5.7L Engine - Service Information: Overview Dodge Challenger III рестайлинг

DESCRIPTION

The 5.7L engine (348 CID) eight-cylinder engine is a 90° V-Type lightweight, deep skirt cast iron block, aluminum heads, single cam, overhead valve engine with hydraulic roller tappets. The heads incorporate splayed valves with a hemispherical style combustion chamber and dual spark plugs. The cylinders are numbered from front to rear; 1, 3, 5, 7 on the left bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2.

OPERATION

The cylinder head closes the combustion chamber allowing the pistons to compress the air fuel mixture to the correct ratio for ignition. The valves located in the cylinder head open and close to either allow clean air into the combustion chamber or to allow the exhaust gases out, depending on the stroke of the engine.

The valve guide seals are made of rubber and incorporate an integral steel valve spring seat. The integral garter spring maintains consistent lubrication control to the valve stems.

Scheme 366

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Scheme 368

1. Disconnect the negative battery cable.
2. Remove the air cleaner assembly and the air intake resonator, Refer to «BODY, AIR CLEANER, REMOVAL, 5.7L»(ref-489305-S07222356612012072600000) .
3. Remove the ignition coil electrical connectors (1).
4. Remove the ignition coils (2).
5. Remove the spark plugs.
6. Using the sequence shown in illustration, remove the cylinder head cover retaining bolts and remove the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL, 5.7L»(ref-489305-S29697708402012072600000) . CAUTION: The rocker shaft assemblies are not interchangeable between the intake and the exhaust, failure to install them in the correct location could result in engine damage. The intake rocker arms (1) are marked with the letter "I" (2). CAUTION: The piston must be at TDC and both valves closed on the cylinder to be serviced. CAUTION: The longer pushrods are for the exhaust side and the shorter pushrods are for the intake side. NOTE: Pushrods must be installed in the same order as removed. NOTE: If removing the intake valve spring, install the pushrod retainer (special tool #9070, Retainer, Push Rod) (1).
7. Using the sequence shown in illustration, remove the exhaust/intake rocker arm shaft retaining bolts. NOTE: Tap the top of the valve spring retainer to loosen the spring retainers locks.
8. Install the rocker arm valve spring compressor shaft (special tool #9065B, Compressor, Valve Spring) (1).
9. Install the spring compressor adapter arm (special tool #9065B, Compressor, Valve Spring) if needed.
10. Insert an air hose (2) into the spark plug hole and charge the cylinder with air. NOTE: A fulcrum assembly (1) must be rotated to the appropriate setting as marked on the tool for proper valve spring alignment. NOTE: Tap the top of the valve spring retainer to loosen the spring retainers locks.
11. Compress the valve spring with valve spring compressor (1) and remove the valve retainer locks.
12. Release the spring compressor and remove valve spring. NOTE: All valve springs and seals are removed in the same manner and are interchangeable between intake and exhaust.
13. Remove the valve seal. NOTE: When the exhaust spring, seal or valve needs servicing. The exhaust adapter arm (1) must be installed to the spring compressor clamp (3).
14. Install tool (special tool #9065B, Compressor, Valve Spring), exhaust adapter arm (1) to the spring compressor (3) for servicing the exhaust side.

Scheme 369

1. Install the valve seal.
2. Install the valve spring.
3. Using the valve spring compressor (special tool #9065B, Compressor, Valve Spring) (1), compress the valve spring and install the valve spring retainer and locks.
4. Remove the exhaust extension arm (1).
5. Remove the spring compressor (3).
6. Remove the air hose from the spark plug hole. NOTE: All valve springs and seals are installed in the same manner. CAUTION: The rocker shaft assemblies are not interchangeable between the intake and the exhaust, failure to install them in the correct location could result in engine damage. The intake rocker arms (1) are marked with the letter "I" (2). CAUTION: Make sure that the retainers (1) and the rocker arms (2) are not overlapped when tightening bolts or engine damage could result. CAUTION: Due to the changes in the pushrod clearance holes in the Eagle 5.7L cylinder heads, close attention must be given when installing the pushrod(s) into the tappet(s). Once the pushrod(s) have been installed, use a suitable light to look down through the pushrod hole(s). This will allow you to verify the pushrod(s) are centered properly in the tappet(s) and avoid engine damage. Recheck after the rocker shaft assembly has been installed and tightened to specification. CAUTION: The longer pushrods are for the exhaust side and the shorter pushrods are for the intake side. NOTE: Pushrods must be installed in the same order as removed.
7. Install the rocker arm shaft and pushrods. Refer to «ROCKER ARM, VALVE, INSTALLATION, 5.7L»(ref-489305-S13214678112012072600000) .
8. Using the sequence shown in illustration, tighten the rocker shaft bolts to 22 N.m (16 ft. lbs.).
9. If used, remove the pushrod retainer (special tool #9070, Retainer, Push Rod) (1). CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur. CAUTION: Do not allow other components including the wire harness to rest on or against the engine cylinder head cover. Prolonged contact with other objects may wear a hole in the cylinder head cover.
10. Clean the cylinder head cover and both sealing surfaces, inspect and replace the gasket as necessary.
11. Install the cylinder head cover and hand start all fasteners. Verify that all double ended studs are in the correct location.
12. Using the sequence shown in illustration, tighten the cylinder head cover retaining bolts to 8 N.m (71 in. lbs.).
13. Install the spark plugs.
14. Before installing the ignition coils, apply dielectric grease to the inside of the spark plug boots.
15. Install the ignition coil (2) on the plugs and tighten the fasteners (3) to 7 N.m (62 in. lbs).
16. Connect the ignition coil electrical connectors (1).
17. Install the air intake resonator and the air cleaner assembly. Refer to «BODY, AIR CLEANER, INSTALLATION, 5.7L»(ref-489305-S17843188502012072600000) .
18. Connect the negative battery cable.

The Variable Cam Timing (VCT) assembly is actuated with engine oil pressure. The oil flow to the VCT assemblies are controlled by an Oil Control Valve (OCV). The OCV consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VCT assemblies. The VCT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VCT assembly rotates the rotor with respect to the stator, thus rotating the exhaust camshaft with respect to the timing chain and intake camshaft. An infinitely variable cam timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM.

Scheme 370

1. Remove the timing chain and sprockets. Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL, 5.7L»(ref-489305-S12112658022012072600000) .
2. Remove the camshaft phaser bolt (1).
3. Remove camshaft phaser (2).

Scheme 371

1. Align the slot (2) in the phaser (1) with the dowel on the camshaft. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result.
2. Position the phaser (2) in place and install phaser retaining bolt (1) and tighten to 122 N.m (90 ft. lbs.).
3. Install the timing chain and sprockets. Refer to «CHAIN AND SPROCKETS, TIMING, INSTALLATION, 5.7L»(ref-489305-S26819067512012072600000) .

Scheme 372

With the crankshaft removed from the cylinder block.

Clean the oil off the main bearing journal.

Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal.

The maximum allowable taper is 0.008 mm (0.0004 inch.) and maximum out of round is 0.005 mm (0.0002 inch). Compare the measured diameter with the journal diameter specification (Main Bearing Fitting Chart). Select the inserts required to obtain the specified bearing-to-journal clearance.

Scheme 373

The main bearings are "select fit" to achieve proper oil clearances. For main bearing selection, the crankshaft counterweight has grade identification marks stamped into it. These marks are read from left to right. The left letter (1) refers to the number one main journal and the right letter (2) refers to the number 5 journal.

Note. Service main bearings are coded. These codes identify what size or grade of the bearing.

MAIN BEARING SELECTION CHART - 5.7L

Scheme 374

Wipe the inserts clean and inspect for abnormal wear patterns and for metal or other foreign material imbedded in the lining. Normal main bearing insert wear patterns are illustrated.

Note. If any crankshaft journals are scored, the crankshaft must be repaired or replaced.

Inspect the back of the inserts for fractures, scrapings or irregular wear patterns.

Inspect the upper insert locking tabs for damage.

Replace all damaged or worn bearing inserts.

Scheme 375

1. Perform the fuel system pressure release procedure. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-489307-S24512055572012072600000) .
2. Remove the engine from the vehicle. Refer to «REMOVAL, 5.7L»(ref-489305-S10604562802012072600000) .
3. Remove the flexplate. Refer to «FLEXPLATE, REMOVAL, 5.7L»(ref-489305-S34698160602012072600000) . CAUTION: Do not damage the rear surface of the camshaft or the core plug sealing surface, when removing the core plug.
4. Using a suitable sharp punch, punch a small hole in the camshaft core hole plug (1).
5. Insert a short sheet metal screw into the small hole in the camshaft core hole plug.
6. Using a suitable slide hammer puller, remove the rear camshaft core hole plug.

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Scheme 383

1. Remove both cylinder heads (2). Refer to «CYLINDER HEAD, REMOVAL, 5.7L»(ref-489305-S36258766752012072600000) . CAUTION: The 5.7L Multi Displacement System (MDS) engine uses both standard roller lifters and deactivating roller lifters. The deactivating roller lifters must be used in cylinders 1, 4, 6, 7. The deactivating lifters can be identified by the two holes in the side of the lifter body, for the latching pins. CAUTION: Whenever the camshaft is replaced, all lifters must be replaced. If the lifter and retainer assemblies are to be reused, identify the lifters to ensure installation in their original location or engine damage could result. CAUTION: The lifter and retainer assembly must be installed as a unit.
2. Remove the lifters (2) and retainer (1) as an assembly. Refer to «LIFTER(S), HYDRAULIC, ROLLER, REMOVAL, 5.7L»(ref-489305-S14046829682012072600000) .
3. Remove the generator. Refer to «GENERATOR, REMOVAL»(ref-489323-S33373725232012072600000) .
4. Remove the A/C compressor. Refer to «COMPRESSOR, A/C, REMOVAL»(ref-489295-S39235681332012072600000) .
5. Remove the radiator (12). Refer to «RADIATOR, ENGINE COOLING, REMOVAL»(ref-489282-S03689879562012072600000) .
6. Remove the A/C condenser (7). Refer to «CONDENSER, A/C, REMOVAL»(ref-489295-S09476269072012072600000) .
7. Raise and support vehicle.
8. Remove the oil pan and oil pump pickup tube (1). Refer to «PAN, OIL, REMOVAL, 5.7L»(ref-489305-S19731860042012072600000) . NOTE: It is not necessary to remove the water pump for timing cover removal.
9. Remove the engine timing cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL, 5.7L»(ref-489305-S34106104722012072600000) .
10. Remove the oil pump. Refer to «PUMP, ENGINE OIL, REMOVAL, 5.7L»(ref-489305-S26926444622012072600000) .
11. Remove the timing chain (5) and camshaft phaser (1). Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL, 5.7L»(ref-489305-S12112658022012072600000) .
12. Remove the camshaft thrust plate (1). CAUTION: Use care when removing the camshaft, do not damage the camshaft bearings with the camshaft lobes.
13. Install a long bolt (2) into the front of the camshaft to aid in removal.
14. Remove the camshaft using care not to damage the camshaft bearings with the camshaft lobes (1).

The crankshaft damper is used to control the resonance that is produced by the engine. The Noise, Vibration, and Harshness (NVH) created from the crankshaft can be controlled by dissipating the torque energy through the damper.

Scheme 384

The crankshaft damper on the engines is held to the crankshaft by means of a harden steel bolt. The damper is pressed onto a specific machined surface of the crankshaft.

Scheme 385

The HEMI® Engines incorporate various crankshaft vibration dampers depending on the engine application. And can be removed depending on the application used.

Scheme 386

Finding the proper puller for the application will ensure no damage will come to the damper. The flange puller is used by installing 3 bolts into the pre-tapped holes in the damper.

Scheme 387

Some pulleys that do not have bolt holes can be removed with a three jaw style (special tool #1023, Puller).

Scheme 388

1. Disconnect negative cable from battery.
2. Remove accessory drive belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-489282-S33381563422012072600000) .
3. Remove the cooling fan. Refer to «FAN, COOLING, REMOVAL»(ref-489282-S31342832962012072600000) .
4. Remove crankshaft damper bolt.
5. Install a flange puller (2) and remove the damper (1).

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Scheme 391

1. Position damper onto crankshaft.
2. Using (special tool #10387, Installer, Vibration Damper), install the threaded rod (1) onto the crankshaft (2).
3. Tighten the threaded rod (4) until it is seated to the face (3) of the crankshaft.
4. Install the press washer, bearing, washer, and the press nut onto the threaded rod.
5. Press the vibration damper on till seated.
6. Install crankshaft damper bolt.
7. Position the (special tool #10386, Holder, Vibration Damper) (2), onto the vibration damper (3).
8. Tighten bolt to 176 N.m (129 ft. lbs.).
9. Install cooling fan. Refer to «FAN, COOLING, INSTALLATION»(ref-489282-S41352265202012072600000) .
10. Install accessory drive belt (1). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-489282-S14236788572012072600000) .
11. Refill cooling system. Refer to «STANDARD PROCEDURE»(ref-489282-S15090009642012072600000) .
12. Connect negative cable to battery.

Scheme 392

1. Remove the transmission. Refer to «REMOVAL»(ref-489308-S25665785932012072600000) .
2. Using the sequence shown in illustration, remove the flexplate retaining bolts.
3. Remove the flexplate.

The Multiple Displacement System (MDS) selectively deactivates cylinders 1, 4, 6 and 7 during steady speed, low acceleration and shallow grade climbing conditions to increase fuel economy.

The MDS can provide a 5 to 20% fuel economy benefit when operating in four-cylinder mode. Depending on driving habits and vehicle usage. For EPA rating purposes the fuel economy is 8 to 15% higher than if the engine was operating on eight-cylinders at all times.

The MDS deactivating lifter (1) can be distinguished from the non-MDS lifter (2) by the disconnecting pin (3) on the side of the MDS lifter.

MDS is integrated into the basic engine architecture requiring these additional components

1. Unique MDS camshaft
2. 8 deactivating roller lifters
3. 4 MDS control valve solenoids
4. MDS control valve solenoid wiring harness
5. Oil temperature sensor

The Multiple Displacement System (MDS) provides cylinder deactivation during steady speed, low acceleration and shallow grade climbing conditions to increase fuel economy. Both four and eight cylinder configurations have even firing intervals to provide smooth operation. The MDS selectively deactivates cylinders 1, 4, 6, and 7, to improve fuel economy. All deactivated cylinders have unique hydraulic lifters that collapse when deactivated to prevent the valves from opening. Engine oil pressure is used to activate and deactivate the valves. Oil is delivered through special oil passages drilled into the cylinder block. The MDS solenoid valves control the flow. When activated, pressurized oil pushes a latching pin on each MDS lifter which becomes a lost motion link. The base of the MDS lifter follows the camshaft while the top remains stationary. The MDS lifter is held in place against the pushrod by light spring pressure but unable to move because of the much higher force of the valve spring.

Note. It is critical to use the recommended oil viscosity in engines that use MDS.

Deactivation occurs during the compression stroke of each cylinder, after air and fuel enter the cylinder. Ignition occurs, but the combustion products remain trapped in the cylinder under high pressure, because the valves no longer open. No fuel/air enters or leaves during subsequent piston strokes, this high pressure gas is repeatedly compressed and expanded like an air spring.

The pistons are made of a high strength aluminum alloy. Piston skirts are coated with a solid lubricant (Molykote®) to reduce friction and provide scuff resistance. The piston top ring groove and land is anodized. The connecting rods are made of forged powdered metal, with a fractured cap design.

Scheme 393

1. To correctly select the proper size piston, use Cylinder Indicator (special tool #C-119, Cylinder Indicator) (2) to 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.
2. Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below the top of bore (4). Start perpendicular (across or at 90°) to the axis of the crankshaft at point A (1) and then take an additional bore reading 90° at point B (1).
3. The coated pistons will be serviced with the piston pin and connecting rod pre-assembled. The piston-rod assembly is specific for the left cylinder bank (odd numbered) and the right cylinder bank (even numbered) and must not be interchanged.
4. Measure the piston diameter with a micrometer at points (1, 2).

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1. Perform the fuel system pressure release procedure. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-489307-S24512055572012072600000) .
2. Disconnect and isolate the negative battery cable (1).
3. Remove the engine cover (2).
4. Loosen clamp and disconnect the air duct at throttle body.
5. Disconnect the intake air temperature sensor (4) electrical connector.
6. Remove the makeup air hose (1).
7. Remove the air cleaner housing retaining bolt (3) and remove the air cleaner housing (2).
8. Remove the cylinder head(s). Refer to «CYLINDER HEAD, REMOVAL, 5.7L»(ref-489305-S36258766752012072600000) .
9. Raise and support the vehicle.
10. Remove the engine mount nuts (1, 2).
11. Remove the steering gear mounting bolts (1) and position the steering gear (2) aside.
12. Remove the engine oil dipstick and tube from the oil pan.
13. Lower the vehicle. NOTE: Do not use air tools to install engine lift fixture.
14. Install the Engine Lift Fixture (special tool #8984B, Fixture, Engine Lifting) (1), Engine Lift Adapter (special tool #8984-UPD, Adapter, Engine Lift) (2) and the Engine Support Fixture (special tool #8534B, Fixture, Driveline Support) (3).
15. Raise the engine to provide clearance to remove the oil pan.
16. Raise and support the vehicle.
17. Remove the oil pan. Refer to «PAN, OIL, REMOVAL, 5.7L»(ref-489305-S19731860042012072600000) .
18. Lower the vehicle.
19. Remove the timing chain cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL, 5.7L»(ref-489305-S34106104722012072600000) .
20. If necessary, remove the ridge on top of the cylinder bores with a reliable ridge reamer before removing the pistons from the cylinder block. Be sure to keep the tops of the pistons covered during this operation. 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 removal to ensure correct reassembly.
21. Raise and support the vehicle.
22. Mark the connecting rod and bearing cap positions using a permanent ink marker or scribe tool. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur. NOTE: Pistons and connecting rods assemblies must be removed from the top of cylinder block. When removing the piston and connecting rod assemblies from the engine, rotate the crankshaft so each connecting rod is centered in the cylinder bore.
23. Remove the connecting rod cap, install the Connecting Rod Guides (special tool #8507, Guides, Connecting Rod) (1) and carefully remove the piston from the cylinder bore, repeat this procedure for each piston being removed.
24. Immediately after removing the piston and connecting rod, install the bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
25. Carefully remove the piston rings from the piston(s), starting from the top ring down.

The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer. For more information, refer to the following

1. Diagnosis and Testing: Refer to «Engine/Engine Block/RETAINER, Crankshaft Rear Oil Seal - Diagnosis and Testing»(ref-489305-S12276616442012072600000) .
2. Removal: Refer to «RETAINER, CRANKSHAFT REAR OIL SEAL, REMOVAL, 5.7L»(ref-489305-S16289079942012072600000) .
3. Installation: Refer to «RETAINER, CRANKSHAFT REAR OIL SEAL, INSTALLATION, 5.7L»(ref-489305-S18613093552012072600000) .

The Multi Displacement System selectively deactivates cylinders 1, 4, 6, and 7, to improve fuel economy. It has two modes of operation

1. 8 cylinders for acceleration and heavy loads.
2. 4 cylinders for cruising and city traffic.

The main components of the Multi Displacement System are

1. Unique MDS camshaft.
2. Deactivating roller tappets.
3. 4 control valves/solenoids.
4. control valve/solenoid wiring harness.
5. oil temp sensor.

Cylinder Deactivation

1. Trap an exhaust charge from a normal combustion event
2. Normal combustion event
3. Don't open the exhaust valve
4. Don't open the intake valve
5. Piston is an air spring
6. Cylinders deactivated in firing sequence

Cylinder Reactivation

1. Open the exhaust valve
2. Empty the cylinder
3. Open the intake valve
4. Normal combustion event
5. Cylinders reactivated in firing sequence

The 5.7L engine is equipped with Variable Valve Timing (VVT). This system uses an oil control valve to direct oil pressure into the camshaft phaser assembly. The camshaft phaser assembly advances and/or retards camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The oil control valve is located under the intake manifold.

The Variable Valve Timing (VVT) assembly is actuated with engine oil pressure. The oil flow to the VVT assemblies are controlled by an Oil Control Valve (OCV). The OCV consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VVT assemblies. The VVT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VVT assembly rotates the rotor with respect to the stator, thus rotating the exhaust camshaft with respect to the timing chain and intake camshaft. An infinitely variable valve timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM.

The oil pressure sensor uses the following three circuits

1. Signal circuit to the PCM
2. Sensor ground circuit through the PCM
3. 5 volt reference circuit from the PCM

The oil pressure sensor returns a voltage signal back to the PCM with reference to oil pressure. Ground for the sensor is supplied by the PCM.

The oil pressure sensor is located on the right side of the engine block. The sensor screws into the engines main oil gallery.

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1. Disconnect and isolate the negative battery cable.
2. Remove the accessory drive belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-489282-S33381563422012072600000) .
3. Remove the upper generator mounting bolt.
4. Raise and support the vehicle.
5. Remove the lower splash shield retaining bolts (1) and the splash shield.
6. Remove the lower generator retaining bolts (1).
7. Lower the vehicle.
8. Position the generator aside to gain access to the oil pressure sensor.
9. Disconnect the oil pressure sensor electrical connector (1).
10. Remove the oil pressure sensor (1).

The oil temperature sensor uses the following two circuits

1. Signal circuit to the PCM
2. Ground circuit from the PCM

The oil temperature sensor is a Negative Thermal Coefficient sensor. The resistance of the sensor changes as oil temperature changes. This results in different output voltages back to the PCM.

The oil temperature sensor is located on the right side of the engine block.

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1. Disconnect and isolate the negative battery cable.
2. Remove the accessory drive belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-489282-S33381563422012072600000) .
3. Remove the generator upper mounting bolt.
4. Raise and support the vehicle.
5. Remove the lower splash shield retaining bolts (1) and the splash shield.
6. Remove the generator lower mounting bolts (1).
7. Lower the vehicle.
8. Position the generator aside to gain access to the oil temperature sensor.
9. Disconnect the oil temperature sensor electrical connector (1).
10. Remove the oil temperature sensor (1).

The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust manifolds are made of high silicon molybdenum cast iron. A multi-layer stainless steel exhaust manifold gasket is used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold, with the exception of the nut, which also secures the oil dipstick tube bracket. That nut should not be backed off.

The exhaust manifolds collect the engine exhaust exiting the combustion chambers, then channels the exhaust gases to the exhaust pipes attached to the manifolds.

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Scheme 404

1. Disconnect and isolate the negative battery cable (1).
2. Remove the engine cover (2).
3. Disconnect the intake air temperature (IAT) sensor (5) connector.
4. Loosen the clamps at the throttle body and the air filter housing and remove the air tube (4).
5. Disconnect the make up air hose (MUA) (2).
6. Remove the air filter housing retaining bolt (3).
7. Remove the air filter housing.
8. Raise and support the vehicle.
9. Remove both front engine mounts (2) and mounting brackets. Refer to «INSULATOR, ENGINE MOUNT, FRONT, REMOVAL, 5.7L»(ref-489305-S36269516742012072600000) and «INSULATOR, ENGINE MOUNT, REAR, REMOVAL, 5.7L»(ref-489305-S10869082872012072600000) . CAUTION: When separating the catalytic converters from the manifolds, disconnect the oxygen sensor connectors. Allowing the catalytic converters hanging from the oxygen sensor wires damages the harness and/or sensors.
10. Raise and support the vehicle.
11. Disconnect the oxygen sensor electrical connectors (2).
12. Saturate the front exhaust pipe/catalytic converter retaining bolts and nuts with Mopar® Rust Penetrant or equivalent and allow 5 minutes for penetration.
13. Remove catalytic converters (4). Refer to «CONVERTER, CATALYTIC, REMOVAL»(ref-489289-S14564354632012072600000) . NOTE: Two knock sensors (1) are used, they are bolted to each side of the cylinder block under each exhaust manifold (3).
14. Remove the heat shields from the knock sensor (shield snaps onto sensor).
15. Disconnect knock sensor electrical connector (3). NOTE: Note the foam strip on the knock sensor retaining bolt threads. This foam is only used to retain the bolts to the knock sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.
16. Remove knock sensor retaining bolt (2) and remove knock sensors (1).
17. Lower the vehicle. NOTE: It is not necessary to remove the hoses from the coolant bottle for coolant bottle removal.
18. Remove coolant bottle retaining bolts (2) and position aside.
19. Remove the Totally Integrated Power Module (TIPM) and mounting bracket. Refer to «MODULE, TOTALLY INTEGRATED POWER (TIPM), REMOVAL»(ref-489283-S32133650032012072600000) .
20. Unfasten the wire harness mounted on the right hand inner fender panel and position aside.
21. Remove the exhaust manifold heat shields. Right side shown in illustration, left similar. Right Side
22. Using the sequence shown in illustration, remove the exhaust manifold retaining bolts. Left Side
23. Using the sequence shown in illustration, remove the exhaust manifold retaining bolts.
24. Remove the exhaust manifold (2) and gasket.
25. Inspect the exhaust manifold for any damage. Refer to «Engine/Manifolds/MANIFOLD, Exhaust - Inspection»(ref-489305-S09422770332012072600000) .
26. Clean the exhaust manifold and the cylinder head (1) mating surfaces.

The timing chain tension is maintained by routing the timing chain through the tensioner assembly. A nylon shoe presses on the timing chain maintaining the correct chain tension.

Scheme 405

Note. Verify that the tensioner is assembled correctly.

Scheme 406

1. Install the washer (1), spring (2), and plunger (3) inside the tensioner body (4).
2. Squeeze the tensioner body (3) and movable guide shoe (2) together and install Tensioner Pin (special tool #8514, Pins, Tensioner) (1).