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INSTALLATION Dodge Dart PF

2.4L Engine - Service Information: Removal & Installation 53 illustrations ~6692 words

INSTALLATION

CAUTIONIf the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.

Scheme 614

Scheme 614
Scheme 614
  1. Attach the transmission to the engine. Refer to «INSTALLATION»(ref-646222-S24966917122014072800000) .
  2. With the engine and the transmission bolted together and on the engine cradle, slowly and carefully lower the vehicle down to a point that the engine assembly can be verified that it is in the proper alignment with the engine bay. NOTE: An assistant may be needed to help align the assembly.
  3. Slowly lower engine assembly in to position.
  4. Install the right engine mount. Refer to «INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION»(ref-646217-S05475237812014072800000) .
  5. Install the left engine mount. Refer to «INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION»(ref-646217-S05475237812014072800000) .
  6. Remove the Engine Support Cradle straps and remove the cradle from below the engine/transmission assembly.
  7. Connect the shifter cables to the transmission. Refer to «CABLE, GEARSHIFT CONTROL, INSTALLATION»(ref-646222-S17760027552014072800000) .
  8. Connect the AC lines at the compressor. Refer to «LINE, A/C DISCHARGE, INSTALLATION»(ref-646220-S03179606782014072800000) .
  9. Connect the heater hose quick connects at the heater core inlet and outlet tubes.
  10. Install the exhaust manifold assembly. Refer to «MANIFOLD, EXHAUST, INSTALLATION»(ref-646217-S20689673422014072800000) .
  11. Connect the hydraulic supply pipe (1) for the concentric slave cylinder (2). Refer to «CYLINDER, CLUTCH SLAVE, INSTALLATION»(ref-646231-S21266678342014072800000) .
  12. Connect the gear shift selector cables (1) at the manual levers (2).
  13. Install the bolt holding the ground strap to left frame rail. Tighten the bolt to 9 N.m (80 in. lbs.).
  14. Attach the hot bottle hose (2) quick connect to the thermostat housing. Install the bolts (1). Tighten the bolts to 9 N.m (80 in. lbs.).
  15. Raise and support the vehicle.
  16. Connect the reverse lamp sensor (1).
  17. Install the ground cable (2) to the transaxle (1). Install the bolt and tighten to 24 N.m (18 ft. lbs.).
  18. Install the exhaust crossunder pipe with new flange gaskets.
  19. Install the intermediate shaft bracket bolts. Tighten bolts to 65 N.m (48 ft. lbs.)
  20. Reposition the engine forward to allow the mount to be inserted into the pocket past the engine bracket (3).
  21. Install the rear engine mount to crossmember through bolt (1). Tighten the bolt to 87 N.m (64 ft. lbs)
  22. Install the rear engine mount to engine bracket (3) through bolt (4) and nut (2). Tighten the bolt to 87 N.m (64 ft. lbs)
  23. Install new oil filter.
  24. Install the front fascia beams (1).
  25. Install the fasteners (2) securing the lower bumper reinforcement (1) to the frame/front end module. Tighten the fasteners to 45 N.m (33 ft. lbs.).
  26. Install the crossmember to fascia support beam bracket and install the four retaining bolts (1) and tighten to 95 N.m (70 ft. lbs.).
  27. Insert the lower ball joint into the knuckle and install the pinch bolt and nut and tighten to 70 N.m (52 ft. lbs.).
  28. Install the radiator. Refer to «RADIATOR, ENGINE COOLING, INSTALLATION»(ref-646235-S26734770022014072800000) .
  29. Install accessory drive belt.
  30. Install the coolant crossover pipe. Install bolts, tighten to 9 N.m (80 in. lbs.)
  31. Install the hoses at the crossover tube.
  32. Install the upper radiator hose.
  33. Fill with coolant. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
  34. Install the front closeout panel.
  35. Install the bellypan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
  36. Install the left and right wheel well liners
  37. Install the left and right axle shafts. Refer to «INSTALLATION»(ref-646219-S37404040972014072800000) .
  38. Install the front wheel and tire assemblies.
  39. Lower the vehicle.
  40. Install the radiator fan assembly. Refer to «FAN, COOLING, INSTALLATION»(ref-646235-S19645703512014072800000) .
  41. Install the fresh air hose to the valve cover.
  42. Install the battery tray. Refer to «TRAY, BATTERY, INSTALLATION»(ref-646227-S37644486382014072800000) .
  43. Lock the harness retainer at the bottom of the battery tray.
  44. Install the windshield washer reservoir to the battery tray. Install the retainer bolt and tighten to 9 N.m (80 in. lbs.).
  45. Install the battery. Refer to «BATTERY, INSTALLATION»(ref-646227-S21166870622014072800000) .
  46. Evacuate and recharge the AC system. Refer to «STANDARD PROCEDURE»(ref-646220-S32937035862014072800000) .
  47. Connect the intermediate connector (1), the generator feed connector (2) and the PCM connector (3).
  48. Install the starter connector (1) at the power block. Tighten the nut to 7 N.m (62 in. lbs.).
  49. Install the three bolts (1) that secure the PDC. Tighten to 9 N.m (80 in. lbs.).
  50. Install the battery cables.
  51. Connect the fuel line (1) and the purge line (2) quick connects.
  52. Connect the brake booster vacuum hose to intake manifold fitting.
  53. Install the air box (1), the resonator (2) and the bolt (3). Tighten to 9 N.m (80 in. lbs.).
  54. Connect the IAT sensor connector.
  55. Tighten the snorkel clamp at the throttle body inlet.
  1. Install the air filter element (2) into the air cleaner housing.
  2. Install the cover (1) so that the rear tabs insert into the lower air box.
  3. Seat the cover onto the housing and tighten the two housing cover screws (1).

Scheme 615

Scheme 615: REMOVAL
Scheme 615: REMOVAL
  1. Loosen the clamp (2) and disengage the hose from the resonator.
  2. Remove the make up air hose (3) from the air cleaner body.
  3. Disengage the coolant line retainer (4) from the air cleaner body.
  4. Remove air cleaner housing retaining bolt (5).
  5. Lift the air cleaner body (1) straight up off of the locating pins.
  1. Install the air cleaner body (1) straight down on the locating pins.
  2. Install the retaining bolt (5).
  3. Install the hose to the resonator and tighten the clamp (2) to 4 N.m (35 in. lbs.).
  4. Engage the coolant line retainer (4) to the air cleaner body.
  5. Install the make up air hose (3).

Scheme 616

Scheme 616: REMOVAL
Scheme 616: REMOVAL

Scheme 617

Scheme 617
Scheme 617
  1. Remove the engine cover.
  2. Disconnect the electrical connector (2) from the Inlet Air Temperature (IAT) sensor.
  3. Loosen the clamp (2) that secures the resonator (1) to the throttle body inlet.
  4. Loosen the clamp (1) and remove the air inlet hose from the resonator (3).
  5. Remove the bolt (2) that secures the resonator to the cylinder head cover.
  6. Pull the resonator (3) up while tipping the top edge of the resonator slightly forward and remove from the vehicle.
  1. Position the resonator (3) between the forward edge of the cowl and the cylinder head cover. Align the openings with the throttle body intake and the airbox flex hose.
  2. Install the bolt. Tighten the bolt to 9 N.m (81 in. lbs.).
  3. Tighten the hose clamp (1).
  4. Tighten the clamp (2) at the resonator outlet (1).
  5. Connect the IAT connector (3).
  6. Install the engine cover. Push downward to make sure all four rubber mounts are secure.

Scheme 618

Scheme 618: DESCRIPTION
Scheme 618: DESCRIPTION

The MultiAir, aluminum cylinder head (7) contains an exhaust camshaft and a variable valve actuator assembly (VVAA) with four valves per cylinder. The valves are arranged in two in-line banks. The exhaust valves (6) face toward the front of the vehicle. The intake valves face the dash panel (5). The valvetrain uses roller rocker arms with hydraulic lifters. The cylinder head incorporates pressed in powdered metal valve guides. The valve guides are not serviceable. The cylinder head is sealed to the block using a multi-layer steel head gasket and retaining bolts. The valves contain a stem seal (4), spring (3), spring retainer (2) and three groove keepers (1).

Integral oil galleries provide lubrication passages to the VVAA, camshaft, and valve mechanisms.

Note. Camshaft bearing caps are marked during engine manufacturing. For example, the front camshaft bearing cap is marked 1, the read cap is marked with a 5. The markings on the caps must be read while looking from the left bank of the engine (closest to the front of the vehicle).

Note. Following the installation of each camshaft bearing cap, visually verify that the camshaft has some endplay.

Scheme 619

Scheme 619: INSTALLATION
Scheme 619: INSTALLATION

Scheme 620

Scheme 620
Scheme 620
  1. Lubricate camshaft journals with clean engine oil.
  2. Apply a seam of Anaerobic Loctite® 518 Sealant on the camshaft housing in the contact area of the front and rear camshaft caps. Torque Sequence NOTE: VVAA removed for clarity
  3. Install the camshaft and camshaft bearing caps. Tighten the twelve bolts in two steps following the sequence shown in illustration: Step 1: All to 5 N.m (44 in. lbs.). Step 2: All to 10 N.m (89 in. lbs.).
  4. Loosen the spring compressors (2), remove the tool (special tool #10259B, Compressor, MultiAir® Spring) (1).
  5. If required, install a new camshaft seal (1). Refer to «SEAL(S), CAMSHAFT, INSTALLATION»(ref-646215-S02880775262014072800000) .
  6. Install the camshaft sprocket and timing chain. Refer to «CHAIN AND SPROCKETS, TIMING, INSTALLATION»(ref-646217-S38825218802014072800000) .
  7. Install the timing cover. Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-646217-S31374882382014072800000) .
  8. Install the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-646217-S10697975412014072800000) .

Note. The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.

Scheme 621

Scheme 621: DESCRIPTION
Scheme 621: DESCRIPTION

The cylinder head cover is made of die cast aluminum. The cylinder head cover is sealed with press-in-place gaskets at the cylinder head and spark plug ports. RTV is used to seal the T-joint at the cylinder head cover, front timing cover and cylinder head. RTV is also used to seal the cylinder head cover to the rear camshaft bearing cap at the vacuum pump.

Scheme 622

Scheme 622
Scheme 622

Scheme 623

Scheme 623
Scheme 623
  1. Remove the engine cover assembly.
  2. Disconnect and isolate the battery negative cable.
  3. Remove the make up air hose from the cylinder head cover fitting.
  4. Remove the positive crankcase ventilation (PCV) hose.
  5. Disconnect and remove the ignition coils. Refer to «COIL, IGNITION, REMOVAL»(ref-646264-S36315389822014072800000) .
  6. Use compressed air to blow dirt and debris off of the cylinder head cover prior to removal.
  7. Remove the push pins that secure the coil harness to the cover. NOTE: If any of the push pins break off in the cover, use a pick to rotate the lodged portion counterclockwise to back the portion out of the hole.
  8. Loosen twelve cylinder head cover mounting bolts and six stud bolts (1).
  9. Remove the cylinder head cover from the cylinder head. NOTE: With the help of an assistant, hold the coil harness up and spread open as the cover is removed through the area between the left and right harness runs.
  10. Remove and discard the cylinder head cover gaskets (1 and 2).
  11. Remove all residual sealant (1) from the cylinder head, timing chain cover, rear exhaust camshaft bearing cap and cylinder head cover mating surfaces. Refer to «ENGINE - STANDARD PROCEDURE»(ref-646217-S05151393892014082600000) .
  1. Install new cylinder head cover gaskets (1 and 2). NOTE: When using RTV, the sealing surfaces must be clean and free from grease and oil. NOTE: When using RTV, components should be assembled within 10 minutes and tighten to specification within 45 minutes.
  2. Apply a 2 to 3 mm wide bead of Mopar® engine sealant RTV or equivalent to the cylinder head/front cover T-joint (1) and the rear exhaust camshaft bearing cap/cylinder head T-joint (1).
  3. Install the cylinder head cover to the cylinder head with twelve bolts and six stud bolts (1). Tighten all eighteen fasteners to 10 N.m (90 in. lbs.).
  4. Install the cylinder cover ground strap and nut. Tighten the nut to 10 N.m (90 in. lbs.)
  5. Install and connect the ignition coils. Refer to «COIL, IGNITION, INSTALLATION»(ref-646264-S09640927192014072800000) .
  6. If removed, install the positive crankcase ventilation (PCV) valve and tighten to 4 N.m (37 in. lbs.). NOTE: Make sure the O-ring is seated on the shoulder of the opening prior to reading the torque.
  7. Connect the PCV hose to the PCV valve.
  8. Connect the make up air hose.
  9. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
  10. Install the engine cover assembly.
  1. Disconnect and isolate the negative battery cable.
  2. Remove the cylinder head cover assembly bolts (1) and remove the cover from the cylinder head.
  3. Install special (1) tool to the cylinder head. With the spring compressors lined up in the 2.4L position of the bridge (3), rotate the screw jacks counterclockwise to compress the springs enough to allow slight movement of the rockers.
  4. Remove the camshaft(s). Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-646217-S15123378442014072800000) . NOTE: If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.
  5. Remove the rocker arm(s). Refer to «ROCKER ARM, VALVE, REMOVAL»(ref-646217-S36729380132014072800000) . NOTE: If the hydraulic lifters are to be reused, identify their positions so that they can be reassembled into their original locations.
  6. Remove the hydraulic lifter(s).
  1. Verify that the hydraulic lifters are at least partially full of oil. There should be little or no plunger travel when the hydraulic lifter is depressed. NOTE: If the hydraulic lifters are being reused, reassemble them into their original locations.
  2. Install the hydraulic lifter(s) NOTE: If the rocker arms are being reused, reassemble them into their original locations.
  3. Install the rocker arm(s). Refer to «ROCKER ARM, VALVE, INSTALLATION»(ref-646217-S02234497982014072800000) .
  4. Install the camshaft. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-646217-S40821436342014072800000) .
  5. Install the VVAA. Refer to «ASSEMBLY, VARIABLE VALVE ACTUATION, INSTALLATION»(ref-646217-S02413844502014072800000) .
  6. Install the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-646217-S10697975412014072800000) .
  7. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 624

Scheme 624: DESCRIPTION
Scheme 624: DESCRIPTION

The valve rocker arms are steel stampings with an integral roller bearing. A spring clip helps to hold the rocker arm in position on the ball socket when removing or installing the variable valve actuation assembly. The rocker arm ball socket also incorporates a 0.5 mm oil hole for roller and camshaft lubrication.

  1. Disconnect and isolate the battery negative cable.
  2. If the exhaust rockers are to be serviced, remove the exhaust camshaft. Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-646217-S15123378442014072800000) . NOTE: If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.
  3. If the intake rockers are to be serviced, remove the Variable Valve Actuator Assembly (VVAA). Refer to «ASSEMBLY, VARIABLE VALVE ACTUATION, REMOVAL»(ref-646217-S27444429722014072800000) .
  4. Remove the rocker arm(s).
  1. Lubricate the rocker arms with clean engine oil before installation. NOTE: If the rocker arms are being reused, reassemble them into their original locations.
  2. Install the rocker arm(s).
  3. If the intake rockers were serviced, install the VVAA Refer to «ASSEMBLY, VARIABLE VALVE ACTUATION, INSTALLATION»(ref-646217-S02413844502014072800000) .
  4. If the exhaust rockers were serviced, Install the camshaft and cylinder head cover. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-646217-S40821436342014072800000) .
  5. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 625

Scheme 625: DESCRIPTION
Scheme 625: DESCRIPTION

Note. Typical valve configuration shown in illustration.

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

Scheme 626

Scheme 626: REMOVAL
Scheme 626: REMOVAL

Note. If the springs are to be reused, identify their positions so that they can be reassembled into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valve springs similar.

Scheme 627

Scheme 627
Scheme 627

Scheme 628

Scheme 628
Scheme 628
  1. Remove the valve spring(s) (2). Refer to «SPRING(S), VALVE, REMOVAL»(ref-646217-S13625247992014072800000) . NOTE: Number 2 cylinder exhaust valve guide seal shown in illustration, all other valve guide seals similar.
  2. Remove the valve guide seal (1) using a valve seal tool (2). Discard the removed seal. NOTE: Number 2 cylinder exhaust valve spring seat shown in illustration. Exhaust valve spring seats are marked with the letter "S" and have a thickness of 0.8 mm (0.031 in.). Intake valve spring seats are marked with the letter "A" and have a thickness of 3.2 mm (0.126 in.).
  3. If required, remove the valve spring seat (1).
  4. If required, remove the valve(s). Refer to «VALVES, INTAKE AND EXHAUST, REMOVAL»(ref-646217-S09484291582014072800000) .

Note. Reassemble the valves into their original locations. If the valves or valve seats have been refinished, verify that the valve stem tip height is within specification. Refer to ENGINE SPECIFICATIONS .

Scheme 629

Scheme 629
Scheme 629
  1. If removed, install the valve(s). Refer to «VALVES, INTAKE AND EXHAUST, INSTALLATION»(ref-646217-S21890509752014072800000) . NOTE: Number 2 cylinder exhaust valve spring seat shown in illustration. Exhaust valve spring seats are marked with the letter "S" and have a thickness of 0.8 mm (0.031 in.). Intake valve spring seats are marked with the letter "A" and have a thickness of 3.2 mm (0.126 in.).
  2. If removed, install the spring seat (1) over the valve guide.
  3. Apply engine oil to the lip of the valve guide seal (3). Install the valve guide seal (3) over the valve stem. Using an appropriate driver (1), push the seal firmly and squarely over the valve guide. Do Not Force the seal against the top of guide. NOTE: Make sure that the garter spring (2) is intact around the top of the valve guide seal (3). Number 2 cylinder exhaust valve guide seal shown in illustration, all other valves similar. NOTE: If the valve springs are being reused, reassemble them into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valves similar.
  4. Install the valve spring(s) (2). Refer to «SPRING(S), VALVE, INSTALLATION»(ref-646217-S15163833812014072800000) .

Scheme 630

Scheme 630: DESCRIPTION
Scheme 630: DESCRIPTION

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

Scheme 631

Scheme 631: ON VEHICLE
Scheme 631: ON VEHICLE

Scheme 632

Scheme 632
Scheme 632

Scheme 633

Scheme 633
Scheme 633

Scheme 634

Scheme 634
Scheme 634
  1. Remove the camshaft(s). Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-646217-S15123378442014072800000) . NOTE: If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.
  2. Remove the rocker arm(s). Refer to «ROCKER ARM, VALVE, REMOVAL»(ref-646217-S36729380132014072800000) .
  3. Install the (special tool #10224, Adapter, Valve Spring) (2) on the (special tool #MD998772A, Compressor, Valve Spring) (1). NOTE: Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.
  4. Remove the spark plug. Refer to «SPARK PLUG, REMOVAL»(ref-646264-S20945443012014072800000) .
  5. Install the (special tool #MD998772A, Compressor, Valve Spring) (1) onto the cylinder head.
  6. Install a spark plug adapter attached to a regulated shop air supply (2). Pressurize the cylinder being serviced to 620.5 - 689 kPa (90 - 100 psi) to hold the valves in place. NOTE: Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar. CAUTION: Air pressure must be maintained as long as the valve springs are removed to prevent the valves from dropping into the cylinders.
  7. Using the (special tool #10224, Adapter, Valve Spring) (2), compress valve spring (4) and remove valve retaining locks (3). NOTE: If the springs are to be reused, identify their positions so that they can be reassembled into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valve springs similar.
  8. Release the valve spring compression and remove the valve spring retainer (1) and valve spring (2).
  9. If required, remove the valve guide seal. Refer to «SEAL(S), VALVE GUIDE, REMOVAL»(ref-646217-S28446605692014072800000) .

Scheme 635

Scheme 635
Scheme 635
  1. Install the (special tool #10224, Adapter, Valve Spring) (2) on the (special tool #MD998772A, Compressor, Valve Spring) (1). NOTE: Number 3 intake valve spring compression shown in illustration, all other valves similar.
  2. Install the (special tool #MD998772A, Compressor, Valve Spring) (1) onto the cylinder head.
  3. Place a ball of rags in the combustion chamber to hold the valves in place. NOTE: Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.
  4. Using the (special tool #10224, Adapter, Valve Spring) (2), compress valve spring (4) and remove valve retaining locks (3). NOTE: If the springs are to be reused, identify their positions so that they can be reassembled into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valve springs similar.
  5. Release the valve spring compression and remove the valve spring retainer (1) and valve spring (2).
  6. If required, remove the valve guide seal. Refer to «SEAL(S), VALVE GUIDE, REMOVAL»(ref-646217-S28446605692014072800000) .

Scheme 636

Scheme 636: INSPECTION
Scheme 636: INSPECTION

When valves have been removed for inspection, reconditioning or replacement, valve springs should be checked against specifications for free-length, spring force and spring installed height. Refer to ENGINE SPECIFICATIONS .

Spring force can be measured with a test fixture (2). Follow the tool manufactures instructions. Replace any springs that do not meet specifications.

Scheme 637

Scheme 637
Scheme 637

Installed height of the valve spring must be checked with the valve assembled into the cylinder head. Refer to SPRING(S), VALVE, INSTALLATION .

If the valves or valve seats have been refinished, check the installed height of the valve springs (4). Make sure the measurement is taken from the top of spring seat (6) to the bottom surface of spring retainer (1). Refer to ENGINE SPECIFICATIONS .

Scheme 638

Scheme 638: ON VEHICLE
Scheme 638: ON VEHICLE

Scheme 639

Scheme 639
Scheme 639
  1. If removed, install the valve guide seal (2) over the valve guide (3). Refer to «SEAL(S), VALVE GUIDE, INSTALLATION»(ref-646217-S25894898622014072800000) . NOTE: Make sure that the garter spring (1) is intact around the top of the valve guide seal (2). Number 2 cylinder exhaust valve guide seal shown in illustration, all other valves similar. NOTE: If the valve springs are being reused, reassemble them into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valves similar.
  2. Install the valve spring (2) and valve spring retainer (1). NOTE: Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.
  3. Using the (special tool #10224, Adapter, Valve Spring) (2) with the (special tool #MD998772A, Compressor, Valve Spring) (1), compress the valve spring (4) only enough to install the valve retaining locks (3).
  4. Relieve the air pressure and remove the spark plug adapter.
  5. Install the spark plug and tighten to 19 N.m (14 ft. lbs.). Refer to «SPARK PLUG, INSTALLATION»(ref-646264-S27190124152014072800000) . NOTE: If the rocker arms are being reused, reassemble them into their original locations.
  6. Install the rocker arm(s) (1). Refer to «ROCKER ARM, VALVE, INSTALLATION»(ref-646217-S02234497982014072800000) .
  7. Install the camshaft(s) and cylinder head cover. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-646217-S40821436342014072800000) .
  8. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 640

Scheme 640: OFF VEHICLE
Scheme 640: OFF VEHICLE
  1. If removed, install the valve(s). Refer to «VALVES, INTAKE AND EXHAUST, INSTALLATION»(ref-646217-S21890509752014072800000) . NOTE: Reassemble the valves into their original locations. If the valves or valve seats have been refinished, verify that the valve stem tip height (5) is within specification. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) .
  2. If removed, install the valve guide seal (2) over the valve guide (3). Refer to «SEAL(S), VALVE GUIDE, INSTALLATION»(ref-646217-S25894898622014072800000) . NOTE: Make sure that the garter spring (1) is intact around the top of the valve guide seal (2). Number 2 cylinder exhaust valve guide seal shown in illustration, all other valves similar. NOTE: If the valve springs are being reused, reassemble them into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valves similar.
  3. Install the valve spring (2) and valve spring retainer (1).
  4. Install the (special tool #10224, Adapter, Valve Spring) (2) on the (special tool #MD998772A, Compressor, Valve Spring) (1). NOTE: Number 3 intake valve spring compression shown in illustration, all other valves similar.
  5. Install the (special tool #MD998772A, Compressor, Valve Spring) (1) onto the cylinder head.
  6. Place a ball of rags in the combustion chamber to hold the valves in place. NOTE: Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.
  7. Using the (special tool #10224, Adapter, Valve Spring) (2) with the (special tool #MD998772A, Compressor, Valve Spring) (1), compress the valve spring (4) only enough to install the valve retaining locks (3).
  8. If the valves or valve seats have been refinished, verify that the installed height of the valve springs (4) are within specification. Make sure the measurement is taken from the top of spring seat (6) to the bottom surface of spring retainer (1). Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) .
  9. Install the cylinder head. Refer to «CYLINDER HEAD, INSTALLATION»(ref-646217-S06655855062014072800000) .
  1. Remove the cylinder head. Refer to «CYLINDER HEAD, REMOVAL»(ref-646217-S25199295112014072800000) . NOTE: If the springs are to be reused, identify their positions so that they can be reassembled into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valve springs similar.
  2. Remove the valve spring(s) (2). Refer to «SPRING(S), VALVE, REMOVAL»(ref-646217-S13625247992014072800000) . CAUTION: Before removing the valves, remove any burrs from the valve stem retainer lock grooves (2) and stem tip (1) to prevent damage to the valve guides.
  3. Remove the valve(s). Identify each valve to ensure installation in the original location.
  4. If required, remove the valve guide seal (2) and spring seat (3). Refer to «SEAL(S), VALVE GUIDE, REMOVAL»(ref-646217-S28446605692014072800000) .
  1. Coat the valve stems (2) with clean engine oil and install the valves into the cylinder head. NOTE: If the valves are being reused, reassemble them into their original locations.
  2. If the valves or valve seats have been refinished, check the valve tip height (5). If the valve tip height (5) exceeds the specification, grind the valve tip until it is within specification. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) . Make sure the measurement is taken from the cylinder head surface (7) to the top of the valve stem (2).
  3. If removed, install the spring seat (3) and valve guide seal (2) over the valve guide. Refer to «SEAL(S), VALVE GUIDE, INSTALLATION»(ref-646217-S25894898622014072800000) . NOTE: Make sure that the garter spring (1) is intact around the top of the valve guide seal (2). Number 2 cylinder exhaust valve guide seal shown in illustration, all other valves similar.
  4. Install the valve spring(s) (2). Refer to «SPRING(S), VALVE, INSTALLATION»(ref-646217-S15163833812014072800000) . NOTE: Reassemble the valves springs into their original locations. If the valves or valve seats have been refinished, verify that the valve spring installed height is within specification. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) . Number 2 cylinder exhaust valve spring shown in illustration, all other valves springs similar.
  5. Install the cylinder head. Refer to «CYLINDER HEAD, INSTALLATION»(ref-646217-S06655855062014072800000) .

Scheme 641

Scheme 641: DESCRIPTION
Scheme 641: DESCRIPTION

The vane-type vacuum pump is mounted to the rear of the cylinder head and is driven by the camshaft. The vacuum pump supplies vacuum to the brake booster.

Scheme 642

Scheme 642: REMOVAL
Scheme 642: REMOVAL

Scheme 643

Scheme 643
Scheme 643

Scheme 644

Scheme 644
Scheme 644

Scheme 645

Scheme 645
Scheme 645
  1. Remove the engine cover. Refer to «RESONATOR, AIR CLEANER, REMOVAL»(ref-646217-S01497312852014072800000) .
  2. Remove the battery. Refer to «BATTERY, REMOVAL»(ref-646227-S35480669362014072800000) . NOTE: Oil may leak from the vacuum pump drive when the pump is removed. Place a shop towel under the pump to prevent oil leakage onto the engine or transmission assembly.
  3. Disconnect the vacuum line at the pump (1).
  4. Remove the vacuum pump mounting bolts (2) and the vacuum pump.
  5. Remove and discard the vacuum pump gasket (1). Note the location of the pump drive tab.
  6. If required, remove the screw (1) and the vacuum fitting (2).
  7. The vacuum fitting O-ring seal (1) can be reused if not damaged.
  1. The vacuum fitting O-ring seal (1) can be reused if not damaged. If removed, lightly lubricate the O-ring seal (1) with clean engine oil and install on the vacuum fitting.
  2. If removed, install the vacuum fitting (2) to the vacuum pump with the screw (1) tightened to 8 N.m (71 in. lbs.).
  3. Clean the mating surfaces of the cylinder head and the vacuum pump. Install a new vacuum pump gasket.
  4. Align the pump drive tab with the pump drive slot located on the cam shaft.
  5. Install the vacuum pump mounting bolts. Tighten the bolts to 20 N.m (15 ft. lbs.).
  6. Connect the vacuum supply line to the pump. CAUTION: When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.
  7. Install the battery (4). Refer to «BATTERY, INSTALLATION»(ref-646227-S21166870622014072800000) .
  8. Install the engine cover. Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-646217-S37132917522014072800000) .
  9. Run the engine a check the vacuum pump for proper operation.

Scheme 646

Scheme 646: DESCRIPTION
Scheme 646: DESCRIPTION

The primary component of variable valve actuation is the variable valve actuation module. The variable valve actuation module is bolted to the top of the camshaft bearing housing above the intake valves, next to the camshaft. The intake lobes on the camshaft operate hydraulic pumping elements instead of directly acting on the valves. The pumping elements provide high-pressure oil to open the intake valves. The relationship between the camshaft lobe and the intake valves is controlled by a solenoid operated hydraulic port. By varying the solenoid operation, the Powertrain Control Module (PCM) is able to control intake valve lift and duration. The actuators sit directly on top of the intake valve tips (circled).

Scheme 647

Scheme 647: OPERATION
Scheme 647: OPERATION

Variable valve actuation controls the operation of the intake valves. By using a hydraulic link between the camshaft and the intake valves, the valve lift and timing can be adjusted infinitely.

The main components of variable valve actuation are the Powertrain Control Module (PCM) programming and the variable valve actuation module. The variable valve actuation module contains one set of the following components for each cylinder

  1. Upper Pumping Element (3)
  2. Solenoid Valve (1)
  3. Hydraulic Brake Pumping Element/Hydraulic Lash Adjusters (2)
  4. Oil Accumulator (4)

Scheme 648

Scheme 648
Scheme 648

The upper pumping elements (1) in the variable valve actuator are filled with oil from the engine lubrication system. The upper pumping elements (1) are driven by the rocker arms through camshaft motion (9) to create high-pressure oil inside the oil chamber (2). As the camshaft continues to rotate and the camshaft lobe ramps down, a spring in the upper pumping element returns the piston and the rocker arm to their home positions.

The high-pressure oil in the oil chamber passageway is delivered to the solenoid valve (8) from the upper pumping element. The solenoid valve (8) is a normally open hydraulic control valve. Therefore, the high-pressure oil is vented from the oil chamber to the accumulator (7) unless the solenoid valve is powered. When the solenoid valve is supplied 12 volts, the valve closes and high pressure oil instead acts upon the hydraulic brake pumping elements (6) to operate the intake valves (5).

The hydraulic brake pumping element (6) is essentially a piston that is operated by the high-pressure oil to open the intake valves (5). It also functions as a brake to stop the movement of the pumping element and intake valves. The braking function is the result of vent holes around the perimeter of the element's cylinder. When the piston approaches full stroke, the lower perimeter vent holes bleed off oil. This stops the piston from moving any farther. When the pressure from the solenoid is taken away, the upper supply holes in the cylinder become bleed holes that allow the piston to return to the home position. The piston is pushed back to the home position by the force of the intake valve springs. As the piston approaches the home position, some of the bleed holes are covered and the speed of the piston is regulated as it approaches the final resting position. This also controls the valve speed as it seats in the cylinder head. The hydraulic brake pumping element also functions as a hydraulic lash adjuster (3) because the valve stem clearance is hydraulically taken up by the piston. This occurs because the hydraulic brake pumping element/hydraulic lash adjuster is always under some oil pressure from the engine oil lubrication system. This creates enough pressure to take up valve clearance.

The variable valve actuator features three areas that function together as an oil reservoir so that the actuator always has a ready supply of engine oil. The engine lubrication system provides oil to the lower reservoir area and keeps it full of oil. To flow from the lower reservoir to the upper reservoir, the oil must pass through very small holes. This helps to purge air from the lower reservoir and to maintain engine oil pressure in the lower reservoir. The third reservoir area, the oil accumulator (7), is filled by oil vented from the oil chamber by the solenoid valve (8). The oil accumulator is a spring loaded accumulator that absorbs the hydraulic shock that would otherwise be created when the solenoid valves are opened. This helps to increase the durability of the system, maintains higher pressure in the lower pressure side of the system and lowers the overall load on the engine oil pump.

Variable valve actuation provides five possible phases of operation. Each phase offers unique advantages compared to normal camshaft operation. The five phases are

Scheme 649

Scheme 649
Scheme 649
  1. Full Lift. When variable valve actuation functions in the full lift phase, all of the camshaft lobe lift is transferred to the intake valves. The intake camshaft lobe is designed with a very aggressive lift and duration profile. This results in good power in the upper RPM ranges with high loads. This profile would rarely be used in everyday driving.

Scheme 650

Scheme 650
Scheme 650
  1. Early intake valve closing (EVIC). When variable valve actuation functions in the EVIC phase, the camshaft lobe lift is transferred to the intake valves at the beginning of the lift duration cycle. However, the hydraulic connection between the camshaft lobe and the valves is taken away before the lobe reaches full lift. The exact timing and lift can be infinitely varied to meet driver requirements. EVIC provides smooth engine performance and more torque at lower engine speeds.

Scheme 651

Scheme 651
Scheme 651
  1. Late intake valve opening (LIVO). When variable valve actuation functions in the LIVO phase, the camshaft lobe lift is NOT transferred to the intake valves at the beginning of the lift duration cycle. The hydraulic connection between the camshaft lobe and the valves is completed after the rocker arm has already begun riding the ramp of the camshaft lobe. When the hydraulic connection is completed, the intake valves will begin to open. The valve lift timing can be varied infinitely within the full profile of the camshaft lobe. Therefore, as long as the hydraulic connection is completed before the camshaft lobe reaches its maximum lift, some valve lift will result. The lift profile will follow the camshaft lobe profile for the time that the hydraulic link is complete. Like EVIC, the exact timing and lift can be infinitely varied to meet driver requirements. LIVO provides lower emissions and a higher efficiency at lower loads or idle conditions.

Scheme 652

Scheme 652
Scheme 652
  1. Multi-Lift. Multi-Lift is a combination of EVIC and LIVO because the hydraulic connection between the camshaft lobe and the intake valves is closed early and then re-opened later in the cycle. This creates a longer duration valve lift with a smaller amount of lift. The result is a higher velocity of air flow into the cylinder over a longer period of time. Multi-Lift may be used in mixed driving of acceleration and deceleration with moderate engine speeds.

Scheme 653

Scheme 653
Scheme 653
  1. Closed. The closed phase simply leaves the intake valves closed by not utilizing the camshaft lobe to lift the intake valves.

Scheme 654

Scheme 654
Scheme 654

Scheme 655

Scheme 655
Scheme 655

Scheme 656

Scheme 656
Scheme 656

Scheme 657

Scheme 657
Scheme 657
  1. Remove the cylinder head cover bolts (1). Remove the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-646217-S03078198452014072800000) .
  2. Unlock and disconnect the four variable valve timing actuator electrical connectors.
  3. Remove four bolts from the VVAA block. NOTE: The bolts need to be removed prior to the installation of the compressor tool due to the tool obstructs access to these bolts once the tool is installed. NOTE: Be sure to follow the sequence shown in illustration above when removing the bolts.
  4. Using special tool 10259A (1), loosen the spring compressors (2) to fit over the valve and spring assemblies. Adjust the tool to align with the 2.4L indicators (3).
  5. Install the (special tool #10259B, Compressor, MultiAir® Spring) spring compressor
  6. Rotate the spring compressors counterclockwise until the springs are fully seated. CAUTION: Do not invert the variable valve actuation assembly when it is removed from the engine. Oil will drain from the assembly and excessive engine cranking will be required to refill the assembly and start the engine.
  7. Remove the remaining five bolts from the VVAA. NOTE: Be sure to follow the sequence shown in illustration above when removing the bolts.
  8. Remove the variable valve timing actuation assembly, with the spring compressor attached, from the camshaft bearing housing.
  9. Set the assembly (1) onto two blocks of wood (2) to store during repairs. NOTE: Be sure to store the assembly in the upright position AT ALL TIMES to prevent oil related issues within the assembly. NOTE: There are two locating pins/dowels that properly position the VVAA. Be careful that both dowels remain installed in cylinder head after removing the VVAA. If a dowel comes loose, locate the missing dowel and discard it A new dowel will need to be used upon installation. DO NOT REUSE A DOWEL THAT HAS BEEN REMOVED FROM THE CYLINDER HEAD.
  10. Remove and discard the variable valve actuation assembly gasket.
  11. If required, remove the rocker arms. Refer to «ROCKER ARM, VALVE, REMOVAL»(ref-646217-S36729380132014072800000) .

Scheme 658

Scheme 658: INSPECTION
Scheme 658: INSPECTION

Because variable valve actuation is so closely monitored, the diagnostics of the system are strongly Diagnostic Trouble Code (DTC) driven. If the system does not perform according to design, many DTCs may be produced from a condition in the variable valve actuation system.

The variable valve actuation module includes very few serviceable components. The module has no internal components that are serviceable. The following components are serviceable

  1. Valve rocker arms (1)
  2. Oil supply O-ring (2)
  3. Oil temperature sensor (3)

Scheme 659

Scheme 659: INSTALLATION
Scheme 659: INSTALLATION

Scheme 660

Scheme 660
Scheme 660

Scheme 661

Scheme 661
Scheme 661

Scheme 662

Scheme 662
Scheme 662

Scheme 663

Scheme 663
Scheme 663

Scheme 664

Scheme 664
Scheme 664

Scheme 665

Scheme 665
Scheme 665

Scheme 666

Scheme 666
Scheme 666
  1. If the dowel/locating pins were removed, install two NEW variable valve actuation assembly locating pins (1).
  2. If removed, install the rocker arms (1). Refer to «ROCKER ARM, VALVE, INSTALLATION»(ref-646217-S02234497982014072800000) . CAUTION: Do not invert the variable valve actuation assembly when it is removed from the engine. Oil will drain from the assembly and excessive engine cranking will be required to refill the assembly and start the engine.
  3. Rotate the spring compressors (2) counterclockwise until fully seated.
  4. Install a new gasket. NOTE: To assist in the proper placement of the assembly, it is recommended to apply NEW/CLEAN MS-272 white grease or similar like Vaseline® onto the tips of the plungers to hold them in the retracted position. This will help to locate the assembly correctly while preventing the plunger tips from interfering with the valve stem tips. Use just enough to hold the plungers retracted.
  5. Set the VVAA into position onto the two dowels. NOTE: It is very important that the plungers of the VVAA are centered over the valve stem tips. When properly aligned, the VVAA will set down onto the cylinder head evenly and will not have a tendency to wobble when set onto the head. NOTE: The VVAA should sit relatively flush to cylinder head with no more then a 1 to 2 mm gap between the mating surfaces. An excessive gap indicates the VVAA is not seated properly.
  6. Visually inspect the alignment of the VVAA plungers.
  7. This is a visual indication of an IMPROPERLY aligned VVAA. The centerline of the plunger (1) and the centerline of the valve stem (2) are misaligned.
  8. This is a visual indication of a PROPERLY aligned VVAA. The centerline (1) of both the plunger and the valve stem are aligned.
  9. Install the six accessible bolts. Hand tighten the VVAA retaining bolts.
  10. Remove the spring compressor and tighten the ten bolts in three steps following the sequence shown in illustration: Step 1: All to 10 N.m (89 in. lbs.). Step 2: All to 22 N.m (16 ft. lbs.). Step 3: All again to 22 N.m (16 ft. lbs.).
  11. Connect and lock the four variable valve timing actuator electrical connectors.
  12. Connect and lock the oil temperature sensor electrical connector.
  13. Engage the oil temperature electrical connector to the bracket.
  14. Install the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-646217-S10697975412014072800000) . NOTE: If the VVAA is being replaced (new part), it is recommended that the VVAA be primed with NEW/CLEAN oil after installation. This will limit the amount of time it takes for the assembly to fill while cranking the engine. If the cylinder head cover is installed the service port can be accessed through the opening at the rear of the cover (1).
  15. Using an oil can with a CLEAN soft tip or similar tool like a NEW plastic syringe, force CLEAN, UNUSED oil into the service port (1). Continue to inject oil until oil flows continuously from the bleed port (2) or until a maximum of 200 mL has been injected.
  16. The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to appropriate Diagnostic Information .