refer to VALVE, OIL PRESSURE RELIEF, INSPECTION.
9. If pressure relief valve is Ok, replace balance shaft module assembly. Refer to PUMP, ENGINE OIL, REMOVAL .

   Fig. 342: Oil Pressure Adapter 9879
   Courtesy of CHRYSLER GROUP, LLC

10. After test is complete, remove oil pressure gauge (2) and adapter (special tool #9879, Adapter, Oil Pressure Test) (1).

    Fig. 343: Oil Temperature Sensor
    Courtesy of CHRYSLER GROUP, LLC

11. Install a new oil pressure temperature sensor (1) and connect electrical connector.

CHECKING VVT OIL PRESSURE

This test can be used to help diagnose VVT faults.

Fig. 344: Oil Sender
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect and remove oil pressure sensor (1).

   Fig. 345: Oil Pressure Gauge
   Courtesy of CHRYSLER GROUP, LLC

   CAUTION:

   Threads in block are 1/8"-28 British Standard Pipe (BSP). Do not install a National Pipe Thread (NPT) threaded adapter, this could crack the cylinder block.

2. Install an 1/8-28 BSP male to 1/8-27 female threaded adapter (2).
3. Install oil pressure gauge (1).
4. Start engine and record oil pressure.

   CAUTION:

   If oil pressure is 0 at idle, do not perform the 3000 RPM test

5. If oil pressure is 0 at idle, shut off engine. Check for pressure relief valve stuck open or a clogged oil pick-up screen.
6. Remove oil pan and inspect for debris. Refer to PAN, OIL, REMOVAL .
7. Remove oil pressure relief valve and inspect, if damaged replace pressure relief valve. Refer to VALVE, OIL PRESSURE RELIEF, REMOVAL.
8. If pressure relief valve is Ok, replace balance shaft module assembly. Refer to PUMP, ENGINE OIL, REMOVAL .

   Fig. 346: Oil Pressure Gauge
   Courtesy of CHRYSLER GROUP, LLC

9. After test is complete, remove test gauge (1) and fitting (2).

   Fig. 347: Oil Sender
   Courtesy of CHRYSLER GROUP, LLC

10. Install oil pressure sensor and electrical connector.

COOLER, OIL

DESCRIPTION

DESCRIPTION

An engine oil cooler is used on some engine packages. The cooler is a coolant-to-oil type and mounted between the oil filter and oil filter adapter.

REMOVAL

REMOVAL

NOTE:

The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, the oil cooler should be replaced.

Fig. 348: Identifying Oil Cooler
Courtesy of CHRYSLER GROUP, LLC

1. Raise vehicle on hoist.
2. Drain cooling system. Refer to STANDARD PROCEDURE .
3. Disconnect oil cooler coolant hoses.
4. Remove oil filter (3).

   Fig. 349: Oil Cooler Mounting
   Courtesy of CHRYSLER GROUP, LLC

5. Remove oil cooler connector bolt (2).
6. Remove oil cooler (1).

INSTALLATION

INSTALLATION

Fig. 350: Oil Cooler Mounting
Courtesy of CHRYSLER GROUP, LLC

1. Replace oil cooler seal (1).
2. Lubricate seal and position oil cooler to oil filter adapter, aligning notch to tab.
3. Install oil cooler connector bolt (2). Tighten connector bolt to 49 N.m (36 ft. lbs.).

   Fig. 351: Identifying Oil Cooler
   Courtesy of CHRYSLER GROUP, LLC

4. Install oil filter (3).
5. Connect oil cooler coolant hose.
6. Lower vehicle.
7. Fill cooling system. Refer to STANDARD PROCEDURE .

FILTER, ENGINE OIL

REMOVAL

REMOVAL

Fig. 352: Oil Filter
Courtesy of CHRYSLER GROUP, LLC

CAUTION:

When servicing the oil filter, avoid deforming the filter can by installing the remove/install tool band strap against the can to base lock seam. The lock seam joining the can to the base is reinforced by the base plate.

1. Using a suitable filter wrench, turn oil filter (1) counterclockwise to remove.

INSTALLATION

INSTALLATION

Fig. 353: Oil Filter
Courtesy of CHRYSLER GROUP, LLC

1. Clean and check filter mounting surface. The surface must be smooth, flat and free of debris or pieces of gasket.
2. Lubricate new oil filter gasket.
3. Screw oil filter (1) on until the gasket contacts base. Tighten to 14 N.m (124 in. lbs.).

OIL

STANDARD PROCEDURE

ENGINE OIL LEVEL CHECK

Fig. 354: Oil Level Indicator
Courtesy of CHRYSLER GROUP, LLC

NOTE:

The engine must be HOT when checking oil level.

The best time to check engine oil level is after the engine is at operating temperature. Allow the engine to be shut off for at least 5 minutes before checking oil level.

Fig. 355: Dip Stick
Courtesy of CHRYSLER GROUP, LLC

Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick (1), and observe oil level. Add oil only when the level is at or below the SAFE mark. If the oil level is in the safe (2) range, do not add oil.

CAUTION:

Do not operate engine if the oil level is above the MAX mark on the dipstick. Excessive oil volume can cause oil aeration which can lead to engine failure due to loss of oil pressure or increase in oil temperature.

ENGINE OIL AND FILTER CHANGE

WARNING:

New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area.

CAUTION:

On export vehicles, refer to the Owner's Manual for the correct grade of oil.

Change engine oil at mileage and time intervals described in the Maintenance Schedule. Refer to MAINTENANCE SCHEDULES, DESCRIPTION .

Fig. 356: Oil Drain Plug & Oil Pan
Courtesy of CHRYSLER GROUP, LLC

1. Run engine until achieving normal operating temperature.
2. Position the vehicle on a level surface and turn engine off.
3. Remove oil fill cap.
4. Raise vehicle on hoist.
5. Place a suitable oil collecting container under oil pan drain plug (2).
6. Remove oil pan drain plug (2) or and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged.

   Fig. 357: Oil Filter
   Courtesy of CHRYSLER GROUP, LLC

7. Remove oil filter (1). Refer to FILTER, ENGINE OIL, REMOVAL .

   Fig. 358: Oil Drain Plug & Oil Pan
   Courtesy of CHRYSLER GROUP, LLC

8. Install oil pan drain plug (2) and tighten drain plug to 40 N.m (30 ft. lbs.).

   Fig. 359: Oil Filter
   Courtesy of CHRYSLER GROUP, LLC

9. Install new oil filter (1). Refer to FILTER, ENGINE OIL, INSTALLATION .
10. Lower vehicle and fill crankcase with specified type and amount of engine oil . Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS and CAPACITIES AND RECOMMENDED FLUIDS, DESCRIPTION .
11. Install oil fill cap.
12. Start engine and inspect for leaks.
13. Stop engine and inspect oil level.

OIL FILTER SPECIFICATION

All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a Mopar® or the equivalent.

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to WARNING under ENGINE OIL AND FILTER CHANGE .

PAN, OIL

REMOVAL

REMOVAL

Fig. 360: Oil Drain Plug & Oil Pan
Courtesy of CHRYSLER GROUP, LLC

1. Raise vehicle on hoist.
2. Remove oil drain plug (2) and drain the engine oil.
3. Remove accessory drive belt splash shield.

   Fig. 361: Locating A/C Compressor
   Courtesy of CHRYSLER GROUP, LLC

4. Remove lower A/C compressor mounting bolt (if equipped).
5. Remove A/C mounting bracket (2).

   Fig. 362: Using Putty Knife To Loosen Seal Around Oil Pan
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Do not use pry points in block to remove oil pan.

6. Remove oil pan retaining bolts.
7. Using a putty knife (1), loosen seal around oil pan (2).
8. Remove oil pan (2).

INSTALLATION

INSTALLATION

Fig. 363: Sealer Location
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Oil pan sealing surfaces must be free of grease or oil.

NOTE:

Parts must be assembled within 10 minutes of applying RTV.

1. Apply Mopar® Engine RTV GEN II at the front cover to engine block parting lines (1).

   Fig. 364: Sealing Oil Pan
   Courtesy of CHRYSLER GROUP, LLC

2. Apply a 2 mm bead of Mopar® Engine RTV GEN II around the oil pan as shown in illustration.
3. Position oil pan and install bolts. Tighten bolts to 12 N.m (105 in. lbs.).

   NOTE:

   The 2 long bolts must be tightened to 22 N.m (195 in. lbs.).

   Fig. 365: Oil Drain Plug & Oil Pan
   Courtesy of CHRYSLER GROUP, LLC

4. Install oil drain plug (2).
5. Lower vehicle and fill engine crankcase with proper oil to correct level.
6. Start engine and check for leaks.

PLUG, OIL

DESCRIPTION

DESCRIPTION

Fig. 366: Tapered Plugs
Courtesy of CHRYSLER GROUP, LLC

The engine block has three tapered plugs sealing the high pressure oil gallery. These threaded plugs do not have a torque specification but instead are installed to a specific depth. Do not attempt to further tighten these plugs, damage to the engine block could result. Whenever these plugs are removed they must be replaced. Service plugs have a lock patch and do not require the application of additional sealant.

REMOVAL

REMOVAL

Fig. 367: Gallery Plug
Courtesy of CHRYSLER GROUP, LLC

CAUTION:

Excessive use of brake parts cleaner to clean threads in block could cause #5 main bearing failure.

NOTE:

Rear plug shown in illustration, other plugs are similar.

1. Remove the plug (2) from the engine block.
2. Use Mopar® Brake Parts Cleaner (or equivalent) sparingly to clean the block.

INSTALLATION

INSTALLATION

Fig. 368: Gallery Plug
Courtesy of CHRYSLER GROUP, LLC

CAUTION:

Excessive use of brake parts cleaner to clean threads in block could cause #5 main bearing failure.

NOTE:

Rear plug shown in illustration, other plugs are similar.

1. Use Mopar® Brake Parts Cleaner (or equivalent) sparingly to clean the block.
2. Install the plug (2) flush with the block boss face (1). The plug (2) is correctly installed when it is flush or protruding no more than 1 mm from the block boss face (1).

PUMP, ENGINE OIL

DESCRIPTION

DESCRIPTION

Fig. 369: Balance Shaft Module & End Caps
Courtesy of CHRYSLER GROUP, LLC

The oil pump is integral to the balance shaft module (BSM) (2). The oil pump cannot be disassembled for inspection. The pressure relief valve is serviceable and can be removed and inspected. The BSM can be identified by the plastic end caps (1).

REMOVAL

REMOVAL

click to open the image

A multimedia supplement to the instructions contained in this article is available. To view the multimedia example of the condition described go to; http://www.youtube.com/user/Mitchell1Tips then type "A00641417.vid2" into the "Search Channel" box.

When removing and installing the Balance Shaft/Oil Pump assembly in the vehicle, it is not necessary to align the plated links on the drive chain as long as the reference marks are created during the procedure.

1. Remove the oil pan. Refer to PAN, OIL, REMOVAL .

   Fig. 370: Aligning Balance Shaft/Oil Pump Drive Gear And Housing Indicator
   Courtesy of CHRYSLER GROUP, LLC

2. Rotate the engine clockwise until the balance shaft/oil pump drive gear and the housing indicator are aligned.

   NOTE:

   IT IS VERY IMPORTANT THAT THE CRANKSHAFT STAYS STATIONARY DURING THE FOLLOWING STEPS. DO NOT MOVE THE CRANKSHAFT UNTIL THE INSTALLATION PROCEDURE IS COMPLETED.

3. Clean the balance shaft/oil pump assembly drive gear with Mopar® brake cleaner or similar.

   NOTE:

   Make sure the gear is clear of any oil to allow for marking.

   Fig. 371: Oil Pump Chain And Sprocket To Module Body Marks
   Courtesy of CHRYSLER GROUP, LLC

4. If the balance shaft/oil pump assembly is being reused, mark the oil pump chain and the sprocket (1) to the module body (2) for reassembly.
5. Install one air-conditioning compressor bracket bolt into the left forward corner thread boss.

   NOTE:

   The bolt will provide a sturdy point to secure a tie strap to hold the tensioner in the compressed position.

   Fig. 372: Positioning Plastic Tie Strap
   Courtesy of CHRYSLER GROUP, LLC

6. Position a plastic tie strap (3) around the chain, tensioner (4) and bolt (2) that was previously installed.
7. Push the chain, guide and tensioner (1) to the compressed position.
8. Tighten the tie strap to hold the components together.

   NOTE:

   The tighter the strap, the more room for removal and installation.

9. Remove the balance shaft/oil pump assembly mounting bolts.
10. Remove assembly from the engine by tilting the rear of the balance shaft/oil pump assembly downward while lifting the drive gear out of the chain links.

INSPECTION

INSPECTION

1. Remove timing chain cover . Refer to COVER(S), ENGINE TIMING, REMOVAL .
2. Remove oil pan. Refer to PAN, OIL, REMOVAL .

Fig. 373: Measuring Distance Between Tensioner Body & Guide Shoe
Courtesy of CHRYSLER GROUP, LLC

3. Measure the distance between the tensioner body and the guide shoe as shown in illustration.
4. If the distance is 10.1 mm (0.397 in.) or greater, replace the chain.

INSTALLATION

INSTALLATION

click to open the image

A multimedia supplement to the instructions contained in this article is available. To view the multimedia example of the condition described go to; http://www.youtube.com/user/Mitchell1Tips then type "A00641417.vid3" into the "Search Channel" box.

CAUTION:

There are two different Balance Shaft Module (BSM) to engine block bolts used. 180 mm bolts with a lock-patch on the threads or 185 mm bolts without lock-patch. Do not reuse the 180 mm bolts. Always discard 180 mm bolts after removing. Failure to replace these bolts can result in engine damage. The 185 mm bolts are reusable. Install the same length bolts that were removed and use either four new 180 mm bolts or four 185 mm bolts.

Fig. 374: Checking Cylinder Head Bolts For Stretching (Necking)
Courtesy of CHRYSLER GROUP, LLC

1. The 185 mm (7.283 in.) length bolts must be checked for stretching. Check the bolts with a straight edge for necking (2). If the bolts are necked down, they must be replaced.
2. Clean the balance shaft/oil pump assembly mounting holes with Mopar® brake parts cleaner.
3. Align the marks on the balance shaft/oil pump assembly and drive sprocket.

   Fig. 375: Aligning Balance Shaft/Oil Pump Drive Gear And Housing Indicator
   Courtesy of CHRYSLER GROUP, LLC

4. With the rear of the balance shaft/oil pump assembly on a slight downward angle, position the gear into the chain links. Make sure the paint marks are aligned.
5. Pivot balance shaft/oil pump assembly upwards and position on ladder frame.

   Fig. 376: BSM Mounting Bolts Tightening Sequence
   Courtesy of CHRYSLER GROUP, LLC

6. Start balance shaft/oil pump assembly mounting bolts by hand.

   NOTE:

   Use a three step procedure when tightening balance shaft/oil pump assembly mounting bolts. For new 180 mm bolts, go to step 7. For 185 mm bolts, go to step 8.

7. Tighten new 180 mm balance shaft/oil pump assembly mounting bolts as follows:
   1. Tighten to 15 N.m (11 ft. lbs.) in the sequence shown in illustration.
   2. Tighten to 33 N.m (24 ft. lbs.) in the sequence shown in illustration.
   3. Rotate bolts an additional 90° in the sequence shown in illustration.
8. Tighten 185 mm balance shaft/oil pump assembly mounting bolts as follows:
   1. Tighten to 15 N.m (11 ft. lbs.) in the sequence shown in illustration.
   2. Tighten to 29 N.m (22 ft. lbs.) in the sequence shown in illustration.
   3. Rotate bolts an additional 90° in the sequence shown in illustration.

   Fig. 377: Oil Pump Chain And Sprocket To Module Body Marks
   Courtesy of CHRYSLER GROUP, LLC

9. Double check the alignment marks to ensure the gear (1) and balance shaft/oil pump assembly indicator (2) is aligned.

   Fig. 378: Positioning Plastic Tie Strap
   Courtesy of CHRYSLER GROUP, LLC

10. Remove the tie strap (3).
11. Remove the bracket bolt (2).
12. Inspect that the tensioner (1) has fully extended and applied pressure to the guide and chain (4).
13. Install the oil pan. Refer to PAN, OIL, INSTALLATION .
14. Fill engine with oil.
15. Start engine and check for leaks.

SENSOR, OIL TEMPERATURE

DESCRIPTION

DESCRIPTION

Fig. 379: Oil Temperature Sensor
Courtesy of CHRYSLER GROUP, LLC

The oil temperature sensor is a two wire sensor located on the variable valve actuation assembly at the cylinder head. The sensor probe is mounted to the variable valve actuation assembly through an access hole. A compression washer seals the oil temperature sensor to the variable valve actuation assembly.

REMOVAL

REMOVAL

1. Disconnect the battery negative cable.

   Fig. 380: Engine Cover
   Courtesy of CHRYSLER GROUP, LLC

2. Remove the engine cover (1).

   Fig. 381: Resonator, Bolt & Clamp
   Courtesy of CHRYSLER GROUP, LLC

   Loosen the intake clamp (1), remove the resonator bolt (2) and resonator (3).

3. Remove the engine cover (1).
4. Remove the wiring harness fastener from the intake manifold.
5. Disconnect oil temperature sensor electrical connector.

   Fig. 382: Oil Temperature Sensor Location
   Courtesy of CHRYSLER GROUP, LLC

6. Remove sensor (1).

INSTALLATION

INSTALLATION

1. If re-using the oil temperature sensor, coat the threads with Mopar® thread sealant.

   Fig. 383: Oil Temperature Sensor Location
   Courtesy of CHRYSLER GROUP, LLC

2. Install oil temperature sensor (1). Tighten to 18 N.m (160 in. lbs.).

   Fig. 384: Resonator, Bolt & Clamp
   Courtesy of CHRYSLER GROUP, LLC

3. Install the resonator (3), bolt (2) and clamp (1). Tighten the bolt to 5 N.m (81 in. lbs.). Tighten the clamp.
4. Connect electrical connector.

   Fig. 385: Engine Cover
   Courtesy of CHRYSLER GROUP, LLC

5. Install the engine cover (1).

SENSOR, OIL PRESSURE

DESCRIPTION

DESCRIPTION

The oil pressure sensor is located on the right front side of the engine block. The oil pressure sensor is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil galley). The sensor is a three terminal device.

OPERATION

OPERATION

The oil pressure sending unit returns a voltage signal back to the PCM relating oil pressure. Ground for the sensor is supplied by the PCM.

REMOVAL

REMOVAL

NOTE:

The oil pressure sensor is screwed into the cylinder block below the water pump.

1. Raise and support the vehicle.
2. Remove the belly pan. Refer to BELLY PAN, REMOVAL .

   Fig. 386: Oil Temperature Sensor & Connector
   Courtesy of CHRYSLER GROUP, LLC

3. Disengage the sensor harness at the block (5).
4. Unlock the connector (3).
5. Disconnect oil temperature sensor electrical connector (4).
6. Unscrew the sensor (2) from the cylinder block.
7. Remove sensor.

INSTALLATION

INSTALLATION

Fig. 387: Oil Temperature Sensor & Connector
Courtesy of CHRYSLER GROUP, LLC

1. Screw the sensor (2) into the block.
2. Tighten the sensor to 48 N.m (35 ft. lbs.).
3. Install the connector (4).
4. Lock the connector (3).
5. Engage the harness retainer (5) into the block.
6. Install the belly pan. Refer to BELLY PAN, INSTALLATION .

VALVE, OIL PRESSURE RELIEF

REMOVAL

REMOVAL

Fig. 388: Oil Pressure Relief Valve
Courtesy of CHRYSLER GROUP, LLC

1. Remove oil pan. Refer to PAN, OIL, REMOVAL .
2. Remove pressure regulating valve cap (2).
3. Remove pressure regulating valve spring (3) and valve (4).

INSPECTION

INSPECTION

Fig. 389: Oil Pressure Relief Valve
Courtesy of CHRYSLER GROUP, LLC

NOTE:

Pressure regulating valve (4) can be serviced separately from the oil pump assembly.

1. Inspect pressure relief valve (4) scoring, gouging, or debris. Replace as needed.
2. Inspect the pressure relief valve bore in the pump for scoring, gouging, or debris.
3. If pump bore is damaged, replace balance shaft module.

INSTALLATION

INSTALLATION

Fig. 390: Oil Pressure Relief Valve
Courtesy of CHRYSLER GROUP, LLC

1. Lightly coat pressure regulating valve with clean engine oil and install valve (4).
2. Install spring (3) and cap (2).
3. Tighten cap to 44 N.m (32 lbs. ft.).

VALVE TIMING

STANDARD PROCEDURE

STANDARD PROCEDURE - VALVE TIMING VERIFICATION

CAUTION:

Painted or colored chain links are used during initial engine assembly and can not be relied upon for valve timing verification. Only use top-dead-center marks, cylinder head cover mounting surface and camshaft sprocket marks to verify valve timing or engine damage may result.

Fig. 391: Timing Cover Mark & Notch
Courtesy of CHRYSLER GROUP, LLC

Correct timing is critical for the NON free-wheeling designed engine. Engine timing can be verified by using the following procedures:

1. Remove the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL .
2. Remove the spark plugs. Refer to SPARK PLUG, REMOVAL .

   CAUTION:

   When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.

3. Rotate the crankshaft clockwise (as viewed from the front) to align the timing cover mark (1) with the damper notch (2) to place the number one cylinder piston at top-dead-center on the compression stroke.

   Fig. 392: Vertical Center Line Of Camshaft, Dowel & Cylinder Head
   Courtesy of CHRYSLER GROUP, LLC

4. While maintaining this alignment, verify that the dowel window (2) on the camshaft sprocket point toward 12 o'clock.
5. Using a straightedge tool (1), place the tool vertically at the center of the cam gear. Using the top edge of the cylinder head (3) as a reference point, the angle between the straightedge and the cylinder head needs to be 90°.
6. If the engine timing is not correct, proceed to Timing Chain and Sprockets for service procedures. Refer to CHAIN AND SPROCKETS, TIMING, REMOVAL .

CHAIN AND SPROCKETS, TIMING

REMOVAL

TIMING CHAIN

1. Remove the timing chain cover. Refer to COVER(S), ENGINE TIMING, REMOVAL .
2. Verify that the number one cylinder piston is still set to top-dead-center on the compression stroke.

   NOTE:

   If the timing chain plated links can no longer be seen, the timing chain links corresponding to the timing marks must be marked prior to removal if the chain is to be reused. Fig. 393: Chain Link & Crankshaft Timing Mark Courtesy of CHRYSLER GROUP, LLC

3. Mark chain link (2) corresponding to crankshaft timing mark (1).

   Fig. 394: Vertical Center Line Of Camshaft, Dowel & Cylinder Head
   Courtesy of CHRYSLER GROUP, LLC

4. While maintaining this alignment, verify that the camshaft dowel (2) is at the 12 o'clock position. The dowel center line (1) will be 90° from the horizontal surface line at the top of the cylinder head (3).
5. Mark the chain links corresponding to camshaft and crankshaft timing marks.

   Fig. 395: Timing Chain, Sprockets, Tensioner & Guides
   Courtesy of CHRYSLER GROUP, LLC

6. Remove timing chain tensioner (6). Refer to TENSIONER, ENGINE TIMING, REMOVAL.
7. Rotate the tensioner guide (3) away from the chain.
8. Remove timing chain (7).

CAMSHAFT SPROCKET

1. Set the timing at TDC. Refer to VALVE TIMING - STANDARD PROCEDURE .

   Fig. 396: Wrench Flats
   Courtesy of CHRYSLER GROUP, LLC

2. Remove the timing cover. Refer to COVER(S), ENGINE TIMING, REMOVAL .
3. Hold the camshaft stationary by the wrench flats (1).

   Fig. 397: Camshaft Center Bolt & Sprocket
   Courtesy of CHRYSLER GROUP, LLC

4. Remove the camshaft center bolt (1) from the sprocket (2).
5. Once the sprocket is clear of the alignment dowel, lower the sprocket to allow chain to slacken, then remove the chain from the sprocket.
6. Remove the sprocket from the engine.

CRANKSHAFT SPROCKET

Fig. 398: BSM Timing Chain Marks
Courtesy of CHRYSLER GROUP, LLC

1. Remove the timing chain. Refer to CHAIN AND SPROCKETS, TIMING, REMOVAL .
2. Remove the oil pan. Refer to PAN, OIL, REMOVAL .
3. Remove the oil pump drive chain tensioner (3).
4. Remove the oil pump drive chain.

   Fig. 399: Crankshaft Sprocket
   Courtesy of CHRYSLER GROUP, LLC

5. Remove the crankshaft sprocket (1).

INSPECTION

INSPECTION

Fig. 400: Measuring Distance From Tensioner Body To Edge Of Chain Guide
Courtesy of CHRYSLER GROUP, LLC

Inspect timing chain for stretching prior to removal.

1. Rotate engine while watching timing chain tensioner plunger. When the plunger reaches its maximum travel stop rotating engine.
2. Measure the distance from the tensioner body and the edge of the chain guide as shown in illustration.
3. If the distance is greater than 20.5 mm (0.81 in.) inspect guide shoes for excessive wear.
4. If guides are okay, replace timing chain.

INSTALLATION

TIMING CHAIN

Fig. 401: Chain Link & Crankshaft Timing Mark
Courtesy of CHRYSLER GROUP, LLC

1. Align the timing chain onto the crank sprocket mark (1) using the painted link (2) as a guide.

   Fig. 402: Sprocket Mark & Painted Link
   Courtesy of CHRYSLER GROUP, LLC

2. Align the timing chain onto the camshaft sprocket mark (2) using the painted link (1) as a guide.

   Fig. 403: Piston, Ratchet Arm & Drill Bit
   Courtesy of CHRYSLER GROUP, LLC

3. Reset the cam chain tensioner. Refer to VALVE TIMING - STANDARD PROCEDURE .

   Fig. 404: Timing Chain, Sprockets, Tensioner & Guides
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Keep the slack in the timing chain on the tensioner side.

4. Install timing chain tensioner (6) and tighten bolts to 12 N.m (105 in. lbs.).
5. Remove the pin (1/8 in. drill bit) from the timing chain tensioner.
6. Verify that the valve timing is correct. Refer to VALVE TIMING - STANDARD PROCEDURE .
7. Install the engine timing cover. Refer to COVER(S), ENGINE TIMING, INSTALLATION .
8. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to OIL - STANDARD PROCEDURE .
9. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
10. Install the resonator. Refer to RESONATOR, AIR CLEANER, INSTALLATION .
11. Install the engine cover.
12. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .

NOTE:

The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.

CAMSHAFT SPROCKET(S)

NOTE:

Do not use an impact wrench to tighten the camshaft sprocket bolt. Damage to the camshaft dowel pin and camshaft may occur. Fig. 405: Camshaft Center Bolt & Sprocket Courtesy of CHRYSLER GROUP, LLC

1. Install the chain onto the sprocket (2), insert the bolt (1).

   Fig. 406: Wrench Flats
   Courtesy of CHRYSLER GROUP, LLC

2. Using a wrench to hold the camshaft flats (1) tighten the sprocket bolt to 10 N.m + 65° (88 in. lbs. + 65°).
3. Verify correct timing. Refer to VALVE TIMING - STANDARD PROCEDURE .
4. Install the timing cover. Refer to COVER(S), ENGINE TIMING, INSTALLATION .
5. Install the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, INSTALLATION .
6. Install engine cover.

CRANKSHAFT SPROCKET

Fig. 407: Crankshaft Sprocket
Courtesy of CHRYSLER GROUP, LLC

1. Install the crankshaft sprocket (1) onto the crankshaft.

   Fig. 408: BSM Timing Chain Marks
   Courtesy of CHRYSLER GROUP, LLC

2. Install the oil pump drive chain. Verify that the oil pump is correctly timed (1, 2, 5, 6).

   Fig. 409: Pushing Tensioner Piston Back Into Tensioner Body
   Courtesy of CHRYSLER GROUP, LLC

3. Reset the oil pump drive chain tensioner by pushing the plunger inward and installing (special tool #9703, Pin, Tensioner).

   Fig. 410: BSM Timing Chain Marks
   Courtesy of CHRYSLER GROUP, LLC

4. Install the oil pump drive chain tensioner (3) and remove (special tool #9703, Pin, Tensioner) (4).
5. Install the timing chain and timing chain cover. Refer to CHAIN AND SPROCKETS, TIMING, INSTALLATION .
6. Install the oil pan. Refer to PAN, OIL, INSTALLATION .
7. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to OIL - STANDARD PROCEDURE .
8. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
9. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .

NOTE:

The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.

COVER(S), ENGINE TIMING

REMOVAL

REMOVAL

1. Perform the fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
2. Disconnect and isolate the battery negative cable.
3. Remove the resonator. Refer to RESONATOR, AIR CLEANER, REMOVAL .
4. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL .
5. Remove the coolant recovery bottle. Refer to BOTTLE, PRESSURIZED COOLANT, REMOVAL .

   Fig. 411: Identifying Six Stud Bolts
   Courtesy of CHRYSLER GROUP, LLC

6. Remove the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL .

   Fig. 412: Timing Cover Mark & Notch
   Courtesy of CHRYSLER GROUP, LLC

7. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
8. Remove the frame cover portion of the right splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL .

   CAUTION:

   When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.

9. Rotate the crankshaft clockwise (as viewed from the front) to align the timing cover mark (1) with the damper notch (2) to place the number one cylinder piston at top-dead-center on the compression stroke.

   Fig. 413: Accessory Drive Components & Belt Routing
   Courtesy of CHRYSLER GROUP, LLC

10. Remove the accessory drive belt (1). Refer to BELT, SERPENTINE, REMOVAL .
11. Remove the accessory drive belt idler pulley (3).
12. Remove the accessory drive belt tensioner (2).
13. Remove the crankshaft damper (4). Refer to DAMPER, VIBRATION, REMOVAL .
14. Remove three bolts (6) and the water pump pulley (5) from the water pump.

    Fig. 414: A/C Compressor & Bracket
    Courtesy of CHRYSLER GROUP, LLC

    NOTE:

    The oil pan will need to be removed and immediately reinstalled. This procedure is necessary because the oil pan sealant must be broken to allow the timing cover to be removed without damage to the oil pan. The reason the pan is to be reinstalled is to allow for a support surface when the timing cover is removed.

15. Remove the oil pan. Refer to PAN, OIL, REMOVAL .
16. Temporarily reinstall the oil pan.
17. Install the oil pan bolts finger tight. Do not install the four oil pan to timing cover bolts (1) at this time.
18. Lower the vehicle.
19. Support the engine with a suitable jack.
20. Remove the right engine mount insulator. Refer to INSULATOR, ENGINE MOUNT, RIGHT, REMOVAL .
21. Remove one M8 studbolt (1), six M6 bolts (2), two M8 bolts (3) and five M10 bolts (4).

    Fig. 415: Timing Chain Cover Pry Points
    Courtesy of CHRYSLER GROUP, LLC

22. Remove the engine timing cover using pry points (1, 2 and 3).

    Fig. 416: Timing Chain Cover Removal/Installation
    Courtesy of CHRYSLER GROUP, LLC

23. Remove the engine timing cover (1) out through the bottom of the vehicle.

INSTALLATION

INSTALLATION

Fig. 417: Applying Engine Sealant RTV (Or Equivalent) At Cylinder Head To Block Parting Line
Courtesy of CHRYSLER GROUP, LLC

NOTE:

When using RTV, the sealing surfaces must be clean and free from grease and oil.

NOTE:

When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes.

1. Install a new crankshaft seal if necessary.
2. Clean all sealing surfaces. Refer to ENGINE - STANDARD PROCEDURE .

3. Apply Mopar® engine sealant RTV (or equivalent) as shown in illustration at the cylinder head to block parting line (1 and 2).

   Fig. 418: Applying Engine Sealant RTV (Or Equivalent) At Ladder Frame To Block Parting Line
   Courtesy of CHRYSLER GROUP, LLC

4. Apply Mopar® engine sealant RTV (or equivalent) as shown in illustration at the ladder frame to block parting line (1 and 2).

   Fig. 419: Engine Block And Cylinder Head To Timing Cover Sealant Application Points
   Courtesy of CHRYSLER GROUP, LLC

5. Apply 2 mm bead of Mopar® MS-GF-46 (or equivalent) to the engine block and cylinder head to timing cover mating surfaces as shown in illustration. Be sure to apply a bead at the two center bolt lands that are between the timing chain.

   Fig. 420: Timing Chain Cover Removal/Installation
   Courtesy of CHRYSLER GROUP, LLC

6. Install timing chain cover (1) upwards from under the vehicle.
7. Install the timing chain cover retaining bolts. Tighten six M6 bolts (2) to 9 N.m (80 in. lbs.), two M8 bolts (3) and one studbolt (1) to 26 N.m (19 ft. lbs.) and five M10 bolts (4) to 65 N.m (48 ft. lbs.).
8. Install the right engine mount. Refer to INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION .
9. Install the coolant reservoir bottle. Tighten bolt to 9 N.m (80 in. lbs.).

   Fig. 421: Accessory Drive Components & Belt Routing
   Courtesy of CHRYSLER GROUP, LLC

10. Install the water pump pulley (5) and tighten three bolts (6) to 9 N.m (80 in. lbs.).
11. Install the crankshaft damper (4). Refer to DAMPER, VIBRATION, INSTALLATION .
12. Install the accessory drive belt tensioner (2).
13. Install the accessory drive belt idler pulley (3). Tighten bolt to 25 N.m (18 ft. lbs.).
14. Install the accessory drive belt (1). Refer to BELT, SERPENTINE, INSTALLATION .
15. Reseal the oil pan. Refer to PAN, OIL, INSTALLATION .
16. Install the right lower splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION .

    Fig. 422: Cylinder Head Cover Bolts
    Courtesy of CHRYSLER GROUP, LLC

17. Install the cylinder head cover and ignition coils . Refer to COVER(S), CYLINDER HEAD, INSTALLATION .
18. Install the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION .

    Fig. 423: Engine Cover & Air Resonator Clamp
    Courtesy of CHRYSLER GROUP, LLC

19. Install the engine cover (1).
20. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to OIL - STANDARD PROCEDURE .
21. Install the resonator (1). Refer to RESONATOR, AIR CLEANER, INSTALLATION .
22. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
23. Run the engine until it reaches normal operating temperature. Check cooling system for possible leaks and correct fluid level. Refer to STANDARD PROCEDURE .

NOTE:

The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.

TENSIONER, ENGINE TIMING

REMOVAL

REMOVAL

1. Remove the engine timing cover. Refer to COVER(S), ENGINE TIMING, REMOVAL .

   Fig. 424: Timing Chain Tensioner Retaining Bolts
   Courtesy of CHRYSLER GROUP, LLC

2. Remove timing chain tensioner retaining bolts (3).
3. Remove the tensioner.

INSTALLATION

INSTALLATION

Fig. 425: Piston, Ratchet Arm & Drill Bit
Courtesy of CHRYSLER GROUP, LLC

1. Reset the cam chain tensioner. Refer to VALVE TIMING - STANDARD PROCEDURE .

   Fig. 426: Timing Chain, Sprockets, Tensioner & Guides
   Courtesy of CHRYSLER GROUP, LLC

   NOTE:

   Keep the slack in the timing chain on the tensioner side.

2. Install timing chain tensioner (6) and tighten bolts to 12 N.m (105 in. lbs.).
3. Remove the pin (1/8 in. drill bit) from the timing chain tensioner.
4. Verify that the valve timing is correct. Refer to VALVE TIMING - STANDARD PROCEDURE .
5. Install the engine timing cover. Refer to COVER(S), ENGINE TIMING, INSTALLATION .
6. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to OIL - STANDARD PROCEDURE .
7. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
8. Install the resonator. Refer to RESONATOR, AIR CLEANER, INSTALLATION .
9. Install the engine cover.
10. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .

NOTE:

The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.