3.5L Engine - Service Information: Removal & Installation Dodge Charger V

INSTALLATION

1. Install special tool # 8534B, engine lifting bracket (2) to the right rear of the cylinder head and install a bolt into the inner most bolt hole (5) next to the bracket (5). see scheme 20 1 - LIFTING CHAIN 2 - UPPER TIMING CHAIN COVER 3 - POWER STEERING PUMP 4 - THERMOSTAT HOUSING
2. Connect a engine hoisting chain (1) to the left timing chain cover (2) lifting point and the engine lifting bracket. see scheme 21 1 - ENGINE 2 - BOLTS 3 - TRANSMISSION CAUTION: Care must be taken when installing the engine to prevent pinching the power steering rack sensor with the left engine mount. Constantly check to assure proper positioning and no damage occurs to other components or harnesses until union is made. NOTE: As the engine is lowered into the engine bay area, install and hand tighten the A/C compressor bolt retaining the transmission cooler lines.
3. Carefully install the engine into the engine bay area and complete the union with the transmission.
4. Properly route the engine wiring harness behind the engine and tighten the accessible transmission bolts to 68N.m (50 ft.lbs.). see scheme 22 1 - FUEL RAIL 2 - IGNITION COIL 3 - CAPACITOR 4 - ENGINE WIRING HARNESS
5. Properly position the right engine harness (4) and connect the oxygen sensor, knock sensor, EGR, fuel injector and ignition coil harness connectors. see scheme 23
6. Connect the capacitor (3) and ground strap (3) to the right cylinder head cover.
7. Install the right intake manifold support braces. 1 - FUEL RAIL 2 - IGNITION COILS 3 - WIRING HARNESS 4 - LOWER INTAKE MANIFOLD
8. Properly position the left engine harness (3) and connect the ignition coil (2) and fuel injector harness connectors. see scheme 24
9. Connect the coolant temperature, cam position, oil pressure sensor harness connectors.
10. Connect the oxygen sensor and the ground wire, to the left cylinder head cover. 1 - COOLANT PIPE 2 - HEATER HOSE 3 - COOLANT RESERVOIR HOSE
11. Connect the heater hose (2) and coolant reservoir hose (3) to the rear coolant pipe (1). see scheme 25
12. Install the upper intake manifold. «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION)»(ref-255939-S07530029082007060500000).
13. Connect the upper radiator hose. 1 - ENGINE 2 - BOLTS 3 - TRANSMISSION
14. Raise and support the vehicle.
15. Install the engine mounting nuts and tighten to 101 N.m (75 lbs.ft.).
16. Install the remaining transmission housing bolts and tighten to 68 N.m (50 ft.lbs.). see scheme 26 1 - OIL PAN 2 - FLYWHEEL 3 - BOLT 4 - CRADLE
17. Install the torque converter bolts (3). Tighten bolts to 75 N.m (55 lbs.ft.). see scheme 27
18. Install the torque converter inspection cover. Tighten bolts to 12 N.m (105 lbs. in.) 1 - EXHAUST UNION 2 - HO2S - #2
19. Connect the right exhaust pipe to the exhaust manifold (1) and connect the oxygen sensor (2). see scheme 28 1 - LEFT FRONT DRIVE AXLE 2 - INTERMEDIATE SHAFT 3 - OIL PAN 4 - FRONT DRIVE AXLE HOUSING
20. Install the front drive axle housing and front axle shafts (if equipped with AWD). see scheme 29 1 - HO2S #1 2 - EXHAUST UNION 3 - HO2S-#2
21. Connect the left exhaust pipe to the exhaust manifold (2) and connect the oxygen sensor (3). see scheme 30
22. Install the crankshaft position sensor. «(Refer to FUEL SYSTEM/FUEL INJECTION/CRANKSHAFT POSITION SENSOR - INSTALLATION)»(ref-255958-S32627074532007060500000). 1 - NEGATIVE BATTERY CABLE 2 - NEGATIVE BATTERY CABLE 3 - BLOCK HEATER HARNESS 4 - ENGINE BLOCK HEATER
23. Connect the engine block heater (4) (if equipped). see scheme 31
24. Connect the ground strap (3) at the right transmission housing. 1 - UPPER RADIATOR HOSE 2 - LOWER RADIATOR HOSE 3 - ENGINE OIL COOLER 4 - COOLANT MODULE
25. Tighten the transmission line bracket at the A/C compressor.
26. Connect the oil cooler hose at the cooler (3) and secure the cooler hose retainer at the transmission. see scheme 32
27. Connect the lower radiator hose (2).
28. Install the starter and spacer plate. «(Refer to ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION)»(ref-255957-S19227345842007060500000). 1 - STEERING COUPLER 2 - CRADLE 3 - STEERING GEAR 4 - BOLT
29. Align and connect the steering column coupler (1) to the steering gear (3). see scheme 33
30. Connect the generator electrical connectors. «(Refer to ELECTRICAL/CHARGING/GENERATOR - INSTALLATION)»(ref-255999-S38906024492007060500000).
31. Install new oil filter.
32. Install the lower engine close out panel.
33. Lower the vehicle.
34. Fill the cooling system to the proper level using the appropriate coolant. Refer to «STANDARD PROCEDURE»(ref-255951-S06865140152007060500000).
35. Fill engine crankcase with proper oil to correct level. «(Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - SPECIFICATIONS)»(ref-255933-S29420419112007060500000).
36. Evacuate and recharge air conditioning.
37. Install the windshield wiper cowl assembly.
38. Install the hood.
39. Connect the negative battery cable.
40. Start engine and run until operating temperature is reached and radiator fans cycle.
41. Check all fluid levels and properly fill.

CYLINDER BLOCK

PISTONS

PISTON PINS

PISTON RINGS

PISTON RING SIDE CLEARANCE

PISTON RING WIDTH

CONNECTING RODS

CRANKSHAFT MAIN BEARING JOURNALS

CONNECTING ROD JOURNALS

CAMSHAFT

VALVE TIMING-INTAKE VALVE

VALVE TIMING-EXHAUST VALVE

CYLINDER HEAD

VALVES

VALVE SPRINGS

OIL PUMP

OIL PRESSURE

1. Install the air filter element (2) into air box. see scheme 63
2. Position the cover (1) so that the rear locking tabs insert into the lower housing.
3. Seat cover (1) onto element housing and assure that the front locking tabs engage.
4. Reconnect the CCV hose (3).

Scheme 250

1. Separate the air inlet duct (5) at the element housing (6).
2. Disconnect the CCV hose (2) at the element housing (6).
3. Remove the housing retaining bolt (1).
4. Pull housing up and off of the locating pin.
5. Remove element housing (6) from vehicle. (Scheme 250)

1. Align the housing (6) with the lower air inlet duct and alignment grommet in the wheel housing.
2. Properly fit the housing (6) and install housing retaining bolt (1). see scheme 65
3. Connect the inlet air duct (5) to the housing (6) and tighten clamp.
4. Connect the CCV hose (2) to housing.

Note. Care must be taken not to scrape or nick the camshaft journals when installing the camshaft into position.

1. Lubricate camshaft (3) bearing journals, camshaft lobes and camshaft seal (4) with clean engine oil and install camshaft (3) into cylinder head. see scheme 126
2. Install the cylinder head. «(Refer to ENGINE/CYLINDER HEAD - INSTALLATION)»(ref-255939-S14735011792007060500000).

REMOVAL

Scheme 251

1. Disconnect and isolate the negative battery cable.
2. Remove the upper intake manifold from the engine. «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(ref-255939-S28469798812007060500000).
3. Cover lower intake manifold (4) with a suitable cover during service.
4. Disconnect and remove the three ignition coils (2). see scheme 127
5. Remove the ground strap/resistor retaining bolt from the cylinder head cover.
6. Lift up on the wire harness track (3) retaining tabs. see scheme 127 1 - CYLINDER HEAD COVER-LEFT SIDE 2 - BOLTS (8)
7. Completely loosen the cylinder head cover retaining bolts and remove the cylinder head cover. (Scheme 251)

Scheme 252

Scheme 253

1. Clean cylinder head and cover mating surfaces. Inspect and replace gasket (1) and seals (2) as necessary. (Scheme 252) 1 - SPECIAL TOOL MD-998306 2 - SPARK PLUG TUBE SEAL
2. To replace spark plug tube seals (2): Using a suitable pry tool, carefully remove tube seals (2). Position new seal (2) with the part number on seal facing cylinder head cover. Install seals using MD-998306 (1). (Scheme 253) 1 - CYLINDER HEAD COVER-LEFT SIDE 2 - BOLTS (8)
3. Install cylinder head cover (1) and bolts (2). Tighten to 12 N.m (105 in. lbs.). 1 - FUEL RAIL 2 - IGNITION COILS 3 - WIRING HARNESS 4 - LOWER INTAKE MANIFOLD
4. Position the wiring harness (3) on the cylinder head cover.
5. Reclip the wire harness track retaining tabs into the cover.
6. Install the ground strap/resistor retaining bolt onto the cylinder head cover.
7. Install the ignition coils (2). Tighten mounting screws to 6.7 N.m (60 in. lbs.)
8. Connect the ignition coil electrical connectors (2).
9. Install upper intake manifold. «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION)»(ref-255939-S07530029082007060500000).
10. Connect negative battery cable.

1. Disconnect the negative battery cable.
2. Remove the upper intake manifold. «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(ref-255939-S28469798812007060500000) .
3. Cover lower intake manifold openings during service.
4. Disconnect and remove the three ignition coils (2).
5. Lift up on the wire harness track retaining tabs (4).
6. Remove the ground strap retaining bolt (3) from the cylinder head cover.
7. Completely loosen the cylinder head cover retaining bolts and remove the cylinder head cover.

Scheme 254

Scheme 255

1. Clean cylinder head and cover mating surfaces. Inspect and replace gasket (1) and seals (2) as necessary. (Scheme 254) 1 - SPECIAL TOOL MD-998306 2 - SPARK PLUG TUBE SEAL
2. To replace spark plug tube seals (2): Using a suitable pry tool, carefully remove tube seals (2). Position new seal (2) with the part number on seal facing cylinder head cover. Install seals using MD-99830 (1). (Scheme 255) 1 - FUEL RAIL 2 - IGNITION COIL 3 - CAPACITOR 4 - ENGINE WIRING HARNESS
3. Install cylinder head cover bolts and tighten to 12 N.m (105 in. lbs.).
4. Install the ground strap retaining bolt (3) to the cylinder head cover.
5. Install the wire harness track (4).
6. Install the ignition coils (2). Tighten mounting screws to 6.7 N.m (60 in. lbs.). see scheme 136
7. Connect the ignition coil electrical connectors (2). see scheme 136
8. Install upper intake manifold. «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION)»(ref-255939-S07530029082007060500000).
9. Connect negative battery cable

1. Remove cylinder head(s). «(Refer to ENGINE/CYLINDER HEAD - REMOVAL)»(ref-255939-S07164512862007060500000) .
2. Remove rocker arm assembly. «(Refer to ENGINE/CYLINDER HEAD/ROCKER ARM/ADJUSTER ASSY - REMOVAL)»(ref-255939-S10422363042007060500000) .
3. Remove valve spring(s). «(Refer to ENGINE/CYLINDER HEAD/VALVE SPRINGS - REMOVAL)»(ref-255939-S07267332462007060500000) .
4. Before removing valve, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location.
5. Remove valve(s) from cylinder head.

Note. Rocker arm and shaft assembly can be installed either prior to or after (preferred) cylinder head installation.

Scheme 256

1. Rotate camshaft gears to the position shown in (1,8,9). see scheme 154 With the camshaft gears in these positions the lobes are in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it.
2. Install the rocker arm and shaft assembly making sure that the identification marks face toward the front of engine for left head and toward the rear of the engine for right head.
3. Tighten rocker arm/shaft assembly bolts in sequence to 31 N.m (275 in. lbs.). (Scheme 256)
4. Install cylinder head covers. Refer to appropriate cylinder head cover installation procedure.

Scheme 257

1. Remove cylinder head cover(s). Refer to appropriate cylinder head cover.
2. Using suitable locking pliers, remove the tube from the cylinder head and discard tube. (Scheme 257)
3. Clean area around spark plug with Mopar® Parts Cleaner or equivalent.

1. Apply Mopar® Stud and Bearing Mount to a new tube (1) approximately 1 mm (0.039 in.) from the end of tube, in a 3 mm (0.118 in.) wide area. see scheme 157
2. Install sealer end of tube (1) into the cylinder head. Then carefully install the tube (1) using a hardwood block and mallet. Install the tube (1) until it is seated into the bottom of the bore.
3. For spark plug tube (1) seal replacement, refer to appropriate cylinder head cover removal procedure.
4. Install cylinder head cover(s). Refer to appropriate cylinder head cover installation procedure.

Scheme 258

1. Remove valve spring. «(Refer to ENGINE/CYLINDER HEAD/VALVE SPRINGS - REMOVAL)»(ref-255939-S07267332462007060500000).
2. Remove valve stem seals by using a valve stem seal tool. (Scheme 258)

Scheme 259

1. The valve stem seal/valve spring seat should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. CAUTION: Do not remove garter spring (2) around the seal at the top of the valve stem seal. (Scheme 259)
2. Install valve spring. «(Refer to ENGINE/CYLINDER HEAD/VALVE SPRINGS - INSTALLATION)»(ref-255939-S14986772502007060500000).

Scheme 260

The valve springs are made from chrome silicon alloy wire and incorporate a "bee-hive" design. Valve spring retainers and locks are common from valve-to-valve. The valve spring seat is integral with the valve stem oil seal, which incorporates a garter spring to maintain consistent lubrication control to the valve stem.

The valve springs are unique for intake compared to exhaust. Both have different lengths and are wound in opposite directions. The valve springs are color coded, intake spring is right hand coil direction with orange dye on the top coils and the exhaust spring is left hand coil direction with a yellow or white dye on the top coils. (Scheme 260)

The exhaust spring with the white dye on the top of the coils has an increased open and closed load when compared to the exhaust spring with the yellow dye. A yellow and a white exhaust valve spring should never be used on a single forked rocker arm. Color coated exhaust springs should always be used in pairs for a forked exhaust rocker springs.

1. Position flex plate (1) with backing plate (3) on the crankshaft. see scheme 198
2. Apply Mopar® Lock & Seal Adhesive to the flex plate bolts (2).
3. Install flex plate bolts (2). see scheme 198 Tighten bolts to 95 N.m (70 ft. lbs.).
4. Install the transmission.

Scheme 261

1. Remove the cylinder heads. «(Refer to ENGINE/CYLINDER HEAD - REMOVAL)»(ref-255939-S07164512862007060500000).
2. Remove the oil pan. «(Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)»(ref-255939-S18379511772007060500000).
3. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore. CAUTION: DO NOT stamp the connecting rods for cylinder identification
4. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them with a paint mark or scribe, if necessary. see scheme 200
5. Remove connecting rod cap. Install protectors, tool 8189, on connecting rod. (Scheme 261) Guide each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals.
6. After removal, install bearing cap on the mating rod.

Scheme 262

Scheme 263

Scheme 264

Scheme 265

1. Install the piston rings. «(Refer to ENGINE/ENGINE BLOCK/PISTON RINGS - INSTALLATION)»(ref-255939-S07277418302007060500000). NOTE: The connecting rod bearing cap bolts must be examined before reuse. If the threads are necked down, the bolts must be replaced.
2. Check connecting rod bolts for necking by holding a scale or straight edge against the threads. If all threads do not contact the scale, the bolt must be replaced. (Scheme 262) 1 - SIDE RAIL UPPER 2 - NO. 1 RING GAP 3 - PISTON PIN 4 - SIDE RAIL LOWER 5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
3. Before installing pistons and connecting rod assemblies into the bore, ensure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. (Scheme 263)
4. Immerse the piston head and rings in clean engine oil, slide the ring compressor over the piston and tighten with the special wrench. see scheme 204 Ensure position of rings does not change during this operation.
5. Install connecting rod bolt protectors, special tool # 8189. see scheme 204
6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert the rod and piston into cylinder bore and guide the rod over the crankshaft journal. CAUTION: Do Not interchange piston assemblies cylinder-to-cylinder or bank-to-bank. 1 - ARROW FACES FRONT OF ENGINE
7. The arrow on top of piston must be pointing toward front of engine. (Scheme 264)1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SQUIRT HOLE CAUTION: View of connecting rod oil squirt hole is from the front of the engine.
8. The oil squirt hole on connecting rod faces the major thrust side of the cylinder bore. (Scheme 265) NOTE: Make sure the rod bearings are seated with the oil squirt hole aligned.
9. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. NOTE: Connecting rod bolts must be lubricated with clean engine oil.
10. Install the rod caps. Install cleaned and inspected connecting rod bolts and tighten to 27 N.m (20 ft. lbs.) Plus 1/4 turn.
11. Install the cylinder head(s). «(Refer to ENGINE/CYLINDER HEAD - INSTALLATION)»(ref-255939-S14735011792007060500000).
12. Install the oil pan. «(Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION.)»(ref-255939-S39231486172007060500000).

Scheme 266

The piston rings include a moly-filled top ring with a symmetric barrel face. The intermediate piston ring is of the standard chrome design OR Micro-Napier design. The Micro-Napier design has a reduced "hook" on the running face, removes the need for chroming and improves oil economy. The oil control package consists of two steel rails and an expander spacer. (Scheme 266)

Scheme 267

Scheme 268

1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 in.) from bottom of cylinder bore. Check gap with feeler gauge. (Scheme 267) For clearance specifications, «(Refer to ENGINE - SPECIFICATIONS)»(ref-255939-S42856702052007060500000). 1 - FEELER GAUGE
2. Check piston ring to groove clearance. (Scheme 268) For clearance specifications, «(Refer to ENGINE - SPECIFICATIONS)»(ref-255939-S42856702052007060500000).

Scheme 269

Scheme 270

1. Remove piston and connecting rod. «(Refer to ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD - REMOVAL)»(ref-255939-S38972879092007060500000).
2. Remove No. 1 and No. 2 piston rings from piston using a ring expander tool. (Scheme 269) 1 - TOP PISTON RING 2 - CHROME INTERMEDIATE PISTON RING 3 - MICRO-NAPIER INTERMEDIATE PISTON RING 4 - OIL CONTROL RINGS 5 - SPACER
3. Remove upper oil control ring side rail. (Scheme 270)
4. Remove lower oil control ring side rail. (Scheme 270)
5. Remove oil control ring expander. (Scheme 270)

Scheme 271

Scheme 272

1. Measure clearance of piston rings to the cylinder bore and piston. «(Refer to ENGINE/ENGINE BLOCK/PISTON RINGS - STANDARD PROCEDURE)»(ref-255939-S35177927812007060500000). The No. 1 and No. 2 piston rings have a different cross section. see scheme 212 Insure that which ever design No. 2 ring is installed, it is installed with manufacturers I.D. mark (dot) facing up, towards top of the piston «(Refer to ENGINE/ENGINE BLOCK/PISTON RINGS - DESCRIPTION)»(ref-255939-S07720948182007060500000). see scheme 212 1 - SIDE RAIL END CAUTION: Install piston rings in the following order: Oil ring expander. Lower oil control ring side rail. Upper oil control ring side rail. No. 2 Intermediate piston ring. No. 1 Upper piston ring.
2. Install the side rail by placing one end between the piston ring groove and the spacer. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander tool during this step. (Scheme 271)
3. Install lower side rail first and then the upper side rail. The No. 1 and No. 2 piston rings have a different cross section. see scheme 214 Insure that which ever design No. 2 ring is installed, it is installed with manufacturers I.D. mark (dot) facing up, towards top of the piston «(Refer to ENGINE/ENGINE BLOCK/PISTON RINGS - DESCRIPTION)»(ref-255939-S07720948182007060500000).
4. Install No. 2 piston ring and then No. 1 piston ring. see scheme 214 1 - SIDE RAIL UPPER 2 - NO. 1 RING GAP 3 - PISTON PIN 4 - SIDE RAIL LOWER 5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
5. Position piston ring end gaps (Scheme 272)
6. Position oil control ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control.

Scheme 273

1. Disconnect negative battery cable.
2. Remove the accessory drive belt. «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)»(ref-255951-S25277980112007060500000).
3. Raise vehicle on hoist. 1 - SPECIAL TOOL 1023 PULLER 2 - SPECIAL TOOL 9020-R INSERT
4. Remove crankshaft damper bolt.
5. Use 1023 puller and insert 9020-R, remove crankshaft damper. (Scheme 273)

Scheme 274

Scheme 275

1. Install crankshaft damper using Special Tools C-4685-C1 (5.9 in.) Bolt, with Nut and Thrust Bearing from 6792 and 6792-1 Installer. (Scheme 274)
2. Install crankshaft damper bolt. Torque bolt to 95 N.m (70 ft. lbs.) while holding damper with Special Tool 9365.
3. Lower vehicle. 1 - DRIVE BELT TENSIONER 2 - POWER STEERING PULLEY 3 - AIR CONDITIONING COMPRESSOR 4 - CRANKSHAFT DAMPER 5 - GENERATOR 6 - DRIVE BELT
4. Install accessory drive belt. see scheme 220
5. Connect negative battery cable.

1. Install the left mount (2) to the engine mounting bracket. see scheme 223 Hand tighten fasteners.
2. Install and hand tighten the engine mount through studs.
3. Tighten the engine mount to mounting bracket fasteners to 75 N.m (55 ft.lbs.).
4. Lower the engine and remove lifting device.
5. Tighten the engine mount through studs to nut to 12 N.m (106 in. lbs.). 1 - LEFT ENGINE MOUNT 2 - HEAT SHIELD 3 - BOLT
6. Install the engine mount heat shield (2). see scheme 224 Tighten fasteners to 11 N.m (97 in. lbs.).
7. Install the left engine mount to cradle nuts and tighten both to 75 N.m (55 ft. lbs.).
8. Lower the vehicle.
9. Connect the negative battery cable.

Scheme 276

1. Disconnect the negative battery cable.
2. Raise and support the vehicle.
3. Remove the left front wheel.
4. Remove the left engine mount to cradle fastener.
5. Place a jack stand under the engine and support the engine weight.
6. Remove the engine mount fasteners and remove the mount. (Scheme 276)

Scheme 277

1. Carefully position the engine mount and hand tighten the mount retaining bolts. (Scheme 277)
2. Tighten the engine mount to bracket bolts to 60 N.m (44 lbs. ft.).
3. Lower the engine onto the cradle and remove the jack stand.
4. Tighten the engine mount to cradle bolt to 75 N.m (55 lbs. ft.).
5. Install the right front wheel.
6. Lower the vehicle.
7. Connect the negative battery cable.

Scheme 278

Scheme 279

1. Disconnect the negative battery cable.
2. Raise and support the vehicle.
3. Remove both of the engine mount to cradle nuts.
4. Remove both of the engine mount through studs.
5. Using a suitable jack stand and a block of wood positioned under the oil pan, raise the engine until the weight is off of the mounts (approximately 5 mm.).
6. Remove the right mount heat shield (2) bolts. (Scheme 278) 1 - BOLT 2 - RIGHT ENGINE MOUNT
7. Remove the engine mount (2). (Scheme 279)

1. Install the engine mount to the engine bracket and hand tighten. see scheme 229 Tighten bolts to 54 N.m (40 lbs. ft.).
2. Install and hand tighten the engine mount through studs.
3. Tighten the engine mount to engine bracket fasteners to 75 N.m (55 lbs. ft.). 1 - BOLT 2 - SHIELD 3 - RIGHT ENGINE MOUNT
4. Install the engine mount heat shield (2). see scheme 230 Tighten the fasteners to 11 N.m (97 in. lbs.).
5. Lower the engine and remove the lifting devise.
6. Tighten the engine mount through studs to 12 N.m (106 in. lbs.).
7. Install the right engine mount to cradle nuts and tighten both engine mount fasteners to 75 N.m (55 lbs. ft.).
8. Lower the vehicle.
9. Connect the negative battery cable.

1. Disconnect the negative battery cable.
2. Raise and support the vehicle.
3. Remove the right front wheel.
4. Place a jack stand under the engine.
5. Remove the engine mount to cradle fastener.
6. Raise the engine with the jack stand and support the engine weight.
7. Remove the engine mount bolts and the engine mount. see scheme 231

1. Carefully position the engine mount and hand tighten the mount retaining bolts. (Scheme 277)
2. Tighten the engine mount to bracket bolts to 60 N.m (44 lbs. ft.).
3. Lower the engine onto the cradle and remove the jack stand.
4. Tighten the engine mount to cradle bolt to 75 N.m (55 lbs. ft.).
5. Install the right front wheel.
6. Lower the vehicle.
7. Connect the negative battery cable.

Scheme 280

Scheme 281

1. Raise vehicle on hoist.
2. Remove cross member to mount bolts (2).
3. Place transmission jack under transmission pan and raise transmission.
4. Remove cross member attaching bolts and remove cross member (1).
5. Remove mount to transmission bolts (2), remove mount (1).

Scheme 282

Scheme 283

1. Install mount to transmission bolts (2) and tighten to 47 N.m (35 ft.lbs.).
2. Install cross member (1) and attaching bolts. Tighten bolts to 68 N.m (50 ft.lbs.).
3. Lower transmission so cross member to mount bolts (2) can be started tightened by hand.
4. Lower transmission and remove jack.
5. Tighten mount bolts (2) to 47 N.m (39 ft.lbs.).

Scheme 284

The oil lubrication system is a full-flow filtration, pressure feed type. The oil pump body is mounted to the engine block. The pump inner rotor is driven by the crankshaft. A windage tray, increases power by minimizing oil windage at high engine RPM. For increased oil cooling, an oil pan mounted, oil-to-coolant oil cooler is used. (Scheme 284)

1. Drain cooling system. (Refer to «STANDARD PROCEDURE»(ref-255951-S06865140152007060500000).
2. Raise vehicle on hoist.
3. Disconnect coolant hoses (2) from oil cooler (1). see scheme 245
4. Remove oil filter (3).
5. Remove oil cooler attaching fastener from center of oil cooler (1).
6. Remove oil cooler (1). see scheme 245

1. Position oil cooler to fitting on oil pan. see scheme 246 NOTE: Remove all oil and debris from the seal retainer surface. The cut out section of the oil cooler seal retainer flange (top), must be aligned with the tab on the oil pan. The oil cooler must be prevented from turning during the tightening sequence.
2. Install oil cooler (1) attaching fastener and tighten to 61 N.m (45 ft. lbs.).
3. Install oil filter (3) and tighten to 12 N.m (106 in. lbs.).
4. Connect coolant hoses to oil cooler (2).
5. Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-255951-S06865140152007060500000).

Note. When servicing the oil filter, avoid deforming the filter can. Install the remove/install tool band strap against the base lock seam. The lock seam joining the can to the base is reinforced by the base plate.

1. Using a suitable oil filter wrench, unscrew filter (3) from base and discard. see scheme 247

1. Wipe base clean, then inspect gasket contact surface.
2. Lubricate gasket of new filter (2) with clean engine oil. see scheme 248
3. Install and tighten filter to 12 N.m (106 in. lbs.) of torque after gasket contacts base. Use filter wrench if necessary.
4. Start engine and check for leaks.

1. Raise vehicle on hoist.
2. Position an oil collecting container under switch location.
3. Disconnect electrical connector.
4. Unscrew oil pressure switch (1). see scheme 274

1. Apply Mopar® Thread Sealant to the switch (1) threads.
2. Install oil pressure switch (1) to fitting. see scheme 275
3. Connect electrical connector.
4. Lower vehicle.
5. Start engine and check for leaks.
6. Check engine oil level and adjust as necessary.

Scheme 285

Scheme 286

Scheme 287

1. Drain the cooling system. «(Refer to COOLING - STANDARD PROCEDURE)»(ref-255951-S06865140152007060500000).
2. Remove the timing belt. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)»(ref-255939-S27602755362007060500000).
3. Remove the crankshaft sprocket. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)»(ref-255939-S27602755362007060500000).
4. Remove the oil pan. «(Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)»(ref-255939-S18379511772007060500000). 1 - OIL PICK UP TUBE WITH STRAINER 2 - BOLT 3 - O-RING 4 - OIL PUMP 5 - WINDAGE TRAY
5. Remove the oil pickup tube. (Scheme 286) 1 - CRANKSHAFT 2 - DOWEL 3 - GASKET 4 - OIL PUMP 5 - FRONT CRANKSHAFT SEAL 6 - CRANKSHAFT GEAR 7 - PIN
6. Remove the oil pump fasteners. Remove the oil pump and gasket from engine. (Scheme 287)

Scheme 288

1. Remove oil pump cover screws (3) and lift off cover (4). (Scheme 288)
2. Remove pump rotors (2, 5).
3. Wash all parts in a suitable solvent and inspect carefully for damage or wear.

1. Prime oil pump (4) before installation by filling rotor cavity with clean engine oil.
2. Install oil pump (4) and gasket (3) carefully over the crankshaft. Position pump onto block and tighten bolts to 28 N.m (250 in. lbs.). 1 - OIL PICK UP TUBE WITH STRAINER 2 - BOLT 3 - O-RING 4 - OIL PUMP 5 - WINDAGE TRAY
3. Install new O-ring (3) on oil pickup tube (1).
4. Install oil pickup tube (1).
5. Install oil pan. «(Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)»(ref-255939-S39231486172007060500000).
6. Install crankshaft sprocket. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(ref-255939-S08223727072007060500000).
7. Install timing belt. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(ref-255939-S08223727072007060500000).
8. Install the timing belt covers. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - INSTALLATION)»(ref-255939-S33254766262007060500000) 1 - DRIVE BELT TENSIONER 2 - POWER STEERING PULLEY 3 - AIR CONDITIONING COMPRESSOR 4 - CRANKSHAFT DAMPER 5 - GENERATOR 6 - DRIVE BELT
9. Install the crankshaft vibration damper (4). «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION)»(ref-255939-S40071277972007060500000).
10. Install the accessory drive belt (6). see scheme 289 «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)»(ref-255951-S41616851582007060500000).
11. Fill the cooling system. «(Refer to COOLING - STANDARD PROCEDURE)»(ref-255951-S06865140152007060500000).
12. Fill engine crankcase with proper oil to the correct level.

Scheme 289

Scheme 290

Scheme 291

Scheme 292

Scheme 293

1. Disconnect negative battery cable.
2. Disconnect the IAT sensor electrical connector.
3. Remove air inlet hose from the throttle body. (Scheme 289)
4. Disconnect the MAP sensor electrical connector. 1 - PCV HOSE 2 - PURGE HOSE 3 - BRAKE BOOSTER HOSE 4 - THROTTLE BRACKET 5 - ELECTRONIC THROTTLE CONTROL
5. Separate the engine electrical harness connectors from the intake manifold.
6. Disconnect the EGR tube, PCV, Purge and power brake booster vacuum hoses from the upper intake manifold.
7. Disconnect the electronic throttle control electrical connector.
8. Remove the throttle bracket (4) fasteners from the throttle body and cylinder head. 1 - Manifold Tuning Valve 2 - Short Runner Valve
9. Disconnect electrical connectors from the Manifold Tuning Valve (MTV) and Short Runner Valve. 1 - INTAKE MANIFOLD 2 - PENCIL BRACKETS
10. Remove the right intake manifold support brackets.
11. Remove the upper intake manifold retaining bolts, insulation foam pad and manifold. Clean all gasket sealing surfaces.

Scheme 294

Scheme 295

1. Perform fuel pressure release procedure. Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE»(ref-255958-S23317207382007060500000).
2. Drain the cooling system. «STANDARD PROCEDURE»(ref-255951-S06865140152007060500000).
3. Disconnect the upper radiator hose from the thermostat housing.
4. Remove the upper intake manifold. «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(ref-255939-S28469798812007060500000).
5. Reposition power steering fluid reservoir and bracket.
6. Disconnect the electrical connectors to fuel injectors and coolant temperature sensor. 1 - COOLANT PIPE 2 - HEATER HOSE 3 - COOLANT RESERVOIR HOSE
7. Disconnect heater hose from the rear intake manifold. see scheme 296
8. Disconnect the coolant container hose at the rear intake manifold. see scheme 296 1 - FUEL RAIL 2 - IGNITION COIL 3 - LOWER INTAKE MANIFOLD 4 - PCV VALVE
9. Disconnect the fuel supply hose from fuel rail. (Scheme 295) «(Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL LINES - STANDARD PROCEDURE)»(ref-255958-S21423720822007060500000).
10. Remove the bolts attaching fuel rail.
11. Remove fuel rail and injectors as an assembly.
12. Remove bolts attaching lower intake and remove intake manifold. (Scheme 294)

1. Exchange the accessory drive belt pulley if necessary. Tighten bolt to 61 N.m (45 ft.lbs.).
2. Install upper front timing belt cover. see scheme 318
3. Install lower timing belt front cover. see scheme 318
4. Tighten the timing cover bolts as follows: M6 bolts - 12N.m (105 in. lbs.) M8 bolts - 28N.m (250 in. lbs.) M10 bolts - 54N.m (40 lbs. ft.)
5. Install power steering pump fasteners. Tighten bolts to 23 N.m (200 lbs. in.).
6. Install crankshaft damper. «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION)»(ref-255939-S40071277972007060500000).
7. Install accessory drive belt tensioner. «(Refer to COOLING/ACCESSORY DRIVE/BELT TENSIONERS - INSTALLATION)»(ref-255951-S34083079772007060500000). Torque fastener to 28 N.m (250 in. lbs.).
8. Install accessory drive belt. «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)»(ref-255951-S41616851582007060500000).
9. Lower vehicle.
10. Connect negative battery cable.

Scheme 296

Note. The rear timing belt cover has O-rings to seal the water pump passages to cylinder block. Do not reuse the O-rings.

1. Perform fuel pressure release procedure. Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE»(ref-255958-S23317207382007060500000).
2. Disconnect the negative battery cable.
3. Remove timing belt. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)»(ref-255939-S27602755362007060500000).
4. Remove camshaft sprockets. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)»(ref-255939-S27602755362007060500000).
5. Remove rear timing belt cover bolts (1, 2, 3). (Scheme 296)
6. Remove the rear cover.

Scheme 297

1. Clean rear timing belt cover O-ring (1) sealing surfaces and grooves. Lubricate new O-rings with Mopar® Dielectric Grease or equivalent to facilitate assembly. (Scheme 297)
2. Position NEW O-rings on cover (2). 1 - M8 FASTENERS (APPLY THREAD SEALANT) 2 - M10 FASTENERS 3 - M6 FASTENERS 4 - M10 FASTENERS (STUD/NUT)
3. Install rear timing belt cover (4). see scheme 321 Tighten bolts to the following specified torque: M10 (2, 5) - 54 N.m (40 ft. lbs.) M8 (1) - 28 N.m (20 ft. lbs.) M6 (3) - 12 N.m (105 in. lbs.)
4. Install camshaft sprockets. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(ref-255939-S08223727072007060500000).
5. Install timing belt. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(ref-255939-S08223727072007060500000).