3.6L Engine - Service Information: Removal & Installation Dodge Avenger II facelift

INSTALLATION

Note. If installing a replacement engine, transfer components such as engine mount brackets, block heater, accessories, heater hoses and tubes to the replacement engine.

1. If required, remove the upper intake manifold. Refer to «MANIFOLD, INTAKE, REMOVAL»(ref-485476-S08989499162012071300000) .
2. Install the Driver Side Engine Lifting Bracket (special tool #10242-1, Brackets, Engine Lifting, Left Side) (1) on the LH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 N.m (15 ft. lbs.).
3. Install the Passenger Side Engine Lifting Bracket (special tool #10242-2, Brackets, Engine Lifting, Right Side) (1) on the RH cylinder head with bolts (2) from the Engine Lifting Bracket. Tighten the bolts to 21 N.m (15 ft. lbs.).
4. Position a load-leveling lifting sling (2), such as OTC® 4305 Engine Load Leveler or equivalent, between the engine lifting brackets (3) and an engine hoist (1).
5. Install the transaxle (2) to the engine (1) if required. Secure with six transaxle upper bellhousing-to-block bolts (3) tightened to 70 N.m (52 ft. lbs.).
6. Position the engine/transaxle assembly on the Power Train Dolly (special tool #6135, Dolly, Power Train) (3) and Engine Support Cradle (special tool #6710A, Cradle, Engine Support) (2).
7. Loosen the cradle engine mounts to allow movement for positioning onto the engine locating holes on the engine block and oil pan rail. Place Adapter (special tool #6848-3, Adapter) (1) on the front post and align to the oil pan mounting stud. Tighten the post mounts to the cradle frame. Secure the engine/transaxle assembly to the dolly/cradle with safety straps (4). Remove the engine lifting brackets.
8. If required, install the following components for installation on the replacement engine: Accessory drive belt tensioner. Upper intake manifold support bracket. Block heater (if equipped).
9. Position the engine/transaxle assembly under the vehicle. Slowly lower the vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for clearance.
10. Install three bolts (1) to the RH engine mount bracket (2) and tighten bolts (1) to 55 N.m (41 ft. lbs.).
11. Install two bolts (1) to the LH engine (transmission) mount bracket (2).
12. Position the main wire harness onto the engine.
13. Engage the wire harness retainer (1) to the gearshift cable bracket (4).
14. Connect two output shaft speed sensors connectors (2 and 3).
15. Connect the gearshift cable (5) from the bracket (4).
16. Connect the gearshift cable (1) from transaxle manual valve lever (2).
17. Connect the oil cooler lines (2) to transaxle.
18. Connect the transmission input shaft speed sensor connector (1).
19. Connect transmission solenoid harness connector (2).
20. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
21. If required, install the four transaxle-to-engine lower bolts (2) and tighten to 70 N.m 52 ft. lbs.).
22. If required, install the torque converter-to-driveplate bolts (1) and tighten to 88 N.m (65 ft. lbs.).
23. If required, install the transaxle torque converter housing dust cover (1) and rubber plugs (2).
24. Install the rear engine mount bracket (1) with four bolts (2). Tighten bolts (2) to 110 N.m (81 ft. lbs.)
25. Install the bolt (3) to the rear engine mount isolator and tighten to 61 N.m (45 ft. lbs.).
26. Lower the vehicle.
27. If required, install the heater core supply tube (1) with two bolts (2) and tighten to 12 N.m (106 in. lbs.).
28. Install the LH upper intake manifold support brackets (1). Loosely install the studbolts (2).
29. Engage three main wire harness retainers (1) to the right cylinder head cover.
30. Connect the oil pump solenoid electrical connector (2).
31. Engage the wire harness retainer (1) to the engine block.
32. Install the power steering pump and bracket as an assembly with three bolts (1) and tighten to 25 N.m (18 ft. lbs.).
33. Engage the wire harness retainer (2) to the power steering pump.
34. Install the power steering pump heat shield (1) Tighten bolts (2) to 25 N.m (18 ft. lbs.).
35. Connect the power cord to the engine block heater (if equipped).
36. Engage the downstream oxygen sensor connector (4) to the engine mount.
37. Engage one wire harness retainer (2) to the engine block and one wire harness retainer (1) to the transmission mounting stud.
38. Connect the Crankshaft Position (CKP) sensor electrical connector (3).
39. Position the heat shield (1) over the Crankshaft Position (CKP) sensor.
40. Install the rear engine mount heat shield (2). Tighten bolts (1) to 14 N.m (124 in. lbs.).
41. Install the A/C compressor (1). Refer to «COMPRESSOR, A/C, INSTALLATION»(ref-485480-S12532763762012071300000) .
42. Install the lower radiator hose (1).
43. Install the starter. Refer to «STARTER, INSTALLATION»(ref-485502-S02283169372012071300000) .
44. Install the front engine mount bracket (1). Tighten bolts (2) to 55 N.m (41 ft. lbs.).
45. Install both catalytic converters (3) and connect the oxygen sensor connectors to the main wire harness. Refer to «CONVERTER, CATALYTIC, INSTALLATION»(ref-485503-S33960274562012071300000) .
46. Install the crossunder pipe (2). Refer to «PIPE, EXHAUST CROSSUNDER, INSTALLATION»(ref-485503-S02364008432012071300000) .
47. Install the front fore and 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) .
48. Install the intermediate shaft and both axle shafts (2). Refer to «INSTALLATION»(ref-485478-S35834915172012071300000) .
49. Install the right lower splash shield (2).
50. Install the left lower splash shield (2).
51. Install both front tire and wheel assemblies (1). Refer to «INSTALLATION»(ref-485473-S08436569672012071300000) .
52. Install the belly pan. Refer to «UNDER BODY PROTECTION»(ref-485477-S28538233622012071300000) .
53. Engage the wire harness retainer (2) to the upper intake manifold support bracket mounting stud.
54. Engage the wire harness retainer (3) to the intake manifold support bracket.
55. Connect the electrical connector (1) to the right Camshaft Position (CMP) sensor.
56. Engage two wire harness retainers (1) to the right cylinder head cover.
57. Connect the electrical connectors (2) to the variable valve timing solenoids on the right cylinder head.
58. Connect the main harness to the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.
59. Connect the main harness to the engine injection/ignition harness (1) at the rear of the left cylinder head.
60. Engage the main wire harness retainer (1) to the rear of the lower intake manifold.
61. 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.
62. Connect the left Camshaft Position (CMP) sensor (5).
63. Connect the Engine Coolant Temperature (ECT) sensor connector (3).
64. Engage two lower wire harness retainers (3) to the intake manifold support brackets.
65. Engage two upper wire harness retainers (2) to the intake manifold support brackets.
66. Connect the left upstream oxygen sensor connector (1) to the main wire harness.
67. Engage three wire harness retainers (1) to the left cylinder head cover.
68. Connect the electrical connectors (2) to the variable valve timing solenoids on the left cylinder head cover.
69. Install the generator (2). Refer to «GENERATOR, INSTALLATION»(ref-485501-S24539340792012071300000) .
70. Install the accessory drive belt (7). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-485484-S29366023502012071300000) .
71. Connect the heater core supply hose (1). Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-485510-S02478018532012071300000) .
72. Install the cooling fan module (3). Refer to «FAN, COOLING, INSTALLATION»(ref-485484-S07186189022012071300000) .
73. Install the upper radiator hose (1).
74. Install the upper intake manifold (2). Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
75. Install the heater core return tube (1) with the nut (2) and bolt (3).
76. Connect the heater core return hose (1).
77. Install the coolant recovery bottle (1). Refer to «BOTTLE, COOLANT RECOVERY, INSTALLATION»(ref-485484-S05736649122012071300000) .
78. Connect the fuel line (1) from the fuel rail inlet.
79. Install the electric vacuum pump and mounting bracket (1). Refer to «PUMP, ELECTRIC VACUUM, INSTALLATION»(ref-485474-S00401658872012071300000) .
80. Install the resonator (1). Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-485476-S11419390602012071300000) .
81. Install the air cleaner body (1). Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-485476-S11483727402012071300000) .
82. 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) .
83. Evacuate and recharge Air Conditioning system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
84. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
85. Install the engine cover (1).
86. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
87. 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.

1. Install the air cleaner element (1) into the air cleaner housing.
2. Seat the cover onto the housing and tighten the four housing cover screws (1).
3. Connect the fresh air makeup hose (2) to the air cleaner housing cover.

REMOVAL

1. Disconnect and isolate the negative battery cable.
2. Remove the engine cover (1).
3. Disconnect the fresh air makeup hose (4) from the air cleaner body (1).
4. Remove the push pin (3).
5. Remove two bolts (2) from the air cleaner body (1).
6. Loosen the clamp (5) at the resonator and remove the air cleaner body (1).

1. Engage the air inlet hose to the resonator and install the air cleaner body (1) with two bolts (2) tightened to 9 N.m (80 in. lbs.).
2. Tighten the air inlet hose to resonator clamp (5) to 4 N.m (35 in. lbs.).
3. Install the push pin (3).
4. Install the fresh air makeup hose (4) to the air cleaner body.
5. Install the engine cover (1).
6. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 418

1. Disconnect and isolate the negative battery cable.
2. Remove the engine cover (1).
3. Disconnect the electrical connector (2) from the Inlet Air Temperature (IAT) sensor.
4. Loosen the clamp (4) and remove the air inlet hose from the resonator (1).
5. Remove the push pin (3).
6. Pull the resonator (1) straight up off of the two locating pins (3) on the right cylinder head cover. Disengage and remove the resonator from the throttle body inlet.

1. Lubricate the two rubber mount sockets (2) on the resonator (1) with Mopar® Rubber Bushing Installation Lube.
2. Install the resonator to the throttle body inlet. Push the resonator (1) down onto the two locating pins (3) on the right cylinder head cover until the rubber mount sockets (2) are fully seated.
3. Install the push pin (3).
4. Install the air inlet hose to the resonator (1) and tighten the clamp (4) to 4 N.m (35 in. lbs.).
5. Connect the electrical connector (2) to the Inlet Air Temperature (IAT) sensor.
6. Install engine cover (1).
7. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 419

The 3.6L aluminum cylinder heads are a unique design with left and right castings. The exhaust manifolds are integrated into the cylinder heads. The cylinder head features four valves per cylinder with pressed in powdered metal valve guides. The valve guides are not serviceable. The DOHC valvetrain uses roller rocker arms with hydraulic lifters. The cylinder head's camshaft bearing caps are made of powdered metal and the location and direction of each cap is marked on the side of the caps. The spark plug tubes are pressed into the cylinder heads and sealed in place. The tubes are a thin wall design and caution must be taken when working in the spark plug tube area.

Note. The LH cylinder head hydraulic lifters are shown in illustration, the RH cylinder head hydraulic lifters are similar. If the hydraulic lifters are being reused, reassemble them into their original locations.

1. Verify that the hydraulic lifters are at least partially full of oil. There should be little or no plunger travel when the hydraulic lifter is depressed.
2. Install the hydraulic lifter(s) (1). NOTE: If the rocker arms are being reused, reassemble them into their original locations.
3. Install the rocker arm(s). Refer to «ROCKER ARM, VALVE, INSTALLATION»(ref-485476-S05860175182012071300000) .
4. Install the camshaft(s), phasers, cylinder head cover(s) and upper intake manifold. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-485476-S09234604562012071300000) .
5. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 420

The rocker arms are steel stampings with an integral roller bearing. The rocker arms incorporate a 0.5 mm oil hole in the lash adjuster socket for roller and camshaft lubrication.

Scheme 421

Note. The LH cylinder head rocker arms are shown in illustration, the RH cylinder head rocker arms are similar.

1. Disconnect and isolate the negative battery cable.
2. Remove the camshaft(s). 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.
3. Remove the rocker arm(s) (1).

Scheme 422

Inspect the cam follower assembly for wear or damage. see scheme 323 Replace as necessary.

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.

1. Lubricate the rocker arms with clean engine oil before installation.
2. Install the rocker arm(s) (1).
3. Install the camshaft(s), phasers, cylinder head cover(s) and upper intake manifold. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-485476-S09234604562012071300000) .
4. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 423

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

Scheme 424

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.

Scheme 425

Scheme 426

1. Remove the valve spring(s) (2). Refer to «SPRING(S), VALVE, REMOVAL»(ref-485476-S33816082722012071300000) . NOTE: Number 5 cylinder exhaust valve guide seal shown in illustration, all other valve guide seals similar.
2. Remove the valve guide seal (1) using a valve seal tool (2). Discard the removed seal. NOTE: Number 5 cylinder exhaust valve spring seat shown in illustration, all other valve spring seats similar.
3. If required, remove the valve spring seat (1).
4. If required, remove the valve(s). Refer to «VALVES, INTAKE AND EXHAUST, REMOVAL»(ref-485476-S15347151852012071300000) .

Scheme 427

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 (1) over the valve guide.
3. Apply engine oil to the lip of the valve guide seal (3). Install the valve guide seal (3) over the valve stem. Using an appropriate driver (1), push the seal firmly and squarely over the valve guide. Do Not Force the seal against the top of guide. NOTE: Ensure that the garter spring (2) is intact around the top of the valve guide seal (3). 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(s) (2). Refer to «SPRING(S), VALVE, INSTALLATION»(ref-485476-S14552911852012071300000) .

Scheme 428

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

Scheme 429

Scheme 430

1. Disconnect and isolate the negative battery cable.
2. Remove the ignition coils. Refer to «COIL, IGNITION, REMOVAL»(ref-485509-S30847409012012071300000) .
3. Using compressed air, blow out any dirt or contaminates from around the top of the spark plugs.
4. Remove the cylinder head cover(s). Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-485476-S14129578282012071300000) .
5. Install the top half of Spark Plug Tube Installer (special tool #10255, Installer, Spark Plug Tube) (1) into the spark plug tube to be removed (2).
6. Using suitable locking pliers (1), remove the spark plug tube (2) from the cylinder head and discard the tube.
7. Clean the area around the spark plug tube mounting with Mopar® Parts Cleaner or equivalent.

Scheme 431

Scheme 432

Scheme 433

1. Remove the spark plug. Refer to «SPARK PLUG, REMOVAL»(ref-485509-S13645825702012071300000) .
2. Install the lower half of Spark Plug Tube Installer (special tool #10255, Installer, Spark Plug Tube) (1) into the cylinder head and tighten to 17.5 N.m (13 ft. lbs.).
3. Apply Mopar® Stud and Bearing Mount to the new spark plug tube approximately 3 mm (0.118 in.) from the end of the tube, in a 2 mm (0.078 in.) wide bead (1).
4. Position the spark plug tube (3) on the top half of Spark Plug Tube Installer (special tool #10255, Installer, Spark Plug Tube) (2) and assemble the tool on the cylinder head. Make sure there are two thrust washers (4) installed. CAUTION: Do not overtighten the bolt (1). Overtightening can damage the cylinder head spark plug threads.
5. Tighten the bolt (1) to draw the spark plug tube into position. When the top half of the tool contacts the bottom half of the tool, the tube is installed. NOTE: LH cylinder head cover shown in illustration, RH cylinder head cover similar. CAUTION: Spark plug torque is critical and must not exceed the specified value. Overtightening stretches the spark plug shell reducing its heat transfer capability resulting in possible catastrophic engine failure.
6. Install the spark plug and tighten to 17.5 N.m (13 ft. lbs.). Refer to «SPARK PLUG, INSTALLATION»(ref-485509-S34872660202012071300000) .
7. If required, install a new spark plug tube seal (2). Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-485476-S23156666322012071300000) .
8. Install the cylinder head cover(s). Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-485476-S23156666322012071300000) . Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 434

The intake valve (6) is made from a one piece forged heat resistant (martensitic) steel. The exhaust valve (7) is a two piece construction with a forged (austenitic) head welded to the (martensitic) stem. Both valves have a nitrided surface treatment to prevent scuffing except at the tip and lock grooves. The four valves per cylinder are actuated by roller rocker arms, which pivot on stationary lash adjusters. All valves use three bead lock keepers (1) to retain springs (3) and to promote valve rotation.

Scheme 435

The intake and exhaust valves have a 45.25 ± 0.25 degree face angle (1). The valve seats (2) have a 44.75 ± 0.25 degree face angle.

Scheme 436

Inspect the remaining margin (5) after the valves are refaced. Refer to Engine - Specifications .

1. Remove the cylinder head(s). Refer to «CYLINDER HEAD, REMOVAL»(ref-485476-S20076592182012071300000) . 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.
2. Remove the valve spring(s) (2). Refer to «SPRING(S), VALVE, REMOVAL»(ref-485476-S33816082722012071300000) . CAUTION: Before removing the valves, remove any burrs from the valve stem retainer lock grooves (2) and stem tip (1) to prevent damage to the valve guides.
3. Remove the valve(s) (3). Identify each valve to ensure installation in the original location.
4. If required, remove the valve guide seal (1) and spring seat (3). Refer to «SEAL(S), VALVE GUIDE, REMOVAL»(ref-485476-S00324130712012071300000) .

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.
4. Install the valve spring(s) (2). Refer to «SPRING(S), VALVE, INSTALLATION»(ref-485476-S14552911852012071300000) . NOTE: Reassemble the valves springs into their original locations. If the valves or valve seats have been refinished, verify that the valve spring installed height is within specification. Refer to «Engine - Specifications»(ref-485476-S24399402942012071300000) . Number 5 cylinder exhaust valve spring shown in illustration, all other valves springs similar.
5. Install the cylinder head(s). Refer to «CYLINDER HEAD, INSTALLATION»(ref-485476-S00213433672012071300000) .

Scheme 437

The cylinder block is a 60 degree high-pressure die cast aluminum design with cast steel cylinder liners. The leading side of the block is on the right side and houses cylinders 1, 3 and 5. The cylinder block is an open deck design with cut slots between each cylinder. Two knock sensors are located in the block valley. The cylinder block has three sets of piston cooling jets which are attached to the main oil gallery. The four powdered metal main bearing caps are a cross-bolted design and have directional arrows molded into the caps. The number 2 main bearing is the location for the two piece upper half thrust bearings. The thrust bearings are installed with the oil groves facing outward. The main bearing caps are a 6-bolt design and cross-bolted for improved lower end strength. There are three oil drain back drillings located on each of the cylinder banks.

Scheme 438

Note. Typical crankshaft journal shown in illustration.

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

Scheme 439

Scheme 440

1. Remove the oil film from surface to be checked. Plastigage is soluble in oil.
2. Place a piece of Plastigage (1) across the entire width of the journal (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Plastigage must not crumble in use. If brittle, obtain fresh stock.
3. Torque the bearing cap bolts of the bearing being checked to the proper specifications. Refer to «Engine - Specifications»(ref-485476-S24399402942012071300000) . NOTE: DO NOT rotate the crankshaft. Plastigage will smear, causing inaccurate results. NOTE: Typical connecting rod cap shown in illustration.
4. Remove the bearing cap and compare the width of the flattened Plastigage (2) with the scale provided on the package (1). Locate the band closest to the same width. This band shows the amount of clearance. Differences in readings between the ends indicate the amount of taper present or the possibility of foreign material trapped under the bearing insert.
5. Record all readings taken. Compare clearance measurements to engine specifications. Refer to «Engine - Specifications»(ref-485476-S24399402942012071300000) . NOTE: Typical connecting rod journal shown in illustration. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale.
6. Install the proper bearings to achieve the specified bearing clearances.
7. Repeat the Plastigage measurement to verify your bearing selection prior to final assembly.

Scheme 441

Before honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area.

1. Used carefully, a cylinder bore sizing hone equipped with 220 grit stones, is the best tool for this job. In addition to deglazing, it will reduce taper and out-of-round, as well as removing light scuffing, scoring and scratches. Usually, a few strokes will clean up a bore and maintain the required limits. CAUTION: DO NOT use rigid type hones to remove cylinder wall glaze.
2. Deglazing of the cylinder walls may be done if the cylinder bore is straight and round. Use of a cylinder surfacing hone equipped with 280 grit stones, about 20-60 strokes, depending on the bore condition, will be sufficient to provide a satisfactory surface. Use a light honing oil, available from major oil distributors. CAUTION: DO NOT use engine or transmission oil, mineral spirits, or kerosene.
3. Honing should be done by moving the hone up and down fast enough to get a crosshatch pattern. The hone marks should INTERSECT at 50° to 60° for proper seating of rings.
4. A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper crosshatch angle (1). The number of up and down strokes per minute can be regulated to get the desired 50° to 60° angle (2). Faster up and down strokes increase the crosshatch angle.
5. After honing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash parts with a solution of hot water and detergent. Dry parts thoroughly. Use a clean, white, lint-free cloth to check that the bore is clean. Oil the bores after cleaning to prevent rusting.

Scheme 442

Scheme 443

1. Wipe the main bearing inserts (1 and 2) clean.
2. Inspect the inserts for abnormal wear patterns, scoring, grooving, fatigue, pitting and for metal or other foreign material imbedded in the lining.
3. Inspect the back of the inserts for fractures, scrapes, or irregular wear patterns.
4. Inspect the insert locking tabs for damage.
5. Inspect the crankshaft thrust washers for scoring, scratches, wear or blueing.
6. Replace any bearing that shows abnormal wear. Refer to «Engine/Engine Block/BEARING(S), Crankshaft - Standard Procedure»(ref-485476-S22844276452012071300000) .
7. Inspect the main bearing bores for signs of scoring, nicks and burrs.
8. If the cylinder block main bearing bores show damage the engine block must be replaced.
9. Use Cylinder Indicator (special tool #C-119, Cylinder Indicator) (2) to correctly measure the inside diameter of the cylinder bore (3). A cylinder bore gauge capable of reading in 0.003 mm (0.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer.
10. Measure the inside diameter of the cylinder bore at three levels below the top of the bore (4). Start at the top of the bore, perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A (1).
11. Repeat the measurement near the middle of the bore, then repeat the measurement near the bottom of the bore.
12. Determine taper by subtracting the smaller diameter from the larger diameter.
13. Rotate measuring device 90° to point B (1) and repeat the three measurements. Verify that the maximum taper is within specifications. Refer to «Engine - Specifications»(ref-485476-S24399402942012071300000) .
14. Determine out-of-roundness by comparing the difference between A and B at each of the three levels. Verify that the maximum out of round is within specifications. Refer to «Engine - Specifications»(ref-485476-S24399402942012071300000) .
15. If cylinder bore taper and out-of-roundness are within specification, the cylinder bore can be honed. Refer to «Engine/Engine Block - Standard Procedure»(ref-485476-S03755150802012071300000) . If the cylinder bore taper or out-of-round condition exceeds the maximum limits, the cylinder block must be replaced.

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

Scheme 444

The connecting rod bearings are "select fit" to achieve proper oil clearance. Connecting rod bearing journal diameter grade markings (2) are stamped into the front crankshaft counterweight. These marks are read from left to right, corresponding with journal number 1, 2, 3, 4, 5, 6. Select the bearing size that corresponds to the crankshaft markings for each rod bearing journal.

Connecting rod bearing journal diameter grade markings correspond to specific journal diameters. The chart below identifies the three crankshaft grade markings and their associated journal diameters.

Scheme 445

Note. Install the rod bearings in pairs. Do not mix sizes or use a new bearing half with an old bearing half.

The connecting rod bearing shells (1) are marked with the bearing size (2) on the bearing lining surface. The bearings are available in three different sizes in order to achieve the desired oil clearance.

Rod bearing shells are available in three sizes. The chart below identifies the three bearing sizes.

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

CONNECTING ROD BEARING REPLACEMENT

The connecting rod bearings (1) are serviced in-vehicle. They must be replaced one-at-a-time in order to prevent the pistons from contacting the valves. The connecting rod bearings are "select fit" to achieve proper oil clearances. Refer to Engine/Engine Block/BEARING(S), Connecting Rod - Standard Procedure .

Scheme 446

Scheme 447

Scheme 448

Scheme 449

1. Disconnect and isolate the negative battery cable.
2. Remove the spark plugs. Refer to «SPARK PLUG, REMOVAL»(ref-485509-S13645825702012071300000) .
3. Remove the oil pan, oil pump pick-up and engine oil pump. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-485476-S19236501352012071300000) .
4. Remove the eight main bearing cap bolts from the windage tray in the sequence shown in illustration and remove the windage tray (1). CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
5. Mark connecting rod and bearing cap positions (1) using a permanent ink marker or scribe tool. NOTE: Typical V6 engine configuration shown in illustration. CAUTION: Replace only one connecting rod bearing at a time while all other connecting rod bearing caps remain properly tightened. If all connecting rod bearing caps are removed, crankshaft rotation will result in valve and/or piston damage. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
6. Remove the connecting rod cap bolts (5) and the connecting rod cap (4). Discard the cap bolts.
7. Remove the plastic guide plates (3) from the Guide Pins (special tool #8189, Guide Pins) (7) and install the Guide Pins to the connecting rod being removed. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur.
8. Rotate the crankshaft away from the connecting rod and remove the bearing shell.
9. If required, select and fit new bearings to the connecting rod. Refer to «Engine/Engine Block/BEARING(S), Connecting Rod - Standard Procedure»(ref-485476-S08098216892012071300000) .
10. Install the bearing shell (8) on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
11. Rotate the crankshaft while guiding the connecting rod into position over the rod journal. CAUTION: The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.
12. Install the bearing shell (6) on the connecting rod cap (4) with the tang inserted into the machined groove in the cap. Lubricate the bearing surface with clean engine oil. NOTE: Do not lubricate the threads of the connecting rod cap bolts (5).
13. Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten the NEW connecting rod cap bolts (5) to 20 N.m (15 ft. lbs.) plus 90°.
14. If required, check the connecting rod side clearance. Refer to «Engine/Engine Block/ROD, Piston and Connecting - Standard Procedure»(ref-485476-S29806254732012071300000) .
15. Repeat the previous steps for each connecting rod bearing being replaced. CAUTION: The main bearing cap bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.
16. Check the main bearing cap bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
17. 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°.
18. Install the engine oil pump, oil pump pick-up and oil pan. Refer to «PUMP, ENGINE OIL, INSTALLATION»(ref-485476-S18747126302012071300000) .
19. Install the spark plugs and ignition coils. Refer to «SPARK PLUG, INSTALLATION»(ref-485509-S34872660202012071300000) .
20. 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) .
21. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
22. Operate the engine until it reaches normal operating temperature.

Note. To remove the crankshaft from the engine, the engine must be removed from the vehicle.

Scheme 450

Scheme 451

1. Remove the engine. Refer to «REMOVAL»(ref-485476-S01887388302012071300000) .
2. Remove the cylinder head covers, spark plugs, upper oil pan, engine timing cover, timing chain and sprockets. Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL»(ref-485476-S28206731252012071300000) .
3. Remove the flexplate and the rear crankshaft oil seal. Refer to «SEAL, CRANKSHAFT OIL, REAR, REMOVAL»(ref-485476-S09556213482012071300000) .
4. Remove the oil pump pick-up and engine oil pump. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-485476-S19236501352012071300000) .
5. Remove the eight main bearing cap bolts from the windage tray in the sequence shown in illustration and remove the windage tray (1). CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
6. Mark connecting rod and bearing cap positions (1) using a permanent ink marker or scribe tool. NOTE: Typical V6 engine configuration shown in illustration. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
7. Remove the connecting rod cap bolts (5) and the connecting rod caps (4). Discard the cap bolts.
8. Remove the plastic guide plates (3) from the Guide Pins (special tool #8189, Guide Pins) (7) and install the Guide Pins to the connecting rod. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur.
9. Push the connecting rod and piston into the cylinder until the connecting rod is clear of the crankshaft journal. Remove the guide pins. Repeat this procedure at each cylinder until all of the connecting rods are clear of the crankshaft. NOTE: Typical V6 engine configuration shown in illustration. Remove the main bearing cross 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.
10. Mark the main bearing cap positions using a permanent ink marker or a scribe tool.
11. Remove the eight main bearing cap bolts in the sequence shown in illustration and remove the main bearing caps. CAUTION: Do not rest the crankshaft on the target wheel (1). Damaged or bent target wheel teeth will destroy the target wheels ability to correctly relay crankshaft position to the crankshaft position sensor.
12. Remove the crankshaft from the engine block.
13. If required, remove the four bolts (2) and the target wheel (1). Discard the four bolts.

Scheme 452

Note. Typical crankshaft journal measurements shown in illustration.

1. Clean the oil off the bearing journals.
2. Determine the maximum diameter of the journals with a micrometer. Measure at two locations 90° apart at each end of the journals.
3. Compare the measured rod journal diameter to the crankshaft connecting rod bearing journal diameter grade marking chart Select the bearing size that corresponds to the crankshaft markings for each rod bearing journal that will provide the proper oil clearance. Refer to «Engine/Engine Block/BEARING(S), Connecting Rod - Standard Procedure»(ref-485476-S08098216892012071300000) .
4. Compare the measured main bearing journal diameter to the crankshaft main bearing journal diameter grade marking chart Obtain the main bearing journal grade identification marks from the engine block and select the upper and lower main bearing sizes that will provide the proper oil clearance. Refer to «Engine/Engine Block/BEARING(S), Crankshaft - Standard Procedure»(ref-485476-S22844276452012071300000) .
5. For connecting rod journals, verify that the maximum taper and maximum out of round are within specifications. Refer to «Engine - Specifications»(ref-485476-S24399402942012071300000) .
6. For main bearing journals, verify that the maximum taper and maximum out of round are within specifications. Refer to «Engine - Specifications»(ref-485476-S24399402942012071300000) .

Scheme 453

1. If required, select and fit new crankshaft main bearings to the engine block. Refer to «Engine/Engine Block/BEARING(S), Crankshaft - Standard Procedure»(ref-485476-S22844276452012071300000) .
2. If required, select and fit new bearings to the connecting rod. Refer to «Engine/Engine Block/BEARING(S), Connecting Rod - Standard Procedure»(ref-485476-S08098216892012071300000) .
3. If removed, install the target wheel (1) to the crankshaft with four new bolts (2). Ensure the threaded holes in the crankshaft are free of residual thread lock adhesive. Tighten the bolts to 10 N.m (89 in. lbs.). NOTE: Typical V6 engine configuration shown in illustration.
4. If removed, lubricate and install the upper main bearing halves (6) into the engine block (7). CAUTION: When installing the crankshaft, use care not to damage bearing surfaces on the crankshaft.
5. Install the crankshaft (4) into the engine block (7). NOTE: Typical V6 engine configuration shown in illustration.
6. Installing thrust washers (1) at the No. 2 main bearing location, using 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.
7. 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.
8. If removed, lubricate and install the lower main bearing halves (3) onto the main caps (1).
9. Install the main bearing caps (1) with two inner main bearing cap bolts (2).
10. Tighten the inner main bearing cap bolts in the sequence shown in illustration to 20 N.m (15 ft. lbs.) plus 90°.
11. Measure crankshaft end play. Refer to «Engine/Engine Block/CRANKSHAFT - Standard Procedure»(ref-485476-S15487145352012071300000) . NOTE: Typical V6 engine configuration shown in illustration.
12. If removed, install the bearing shell (8) on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
13. Remove the plastic guide plates (3) from the Guide Pins (special tool #8189, Guide Pins) (7) and install the Guide Pins to the connecting rod. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur.
14. Pull the connecting rod and piston toward the crankshaft until the connecting rod is seated on the crankshaft journal. Remove the guide pins. CAUTION: The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.
15. If removed, install the bearing shell (6) on the connecting rod cap (4) with the tang inserted into the machined groove in the cap. Lubricate the bearing surface with clean engine oil. NOTE: Do not lubricate the threads of the connecting rod cap bolts (5).
16. Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten the NEW connecting rod cap bolts (5) to 20 N.m (15 ft. lbs.) plus 90°.
17. If required, check the connecting rod side clearance. Refer to «Engine/Engine Block/ROD, Piston and Connecting - Standard Procedure»(ref-485476-S29806254732012071300000) .
18. Repeat the previous steps for the remaining connecting rods.
19. Install the windage tray (1) 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.
20. Install the eight main bearing tie bolts. Tighten the bolts in the sequence shown in illustration to 28 N.m (21 ft. lbs.).
21. Install the engine oil pump and oil pump pick-up. Refer to «PUMP, ENGINE OIL, INSTALLATION»(ref-485476-S18747126302012071300000) .
22. Install the rear crankshaft oil seal and flexplate. Refer to «SEAL, CRANKSHAFT OIL, REAR, INSTALLATION»(ref-485476-S04528207062012071300000) .
23. Install the timing chain and sprockets, engine timing cover, oil pans, spark plugs and cylinder head covers. Refer to «CHAIN AND SPROCKETS, TIMING, INSTALLATION»(ref-485476-S22769978542012071300000) .
24. Install the engine. Refer to «INSTALLATION»(ref-485476-S02110872472012071300000) .
25. 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) .
26. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
27. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
28. Operate 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 454

1. Remove the accessory drive belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-485484-S39989615472012071300000) . NOTE: A force greater than 350 N.m (260 ft. lbs.) may be required to remove the crankshaft vibration damper bolt.
2. Hold the crankshaft vibration damper (1) with Vibration Damper Holder (special tool #10198, Holder, Vibration Damper) (2) and remove the crankshaft vibration damper bolt.
3. Pull the crankshaft vibration damper (1) off of the crankshaft.

Scheme 455

Scheme 456

1. Apply a light coating of engine oil to the front crankshaft seal surface (1).
2. Align the crankshaft vibration damper (1) to the flywheel key on the crankshaft and install the damper. Seat the damper on the crankshaft sprocket.
3. Install and hand tighten the crankshaft vibration damper bolt (2).
4. Hold the crankshaft vibration damper (1) with Vibration Damper Holder (special tool #10198, Holder, Vibration Damper) (2) and tighten the crankshaft vibration damper bolt to 40 N.m + 105° (30 ft. lbs. + 105°).
5. Install the accessory drive belt. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-485484-S29366023502012071300000) .

Scheme 457

1. Remove the transmission. Refer to «REMOVAL»(ref-485526-S38232624722012071300000) .
2. Remove the bolts (1) and the spacer plate (2).
3. Remove the flexplate (3).

1. Position the flexplate (3) onto the crankshaft.
2. Install the spacer (2) and the bolts (1) hand tight.
3. Tighten the flexplate retaining bolts (1) to 95 N.m (70 ft. lbs.) in a criss-cross pattern.
4. Install the transmission. Refer to «INSTALLATION»(ref-485526-S07738426872012071300000) .

Scheme 458

Scheme 459

1. Wipe the cylinder bore clean.
2. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder to a position 12 mm (0.50 in.) from the bottom of the cylinder bore.
3. Using a feeler gauge (1), check the ring end gap. Replace any rings not within specification. Ring Position Ring End Gap No. 1 (top) Ring 0.25 - 0.40 mm (0.010 - 0.016 in.) No. 2 (center) Ring 0.30 - 0.45 mm (0.012 - 0.018 in.) Oil Control Ring (Steel Rail) 0.15 - 0.66 mm (0.006- 0.26 in.)
4. Clean the piston ring grooves. Remove any nicks or burrs.
5. Measure the ring side clearance as shown in illustration. Make sure the feeler gauge (1) fits snugly between the ring land and the ring. Replace any ring not within specification.

Scheme 460

Note. Typical piston shown in illustration.

Scheme 461

Scheme 462

1. Remove the piston and connecting rod(s). Refer to «ROD, PISTON AND CONNECTING, REMOVAL»(ref-485476-S16166799392012071300000) . CAUTION: To avoid damage to the piston rings, they must be removed in the following order: No. 1 (upper) piston ring (1) No. 2 (intermediate) piston ring (2) Oil ring upper side rail (3) Oil ring lower side rail (4) Oil ring expander (5) NOTE: Typical piston shown in illustration.
2. Remove the No. 1 (upper) piston ring using a ring expander tool.
3. Remove the No. 2 (intermediate) piston ring using a ring expander tool. NOTE: Typical piston shown in illustration. Do not use a piston ring expander to remove the oil ring side rails.
4. Remove the oil ring upper side rail.
5. Remove the oil ring lower side rail.
6. Remove the oil ring expander (1).

Note. Typical piston shown in illustration.

Scheme 463

Scheme 464

1. If required, fit new rings to the piston. Refer to «Engine/Engine Block/RING(S), Piston - Standard Procedure»(ref-485476-S05331926452012071300000) . CAUTION: To avoid damage to the piston rings, they must be installed in the following order: Oil ring expander (5) Oil ring lower side rail (4) Oil ring upper side rail (3) No. 2 (intermediate) piston ring (2) No. 1 (upper) piston ring (1) NOTE: Typical piston shown in illustration. Do not use a piston ring expander to install the oil ring side rails.
2. Install the oil ring expander (1).
3. Install the oil ring lower side rail by placing one end between the piston ring groove and the oil ring expander. Hold this end firmly and press down the portion to be installed until the side rail is in position.
4. Install the oil ring upper side rail in the same manner as the lower side rail. NOTE: The No. 1 (upper) piston ring (1) and No. 2 (intermediate) piston ring (3) have a different cross section. Install the rings with manufacturers I.D. mark (dot) (2) facing up, towards the top of the piston. NOTE: Typical piston shown in illustration.
5. Install the No. 2 (intermediate) piston ring using a ring expander tool.
6. Install the No. 1 (upper) piston ring using a ring expander tool.
7. Rotate the rings around the piston, the rings must rotate in the grooves with out binding.
8. Position the piston ring end gaps as follows: Oil ring expander gap (5) Oil ring lower side rail end gap (4) Oil ring upper side rail end gap (1) No. 2 (intermediate) ring end gap (5) No. 1 (upper) ring end gap (2)
9. Install the piston and connecting rod(s). Refer to «ROD, PISTON AND CONNECTING, INSTALLATION»(ref-485476-S08994597382012071300000) .

Scheme 465

The pistons are a lightweight design with ultra low tension piston rings for improved fuel economy. The pistons are made of a high strength aluminum alloy and the piston skirt has a Moly® coating. The top piston ring land has an anodized coating for improved wear. The piston is connected to the rod using a full floating pin with two locking clips. The connecting rod is forged steel with a bolted cracked cap design. The connecting rod bolts are not reusable. Pistons are available in two different diameters with grade markings for each bore indicated on the side of the cylinder block. The upper compression ring is a 1.2 mm steel ring with a spray coating. The intermediate compression ring is 1.2 mm micro napier design. Both compression rings have a dot or a mark on the piston ring. The marked side of the ring must face the top of the piston. The 2 mm three piece oil control ring is very thin. These are chrome plated rings and have a stainless steel expander.

1. Disconnect and isolate the negative battery cable.
2. Remove the oil pans, engine timing cover and cylinder heads. Refer to «CYLINDER HEAD, REMOVAL»(ref-485476-S20076592182012071300000) .
3. Remove the engine oil pump. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-485476-S19236501352012071300000) .
4. Remove the eight main bearing cap bolts from the windage tray in the sequence shown in illustration and remove the windage tray (1).
5. If necessary, remove the top ridge of the cylinder bores with a reliable ridge reamer before removing the pistons from the engine block. Be sure to keep the tops of pistons covered during this operation. Pistons and connecting rods must be removed from the top of the engine block. When removing piston and connecting rod assemblies from the engine, rotate the crankshaft CW so that each connecting rod is centered in the cylinder bore. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
6. Mark connecting rod and bearing cap positions (1) using a permanent ink marker or scribe tool. NOTE: Typical V6 engine configuration shown in illustration. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
7. Remove the connecting rod cap bolts (5) and the connecting rod cap (4). Discard the cap bolts. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur.
8. Remove the plastic guide plates (3) from the Guide Pins (special tool #8189, Guide Pins) (7) and install the Guide Pins to the connecting rod being removed. CAUTION: Avoid contact with the piston oil cooler jet(s). Positioning of the oil cooler jet(s) is critical for proper engine operation.
9. Remove the piston and connecting rod (1) from cylinder bore.
10. Repeat the previous steps for each piston being removed.
11. Immediately after piston and connecting rod removal, reinstall the bearing cap (4) on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
12. If required, remove the piston rings. Refer to «RING(S), PISTON, REMOVAL»(ref-485476-S22851836242012071300000) .
13. Repeat the previous steps for each piston being removed.

1. Install the left transmission mount onto the vehicle. Tighten bolts (1 and 3) to 50 N.m (37 ft. lbs.).
2. Lower the vehicle.
3. Install the PCM. Refer to «MODULE, POWERTRAIN CONTROL, INSTALLATION»(ref-485482-S19357068902012071300000) .
4. Install the two transmission mount to transmission bolts (1). Tighten bolts (1) to 100 N.m (74 ft. lbs.).
5. Remove the floor jack.
6. Install the front fore and aft crossmember. 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) .
7. Lower the vehicle.
8. Install the air cleaner body. Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-485476-S11483727402012071300000) .
9. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 466

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
2. Remove the belly pan.
3. Lower the vehicle.
4. Carefully position a floor jack under the engine to support.
5. Remove the ground strap (4) from upper engine mount bracket (2).
6. Remove the three bolts (1) and two nuts (5) and the upper engine mount bracket (2).
7. Remove bolts (6) and the right engine mount insulator (3).
8. If necessary, remove bolts (2 and 3) and the right engine mount bracket (1).

1. If removed, install the right engine mount bracket (1) and tighten bolts (2 and 3) to: Tighten M10 bolts (2) to 55 N.m (41 ft. lbs.) Tighten M8 bolt (3) to 25 N.m (18 ft. lbs.).
2. Install the right engine mount isolator (3). Tighten bolts (6) to 50 N.m (37 ft. lbs.).
3. Install the upper engine mount bracket (2) and tighten bolts: Tighten bolts (1) to 55 N.m (41 ft. lbs.). Tighten nuts (5) to 20 N.m (15 ft. lbs.).
4. Install the ground strap (4) to the upper engine mount bracket (2).
5. Remove the floor jack.
6. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
7. Install the belly pan.
8. Lower the vehicle.

Scheme 467

1. Remove the belly pan. Refer to «UNDER BODY PROTECTION»(ref-485477-S28538233622012071300000) .
2. Remove two bolts (1) and the rear engine mount heat shield (2).
3. Remove the bolt (3) from the rear engine mount isolator.
4. Remove four bolts (2) and the rear engine mount bracket (1).
5. Remove bolts (1 and 3) and the rear mount (2).

1. Install the rear mount (2). Tighten bolts (1 and 3) to 54 N.m (40 ft. lbs.).
2. Install the four rear mount bracket bolts (2) to 110 N.m (81 ft. lbs.).
3. Install the rear mount through bolt (3) and tighten to 61 N.m (45 ft. lbs.).
4. Install the rear mount heat shield (2). Tighten bolts (1) to 14 N.m (124 in. lbs.).
5. Install the belly pan. Refer to «UNDER BODY PROTECTION»(ref-485477-S28538233622012071300000) .

1. Remove the front fore and aft crossmember. 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) .
2. If required, remove the three bolts (2) and the front engine mount bracket (1).

1. If required, install the front engine mount bracket (1). Tighten bolts (2) to 55 N.m (41 ft. lbs.).
2. Install the front fore and aft crossmember. 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) .

Note. Always use new dry seals (1) when installing the oil cooler. Do not lubricate the seals.

1. Install the new oil cooler seals (1) onto the oil filter housing (2).
2. Position the oil cooler (4) on the oil filter housing.
3. Install two screws (1) and (3). Tighten the screws to 4 N.m (35 in. lbs.).
4. Install four bolts (2) and tighten to 12 N.m (106 in. lbs.).
5. Install the upper and lower intake manifolds and air cleaner housing assembly. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
6. Fill the engine crankcase with the proper oil to the correct level. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .
7. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
8. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
9. Operate the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

Scheme 468

All engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler Corporation recommends a Mopar® or equivalent oil filter be used.

Scheme 469

1. 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).
2. Rotate the oil filter cap (1) counterclockwise and remove the cap (1) and filter (3) from the oil filter housing.
3. Remove the oil filter (3) from the oil filter cap (2).
4. 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.

Scheme 470

1. Lightly lubricate the new O-ring seal (1) with clean engine oil.
2. Install the O-ring seal (1) on the filter cap (2).
3. Install the new oil filter (3) into the oil filter cap (2).
4. Thread the oil filter cap (1) into the oil filter housing and tighten to 25 N.m (18 ft. lbs.).
5. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .

1. Lubricate a new O-ring seal (1) with engine oil and install on the piston oil cooler jet(s). NOTE: Piston oil cooler jet for cylinders one/two shown in illustration. Piston oil cooler jets for cylinders three/four and five/six are similar.
2. Install the piston oil cooler jet(s) (2) into the engine block and tighten the retaining bolt (1) to 6 N.m (53 in. lbs.).
3. Install the crankshaft. Refer to «CRANKSHAFT, INSTALLATION»(ref-485476-S08715587462012071300000) .
4. 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) .
5. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
6. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
7. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

1. Lightly lubricate the new O-ring seal (1) with engine oil and install on the oil pick-up tube.
2. Install the oil pick-up tube (2). Tighten the bolt (1) to 12 N.m (106 in. lbs.).
3. Install the upper oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-485476-S34328764342012071300000) .
4. 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) .
5. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
6. Run the engine until it reaches normal operating temperature.

Scheme 471

The vane type engine oil pump is mounted to the underside of the cylinder block and is driven by the oil pump chain off the crankshaft at a 1:1 drive ratio. This pump location improves efficiency compared to an on-crankshaft location. The pump is driven with a silent chain which is tensioned using a spring loaded tensioner. The pump is not timed to the engine.

An internal mechanical ball and spring type relief valve prevents excess pressure in the engine by dumping oil into the sump and provides emergency protection at conditions such as a cold start with high engine speed.

The pump has a moving slide mechanism for variable displacement capability and an on-off solenoid for two-stage pressure regulation. The pump and the solenoid are not to be disassembled. Both are non-serviceable items and are to be replaced as a complete assembly.

Scheme 472

The engine oil pump features seven vanes and a moving element (1) that continuously adjusts to maintain a regulated oil pressure supply by varying the displacement of the pump. The pump has two regulated pressure stages of operation controlled by an on/off solenoid (2). Low pressure mode regulation (solenoid on) is approximately 200 kPa (29 psi) and high pressure mode regulation (solenoid off) is approximately 450 kPa (65 psi). The Powertrain Control Module (PCM) switches the pump between stages based on engine operating conditions, oil and coolant temperatures, speed and load. Under most typical conditions, the pump will run in low mode from idle up to around 3000 rpm, and switch from low to high mode between 3000 and 4000 rpm.

The maximum oil pressure in the engine is limited to 1000 kPa (145 psi) by the relief valve (3). Pressure in the main oil gallery of the engine can be monitored with diagnostic equipment through the oil pressure sensor mounted on the rear of the oil filter module. The minimum pressure for the engine is 41 kPa (6 psi) at any operating condition. Anything under this pressure could result in damage to critical moving parts.

Scheme 473

In high pressure mode regulation (solenoid off) main gallery oil pressure (2) is applied to the moving element (1). The main gallery oil pressure works against spring pressure (3) to move the element to a more concentric location about the pump driveshaft (4) thus reducing displacement and pump output.

Scheme 474

In low pressure mode regulation (solenoid on) the energized solenoid opens an additional chamber (1) to main gallery oil pressure increasing the force on the spring (2) to further reduce displacement and output pressure.

Scheme 475

Scheme 476

Scheme 477

Scheme 478

Scheme 479

Scheme 480

Scheme 481

Scheme 482

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 oil pump pick-up (2). Refer to «PICK-UP, OIL PUMP, REMOVAL»(ref-485476-S41712782432012071300000) .
4. Disconnect the engine wire harness from the oil pump solenoid electrical connector (1).
5. Depress the connector retention lock tab (1) to disengage the oil pump solenoid electrical connector from the engine block.
6. Remove bolts (2) and the timing gear splash shield (1). NOTE: Graphic shows the engine timing cover removed for clarity.
7. Push the oil pump solenoid electrical connector into the engine block, rotate the connector slightly CW, push it past the primary chain tensioner mounting bolt (1) and into the engine.
8. Push back the oil pump chain tensioner (2) and insert a suitable retaining pin (1) such as a 3 mm Allen wrench. 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.
9. Mark the direction of rotation on the oil pump chain (3) and sprocket (4) using a paint pen or equivalent to aid in reassembly. NOTE: There are no timing marks on the oil pump gear or chain. Timing of the oil pump is not required.
10. Remove the oil pump sprocket T45 retaining bolt (2) and remove the oil pump sprocket (4).
11. Remove the retaining pin (3) and disengage the oil pump chain tensioner spring (1) from the dowel pin (2).
12. Remove the oil pump chain tensioner from the oil pump.
13. Remove the four oil pump bolts (1) and remove the oil pump (3).

Scheme 483

Note. The 3.6L Oil pump is released as an assembly. The assembly includes both the pump and the solenoid. There are no serviceable sub-assembly components. In the event the oil pump or solenoid are not functioning or out of specification they must be replaced as an assembly.

1. Inspect the solenoid wires (1) for cuts or chaffing.
2. Inspect the condition of the connector O-ring seal (3).
3. Inspect the connector retention lock tab (2) for fatigue or damage.

1. Align the locator pins (2) to the engine block and install the oil pump (3) with four bolts (1). Tighten the bolts to 12 N.m (106 in. lbs.).
2. Install the oil pump chain tensioner on the oil pump.
3. Position the oil pump chain tensioner spring (1) above the dowel pin (2).
4. Push back the oil pump chain tensioner and insert a suitable retaining pin (3) such as a 3 mm Allen wrench. NOTE: There are no timing marks on the oil pump gear or chain. Timing of the oil pump is not required. 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.
5. Place the oil pump sprocket (4) into the oil pump chain (3). Align the oil pump sprocket with the oil pump shaft and install the sprocket. Install the T45 retaining bolt (2) and tighten to 25 N.m (18 ft. lbs.).
6. Remove the retaining pin (1). Verify that the oil pump chain is centered on the tensioner and crankshaft sprocket.
7. Rotate the crankshaft CW one complete revolution to verify proper oil pump chain installation. NOTE: Graphic shows the engine timing cover removed for clarity.
8. Position the oil pump solenoid electrical connector (2) into the engine block. Rotate the connector so that it can be pushed past the primary chain tensioner mounting bolt (1). Then rotate the connector slightly CCW and push it into the engine block until it locks in place.
9. Install the timing gear splash shield (1). Tighten bolts (2) to 5 N.m (35 in. lbs.).
10. Verify that the oil pump solenoid electrical connector retention lock tab (1) is engaged to the engine block.
11. Connect the engine wire harness to the oil pump solenoid electrical connector (1).
12. Install the oil pump pick-up (2). Refer to «PICK-UP, OIL PUMP, INSTALLATION»(ref-485476-S24062608712012071300000) .
13. Install the oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-485476-S34328764342012071300000) .
14. 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) .
15. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.). CAUTION: A MIL or low oil pressure indicator that remains illuminated for more than 2 seconds may indicate low or no engine oil pressure. Stop the engine and investigate the cause of the indication.
16. Start and run the engine until it reaches normal operating temperature.

1. Install the oil pressure sensor (2) and tighten to 20 N.m (177 in. lbs.).
2. Connect the oil pressure sensor electrical connector (3).
3. Install the upper and lower intake manifolds and air cleaner housing assembly. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
4. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

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 air inlet hose, upper intake manifold and lower intake manifold with the fuel injectors and fuel rail (2). Refer to «MANIFOLD, INTAKE, REMOVAL»(ref-485476-S08989499162012071300000) .
4. Disconnect the oil temperature sensor electrical connector (5).
5. Remove the oil temperature sensor (1) from the oil filter housing (3).

Install the oil temperature sensor (1) and tighten to 20 N.m (177 in. lbs.).

1. Connect the oil temperature sensor electrical connector (4).
2. Install the upper and lower intake manifolds and air cleaner housing assembly. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
3. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Note. The Variable Valve Timing (VVT) assemblies (Phasers) and Oil Control Valves (OCVs) can be serviced without removing the engine timing cover. Refer to ASSEMBLY, VARIABLE VALVE TIMING, PHASER / OIL CONTROL VALVE, REMOVAL .

Scheme 484

Scheme 485

Scheme 486

1. Disconnect and isolate the negative battery cable.
2. Remove the air cleaner housing assembly and upper intake manifold. Refer to «MANIFOLD, INTAKE, REMOVAL»(ref-485476-S08989499162012071300000) .
3. Remove both cylinder head covers. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-485476-S14129578282012071300000) .
4. Remove the spark plugs. Refer to «SPARK PLUG, REMOVAL»(ref-485509-S13645825702012071300000) .
5. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
6. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
7. Remove the oil pan, accessory drive belts, crankshaft vibration damper and engine timing cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-485476-S33092042822012071300000) . NOTE: Take this opportunity to measure timing chain wear. Refer to «Engine/Valve Timing - Standard Procedure»(ref-485476-S07176515242012071300000) . CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.
8. Rotate the crankshaft clockwise (as viewed from the front) to place the number one cylinder piston at top-dead-center on the exhaust stroke by aligning the dimple (4) on the crankshaft with the block/bearing cap junction (5).
9. While maintaining this alignment, verify that the ARROWS (2) on the left side cam phasers point toward each other and are parallel to the cylinder head cover mounting 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 cylinder head cover mounting surface (8). 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.
10. 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. 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.
11. Mark the direction of rotation on the following timing chains using a paint pen or equivalent to aid in reassembly: Left side cam chain Right side cam chain Oil pump chain Primary chain
12. Reset the right side cam chain tensioner by pushing back the tensioner piston and installing Tensioner Pin (special tool #8514, Pins, Tensioner) (1).
13. Reset the left side 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) .
14. Remove the bolts (2) and the timing gear splash shield (1).
15. Disengage the oil pump chain tensioner spring (3) from the dowel pin (2) and remove the oil pump chain tensioner (1).
16. Remove the oil pump sprocket T45 retaining bolt (4) and remove the oil pump sprocket (5) and oil pump chain (6). NOTE: It may be necessary to rock the camshaft slightly (a few degrees) with a wrench (4) when installing the camshaft phaser lock.
17. Install the (special tool #10202-1, Lock, Camshaft/Phaser, Right Side) (1) with the tool number facing up.
18. Loosen, but do not remove, the exhaust oil control valve (3) and the intake oil control valve (2).
19. Remove the (special tool #10202-1, Lock, Camshaft/Phaser, Right Side) (1).
20. Remove the oil control valve (2) from the right side intake cam phaser.
21. Pull the right side intake cam phaser off of the camshaft and remove the right side cam chain.
22. If required, remove the oil control valve (3) and pull the right side exhaust cam phaser off of the camshaft. NOTE: It may be necessary to rock the camshaft slightly (a few degrees) with a wrench (4) when installing the camshaft phaser lock.
23. Install the (special tool #10202-2, Lock, Camshaft/Phaser, Left Side) (1) with the tool number facing up.
24. Loosen, but do not remove, the exhaust oil control valve (2) and the intake oil control valve (3).
25. Remove the (special tool #10202-2, Lock, Camshaft/Phaser, Left Side) (1).
26. Remove the oil control valve (2) from the left side exhaust cam phaser.
27. Pull the left side exhaust cam phaser off of the camshaft and remove the left side cam chain.
28. If required, remove the oil control valve (3) and pull the left side intake cam phaser off of the camshaft.
29. Reset the primary chain tensioner (5) by pushing back the tensioner piston and installing Tensioner Pin (special tool #8514, Pins, Tensioner) (3). Remove two T30 bolts (4) and remove the primary chain tensioner.
30. Remove the T30 bolt (1) and the primary chain guide (2).
31. Remove the idler sprocket T45 retaining bolt (2) and washer (3).
32. Remove the primary chain, idler sprocket and crankshaft sprocket as an assembly.
33. If required, remove two T30 bolts (6) and the left side cam chain tensioner (5).
34. If required, remove two T30 bolts (4) and the left side cam chain guide (2) and tensioner arm (1).
35. If required, remove two T30 bolts (4) and the right side cam chain tensioner (3).
36. If required, remove three T30 bolts (2) and the right side cam chain guide (1) and tensioner arm (6).
37. Inspect all sprockets and chain guides. Replace if damaged.

Scheme 487

Scheme 488

Scheme 489

1. Inspect all sprockets and chain guides. Replace if damaged.
2. If removed, install the right side cam chain guide (1) and tensioner arm (6). Tighten attaching T30 bolts (2) to 12 N.m (106 in. lbs.).
3. If removed, install the right side cam chain tensioner (3) to the engine block with two bolts (4). Tighten the T30 bolts (4) to 12 N.m (106 in. lbs.).
4. Reset the right side cam chain tensioner (3) by pushing back the tensioner piston and installing Tensioner Pin (special tool #8514, Pins, Tensioner) (5).
5. If removed, install the left side cam chain guide (2) and tensioner arm (1). Tighten attaching T30 bolts (4) to 12 N.m (106 in. lbs.).
6. If removed, install the left side cam chain tensioner (5) to the cylinder head with two bolts (6). Tighten the T30 bolts (6) to 12 N.m (106 in. lbs.).
7. Reset the left side 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) .
8. Verify that the key (3) is installed in the crankshaft.
9. Verify that the number one cylinder piston is positioned at top-dead-center by aligning the dimple (2) on the crankshaft with the block/bearing cap junction (1).
10. Verify that the camshafts are set at top-dead-center by positioning the alignment holes (1) vertically. 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.
11. Place the primary chain onto the crankshaft sprocket (3) so that the arrow (2) is aligned with the plated link (1) on the timing chain.
12. While maintaining this alignment, invert the crankshaft sprocket and timing chain and place the idler sprocket (4) into the timing chain so that the dimple (2) is aligned with the plated link (1) on the timing chain.
13. While maintaining this alignment, lubricate the idler sprocket bushing with clean engine oil and install the sprockets and timing chain on the engine. To verify that the timing is still correct, the timing chain plated link (6) should be located at 12:00 (1) when the dimple (5) on the crankshaft is aligned with the block/bearing cap junction (4).
14. Install the idler sprocket retaining bolt (2) and washer (3). Tighten the T45 bolt (2) to 25 N.m (18 ft. lbs.).
15. Install the primary chain guide (2). Tighten attaching T30 bolt (1) to 12 N.m (106 in. lbs.).
16. Reset the primary chain tensioner (5) by pushing back the tensioner piston and installing Tensioner Pin (special tool #8514, Pins, Tensioner) (3).
17. Install the primary chain tensioner (5) to the engine block with two bolts (4). Tighten the T30 bolts (4) to 12 N.m (106 in. lbs.) and remove the Tensioner Pin (special tool #8514, Pins, Tensioner) (3).
18. Press the left side intake cam phaser onto the intake camshaft. Install and hand tighten the oil control valve (6). NOTE: The left side and right side cam chains are identical. 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 left side 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 cylinder head cover mounting 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 (special tool #10202-2, Lock, Camshaft/Phaser, Left Side) (4) with the tool number facing up.
22. Tighten the oil control valves (2) and (6) to 150 N.m (110 ft. lbs.).
23. Remove the Camshaft Phaser Lock (4).
24. Press the right side exhaust cam phaser onto the exhaust camshaft. Install and hand tighten the oil control valve (7). 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.
25. Drape the right side cam chain over the right side 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.
26. 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 cylinder head cover mounting 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.
27. Install the (special tool #10202-1, Lock, Camshaft/Phaser, Right Side) (5) with the tool number facing up.
28. Tighten the oil control valves (2) and (7) to 150 N.m (110 ft. lbs.).
29. Remove the Camshaft Phaser Lock (5). NOTE: There are no timing marks on the oil pump gear or chain. 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. Place the oil pump sprocket (5) into the oil pump chain (6). Place the oil pump chain onto the crankshaft sprocket while aligning the oil pump sprocket with the oil pump shaft. Install the oil pump sprocket T45 retaining bolt (4) and tighten to 25 N.m (18 ft. lbs.).
31. Install the oil pump chain tensioner (1). Insure that the spring (3) is positioned above the dowel pin (2).
32. Install the timing gear splash shield (1). Tighten the bolts (2) to 5 N.m (35 in. lbs.).
33. Remove the Tensioner Pins (special tool #8514, Pins, Tensioner) (1) and (6) from the right side and left side cam chain tensioners.
34. Rotate the crankshaft clockwise (as viewed from the front) two complete revolutions stopping when the dimple (4) on the crankshaft is aligned with the block/bearing cap junction (5).
35. While maintaining this alignment, verify that the ARROWS (2) on the left side cam phasers point toward each other and are parallel to the cylinder head cover mounting 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 cylinder head cover mounting surface (8).
36. There should be 12 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.
37. If the engine timing is not correct, repeat this procedure.
38. Install the engine timing cover, crankshaft vibration damper, accessory drive belts and oil pan. Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-485476-S03582090622012071300000) .
39. Install the spark plugs. Tighten to 17.5 N.m (13 ft. lbs.). Refer to «SPARK PLUG, INSTALLATION»(ref-485509-S34872660202012071300000) .
40. Install the cylinder head covers. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-485476-S23156666322012071300000) .
41. Install the upper intake manifold and air cleaner housing assembly. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-485476-S22061755042012071300000) .
42. Fill the engine crankcase with the proper oil to the correct level. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-485476-S01803551652012071300000) .
43. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
44. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
45. Operate 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 490

Scheme 491

Scheme 492

Scheme 493

Scheme 494

Scheme 495

Scheme 496

Scheme 497

Scheme 498

1. Disconnect and isolate the negative battery cable.
2. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
3. Remove the upper radiator hose (2) and thermostat housing (1). Refer to «THERMOSTAT, REMOVAL»(ref-485484-S06347051122012071300000) .
4. Remove the heater core return hose (1) from the water pump housing.
5. Remove the lower radiator hose (2) from the water pump housing.
6. Remove the heater core supply hose (1) from the coolant outlet housing (2).
7. Remove the bolt (2) and reposition the heater core supply tube (1).
8. Remove the accessory drive belt (7). Refer to «BELT, SERPENTINE, REMOVAL»(ref-485484-S39989615472012071300000) .
9. Remove the accessory drive belt tensioner (8). Refer to «TENSIONER, BELT, REMOVAL»(ref-485484-S08575202642012071300000) .
10. Remove the accessory idler pulley (2). Refer to «PULLEY, IDLER, REMOVAL»(ref-485484-S09929724162012071300000) .
11. Remove the power steering pump pulley (1). Refer to «PULLEY, POWER STEERING PUMP, REMOVAL»(ref-485479-S07043077302012071300000) .
12. Remove the crankshaft vibration damper (6). Refer to «DAMPER, VIBRATION, REMOVAL»(ref-485476-S14126021502012071300000) . NOTE: Left cylinder head cover shown in illustration, right cylinder head cover similar.
13. Remove the right and left cylinder head covers. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-485476-S14129578282012071300000) .
14. Remove the upper and lower oil pans. Refer to «PAN, OIL, REMOVAL»(ref-485476-S01269687182012071300000) .
15. Temporarily reinstall the front fore and aft crossmember (4). 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) .
16. Remove the right engine mount isolator and bracket (1). Refer to «INSULATOR, ENGINE MOUNT, LEFT, REMOVAL»(ref-485476-S02313871212012071300000) , «INSULATOR, ENGINE MOUNT, RIGHT, REMOVAL»(ref-485476-S09648900572012071300000) , «INSULATOR, ENGINE MOUNT, REAR, REMOVAL»(ref-485476-S39056195622012071300000) and «INSULATOR, ENGINE MOUNT, FRONT, REMOVAL»(ref-485476-S23870873392012071300000) . NOTE: It is not necessary to remove the water pump or the coolant outlet housing for engine timing cover removal.
17. Remove the twenty-two M6 bolts (3) and one M8 bolt (4) from the timing cover.
18. Using the seven indicated pry points, carefully remove the timing cover.
19. If required, remove the remaining four M6 bolts (2) and the coolant outlet housing (1) from the engine timing cover.
20. If required, remove the remaining four M6 bolts (4) and the water pump (3) from the engine timing cover. 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.
21. Remove all residual sealant from the timing chain cover, cylinder head and engine block mating surfaces. Refer to «Engine - Standard Procedure»(ref-485476-S02028931392012071300000) .
22. Remove and discard the coolant outlet housing gasket (1) and the water pump gasket (2).

1. If removed, install the coolant outlet housing (1) to the timing cover with a new gasket using only the four bolts (2) shown in illustration tightened to 12 N.m (106 in. lbs.).
2. If removed, install the water pump (3) to the timing cover using only the four bolts (4) shown in illustration tightened to 12 N.m (106 in. lbs.). Refer to «PUMP, WATER, INSTALLATION»(ref-485484-S41972622452012071300000) .
3. Install the coolant outlet housing gasket (1) and the water pump gasket (2).
4. Clean the engine timing cover, cylinder head and 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.
5. Apply a 2 to 3 mm wide bead of Mopar® Threebond Engine RTV Sealant to the front cover as shown in illustration in the following locations: Three cylinder head bosses (1) Right and left flanges (2) Four cylinder head to engine block T-joints (3) Cover to right cam chain tensioner gap (4)
6. Align the locator pins (5) on the engine block to the engine timing cover and install the cover.
7. Install twenty-two M6 bolts (3) and one M8 bolt (4). Tighten the M6 bolts (3) to 12 N.m (106 in. lbs.) and the M8 bolt (4) to 25 N.m (18 ft. lbs.).
8. Install the right engine mount bracket and isolator. Refer to «INSULATOR, ENGINE MOUNT, LEFT, INSTALLATION»(ref-485476-S23654415742012071300000) , «INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION»(ref-485476-S15797285582012071300000) , «INSULATOR, ENGINE MOUNT, REAR, INSTALLATION»(ref-485476-S34182425092012071300000) and «INSULATOR, ENGINE MOUNT, FRONT, INSTALLATION»(ref-485476-S18377206482012071300000) . Remove the temporarily installed front fore and aft crossmember (4). 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) .
9. Install the upper and lower oil pans, front fore-aft crossmember, crossunder pipe and right halfshaft assembly. Refer to «PAN, OIL, INSTALLATION»(ref-485476-S34328764342012071300000) . NOTE: Left cylinder head cover shown in illustration, right cylinder head cover similar.
10. Install the right and left cylinder head covers and upper intake manifold. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-485476-S23156666322012071300000) .
11. Install the crankshaft vibration damper (6). Refer to «DAMPER, VIBRATION, INSTALLATION»(ref-485476-S32510645082012071300000) .
12. Install the power steering pump pulley (1). Refer to «PULLEY, POWER STEERING PUMP, INSTALLATION»(ref-485479-S15873386222012071300000) .
13. Install the accessory idler pulley (2). Refer to «PULLEY, IDLER, INSTALLATION»(ref-485484-S18498497172012071300000) .
14. Install accessory drive belt tensioner (8). Refer to «TENSIONER, BELT, INSTALLATION»(ref-485484-S32147169262012071300000) .
15. Install the accessory drive belt (7). Refer to «BELT, SERPENTINE, REMOVAL»(ref-485484-S39989615472012071300000) .
16. Install the heater core supply tube (1) with one bolt (2) tightened to 12 N.m (106 in. lbs.).
17. Install the heater core supply hose (1) to the coolant outlet housing (2).
18. Install the lower radiator hose (2) to the water pump housing.
19. Install the heater core return hose (1) to the water pump housing.
20. Install the thermostat housing (1) and upper radiator hose (2). Refer to «THERMOSTAT, REMOVAL»(ref-485484-S06347051122012071300000) .
21. Install the electric vacuum pump. Refer to «PUMP, ELECTRIC VACUUM, INSTALLATION»(ref-485474-S00401658872012071300000) .
22. 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) .
23. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
24. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
25. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .