5.7L Engine - Service Information: Removal & Installation Dodge Challenger III рестайлинг

INSTALLATION

Note. Do not use air tools to install Engine Lift Fixture and Adapter (special tool #8984B, Fixture, Engine Lifting) (2, 3).

Scheme 438

Scheme 439

Scheme 440

Scheme 441

Scheme 442

1. Install the engine lift fixture (special tool #8984B, Fixture, Engine Lifting) (2) and adapter (special tool #8984-UPD, Adapter, Engine Lift) (4).
2. Using a suitable engine hoist, lower the engine into in the engine compartment.
3. Automatic transmission equipped vehicles, align the engine with the transmission.
4. Install two transmission to engine block mounting bolts finger tight.
5. Lower the engine assembly until the engine mounts rest in the engine cradle crossmember. NOTE: Left side shown in illustration, right side similar.
6. Align the engine mounts, install both left and right engine mount to frame retaining bolts (2) and tighten to 68 N.m (50 ft. lbs.).
7. Position both left and right engine mount heat shields (4), install the retaining nuts (3) and tighten to 27 N.m (20 ft. lbs.).
8. Remove the engine hoist and the jack supporting the transmission.
9. Raise and support the vehicle.
10. Manual transmission equipped vehicles, install the transmission. Refer to «INSTALLATION»(ref-489302-S03167265792012072600000) .
11. Automatic transmission equipped vehicles, Install the transmission to oil pan bolts (1) and tighten to 54 N.m (40 ft. lbs.).
12. Install the remaining transmission bell housing to engine block bolts (2) and tighten to 68 N.m (50 ft. lbs.). CAUTION: It is essential that the correct length bolts are used to attach the converter to the flexplate. Bolts that are too long will damage the clutch surface inside the torque converter.
13. Rotate the crankshaft in clockwise direction and install all torque converter to flexplate bolts (1) finger tight.
14. Verify that the torque converter is pulled flush to the flexplate and tighten bolts to 88 N.m (65 ft. lbs.).
15. Install the inspection cover (1) and tighten the retaining bolt (2) to 11 N.m (8 ft. lbs.). NOTE: The Crankshaft Position (CKP) sensor is located at the right rear side of the engine block.
16. Connect the CKP sensor electrical connector (1).
17. Position the starter motor (1) into the transmission.
18. Install the three starter motor retaining bolts (2) and tighten to 54 N.m (40 ft. lbs.).
19. Connect the solenoid wire to the starter motor (snaps in place).
20. Position the battery cable to the solenoid stud, install the battery cable eyelet nut and tighten to 11 N.m (8 ft. lbs.).
21. Position the starter heat shield (4) and install the retaining nuts (3).
22. Position the catalytic converters (4) onto the exhaust manifold flanges, install the flange nuts (3) and tighten to 41 N.m (30 ft. lbs.).
23. Connect the oxygen sensor electrical connectors (2). NOTE: Left side shown in illustration, right side similar.
24. Connect the right and left knock sensor (1) electrical connectors (5).
25. Install the heat shields onto both knock sensors (shield snaps on/off sensor).
26. Connect the transmission oil cooler lines to their retainers at the oil pan. 1 - LOWER RADIATOR HOSE 2 - RADIATOR FAN ASSEMBLY
27. Install the lower radiator hose (1).
28. Lower the vehicle.
29. Remove the engine lift fixture (special tool #8984B, Fixture, Engine Lifting) (2) and adapter (special tool #8984-UPD, Adapter, Engine Lift) (4).
30. Position the left and right side wiring harness.
31. Lubricate the oil control valve (OCV) rubber O-ring seal with clean engine oil.
32. Install the OCV (3) and rotate into position.
33. Install the OCV retaining bolt (2) and tighten to 11 N.m (8 ft. lbs.).
34. Connect the OCV electrical connector (1).
35. Install the heater core tube (3) into the water pump.
36. Install the heater core tube retaining bolt (1) and tighten to 11 N.m (8 ft. lbs.).
37. Connect the electrical connector to the coolant temperature (ECT) sensor (2).
38. Connect the camshaft position sensor electrical connector (4). NOTE: Install the intake manifold and throttle body as an assembly.
39. Install the intake manifold. Refer to «MANIFOLD, INTAKE, INSTALLATION, 5.7L»(ref-489305-S37168400762012072600000) .
40. Connect the heater hoses (1, 2).
41. Connect the ground wires to the rear of each cylinder head. NOTE: The ignition capacitor (2) is attached to the rear of the left cylinder head.
42. Connect the ignition capacitor (2) electrical connector (1).
43. Connect the oil pressure sensor electrical connector (1).
44. Connect the oil temperature sensor electrical connector.
45. Position the generator (2) and install two generator mounting bolts (1) finger tight.
46. Raise and support the vehicle.
47. Position the generator support bracket (3) to the engine mount, install the retaining nut (1) finger tight.
48. Position the generator support bracket (3) to the generator, install the retaining bolt (2) and tighten to 65 N.m (48 ft. lbs.).
49. Tighten the generator support bracket (3) to engine mount retaining nut (1) to 28 N.m (21 ft. lbs.).
50. Install the A/C compressor (3). Refer to «COMPRESSOR, A/C, REMOVAL»(ref-489295-S39235681332012072600000) .
51. Position the belly pan and install the belly pan retainers (1).
52. Lower the vehicle.
53. Tighten two generator mounting bolts (1) to 65 N.m (48 ft. lbs.).
54. Snap the field wire connector into the rear of the generator.
55. Position the generator B+ terminal eyelet to the generator output stud, install the retaining nut and tighten to 13 N.m (10 ft. lbs.).
56. Snap the plastic insulator cap onto the B+ output terminal.
57. Position the front section of the A/C suction line (2) into the engine compartment.
58. Remove the tape or plugs from the fittings that connect the front section of the A/C suction line to the rear section of the A/C suction line (3). NOTE: Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
59. Lubricate a new dual plane seal with clean refrigerant oil and install it onto the suction line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
60. Connect the front section of the A/C suction line to the rear section of the A/C suction line.
61. Install the nut (1) that secures the front section of the A/C suction line to the rear section of the A/C suction line and tighten the nut to 22 N.m (16 ft. lbs.).
62. Position the front section of the A/C liquid line into the engine compartment.
63. Remove the tape or plugs from the fittings that connect the front section of the A/C liquid line to the rear section of the A/C liquid line (3). NOTE: Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
64. Lubricate a new dual plane seal with clean refrigerant oil and install it onto the liquid line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
65. Connect the front section of the A/C liquid line to the rear section of the A/C liquid line.
66. Install the nut (1) that secures the front section of the A/C liquid line to the rear section of the A/C liquid line and tighten the nut to 22 N.m (16 ft. lbs.).
67. Position the ignition coil electrical harness and connect all ignition coil electrical connectors (1).
68. Position the coolant bottle (1) and install the coolant bottle retaining bolts (2).
69. Install the Totally Integrated Power Module (TIPM) mounting bracket.
70. Install the TIPM. Refer to «MODULE, TOTALLY INTEGRATED POWER (TIPM), INSTALLATION»(ref-489283-S25475398282012072600000) .
71. Position the wire harness and secure to the right hand inner fender panel. CAUTION: Do not let the tensioner arm snap back to the freearm position, sever damage may occur to the tensioner.
72. Rotate the accessory drive belt tensioner (8) clockwise until it contacts the stop and install the accessory drive belt (2) onto the pulleys, then slowly release the tensioner.
73. Install the cooling fan. Refer to «FAN, COOLING, INSTALLATION»(ref-489282-S41352265202012072600000) . 1 - UPPER RADIATOR CLOSURE PANELS 2 - UPPER RADIATOR HOSE 3 - RADIATOR FAN ELECTRICAL CONNECTOR 4 - RADIATOR FAN ASSEMBLY
74. Install the upper radiator hose (2).
75. Install the strut tower support (6) and tighten bolts to 38 N.m (28 ft. lbs.).
76. Install the cowl panel cover (1). Refer to «COVER, COWL PANEL, INSTALLATION»(ref-489285-S23481209722012072600000) .
77. Fill the crankcase with the specified type and amount of engine oil. Refer to «CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS»(ref-489279-S02053359422012072600000) .
78. Fill the cooling system with the specified type and amount of engine coolant. Refer to «STANDARD PROCEDURE»(ref-489282-S15090009642012072600000) .
79. Position the engine cover (2) and secure the retaining grommets onto the ball studs.
80. Connect the negative battery cable and tighten nut (1) to 5 N.m (45 in. lbs.).
81. Perform the Refrigerant System Charge procedure. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-489295-S09639003932012072600000) .
82. Start the engine and check for leaks.

1. Clean any dirt or foreign matter from the inside of the air cleaner housing. NOTE: The air cleaner element must be properly seated for the air cleaner housing cover to fit correctly.
2. Install the air cleaner element into the air cleaner housing.
3. Position the air cleaner housing cover in place and secure the two retainer clips (1).

REMOVAL

1. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (1).
2. Disconnect the intake air temperature (IAT) sensor (5) electrical connector.
3. Loosen the air duct retaining clamps at the throttle body and the air cleaner housing and remove the air duct (4).
4. Disconnect the make up air hose (MUA) (2).
5. Remove the air cleaner housing retaining bolt (3).
6. Remove the air cleaner housing from the vehicle.

1. Position the air cleaner housing into the engine compartment.
2. Install the air cleaner housing retaining bolt (3) and tighten to 5 N.m (44 in. lbs.).
3. Connect the air duct to the throttle body and the air cleaner housing and tighten clamps to 3 N.m (30 in. lbs.).
4. Connect the make up air hose (MUA) (2).
5. Connect the intake air temperature (IAT) sensor (5) electrical connector.
6. Position the engine cover (1) and secure the retaining grommets onto the ball studs.

Note. Left side shown in illustration, right side similar.

Scheme 443

Scheme 444

Scheme 445

Scheme 446

1. If replacing the cylinder head, transfer the valves, valve seals and valve springs to the new cylinder head. Refer to «VALVES, INTAKE AND EXHAUST, INSTALLATION, 5.7L»(ref-489305-S38428171212012072600000) . If valve refacing is necessary, refer to «Engine/Cylinder Head/VALVES, Intake and Exhaust - Standard Procedure»(ref-489305-S03107866802012072600000) .
2. If replacing the cylinder head, transfer the spark plugs to the new cylinder head. Refer to «SPARK PLUG, INSTALLATION»(ref-489335-S15557627382012072600000) .
3. If replacing the cylinder head, transfer the exhaust manifold to the new cylinder head using a new gasket.
4. Using the sequence shown in illustration, tighten the exhaust manifold bolts/studs to 25 N.m (18 ft. lbs.). CAUTION: The cylinder head gaskets are not interchangeable between the left and right sides. They are marked with an "L" and "R" to indicate the left or right side and they are marked "TOP" to indicate which side goes up.
5. Clean all gasket sealing surfaces of the cylinder block and cylinder heads using a suitable solvent. NOTE: Left side shown in illustration, right side similar.
6. Position the new cylinder head gaskets (5) onto the cylinder block.
7. Position the cylinder heads (4) onto the head gaskets (5) and the cylinder block. NOTE: Left side shown in illustration, right side similar.
8. Using the sequence shown in illustration, tighten the cylinder head bolts 1 through 10 to 34 N.m (25 ft. lbs.).
9. Using the sequence shown in illustration, tighten the cylinder head bolts 11 through 15 to 20 N.m (15 ft. lbs.).
10. Using the sequence shown in illustration, tighten the cylinder head bolts 1 through 10 to 54 N.m (40 ft. lbs.).
11. Using the sequence shown in illustration, tighten the cylinder head bolts 11 through 15 to 20 N.m (15 ft. lbs.).
12. Using the sequence shown in illustration, rotate the cylinder head bolts 1 through 10 an additional 90° turn.
13. Using the sequence shown in illustration, tighten the cylinder head bolts 11 through 15 to 34 N.m (25 ft. lbs.).
14. Install the push rods and rocker arm assemblies in their original position, using Pushrod Retainer (special tool #9070, Retainer, Push Rod) (1). Refer to «ROCKER ARM, VALVE, INSTALLATION, 5.7L»(ref-489305-S13214678112012072600000) .
15. If Install the right cylinder head, position the engine oil dip stick tube and install the retaining nut at the exhaust manifold.
16. Position the cylinder head covers (1), using the sequence shown in illustration, tighten the retaining bolts to 8 N.m (70 in. lbs.). CAUTION: Do not let the tensioner arm snap back to the freearm position, sever damage may occur to the tensioner.
17. Rotate the accessory drive belt tensioner (8) clockwise until it contacts the stop and install the accessory drive belt (2) onto the pulleys, then slowly release the tensioner.
18. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-489279-S05318852982012072600000) .
19. Position the catalytic converters (4) onto the exhaust manifold flanges, install the flange nuts (3) and tighten to 41 N.m (30 ft. lbs.).
20. Connect the oxygen sensor electrical connectors (2).
21. Position the belly pan and install the belly pan retainers (1).
22. Lower the vehicle. NOTE: Install the intake manifold and throttle body as an assembly.
23. Install the intake manifold. Refer to «MANIFOLD, INTAKE, INSTALLATION, 5.7L»(ref-489305-S37168400762012072600000) .
24. Change the engine oil and oil filter. Refer to «CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS»(ref-489279-S02053359422012072600000) .
25. Fill the cooling system with the specified type and amount of engine coolant. Refer to «STANDARD PROCEDURE»(ref-489282-S15090009642012072600000) .
26. Position the engine cover (2) and secure the retaining grommets onto the ball studs.
27. Connect the negative battery cable and tighten nut (1) to 5 N.m (45 in. lbs.).
28. Start the engine and check for leaks.

Scheme 447

Scheme 448

1. Disconnect the negative battery cable (1).
2. Remove the engine cover (2). NOTE: Right side shown in illustration, left side similar.
3. Disconnect the ignition coil electrical connectors (1).
4. Position the electrical harness (2) aside.
5. Remove the ignition coil retaining bolts (3) and remove the ignition coils.
6. Using the sequence shown in illustration, remove the cylinder head cover retaining bolts. CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur.
7. Remove the cylinder head cover (1).
8. Clean the sealing surface of the cylinder head (2) and cover.

Note. The cylinder head cover gasket may be used again, provided no cuts, tears, or deformation have occurred.

Note. The cylinder head cover gasket may be used again, provided no cuts, tears, or deformation have occurred.

Scheme 449

1. Clean the cylinder head cover (1) and the sealing surface of the cylinder head (2). Inspect and replace gasket if necessary.
2. Install the cylinder head cover and hand start all fasteners.
3. Using the sequence shown in illustration, tighten the cylinder head cover bolts to 8 N.m (70 lbs in.).
4. Before installing the ignition coils, apply dielectric grease to the inside of the spark plug boots (1).
5. Install the ignition coils. NOTE: Right side shown in illustration, left side similar.
6. Tighten the ignition coil retaining bolts (3) to 7 N.m (62 in. lbs.).
7. Position the electrical harness (2).
8. Connect the ignition coil electrical connectors (1).
9. Install the engine cover (2).
10. Connect the negative battery cable (1).

Scheme 450

Scheme 451

1. Disconnect the negative battery cable (1).
2. Remove the engine cover (2).
3. Remove the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL, 5.7L»(ref-489305-S29697708402012072600000) .
4. Install the pushrod retainer (special tool #9070, Retainer, Push Rod) (1).
5. Using the sequence shown in illustration, loosen the rocker shafts retaining bolts. 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: Do not remove the retainers (1) from the rocker shaft (3).
6. Remove the rocker shaft (3). Note the rocker shaft location for reassembly. CAUTION: The longer pushrods are for the exhaust side and the shorter pushrods are for the intake side.
7. Remove the pushrods. Note the pushrod location for reassembly.

1. Install the pushrods in the same order as removed.
2. Install the pushrod retainer (special tool #9070, Retainer, Push Rod) (1). 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 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).
3. Install the rocker shaft assemblies in the same order as removed.
4. Using the sequence shown in illustration, tighten the rocker shaft bolts to 22 N.m (16 ft. lbs.). CAUTION: Do Not rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about five minutes).
5. Remove pushrod retainer (special tool #9070, Retainer, Push Rod) (1).
6. Install the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION, 5.7L»(ref-489305-S10130331792012072600000) .
7. Install the engine cover (2).
8. Connect the negative battery cable (1).

1. Remove the cylinder head. Refer to «CYLINDER HEAD, REMOVAL, 5.7L»(ref-489305-S36258766752012072600000) .
2. Compress valve springs using Valve Spring Compressor Tool (special tool #C-3422-D, Compressor, Valve Spring) and Adapter (special tool #8464, Adapter, Valve Spring).
3. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs.
4. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location.

1. Clean valves thoroughly. Discard burned, warped and cracked valves.
2. Remove the carbon and varnish deposits from the inside of the valve guides with a reliable guide cleaner.
3. Measure the valve stems for wear. If the wear exceeds 0.051 mm (0.002 inch), replace the valve.
4. Coat the valve stems with clean engine oil and insert them into the cylinder head.
5. If the valves or seats are ground, check the valve stem height. If the valve stem is too long, replace the cylinder head.
6. Install new seals on all valve guides. Install the valve springs and valve retainers.
7. Compress the valve springs with the Valve Spring Compressor (special tool #C-3422-D, Compressor, Valve Spring) and Valve Spring Adapter (special tool #8464, Adapter, Valve Spring). Install the locks and release the tool. If the valves and/or seats are ground, measure the installed height of the springs. Make sure the measurement is taken from the bottom of the spring seat in the cylinder head to the bottom surface of the spring retainer.
8. Install the cylinder head. Refer to «CYLINDER HEAD, INSTALLATION, 5.7L»(ref-489305-S13350322482012072600000) .

1. Position the flexplate onto the crankshaft and install the retaining bolts hand tight.
2. Using the sequence shown in illustration, tighten the flexplate retaining bolts to 95 N.m (70 ft. lbs.).
3. Install the transmission. Refer to «INSTALLATION»(ref-489233-S06140661732012072600000) .

The Multiple Displacement System (MDS) provides cylinder deactivation during steady speed, low acceleration and shallow grade climbing conditions to increase fuel economy.

1. Lubricate the tappet guide holder (1) and tappets (2). CAUTION: If the lifters and guide holder assembly are to be reused, they must me installed in their original location.
2. Install the tappet guide holder (2) and tappets.
3. Tighten the tappet retainer bolt (1) to 12 N.m (9 ft. lbs.).
4. Install the cylinder head. Refer to «CYLINDER HEAD, INSTALLATION, 5.7L»(ref-489305-S13350322482012072600000) .
5. Connect the negative battery cable. CAUTION: To prevent damage to valve assemblies, do not run the engine above fast idle until all hydraulic lifters have filled with oil and have become quiet.
6. Start the engine and check for leaks.
7. Road test the vehicle.

Note. The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer and must be replaced as an assembly.

Note. The crankshaft rear oil seal retainer can not be reused after removal.

Note. This procedure can be performed in vehicle.

1. Disconnect the negative battery cable.
2. Remove the transmission. Refer to appropriate Transmission and Transfer Case article.
3. Remove the flexplate. Refer to «FLEXPLATE, REMOVAL, 5.7L»(ref-489305-S34698160602012072600000) .
4. Remove the oil pan. Refer to «PAN, OIL, REMOVAL, 5.7L»(ref-489305-S19731860042012072600000) .
5. Using the sequence shown in illustration, remove the rear oil seal retainer mounting bolts.
6. Carefully remove the retainer from the engine block.

Note. The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer and must be replaced as an assembly.

Note. The crankshaft rear oil seal retainer can not be reused after removal.

1. Thoroughly clean all gasket residue from the engine block.
2. Position the gasket onto the new crankshaft rear oil seal retainer.
3. Position the crankshaft rear oil seal retainer onto the engine block.
4. Using the sequence shown in illustration, install the crankshaft rear oil seal retainer mounting bolts and tighten to 15 N.m (11 ft. lbs.).
5. Install the oil pan. Refer to «PAN, OIL, INSTALLATION, 5.7L»(ref-489305-S19861274902012072600000) .
6. Install the flexplate. Refer to «FLEXPLATE, INSTALLATION, 5.7L»(ref-489305-S25174466402012072600000) .
7. Install the transmission. Refer to appropriate Transmission and Transfer Case article.
8. Fill the engine with oil.
9. Start the engine and check for leaks.

Scheme 452

Note. Before reinstalling used rings or installing new rings, the ring clearances must be checked.

1. Wipe the cylinder bore clean.
2. Insert the ring in the cylinder bore. NOTE: The ring gap measurement must be made with the ring positioned at least 12 mm (0.50 inch.) from bottom of cylinder bore.
3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder.
4. Using a feeler gauge check the ring end gap. Replace any rings not within specification.

1. Verify the MDS solenoid bores are free of debris before installing the MDS solenoid into the engine block.
2. Install the MDS solenoid(s) (3), ensure the seal is fully seated into the engine block.
3. Install the retaining bolt(s) (2) and tighten to 11 N.m (8 ft. lbs.).
4. Connect the MDS electrical connector to the solenoid(s) (3).
5. Install the foam insulator pad (1).
6. Install the intake manifold. Refer to «MANIFOLD, INTAKE, INSTALLATION, 5.7L»(ref-489305-S37168400762012072600000) .

Scheme 453

Scheme 454

Scheme 455

1. Disconnect the negative battery cable (1).
2. Remove the intake manifold. Refer to «MANIFOLD, INTAKE, REMOVAL, 5.7L»(ref-489305-S17410474082012072600000) . NOTE: The Oil Control Valve (OCV) (3) is located under the intake manifold.
3. Disconnect OCV electrical connector (1).
4. Remove OCV retaining bolt (2). NOTE: To remove the OCV, the engine must be at room temperature.
5. While rotating the OCV back and forth to break the seal, remove the OCV.
6. Remove the engine oil dipstick tube retaining nut at the right exhaust manifold and remove the dipstick tube.
7. Raise and support the vehicle.
8. Remove the belly pan retainers (1) and remove the belly pan.
9. Remove the generator support bracket to engine mount retaining nut (1).
10. Remove the generator support bracket retaining bolt (2) and remove the support bracket (3).
11. Lower the vehicle. NOTE: Left side shown in illustration, right side similar.
12. Remove both left/right engine mount heat shield (4) retaining nuts (3) and remove the heat shields
13. Remove both left/right engine mount to frame retaining bolts (2). NOTE: Do not use air tools to install the 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 engine mounts. NOTE: Left side shown in illustration, right side similar.
16. Remove both left/right engine mount retaining bolts (1) and remove the engine mounts (2). NOTE: Left side shown in illustration, right side similar.
17. If required, remove the engine mount to engine block mounting bracket(s) retaining bolts (1) and remove the mounting bracket(s) (2).

Note. Left side shown in illustration, right side similar.

1. If removed, position the engine mount to engine block mounting brackets, install the retaining bolts and tighten to 61 N.m (45 ft. lbs.). NOTE: Left side shown in illustration, right side similar.
2. Position the engine mounts (2), Install the retainers (1) and tighten to 61 N.m (45 ft. lbs.).
3. Lower the vehicle.
4. Using 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), lower the engine until the engine mounts are seated on the engine cradle.
5. Remove 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). NOTE: Left side shown in illustration, right side similar.
6. Install both left/right engine mount isolators to engine cradle retaining bolts (2) and tighten to 61 N.m (45 ft. lbs.).
7. Position both left/right engine mount heat shields (4), install the retaining nuts (3) and tighten to 25 N.m (18 ft. lbs.).
8. Raise and support the vehicle.
9. Position the generator support bracket (3) to the engine mount, install the retaining nut (1) and tighten finger tight.
10. Position the generator support bracket (3) to the generator, install the retaining bolt (2) and tighten to 65 N.m (48 ft. lbs.).
11. Tighten the generator support bracket (3) to engine mount retaining nut (1) to 28 N.m (21 ft. lbs.).
12. Position the belly pan and install the belly pan retainers (1).
13. Lower the vehicle.
14. Position the engine oil dipstick tube and install retaining nut at the exhaust manifold.
15. Position the OCV (3), install the retaining bolt (2) and tighten to 11 N.m (8 ft. lbs.).
16. Connect OCV electrical connector (1).
17. Install the intake manifold. Refer to «MANIFOLD, INTAKE, INSTALLATION, 5.7L»(ref-489305-S37168400762012072600000) .
18. Connect the negative battery cable and tighten nut (1) to 5 N.m (45 in. lbs.).

Scheme 456

Scheme 457

Scheme 458

1. Raise and support the vehicle.
2. Using a suitable jack, support the transmission.
3. Remove the rear transmission mount isolator bolts (2).
4. Remove the rear cross member retaining bolts (1, 3) and remove the cross member (4).
5. Remove the rear transmission mount isolator (3) retaining bolts (1) and remove the isolator.
6. If required, remove the rear transmission mount bracket (2) retaining bolts (1) and remove the bracket.

Scheme 459

Scheme 460

1. Raise and support the vehicle.
2. Using a suitable jack, support the transmission.
3. Remove the rear transmission mount isolator nuts (1).
4. Remove the rear cross member retaining bolts (2) and remove the cross member.
5. Remove the rear transmission mount isolator (2) retaining bolts (1) and remove the isolator.

Note. The Oil Control Valve (OCV) (3) is located under the intake manifold.

1. Remove intake manifold. Refer to «MANIFOLD, INTAKE, REMOVAL, 5.7L»(ref-489305-S17410474082012072600000) .
2. Disconnect OCV electrical connector (1).
3. Remove OCV retaining bolt (2). NOTE: To remove the oil control valve, the engine must be at room temperature.
4. Rotate the OCV to break the seal and remove.

1. Lubricate the oil control valve (OCV) rubber O-ring seal with clean engine oil.
2. Install the OCV and rotate into position.
3. Install the OCV (3) retaining bolt (2) and tighten to 11 N.m (8 ft. lbs.).
4. Connect the OCV electrical connector (1).
5. Install the intake manifold. Refer to «MANIFOLD, INTAKE, INSTALLATION, 5.7L»(ref-489305-S37168400762012072600000) .

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.

1. Position a drain pan under the oil filter.
2. Using a suitable oil filter wrench loosen filter.
3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss.
4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter.
5. With a wiping cloth, clean the gasket sealing surface of oil and grime.

Scheme 461

1. Lightly lubricate oil filter gasket (2) with engine oil.
2. Thread filter (3) onto adapter nipple. When gasket makes contact with sealing surface (1), hand tighten filter one half turn, or 180°. Do not over tighten.
3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks.

1. Remove the oil pan. Refer to «PAN, OIL, REMOVAL, 5.7L»(ref-489305-S19731860042012072600000) .
2. Remove the timing cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL, 5.7L»(ref-489305-S34106104722012072600000) .
3. Remove the four bolts (2) and the oil pump (1).

Note. Apply Mopar® Thread Sealant with PTFE to the sensor threads before installing into the engine block.

1. Install the oil pressure sensor (1).
2. Connect the oil pressure sensor electrical connector (1).
3. Position the generator and install the upper mounting bolt finger tight.
4. Raise and support the vehicle.
5. Install the lower mounting bolts (1) and tighten to 55 N.m (41 ft. lbs).
6. Position the lower splash shield and install the retaining bolts (1).
7. Lower the vehicle
8. Tighten the upper generator mounting bolt to 55 N.m (41 ft. lbs). CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat.
9. Install the accessory drive belt. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-489282-S14236788572012072600000) .
10. Connect the negative battery cable.

Note. Apply Mopar® Thread Sealant with PTFE to the sensor threads before installing into the engine block.

1. Install the oil temperature sensor (1).
2. Connect the oil temperature sensor electrical connector (1).
3. Position the generator and install the upper mounting bolt finger tight.
4. Raise and support the vehicle.
5. Install the generator lower mounting bolts (1) and tighten to 55 N.m (41 ft. lbs.).
6. Position the lower splash shield and install the splash shield retaining bolts (1).
7. Lower the vehicle.
8. Tighten the generator upper mounting bolt to 55 N.m (41 ft. lbs.). CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat.
9. Install the accessory drive belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-489282-S33381563422012072600000) .
10. Connect the negative battery cable.

Note. Left side shown in illustration, right similar.

1. Prior to installation, make sure all gasket mating surfaces (1, 2) are clean and free of any debris.
2. Using a new exhaust manifold gasket, position the exhaust manifold to the cylinder head, align the gasket and start two upper retaining blots finger tight. Left side
3. Using the sequence shown in illustration, Install the exhaust manifold retaining bolts and tighten to 25 N.m (18 ft. lbs.). Right side
4. Using the sequence shown in illustration, install the exhaust manifold retaining bolts and tighten to 25 N.m (18 ft. lbs.).
5. Install the heat shields and tighten nuts to 8 N.m (70 in. lbs.).
6. Position the wire harness mounted onto the right hand inner fender panel and secure fasteners.
7. Install the Totally Integrated Power Module (TIPM) and mounting bracket. Refer to «MODULE, TOTALLY INTEGRATED POWER (TIPM), INSTALLATION»(ref-489283-S25475398282012072600000) .
8. Position the coolant bottle (1) and install the retaining bolts (2).
9. Raise and support the vehicle. CAUTION: Over or under tightening the knock sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. NOTE: Left side shown in illustration, right side similar.
10. Position knock sensor (1) onto the engine block. NOTE: The foam strip used on bolt threads is used only to retain the bolts to the sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.
11. Install knock sensor retaining bolt (2) and tighten to 20 N.m (15 ft. lbs.).
12. Connect knock sensor electrical connector (3).
13. Snap the heat shields onto knock sensor.
14. Install catalytic converters (4). Refer to «CONVERTER, CATALYTIC, INSTALLATION»(ref-489289-S11218508362012072600000) .
15. Connect the oxygen sensor electrical connectors (2).
16. Install both front engine mount mounting brackets and engine mounts (2). Refer to «INSULATOR, ENGINE MOUNT, FRONT, INSTALLATION, 5.7L»(ref-489305-S11766821292012072600000) and «INSULATOR, ENGINE MOUNT, REAR, INSTALLATION, 5.7L»(ref-489305-S39309744082012072600000) .
17. Lower the vehicle.
18. Position the air filter housing into the engine compartment.
19. Install the air filter housing retaining bolt (3) and tighten to 5 N.m (44 in. lbs.).
20. Connect the clean air tube to the throttle body and the air filter housing and tighten clamps to 3 N.m (30 in. lbs.).
21. Connect the make up air hose (MUA) (2).
22. Connect the intake air temperature (IAT) sensor (5) connector.
23. Position the engine cover (2) and secure the retaining grommets onto the ball studs.
24. Connect the negative battery cable and tighten nut (1) to 5 N.m (45 in. lbs.).
25. Start the engine and check for leaks.

Scheme 462

The intake manifold is made of a composite material with the runners tuned to give the best balance of power and torque. The manifold uses a single plane sealing system and separate PCV port seals to prevent leaks. The screws connecting the manifold to the head use a thread lock patch, and must be replaced when the manifold is serviced.

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. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (2).
4. Disconnect the fuel supply line. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-489307-S24042286862012072600000) .
5. Disconnect the intake air temperature (IAT) sensor (5) electrical connector.
6. Loosen the clamps at the throttle body and the air filter housing and remove the air tube (4).
7. Disconnect the make up air hose (MUA) (2).
8. Remove the air filter housing retaining bolt (3).
9. Remove the air filter housing from the vehicle.
10. Disconnect the brake booster hose and the EVAP purge line.
11. Disconnect the electrical connectors from the following components: Manifold Absolute Pressure (MAP) Sensor Fuel Injectors Electronic Throttle Control (ETC) NOTE: Remove the intake manifold and throttle body as an assembly.
12. Using the sequence shown in illustration, remove the intake manifold retaining bolts.
13. Remove the intake manifold and throttle body as an assembly from the vehicle.