3.6L Engine - Service Information: Other Dodge Avenger II facelift

CYLINDER COMPRESSION PRESSURE LEAKAGE

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

Note. Ensure 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 DELIVERY, GAS, STANDARD PROCEDURE»(ref-485510-S12963059542012071300000) .
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»(ref-485476-S02894849892012071300000) .

CYLINDER COMBUSTION PRESSURE LEAKAGE

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

Combustion pressure leakage testing will detect

1. Exhaust and intake valve leaks (improper seating).
2. Leaks between adjacent cylinders or into water jacket.
3. 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.

Refer to CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART .

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART

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.
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.

REPAIR DAMAGED OR WORN THREADS

Damaged or worn threads can be repaired. Essentially, this repair consists of

1. Drilling out worn or damaged threads.
2. Tapping the hole with a special Heli-Coil Tap, or equivalent.
3. Installing an insert into the tapped hole to bring the hole back to its original thread size.

FORM-IN-PLACE GASKETS AND SEALERS

Note. All of the sealants mentioned below are not used on every engine, they are listed as a general reference guide. See 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® THREEBOND ENGINE RTV SEALANT is a unique gasket material that is specially made to retain adhesion and sealing properties when used to seal components exposed to engine oil.

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

1. Loss of engine power
2. Engine misfiring
3. Poor fuel economy

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

1. Engine overheating
2. Loss of coolant
3. Excessive steam (white smoke) emitting from exhaust
4. Coolant foaming

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 cylinder head. Low speed running up to 1 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 restrictor in cylinder head gasket 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 cylinder head.
11. Faulty lash adjuster.

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

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1. Perform the fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-485510-S12963059542012071300000) .
2. Disconnect and isolate the negative battery cable.
3. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
4. Remove the belly pan. Refer to «UNDER BODY PROTECTION»(ref-485477-S28538233622012071300000) .
5. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
6. Drain the engine oil. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .
7. Lower the vehicle.
8. Remove the engine cover (1).
9. Recover the refrigerant from the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
10. Remove the air cleaner body (1). Refer to «BODY, AIR CLEANER, REMOVAL»(ref-485476-S11662508332012071300000) .
11. Remove the resonator (1). Refer to «RESONATOR, AIR CLEANER, REMOVAL»(ref-485476-S12665908032012071300000) .
12. Remove the upper and lower intake manifolds (2) and insulator. Refer to «MANIFOLD, INTAKE, REMOVAL»(ref-485476-S08989499162012071300000) .
13. Remove the accessory drive belt (7). Refer to «BELT, SERPENTINE, REMOVAL»(ref-485484-S39989615472012071300000) .
14. Remove three bolts (2) and the power steering pump heat shield (1).
15. Disengage the wire harness retainer (2) from the power steering pump.
16. Remove three bolts (1) and reposition the power steering pump and bracket as an assembly. Do not disconnect the power steering lines from the pump.
17. Remove two bolts (2) and the heater core supply tube (1).
18. Disconnect the ignition coil capacitor electrical connector.
19. Disengage the wire harness retainer (3) from the intake manifold support bracket.
20. Remove the studbolt (2) and remove the upper intake manifold support bracket.
21. Remove the spark plugs. Refer to «SPARK PLUG, REMOVAL»(ref-485509-S13645825702012071300000) .
22. Remove the cylinder head covers, lower and upper oil pans, crankshaft vibration damper and engine timing cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-485476-S33092042822012071300000) . CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.
23. Rotate the crankshaft CW to place the number one piston at TDC on the exhaust stroke by aligning the dimple (4) on the crankshaft with the block/bearing cap junction (5). The left side cam phaser arrows (2) should point toward each other and be parallel to the valve cover sealing surface (3). The right side cam phaser arrows (7) should point away from each other and the scribe lines (9) should be parallel to the valve cover sealing surface (8). CAUTION: Always reinstall timing chains so that they maintain the same direction of rotation. Inverting a previously run chain on a previously run sprocket will result in excessive wear to both the chain and sprocket.
24. Mark the direction of rotation on the timing chain using a paint pen or equivalent to aid in reassembly. CAUTION: When the timing chains are removed and the cylinder heads are still installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.
25. Reset the RH cam chain tensioner by pushing back the tensioner piston and installing Tensioner Pin (special tool #8514, Pins, Tensioner) (1). NOTE: Minor rotation of a camshaft (a few degrees) may be required to install the camshaft phaser lock.
26. Install the RH Camshaft Phaser Lock (special tool #10202, Locks, Camshaft/Phaser) (5).
27. Loosen both the intake oil control valve (2) and exhaust oil control valve (7).
28. Remove the RH Camshaft Phaser Lock (special tool #10202, Locks, Camshaft/Phaser) (5).
29. Remove the oil control valve (2) from the right side intake cam phaser and pull the phaser off of the camshaft.
30. Remove the oil control valve (7) from the right side exhaust cam phaser and pull the phaser off of the camshaft.
31. Remove the RH cam chain tensioner arm (6).
32. Remove two T30 bolts (4) and the RH cam chain tensioner (3).
33. Remove three T30 bolts (2) and the RH cam chain guide (1).
34. Remove the right camshafts. Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-485476-S02001420762012071300000) . NOTE: If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.
35. Remove the rocker arms. Refer to «ROCKER ARM, VALVE, REMOVAL»(ref-485476-S18060150142012071300000) . NOTE: If the hydraulic lifters are to be reused, identify their positions so that they can be reassembled into their original locations.
36. If required, remove the hydraulic lifters. Refer to «LIFTER(S), HYDRAULIC, REMOVAL»(ref-485476-S12959148312012071300000) .
37. Using the sequence shown in illustration, remove the cylinder head retaining bolts. WARNING: The multi-layered steel head gaskets have very sharp edges that could cause personal injury if not handled carefully. NOTE: The head gasket (1) crimps the locating dowels (2) and the dowels may pull out of the engine block when the head gasket is removed.
38. Remove the cylinder head and gasket. Discard the gasket. CAUTION: Do not lay the cylinder head on its gasket sealing surface, due to the design of the cylinder head gasket, any distortion to the cylinder head sealing surface may prevent the gasket from properly sealing resulting in leaks.
39. If required, remove the bolt (2) and the ignition coil capacitor (1).

LEFT

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1. Perform the fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-485510-S12963059542012071300000) .
2. Disconnect and isolate the negative battery cable.
3. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
4. Remove the belly pan. Refer to «UNDER BODY PROTECTION»(ref-485477-S28538233622012071300000) .
5. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
6. Drain the engine oil. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .
7. Lower the vehicle.
8. Remove the engine cover (1).
9. Recover the refrigerant from the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
10. Remove the air cleaner body (1). Refer to «BODY, AIR CLEANER, REMOVAL»(ref-485476-S11662508332012071300000) .
11. Remove the resonator (1). Refer to «RESONATOR, AIR CLEANER, REMOVAL»(ref-485476-S12665908032012071300000) .
12. Disconnect the heater core return hose (1).
13. Disconnect the left upstream oxygen sensor connector (1) from the main wire harness.
14. Disengage two upper wire harness retainers (2) from the intake manifold support brackets.
15. Disengage two lower wire harness retainers (3) from the intake manifold support brackets.
16. Remove the nut (2), bolt (3) and the heater core return tube (1).
17. Remove the bolt (2) and the oil level indicator tube (1).
18. Remove the upper and lower intake manifolds (2) and insulator. Refer to «MANIFOLD, INTAKE, REMOVAL»(ref-485476-S08989499162012071300000) .
19. Remove the bolts (2) and remove the LH upper intake manifold support brackets (1).
20. Remove the accessory drive belt (7). Refer to «BELT, SERPENTINE, REMOVAL»(ref-485484-S39989615472012071300000) .
21. Remove the generator (2). Refer to «GENERATOR, REMOVAL»(ref-485501-S37216265192012071300000) .
22. Remove the A/C compressor (1) from the engine compartment. Refer to «COMPRESSOR, A/C, REMOVAL»(ref-485480-S16902540862012071300000) .
23. Disconnect the ignition coil capacitor electrical connector.
24. Disconnect the Engine Coolant Temperature (ECT) sensor connector.
25. Disconnect the main harness from the engine injection/ignition harness (1) at the rear of the left cylinder head.
26. Disconnect the main harness from the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.
27. Remove the spark plugs. Refer to «SPARK PLUG, REMOVAL»(ref-485509-S13645825702012071300000) .
28. Remove the cylinder head covers, lower and upper oil pans, crankshaft vibration damper and engine timing cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-485476-S33092042822012071300000) . CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.
29. Rotate the crankshaft CW to place the number one piston at TDC on the exhaust stroke by aligning the dimple (4) on the crankshaft with the block/bearing cap junction (5). The left side cam phaser arrows (2) should point toward each other and be parallel to the valve cover sealing surface (3). The right side cam phaser arrows (7) should point away from each other and the scribe lines (9) should be parallel to the valve cover sealing surface (8). CAUTION: Always reinstall timing chains so that they maintain the same direction of rotation. Inverting a previously run chain on a previously run sprocket will result in excessive wear to both the chain and sprocket.
30. Mark the direction of rotation on the timing chain using a paint pen or equivalent to aid in reassembly. CAUTION: When the timing chains are removed and the cylinder heads are still installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.
31. Reset the LH cam chain tensioner by lifting the pawl (1), pushing back the piston (2) and installing Tensioner Pin (special tool #8514, Pins, Tensioner) (3). Refer to «Engine/Valve Timing - Standard Procedure»(ref-485476-S07176515242012071300000) . NOTE: Minor rotation of a camshaft (a few degrees) may be required to install the camshaft phaser lock.
32. Install the LH Camshaft Phaser Lock (special tool #10202, Locks, Camshaft/Phaser) (4).
33. Loosen both the intake oil control valve (6) and exhaust oil control valve (2).
34. Remove the LH Camshaft Phaser Lock (special tool #10202, Locks, Camshaft/Phaser) (4).
35. Remove the oil control valve (2) from the left side exhaust cam phaser and pull the phaser off of the camshaft.
36. Remove the oil control valve (6) from the left side intake cam phaser and pull the phaser off of the camshaft.
37. Remove the LH cam chain tensioner arm (1).
38. Remove two T30 bolts (6) and the LH cam chain tensioner (5).
39. Remove two T30 bolts (4) and the LH cam chain guide (2).
40. Remove the left camshafts. Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-485476-S02001420762012071300000) . NOTE: If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.
41. Remove the rocker arms. Refer to «ROCKER ARM, VALVE, REMOVAL»(ref-485476-S18060150142012071300000) . NOTE: If the hydraulic lifters are to be reused, identify their positions so that they can be reassembled into their original locations.
42. If required, remove the hydraulic lifters. Refer to «LIFTER(S), HYDRAULIC, REMOVAL»(ref-485476-S12959148312012071300000) .
43. Using the sequence shown in illustration, remove the cylinder head retaining bolts. NOTE: Right head gasket shown in illustration, left head gasket similar. WARNING: The multi-layered steel head gaskets have very sharp edges that could cause personal injury if not handled carefully. NOTE: The head gasket (1) crimps the locating dowels (2) and the dowels may pull out of the engine block when the head gasket is removed. CAUTION: Do not lay the cylinder head on its gasket sealing surface, due to the design of the cylinder head gasket, any distortion to the cylinder head sealing surface may prevent the gasket from properly sealing resulting in leaks.
44. Remove the cylinder head and gasket (1). Discard the gasket.
45. If required, remove the Engine Coolant Temperature (ECT) sensor (4).
46. If required, remove the bolt (2) and the ignition coil capacitor (1).
47. If required, remove the bolt (3) and the engine wire harness retainer bracket (5).

CLEANING

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»(ref-485476-S02028931392012071300000) . Be careful not to gouge or scratch the aluminum head sealing surface.
2. Clean all engine oil passages. CAUTION: Non-compressible debris such as oil, coolant or RTV sealants that are not removed from bolt holes can cause the aluminum casting to crack when tightening the bolts.
3. Clean out the cylinder head bolt holes in the engine block.

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1. Check cylinder head warpage with a straight edge (2) and feeler gauge (1).
2. Cylinder head must be flat within specification. Refer to «Engine - Specifications»(ref-485476-S24399402942012071300000) .
3. Verify that the valve tappets move freely in theirs bores and that they have been rotating.
4. Inspect camshaft bearing journals for scoring.
5. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
6. Inspect the following components and verify that they are within specification : Refer to «Engine - Specifications»(ref-485476-S24399402942012071300000) . Camshafts Valve Tappets Springs Valve Seats Valve Guides Valves

RIGHT

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1. If removed, install the ignition coil capacitor (1) with a M6 bolt (2) tightened to 10 N.m (89 in. lbs.). 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. NOTE: Typical cylinder head bolt shown in illustration.
2. Check 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. 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.
3. Clean and prepare the gasket sealing surfaces of the cylinder head and block. Refer to «Engine - Standard Procedure»(ref-485476-S02028931392012071300000) . CAUTION: Non-compressible debris such as oil, coolant or RTV sealants that are not removed from bolt holes can cause the aluminum casting to crack when tightening the bolts.
4. Clean out the cylinder head bolt holes in the engine block. WARNING: The multi-layered steel head gaskets have very sharp edges that could cause personal injury if not handled carefully. CAUTION: The cylinder head gaskets are not interchangeable between the left and right cylinder heads and are clearly marked (3) with "R" for right and "L" for left.
5. Position the new cylinder head gasket (1) on the locating dowels (2).
6. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels. NOTE: Do not apply any additional oil to the bolt threads.
7. Install the eight head bolts finger tight.
8. Tighten the cylinder head bolts in the sequence shown in illustration, following this 9 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 45 N.m (33 ft. lbs.) Step 3: All + 75° Turn Do not use a torque wrench for this step. Step 4: All + 50° Turn Do not use a torque wrench for this step. Step 5: Loosen all fasteners in reverse of sequence shown in illustration Step 6: All to 30 N.m (22 ft. lbs.) Step 7: All to 45 N.m (33 ft. lbs.) Step 8: All + 70° Turn Do not use a torque wrench for this step. Step 9: All + 70° Turn Do not use a torque wrench for this step. NOTE: If the hydraulic lifters are being reused, reassemble them into their original locations.
9. If removed, install the hydraulic lifters. Refer to «LIFTER(S), HYDRAULIC, INSTALLATION»(ref-485476-S42292792802012071300000) . NOTE: If the rocker arms are being reused, reassemble them into their original locations.
10. Install the rocker arms and camshafts. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-485476-S09234604562012071300000) . CAUTION: Do not rotate the camshafts more than a few degrees independently of the crankshaft. Valve to piston contact could occur resulting in possible valve damage. If the camshafts need to be rotated more than a few degrees, first move the pistons away from the cylinder heads by rotating the crankshaft counterclockwise to a position 30° before-top-dead-center. Once the camshafts are returned to their top-dead-center position, rotate the crankshaft clockwise to return the crankshaft to top-dead-center.
11. Verify that the camshafts are set at TDC by positioning the alignment holes (1) vertically.
12. Install the RH cam chain guide (1) with three bolts (2). Tighten the T30 bolts (2) to 12 N.m (106 in. lbs.).
13. Install the RH cam chain tensioner (3) to the engine block with two bolts (4). Tighten the T30 bolts (4) to 12 N.m (106 in. lbs.).
14. Reset the RH cam chain tensioner (3) by pushing back the tensioner piston and installing Tensioner Pin (special tool #8514, Pins, Tensioner) (5).
15. Install the RH tensioner arm (6).
16. Press the RH exhaust cam phaser onto the exhaust camshaft. Install and hand tighten the oil control valve. CAUTION: Always reinstall timing chains so that they maintain the same direction of rotation. Inverting a previously run chain on a previously run sprocket will result in excessive wear to both the chain and sprocket.
17. Drape the right side cam chain over the RH exhaust cam phaser and onto the idler sprocket (1) so that the dimple (2) is aligned with the plated link (3) on the cam chain.
18. While maintaining this alignment, route the cam chain around the exhaust and intake cam phasers so that the plated links are aligned with the phaser timing marks (1). Position the right side cam phasers so that the arrows (3) point away from each other and the scribe lines (4) are parallel to the valve cover sealing surface (6). Press the intake cam phaser onto the intake cam, install and hand tighten the oil control valve (2). NOTE: Minor rotation of a camshaft (a few degrees) may be required to install the camshaft phaser or phaser lock.
19. Install the RH Camshaft Phaser Lock (special tool #10202, Locks, Camshaft/Phaser) (5) and tighten the oil control valves (2) and (7) to 150 N.m (110 ft. lbs.).
20. Remove the RH Camshaft Phaser Lock (special tool #10202, Locks, Camshaft/Phaser).
21. Remove the Tensioner Pin (special tool #8514, Pins, Tensioner) (6) from the RH cam chain tensioner.
22. Rotate the crankshaft CW two complete revolutions stopping when the dimple (4) on the crankshaft is aligned the with the block/bearing cap junction (5).
23. While maintaining this alignment, verify that the arrows on the left side cam phasers (2) point toward each other and are parallel to the valve cover sealing surface (3) and that the right side cam phaser arrows (7) point away from each other and the scribe lines (9) are parallel to the valve cover sealing surface (8).
24. There should be 12 chain pins (2) between the exhaust cam phaser triangle marking (1) and the intake cam phaser circle marking (3).
25. If the engine timing is not correct, repeat this procedure.
26. Install the engine timing cover, crankshaft vibration damper, upper and lower oil pans and cylinder head covers. Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-485476-S03582090622012071300000) .
27. Install the spark plugs. Tighten to 17.5 N.m (13 ft. lbs.). Refer to «SPARK PLUG, INSTALLATION»(ref-485509-S34872660202012071300000) .
28. Install the upper intake manifold support bracket (2) with the studbolt (3) hand tight.
29. Engage the wire harness retainer (3) from the intake manifold support bracket.
30. Connect the ignition coil capacitor electrical connector.
31. Install the heater core supply tube (1) with one bolt (2) tightened to 12 N.m (106 in. lbs.).
32. Reposition the power steering pump and bracket as an assembly and install three bolts (1). Tighten bolts (1) to 25 N.m (18 ft. lbs.).
33. Disengage the wire harness retainer (2) from the power steering pump.
34. Install the power steering pump heat shield (1) and three bolts (2). Tighten bolts to 25 N.m (18 ft. lbs.).
35. Install the accessory drive belt (7). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-485484-S29366023502012071300000) .
36. Install the upper and lower intake manifolds (2) and insulator. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
37. Install the resonator (1). Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-485476-S11419390602012071300000) .
38. Install the air cleaner body (1). Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-485476-S11483727402012071300000) .
39. Evacuate and charge the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
40. Install the engine cover (1).
41. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .
42. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
43. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
44. Install the belly pan. Refer to «UNDER BODY PROTECTION»(ref-485477-S28538233622012071300000) .
45. Lower the vehicle.
46. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
47. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

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.

Scheme 550

Scheme 551

1. If removed, install the Engine Coolant Temperature (ECT) sensor (4) and tighten to 11 N.m (97 in. lbs.).
2. If removed, install the ignition coil capacitor (1) with a M6 bolt (2) tightened to 10 N.m (89 in. lbs.).
3. If removed, install the engine wire harness retainer bracket (5) with a T30 bolt (3) tightened to 12 N.m (106 in. lbs.). 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. NOTE: Typical cylinder head bolt shown in illustration.
4. Check 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: Right head gasket shown in illustration, left head gasket similar. 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.
5. Clean and prepare the gasket sealing surfaces of the cylinder head and block. Refer to «Engine - Standard Procedure»(ref-485476-S02028931392012071300000) . CAUTION: Non-compressible debris such as oil, coolant or RTV sealants that are not removed from bolt holes can cause the aluminum casting to crack when tightening the bolts.
6. Clean out the cylinder head bolt holes in the engine block. WARNING: The multi-layered steel head gaskets have very sharp edges that could cause personal injury if not handled carefully. CAUTION: The cylinder head gaskets are not interchangeable between the left and right cylinder heads and are clearly marked (3) with "R" for right and "L" for left.
7. Position the new cylinder head gasket (1) on the locating dowels (2).
8. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels. NOTE: Do not apply any additional oil to the bolt threads.
9. Install the eight head bolts finger tight.
10. Tighten the cylinder head bolts in the sequence shown in illustration, following this 9 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 45 N.m (33 ft. lbs.) Step 3: All + 75° Turn Do not use a torque wrench for this step. Step 4: All + 50° Turn Do not use a torque wrench for this step. Step 5: Loosen all fasteners in reverse of sequence shown in illustration Step 6: All to 30 N.m (22 ft. lbs.) Step 7: All to 45 N.m (33 ft. lbs.) Step 8: All + 70° Turn Do not use a torque wrench for this step. Step 9: All + 70° Turn Do not use a torque wrench for this step. NOTE: If the hydraulic lifters are being reused, reassemble them into their original locations.
11. If removed, install the hydraulic lifters. Refer to «LIFTER(S), HYDRAULIC, INSTALLATION»(ref-485476-S42292792802012071300000) . NOTE: If the rocker arms are being reused, reassemble them into their original locations.
12. Install the rocker arms and camshafts. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-485476-S09234604562012071300000) .
13. Rotate the camshafts CW to TDC by positioning the alignment holes (1) vertically.
14. Install the LH cam chain guide (2) with two bolts (4). Tighten the T30 bolts (4) to 12 N.m (106 in. lbs.).
15. Install the LH cam chain tensioner (5) to the cylinder head with two bolts (6). Tighten the T30 bolts (6) to 12 N.m (106 in. lbs.).
16. Reset the LH cam chain tensioner (5) by lifting the pawl (3), pushing back the piston and installing Tensioner Pin (special tool #8514, Pins, Tensioner) (7). Refer to «Engine/Valve Timing - Standard Procedure»(ref-485476-S07176515242012071300000) .
17. Install the LH tensioner arm (1).
18. Press the LH intake cam phaser onto the intake camshaft. Install and hand tighten the oil control valve. CAUTION: Always reinstall timing chains so that they maintain the same direction of rotation. Inverting a previously run chain on a previously run sprocket will result in excessive wear to both the chain and sprocket.
19. Drape the left side cam chain over the LH intake cam phaser and onto the idler sprocket (1) so that the arrow (3) is aligned with the plated link (2) on the cam chain.
20. While maintaining this alignment, route the cam chain around the exhaust and intake cam phasers so that the plated links are aligned with the phaser timing marks (1). Position the left side cam phasers so that the arrows (3) point toward each other and are parallel to the valve cover sealing surface (5). Press the exhaust cam phaser onto the exhaust cam, install and hand tighten the oil control valve (2). NOTE: Minor rotation of a camshaft (a few degrees) may be required to install the camshaft phaser or phaser lock.
21. Install the LH Camshaft Phaser Lock (special tool #10202, Locks, Camshaft/Phaser) (4) and tighten the oil control valves (2) and (6) to 150 N.m (110 ft. lbs.).
22. Remove the LH Camshaft Phaser Lock (special tool #10202, Locks, Camshaft/Phaser).
23. Remove the Tensioner Pin (special tool #8514, Pins, Tensioner) (1) from the LH cam chain tensioner.
24. Rotate the crankshaft CW two complete revolutions stopping when the dimple (4) on the crankshaft is aligned the with the block/bearing cap junction (5).
25. While maintaining this alignment, verify that the arrows on the left side cam phasers (2) point toward each other and are parallel to the valve cover sealing surface (3) and that the right side cam phaser arrows (7) point away from each other and the scribe lines (9) are parallel to the valve cover sealing surface (8).
26. There should be 12 chain pins (2) between the exhaust cam phaser triangle marking (1) and the intake cam phaser circle marking (3).
27. If the engine timing is not correct, repeat this procedure.
28. Install the engine timing cover, crankshaft vibration damper, upper and lower oil pans and cylinder head covers. Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-485476-S03582090622012071300000) .
29. Install the spark plugs. Tighten to 17.5 N.m (13 ft. lbs.). Refer to «SPARK PLUG, INSTALLATION»(ref-485509-S34872660202012071300000) .
30. Connect the main harness to the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.
31. Connect the main harness to the engine injection/ignition harness (1) at the rear of the left cylinder head.
32. Connect the Engine Coolant Temperature (ECT) sensor connector.
33. Connect the ignition coil capacitor electrical connector.
34. Install the A/C compressor (1) from the engine compartment. Refer to «COMPRESSOR, A/C, INSTALLATION»(ref-485480-S12532763762012071300000) .
35. Remove the generator (2). Refer to «GENERATOR, INSTALLATION»(ref-485501-S24539340792012071300000) .
36. Remove the accessory drive belt (7). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-485484-S29366023502012071300000) .
37. Install the LH upper intake manifold support brackets (1). Loosely install the studbolts (2).
38. Install the lower and upper intake manifolds (2) and insulator. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
39. Install the oil level indicator tube (1) and the bolt (2). Tighten bolt (2) to 12 N.m (106 in. lbs.).
40. Install the heater core return tube (1) the nut (2), and bolt (3). Tighten nut (2) and bolt (3) 12 N.m (106 in. lbs.).
41. Engage two lower wire harness retainers (3) from the intake manifold support brackets.
42. Engage two upper wire harness retainers (2) from the intake manifold support brackets.
43. Connect the left upstream oxygen sensor connector (1) to the main wire harness.
44. Connect the heater core return hose (1).
45. Install the resonator (1). Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-485476-S11419390602012071300000) .
46. Install the air cleaner body (1). Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-485476-S11483727402012071300000) .
47. Evacuate and charge the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
48. Install the engine cover (1).
49. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .
50. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
51. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
52. Install the belly pan. Refer to «UNDER BODY PROTECTION»(ref-485477-S28538233622012071300000) .
53. Lower the vehicle.
54. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
55. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

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.

Scheme 552

The 3.6L engine is equipped with Variable Valve Timing (VVT). This system adjusts the timing of all four camshafts independently using solenoids and oil control valves to direct oil pressure into the camshaft phaser assemblies. The camshaft phaser assembly advances and/or retards camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The four phasers are located on the front of the camshafts, behind the VVT solenoids, inside of the engine timing cover. The exhaust phasers are identified with EXH and the intake phasers are identified with INT. The exhaust phaser has a clockspring, the intake phaser does not. The camshaft sprockets are integrated with the camshaft phaser and are serviced as an assembly. Do not attempt to disassemble the phasers, they are not serviceable. Phasers are interchangeable between the right and left cylinder heads but should be installed in the same location as removed.

The 3.6L engine has an Oil Control Valve (OCV) for each phaser. The OCV also acts as a bolt for mounting the Phaser to the camshaft. The OCVs spool valve is spring loaded and should move freely within the OCV body. The four OCVs are identical but should be installed in the same location as removed.

Scheme 553

Each phaser position is adjusted using regulated oil pressure through the Oil Control Valve (OCV) (3). To begin phaser movement, a voltage signal is applied to the VVT solenoid (1) to extend or retract the solenoid pintle (4). The pintle pushes against an internal spool valve (2) within the OCV moving the valve forwards and backwards to direct oil flow.

Scheme 554

At engine startup, system oil pressure overcomes spring pressure and unlocks the phaser lock-pin (1) in preparation for phasing. The phasers remain in this position until a PCM signal is given to pulse-width modulate the VVT solenoid. At engine shutdown, as oil pressure is reduced, both Phasers return to their lock-pin position (1). However, because the exhaust Phaser needs to travel to a position above and beyond the standard camshaft clockwise rotation, the assistance of a clock spring is required. The intake Phaser on the other hand, simply relies on the torsional resistance from the valvetrain to push it back towards lock-pin position.

Scheme 555

The position of the spool valve (1) inside the OCV (2) determines which ports and chambers inside the phaser are being fed, either to advance (3), hold (4) or retard (5) the timing of the phaser sprocket relative to the camshaft. The spool valve also returns oil from the chambers to the sump (6). The Camshaft Position (CMP) sensor monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM. As oil pressure pushes against the vanes (6) of the phaser rotor, the rotor begins to move. Since this rotor is physically attached to the camshaft, rotor rotation causes the camshaft position to rotate relative to the standard sprocket (7) position.

Scheme 556

Scheme 557

Scheme 558

Scheme 559

Scheme 560

Scheme 561

Scheme 562

1. Remove the upper intake manifold, left ignition coils and left cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-485476-S14129578282012071300000) .
2. Remove the right ignition coils and all spark plugs. Refer to «SPARK PLUG, REMOVAL»(ref-485509-S13645825702012071300000) . 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. Mount Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) (1) to a stationary point on the engine, such as the left camshaft position (CMP) sensor mount. Position the indicator probe into the number four cylinder, rotate the crankshaft clockwise (as viewed from the front) to place the number four cylinder piston at top-dead-center on the compression stroke and set the indicator dial to zero.
4. The left side cam phaser SCRIBE LINES (3) should face away from each other and the ARROWS (1) should point toward each other and be parallel to the cylinder head cover mounting surface (2) when the number four cylinder piston is positioned at top-dead-center on the compression stroke. NOTE: The phaser markings (1 and 3) could align with either an external or internal chain link. Either alignment is acceptable as long as there are twelve chain pins between the markings.
5. There should be twelve chain pins (2) BETWEEN the exhaust cam phaser triangle marking (3) and the intake cam phaser circle marking (1) as viewed from either the front or rear of the cam phasers.
6. Mark both sides of the cam chain at the phaser timing marks (1 and 3) using a paint pen or equivalent to aid in reassembly. NOTE: It may be necessary to rock the camshaft slightly (a few degrees) with a wrench (4) when installing the camshaft phaser lock.
7. Install the (special tool #10202-2, Lock, Camshaft/Phaser, Left Side) (1) against the cylinder head cover mounting surface with the tool number facing up.
8. Loosen, but do not remove, the exhaust oil control valve (2) and the intake oil control valve (3).
9. Remove the (special tool #10202-2, Lock, Camshaft/Phaser, Left Side) (1). NOTE: Graphic shows engine timing cover removed for clarity.
10. Using (special tool #10200-3, Pin) (2), lift the pawl off of the rack (3). While holding the pawl off of the rack, push (special tool #10200-1, Holder, Timing Chain, Left Side) (1) into place between the cylinder head boss and the tensioner arm to force the rack and piston back into the tensioner body. The Timing Chain Holder remains in place while the phasers are removed. Refer to «Engine/Valve Timing - Standard Procedure»(ref-485476-S07176515242012071300000) .
11. Remove the oil control valve (4) and pull the left side exhaust cam phaser off of the camshaft.
12. Remove the oil control valve (3) and pull the left side intake cam phaser off of the camshaft.

Scheme 563

Scheme 564

Scheme 565

Scheme 566

Scheme 567

Scheme 568

Scheme 569

1. Remove the upper intake manifold, right ignition coils and right cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-485476-S14129578282012071300000) .
2. Remove the left ignition coils and all spark plugs. Refer to «SPARK PLUG, REMOVAL»(ref-485509-S13645825702012071300000) . 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. Mount Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) (1) to a stationary point on the engine, such as the number six cylinder ignition coil mount. Position the indicator probe into the number four cylinder, rotate the crankshaft clockwise (as viewed from the front) to place the number four cylinder piston at top-dead-center on the compression stroke and set the indicator dial to zero.
4. The right side cam phaser ARROWS (2) should point away from each other and the SCRIBE LINES (1) should be parallel to the cylinder head cover mounting surface (3) when the left side number four cylinder piston is positioned at top-dead-center on the compression stroke. NOTE: The phaser markings (1 and 3) could align with either an external or internal chain link. Either alignment is acceptable as long as there are twelve chain pins between the markings.
5. There should be twelve chain pins (2) BETWEEN the exhaust cam phaser triangle marking (1) and the intake cam phaser circle marking (3) as viewed from either the front or rear of the cam phasers.
6. Mark both sides of the cam chain at the phaser timing marks (1 and 3) using a paint pen or equivalent to aid in reassembly. NOTE: It may be necessary to rock the camshaft slightly (a few degrees) with a wrench (4) when installing the camshaft phaser lock.
7. Install the (special tool #10202-1, Lock, Camshaft/Phaser, Right Side) (1) against the cylinder head cover mounting surface with the tool number facing up.
8. Loosen, but do not remove, the exhaust oil control valve (3) and the intake oil control valve (2).
9. Remove the (special tool #10202-1, Lock, Camshaft/Phaser, Right Side) (1). CAUTION: Do not insert the Timing Chain Holder into position without first compressing the tensioner. The Timing Chain Holder is not designed to compress the tensioner and excessive force can damage the timing chain tensioner arm.
10. Use the timing chain to compress the tensioner by slightly rotating the exhaust camshaft clockwise (4). Insert (special tool #10369, Holder, Timing Chain) (1) into place between the cylinder head boss and the tensioner arm to hold the tensioner in the compressed position. The Timing Chain Holder remains in place while the phasers are removed. NOTE: If the Timing Chain Holder (1) does not engage or slips from position, wedge a trim stick (2) or equivalent between the front cover and the tensioner arm (3) to push the tensioner arm towards the rear of the engine and then repeat the previous step.
11. Remove the oil control valve (3) and pull the right side exhaust cam phaser off of the camshaft.
12. Remove the oil control valve (2) and pull the right side intake cam phaser off of the camshaft.

Scheme 570

Scheme 571

1. Verify that the indicator dial (1) is set to zero when the left side number four cylinder piston is positioned at top-dead-center on the compression stroke.
2. Verify that the camshafts are set at top-dead-center by positioning the alignment holes (1) vertically. NOTE: The Timing Chain Holder (1) should still be in place as inserted during the Removal procedure. If required, the Timing Chain Holder can be reinserted by repeating Step 10 of the Removal procedure. Refer to «ASSEMBLY, VARIABLE VALVE TIMING, PHASER / OIL CONTROL VALVE, REMOVAL»(ref-485476-S19136186582012071300000) . NOTE: Minor rotation of a camshaft (a few degrees) may be required to install the camshaft phaser.
3. Route the cam chain around the left intake cam phaser while aligning the paint mark with the phaser timing mark (1). Press the left intake cam phaser onto the intake camshaft. Install and hand tighten the oil control valve (7).
4. While maintaining this alignment, route the cam chain around the exhaust cam phaser so that the paint mark is aligned with the phaser timing mark (3). Press the exhaust cam phaser onto the exhaust cam, install and hand tighten the oil control valve (4).
5. The SCRIBE LINES (5) on the cam phasers should face away from each other and the ARROWS (6) should point toward each other and be parallel to the cylinder head cover mounting surface. There should be twelve chain pins (2) BETWEEN the exhaust cam phaser triangle marking (3) and the intake cam phaser circle marking (1). NOTE: It may be necessary to rock the camshaft slightly (a few degrees) with a wrench (4) when installing the camshaft phaser lock.
6. Install the (special tool #10202-2, Lock, Camshaft/Phaser, Left Side) (1) against the cylinder head cover mounting surface with the tool number facing up.
7. Tighten the oil control valves (2) and (3) to 150 N.m (110 ft. lbs.).
8. Remove the Camshaft Phaser Lock (1) and the Timing Chain Holder.
9. Rotate the crankshaft clockwise two complete revolutions stopping when the left side number four cylinder piston is again positioned at top-dead-center on the compression stroke. To assure correct engine timing, verify the following; The indicator dial is set to ZERO when the left side number four cylinder piston is positioned at top-dead-center on the compression stroke. The SCRIBE LINES (3) on the left side cam phasers face away from each other. The ARROWS (4) on the left side cam phasers point toward each other and are parallel to the cylinder head cover mounting surface. There are twelve chain pins (2) BETWEEN the exhaust cam phaser triangle marking (1) and the intake cam phaser circle marking (3).
10. If the engine timing is not correct, repeat this procedure.
11. Install the spark plugs. Refer to «SPARK PLUG, INSTALLATION»(ref-485509-S34872660202012071300000) .
12. Install the right ignition coils. Refer to «COIL, IGNITION, INSTALLATION»(ref-485509-S40080226732012071300000) .
13. Install the left cylinder head cover and left ignition coils. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-485476-S23156666322012071300000) .
14. Install the upper intake manifold and air cleaner housing assembly. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
15. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
16. Start the engine and perform the appropriate POWERTRAIN VERIFICATION TEST located in appropriate Electrical Diagnostics article. Cam/Crank Variation Relearn Target Coefficient Relearn

Note. Following the first restart after a DTC driven phaser replacement, clear all DTCs and verify that subsequent restarts do not set any additional codes. For any DTCs that reset, refer to appropriate Electrical Diagnostics article.

Scheme 572

Scheme 573

1. Verify that the indicator dial (1) is set to zero when the left side number four cylinder piston is positioned at top-dead-center on the compression stroke.
2. Verify that the camshafts are set at top-dead-center by positioning the alignment holes (1) vertically. NOTE: The Timing Chain Holder (1) should still be in place as inserted during the Removal procedure. If required, the Timing Chain Holder can be reinserted by installing the exhaust cam phaser and repeating Step 10 of the Removal procedure. Refer to «ASSEMBLY, VARIABLE VALVE TIMING, PHASER / OIL CONTROL VALVE, REMOVAL»(ref-485476-S19136186582012071300000) . NOTE: Minor rotation of a camshaft (a few degrees) may be required to install the camshaft phaser.
3. Route the cam chain around the right exhaust cam phaser while aligning the paint mark with the phaser timing mark (1). Press the right exhaust cam phaser onto the exhaust camshaft. Install and hand tighten the oil control valve (7).
4. While maintaining this alignment, route the cam chain around the intake cam phaser so that the paint mark is aligned with the phaser timing mark (3). Press the intake cam phaser onto the intake cam, install and hand tighten the oil control valve (4).
5. The ARROWS (5) on the cam phasers should point away from each other and the SCRIBE LINES (6) should be parallel to the cylinder head cover mounting surface. There should be twelve chain pins (2) BETWEEN the exhaust cam phaser triangle marking (1) and the intake cam phaser circle marking (3). NOTE: It may be necessary to rock the camshaft slightly (a few degrees) with a wrench (4) when installing the camshaft phaser lock.
6. Install the (special tool #10202-1, Lock, Camshaft/Phaser, Right Side) (1) against the cylinder head cover mounting surface with the tool number facing up.
7. Tighten the oil control valves (2) and (3) to 150 N.m (110 ft. lbs.).
8. Remove the Camshaft Phaser Lock (1) and the Timing Chain Holder.
9. Rotate the crankshaft clockwise two complete revolutions stopping when the left side number four cylinder piston is again positioned at top-dead-center on the compression stroke. To assure correct engine timing, verify the following; The indicator dial is set to ZERO when the left side number four cylinder piston is positioned at top-dead-center on the compression stroke. The ARROWS (4) on the right side cam phasers point away from each other. The SCRIBE LINES (5) on the right side cam phasers are parallel to the cylinder head cover mounting surface. There are twelve chain pins (2) BETWEEN the exhaust cam phaser triangle marking (1) and the intake cam phaser circle marking (3).
10. If the engine timing is not correct, repeat this procedure.
11. Install the spark plugs. Refer to «SPARK PLUG, INSTALLATION»(ref-485509-S34872660202012071300000) .
12. Install the left ignition coils. Refer to «COIL, IGNITION, INSTALLATION»(ref-485509-S40080226732012071300000) .
13. Install the right cylinder head cover and right ignition coils. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-485476-S23156666322012071300000) .
14. Install the upper intake manifold and air cleaner housing assembly. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
15. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
16. Start the engine and perform the appropriate POWERTRAIN VERIFICATION TEST located in appropriate Electrical Diagnostics article. Cam/Crank Variation Relearn Target Coefficient Relearn

Note. Following the first restart after a DTC driven phaser replacement, clear all DTCs and verify that subsequent restarts do not set any additional codes. For any DTCs that reset, refer to appropriate Electrical Diagnostics article.

Scheme 574

The 3.6L engine uses a Dual Over Head Camshaft (DOHC) configuration. The camshafts are a nodular cast iron design and have a pressed on magnetic timing wheel that is magnetic encoded. The two Camshaft Position (CMP) sensors are located between the timing wheels. Attached to the rear of the right exhaust camshaft is a centrifuge which is part of the crankcase ventilation system. The centrifuge is used to separate oil droplets from the crankcase gases before they enter the PCV valve. Four bearing journals are machined into the camshaft. Camshaft end play is controlled by two thrust walls that border the nose piece journal.

Scheme 575

Note. RH camshafts shown in illustration, LH camshafts similar.

The camshaft has precisely machined (egg shaped) lobes to provide accurate valve timing and duration. The camshaft is driven by the crankshaft via drive sprockets and chains.

Scheme 576

Note. Right intake camshaft shown in illustration, other camshafts similar.

1. Remove the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-485476-S14129578282012071300000) .
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»(ref-485476-S24399402942012071300000) .

Scheme 577

1. Remove the upper intake manifold, all ignition coils, all spark plugs, left cylinder head cover and left cam phasers. Refer to «ASSEMBLY, VARIABLE VALVE TIMING, PHASER / OIL CONTROL VALVE, REMOVAL»(ref-485476-S19136186582012071300000) .
2. Rotate the camshafts counterclockwise to position the alignment holes (1) approximately 30° before top-dead-center. This places the camshafts in the neutral position (no valve load). NOTE: Camshaft bearing caps should have been marked during engine manufacturing. For example, the number one exhaust camshaft bearing cap is marked "1E->". The caps should be installed with the notch forward.
3. Loosen the camshaft bearing cap bolts in the sequence shown in illustration. NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing the camshaft.
4. Remove the camshaft bearing caps and the camshafts.

Scheme 578

1. Remove the upper intake manifold, all ignition coils, all spark plugs, right cylinder head cover and right cam phasers. Refer to «ASSEMBLY, VARIABLE VALVE TIMING, PHASER / OIL CONTROL VALVE, REMOVAL»(ref-485476-S19136186582012071300000) . NOTE: Camshaft bearing caps should have been marked during engine manufacturing. For example, the number one exhaust camshaft bearing cap is marked "1E->". The caps should be installed with the notch forward.
2. Loosen the camshaft bearing cap bolts in the sequence shown in illustration. NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing the camshaft.
3. Remove the camshaft bearing caps and the camshafts.

Scheme 579

Note. RH intake camshaft shown in illustration, other camshafts similar.

1. Inspect camshaft bearing journals (4) for damage and binding. If journals are binding, check the cylinder head for damage. Also check cylinder head oil holes for clogging.
2. Check the surface of the cam lobes (5) for abnormal wear (3). Measure and compare the unworn area (1) to the worn area (2). Replace camshafts that are not within specification. Refer to «Engine - Specifications»(ref-485476-S24399402942012071300000) .

Scheme 580

1. Lubricate the camshaft journals with clean engine oil.
2. Install the left side camshaft(s) with the alignment holes (1) positioned approximately 30° before top-dead-center. This will place the camshafts at the neutral position (no valve load) easing the installation of the camshaft bearing caps.
3. Install the camshaft bearing caps and hand tighten the retaining bolts to 2 N.m (18 in. lbs.). NOTE: Caps are identified numerically (1 through 4), intake or exhaust (I or E) and should be installed from the front to the rear of the engine. All caps should be installed with the notch forward so that the stamped arrows (<) on the caps point toward the front of the engine.
4. Tighten the bearing cap retaining bolts in the sequence shown in illustration to 9.5 N.m (84 in. lbs.).
5. Rotate the camshafts clockwise to top-dead-center by positioning the alignment holes (1) vertically.
6. Install the left cam phasers, cylinder head cover, spark plugs, ignition coils and the upper intake manifold. Refer to «ASSEMBLY, VARIABLE VALVE TIMING, PHASER / OIL CONTROL VALVE, INSTALLATION»(ref-485476-S13326172312012071300000) .

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.

Scheme 581

1. Lubricate camshaft journals with clean engine oil.
2. Install the right side camshaft(s) at top-dead-center by positioning the alignment holes (1) vertically. This will place the camshafts at the neutral position (no valve load) easing the installation of the camshaft bearing caps.
3. Install the camshaft bearing caps and hand tighten the retaining bolts to 2 N.m (18 in. lbs.). NOTE: Caps are identified numerically (1 through 4), intake or exhaust (I or E) and should be installed from the front to the rear of the engine. All caps should be installed with the notch forward so that the stamped arrows (<) on the caps point toward the front of the engine.
4. Tighten the bearing cap retaining bolts in the sequence shown in illustration to 9.5 N.m (84 in. lbs.).
5. Install the right cam phasers, cylinder head cover, spark plugs, ignition coils and the upper intake manifold. Refer to «ASSEMBLY, VARIABLE VALVE TIMING, PHASER / OIL CONTROL VALVE, INSTALLATION»(ref-485476-S13326172312012071300000) .

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.

Scheme 582

The cylinder head covers are made of a carbon and fiberglass composite. The cylinder head covers are not interchangeable from side-to-side. The cylinder head covers are sealed with a press-in-place gasket that is designed to isolate the cover from the cylinder head for improved NVH. There are two dowel pins on the outboard side of the cover flange to locate the cover to holes in the cylinder head. RTV is used to seal the T-joint at the timing cover, cylinder head and cylinder head cover.

Scheme 583

Scheme 584

Scheme 585

Scheme 586

Scheme 587

Scheme 588

Scheme 589

Scheme 590

Scheme 591

Scheme 592

1. Disconnect and isolate the negative battery cable.
2. Remove the air cleaner body, resonator and upper intake manifold (2). Refer to «MANIFOLD, INTAKE, REMOVAL»(ref-485476-S08989499162012071300000) .
3. Cover the open intake ports (1) to prevent debris from entering the engine. NOTE: Mark the variable valve timing solenoid connectors (2) with a paint pen or equivalent so that they may be reinstalled in their original locations.
4. Disconnect the electrical connectors (2) from the variable valve timing solenoids on the right cylinder head.
5. Disengage two wire harness retainers (1) from the right cylinder head cover.
6. Mark the variable valve timing solenoids (2 and 4) with a paint pen or equivalent so that they may be reinstalled in their original locations.
7. Remove the variable valve timing solenoids. Refer to «SOLENOID, VARIABLE VALVE TIMING [ERB], REMOVAL»(ref-485509-S14418516102012071300000) .
8. Disengage three main wire harness retainers (1) from the right cylinder head cover.
9. Disconnect the electrical connector (1) from the right Camshaft Position (CMP) sensor. NOTE: If removing both RH and LH CMP sensors, mark the sensors so they can be installed in their original locations.
10. Remove the camshaft position sensor. Refer to «SENSOR, CAMSHAFT POSITION, REMOVAL»(ref-485509-S16151093322012071300000) .
11. Disengage three injection/ignition harness retainers (1) from the right cylinder head cover. NOTE: The LH ignition coils are shown in illustration, the RH ignition coils are similar.
12. Remove the ignition coils (2). Refer to «COIL, IGNITION, REMOVAL»(ref-485509-S30847409012012071300000) .
13. Remove the PCV valve (1). Refer to «VALVE, POSITIVE CRANKCASE VENTILATION (PCV), REMOVAL»(ref-485524-S07644830472012071300000) .
14. Remove the two resonator mounts (1) from the studbolts.
15. Loosen nine cylinder head cover mounting bolts (1) and three studbolts (2) and remove the cylinder head cover. NOTE: The LH cylinder head cover is shown in illustration, the RH cylinder head cover is similar.
16. Remove and discard the cylinder head cover gasket (1).
17. The spark plug tube seals (2) can be reused if not damaged. NOTE: The LH cylinder head cover T-joints are shown in illustration, the RH cylinder head cover T-joints are similar. CAUTION: Do not use oil based liquids, wire brushes, abrasive wheels or metal scrapers to clean the engine gasket surfaces. Use only isopropyl (rubbing) alcohol, along with plastic or wooden scrapers. Improper gasket surface preparation may result in engine fluid leakage.
18. Remove all residual sealant (1) from the cylinder head, timing chain cover and cylinder head cover mating surfaces. Refer to «Engine - Standard Procedure»(ref-485476-S02028931392012071300000) .

Scheme 593

Scheme 594

Scheme 595

1. Disconnect and isolate the negative battery cable.
2. Remove the air cleaner body, resonator and upper intake manifold (2). Refer to «MANIFOLD, INTAKE, REMOVAL»(ref-485476-S08989499162012071300000) .
3. Cover the open intake ports (1) to prevent debris from entering the engine.
4. Remove the insulator (2) from the LH cylinder head cover. NOTE: Mark the variable valve timing solenoid connectors (2) with a paint pen or equivalent so that they may be reinstalled in their original locations.
5. Disconnect the electrical connectors (2) from the variable valve timing solenoids on the left cylinder head cover.
6. Disengage three wire harness retainers (1) from the left cylinder head cover.
7. Mark the variable valve timing solenoids (2 and 4) with a paint pen or equivalent so that they may be reinstalled in their original locations.
8. Remove the variable valve timing solenoids. Refer to «SOLENOID, VARIABLE VALVE TIMING [ERB], REMOVAL»(ref-485509-S14418516102012071300000) .
9. Disconnect the left Camshaft Position (CMP) sensor (5).
10. Disengage one main wire harness retainer (2) from the cylinder head cover and one main wire harness retainer (4) from the cylinder head cover mounting stud. NOTE: The RH CMP sensor is shown in illustration, the LH CMP sensor is similar. If removing both RH and LH CMP sensors, mark the sensors so they can be installed in their original locations.
11. Remove the camshaft position sensor. Refer to «SENSOR, CAMSHAFT POSITION, REMOVAL»(ref-485509-S16151093322012071300000) .
12. Disengage two injection/ignition harness retainers (1) from the left cylinder head cover.
13. Remove the ignition coils (2). Refer to «COIL, IGNITION, REMOVAL»(ref-485509-S30847409012012071300000) .
14. Loosen ten cylinder head cover mounting bolts (1) and two studbolts (2) and remove the cylinder head cover.
15. Remove and discard the cylinder head cover gasket (1).
16. The spark plug tube seals (2) can be reused if not damaged. CAUTION: Do not use oil based liquids, wire brushes, abrasive wheels or metal scrapers to clean the engine gasket surfaces. Use only isopropyl (rubbing) alcohol, along with plastic or wooden scrapers. Improper gasket surface preparation may result in engine fluid leakage.
17. Remove all residual sealant (1) from the cylinder head, timing chain cover and cylinder head cover mating surfaces. Refer to «Engine - Standard Procedure»(ref-485476-S02028931392012071300000) .

Note. The LH cylinder head cover is shown in illustration, the RH cylinder head cover is similar.

Scheme 596

Scheme 597

1. Install the cylinder head cover gasket (1).
2. The spark plug tube seals (2) can be reused if not damaged.
3. If required, install new spark plug tube seals (2) in the cylinder head cover: Lubricate the spark plug tube seal inner and outer diameters with clean engine oil. Place the spark plug tube seal (2) on the Cam Sensor/Spark Plug Tube Seal Installer (special tool #10256, Installer, Cam Installer, Cam Sensor/ Spark Plug Tube Seal) (1). Push the seal into the cylinder head cover until the base of the seal is seated. Remove the tool. NOTE: The LH cylinder head cover T-joint is shown in illustration, the RH cylinder head cover T-joint is similar.
4. Clean the engine timing cover, cylinder head and cylinder head cover mating surfaces with isopropyl alcohol in preparation for sealant application. CAUTION: Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Threebond Engine RTV Sealant may result in engine fluid leakage. CAUTION: Following the application of Mopar® Threebond Engine RTV Sealant to the gasket surfaces, the components must be assembled within 20 minutes and the attaching fasteners must be tightened to specification within 45 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.
5. Apply a 2 to 3 mm wide bead of Mopar® Threebond Engine RTV Sealant (1) to the two engine timing cover to cylinder head T-joints as shown in illustration.
6. Align the locator pins (1) to the cylinder head and install the cylinder head cover.
7. Tighten the cylinder head cover bolts and double ended studs in the sequence shown in illustration to 12 N.m (106 in. lbs.).
8. Install the two resonator mounts (1) to the studbolts.
9. Install the PCV valve (1). Refer to «VALVE, POSITIVE CRANKCASE VENTILATION (PCV), REMOVAL»(ref-485524-S07644830472012071300000) . NOTE: The LH ignition coils are shown in illustration, the RH ignition coils are similar.
10. If removed, install the spark plugs. Refer to «SPARK PLUG, INSTALLATION»(ref-485509-S34872660202012071300000) .
11. Install the ignition coils (2). Refer to «COIL, IGNITION, INSTALLATION»(ref-485509-S40080226732012071300000) .
12. Engage three injection/ignition harness retainers (1) to the right cylinder head cover. NOTE: If both RH and LH CMP sensors where removed, install them into their original locations.
13. Install the camshaft position sensor. Refer to «SENSOR, CAMSHAFT POSITION, INSTALLATION»(ref-485509-S07255143702012071300000) .
14. Connect the electrical connector (1) to the right Camshaft Position (CMP) sensor.
15. Engage three main wire harness retainers (1) to the right cylinder head cover.
16. Refer to the markings made at disassembly and install the variable valve timing solenoids (2 and 4) in their original locations. Refer to «SOLENOID, VARIABLE VALVE TIMING [ERB], INSTALLATION»(ref-485509-S08808689932012071300000) .
17. Connect the electrical connectors (2) to the variable valve timing solenoids on the right cylinder head.
18. Engage two wire harness retainers (1) to the right cylinder head cover.
19. If removed, install the insulator (2) to the two alignment posts (3) on top of the LH cylinder head cover.
20. Install the upper intake manifold (1), support brackets, resonator and air cleaner body. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
21. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

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.

Scheme 598

Scheme 599

1. Install the cylinder head cover gasket (1).
2. The spark plug tube seals (2) can be reused if not damaged.
3. If required, install new spark plug tube seals (2) in the cylinder head cover: Lubricate the spark plug tube seal inner and outer diameters with clean engine oil. Place the spark plug tube seal (2) on the Cam Sensor/Spark Plug Tube Seal Installer (special tool #10256, Installer, Cam Installer, Cam Sensor/ Spark Plug Tube Seal) (1). Push the seal into the cylinder head cover until the base of the seal is seated. Remove the tool.
4. Clean the timing engine timing cover, cylinder head and cylinder head cover mating surfaces with isopropyl alcohol in preparation for sealant application. CAUTION: Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Threebond Engine RTV Sealant may result in engine fluid leakage. CAUTION: Following the application of Mopar® Threebond Engine RTV Sealant to the gasket surfaces, the components must be assembled within 20 minutes and the attaching fasteners must be tightened to specification within 45 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.
5. Apply a 2 to 3 mm wide bead of Mopar® Threebond Engine RTV Sealant (1) to the two engine timing cover to cylinder head T-joints as shown in illustration.
6. Align the locator pins (1) to the cylinder head and install the cylinder head cover.
7. Tighten the cylinder head cover bolts and double ended studs in the sequence shown in illustration to 12 N.m (106 in. lbs.).
8. If removed, install the spark plugs. Refer to «SPARK PLUG, INSTALLATION»(ref-485509-S34872660202012071300000) .
9. Install the ignition coils. Refer to «COIL, IGNITION, INSTALLATION»(ref-485509-S40080226732012071300000) .
10. Engage two injection/ignition harness retainers (1) to the left cylinder head cover. NOTE: The RH CMP sensor is shown in illustration, the LH CMP sensor is similar. If both RH and LH CMP sensors where removed, install them into their original locations.
11. Install the camshaft position sensor. Refer to «SENSOR, CAMSHAFT POSITION, INSTALLATION»(ref-485509-S07255143702012071300000) .
12. Connect the electrical connector (5) to the left Camshaft Position (CMP) sensor.
13. Engage one main wire harness retainer (2) to the cylinder head cover and one main wire harness retainer (4) to the cylinder head cover mounting stud.
14. Refer to the markings made at disassembly and install the variable valve timing solenoids (2 and 4) in their original locations. Refer to «SOLENOID, VARIABLE VALVE TIMING [ERB], INSTALLATION»(ref-485509-S08808689932012071300000) .
15. Engage three wire harness retainers (1) to the left cylinder head cover.
16. Connect the electrical connectors (2) to the left variable valve timing solenoids.
17. Install the insulator (2) to the two alignment posts (3) on top of the LH cylinder head cover.
18. Install the upper intake manifold (1), support brackets, resonator and air cleaner body. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
19. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

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.

IN VEHICLE

Scheme 600

Scheme 601

1. Disconnect and isolate the negative battery cable.
2. Remove both cylinder head covers. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-485476-S14129578282012071300000) . NOTE: The LH cylinder head rocker arms are shown in illustration, the RH cylinder head rocker arms are similar. NOTE: Only remove the camshafts from one head at a time. The opposite head must remain assembled in order to lock the crankshaft against rotation. 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) (1). Refer to «ROCKER ARM, VALVE, REMOVAL»(ref-485476-S18060150142012071300000) . NOTE: RH camshaft phaser lock shown in illustration, LH camshaft phaser lock similar. CAUTION: Air pressure applied to the cylinder holds the valves in place. This air pressure also has a tendency to force the piston down and rotate the crankshaft. Do not allow the crankshaft to rotate. Crankshaft rotation may damage the timing chain or front timing cover and affect camshaft timing.
4. If removing the LH camshafts, install the RH Camshaft Phaser Lock (special tool #10202, Locks, Camshaft/Phaser) (5) to lock the crankshaft against rotation. If removing the RH camshafts, install the LH Camshaft Phaser Lock (special tool #10202, Locks, Camshaft/Phaser) to lock the crankshaft against rotation. NOTE: Number 4 cylinder intake valve spring compression shown in illustration, all other valves similar.
5. Remove the spark plug. Refer to «SPARK PLUG, REMOVAL»(ref-485509-S13645825702012071300000) .
6. Install Valve Spring Compressor (special tool #MD998772A, Compressor, Valve Spring) (2) onto the cylinder head.
7. Install a spark plug adapter attached to a regulated shop air supply (1). Pressurize the cylinder being serviced to 620.5 - 689 kPa (90 - 100 psi) to hold the valves in place. 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 Valve Spring Compressor Adapter (special tool #10224, Adapter, Valve Spring) (3), compress valve spring (4) and remove valve retaining locks (5). NOTE: If the springs are to be reused, identify their positions so that they can be reassembled into their original locations. Number 5 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 and spring seat. Refer to «SEAL(S), VALVE GUIDE, REMOVAL»(ref-485476-S00324130712012071300000) .

Scheme 602

Scheme 603

1. Remove the cylinder head(s). Refer to «CYLINDER HEAD, REMOVAL»(ref-485476-S20076592182012071300000) .
2. Position the Valve Spring Compressor Adapter (special tool #10224, Adapter, Valve Spring) (2) in the Valve Spring Compressor (special tool #C-3422-D, Compressor, Valve Spring) (1). NOTE: Number 3 cylinder intake valve spring compression shown in illustration, all other valves similar.
3. Compress the valve spring (3) and remove the valve retaining locks (4). NOTE: If the springs are to be reused, identify their positions so that they can be reassembled into their original locations. Number 5 cylinder exhaust valve spring shown in illustration, all other valves similar.
4. Release the valve spring compression and remove the valve spring retainer (1) and valve spring (2).
5. If required, remove the valve(s). Refer to «VALVES, INTAKE AND EXHAUST, REMOVAL»(ref-485476-S15347151852012071300000) .
6. If required, remove the valve guide seal and spring seat. Refer to «SEAL(S), VALVE GUIDE, REMOVAL»(ref-485476-S00324130712012071300000) .

Scheme 604

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.

Scheme 605

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 and the installed valve spring height (4) is greater than 40.0 mm (1.575 in.), install an additional spring seat (8) in the head counterbore under the original valve spring seat (8) to bring the spring height back within specification. Make sure the measurement is taken from the top of spring seat (6) to the bottom surface of spring retainer (1).

Scheme 606

1. If removed, install the spring seat (3) and valve guide seal (1) over the valve guide. Refer to «SEAL(S), VALVE GUIDE, INSTALLATION»(ref-485476-S21154558342012071300000) . NOTE: Ensure that the garter spring (2) is intact around the top of the valve guide seal (1). Number 5 cylinder exhaust valve guide seal shown in illustration, all other valves similar. NOTE: If the valve springs are being reused, reassemble them into their original locations. Number 5 cylinder exhaust valve spring shown in illustration, all other valves similar.
2. Install the valve spring (2) and valve spring retainer (1). NOTE: Number 4 cylinder intake valve spring compression shown in illustration, all other valves similar.
3. Using Valve Spring Compressor Adapter (special tool #10224, Adapter, Valve Spring) (3) with Valve Spring Compressor (special tool #MD998772A, Compressor, Valve Spring) (2), compress the valve spring (4) only enough to install the valve retaining locks (5).
4. Relieve the air pressure and remove the spark plug adapter.
5. Install the spark plug and tighten to 17.5 N.m (13 ft. lbs.). Refer to «SPARK PLUG, INSTALLATION»(ref-485509-S34872660202012071300000) . NOTE: The LH cylinder head rocker arms are shown in illustration, the RH cylinder head rocker arms are similar. If the rocker arms are being reused, reassemble them into their original locations.
6. Install the rocker arm(s) (1). Refer to «ROCKER ARM, VALVE, INSTALLATION»(ref-485476-S05860175182012071300000) .
7. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

OFF VEHICLE

1. If removed, install the valve(s). Refer to «VALVES, INTAKE AND EXHAUST, INSTALLATION»(ref-485476-S35164345062012071300000) . 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»(ref-485476-S24399402942012071300000) . Number 5 cylinder exhaust valve shown in illustration, all other valves similar.
2. If removed, install the spring seat (3) and valve guide seal (1) over the valve guide. Refer to «SEAL(S), VALVE GUIDE, INSTALLATION»(ref-485476-S21154558342012071300000) . NOTE: Ensure that the garter spring (2) is intact around the top of the valve guide seal (1). Number 5 cylinder exhaust valve guide seal shown in illustration, all other valves similar. NOTE: If the valve springs are being reused, reassemble them into their original locations. Number 5 cylinder exhaust valve spring shown in illustration, all other valves similar.
3. Install the valve spring (2) and valve spring retainer (1). NOTE: Number 3 cylinder intake valve spring compression shown in illustration, all other valves similar.
4. Compress valve springs (3) with the Valve Spring Compressor Adapter (special tool #10224, Adapter, Valve Spring) (2) mounted in the Valve Spring Compressor (special tool #C-3422-D, Compressor, Valve Spring) (1). Install the retaining locks (4) and release the valve spring compression.
5. If the valves or valve seats have been refinished, check the installed height of the valve springs (4). If the installed valve spring height (4) is greater than 40.0 mm (1.575 in.), install an additional spring seat (8) in the head counterbore under the original valve spring seat (8) to bring the spring height back within specification. Make sure the measurement is taken from the top of spring seat (6) to the bottom surface of spring retainer (1).
6. Install the cylinder head(s). Refer to «CYLINDER HEAD, INSTALLATION»(ref-485476-S00213433672012071300000) .

VALVE SEATS

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. Total runout should not exceed 0.050 mm (0.002 inch.) total indicator reading.
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 seat should be 1.0 - 1.2 mm (0.04 - 0.05 in.) and the exhaust seats should be 1.41 - 1.61 mm (0.055 - 0.063 in.).

VALVE AND SPRING INSTALLED HEIGHT

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»(ref-485476-S24399402942012071300000) . Make sure the measurement is taken from the cylinder head surface (7) to the top of the valve stem (2).
3. If removed, install the spring seat (3) and valve guide seal (1) over the valve guide. Refer to «SEAL(S), VALVE GUIDE, INSTALLATION»(ref-485476-S21154558342012071300000) . NOTE: Ensure that the garter spring (2) is intact around the top of the valve guide seal (1). Number 5 cylinder exhaust valve guide seal shown in illustration, all other valves similar. NOTE: If the valve springs are being reused, reassemble them into their original locations. Number 5 cylinder exhaust valve spring shown in illustration, all other valves similar.
4. Install the valve spring (2) and valve spring retainer (1). NOTE: Number 3 cylinder intake valve spring compression shown in illustration, all other valves similar.
5. Compress valve springs (3) with the Valve Spring Compressor Adapter (special tool #10224, Adapter, Valve Spring) (2) mounted in the Valve Spring Compressor (special tool #C-3422-D, Compressor, Valve Spring) (1). Install the retaining locks (4) and release the valve spring compression.
6. If the valves or valve seats have been refinished, check the installed height of the valve springs (4). If the installed valve spring height (4) is greater than 40.0 mm (1.575 in.), install a second spring seat (8) in the head counterbore under the valve spring seat (8) to bring the spring height back within specification. Make sure the measurement is taken from the top of spring seat (6) to the bottom surface of spring retainer (1).

VALVES

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»(ref-485476-S24399402942012071300000) .

Scheme 607

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»(ref-485476-S24399402942012071300000) .

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.

MAIN BEARING FITTING

The upper and lower main bearings are "select fit" to achieve proper oil clearances. Crankshaft main bearing journal diameter grade markings (1) are stamped into the front crankshaft counterweight. These marks are read from left to right, corresponding with journal number 1, 2, 3, 4.

Crankshaft main bearing journal diameter grade markings correspond to specific journal diameters. The chart below identifies the five crankshaft grade markings and their associated journal diameters.

Scheme 608

Engine block main bearing journal diameter grade markings (2) are stamped into the left side of the engine block. These marks are read from left to right, corresponding with journal number 1, 2, 3, 4.

Engine block main bearing journal grade markings correspond to specific journal diameters. The chart below identifies the five engine block grade markings and their associated journal diameters.

For upper and lower main bearing selection, obtain the grade identification marks from the crankshaft and engine block. Main bearings are available in five sizes. Upper and lower sizes can be mixed on a journal in order to achieve the desired oil clearance. The chart below identifies the five sizes available and how they should be selected based on crankshaft and engine block grade markings.

The upper main bearing shell (2) and lower main bearing shell (1) are marked with the bearing size (3) on the bearing lining surface. The upper and lower bearings are available in five different sizes and can be mixed on a journal in order to achieve the proper oil clearance.

Upper and lower main bearing shells are available in five sizes. The chart below identifies the five bearing sizes.

Note. Crankshaft thrust washers are not selectable and are only available in a single thickness.

Bearing oil clearance can also be determined by using Plastigage or equivalent. Refer to Engine/Engine Block - Standard Procedure .

Scheme 609

The upper and lower main bearings are "select fit" to achieve proper oil clearances. Refer to Engine/Engine Block/BEARING(S), Crankshaft - Standard Procedure .

Scheme 610

Scheme 611

Scheme 612

Scheme 613

Scheme 614

Scheme 615

Scheme 616

Scheme 617

1. Disconnect and isolate the negative battery cable.
2. Remove the spark plugs. Refer to «SPARK PLUG, REMOVAL»(ref-485509-S13645825702012071300000) .
3. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
4. Remove the right halfshaft assembly (2) and the intermediate shaft. Refer to «REMOVAL»(ref-485478-S16823732752012071300000) .
5. Remove the oil pan, oil pump pick-up and engine oil pump. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-485476-S19236501352012071300000) .
6. Remove the accessory drive belt (7). Refer to «BELT, SERPENTINE, REMOVAL»(ref-485484-S39989615472012071300000) .
7. Remove the bolts (1 and 3) and reposition the A/C compressor (2). Remove the nut (2), bolt (3) and reposition the heater core return tube (1).
8. Remove the three bolts (2) and the front engine mount bracket (1).
9. Remove the eight main bearing cap bolts from the windage tray in the sequence shown in illustration and remove the windage tray (1). NOTE: Typical V6 engine configuration shown in illustration.
10. Remove the eight main bearing tie bolts in the sequence shown in illustration. CAUTION: DO NOT use a number stamp or a punch to mark main bearing caps, as damage to main bearings could occur. NOTE: Main bearing caps are not interchangeable and are marked to insure correct assembly.
11. Mark the main bearing cap positions using a permanent ink marker or a scribe tool. NOTE: Typical V6 engine configuration shown in illustration. CAUTION: Replace only one main bearing at a time while all other main bearing caps remain properly tightened. If all main bearing caps are removed, the weight of the unsupported crankshaft will damage the crankshaft oil seals. NOTE: Replace the main bearings in the following order; 2, 3, 1, 4.
12. Remove the two cap bolts (2) and remove the main bearing cap (1).
13. When removing the No. 2 bearing cap, also remove the thrust washers (5).
14. Slide the upper main bearing half (6) out from between the crankshaft and the engine block.
15. If required, select fit new main bearings to the engine block. Refer to «Engine/Engine Block/BEARING(S), Crankshaft - Standard Procedure»(ref-485476-S22844276452012071300000) .
16. Lubricate the upper main bearing half (6) with clean engine oil and slide the bearing into position. NOTE: Typical V6 engine configuration shown in illustration.
17. When installing thrust washers (1) at the No. 2 main bearing location, use the following procedure: Move the crankshaft forward to the limit of travel. Lubricate and install the front thrust washer (1) by rolling the washer onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface. Move the crankshaft rearward to the limit of travel. Lubricate and install the rear thrust washer by rolling the washer onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface. 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.
18. 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. NOTE: Typical V6 engine configuration shown in illustration.
19. Lubricate and install the lower bearing half (3) onto the main cap (1).
20. Install the main bearing cap (1) with two inner main bearing cap bolts (2) tightened to 20 N.m (15 ft. lbs.) plus 90°.
21. Repeat the previous steps for main bearings 3, 1 and 4.
22. Measure crankshaft end play. Refer to «Engine/Engine Block/CRANKSHAFT - Standard Procedure»(ref-485476-S15487145352012071300000) .
23. Install the windage tray with eight main bearing cap bolts. Tighten the bolts in the sequence shown in illustration to 21 N.m (16 ft. lbs.) plus 90°. NOTE: Typical V6 engine configuration shown in illustration.
24. Install the eight main bearing tie bolts. Tighten the bolts in the sequence shown in illustration to 28 N.m (21 ft. lbs.).
25. Install the front engine mount bracket (1). Tighten bolts (2) to 55 N.m (41 ft. lbs.).
26. Install the A/C compressor and hand tighten all the bolts (1 and 3) that secure the A/C compressor to the engine. Then tighten the bolts to 25 N.m (18 ft. lbs.).
27. Install the accessory drive belt (7). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-485484-S29366023502012071300000) .
28. Install the engine oil pump, oil pump pick-up, oil pans, oil level indicator, front fore-aft crossmember (1) and crossunder pipe (2). Refer to «PUMP, ENGINE OIL, INSTALLATION»(ref-485476-S18747126302012071300000) .
29. Install the heater core return tube (1) with the nut (2) and bolt (3). Tighten the fasteners to 12 N.m (106 in. lbs.).
30. Install the intermediate shaft and right halfshaft assembly (2). Refer to «INSTALLATION»(ref-485478-S35834915172012071300000) .
31. Install the spark plugs and ignition coils. Refer to «SPARK PLUG, INSTALLATION»(ref-485509-S34872660202012071300000) .
32. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .
33. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
34. Operate the engine until it reaches normal operating temperature.

Scheme 618

The crankshaft is a cast design and is constructed using ductile iron. The crankshaft is a three throw split pin design with counterweights for balancing purposes. The main journals are crossed drilled for rod bearing lubrication. The crankshaft is supported by four select fit main bearings with number 2 serving as the thrust washer location. The rear counterweight has provisions for crankshaft position sensor target wheel mounting. Both the front and rear seals are a single piece design and are mounted to the timing cover and cylinder block.

Scheme 619

Note. Typical V6 engine shown in illustration.

1. Mount Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) to a stationary point at the front of the engine. Locate the probe perpendicular against the nose of the crankshaft.
2. Move the crankshaft all the way to the rear of its travel.
3. Zero the dial indicator.
4. Move the crankshaft forward to the limit of travel and read the dial indicator. Compare the measured end play to the specification. Refer to «Engine - Specifications»(ref-485476-S24399402942012071300000) .

Note. Crankshaft thrust washers are not selectable and are only available in a single thickness.

PISTON FITTING

The pistons are "select fit" to achieve proper oil clearance. Engine block cylinder bore diameter grade markings (1) are stamped into the left side of the engine block. These marks are read from left to right, corresponding with cylinder number 1, 2, 3, 4, 5, 6.

Engine block cylinder bore diameter grade markings correspond to specific cylinder bore diameters. The chart below identifies the two engine block grade markings and their associated cylinder bore diameters.

Scheme 620

The piston is marked with the piston size (1 and 2) on the piston crown. The pistons are available in two 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 two sizes. The chart below identifies the two piston sizes.

Scheme 621

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.

Scheme 622

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»(ref-485476-S24399402942012071300000) .
5. Repeat this procedure for each connecting rod. Rotate the crankshaft for connecting rod accessibility.

Scheme 623

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»(ref-485476-S24399402942012071300000) .
2. Repeat this procedure for each connecting rod. Rotate the crankshaft for connecting rod accessibility.

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.

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 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 below.

STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE

Change the engine oil and filter at mileage and time intervals described in the Maintenance Schedule. Refer to MAINTENANCE SCHEDULES, DESCRIPTION .

Scheme 624

1. Run the engine until achieving normal operating temperature.
2. Position the vehicle on a level surface and turn the engine off.
3. Remove the engine cover (1). NOTE: Graphic shows engine cover removed for clarity. CAUTION: When performing an engine oil change, the oil filter cap must be removed. Removing the oil filter cap releases oil held within the oil filter cavity and allows it to drain into the sump. Failure to remove the cap prior to reinstallation of the drain plug will not allow complete draining of the used engine oil.
4. Place an oil absorbent cloth around the oil filter housing at the base of the oil filter cap. NOTE: The oil filter (3) is attached to the oil filter cap (2).
5. Rotate the oil filter cap (1) counterclockwise and remove the cap (1) and filter (3) from the oil filter housing.
6. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
7. Place a suitable drain pan under the crankcase drain plug (1).
8. Remove the drain plug (1) from oil pan and allow the oil to drain into the pan. Inspect the drain plug threads for stretching or other damage. Replace the drain plug and gasket if damaged.
9. Install the drain plug (1) in the oil pan and tighten to 27 N.m (20 ft. lbs.).
10. Lower the vehicle.
11. Remove the oil filter (3) from the oil filter cap (2).
12. Remove and discard the O-ring seal (1). NOTE: It is not necessary to pre-oil the oil filter or fill the oil filter housing.
13. Lightly lubricate the new O-ring seal (1) with clean engine oil.
14. Install the O-ring seal (1) on the filter cap (2).
15. Install the new oil filter (3) into the oil filter cap (2). NOTE: Graphic shows engine cover removed for clarity.
16. Thread the oil filter cap (1) into the oil filter housing and tighten to 25 N.m (18 ft. lbs.).
17. Remove the oil fill cap. Fill the crankcase with the specified type and amount of engine oil. Refer to «CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS»(ref-485472-S24485616782012071300000) .
18. Install the oil fill cap.
19. Start the engine and inspect for leaks.
20. Stop the engine and check the oil level.
21. Install the engine cover (1).

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing of used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above.

Scheme 625

There is an upper and lower oil pan. The upper oil pan is cast aluminum and also serves as the lower end structural support. The lower pan is a stamped steel design. Both upper and lower oil pans are sealed using Mopar® Threebond Engine RTV Sealant. The lower oil pan must be removed in order to access all of the upper oil pan attaching bolts.

Scheme 626

The high pressure die cast aluminum windage tray is mounted to the main bearing caps and is designed to keep oil off of the connecting rods as the crankshaft rotates. When the oil is kept off the connecting rods, the engine rotates easier and oil foaming decreases. Like the oil pan, the windage tray is designed to stiffen the lower end of the engine. The tray is directional and the main bearing cap bolts hold it in place.

Scheme 627

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
2. Drain the engine oil. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .
3. Remove the belly pan.
4. Remove inner splash shield. NOTE: The lower oil pan must be removed to access all of the upper oil pan retaining bolts.
5. Remove fifteen bolts (1), two nuts (2) and two studs (3) from the flange of the lower oil pan. CAUTION: Do not pry on the lower oil pan flange. There are no designated pry points for lower oil pan removal. Prying on only one or a few locations could bend the flange and damage the pan.
6. Using a pry bar (2), apply a side force to the lower oil pan (1) in order to shear the sealant bond and remove the pan.
7. Remove all residual sealant (1) from the upper and lower oil pans. Refer to «PAN, OIL, CLEANING»(ref-485476-S14923747292012071300000) .

Scheme 628

Scheme 629

Scheme 630

Scheme 631

Scheme 632

1. Disconnect and isolate the negative battery cable.
2. Remove the bolt (2) and the oil level indicator (1).
3. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
4. Remove the belly pan. Refer to «UNDER BODY PROTECTION»(ref-485477-S28538233622012071300000) .
5. Drain the engine oil. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .
6. Remove the right halfshaft assembly (1) from the intermediate shaft (3). Refer to «REMOVAL»(ref-485478-S16823732752012071300000) . NOTE: The lower oil pan must be removed to access all of the upper oil pan retaining bolts.
7. Remove the lower oil pan. Refer to «PAN, OIL, REMOVAL»(ref-485476-S01269687182012071300000) .
8. Remove the crossunder pipe (2). Refer to «PIPE, EXHAUST CROSSUNDER, REMOVAL»(ref-485503-S41492710422012071300000) .
9. Remove the front fore-aft crossmember (1). Refer to «CROSSMEMBER, FRONT FORE AND AFT, REMOVAL»(ref-485477-S17979691932012071300000) , «CROSSMEMBER, FRONT SUSPENSION, REMOVAL»(ref-485477-S35953511442012071300000) and «CROSSMEMBER, REAR SUSPENSION, REMOVAL»(ref-485477-S22760813262012071300000) .
10. Remove the bolt (1) securing the coolant tube (2) to the oil pan.
11. Remove the five oil pan to transmission bolts (1).
12. Remove the torque converter bolt access cover (1).
13. Remove two rubber plugs (2) covering the rear oil seal retainer flange bolts. NOTE: Shown in illustration with transmission removed for clarity. CAUTION: There are two hidden M6 bolts that must be removed from the rear of the upper oil pan flange. If these bolts are not removed, the rear oil seal retainer flange will be severely damaged.
14. Remove two M6 bolts (1) from the rear oil seal retainer flange.
15. Remove nineteen M8 oil pan mounting bolts (1).
16. Using the four indicated pry points, carefully remove the upper oil pan.
17. Remove all residual sealant (1) from the upper and lower oil pans, timing chain cover, rear seal retainer and engine block mating surfaces. Refer to «PAN, OIL, CLEANING»(ref-485476-S14923747292012071300000) .

Scheme 633

Scheme 634

1. Clean the oil pan in solvent and wipe dry with a clean cloth. CAUTION: Do not use oil based liquids, wire brushes, abrasive wheels or metal scrapers to clean the engine gasket surfaces. Use only isopropyl (rubbing) alcohol, along with plastic or wooden scrapers. Improper gasket surface preparation may result in engine fluid leakage.
2. Remove all residual sealant (1) from the upper and lower oil pans. Refer to «Engine - Standard Procedure»(ref-485476-S02028931392012071300000) .

LOWER

1. Clean the upper and lower oil pan mating surfaces with isopropyl alcohol in preparation for sealant application. CAUTION: Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Threebond Engine RTV Sealant may result in engine fluid leakage. CAUTION: Following the application of Mopar® Threebond Engine RTV Sealant to the gasket surfaces, the components must be assembled within 20 minutes and the attaching fasteners must be tightened to specification within 45 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.
2. Apply a 2 to 3 mm wide bead of Mopar® Threebond Engine RTV Sealant (1) to the lower oil pan as shown in illustration.
3. Install two studs (3) into the upper oil pan flange.
4. Install the lower oil pan to the upper oil pan with fifteen bolts (1) and two nuts (2) tightened to 11 N.m (97 in. lbs.). CAUTION: Following assembly, the Mopar® Threebond Engine RTV Sealant must be allowed to dry for 45 minutes prior to adding oil and engine operation. Premature exposure to oil prior to drying may result in engine fluid leakage.
5. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .
6. Run the engine until it reaches normal operating temperature.

Scheme 635

1. Clean the upper and lower oil pans, timing chain cover, rear seal retainer and engine block mating surfaces with isopropyl alcohol in preparation for sealant application. CAUTION: Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Threebond Engine RTV Sealant may result in engine fluid leakage. CAUTION: Following the application of Mopar® Threebond Engine RTV Sealant to the gasket surfaces, the components must be assembled within 20 minutes and the attaching fasteners must be tightened to specification within 45 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.
2. Apply a 2 to 3 mm wide bead of Mopar® Threebond Engine RTV Sealant to the upper oil pan as shown in illustration in the following locations: Oil pan to engine block flange (1) Two timing cover to engine block T-joints (2) Two rear seal retainer to engine block T-joints (3) CAUTION: Make sure that the rear face of the oil pan is flush to the transmission bell housing before tightening any of the oil pan mounting bolts. A gap between the oil pan and the transmission could crack the oil pan or transmission casting.
3. Install the oil pan to the engine block and flush to the transmission bell housing. Secure the oil pan to the engine block with nineteen M8 oil pan mounting bolts (1) finger tight.
4. Install the five oil pan to transmission bolts (1) and tighten to 55 N.m (41 ft. lbs.).
5. Tighten the nineteen previously installed M8 oil pan mounting bolts (3) to 25 N.m (18 ft. lbs.). NOTE: Shown in illustration with transmission removed for clarity.
6. Install the two M6 bolts (1) to the rear oil seal retainer flange and tighten to 12 N.m (9 ft. lbs.).
7. Install the torque converter bolt access cover (1).
8. Install the two rubber plugs (2) covering the rear oil seal retainer flange bolts.
9. Install the bolt (1) securing the coolant tube (2) to oil pan and tighten to 12 N.m (106 in. lbs.).
10. Install the lower oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-485476-S34328764342012071300000) .
11. Install the front fore-aft crossmember (1). Refer to «CROSSMEMBER, FRONT FORE AND AFT, INSTALLATION»(ref-485477-S30914186772012071300000) , «CROSSMEMBER, FRONT SUSPENSION, INSTALLATION»(ref-485477-S39011195842012071300000) and «CROSSMEMBER, REAR SUSPENSION, INSTALLATION»(ref-485477-S04203009532012071300000) .
12. Install the crossunder pipe (2). Refer to «PIPE, EXHAUST CROSSUNDER, INSTALLATION»(ref-485503-S02364008432012071300000) .
13. Install the right halfshaft assembly, steering knuckle, wheel and tire. Refer to «INSTALLATION»(ref-485478-S35834915172012071300000) .
14. Install the belly pan. Refer to «UNDER BODY PROTECTION»(ref-485477-S28538233622012071300000) .
15. Lower the vehicle.
16. Install the oil level indicator (1) with bolt (2) tightened 12 N.m (106 in. lbs.).
17. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .
18. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
19. Run the engine until it reaches normal operating temperature.

Scheme 636

Scheme 637

1. Disconnect and isolate the negative battery cable.
2. Remove the upper oil pan. Refer to «PAN, OIL, REMOVAL»(ref-485476-S01269687182012071300000) .
3. Remove the bolt (1) and the oil pick-up tube (2) from the oil pump.
4. Remove and discard the O-ring seal (1) from the oil pick-up tube.

Scheme 638

Scheme 639

Scheme 640

1. Release fuel system pressure. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-485510-S12963059542012071300000) .
2. Disconnect and isolate the negative battery cable.
3. Remove the resonator and upper intake manifold (2). Refer to «MANIFOLD, INTAKE, REMOVAL»(ref-485476-S08989499162012071300000) .
4. Remove the insulator (2) from the LH cylinder head cover.
5. Disconnect the fuel supply hose (1) from the fuel rail inlet. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-485510-S02478018532012071300000) .
6. Disconnect the fuel injector electrical connectors.
7. Disengage the injection/ignition harness retainer (1) form the rear of the lower intake manifold.
8. Disengage the main wire harness retainer (2) form the rear of the lower intake manifold.
9. Remove the eight lower intake manifold attaching bolts (1).
10. Remove the lower intake manifold (2) with the fuel injectors and fuel rail.
11. Remove and discard the six lower intake manifold to cylinder head seals (1).
12. If required, remove the fuel rail (2) and fuel injectors from the lower intake manifold. Refer to «RAIL, FUEL, REMOVAL»(ref-485510-S17104042232012071300000) .

Scheme 641

Note. When the upper intake manifold (3) and lower intake manifold (1) are not aligned properly, cross threading of the upper intake manifold attaching bolts can occur. The graphic shows non-repairable damage to the lower intake manifold (1) due to cross threading of an upper intake manifold attaching bolt (2).

Check both the upper and lower intake manifolds for

1. Damage and cracks
2. Gasket surface damage or warping

Check the lower intake manifold for

1. Damaged fuel injector ports

If either the upper or lower manifold exhibits any damaged or warped conditions, replace the manifold.

Scheme 642

Note. Prior to installing the upper intake manifold, verify that the four fuel rail bolts were not inadvertently loosened. The bolts must tightened in the sequence shown in illustration to 7 N.m (62 in. lbs.). Refer to RAIL, FUEL, INSTALLATION .

Scheme 643

1. Clean and inspect the sealing surfaces. Install new upper to lower intake manifold seals (1). NOTE: Make sure the fuel injectors and wiring harnesses are in the correct position so that they don't interfere with the upper intake manifold installation.
2. If removed, install the insulator (2) to the two alignment posts (3) on top of the LH cylinder head cover.
3. Lift and hold the seven upper intake attaching bolts (1) clear of the mating surface. Back the bolts out slightly or if required, use an elastic band to hold the bolts clear of the mating surface.
4. Position the upper intake manifold (1) onto the lower intake manifold so that the two locating posts (2) on the upper intake manifold align with corresponding holes (3) in the lower intake manifold.
5. Install the seven upper intake manifold attaching bolts. Tighten the bolts in the sequence shown in illustration to 8 N.m (71 in. lbs.).
6. Install two nuts (1) to the upper intake manifold support bracket (5). Tighten the nuts (1) to 10 N.m (89 in. lbs.) and tighten the studbolt (2) to 20 N.m (177 in. lbs.)
7. Engage the wire harness retainer (3) to the studbolt (2).
8. Engage the wire harness retainer (4) to the upper intake manifold support bracket (5).
9. Install two upper intake manifold support brackets (2) with two studbolts (3) and two nuts (1). Tighten the studbolts (3) to 20 N.m (177 in. lbs.) and tighten the nuts (1) to 10 N.m (89 in. lbs.).
10. Install the nut (2) to the support bracket of the heater core return tube (1) and tighten to 12 N.m (106 in. lbs.).
11. Connect the following hoses to the upper intake manifold: Positive Crankcase Ventilation (PCV) (3) vapor purge (6) brake booster (2)
12. Connect the electrical connectors to the Manifold Absolute Pressure (MAP) sensor (1) and the Electronic Throttle Control (ETC) (7).
13. Secure the ETC harness to the clip (7) on the throttle body and engage the wire harness retainers (4 and 5) to the upper intake manifold near the MAP sensor.
14. Install the resonator (1). Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-485476-S11419390602012071300000) .
15. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
16. Start and run the engine until it reaches normal operating temperature.
17. Install the engine cover (1).

Scheme 644

1. Clean and inspect the sealing surfaces. Install new lower intake manifold to cylinder head seals (1).
2. If removed, install the fuel injectors and the fuel rail (1) to the lower intake manifold. Tighten the four bolts in the sequence shown in illustration to 7 N.m (62 in. lbs.). Refer to «RAIL, FUEL, INSTALLATION»(ref-485510-S05795597622012071300000) .
3. Position the lower intake manifold (1) on the cylinder head surfaces.
4. Install the manifold attaching bolts and tighten in the sequence shown in illustration to 8 N.m (71 in. lbs.).
5. Engage the main wire harness retainer (2) to the rear of the lower intake manifold.
6. Engage the injection/ignition harness retainer (1) to the rear of the lower intake manifold.
7. Connect the fuel injector electrical connectors.
8. Connect the fuel supply hose (1) to the fuel rail inlet. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-485510-S02478018532012071300000) .
9. Install the insulator (2) to the two alignment posts (3) on top of the LH cylinder head cover.
10. Install the upper intake manifold (1), support brackets and resonator. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
11. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
12. Start the engine and check for leaks.

Scheme 645

The timing drive uses four silent chains. The silent chain link design improves sprocket engagement and reduces noise, vibration and harshness (NVH). One chain (5) drives the oil pump (4) and three chains drive the camshafts in a two stage design. The left secondary camshaft chain (1) uses an oil pressure controlled chain tensioner (9) with a ratcheting device. The right secondary camshaft chain (8) uses an oil pressure controlled tensioner (7) without a ratchet. The primary chain (2) also uses an oil pressure controlled tensioner (6) without a ratchet. A spring loaded tensioner (3) takes up the slack in the oil pump chain (5). The chain guides and tensioner arms are made of glass filled nylon with nylon wear faces.

Scheme 646

The primary timing chain is a silent type. The primary chain drives the 28 tooth idler sprocket directly from a 21 tooth crankshaft sprocket. This results in a 75% speed reduction to the idler sprocket. The idler sprocket assembly connects the primary chain drive and the secondary chain drive. The idler sprocket assembly consists of two integral 22 tooth sprockets a 28 tooth sprocket. The idler sprocket assembly spins on a stationary idler shaft. The idler shaft is a light press-fit into the cylinder block. A large washer on the idler shaft bolt and the rear flange of the idler shaft are used to control sprocket thrust movement. Pressurized oil is routed through the center of the idler shaft to provide lubrication for the bushings used in the idler sprocket assembly. Primary chain motion is controlled by a hydraulic oil damped tensioner and a fixed guide. The tensioner and the guide both use nylon plastic wear faces for low friction and long wear. The primary chain receives oil splash lubrication.

Scheme 647

There are two identical secondary drive chains, both are silent type, one to drive the camshafts in each double overhead cam (DOHC) cylinder head. The secondary chains drive the 33 tooth camshaft sprockets directly from the 22 tooth idler sprockets. This speed reduction combined with the crankshaft to idler sprocket speed reduction produces the required 2:1 camshaft drive ratio. A fixed chain guide and a hydraulic oil damped tensioner are used to maintain tension in each secondary chain system. The left hydraulic secondary chain tensioner is fed from the main oil gallery through the cylinder head. The right hydraulic secondary chain tensioner is fed from the number one main bearing journal. Each tensioner incorporates a controlled leak path through a device known as a vent disc located in the nose of the piston to manage chain loads. Only the left tensioner has a mechanical ratchet system that limits chain slack if the tensioner piston bleeds down after engine shut down. The tensioner arms and guides also utilize nylon wear faces for low friction and long wear. The two secondary timing chains are lubricated by holes in the oil controlled tensioners that spray oil through an opening in the tensioner arms. The holes are protected from clogging by a fine mesh screen which is located on the back of the hydraulic tensioners.

Scheme 648

The left side cam chain tensioner used on the 3.6L engine is equipped with a ratchet. The ratchet consists of a rack (2) and a pawl (1). In use, the rack (2) extends with the piston (3) from the tensioner body. The pawl (1) will not allow the rack (2) to retract back into the tensioner body. In order to reset the tensioner, the pawl (1) must be disengaged from the rack (2) so that the piston (3) and rack (2) can be pushed back (4) into the tensioner body.

Scheme 649

Note. The slot (2) in the rack provides an anchor point for a pin that holds the rack in the retracted position.

Scheme 650

1. Using a suitable tool, such as an allen wrench (1), lift the pawl off of the rack.
2. While holding the pawl off of the rack, push the rack and the piston into the tensioner body.
3. When the slot is aligned with the hole in the tensioner body, insert Tensioner Pin (special tool #8514, Pins, Tensioner) (1) to hold the rack and piston in the retracted position.

WITH ENGINE TIMING COVER INSTALLED

Note. Graphic shows timing cover removed for clarity.

Scheme 651

1. Using (special tool #10200-3, Pin) (2), lift the pawl off of the rack (3).
2. While holding the pawl off of the rack, push (special tool #10200-1, Holder, Timing Chain, Left Side) (1) into place between the cylinder head and the cam chain guide to force the rack and piston back into the tensioner body. The holder must remain in place during service to keep the rack and piston in the retracted position.

Scheme 652

1. Remove the engine timing chain cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-485476-S33092042822012071300000) .
2. To determine if the timing chains are worn, rotate the crankshaft clockwise until maximum tensioner piston extension (1) is obtained on the RH cam chain tensioner (2). Measure the distance between the secondary timing chain tensioner housing and the step ledge on the tensioner piston (1). Piston extension (1) must be less than 16 mm (0.630 in.).
3. Piston extension greater than 16 mm (0.630 in.) indicates that all timing chains are worn and require replacement. Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL»(ref-485476-S28206731252012071300000) .

ENGINE TIMING VERIFICATION

Correct timing is critical for the NON free-wheeling designed, 3.6L engine. Engine timing can be verified by using the following procedures

Scheme 653

1. Remove the upper intake manifold and both cylinder head covers. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-485476-S14129578282012071300000) .
2. Remove the spark plugs. Refer to «SPARK PLUG, REMOVAL»(ref-485509-S13645825702012071300000) . 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. Mount Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) (1) to a stationary point on the engine, such as the left camshaft position (CMP) sensor mount. Position the indicator probe into the number four cylinder, rotate the crankshaft clockwise (as viewed from the front) to place the number four cylinder piston at top-dead-center on the compression stroke and set the indicator dial to ZERO .
4. While maintaining this alignment, verify that the ARROWS (1) on the left side cam phasers point toward each other and are parallel to the cylinder head cover mounting surface (2) and that the right side cam phaser ARROWS (3) point away from each other and the SCRIBE LINES (5) are parallel to the cylinder head cover mounting surface (4). NOTE: The phaser markings (1 and 3) could align with either an external or internal chain link. Either alignment is acceptable as long as there are twelve chain pins between the markings.
5. There should be twelve chain pins (2) BETWEEN the exhaust cam phaser triangle marking (1) and the intake cam phaser circle marking (3) as viewed from either the front or rear of the cam phasers.
6. If the engine timing is not correct, proceed to Timing Chain and Sprockets for service procedures. Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL»(ref-485476-S28206731252012071300000) .