5.7L Engine - Service Information: Overview Dodge Charger VI

DESCRIPTION

The 5.7L engine (345 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.

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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-481419-S30737879042012062200000) .
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-481419-S13873620252012062200000) . 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.

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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-481419-S08380116232012062200000) .
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-481419-S02823964902012062200000) .
18. Connect the negative battery cable.

The structural dust cover is made of die cast aluminum and joins the lower half of the transmission bell housing to the engine.

The structural cover provides additional powertrain stiffness and reduces noise and vibration.

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1. Raise and support the vehicle.
2. Remove the steering rack to frame mounting bolts (1) and lower the steering rack enough to gain clearance for the structural dust cover removal.
3. Remove the transmission mount to crossmember retaining nuts (1).
4. Using a suitable jack, lift the transmission enough to gain clearance for the structural dust cover removal.
5. Remove the structural dust cover retaining bolts (1, 3 & 4).
6. Remove the structural dust cover (2).

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.

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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.

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

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.

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

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1. Disconnect negative cable from battery.
2. Remove accessory drive belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-481395-S18804586092012062200000) .
3. Remove the cooling fan. Refer to «FAN, COOLING, REMOVAL»(ref-481395-S11663330002012062200000) .
4. Remove crankshaft damper bolt.
5. Install a flange puller (2) and remove the damper (1).

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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-481395-S03334955432012062200000) .
10. Install accessory drive belt (1). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-481395-S24360488082012062200000) .
11. Refill cooling system. Refer to «STANDARD PROCEDURE»(ref-481395-S18502976792012062200000) .
12. Connect negative cable to battery.

Scheme 390

1. Remove the transmission. Refer to «REMOVAL»(ref-481422-S25068061202012062200000) .
2. Using the sequence shown in illustration, remove the flexplate retaining bolts.
3. Remove the flexplate.

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.

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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-481421-S10151260592012062200000) .
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-481419-S00937879232012062200000) .
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-481419-S38833785482012062200000) and «PAN, OIL, AWD, REMOVAL, 5.7L»(ref-481419-S07907193462012062200000) .
18. Lower the vehicle.
19. Remove the timing chain cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL, 5.7L»(ref-481419-S42091112162012062200000) .
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-481419-S15108943952012062200000) .
2. Removal: Refer to «RETAINER, CRANKSHAFT REAR OIL SEAL, REMOVAL, 5.7L»(ref-481419-S21313387562012062200000) .
3. Installation: Refer to «RETAINER, CRANKSHAFT REAR OIL SEAL, INSTALLATION, 5.7L»(ref-481419-S05173862162012062200000) .

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.

An engine oil cooler is used on the 5.7L engine, equipped with the police package. The cooler is a coolant-to-oil type and mounted between the oil filter and oil filter adapter.

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-481395-S18804586092012062200000) .
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-481395-S18804586092012062200000) .
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).