1.4L Engine - Service Information: Removal & Installation Dodge Dart PF

REMOVAL

Note. The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, replace the oil cooler. Refer to COOLER, OIL, REMOVAL .

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1. Remove the engine cover.
2. Perform the fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS , STANDARD PROCEDURE»(ref-646230-S42658421212014072800000) .
3. Remove the air cleaner body. Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646215-S35238296702014072800000) .
4. Disconnect and remove the battery. Refer to «BATTERY, REMOVAL»(ref-646227-S35480669362014072800000) .
5. Remove the battery tray assembly. Refer to «TRAY, BATTERY, REMOVAL»(ref-646227-S29548343982014072800000) .
6. Recover the refrigerant from the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-646220-S33335783492014072800000) .
7. Disconnect the PCV hose (1) from the intake manifold and set aside.
8. Disconnect the vent hose (3) from the cylinder head cover.
9. Remove the three bolts (2) and remove the oil separator housing (4) from the cylinder head cover. 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.
10. Remove the cooling fan module. Refer to «FAN, COOLING, REMOVAL»(ref-646235-S02837375212014072800000) .
11. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
12. Remove the belly pan. Refer to «BELLY PAN, REMOVAL»(ref-646214-S24731623582014072800000) .
13. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
14. Remove both front tire and wheel assemblies. Refer to «REMOVAL»(ref-646212-S02251014372014072800000) .
15. Remove both front inner wheel well splash shields. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL»(ref-646233-S05943217422014072800000) .
16. Remove the lower closeout panel.
17. Remove the ground cable bolt (1) and ground cable (2) from the transmission case.
18. Remove the four bracket retaining bolts (1) from the cross member to fascia support beams bracket, then remove the bracket.
19. Remove the fasteners (2) securing the lower bumper reinforcement (1) and front fascia support beams to the frame/front end module.
20. Remove the front fascia support beams (1).
21. Disconnect the charge air cooler (CAC) hose connections at the cooler inlet and outlet.
22. Remove the exhaust pipe bracket bolt (2).
23. Remove the exhaust flange nuts (1) and the flange gasket.
24. Disconnect the wire harness connectors from the upstream (1) and downstream (2) oxygen sensors.
25. Disengage the oxygen sensor wire harness from the retainer (3).
26. Remove the left and right axle shafts. Refer to «REMOVAL»(ref-646219-S30341200882014072800000) .
27. Remove the intermediate shaft.
28. Disconnect the lower coolant hose from the radiator.
29. Remove the rear engine mount (Refer to «ENGINE MOUNTING»(ref-646215-S35809285072014072800000) )
30. Lower the vehicle.
31. Remove the upper radiator hose.
32. Disconnect the cooling fan electrical connector and retainer (3).
33. Remove the bolt (2) and disconnect the A/C liquid line and the A/C discharge line from the A/C condenser tapping block. Remove and discard the dual plain seals.
34. Install plugs in, or tape over, the opened refrigerant line fittings and condenser ports.
35. Remove the suction line from the compressor. Refer to «LINE, A/C SUCTION, REMOVAL»(ref-646220-S09993273302014072800000) .
36. Remove the discharge line from the compressor. Refer to «LINE, A/C DISCHARGE, REMOVAL»(ref-646220-S30866693762014072800000) .
37. Disconnect the after-run coolant pump hoses (1 and 2).
38. Remove the coolant hose (3) from the pressurized coolant bottle (1).
39. Remove the two bolts and reposition the pressurized coolant bottle.
40. Disconnect the boost pressure sensor wire harness connector (1).
41. Disengage the EVAP purge hose (4) from the retaining clip (2) and remove the hose from the charge air cooler outlet hose (5).
42. Loosen the clamp securing the charge air cooler outlet hose to the throttle body.
43. Remove the bolt (3) and remove the charge air cooler outlet hose (5) from the vehicle.
44. Pull the retaining clip (1) to disengage the concentric slave cylinder hose (2). Remove and reposition the hose.
45. For automatic transmissions , remove the Park cable bracket.
46. For manual transmissions , disconnect the shift selector cables from the shift levers. Refer to «CABLE, GEARSHIFT CONTROL, REMOVAL»(ref-646222-S40924175722014072800000) .
47. Disconnect the heater core outlet and inlet hoses from the heater core quick connects.
48. Disconnect the A/C lines from the A/C expansion valve. Install plugs in, or tape over all the opened refrigerant line fittings and expansion valve ports.
49. Open the hose retainer (3) and disconnect the fuel purge hose (2). Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) .
50. Disconnect the fuel line (1) from the fuel rail. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) .
51. Reposition the main wire harness away from the engine.
52. Raise and position vehicle height to allow Power Train Dolly (special tool #6135, Dolly, Power Train) (3) and Engine Support Cradle (special tool #6710A, Cradle, Engine Support) (2) to be installed under the engine/transaxle assembly.
53. Loosen the cradle engine mounts to allow movement for positioning onto the engine locating holes on the engine block and oil pan rail. Place Adapter (special tool #6848-3, Adapter) (1) on the front post and align to the oil pan mounting stud. Lower the vehicle and position cradle until the engine is resting on the posts. Tighten the post mounts to the cradle frame. Secure the engine/transaxle assembly to the dolly/cradle with safety straps (4).
54. Remove the left engine mount. Refer to «INSULATOR, ENGINE MOUNT, LEFT, REMOVAL»(ref-646215-S03507060552014072800000) .
55. Remove the right engine mount (Refer to «ENGINE MOUNTING»(ref-646215-S35809285072014072800000) ).
56. Raise the vehicle off of the engine and transmission assembly. NOTE: Perform the following steps to remove the transmission from the engine if required. NOTE: The flywheel dust cover (3) is bolted to the oil pan and cannot be removed at this time.
57. Remove the two bolts (1) from the flywheel dust cover.
58. Remove the lower transmission bell housing bolts (2).
59. Remove the nut (4) from the transmission stud (5).
60. Remove the starter assembly (5). Refer to «STARTER, REMOVAL»(ref-646258-S23557664662014072800000) .
61. Position a transmission jack under the transmission. Secure the transmission to the jack.
62. Remove the upper bell housing bolts (1) and separate the transmission from the engine.
63. Remove the two bolts (1) and the flywheel dust covers (2 and 3). NOTE: Perform the following steps to remove components for installation on a replacement engine if required.
64. Remove bolts (1) and the clutch and pressure plate.
65. Remove bolts (1) and the flywheel.
66. Remove the accessory drive belt (4). Refer to «BELT, SERPENTINE, REMOVAL»(ref-646235-S33730159442014072800000) .
67. Remove the generator (3). Refer to «GENERATOR, REMOVAL»(ref-646257-S12486152662014072800000) .
68. Remove the A/C compressor. Refer to «COMPRESSOR, A/C, REMOVAL»(ref-646220-S17088941942014072800000) .
69. Remove the bolt (2) and the oil level indicator tube (1).
70. Remove the bolt (5) and the ground wire.
71. Remove the three bolts (4), two nuts (2 and 3) and the accessory drive mounting bracket (1).
72. Remove the block heater (3) (if equipped). Refer to «HEATER, ENGINE BLOCK, REMOVAL»(ref-646235-S15947835822014072800000) .

INSTALLATION

Note. Perform the following steps to prepare a replacement engine for installation into the vehicle.

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1. Install the block heater (3) (if equipped). Refer to «HEATER, ENGINE BLOCK, INSTALLATION»(ref-646235-S32634003762014072800000) .
2. Install the accessory drive mounting bracket (1). Tighten the to nuts (2 and 3) and the three bolts (4) as follows: Three bolts (4) to 50 N.m (37 ft. lbs.). One nut (3) to 50 N.m (37 ft. lbs.). One nut (2) to 25 N.m (18 ft. lbs.).
3. Install the ground wire and tighten the bolt (5) to 9 N.m (80 in. lbs.).
4. Install the oil level indicator tube (1). Tighten bolt (2) 9 N.m (80 in. lbs.).
5. Install the A/C compressor (1). Refer to «COMPRESSOR, A/C, INSTALLATION»(ref-646220-S26826649852014072800000) .
6. Install the generator (3). Refer to «GENERATOR, INSTALLATION»(ref-646257-S03811372862014072800000) .
7. Install the accessory drive belt (4). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .
8. Install the flywheel. Using a star pattern, tighten the bolts (1) to 15 N.m (11 ft. lbs.) plus an additional 40 degrees.
9. Using new bolts (1), install the clutch and pressure plate. Refer to «DISC, CLUTCH, INSTALLATION»(ref-646231-S08719902062014072800000) .
10. Install the flywheel dust covers (2 and 3). Tighten bolts (1) to 9 N.m (80 in. lbs.). NOTE: Perform the following steps to Install the transmission to the engine if required.
11. Mate the transmission to the engine. Tighten the upper bell housing bolts (1) to 60 N.m (44 ft. lbs.).
12. Install the nut (4) to the transmission stud (5). Tighten Nut (4) to 60 N.m (44 ft. lbs.).
13. Install the remaining transmission bell housing bolts (2). Tighten bolts (2) 40 N.m (30 ft. lbs.).
14. Install the two bolts (1) to the flywheel dust cover and tighten to 9 N.m (80 in. lbs.).
15. Install the starter assembly (5) and connect the electrical wiring (2). Refer to «STARTER, INSTALLATION»(ref-646258-S29245182242014072800000) .
16. Position vehicle height to allow Power Train Dolly, cradle and engine to be installed into the engine compartment. (3) and Engine Support Cradle (2) to be installed under the engine/transaxle assembly.
17. Install the right engine mount assembly (Refer to «ENGINE MOUNTING»(ref-646215-S35809285072014072800000) )
18. Install the left engine mount assembly. Refer to «INSULATOR, ENGINE MOUNT, LEFT, INSTALLATION»(ref-646215-S15249086532014072800000) . 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. CAUTION: The vacuum hose and the pressurized coolant bottle return hose have the same quick-connect fitting end. Verify that the hoses are correctly installed. Failure to properly install the hoses can result in engine damage.
19. If removed during engine removal, install the vacuum pump (1) and wiring harness bracket. Refer to «PUMP, VACUUM, REMOVAL»(ref-646215-S40725219682014072800000) .
20. Connect the main wire harness connector to the engine harness.
21. Connect the fuel line (1) to the fuel rail.
22. Connect the fuel vapor purge hose (2) to the intake manifold and close the hose retainer (3).
23. Install the A/C lines with new seals to the A/C expansion valve. Install the nut and tighten to 20 N.m (15 ft. lbs.).
24. Connect the heater core inlet hose and outlet hose to the heater core fittings.
25. Connect the shift cables to the levers. Refer to «CABLE, GEARSHIFT CONTROL, INSTALLATION»(ref-646222-S17760027552014072800000) .
26. Install the hydraulic clutch slave cylinder hose (2) and install the retaining clip (1).
27. Install the charge air cooler outlet hose (5) to the vehicle. Tighten bolt (3) to 9 N.m (80 in. lbs.).
28. Tighten the clamp securing the charge air cooler outlet hose to the throttle body.
29. Install the EVAP purge hose (4) to the charge air cooler outlet hose (5) and engage the hose to the retaining clip (2).
30. Connect the boost pressure sensor wire harness connector (1).
31. Install the pressurized coolant bottle. Tighten the two bolts to 8 N.m (70 in. lbs.).
32. Install the afterrun pump hoses (1 and 2) and secure the clamps in position.
33. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
34. Position rear mount into the crossmember pocket.
35. Install the through bolt (1) into the crossmember portion of the mount.
36. Position the front arm of the mount around the bracket (3) and install the through bolt and nut (4 and 2)
37. Tighten both to 47 N.m (35 ft. lbs.).
38. Install the rear engine mount isolator (3) to the transmission with the rear engine mount bracket bolt (4) and tightened to 80 N.m (59 ft. lbs.).
39. Install the rear engine mount bracket (2) with two bolts (1).
40. Install the rear engine mount bracket bolt and nut (5). Tighten to 80 N.m (59 ft. lbs.).
41. Install the intermediate shaft and both axle shafts. Refer to «INSTALLATION»(ref-646219-S37404040972014072800000) .
42. Install the front fascia beams (1).
43. 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.).
44. Install the crossmember to fascia support beam bracket and install the four retaining bolts (1) and tighten to 95 N.m (70 ft. lbs.).
45. Install the lower radiator hose to the engine.
46. Install the crossunder pipe. Refer to «PIPE, EXHAUST CROSSUNDER, INSTALLATION»(ref-646259-S32847019502014072800000) .
47. Engage the oxygen sensor wire harness to the retainer.
48. Connect the wire harness connectors to the upstream and downstream oxygen sensors.
49. Install the ground cable (2) to the transmission case. Tighten the bolt to 24 N.m (18 ft. lbs.). Install the frame splash shield with three screws.
50. Install both front inner wheel well splash shields. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION»(ref-646233-S24910490662014072800000) .
51. Install both front tire and wheel assemblies. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000) .
52. Install the belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
53. Lower the vehicle.
54. Position the battery tray and PCM in the vehicle. Route the wire harness and close the wire harness retainers (3).
55. Install the ground strap (4) with nut (1) tightened to 5 N.m (44 in. lbs.).
56. Position the wire harness into wire harness retainers (3) and close retainers.
57. Install the battery tray. Refer to «TRAY, BATTERY, INSTALLATION»(ref-646227-S37644486382014072800000) .
58. Connect the Powertrain Control Module (PCM) harness connectors.
59. Install the upper radiator hose to the engine.
60. Fill the transmission with the proper fluid to the correct level. Refer to «FLUID, STANDARD PROCEDURE»(ref-646222-S00307436282014072800000) .
61. Lower the vehicle.
62. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 N.m (115 in. lbs.).
63. Connect the vent hose (3) to the cylinder head cover.
64. Connect the PCV hose (1) to the intake manifold.
65. Install the air cleaner body. Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646215-S04758408592014072800000) .
66. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «OIL - STANDARD PROCEDURE»(ref-646215-S41491917222014072800000) .
67. Fill the transmission. Refer to «FLUID, STANDARD PROCEDURE»(ref-646222-S00307436282014072800000) .
68. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
69. Install and connect the battery. Refer to «BATTERY, INSTALLATION»(ref-646227-S21166870622014072800000) .
70. Evacuate and charge the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-646220-S33335783492014072800000) .
71. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
72. The Clear Misfire TLC Miscellaneous Function 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 .

1. Install the air filter into the housing if it was removed. Tighten the two screws (1) that hold the housing halves together.
2. Install the air box retainer bolt (5). Tighten to 9 N.m (80 in. lbs.).
3. Install the turbocharger inlet duct to the turbocharger inlet and tighten the clamp (3) to 4 N.m (35 in. lbs.).
4. Install the fresh air make-up hose and hose clamp (2).
5. Connect the EVAP hose quick release fitting (4) to the turbocharger inlet duct.
6. Connect the wastegate solenoid vent hose (6) to the turbocharger inlet duct.

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The 1.4L aluminum cylinder head features four valves per cylinder with pressed in metal valve guides. The valve guides are not serviceable.

Note. Refer to the timing belt removal service procedure for special tool information. Refer to BELT, TIMING, REMOVAL .

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1. Disconnect and isolate the negative battery cable.
2. Perform the fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS , STANDARD PROCEDURE»(ref-646230-S42658421212014072800000) .
3. Remove the camshaft bearing housing. Refer to «HOUSING, CAMSHAFT BEARING, REMOVAL»(ref-646215-S29632010322014072800000) .
4. Remove the exhaust manifold (4). Refer to «MANIFOLD, EXHAUST, REMOVAL»(ref-646215-S25028666292014072800000) .
5. Remove the intake manifold. Refer to «MANIFOLD, INTAKE, REMOVAL»(ref-646215-S03151381552014072800000) .
6. Remove the bolt (2) and the side timing belt cover (1). CAUTION: The vacuum hose and the afterrun coolant pump hose have the same quick-connect fitting end. If removing both hoses, it is recommended that the hoses be marked at disassembly to avoid an incorrect installation. Failure to properly install the hoses can result in engine damage.
7. Disconnect the afterrun coolant pump hose (2).
8. Loosen the clamp (3) and disconnect the lower radiator hose.
9. Remove the bolt (4) and disconnect the oil filter housing coolant return hose.
10. Unlock and disconnect the Engine Coolant Temperature (ECT) sensor wire harness connector (2).
11. Disconnect the heater core inlet hose (1).
12. Using the sequence shown in illustration, remove the cylinder head retaining bolts.
13. Remove the cylinder head and gasket (1). Discard the gasket.
14. If required, remove the bolts (2) and the thermostat housing from the cylinder head.
15. If required, remove the tensioner lock nut (1) and the tensioner (2) from the cylinder head.

Note. Camshaft bearing caps are marked during engine manufacturing. For example, the center camshaft bearing cap is marked "C". The markings on the caps (1) should align with the markings on the camshaft housing (2).

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

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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.
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 (3), remove the four bolts (1) and the (special tool #10259B, Compressor, MultiAir® Spring) (2).
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 belt. Refer to «BELT, TIMING, INSTALLATION»(ref-646215-S23117408282014072800000) .
7. Install the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-646215-S15525197162014072800000) .

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.

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The cylinder head cover is made of die cast aluminum. The cylinder head cover is sealed with a press-in-place gasket. RTV is used to seal the T-joint at the camshaft bearing caps, variable valve actuator and cylinder head cover.

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1. Perform the fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS , STANDARD PROCEDURE»(ref-646230-S42658421212014072800000) .
2. Disconnect and isolate the negative battery cable.
3. Recover the refrigerant from the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-646220-S33335783492014072800000) .
4. Remove the engine cover (1).
5. Remove the air cleaner body (6). Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646215-S35238296702014072800000) .
6. Disconnect the PCV hose (1) from the intake manifold.
7. Disconnect the vent hose (3) from the oil filler neck.
8. Remove three bolts (2) and remove the oil separator housing (4) from the cylinder head cover.
9. Disconnect the fuel vapor purge hose (3) from the intake manifold.
10. Open the hose retainer (1) and disconnect the fuel line (2) from the fuel rail. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) .
11. Unlock and disconnect the IAT/MAP sensor electrical connector (3).
12. Unlock and disconnect the evaporative emissions purge solenoid electrical connector (1).
13. Unlock and disconnect the fuel injector wire harness electrical connector (2).
14. Unlock and disconnect the electrical connector (3) from the Electronic Throttle Control (ETC) (4) and disengage the ETC harness from the clip (2) on the throttle body. 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.
15. Disconnect the vacuum line from the vacuum pump (1).
16. Remove two bolts (2), one nut (3) and reposition the oil separator housing bracket (1). NOTE: Number 1 cylinder ignition coil shown in illustration, all others similar.
17. Remove the ignition coils (1). Refer to «COIL, IGNITION, REMOVAL, 1.4L»(ref-646263-S23687984942014072800000) .
18. Remove the bolt (2) and the ground lug from the cylinder head cover.
19. Remove two bolts (3) and reposition the wire harness duct (1).
20. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
21. Remove the belly pan. Refer to «BELLY PAN, REMOVAL»(ref-646214-S24731623582014072800000) .
22. Remove two bolts (4) and the right vertical brace (5).
23. Remove two screws (2) from the front wheelhouse splash shield.
24. Remove three screws (1) and the frame splash shield (3).
25. Remove the accessory drive belt (4). Refer to «BELT, SERPENTINE, REMOVAL»(ref-646235-S33730159442014072800000) .
26. Remove the A/C compressor (1). Refer to «COMPRESSOR, A/C, REMOVAL»(ref-646220-S17088941942014072800000) .
27. Open the two wire harness retainers (1) and reposition the wire harness.
28. Remove six of the seven intake manifold flange bolts (1).
29. Lower the vehicle.
30. Remove the remaining intake manifold flange bolt (3), the intake manifold support bolt (2) and reposition the intake manifold (1).
31. Remove and discard the four intake manifold seals (1).
32. Cover the open intake ports to prevent debris from entering the engine.
33. Remove the bolt (3) from the upper timing belt cover (1).
34. Remove twelve bolts (2), the fuel rail blocker (3) and the cylinder head cover (1).
35. Remove and discard the cylinder head cover gasket (1).
36. The spark plug tube seals (2) can be reused if not damaged. CAUTION: Do not use oil based liquids, wire brushes, abrasive wheels or metal scrapers to clean the engine gasket surfaces. Use only isopropyl (rubbing) alcohol, along with plastic or wooden scrapers. Improper gasket surface preparation may result in engine fluid leakage.
37. Remove all residual sealant (1) from the variable valve actuator assembly, camshaft caps, camshaft housing and cylinder head cover mating surfaces. Refer to «ENGINE - STANDARD PROCEDURE»(ref-646215-S00715361092014072800000) .
38. If required, remove the bolt (3), oil filler neck lock (2) and the oil filler neck (1) from the cylinder head cover.
39. The oil filler neck O-ring (1) can be reused if not damaged.

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1. If required, install a new oil filler neck O-ring (1).
2. If required, install the oil filler neck (1) to the cylinder head cover. Secure the oil filler neck (1) with the oil filler neck lock (2) and bolt (3) tightened to 9 N.m (80 in. lbs.). 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.
3. Install the cylinder head cover gasket (1).
4. The spark plug tube seals (2) can be reused if not damaged.
5. Clean the variable valve actuator assembly, camshaft caps, camshaft housing and cylinder head cover mating surfaces with isopropyl alcohol in preparation for sealant application. CAUTION: Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Engine RTV GEN II may result in engine fluid leakage. CAUTION: Following the application of Mopar® Engine RTV GEN II to the gasket surfaces, the components must be assembled within 10 minutes and the attaching fasteners must be tightened to specification within the next 10 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.
6. Apply a 2 to 3 mm wide bead of Mopar® Engine RTV GEN II sealant (1) to the cylinder head cover T-joints as shown in illustration.
7. Install the cylinder head cover and fuel rail blocker (1) with twelve bolts. 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 9 N.m (80 in. lbs.).
8. Install the upper timing belt cover (1) with two bolts (2 and 3) tightened to 9 N.m (80 in. lbs.).
9. Install four new intake manifold seals (1).
10. Loosely install an intake manifold flange bolt (3) and the support bolt (2) to hold the intake manifold in position.
11. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
12. Install the remaining six of the seven intake manifold flange bolts (1). Tighten all seven intake manifold flange bolts in the sequence shown in illustration to 15 N.m (11 ft. lbs.).
13. Position the wire harness and close the two wire harness retainers (1).
14. Lower the vehicle.
15. Tighten the intake manifold support bolt (2) to 9 N.m (80 in. lbs.).
16. Install the A/C compressor (1). Refer to «COMPRESSOR, A/C, INSTALLATION»(ref-646220-S26826649852014072800000) .
17. Install the accessory drive belt (4). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .
18. Install the frame splash shield (3) with three screws (1).
19. Install two screws (2) to the front wheelhouse splash shield.
20. Install the right vertical brace (5) with two bolts (4) tightened to 45 N.m (33 ft. lbs.).
21. Install the belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
22. Install the wiring harness duct (1) to the cylinder head cover with two bolts (3) tightened to 9 N.m (80 in. lbs.).
23. Install the ground lug (2) to the cylinder head cover and tighten the bolt (2) to 9 N.m (80 in. lbs.). NOTE: Number 1 cylinder ignition coil shown in illustration, all others similar.
24. Install the ignition coils (1). Refer to «COIL, IGNITION, INSTALLATION, 1.4L»(ref-646263-S16866518592014072800000) .
25. Install the oil separator housing bracket (1) with two bolts (2) and one nut (3). Tighten the three fasteners to 13 N.m (115 in. lbs.).
26. Connect the vacuum line to the vacuum pump (1).
27. Connect and lock the electrical connector (3) to the Electronic Throttle Control (ETC) (4) and engage the ETC harness to the clip (2) on the throttle body.
28. Connect and lock the fuel injector wire harness electrical connector (2).
29. Connect and lock the evaporative emissions purge solenoid electrical connector (1).
30. Connect and lock the IAT/MAP sensor electrical connector (3).
31. Connect the fuel vapor purge hose (3) to the intake manifold.
32. Connect the fuel line (2) to the fuel rail and close the hose retainer (1). Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) .
33. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 N.m (115 in. lbs.).
34. Connect the vent hose (3) to the oil filler neck.
35. Connect the PCV hose (1) to the intake manifold.
36. Install the air cleaner body (6). Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646215-S04758408592014072800000) .
37. Evacuate and charge the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-646220-S33335783492014072800000) .
38. Install the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
39. Install the engine cover (1).
40. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

Scheme 94

The camshaft bearing housing is bolted to the top of the cylinder head. The camshaft bearing housing primarily supports the camshaft, hydraulic valve lash adjusters and the variable valve actuator assembly. The spark plug tubes are threaded into the camshaft bearing housing and the vacuum pump is bolted to the rear camshaft bearing cap and the housing. The camshaft bearing housing supplies oil to the camshaft bearings, hydraulic valve lash adjusters, vacuum pump and the variable valve actuator assembly. A removable filter screen is installed in the housing for the variable valve actuation oil supply.

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

1. Disconnect and isolate the negative battery cable.
2. Remove the camshaft. Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-646215-S04149363582014072800000) . NOTE: If the hydraulic lifters are to be reused, identify their positions so that they can be reassembled into their original locations.
3. Remove the hydraulic lifter(s) (1).
4. Unlock and disconnect the oil temperature sensor electrical connector (1).
5. Disengage the oil temperature electrical connector from the bracket (2).
6. Unlock and disconnect the four variable valve timing actuator electrical connectors (5).
7. Install the (special tool #10259B, Compressor, MultiAir® Spring) (2) with four bolts (1) tightened to 9 N.m (80 in. lbs.).
8. Rotate the spring compressors (3) CCW until 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.
9. Remove the ten bolts in the sequence shown in illustration.
10. Remove the variable valve timing actuation assembly, with the spring compressor attached, from the camshaft bearing housing.
11. Remove and discard the variable valve actuation assembly gasket (1).
12. Remove the bolt (2) and the oil level indicator tube (1).
13. Unlock and disconnect the camshaft position (CMP) sensor electrical connector (1).
14. Using the sequence shown in illustration, remove the ten camshaft bearing housing retaining bolts and the camshaft bearing housing.
15. Remove the camshaft bearing housing gasket (1).
16. If required, remove the mounting bolt (2) and Camshaft Position (CMP) sensor (1) from the camshaft bearing housing.
17. If required, remove the MultiAir actuator oil supply filter (2) from the camshaft bearing housing.

1. If removed, install a new O-ring (1) lubricated with engine oil on the MultiAir actuator oil supply filter (2). Install the filter into the camshaft bearing housing and tighten to 27 N.m (20 ft. lbs.).
2. If removed, apply engine oil to the O-ring seal and install the Camshaft Position (CMP) sensor (1) with bolt (2) tightened to 9 N.m (80 in. lbs.).
3. Install two camshaft bearing housing locating pins (2).
4. Install the camshaft bearing housing gasket (1).
5. Install the camshaft bearing housing with ten bolts. Tighten the ten bolts in three steps following the sequence shown in illustration: Step 1: All to 7 N.m (62 in. lbs.). Step 2: Positions 1 through 8 to 25 N.m (18 ft. lbs.). Step 3: Positions 9 and 10 to 30 N.m (22 ft. lbs.).
6. Install the oil level indicator tube (1). Tighten the bolt (2) to 9 N.m (80 in. lbs.).
7. Connect and lock the Camshaft Position (CMP) sensor electrical connector (1).
8. Install the three variable valve actuation assembly locating pins (2).
9. Install the variable valve actuation assembly gasket (1).
10. If removed, install the rocker arms (1). Refer to «ROCKER ARM, VALVE, INSTALLATION»(ref-646215-S38999371732014072800000) . 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.
11. If removed, install the (special tool #10259B, Compressor, MultiAir® Spring) (2) with four bolts (1) tightened to 9 N.m (80 in. lbs.).
12. Rotate the spring compressors (3) CCW until fully seated.
13. Install the variable valve actuation assembly O-ring (1).
14. Install the variable valve actuation assembly with the spring compressor in place. Install and hand tighten the retaining bolts.
15. 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.).
16. Connect and lock the four variable valve timing actuator electrical connectors.
17. Connect and lock the oil temperature sensor electrical connector (1).
18. Engage the oil temperature electrical connector to the bracket (2). NOTE: If the hydraulic lifters are being reused, reassemble them into their original locations.
19. 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.
20. Install the hydraulic lifter(s) (1).
21. Install the camshaft(s). Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-646215-S42301712782014072800000) .
22. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

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. Refer to appropriate Diagnostic Information .

1. Disconnect and isolate the negative battery cable.
2. Remove the camshaft. Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-646215-S04149363582014072800000) . NOTE: If the hydraulic lifters are to be reused, identify their positions so that they can be reassembled into their original locations.
3. Remove the hydraulic lifter(s) (1).

Note. If the hydraulic lifters are being reused, reassemble them into their original locations.

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.
2. Install the hydraulic lifter(s) (1).
3. Install the camshaft(s). Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-646215-S42301712782014072800000) .
4. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 100

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 negative battery cable.
2. Remove the variable valve actuation assembly. Refer to «ASSEMBLY, VARIABLE VALVE ACTUATION, REMOVAL»(ref-646215-S08823232592014072800000) . NOTE: If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.
3. Disengage the retaining clip and remove the rocker arm(s) (1).

1. Lubricate the rocker arms with clean engine oil before installation.
2. Install the rocker arm(s) (1) and engage the retaining clip.
3. Install the variable valve actuation assembly. Refer to «ASSEMBLY, VARIABLE VALVE ACTUATION, INSTALLATION»(ref-646215-S40366843092014072800000) .
4. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 101

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 102

Scheme 103

Scheme 104

Scheme 105

1. Remove the engine cover (1).
2. Remove the air cleaner body (6). Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646215-S35238296702014072800000) .
3. Disconnect the PCV hose (1) from the intake manifold.
4. Disconnect the vent hose (3) from the oil filler neck.
5. Remove three bolts (2) and remove the oil separator housing (4) from the cylinder head cover. 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.
6. Remove the battery (4). Refer to «BATTERY, REMOVAL»(ref-646227-S35480669362014072800000) .
7. Remove two bolts (2), one nut (3) and reposition the oil separator housing bracket (1). 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.
8. Disconnect the vacuum line at the pump (1).
9. Remove the vacuum pump mounting bolts (2) and the vacuum pump (1).
10. Remove and discard the vacuum pump gasket (1). Note the location of the pump drive tab.
11. If required, remove the screw (1) and the vacuum fitting (2).
12. 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 (1).
4. Align the pump drive tab with the pump drive slot located on the cam shaft.
5. Install the vacuum pump mounting bolts (2). Tighten the bolts to 20 N.m (15 ft. lbs.).
6. Connect the vacuum supply line to the pump (1).
7. Install the oil separator housing bracket (1) with two bolts (2) and one nut (3). Tighten the three fasteners to 13 N.m (115 in. lbs.). 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.
8. Install the battery (4). Refer to «BATTERY, INSTALLATION»(ref-646227-S21166870622014072800000) .
9. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 N.m (115 in. lbs.).
10. Connect the vent hose (3) to the oil filler neck.
11. Connect the PCV hose (1) to the intake manifold.
12. Install the air cleaner body (6). Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646215-S04758408592014072800000) .
13. Install the engine cover (1).
14. Run the engine a check the vacuum pump for proper operation.

Scheme 106

1. Remove the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-646215-S11279337302014072800000) .
2. Remove the camshaft pulley. Refer to «SPROCKET(S), TIMING BELT AND CHAIN, REMOVAL»(ref-646215-S05649411892014072800000) .
3. Remove the bolts and the camshaft cap (1).
4. Remove the camshaft seal (2).

Scheme 107

Scheme 108

1. Apply engine oil to the seal pilot diameter of the (special tool #10278, Installer, Camshaft Oil Seal) (1) and to the inside diameter of the camshaft oil seal (2).
2. Carefully install the oil seal onto the seal installer. NOTE: Make sure that the garter spring (3) is intact around the inside of the oil seal lip.
3. Apply engine oil to the outside diameter of the oil seal.
4. Position the seal installer (1) on the camshaft and install the camshaft sprocket bolt (2).
5. Tighten the camshaft sprocket bolt (2) until the camshaft oil seal is seated in the camshaft bearing housing.
6. Verify that the oil seal is uniformly seated and that the seal lip (1) is not curled inward toward the engine.
7. Install the camshaft sprocket and timing belt. Refer to «BELT, TIMING, INSTALLATION»(ref-646215-S23117408282014072800000) .

Scheme 109

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 110

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 111

Scheme 112

1. Remove the valve spring(s) (2). Refer to «SPRING(S), VALVE, REMOVAL»(ref-646215-S18753221982014072800000) . 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-646215-S27859123452014072800000) .

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 113

1. If removed, install the valve(s). Refer to «VALVES, INTAKE AND EXHAUST, INSTALLATION»(ref-646215-S40373213232014072800000) . 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-646215-S04548121962014072800000) .

Scheme 114

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 115

Scheme 116

1. Remove the camshaft bearing housing. Refer to «HOUSING, CAMSHAFT BEARING, REMOVAL»(ref-646215-S29632010322014072800000) .
2. Install the (special tool #10224, Adapter, Valve Spring) (2) and the (special tool #10275, Studs, Valve Spring Compressor) (3) on the (special tool #MD998772A, Compressor, Valve Spring) (1). NOTE: Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.
3. Remove the spark plug. Refer to «SPARK PLUG, REMOVAL»(ref-646263-S33174100562014072800000) .
4. Install the (special tool #MD998772A, Compressor, Valve Spring) (1) onto the cylinder head.
5. 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. CAUTION: Air pressure must be maintained as long as the valve springs are removed to prevent the valves from dropping into the cylinders.
6. Using the (special tool #10224, Adapter, Valve Spring) (3), compress valve spring (5) and remove valve retaining locks (4). 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.
7. Release the valve spring compression and remove the valve spring retainer (1) and valve spring (2).
8. If required, remove the valve guide seal and spring seat. Refer to «SEAL(S), VALVE GUIDE, REMOVAL»(ref-646215-S33511154492014072800000) .

Scheme 117

Scheme 118

1. Remove the cylinder head. Refer to «CYLINDER HEAD, REMOVAL»(ref-646215-S40589777212014072800000) .
2. Position the (special tool #10224, Adapter, Valve Spring) (2) in the (special tool #C-3422-D, Compressor, Valve Spring) (1). NOTE: Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.
3. Compress the valve spring (4) and remove the 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 valves similar.
4. Release the valve spring compression and remove the valve spring retainer (1) and valve spring (2).
5. If required, remove the valve(s). Refer to «VALVES, INTAKE AND EXHAUST, REMOVAL»(ref-646215-S27859123452014072800000) .
6. If required, remove the valve guide seal and spring seat. Refer to «SEAL(S), VALVE GUIDE, REMOVAL»(ref-646215-S33511154492014072800000) .

Scheme 119

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 120

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 121

1. If removed, install the spring seat (3) and valve guide seal (2) over the valve guide. Refer to «SEAL(S), VALVE GUIDE, INSTALLATION»(ref-646215-S04115957832014072800000) . 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) (3) with the (special tool #MD998772A, Compressor, Valve Spring) (2), compress the valve spring (5) only enough to install the valve retaining locks (4).
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-646263-S15131110172014072800000) .
6. Install the camshaft bearing housing. Refer to «HOUSING, CAMSHAFT BEARING, INSTALLATION»(ref-646215-S38685383942014072800000) .
7. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

1. Remove the cylinder head. Refer to «CYLINDER HEAD, REMOVAL»(ref-646215-S40589777212014072800000) . 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-646215-S18753221982014072800000) . 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-646215-S33511154492014072800000) .

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-646215-S03916579012014072800000) . 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-646215-S04115957832014072800000) . 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-646215-S04548121962014072800000) . 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-646215-S03916579012014072800000) . 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-646215-S04539266812014072800000) .

Scheme 122

The engine block (1) is made from cast iron. The crankshaft is supported by five main bearings. The thrust bearings are attached to the center upper main bearing. The cylinder block has four piston cooling jets located under the main bearing shells. The cylinders are formed directly into the engine block and are divided into three size categories. Special channels formed in the crankcase walls allow the passage of coolant and lubrication oil. A knock sensor is located on the left side of the block.

The bedplate (2) is made from die-cast aluminum alloy and has cast iron cast-in bearing caps. The supports and main bearing caps are machined while assembled together with the engine block. Bolts and locating dowels are used to assure precision assembly of the bedplate and engine block. There is a bead of sealant between the bedplate and engine block to prevent oil leaks.

The function of the bedplate is to

1. form the load carrying structure with the engine block
2. support the crankshaft
3. allow return of the engine lubrication oil to the pan
4. support the engine oil pan

Scheme 123

Note. Typical crankshaft journal shown in illustration.

Engine crankshaft and connecting rod bearing clearances can be determined by the use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage

Scheme 124

Scheme 125

1. Remove the oil film from surface to be checked. Plastigage is soluble in oil.
2. Place a piece of Plastigage (1) across the entire width of the journal (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Plastigage must not crumble in use. If brittle, obtain fresh stock.
3. Torque the bearing cap bolts of the bearing being checked to the proper specification. Refer to «TORQUE SPECIFICATIONS»(ref-646215-S01818345202014072800000) . NOTE: DO NOT rotate the crankshaft. Plastigage will smear, causing inaccurate results. NOTE: Typical connecting rod cap shown in illustration.
4. Remove the bearing cap and compare the width of the flattened Plastigage (2) with the scale provided on the package (1). Locate the band closest to the same width. This band shows the amount of clearance. Differences in readings between the ends indicate the amount of taper present or the possibility of foreign material trapped under the bearing insert.
5. Record all readings taken. Compare clearance measurements to. Refer to «ENGINE SPECIFICATIONS»(ref-646215-S03916579012014072800000) . NOTE: Typical connecting rod journal shown in illustration. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale.
6. Install the proper bearings to achieve the specified bearing clearances.
7. Repeat the Plastigage measurement to verify your bearing selection prior to final assembly.

Scheme 126

Before deglazing, mask the crankcase area to keep abrasive materials from entering the engine lower end. Tape off the water jacket and any openings to the oil circuit to prevent abrasive material from entering the coolant and oil circuits.

1. Select an appropriate size flexible ball hone.
2. Deglazing of the cylinder walls may be done if the cylinder bore is straight and round. About 20-60 strokes, depending on the condition of the cylinder bore, will be sufficient to provide a satisfactory surface. Use a light honing oil, available from major oil distributors. CAUTION: DO NOT use engine or transmission oil, mineral spirits, or kerosene.
3. Deglazing should be done by moving the hone up and down fast enough to get a crosshatch pattern. The hone marks should intersect at 30° to 60° inclusive angle for proper seating of rings.
4. A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper crosshatch angle (1). The number of up and down strokes per minute can be regulated to get the desired 30° to 60° inclusive angle (2). Faster up and down strokes increase the crosshatch angle.
5. After deglazing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash parts with a solution of hot water and detergent. Dry parts thoroughly. Use a clean, white, lint-free cloth to check that the bore is clean. Oil the bores after cleaning to prevent rusting. Upon completion, perform a visual inspection of the cylinder block passages to inspect for abrasive debris. If any debris is found, repeat the cleaning process. NOTE: Cylinder bore diameter should not increase more than 20 microns during deglazing process from original nominal bore diameter, if the maximum of 20 microns is exceeded, the cylinder block must be replaced. If deglazing the cylinder bore cannot remove the light scratches and scuffs the cylinder block should be replaced.

Scheme 127

Scheme 128

Scheme 129

1. Wipe the main bearing inserts (1) clean.
2. Inspect the inserts for abnormal wear patterns, scoring, grooving, fatigue, pitting and for metal or other foreign material imbedded in the lining.
3. Inspect the back of the inserts for fractures, scrapes, or irregular wear patterns.
4. Inspect the insert locking tabs for damage.
5. Inspect the crankshaft thrust washers (1) for scoring, scratches, wear or blueing.
6. Replace any bearing that shows abnormal wear. Refer to «BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE»(ref-646215-S10477843872014072800000) .
7. Inspect the main bearing bores for signs of scoring, nicks and burrs.
8. If the cylinder block main bearing bores show damage the engine block must be replaced.
9. Use Cylinder Indicator (special tool #C-119, Cylinder Indicator) (2) to correctly 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.
10. Measure the inside diameter of the cylinder bore at three levels below the top of the bore (4). Start at the top of the bore, perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A (1).
11. Repeat the measurement near the middle of the bore, then repeat the measurement near the bottom of the bore.
12. Determine taper by subtracting the smaller diameter from the larger diameter.
13. Rotate measuring device 90° to point B (1) and repeat the three measurements. Verify that the maximum taper is within specifications. Refer to «ENGINE SPECIFICATIONS»(ref-646215-S03916579012014072800000) .
14. Determine out-of-roundness by comparing the difference between A and B at each of the three levels. Verify that the maximum out of round is within specifications. Refer to «ENGINE SPECIFICATIONS»(ref-646215-S03916579012014072800000) .
15. If cylinder bore taper and out-of-roundness are within specification, the cylinder bore can be honed. Refer to «ENGINE SPECIFICATIONS»(ref-646215-S03916579012014072800000) . If the cylinder bore taper or out-of-round condition exceeds the maximum limits, the cylinder block must be replaced.

Note. A slight amount of taper always exists in the cylinder bore after the engine has been in use for a period of time.

Scheme 130

The connecting rod bearings must be replaced one-at-a-time in order to prevent the pistons from contacting the valves.

Scheme 131

Scheme 132

1. Remove the spark plugs. Refer to «SPARK PLUG, REMOVAL»(ref-646263-S33174100562014072800000) .
2. Remove the oil pan and oil pump pick-up (1). Refer to «PICK-UP, OIL PUMP, REMOVAL»(ref-646215-S17192864682014072800000) . 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 removing to ensure correct reassembly.
3. Mark connecting rod and bearing cap positions (1) using a permanent ink marker or scribe tool. CAUTION: Replace only one connecting rod bearing at a time while all other connecting rod bearing caps remain properly tightened. If all connecting rod bearing caps are removed, crankshaft rotation will result in valve and/or piston damage. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
4. Remove the connecting rod cap bolts (2) and the connecting rod cap (1). Discard the cap bolts.
5. Install the Connecting Rod Guides (special tool #10281, Pins, Connecting Rod Guide) (4) on the connecting rod. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur.
6. Rotate the crankshaft away from the connecting rod and remove the bearing shell from the connecting rod.
7. Install the replacement bearing shell on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
8. Rotate the crankshaft while guiding the connecting rod into position over the rod journal. CAUTION: The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.
9. Install the replacement bearing shell (3) on the connecting rod cap (1) with the tang inserted into the machined groove in the cap. Lubricate the bearing surface with clean engine oil. NOTE: Do not lubricate the threads of the connecting rod cap bolts (2).
10. Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten the NEW connecting rod cap bolts (5) to 20 N.m (15 ft. lbs.) plus 40°.
11. If required, check the connecting rod side clearance. Refer to «ROD, PISTON AND CONNECTING - STANDARD PROCEDURE»(ref-646215-S02867822902014072800000) .
12. Repeat the previous steps for each connecting rod bearing being replaced.
13. Install the oil pump pick-up (1) and oil pan. Refer to «PICK-UP, OIL PUMP, INSTALLATION»(ref-646215-S20744176092014072800000) .
14. Install the spark plugs and ignition coils. Refer to «SPARK PLUG, INSTALLATION»(ref-646263-S15131110172014072800000) .
15. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «OIL - STANDARD PROCEDURE»(ref-646215-S41491917222014072800000) .
16. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
17. Start and run the engine until it reaches normal operating temperature.

Scheme 133

1. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
2. Using a blunt tool such as a drift or a screw driver and a hammer, strike the bottom edge of the cup plug (5).
3. Using a suitable pair of pliers, grasp the core plug (5) and remove.

Note. Thoroughly clean core plug bore, remove all of the old sealer.

1. Coat the edges of the engine core plug and the core plug bore with Mopar® Gasket Maker, or equivalent. NOTE: It is not necessary to wait for the sealant to cure on the core plugs. The cooling system can be filled and the vehicle returned to service immediately.
2. Using proper plug driver, drive core plug into the core plug bore. The sharp edge of the core plug should be at least 0.50 mm (0.020 in.) inside the lead in chamfer.
3. Refill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

Note. To remove the crankshaft from the engine, the engine must be removed from the vehicle.

Scheme 134

1. Remove the engine. Refer to «REMOVAL»(ref-646215-S41138294822014072800000) .
2. Remove the rear crankshaft oil seal. Refer to «SEAL, CRANKSHAFT OIL, REAR, REMOVAL»(ref-646215-S35020300192014072800000) .
3. Remove the engine oil pump. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-646215-S04144592822014072800000) .
4. Remove the two bolts (1 and 3) and the oil filter housing oil return tube (2). 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 removing to ensure correct reassembly.
5. Mark connecting rod and bearing cap positions (1) 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.
6. Remove the connecting rod cap bolts (2) and the connecting rod caps (1). Discard the cap bolts.
7. Install the (special tool #10281, Pins, Connecting Rod Guide) (4) on the connecting rod. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur.
8. Push the connecting rod and piston into the cylinder until the connecting rod is clear of the crankshaft journal. Remove the connecting rod guides (4). Repeat this procedure at each cylinder until all of the connecting rods are clear of the crankshaft.
9. Remove the twenty bedplate cap bolts in the sequence shown in illustration and remove the bedplate.
10. Remove the crankshaft (1) from the engine block.
11. If required, remove the piston oil cooler jet(s). Refer to «JET, PISTON OIL COOLER, REMOVAL»(ref-646215-S31002667842014072800000) .
12. Remove all residual sealant from the cylinder block and bedplate.

Scheme 135

Note. Typical crankshaft journal measurements shown in illustration.

1. Clean the oil off the bearing journals.
2. Determine the maximum diameter of the journals with a micrometer. Measure at two locations 90° apart at each end of the journals.
3. Compare the measured main bearing journal diameter to the crankshaft main bearing journal diameter grade marking chart Obtain the main bearing journal grade identification marks from the engine block and select the upper and lower main bearing sizes that will provide the proper oil clearance. Refer to «BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE»(ref-646215-S10477843872014072800000) .
4. For connecting rod journals, verify that the diameter, maximum taper and maximum out of round are within specifications. Refer to «ENGINE SPECIFICATIONS»(ref-646215-S03916579012014072800000) .
5. For main bearing journals, verify that the maximum taper and maximum out of round are within specifications. Refer to «ENGINE SPECIFICATIONS»(ref-646215-S03916579012014072800000) .

1. If removed, install the piston oil cooler jet(s). Refer to «JET, PISTON OIL COOLER, INSTALLATION»(ref-646215-S35147273942014072800000) .
2. If required, select and fit new crankshaft main bearings to the engine block. Refer to «BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE»(ref-646215-S10477843872014072800000) .
3. If required, select and fit new bearings to the connecting rod. Refer to «BEARING(S), CONNECTING ROD - STANDARD PROCEDURE»(ref-646215-S28109231862014072800000) . NOTE: The upper center main bearing (1) has the thrust washers attached.
4. If removed, lubricate and install the upper main bearing halves (1 and 2) into the engine block.
5. Install two bedplate locating dowels (3). CAUTION: When installing the crankshaft, use care not to damage bearing surfaces on the crankshaft.
6. Install the crankshaft (1) into the engine block. CAUTION: The bedplate bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.
7. Check the bedplate bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
8. If removed, lubricate and install the lower main bearing halves (1) into the bedplate.
9. Clean the cylinder block and bedplate mating surfaces with isopropyl alcohol in preparation for sealant application. CAUTION: Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Engine RTV GEN II may result in engine fluid leakage. CAUTION: Following the application of Mopar® Engine RTV GEN II to the gasket surfaces, the components must be assembled within 10 minutes and the attaching fasteners must be tightened to specification within the next 10 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.
10. Apply a 2 to 3 mm wide bead of Mopar® Engine RTV GEN II sealant (2) to the bedplate as shown in illustration.
11. Position the bedplate onto the cylinder block. Make sure the bedplate seats fully over the locating dowels.
12. Install the twenty bedplate bolts finger tight.
13. Tighten the bedplate bolts in the sequence shown in illustration, following this 5 step torque plus angle method. Tighten according to the following torque values: Step 1: 1 through 10 to 20 N.m (15 ft. lbs.). Step 2: 11 through 20 to 15 N.m (11 ft. lbs.). Step 3: 1 through 10 again to 20 N.m (15 ft. lbs.). Step 4: 1 through 10 + 80° Turn Do not use a torque wrench for this step. Step 5: 11 through 20 to 32 N.m (27 ft. lbs.).
14. Measure crankshaft end play. Refer to «CRANKSHAFT - STANDARD PROCEDURE»(ref-646215-S32443296812014072800000) .
15. If removed, install the bearing shell on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
16. Install the (special tool #10281, Pins, Connecting Rod Guide) (4) on the connecting rod. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur.
17. Pull the connecting rod and piston toward the crankshaft until the connecting rod is seated on the crankshaft journal. Remove the connecting rod guides. CAUTION: The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.
18. If removed, install the bearing shell (3) on the connecting rod cap (1) with the tang inserted into the machined groove in the cap. Lubricate the bearing surface with clean engine oil. NOTE: Do not lubricate the threads of the connecting rod cap bolts (5).
19. Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten the NEW connecting rod cap bolts (2) to 20 N.m (15 ft. lbs.) plus 40 degrees.
20. If required, check the connecting rod side clearance. Refer to «ROD, PISTON AND CONNECTING - STANDARD PROCEDURE»(ref-646215-S02867822902014072800000) .
21. Repeat the previous steps for the remaining connecting rods.
22. Install a new oil filter housing oil return tube O-ring seal (1).
23. Install the oil filter housing oil return tube (2) between the bedplate and oil filter housing with two gaskets (4). Tighten the bolt (3) to 9 N.m (80 in. lbs.) and tighten the bolt (1) to 33 N.m (24 ft. lbs.).
24. Install the engine oil pump, timing belt and sprockets. Refer to «PUMP, ENGINE OIL, INSTALLATION»(ref-646215-S34382702032014072800000) .
25. Install the rear crankshaft oil seal and transmission. Refer to «SEAL, CRANKSHAFT OIL, REAR, INSTALLATION»(ref-646215-S35086570382014072800000) .
26. Install the engine. Refer to «INSTALLATION»(ref-646215-S32878294612014072800000) .
27. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «OIL - STANDARD PROCEDURE»(ref-646215-S41491917222014072800000) .
28. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
29. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
30. Operate the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

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 136

Scheme 137

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
2. Remove the right front wheel and tire assembly. Refer to «REMOVAL»(ref-646212-S02251014372014072800000) .
3. Remove two bolts (4) and the right vertical brace (5).
4. Remove two screws (2) from the front wheelhouse splash shield.
5. Remove three screws (1) and the frame splash shield (3).
6. Remove the accessory drive belt (4). Refer to «BELT, SERPENTINE, REMOVAL»(ref-646235-S33730159442014072800000) .
7. Remove the three bolts (2) and the vibration damper (1).

1. Align the locator pin on the crankshaft sprocket with the hole in the vibration damper (1). Install the vibration damper (1) with three bolts (2) tightened to 25 N.m (19 ft. lbs.).
2. Install the accessory drive belt (4). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .
3. Install the frame splash shield (3) with three screws (1).
4. Install two screws (2) to the front wheelhouse splash shield.
5. Install the right vertical brace (5) with two bolts (4) tightened to 45 N.m (33 ft. lbs.).
6. Install the right front wheel and tire assembly. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000) .

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. Refer to appropriate Diagnostic Information .

Scheme 138

Scheme 139

1. Wipe the cylinder bore clean.
2. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder to a position 12 mm (0.50 in.) from the bottom of the cylinder bore.
3. Using a feeler gauge (1), check the ring end gap. Replace any rings not within specification. Ring Position Ring End Gap No. 1 Ring (Top) 0.20 - 0.35 mm (0.008 - 0.014 in.) No. 2 Ring (Center) 0.40 - 0.60 mm (0.016 - 0.024 in.) Oil Control Ring (Bottom) 0.20 - 0.40 mm (0.008 - 0.016 in.)
4. Clean the piston ring grooves. Remove any nicks or burrs.
5. Measure the ring side clearance as shown in illustration. Make sure the feeler gauge (1) fits snugly between the ring land and the ring. Replace any ring not within specification.

Scheme 140

Note. Typical piston shown in illustration.

Scheme 141

Scheme 142

1. Remove the piston and connecting rod(s). Refer to «ROD, PISTON AND CONNECTING, REMOVAL»(ref-646215-S31725676512014072800000) . CAUTION: To avoid damage to the piston rings, they must be removed in the following order: No. 1 (upper) piston ring (1) No. 2 (intermediate) piston ring (2) Oil control ring (3) Oil control ring expander (4) NOTE: Typical piston shown in illustration.
2. Remove the No. 1 (upper) piston ring using a ring expander tool.
3. Remove the No. 2 (intermediate) piston ring using a ring expander tool. NOTE: Typical piston shown in illustration. Do not use a piston ring expander to remove the oil control ring (1).
4. Remove the oil control ring (1).
5. Remove the oil control ring expander.

Note. Typical piston shown in illustration.

Scheme 143

Scheme 144

1. If required, fit new rings to the piston. Refer to «RING(S), PISTON - STANDARD PROCEDURE»(ref-646215-S14082111112014072800000) . CAUTION: To avoid damage to the piston rings, they must be installed in the following order: Oil control ring expander (4) Oil control ring (3) No. 2 (intermediate) piston ring (2) No. 1 (upper) piston ring (1) NOTE: Typical piston shown in illustration. Do not use a piston ring expander to install the oil control ring (1).
2. Install the oil control ring expander.
3. Install the oil control ring (1) over the ring expander. NOTE: Typical piston shown in illustration. The No. 1 (upper) piston ring (1) and No. 2 (intermediate) piston ring (3) have a different cross section thickness. Install the rings with manufacturers I.D. mark (dot) (2) facing up, towards the top of the piston. NOTE: Typical piston shown in illustration.
4. Install the No. 2 (intermediate) piston ring using a ring expander tool.
5. Install the No. 1 (upper) piston ring using a ring expander tool.
6. Rotate the rings around the piston, the rings must rotate in the grooves without binding.
7. Position the piston ring end gaps as follows: Oil control ring expander gap (5) Oil control ring end gap (2) No. 2 (intermediate) ring end gap (4) No. 1 (upper) ring end gap (1)
8. Install the piston and connecting rod(s). Refer to «ROD, PISTON AND CONNECTING, INSTALLATION»(ref-646215-S06783061622014072800000) .

Scheme 145

The pistons are a lightweight design with low tension piston rings for improved fuel economy. The pistons are made of a high strength silicon aluminum alloy and the piston skirt has a Moly® coating. The piston pin is a press fit into the rod. The connecting rod is forged steel with a bolted cracked cap design. The connecting rod bolts are not reusable. Pistons are available in three different diameters with grade markings for each bore indicated on the side of the cylinder block. The piston rings have a dot or a mark that must face the top of the piston. The pistons have an arrow stamped on the crown for assembly. Piston, pins and rods are only available as an assembly.

Scheme 146

The pistons are "select fit" to achieve proper oil clearance. Engine block cylinder bore diameter grade markings are stamped into the right side of the engine block. These marks are read from front to rear, corresponding with cylinder number 1, 2, 3, 4.

Engine block cylinder bore diameter grade markings correspond to specific cylinder bore diameters. The chart below identifies the three engine block grade markings and their associated cylinder bore diameters.

Scheme 147

The piston is marked with the piston size (1) on the piston crown. The pistons are available in three different sizes in order to achieve the desired oil clearance. Select the piston size that corresponds to the engine block cylinder bore diameter grade markings for each cylinder.

Pistons are available in three sizes. The chart below identifies the three piston sizes.

Scheme 148

Note. Typical coated piston shown in illustration.

The coated pistons are serviced with the piston pin and connecting rod pre-assembled. The coating material (1 and 2) is applied to the piston after the final piston machining process. Piston installation into the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.

Scheme 149

1. Mount Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) to a stationary point on the engine. Locate the probe perpendicular to and resting against the connecting rod cap being checked.
2. Move the connecting rod all the way to the rear of its travel.
3. Zero the dial indicator.
4. Move the connecting rod forward to the limit of travel and read the dial indicator. Compare the measured side clearance to the specification. Refer to «ENGINE SPECIFICATIONS»(ref-646215-S03916579012014072800000) .
5. Repeat this procedure for each connecting rod. Rotate the crankshaft for connecting rod accessibility.

Scheme 150

Note. Typical four cylinder engine shown in illustration.

1. Slide a snug-fitting feeler gauge between the connecting rod and crankshaft journal flange. Compare the measured side clearance to the specification. Refer to «ENGINE SPECIFICATIONS»(ref-646215-S03916579012014072800000) .
2. Repeat this procedure for each connecting rod. Rotate the crankshaft for connecting rod accessibility.

Note. To remove the pistons and connecting rods from the engine, the engine must be removed from the vehicle.

Scheme 151

1. Remove the engine. Refer to «REMOVAL»(ref-646215-S41138294822014072800000) .
2. Remove the cylinder head. Refer to «CYLINDER HEAD, REMOVAL»(ref-646215-S40589777212014072800000) .
3. Remove the oil pan and oil pump pick-up. Refer to «PICK-UP, OIL PUMP, REMOVAL»(ref-646215-S17192864682014072800000) .
4. If necessary, remove the top ridge of the cylinder bores with a reliable ridge reamer before removing the pistons from the engine block. Make sure to keep the tops of pistons covered during this operation. Pistons and connecting rods must be removed from the top of the engine block. When removing piston and connecting rod assemblies from the engine, rotate the crankshaft CW so that each connecting rod is centered in the cylinder bore. 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 removing to ensure correct reassembly.
5. Mark connecting rod and bearing cap positions (1) 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.
6. Remove the connecting rod cap bolts (4) and the connecting rod cap (3). Discard the cap bolts.
7. Install the (special tool #10281, Pins, Connecting Rod Guide) (6) on the connecting rod. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur.
8. Remove the piston and connecting rod (1) from cylinder bore.
9. Repeat the previous steps for each piston being removed.
10. Immediately after piston and connecting rod removal, reinstall the bearing cap (3) on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
11. If required, remove the piston rings. Refer to «RING(S), PISTON, REMOVAL»(ref-646215-S17190122252014072800000) .
12. Repeat the previous steps for each piston being removed.

1. Set the mount into position.
2. Tighten the left mount to strut tower bolt (2) finger tight.
3. Tighten the left mount to transaxle bracket bolts (2) finger tight.
4. Tighten the left mount to frame rail bolts (3) finger tight.
5. Tighten the left mount to strut tower bolt (2) to 50 N.m (37 ft. lbs.).
6. Tighten the left mount to frame rail bolts to 87 N.m (64 ft. lbs.).
7. Tighten the left mount to transaxle bracket bolts to 105 N.m (77 ft. lbs.).
8. Install the coolant tube bracket bolt (1). Tighten to 9 N.m (80 in. lbs.).
9. Remove the jack.
10. Install the battery tray. Refer to «TRAY, BATTERY, INSTALLATION»(ref-646227-S37644486382014072800000) .
11. Install the belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
12. Install the engine cover assembly.

1. Raise and support the vehicle.
2. Remove the belly pan.
3. Remove the mount to bracket through bolt (4) and nut (2).
4. Remove the mount to crossmember through bolt (1).
5. Reposition the engine forward to allow the mount to be removed from the pocket past the engine bracket (3). NOTE: The exhaust system can remain intact. Carefully pry the engine forward enough to clear the bracket but not to overextend the exhaust hangers.
6. Remove rear mount.

1. Position rear mount into the crossmember pocket.
2. Install the through bolt (1) into the cradle portion of the mount.
3. Position the front arm of the mount around the bracket (3) and install the through bolt and nut (4 and 2).
4. Tighten bolt (1) to 105 N.m (77 ft. lbs.).
5. Tighten the rear mount to engine bracket through bolt and nut (4 and 2) to 80 N.m (59 ft. lbs.).
6. Install belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .

Scheme 152

Scheme 153

1. Remove the engine cover.
2. Remove the air cleaner assembly. Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646215-S35238296702014072800000) .
3. Remove the coolant reservoir bolts and set the reservoir aside.
4. Remove the belly pan. Refer to «BELLY PAN, REMOVAL»(ref-646214-S24731623582014072800000) .
5. Properly support the powertrain with a suitable jack or stand.
6. Remove the three mount to timing cover bolts (2).
7. Remove the two mount to frame bolts (1).
8. Loosen, but do not remove the mount (1) to strut tower (3) bolt (2).
9. Remove the engine mount (3).

1. Set the mount (3) into position.
2. Tighten the right mount to strut tower bolt (2) finger tight.
3. Install engine mount to frame retaining bolts (1). Finger tighten the bolts.
4. Install the right mount to timing cover bolts (2). Finger tighten the bolts.
5. Tighten the right mount to strut tower (2) bolt to 50 N.m (37 ft. lbs.).
6. Tighten the right mount to frame rail bolts (1) to 63 N.m (46 ft lbs.).
7. Tighten the engine mount to timing cover bolts (2). Tighten to 63 N.m (46 ft. lbs.).
8. Tighten the strut tower bolt (2) to 88 N.m (65 ft. lbs.).
9. Install the coolant reservoir bottle. Install and tighten the bolts to 9 N.m (80 in. lbs.).
10. Install the air box assembly. Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646215-S04758408592014072800000) .
11. Install the engine cover.
12. Remove the jack stand.
13. Install the belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
14. Start the engine and check for vibrations.

Scheme 154

The lubrication system features pressure regulated full flow filtration. The lubrication system consists of the following components

1. Oil pump pick-up tube attached to the oil pump
2. Oil pump that is directly coupled to the crankshaft and is mounted to the front of the engine as part of the oil pump housing
3. Pressure relief valve in the oil pump that controls system pressure
4. Oil filter housing that supports the oil filter and oil cooler
5. Oil cooler mounted to the oil filter housing
6. Oil filter located in the oil filter housing
7. Four piston oil cooler jets mounted to the engine block
8. Filter screen mounted in the variable valve actuation assembly
9. Variable valve actuation assembly that uses pressurized engine oil to open the intake valves
10. Oil pressure switch located on the oil pump housing
11. Oil temperature sensor located on the variable valve actuation assembly

1. Install the new oil cooler seal (1) onto the oil filter housing.
2. Position the oil cooler (1) on the oil filter housing.
3. Install six bolts (2) and tighten to 9 N.m (80 in. lbs.).
4. Install the lower oil cooler housing heatshield (2) with four bolts (3) tightened to 3 N.m (26 in. lbs.).
5. Fill the engine crankcase with the proper oil to the correct level. Refer to «OIL - STANDARD PROCEDURE»(ref-646215-S41491917222014072800000) .
6. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
7. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
8. Operate the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

Scheme 155

All engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler LLC recommends a Mopar® or equivalent oil filter be used.

Scheme 156

1. Place an oil absorbent cloth around the oil filter housing at the base of the oil filter cap. NOTE: The oil filter (3) is attached to the oil filter cap (2).
2. Rotate the oil filter cap (1) counterclockwise and remove the cap (1) and filter (3) from the oil filter housing.
3. Remove the oil filter (3) from the oil filter cap (1).
4. Remove and discard the O-ring seal (2).

Note. It is not necessary to pre-oil the oil filter or fill the oil filter housing.

Scheme 157

1. Lightly lubricate the new O-ring seal (2) with clean engine oil.
2. Install the O-ring seal (2) on the filter cap (1).
3. Install the new oil filter (3) into the oil filter cap (1).
4. Thread the oil filter cap (1) into the oil filter housing and tighten to 25 N.m (18 ft. lbs.).
5. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Refer to «OIL - STANDARD PROCEDURE»(ref-646215-S41491917222014072800000) .

Scheme 158

The 1.4L engine has four engine blocked-mounted oil jets (1) installed to cool the underside of each piston. The oil jets are fed by the main oil gallery, and spray upward on the bottom of the pistons and cylinder walls. Each jet has a check valve which closes to maintain ample oil pressure at idle. All four oil jets are identical and are a press fit to the engine block.

Scheme 159

Note. Piston oil cooler jet for cylinder one shown in illustration. Piston oil cooler jets for cylinders two, three and four are similar.

1. Remove the piston and connecting rod(s). Refer to «ROD, PISTON AND CONNECTING, REMOVAL»(ref-646215-S31725676512014072800000) .
2. Remove the crankshaft. Refer to «CRANKSHAFT, REMOVAL»(ref-646215-S06055358142014072800000) .
3. Using a suitable drift (1), drive the piston oil cooler jet(s) (2) from the engine block.
4. Discard the piston oil cooler jet(s), they are not reusable.

Scheme 160

Note. Piston oil cooler jet for cylinder three shown in illustration. Piston oil cooler jets for cylinders one, two and four are similar.

1. Using a suitable driver (1), install the piston oil cooler jet(s) (2) into the engine block.
2. Install the crankshaft. Refer to «CRANKSHAFT, INSTALLATION»(ref-646215-S29635557422014072800000) .
3. Install the piston and connecting rod(s). Refer to «ROD, PISTON AND CONNECTING, INSTALLATION»(ref-646215-S06783061622014072800000) .
4. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «OIL - STANDARD PROCEDURE»(ref-646215-S41491917222014072800000) .
5. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
6. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
7. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

Scheme 161

1. Remove the RH engine mount bracket (1) (Refer to «ENGINE MOUNTING»(ref-646215-S35809285072014072800000) ).
2. Remove the MultiAir actuator oil supply filter (2) from the camshaft bearing housing.

1. Install a new O-ring (1) lubricated with engine oil on the MultiAir actuator oil supply filter (2). Install the filter into the camshaft bearing housing and tighten to 27 N.m (20 ft. lbs.).
2. Install the RH engine mount bracket (1) (Refer to «ENGINE MOUNTING»(ref-646215-S35809285072014072800000) ).
3. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «OIL - STANDARD PROCEDURE»(ref-646215-S41491917222014072800000) .

Scheme 162

The oil filter housing is located on the left side of the cylinder block and is connected to the oil pump. The oil filter element is located within the housing and the engine oil cooler is attached to the side of the housing.

Scheme 163

Oil flows from the oil pump housing through the oil pump/oil filter housing interface (1) and into the oil filter housing. Within the oil filter housing the oil first travels through the oil cooler and then through the oil filter. After the oil is filtered and cooled it travels back to the oil pump housing through the oil pump/oil filter housing interface (1) and to the main engine oil gallery. Removing the oil filter cap from the housing allows oil to drain from the oil filter cavity into to the crankcase (3).

Engine coolant flows from the thermostat housing into the oil filter housing (4) and into the oil cooler. The coolant flows through the oil cooler and exits the housing (2) where it is returned to the water pump inlet.

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

1. Disconnect and isolate the negative battery cable.
2. Drain the engine oil. Refer to «OIL - STANDARD PROCEDURE»(ref-646215-S41491917222014072800000) .
3. Remove the maniverter (4). Refer to «MANIFOLD, EXHAUST, REMOVAL»(ref-646215-S25028666292014072800000) .
4. Remove six bolts (3 and 4) and the upper (1) and lower (2) oil cooler housing heat shields.
5. Remove the nut (3) from the support bracket on the water pump coolant inlet tube.
6. Remove the two bolts (2 and 4) and remove the oil filter housing coolant supply tube (1).
7. Remove the two bolts (1 and 3) and the oil filter housing oil return tube (2).
8. Loosen the nut (2), remove the bolt (3) and remove the oil filter housing coolant return tube (1).
9. Remove bolt (2) and the water pump coolant inlet tube (1).
10. Remove the three bolts (2 and 3) and the oil filter housing (1).
11. Remove and discard the oil filter housing seal (2).
12. If required, remove the oil cooler (1) from the oil filter housing. Refer to «COOLER, OIL, REMOVAL»(ref-646215-S40705906402014072800000) .
13. If required, remove the oil filter (3) from the oil filter housing. Refer to «FILTER, ENGINE OIL, REMOVAL»(ref-646215-S23394869042014072800000) .

Scheme 170

Scheme 171

Scheme 172

Scheme 173

1. If removed, install the oil cooler (1) onto the oil filter housing. Refer to «COOLER, OIL, INSTALLATION»(ref-646215-S29729599782014072800000) .
2. Install a new oil filter housing seal (2) onto the oil filter housing.
3. Install new O-ring seals (1 and 2) on the oil filter housing to oil pump bolt.
4. Position the oil filter housing (1) on the engine block.
5. Install the oil filter housing to oil pump bolt (3) and the two oil filter housing to engine block bolts (2). Tighten the oil filter housing to oil pump bolt (3) first to 45 N.m (33 ft. lbs.) then tighten the two oil filter housing to engine block bolts (2) to 50 N.m (37 ft. lbs.).
6. Install a new seal (1) on the water pump inlet tube.
7. Install the water pump inlet tube (1) to the engine block. Tighten the bolt (2) to 9 N.m (80 in. lbs.).
8. Install the oil filter housing coolant return tube O-ring seal (1) in the water pump inlet tube.
9. Install the oil filter housing coolant return tube (1) between the water pump coolant inlet tube and oil filter housing with two gaskets (4). Tighten the nut (2) to 33 N.m (24 ft. lbs.) and tighten the bolt (3) to 33 N.m (24 ft. lbs.).
10. Install a new oil filter housing oil return tube O-ring seal (1).
11. Install the oil filter housing oil return tube (2) between the bedplate and oil filter housing with two gaskets (4). Tighten the bolt (3) to 9 N.m (80 in. lbs.) and tighten the bolt (1) to 33 N.m (24 ft. lbs.).
12. Install the oil filter housing coolant supply tube O-ring seals (1 and 2).
13. Install the oil filter housing coolant supply tube (1) between the thermostat housing and the oil filter housing with a bolt at each end (2 and 4) tightened to 9 N.m (80 in. lbs.). Secure the support bracket to the water pump coolant inlet tube with a nut (3) tightened to 9 N.m (80 in. lbs.).
14. Install the upper (1) and lower (2) oil cooler housing heat shields with six bolts (3 and 4) tightened to 3 N.m (26 in. lbs.).
15. Install the maniverter. Refer to «MANIFOLD, EXHAUST, INSTALLATION»(ref-646215-S04070668102014072800000) .
16. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «OIL - STANDARD PROCEDURE»(ref-646215-S41491917222014072800000) .
17. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
18. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
19. Start and run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

1. Lightly lubricate the new O-ring seal (1) with engine oil and install on the oil pump.
2. Install the oil pick-up tube (1) with two bolts (2). Tighten the bolts to 10 N.m (89 in. lbs.).
3. Install the oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-646215-S07106931812014072800000) .
4. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «OIL - STANDARD PROCEDURE»(ref-646215-S41491917222014072800000) .
5. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
6. Run the engine until it reaches normal operating temperature.

Scheme 174

The gerotor type engine oil pump is mounted to the front of the engine as part of the oil pump housing. The oil pump is directly coupled to the crankshaft.

The oil pump housing provides mounting points for the following components

1. Oil pick-up tube
2. Front crankshaft oil seal
3. Crankshaft Position (CKP) sensor
4. Oil pressure switch

The oil pump housing is also coupled to the oil filter housing where the pressurized oil is filtered and cooled.

Scheme 175

Note. Pump cover removed for clarity.

The gerotor type engine oil pump is part of the oil pump housing. The oil pump is directly coupled to the crankshaft.

Engine oil is drawn up from the sump through the oil pick-up tube (1). An internal mechanical plunger (2) and spring type pressure relief valve diverts excess oil from the pump outlet back to the pump inlet. The pressure controlled oil flows through the oil pump/oil filter housing interface (3) and into the oil filter housing. After the oil is filtered and cooled it travels back to the oil pump housing through the oil pump/oil filter housing interface (4) where it is routed to the main engine oil gallery (5).

The gerotor pump is not to be disassembled. The gerotor pump is a non-serviceable component of the oil pump housing and is replaced as a complete assembly. The pressure relief valve is serviceable and can be removed and inspected.

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

1. Perform the fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS , STANDARD PROCEDURE»(ref-646230-S42658421212014072800000) .
2. Remove the engine cover.
3. Disconnect the battery negative cable.
4. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
5. Remove the belly pan. Refer to «BELLY PAN, REMOVAL»(ref-646214-S24731623582014072800000) .
6. Drain the engine oil. Refer to «OIL - STANDARD PROCEDURE»(ref-646215-S41491917222014072800000) .
7. Remove the right front wheel and tire assembly. Refer to «REMOVAL»(ref-646212-S02251014372014072800000) .
8. Remove two screws (2) from the front wheelhouse splash shield.
9. Remove three screws and the frame splash shield.
10. Remove the accessory drive belt (4). Refer to «BELT, SERPENTINE, REMOVAL»(ref-646235-S33730159442014072800000) .
11. Remove the crankshaft position sensor electrical connector (1).
12. Remove the mounting bolt (2) and crankshaft position sensor (3).
13. Remove the vibration damper (1). Refer to «DAMPER, VIBRATION, REMOVAL»(ref-646215-S06986049162014072800000) .
14. Position the (special tool #10307, Holder, Crankshaft Sprocket) (1) as shown in illustration.
15. Rotate the crankshaft until the vibration damper locating pin is centered in the clearance hole (4).
16. Install the (special tool #10307, Holder, Crankshaft Sprocket) (1) with three bolts (2) tightened to 25 N.m (15 ft. lbs.).
17. With the (special tool #10307, Holder, Crankshaft Sprocket) (1) resting against the accessory bracket bolt (5), loosen but do not remove the crankshaft bolt (3).
18. Remove the exhaust crossunder pipe. Refer to «PIPE, EXHAUST CROSSUNDER, REMOVAL»(ref-646259-S35977026882014072800000) .
19. Lower the vehicle.
20. Remove the catalytic converter. Refer to «CONVERTER, CATALYTIC, REMOVAL»(ref-646259-S10291058352014072800000) . CAUTION: The maniverter studs are installed in the cylinder head with a thread sealant. If the studs rotate during service this indicates that the seal is broken and the stud must be replaced. Failure to replace the studs can result in engine oil leaking onto the exhaust manifold.
21. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
22. Remove the two bolts (1) from the flywheel dust cover.
23. Remove the two lower transmission bell housing bolts (3). NOTE: The flywheel dust cover is bolted to the oil pan and cannot be removed at this time.
24. Remove 14 bolts (1), 2 nuts and 2 studs (2) from the flange of the oil pan.
25. Using the four indicated pry points, carefully remove the oil pan and flywheel dust cover.
26. Remove all residual sealant (1) from the oil pan, engine block, oil pump and rear seal retainer. Refer to «PAN, OIL, CLEANING»(ref-646215-S37255093812014072800000) .
27. Remove the bolts (2) and remove the oil pump pick-up tube (1) from the oil pump.
28. Remove and discard the O-ring seal (1) from the oil pump.
29. Lower the vehicle. 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.
30. Disconnect the vacuum line at the pump (1).
31. Remove the vacuum pump mounting bolts (2) and the vacuum pump (1).
32. Remove and discard the vacuum pump gasket (1). Note the location of the pump drive tab.
33. Install the (special tool #10277, Tool, Camshaft Timing Locking) (1) to the rear of the camshaft. Rotate the crankshaft clockwise to align the tool with the vacuum pump mounting. Install three bolts (2) and tighten to 20 N.m (15 ft. lbs.).
34. Reposition the coolant recovery bottle (5). Refer to «BOTTLE, PRESSURIZED COOLANT, REMOVAL»(ref-646235-S12438365052014072800000) .
35. Support the engine with a floor jack positioned under the bedplate.
36. Remove six bolts (1 and 3) and the RH engine mount isolator (4).
37. Remove the bolts (2 and 3) and the upper timing belt cover (1).
38. Remove the right engine mount bracket (Refer to «ENGINE MOUNTING»(ref-646215-S35809285072014072800000) ).
39. Remove the bolt (2) and the lower timing belt cover (1). NOTE: If the timing belt is to be reused, mark the direction of rotation using a paint pen or equivalent to aid in reassembly.
40. Loosen the tensioner lock nut (3) and remove the timing belt (1).
41. Temporarily reinstall the RH engine mount bracket with two bolts hand tight. CAUTION: When the timing belt is removed and the cylinder head is still installed, DO NOT rotate the camshaft or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.
42. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
43. Remove the crankshaft sprocket (4): If required, install (special tool #10307, Holder, Crankshaft Sprocket) (1) with three bolts (3) tightened to 25 N.m (15 ft. lbs.) and remove the bolt (2). Remove the crankshaft sprocket (4). Discard the bolt (2).
44. Remove four bolts (3) and the lower oil cooler housing heat shield (2).
45. Remove the oil filter housing to oil pump bolt (1).
46. Remove the seven oil pump bolts (2) and remove the oil pump (1).
47. Remove and discard the oil pump gasket (1).
48. Remove and discard the oil filter housing seal (2).
49. Remove all residual sealant (1) from the engine block, bedplate and oil pump.
50. If required, remove the front crankshaft oil seal (1). NOTE: The oil pressure switch has a lock patch on the threads and if removed can not be reinstalled.
51. If required, remove and discard the oil pressure switch (2). Refer to «SWITCH, OIL PRESSURE, REMOVAL»(ref-646215-S09171637762014072800000) .
52. If required, remove the oil pressure regulator cap (5), spring (3) and plunger (2) from the oil pump (1).

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

1. If removed, install the plunger (2), spring (3) and oil pressure regulator cap (5) with a new O-ring seal (4) to the oil pump (1).
2. Install a new oil pump gasket (1) to the oil pump. Roll the three gasket retaining tabs over the pump flange at the indicated locations.
3. Install a new oil filter housing seal (2) onto the oil filter housing.
4. Clean the cylinder block and bedplate mating surfaces with isopropyl alcohol in preparation for sealant application. CAUTION: Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Engine RTV GEN II may result in engine fluid leakage. CAUTION: Following the application of Mopar® Engine RTV GEN II to the gasket surfaces, the components must be assembled within 10 minutes and the attaching fasteners must be tightened to specification within the next 10 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.
5. Apply a 2 to 3 mm wide bead of Mopar® Engine RTV GEN II sealant (1) to the two cylinder block to bedplate T-joints as shown in illustration.
6. Install the oil pump and gasket (1) with seven bolts (2) hand tight.
7. Attach the (special tool #8225, Alignment Fixture) (2) to the oil pan mounting flange using the oil pan bolts (1). Tighten the bolts to 9 N.m (80 in. lbs.). NOTE: Make sure that the "2.7L" stamped on the alignment fixture is facing the cylinder block (flat side of tools against oil pan mounting flange).
8. Allow the oil pump to center itself on the crankshaft and position the oil pump so that the distance between the oil pump flange and the alignment fixture is equal on both sides (1). NOTE: Do not force the oil pump flange down against the alignment fixture.
9. While maintaining this alignment, tighten the seven bolts in the sequence shown in illustration to 10 N.m (89 in. lbs.).
10. Install new O-ring seals (1 and 2) on the oil filter housing to oil pump bolt.
11. Install the oil filter housing to oil pump bolt (1) and tighten to 45 N.m (33 ft. lbs.).
12. Install the lower oil cooler housing heatshield (2) with four bolts tightened to 3 N.m (26 in. lbs.). CAUTION: When the timing belt is removed and the cylinder head is still installed, DO NOT rotate the camshaft or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.
13. If removed, install the front crankshaft oil seal (1). Refer to «SEAL, CRANKSHAFT OIL, FRONT, INSTALLATION»(ref-646215-S04148349982014072800000) . CAUTION: When the timing belt is removed and the cylinder head is still installed, DO NOT rotate the camshaft or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.
14. Align the crankshaft sprocket locator key to the crankshaft keyway and install the sprocket (1) with a new bolt (2) on the crankshaft. Hand tighten the bolt (2) at this time. The bolt (2) will be tightened to specification after the timing belt is installed.
15. Install the (special tool #10276, Tool, Crankshaft Timing Locking) (1) with three bolts (3) tightened to 25 N.m (18 ft. lbs.) and one bolt (2) tightened to 9 N.m (80 in. lbs.).
16. If removed, install the (special tool #10277, Tool, Camshaft Timing Locking) (1) to the rear of the camshaft. Install three bolts (2) and tighten to 20 N.m (15 ft. lbs.).
17. Support the engine with a floor jack positioned under the bedplate.
18. Carefully raise the front of the engine and remove the bolts and the RH engine mount bracket that were temporarily reinstalled at disassembly.
19. Use the (special tool #6847, Holder, Camshaft Sprocket) (2) to hold the camshaft sprocket (3) and loosen the bolt (1). The camshaft sprocket (3) should now be free to rotate on the camshaft. NOTE: If the original timing belt (1) is being reused, install the belt so that it maintains the same direction of rotation as when it was removed.
20. Install the timing belt starting with the crankshaft sprocket, then the water pump sprocket, finishing with the camshaft sprocket.
21. Install the timing belt tensioner (1) and adjust the tensioner so that the silver tab (2) is centered in the middle of the window. Tighten the lock nut (3) to 28 N.m (21 ft. lbs.).
22. Use the (special tool #6847, Holder, Camshaft Sprocket) (2) to hold the camshaft sprocket (3) and tighten the camshaft sprocket bolt (1) to 120 N.m (88 ft. lbs.).
23. Remove the (special tool #10277, Tool, Camshaft Timing Locking) and the (special tool #10276, Tool, Crankshaft Timing Locking).
24. Rotate the crankshaft clockwise at least two complete revolutions to center the timing belt on the sprockets.
25. Verify that the silver tab (2) is still centered in the middle of the window. If required, loosen the tensioner lock nut (3), readjust the timing belt tensioner (2) and tighten the lock nut (3) to 28 N.m (21 ft. lbs.). NOTE: Reinstall the timing locking tools to verify correct camshaft timing.
26. Install the (special tool #10277, Tool, Camshaft Timing Locking) (1) to the rear of the camshaft. Install three bolts (2) and tighten to 20 N.m (15 ft. lbs.).
27. Install the (special tool #10276, Tool, Crankshaft Timing Locking) (1) with three bolts (3) tightened to 25 N.m (18 ft. lbs.) and one bolt (2) tightened to 9 N.m (80 in. lbs.). NOTE: If the bolt (2) does not align with the lower timing belt cover mounting boss, the camshaft timing is not correct. Loosen the tensioner lock nut and the camshaft sprocket bolt and repeat this procedure.
28. Remove the (special tool #10277, Tool, Camshaft Timing Locking) and the (special tool #10276, Tool, Crankshaft Timing Locking).
29. Install the lower timing belt cover (1) with bolt (2) tightened to 9 N.m (80 in. lbs.).
30. Install the RH engine mount bracket (Refer to «ENGINE MOUNTING»(ref-646215-S35809285072014072800000) ).
31. Install the upper timing belt cover (1) with two bolts (2 and 3) tightened to 9 N.m (80 in. lbs.).
32. Install the pressurized coolant bottle (5). Refer to «BOTTLE, PRESSURIZED COOLANT, INSTALLATION»(ref-646235-S22100940262014072800000) .
33. Clean the mating surfaces of the cylinder head and the vacuum pump. Install a new vacuum pump gasket (1).
34. Align the pump drive tab with the pump drive slot located on the cam shaft.
35. Install the vacuum pump mounting bolts (2). Tighten the bolts to 20 N.m (15 ft. lbs.).
36. Connect the vacuum supply line to the pump (1).
37. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
38. Lightly lubricate the new O-ring seal (1) with engine oil and install on the oil pump.
39. Install the oil pick-up tube (1) with two bolts (2) tightened to 10 N.m (89 in. lbs.).
40. Clean the oil pan, engine block, oil pump and rear seal retainer mating surfaces with isopropyl alcohol in preparation for sealant application. CAUTION: Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Engine RTV GEN II may result in engine fluid leakage. CAUTION: Following the application of Mopar® Engine RTV GEN II to the gasket surfaces, the components must be assembled within 10 minutes and the attaching fasteners must be tightened to specification within the next 10 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.
41. Apply a 2 to 3 mm wide bead of Mopar® Engine RTV GEN II sealant to the oil pan as shown in illustration in the following locations: Oil pan to engine block flange (1) Two oil pump to engine block T-joints (3) Two rear seal retainer to engine block T-joints (2)
42. Install the flywheel dust cover (2) to the oil pan. Tighten the bolt (1) to 9 N.m (80 in. lbs.).
43. Install the oil pan with fourteen bolts (1), two studs and two nuts (2) hand tight.
44. Install the two lower transmission bell housing bolts (3) and tighten to 40 N.m (30 ft. lbs.).
45. Tighten the sixteen oil pan fasteners in two steps following the sequence shown in illustration: Step 1: All to 4 N.m (35 in. lbs.). Step 2: All to 9 N.m (80 in. lbs.).
46. Install the two bolts (1) to the flywheel dust cover and tighten to 9 N.m (80 in. lbs.).
47. Lower the vehicle.
48. Install the catalytic converter. Refer to «CONVERTER, CATALYTIC, INSTALLATION»(ref-646259-S27465961402014072800000) .
49. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
50. Install the exhaust crossunder pipe. Refer to «PIPE, EXHAUST CROSSUNDER, INSTALLATION»(ref-646259-S32847019502014072800000) .
51. Position the (special tool #10307, Holder, Crankshaft Sprocket) (1) against the accessory bracket boss (4) as shown in illustration.
52. Rotate the crankshaft until the vibration damper locating pin is centered in the clearance hole (3).
53. Install the (special tool #10307, Holder, Crankshaft Sprocket) (1) with three bolts (2) tightened to 25 N.m (15 ft. lbs.).
54. With the (special tool #10307, Holder, Crankshaft Sprocket) (1) resting against the accessory bracket boss (3), initially tighten the crankshaft bolt to 20 N.m (15 ft. lbs.).
55. Using a torque angle measuring device, such as OTC Torque Angle Gauge 4554 (2), tighten the crankshaft bolt an additional 110 degrees.
56. Align the locator pin on the crankshaft sprocket with the hole in the vibration damper (1). Install the vibration damper (1) with three bolts (2) tightened to 25 N.m (19 ft. lbs.).
57. Install the crankshaft position sensor (3) with mounting bolt (2). Tighten the mounting bolt to 9 N.m (80 in. lbs.).
58. Connect the electrical connector (1). NOTE: The oil pressure switch has a lock patch on the threads and if removed can not be reinstalled.
59. Install a new oil pressure switch (2) and tighten to 32 N.m (24 ft. lbs.).
60. Connect the oil pressure switch electrical connector (1).
61. Install the accessory drive belt (4). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .
62. Install the wheel well liner. Install the push pins (3) and the screws (2).
63. Install the right front wheel and tire assembly. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000) .
64. Install the belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
65. Lower the vehicle. NOTE: A new engine oil pump must be primed with oil before engine operation.
66. If installing a new engine oil pump, remove the oil filter and prime the new pump through the oil filter housing with approximately 0.5 liter (0.5 quart) of engine oil. Direct the oil into the side port (filter inlet) (1) as shown in illustration and not the center port (filter outlet). Refer to «FILTER, ENGINE OIL, REMOVAL»(ref-646215-S23394869042014072800000) .
67. Install the air cleaner body (6). Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646215-S04758408592014072800000) .
68. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «OIL - STANDARD PROCEDURE»(ref-646215-S41491917222014072800000) .
69. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
70. Install the engine cover.
71. Start and run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

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. Refer to appropriate Diagnostic Information .

Scheme 198

The oil temperature sensor is a two wire sensor located on the variable valve actuation assembly. The sensor probe is mounted to the variable valve actuation assembly through an access hole. A compression washer seals the oil temperature sensor to the variable valve actuation assembly.

1. The oil temperature sensor gasket (1) can be reused if not damaged. Lightly lubricate the sensor threads with clean engine oil.
2. Use an appropriate socket (2) and install the oil temperature sensor (1). Tighten the oil temperature sensor to 18 N.m (13 ft. lbs.).
3. Engage the oil temperature harness connector to the bracket (2).
4. Connect and lock the oil temperature sensor harness connector (1).
5. Install the air cleaner body. Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646215-S04758408592014072800000) .

Scheme 199

The oil pressure switch is mounted on the oil pump housing on the left front side of the engine. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure. The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block).

Note. The oil pressure switch has a lock patch on the threads and if removed can not be reinstalled.

1. Disconnect the battery cable.
2. Raise the vehicle.
3. If equipped, remove the lower belly pan.
4. Disconnect the oil pressure switch electrical connector (1).
5. Remove the oil pressure switch (2) from the oil pump housing.

Note. The oil pressure switch has a lock patch on the threads and if removed can not be reinstalled.

1. Install the oil pressure switch (2) and tighten to 32 N.m (24 ft. lbs.).
2. Connect the oil pressure switch electrical connector (1).
3. If equipped, install the lower belly pan.
4. Lower the vehicle.
5. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Note. The turbocharger and exhaust manifold must be removed from the cylinder head as an assembly.

Scheme 200

1. Remove the turbocharger.
2. Remove and discard the four nuts (1).
3. Lift the manifold up and off of the turbocharger. Remove and discard the gasket.

Note. The turbocharger and exhaust manifold must be installed to the cylinder head as an assembly.

Scheme 201

1. Install a new gasket onto the manifold/turbocharger mating surface.
2. Set the manifold onto the turbocharger studs and install four new nuts (1) by hand.
3. Tighten the four nuts to 24 N.m (18 ft. lbs.).
4. Install the turbocharger and exhaust manifold to the cylinder head.

Scheme 202

The intake manifold is an injection molded nylon composite design. The intake manifold is sealed to the cylinder head using four individual press-in-place port silicone gaskets. Replace the gaskets whenever the intake manifold is removed from the engine. If the intake manifold is damaged or cracked, it must be replaced.

The intake manifold provides ports for Positive Crankcase Ventilation (PVC) and emissions control. The following components are attached to the intake manifold

1. Electronic Throttle Control (ETC)
2. Fuel rail
3. Fuel injectors
4. Combination Manifold Air Pressure (MAP)/ Intake Air Temperature (IAT) sensor
5. Evaporative emissions solenoid

The fuel injection fuel rail is made of high impact metal. The intake manifold can be serviced without removing the fuel injector rail. Always install new O-rings on the fuel injectors.

1. If required, install the following components on the intake manifold: Throttle body. Refer to «THROTTLE BODY, INSTALLATION»(ref-646230-S35529648962014072800000) . Fuel rail. Refer to «RAIL, FUEL, INSTALLATION»(ref-646230-S39143070532014072800000) . Fuel injector(s). Refer to «INJECTOR(S), FUEL, INSTALLATION»(ref-646230-S37932204292014072800000) . Evaporative emissions purge valve. IAT/MAP sensor. Refer to «SENSOR, MANIFOLD AIR PRESSURE (MAP), INSTALLATION»(ref-646230-S09535756412014072800000) .
2. Install four new intake manifold seals (1). 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.
3. Install the intake manifold (1) to the engine through the space normally occupied by the battery. Loosely install an intake manifold flange bolt and the support bolt to hold the intake manifold in position.
4. Install the remaining six of the seven intake manifold flange bolts. Tighten all seven intake manifold flange bolts to 15 N.m (11 ft. lbs.).
5. Install the bolt (2) securing the hose retainer (1) to the intake manifold and securely tighten.
6. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
7. Position the wire harness into the two wire harness retainers (1) and close retainers.
8. Lower the vehicle.
9. Connect the heater core outlet hose (3) and inlet hose (4) to the heater core.
10. Install the A/C compressor (1). Refer to «COMPRESSOR, A/C, INSTALLATION»(ref-646220-S26826649852014072800000) .
11. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
12. Install the accessory drive belt (4). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .
13. Install the frame splash shield (3) with three screws (1).
14. Install two screws (2) to the front wheelhouse splash shield.
15. Install the right vertical brace (5) with two bolts (4) tightened to 45 N.m (33 ft. lbs.).
16. Install both front wheels and tires. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000) .
17. Install the tunnel support brace (2). Tighten bolts (1) to 100 N.m (74 ft. lbs.).
18. Install the belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
19. Lower the vehicle.
20. Install the support bracket (4), nut (3), bolt (6), and tighten to 9 N.m (80 in. lbs.).
21. Engage the retainers (5) to the support bracket (4).
22. Install the bracket (2), two nuts (1), bolt (7), and tighten to N.m (80 in. lbs.).
23. Connect the vacuum supply line to the pump (1).
24. Reposition and engage the purge flow control solenoid (1) to the bracket (4).
25. Connect and lock and the fuel injector wire harness connector (1).
26. Connect and lock the IAT/MAP sensor harness connector (1). 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.
27. Connect the vacuum line to the vacuum pump (1).
28. Connect the fuel vapor purge hose and close the hose retainer (2).
29. Connect the fuel line (1) to the fuel rail. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) .
30. Install the hose and connect the charge air cooler outlet hose (5) to the charge air outlet manifold.
31. Install the bolts (3) to the charge air cooler outlet hose (5) and securely tighten
32. Connect the boost pressure sensor wire harness connector (1).
33. Install the hose to the charge air cooler outlet hose (5) and engage the EVAP purge hose (4) to the retaining clip (2).
34. Install the oil separator housing bracket (1) with two bolts (2) and one nut (3). Tighten the three fasteners to 13 N.m (115 in. lbs.).
35. Tighten the clamp (2) securing the charge air cooler outlet hose to throttle body.
36. Connect the EVAP purge hose (4) to the retaining clip (3).
37. Connect and lock the wire harness connector (3) to the Electronic Throttle Control (ETC).
38. Position the battery tray (3) and PCM in the vehicle.
39. Install the battery tray nut (5) and two bolts (1). Tighten all three fasteners to 25 N.m (18 ft. lbs.).
40. Engage the engine wire harness connector (2) to the battery tray (3).
41. Engage two engine wire harness retainers (4) to the battery tray (3). 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.
42. Connect the Powertrain Control Module (PCM) harness connectors (1 and 2).
43. Install the oil separator housing to the cylinder head cover with three bolts tightened to 13 N.m (115 in. lbs.).
44. Connect the vent hose to the cylinder head cover.
45. Connect the PCV hose to the intake manifold.
46. Install the engine cover assembly.
47. Evacuate and charge the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-646220-S33335783492014072800000) .
48. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
49. Install and connect the battery. Refer to «BATTERY, INSTALLATION»(ref-646227-S21166870622014072800000) .
50. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

Scheme 203

Scheme 204

Scheme 205

1. Disconnect the battery negative cable. Refer to «BATTERY, REMOVAL»(ref-646227-S35480669362014072800000) .
2. Raise and support the vehicle.
3. Remove the from bumper fascia. Refer to «FASCIA, FRONT, REMOVAL»(ref-646214-S35831020322014072800000) .
4. Disconnect charge air cooler hose (2) inlet quick connect (4).
5. Remove bolt (3) from charge air cooler hose (2).
6. Loosen clamp (1) at charge air cooler hose (2).
7. Carefully remove charge air cooler hose from vehicle.
8. Disconnect the evaporative purge hose from charge air cooler outlet hose (5).
9. Disconnect the pressure sensor from the charge air cooler outlet hose (5).
10. Remove the bolts (2 and 3) from the hose.
11. Disconnect the charge air cooler hose (5) outlet quick connect (4).
12. Loosen the clamp (1) at charge the air cooler hose (5).
13. Carefully remove the charge air cooler outlet hose (5) from the vehicle.
14. Remove the bolts (1) from the charge air cooler (2).
15. Lift the charge air cooler (2) out of the vehicle.

1. Install the charge air cooler (2). Set the bottom of the cooler onto the tabs.
2. Install the bolts (1) and tighten to 9 N.m (80 in. lbs.).
3. Install the outlet hose (5) onto the air charge cooler.
4. Seat the quick (4) onto charge air cooler outlet.
5. Tighten clamp (1) at the throttle body inlet.
6. Install the bolts (2 and 3) that secure the outlet hose. Tighten to 9 N.m (80 in. lbs.).
7. Connect the pressure sensor connector.
8. Install the evaporative purge hose onto the charge air cooler hose and set clamp in place.
9. Install the charge air cooler inlet hose.
10. Tighten the clamp (1) at the turbo charger outlet.
11. Seat the quick connect (4) at the cooler inlet.
12. Install bolt (3) and tighten to 9 N.m (80 in.
13. Install the front fascia. Refer to «FASCIA, FRONT, INSTALLATION»(ref-646214-S28568245192014072800000) .
14. Lower the vehicle.
15. Connect the battery negative cable. Refer to «BATTERY, INSTALLATION»(ref-646227-S21166870622014072800000) .

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

Scheme 211

1. Disconnect and isolate the battery negative cable.
2. Raise and support the vehicle.
3. Remove the engine cover.
4. Remove the air box. Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646215-S35238296702014072800000) .
5. Remove the Charge Air Cooler (CAC) inlet hose. Refer to «COOLER AND HOSES, CHARGE AIR, REMOVAL»(ref-646215-S30017359832014072800000) .
6. Drain the coolant. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
7. Remove the crossunder Pipe. Refer to «PIPE, EXHAUST CROSSUNDER, REMOVAL»(ref-646259-S35977026882014072800000) .
8. Remove the turbocharger bracket bolts (1).
9. Remove and discard the bracket nut (3).
10. Remove the turbocharger bracket (2).
11. Remove the turbocharger upper heat shield bolts (1). Remove and discard the nuts (2).
12. Remove the catalytic converter heat shield (3). CAUTION: The oil supply and return lines MUST be replaced whenever the lines are loosened or removed.
13. Disconnect the wastegate supply line from the actuator pump (2).
14. Remove the coolant return line banjo bolt located on the rear side of the turbocharger. Discard the banjo washers.
15. Remove the coolant supply banjo bolt (4) and position the line aside. Discard the banjo washers.
16. Remove the oil supply line banjo bolt (3). Remove the line as an assembly. The oil supply and return lines must be replaced. The oil line banjo bolts and banjo washers must be replaced.
17. Remove the lower oil return line (5). The oil supply and return lines must be replaced. The oil line banjo bolts and banjo washers must be replaced.
18. Disconnect the turbocharger surge valve connector (6). NOTE: Remove the surge valve from the turbocharger. It will be necessary to install the surge valve onto the new turbocharger assembly.
19. Remove the lower catalytic converter support mount (2).
20. Disconnect the upstream oxygen sensor connector.
21. Loosen the catalytic converter clamp (2) at the turbocharger (1) and remove the converter assembly from vehicle.
22. Remove and discard the converter to turbo seal ring (1). NOTE: Install the (special tool #10368, Set, Universal Protective Cap) into the open bores on the turbo to avoid any foreign material to enter the turbocharger.
23. Remove the two bolts that secure the shield to the exhaust manifold. Remove and discard the nut.
24. Remove the shield. NOTE: The turbocharger has been removed for clarity.
25. Remove and discard the nine exhaust manifold nuts (1). Remove the nine washers.
26. Remove and discard the nine exhaust manifold studs. NOTE: The exhaust manifold nuts and studs must be replaced. The washers can be reused. The exhaust manifold gasket and the turbocharger to manifold gasket must be replaced.
27. With the manifold removed, invert the manifold and turbocharger as an assembly. Remove and discard the four nuts (1). NOTE: The turbocharger mounting nuts must be replaced.
28. Lift the manifold up and off of the turbocharger. Remove and discard the gasket.

Scheme 212

1. With the manifold removed, invert the manifold and turbocharger.
2. Install a new gasket onto the manifold/turbocharger mating surface.
3. Set the manifold onto the turbocharger studs and install four new nuts (1) by hand.
4. Tighten the four nuts to 24 N.m (18 ft. lbs.).
5. After the nuts are tightened to 24 N.m (18 ft. lbs.) once, repeat the step to be sure that all nuts are at the proper torque. NOTE: Replace any stud that loosens during removal. If a stud is to be replaced, tighten the new stud to 11 N.m (97 in. lbs.). Age of the vehicle and environment impact how many of the studs come out. Any that stay in the head also need to be checked for the 11 N.m (97 in. lbs.). NOTE: The turbocharger has been removed for clarity. NOTE: When screwing the studs into the head, install them dry. Do not apply any lubricants, adhesives, sealants or the like to the threads. The new studs have a locking adhesive impregnated into the threads.
6. Install new manifold studs. Tighten the studs to 11 N.m (97 in. lbs.).
7. Install a new manifold gasket/shield assembly.
8. Set the manifold and turbocharger assembly onto the cylinder head studs.
9. Install the nine exhaust manifold washers and new nuts (1).
10. 1) Tighten to 15 N.m (133 in. lbs.) in order from 1 to 9.
11. 2) Retighten to 15 N.m (133 in. lbs.) in order from 1 to 4 only .
12. 3) Add additional 30 degrees (one 1/8 of a turn) of clockwise rotation to all in order from 1 to 9.
13. Position the exhaust manifold shield and install the two bolts and one new nut.
14. Tighten the shield bolts to 9 N.m (80 in. lbs.). CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the hourglass shaped center block. Once this occurs, the clamp has lost clamping force and must be replaced.
15. Install the new converter to turbo seal ring (1).
16. Install the catalytic converter assembly (3).
17. Install the catalytic converter v-clamp (2) at the turbocharger (1).
18. Tighten clamp to 8 N.m (71 in. lb).
19. Connect the O2 sensor connector.
20. Install the catalytic converter lower support bracket (2).
21. Install and tighten the bracket bolts (3) to 56 N.m (41 ft. lbs.).
22. Install a new converter to pipe gasket.
23. Install the crossunder pipe. Refer to «PIPE, EXHAUST CROSSUNDER, INSTALLATION»(ref-646259-S32847019502014072800000) .
24. Install the nuts that secure the cross under pipe to the catalytic converter.
25. Tighten the front exhaust pipe nuts to 56 N.m (41 ft. lbs.).
26. Install the exhaust flange nuts (1). Tighten to 69 N.m (51 ft. lbs.). NOTE: Banjo bolts and banjo bolt gaskets must be replaced during assembly. NOTE: The oil supply and return lines must be replaced during assembly or ANY TIME the fittings are loosened to prevent turbine bearing failure due to debris.
27. Connect the wastegate supply hose to the actuator pump (2).
28. Connect the turbocharger pressure sensor hose (1).
29. Install the coolant return line with new washers located on the rear side of the turbocharger. Tighten to 38 N.m (28 ft. lbs.).
30. Install the coolant supply banjo bolt (4) and new washers. Tighten to 38 N.m (28 ft. lbs.).
31. Install the new oil supply line, banjo bolts (3) and washers. Tighten to 30 N.m (22 ft. lbs.).
32. Install the lower new oil return line (5) and new upper gasket. Tighten the bolt to 14 N.m (124 in. lbs.).
33. Install the previously removed surge valve and tighten the bolts to 9 N.m (80 in. lbs.)
34. Connect the turbocharger surge valve connector (6).
35. Install the Charge Air Cooler (CAC) inlet hose. Refer to «COOLER AND HOSES, CHARGE AIR, INSTALLATION»(ref-646215-S42868019272014072800000) .
36. Install the catalytic converter heat shield (3). Install the bolts and new nuts. Tighten the nuts and bolts to 8 N.m (71 in. lbs.).
37. Install the upper heat shield. Install the three bolts and the two new nuts. Tighten the bolts and the nuts to 9 N.m (80 in. lbs.). Care must be taken when tightening the shield bolts. If torque value is not correct, noise will occur.
38. Connect the upstream and downstream oxygen sensor connectors.
39. Install the turbocharger bracket (2), bolts (1) and new nut (3).
40. Tighten the bolts and nut to 25 N.m (18 ft. lbs.).
41. Install the air box. Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646215-S04758408592014072800000) .
42. Install the engine cover.
43. Add any coolant that was lost during the repair. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

Scheme 213

1. Remove the air cleaner body. Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646215-S04758408592014072800000) .
2. Disconnect the fresh air intake hose (2). Remove the air cleaner assembly.
3. Disconnect the electrical connector (3).
4. Remove the vacuum supply (2) and wastegate actuator (1) hoses.
5. Remove the nut (5) securing the solenoid mounting bracket to the timing cover.
6. Remove the solenoid (4).

1. Install the wastegate actuator (4).
2. Install the nut (5). Tighten to 8 N.m (71 in. lbs.).
3. Install the air cleaner body. Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646215-S35238296702014072800000) .

Scheme 214

1. The turbocharger boost pressure sensor (1) is mounted to the charge air cooler (CAC) duct near the throttle body inlet.
2. Disconnect battery cables.
3. Remove the battery from the tray.
4. Remove the battery tray.
5. Disconnect the boost pressure sensor connector.
6. Remove the screw securing the boost pressure sensor to the CAC duct.
7. Remove the boost pressure sensor.

1. Install the boost pressure sensor (1) into the duct.
2. Install the screw to secure the boost pressure sensor to the charge air cooler (CAC duct). Do not over tighten.
3. Install the battery tray.
4. Install the battery.
5. Connect the battery cables.

Scheme 215

Scheme 216

1. Disconnect and isolate the negative battery cable.
2. Disconnect the two vacuum fittings (4), loosen the clamp (3) at the air to turbocharger inlet tube.
3. Disconnect the fresh air intake hose (2).
4. Remove the air cleaner assembly (1).
5. Remove and discard the two nuts (2) and three bolts (1) that secure the upper heat shield.
6. Disconnect the surge valve connector (2)
7. Remove the three bolts (1).
8. Remove the surge valve (3).

1. Install the surge vale into the turbocharger housing.
2. Install the three bolts (1). Tighten the bolts and the nuts to 9 N.m (80 in. lbs.)
3. Connect the surge valve connector (2).
4. Install the upper heat shield.
5. Install the new nuts (2) and the three bolts (1). Tighten to 9 N.m (80 in. lbs.)
6. Install the air cleaner assembly (1)
7. Connect the two vacuum fittings (4), tighten the clamp (3) at the air to turbocharger inlet tube.
8. Connect the fresh air intake hose (2).

Scheme 217

The timing drive system has been designed to provide quiet performance and reliability to support a NON free-wheeling engine.

The timing drive components include a crankshaft sprocket (2), camshaft sprocket (5), tensioner pulley (4) and a timing belt (1). The water pump (3) is also driven by the timing belt. The camshaft sprocket is not keyed to the camshaft.

1. Disconnect and isolate the negative battery cable.
2. Remove the engine cover (1).
3. Remove the bolts (2 and 3) and the upper timing belt cover (1).
4. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
5. Remove the right front wheel and tire assembly. Refer to «REMOVAL»(ref-646212-S02251014372014072800000) .
6. Remove two bolts (4) and the right vertical brace (5).
7. Remove two screws (2) from the front wheelhouse splash shield.
8. Remove three screws (1) and the frame splash shield (3).
9. Remove the accessory drive belt (4). Refer to «BELT, SERPENTINE, REMOVAL»(ref-646235-S33730159442014072800000) .
10. Remove the vibration damper (1). Refer to «DAMPER, VIBRATION, REMOVAL»(ref-646215-S06986049162014072800000) .
11. Remove the bolt (2) and the lower timing belt cover (1).
12. Remove the bolt (2) and the side timing belt cover (1).

1. Install the side timing belt cover (1) with bolt (2) tightened to 25 N.m (18 ft. lbs.).
2. Install the lower timing belt cover (1) with bolt (2) tightened to 9 N.m (80 in. lbs.).
3. Install the vibration damper (1). Refer to «DAMPER, VIBRATION, INSTALLATION»(ref-646215-S17405398102014072800000) .
4. Install the accessory drive belt (4). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .
5. Install the frame splash shield (3) with three screws (1).
6. Install two screws (2) to the front wheelhouse splash shield.
7. Install the right vertical brace (5) with two bolts (4) tightened to 45 N.m (33 ft. lbs.).
8. Install the right front wheel and tire assembly. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000) .
9. Lower the vehicle.
10. Install the upper timing belt cover (1) with two bolts (2 and 3) tightened to 9 N.m (80 in. lbs.).
11. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
12. Install the engine cover (1).

Scheme 218

Scheme 219

Scheme 220

1. Perform the fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS , STANDARD PROCEDURE»(ref-646230-S42658421212014072800000) .
2. Disconnect and isolate the negative battery cable.
3. Remove the engine cover (1).
4. Remove the air cleaner body (6). Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646215-S35238296702014072800000) .
5. Disconnect the PCV hose (1) from the intake manifold.
6. Disconnect the vent hose (3) from the oil filler neck.
7. Remove three bolts (2) and remove the oil separator housing (4) from the cylinder head cover.
8. Disconnect the fuel vapor hose (3) from the intake manifold.
9. Open the hose retainer (1) and disconnect the fuel line (2) from the fuel rail. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) .
10. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
11. Remove the belly pan. Refer to «BELLY PAN, REMOVAL»(ref-646214-S24731623582014072800000) .
12. Remove four bolts (1) and the tunnel support brace (2).
13. Remove the right front wheel and tire assembly. Refer to «REMOVAL»(ref-646212-S02251014372014072800000) .
14. Remove two bolts (4) and the right vertical brace (5).
15. Remove two screws (2) from the front wheelhouse splash shield.
16. Remove three screws (1) and the frame splash shield (3).
17. Remove the accessory drive belt (4). Refer to «BELT, SERPENTINE, REMOVAL»(ref-646235-S33730159442014072800000) .
18. Remove the vibration damper (1). Refer to «DAMPER, VIBRATION, REMOVAL»(ref-646215-S06986049162014072800000) .
19. Position the (special tool #10307, Holder, Crankshaft Sprocket) (1) as shown in illustration.
20. Rotate the crankshaft until the vibration damper locating pin is centered in the clearance hole (4).
21. Install the (special tool #10307, Holder, Crankshaft Sprocket) (1) with three bolts (2) tightened to 25 N.m (15 ft. lbs.).
22. With the (special tool #10307, Holder, Crankshaft Sprocket) (1) resting against the accessory bracket bolt (5), loosen but do not remove the crankshaft bolt (3).
23. If equipped with a manual transmission, remove the rear engine mount bracket bolt (3) and nut (6), loosen the isolator bolt (1) and reposition the rear engine mount isolator (7) away from the bracket (5).
24. If equipped with an automatic transmission, remove two bolts (4) from the rear engine mount bracket (3), loosen the bolt (1) and reposition the rear engine mount link (5) away from the bracket (3). 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.
25. Lower the vehicle.
26. Remove the vacuum pump (1). Refer to «PUMP, VACUUM, REMOVAL»(ref-646215-S40725219682014072800000) .
27. Install the (special tool #10277, Tool, Camshaft Timing Locking) (1) to the rear of the camshaft. Rotate the crankshaft clockwise to align the tool with the vacuum pump mounting. Install three bolts (2) and tighten to 20 N.m (15 ft. lbs.).
28. Reposition the coolant recovery bottle (5). Refer to «BOTTLE, PRESSURIZED COOLANT, REMOVAL»(ref-646235-S12438365052014072800000) .
29. Support the engine with a floor jack positioned under the oil pan.
30. Remove six bolts (1 and 3) and the RH engine mount isolator (4).
31. Remove the bolts (2 and 3) and the upper timing belt cover (1).
32. Carefully raise the front of the engine and remove the six bolts (2) and the RH engine mount bracket (1).
33. Remove the bolt (2) and the lower timing belt cover (1). NOTE: If the timing belt is to be reused, mark the direction of rotation using a paint pen or equivalent to aid in reassembly.
34. Loosen the tensioner lock nut (3) and remove the timing belt (1). CAUTION: When the timing belt is removed and the cylinder head is still installed, DO NOT rotate the camshaft or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.
35. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
36. If required, remove the crankshaft sprocket (4): Install the (special tool #10307, Holder, Crankshaft Sprocket) (1) with three bolts (3) tightened to 25 N.m (15 ft. lbs.). Remove the bolt (2) and the crankshaft sprocket (4). Discard the bolt (2).
37. Lower the vehicle.
38. If required, use (special tool #6847, Holder, Camshaft Sprocket) (2) and remove the bolt (1) and the camshaft sprocket (3).

1. Align the crankshaft sprocket locator key to the crankshaft keyway and install the sprocket (1) with a new bolt (2) on the crankshaft. Hand tighten the bolt (2) at this time. The bolt (2) will be tightened to specification after the timing belt is installed.
2. Install the (special tool #10276, Tool, Crankshaft Timing Locking) (1) with three bolts (3) tightened to 25 N.m (18 ft. lbs.) and one bolt (2) tightened to 9 N.m (80 in. lbs.).
3. If removed, install the (special tool #10277, Tool, Camshaft Timing Locking) (1) to the rear of the camshaft. Install three bolts (2) and tighten to 20 N.m (15 ft. lbs.).
4. Use the (special tool #6847, Holder, Camshaft Sprocket) (2) to hold the camshaft sprocket (3) and loosen the bolt (1). The camshaft sprocket (3) should now be free to rotate on the camshaft. NOTE: If the original timing belt (1) is being reused, install the belt so that it maintains the same direction of rotation as when it was removed.
5. Install the timing belt starting with the crankshaft sprocket, then the water pump sprocket, finishing with the camshaft sprocket.
6. Install the timing belt tensioner (1) and adjust the tensioner so that the silver tab (2) is centered in the middle of the window. Tighten the lock nut (3) to 28 N.m (21 ft. lbs.).
7. Use the (special tool #6847, Holder, Camshaft Sprocket) (2) to hold the camshaft sprocket (3) and tighten the camshaft sprocket bolt (1) to 120 N.m (88 ft. lbs.).
8. Remove the (special tool #10277, Tool, Camshaft Timing Locking) and the (special tool #10276, Tool, Crankshaft Timing Locking).
9. Rotate the crankshaft clockwise at least two complete revolutions to center the timing belt on the sprockets.
10. Verify that the silver tab (2) is still centered in the middle of the window. If required, loosen the tensioner lock nut (3), readjust the timing belt tensioner (2) and tighten the lock nut (3) to 28 N.m (21 ft. lbs.). NOTE: Reinstall the timing locking tools to verify correct camshaft timing.
11. Install the (special tool #10277, Tool, Camshaft Timing Locking) (1) to the rear of the camshaft. Install three bolts (2) and tighten to 20 N.m (15 ft. lbs.).
12. Install the (special tool #10276, Tool, Crankshaft Timing Locking) (1) with three bolts (3) tightened to 25 N.m (18 ft. lbs.) and one bolt (2) tightened to 9 N.m (80 in. lbs.). NOTE: If the bolt (2) does not align with the lower timing belt cover mounting boss, the camshaft timing is not correct. Loosen the tensioner lock nut and the camshaft sprocket bolt and repeat this procedure.
13. Remove the (special tool #10277, Tool, Camshaft Timing Locking) and the (special tool #10276, Tool, Crankshaft Timing Locking).
14. Install the lower timing belt cover (1) with bolt (2) tightened to 9 N.m (80 in. lbs.).
15. Install the RH engine mount bracket (1) with six bolts (2) tightened to 25 N.m (18 ft. lbs.).
16. Install the upper timing belt cover (1) with two bolts (2 and 3) tightened to 9 N.m (80 in. lbs.).
17. Install the RH engine mount isolator (3) and support bracket (1) to the engine mount bracket with three bolts. Tighten the isolator to engine bracket bolts in the sequence shown in illustration to 60 N.m (44 ft. lbs.).
18. Install the RH engine mount isolator (3) to the body with three bolts (2). Tighten the isolator to body bolts (2) to 60 N.m (44 ft. lbs.).
19. Install the pressurized coolant bottle (5). Refer to «BOTTLE, PRESSURIZED COOLANT, INSTALLATION»(ref-646235-S22100940262014072800000) .
20. Install the vacuum pump (1). Refer to «PUMP, VACUUM, REMOVAL»(ref-646215-S40725219682014072800000) .
21. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
22. If equipped with a manual transmission, install the rear engine mount isolator (7) to the transmission with the rear engine mount bracket bolt (3) and nut (6) tightened to 80 N.m (59 ft. lbs.) and tighten the isolator bolt (1) to 130 N.m (96 ft. lbs.).
23. If equipped with an automatic transmission, install the rear engine mount isolator (5) in the bracket (3) with two bolts (4) tighten to 60 N.m (44 ft. lbs.). Install the isolator bolt (1) and tighten to 130 N.m (96 ft. lbs.).
24. Position the (special tool #10307, Holder, Crankshaft Sprocket) (1) against the accessory bracket boss (4) as shown in illustration.
25. Rotate the crankshaft until the vibration damper locating pin is centered in the clearance hole (3).
26. Install the (special tool #10307, Holder, Crankshaft Sprocket) (1) with three bolts (2) tightened to 25 N.m (15 ft. lbs.).
27. With the (special tool #10307, Holder, Crankshaft Sprocket) (1) resting against the accessory bracket boss (3), initially tighten the crankshaft bolt to 20 N.m (15 ft. lbs.).
28. Using a torque angle measuring device, such as OTC Torque Angle Gauge 4554 (2), tighten the crankshaft bolt an additional 110°.
29. Install the vibration damper (1). Refer to «DAMPER, VIBRATION, INSTALLATION»(ref-646215-S17405398102014072800000) .
30. Install the accessory drive belt (4). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .
31. Install the frame splash shield (3) with three screws (1).
32. Install two screws (2) to the front wheelhouse splash shield.
33. Install the right vertical brace (5) with two bolts (4) tightened to 45 N.m (33 ft. lbs.).
34. Install the tunnel support brace (2) with four bolts (1) tightened to 90 N.m (60 ft. lb.).
35. Install the belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
36. Install the right front wheel and tire assembly. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000) .
37. Lower the vehicle.
38. Connect the fuel vapor purge hose (3) to the intake manifold.
39. Connect the fuel line (2) to the fuel rail and close the hose retainer (1). Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) .
40. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 N.m (115 in. lbs.).
41. Connect the vent hose (3) to the oil filler neck.
42. Connect the PCV hose (1) to the intake manifold.
43. Install the air cleaner body (6). Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646215-S04758408592014072800000) .
44. Connect the negative battery cable. Tighten nut to 5 N.m (45 in. lb.).
45. Install the engine cover (1).
46. Start and run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

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. Refer to appropriate Diagnostic Information .

Scheme 221

The timing belt tensioner (1) is mounted to the cylinder head. It has a spring loaded offset hub and a tension indicator (2). Rotating the tensioner hub counterclockwise against internal spring pressure applies tension to the timing belt. When the silver tab is centered in the window the timing belt tension is correct. Lock the tensioner in this position by tightening the nut (3).

Note. If the silver tab is to the right side of the window, timing belt tension is insufficient. If the silver tab is left of the window, timing belt tension is excessive.

1. Perform the fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS , STANDARD PROCEDURE»(ref-646230-S42658421212014072800000) .
2. Disconnect and isolate the negative battery cable.
3. Remove the engine cover (1).
4. Remove the air cleaner body (6). Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646215-S35238296702014072800000) .
5. Disconnect the PCV hose (1) from the intake manifold.
6. Disconnect the vent hose (3) from the oil filler neck.
7. Remove three bolts (2) and remove the oil separator housing (4) from the cylinder head cover.
8. Disconnect the fuel vapor hose (3) from the intake manifold.
9. Open the hose retainer (1) and disconnect the fuel line (2) from the fuel rail. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) . 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.
10. Remove the vacuum pump (1). Refer to «PUMP, VACUUM, REMOVAL»(ref-646215-S40725219682014072800000) .
11. Install the (special tool #10277, Tool, Camshaft Timing Locking) (1) to the rear of the camshaft. Rotate the crankshaft vibration damper clockwise to align the tool with the vacuum pump mounting. Install three bolts (2) and tighten to 20 N.m (15 ft. lbs.).
12. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
13. Remove the belly pan. Refer to «BELLY PAN, REMOVAL»(ref-646214-S24731623582014072800000) .
14. Remove four bolts (1) and the tunnel support brace (2).
15. If equipped with a manual transmission, remove the rear engine mount bracket bolt (3) and nut (6), loosen the isolator bolt (1) and reposition the rear engine mount isolator (7) away from the bracket (5).
16. If equipped with an automatic transmission, remove two bolts (4) from the rear engine mount bracket (3), loosen the bolt (1) and reposition the rear engine mount link (5) away from the bracket (3).
17. Remove the right front wheel and tire assembly. Refer to «REMOVAL»(ref-646212-S02251014372014072800000) .
18. Remove two bolts (4) and the right vertical brace (5).
19. Remove two screws (2) from the front wheelhouse splash shield.
20. Remove three screws (1) and the frame splash shield (3).
21. Remove the accessory drive belt (4). Refer to «BELT, SERPENTINE, REMOVAL»(ref-646235-S33730159442014072800000) .
22. Remove the vibration damper (1). Refer to «DAMPER, VIBRATION, REMOVAL»(ref-646215-S06986049162014072800000) .
23. Lower the vehicle.
24. Reposition the coolant recovery bottle (5). Refer to «BOTTLE, PRESSURIZED COOLANT, REMOVAL»(ref-646235-S12438365052014072800000) .
25. Support the engine with a floor jack positioned under the oil pan.
26. Remove six bolts (1 and 3) and the RH engine mount isolator (4).
27. Remove the bolts (2 and 3) and the upper timing belt cover (1).
28. Carefully raise the front of the engine and remove the six bolts (2) and the RH engine mount bracket (1).
29. Remove the bolt (2) and the lower timing belt cover (1).
30. Install the (special tool #10276, Tool, Crankshaft Timing Locking) (1) with three bolts (3) tightened to 25 N.m (18 ft. lbs.) and one bolt (2) tightened to 9 N.m (80 ft. lbs.). NOTE: If the bolt (2) does not align with the lower timing belt cover mounting boss, the camshaft timing is not correct. Proceed to Timing Belt Installation for service procedures. Refer to «BELT, TIMING, INSTALLATION»(ref-646215-S23117408282014072800000) . NOTE: If the timing belt is to be reused, mark the direction of rotation using a paint pen or equivalent to aid in reassembly.
31. Remove the tensioner lock nut (3) and the tensioner (2).

Note. If the original timing belt (1) is being reused, install the belt so that it maintains the same direction of rotation as when it was removed.

1. If removed, install the timing belt starting with the crankshaft sprocket, then the water pump sprocket, finishing with the camshaft sprocket.
2. Install the timing belt tensioner (1) and adjust the tensioner so that the silver tab (2) is centered in the middle of the window. Tighten the lock nut (3) to 28 N.m (21 ft. lbs.).
3. Remove the (special tool #10277, Tool, Camshaft Timing Locking) and the (special tool #10276, Tool, Crankshaft Timing Locking).
4. Rotate the crankshaft clockwise at least two complete revolutions to center the timing belt on the sprockets.
5. Verify that the silver tab (2) is still centered in the middle of the window. If required, loosen the tensioner lock nut (3), readjust the timing belt tensioner (2) and tighten the lock nut (3) to 28 N.m (21 ft. lbs.). NOTE: Reinstall the timing locking tools to verify correct camshaft timing.
6. Install the (special tool #10277, Tool, Camshaft Timing Locking) (1) to the rear of the camshaft. Install three bolts (2) and tighten to 20 N.m (15 ft. lbs.).
7. Install the (special tool #10276, Tool, Crankshaft Timing Locking) (1) with three bolts (3) tightened to 25 N.m (18 ft. lbs.) and one bolt (2) tightened to 9 N.m (80 in. lbs.). NOTE: If the bolt (2) does not align with the lower timing belt cover mounting boss, the camshaft timing is not correct. Proceed to Timing Belt Installation for service procedures. Refer to «BELT, TIMING, INSTALLATION»(ref-646215-S23117408282014072800000) .
8. Remove the (special tool #10277, Tool, Camshaft Timing Locking) and the (special tool #10276, Tool, Crankshaft Timing Locking).
9. Install the lower timing belt cover (1) with bolt (2) tightened to 9 N.m (80 in. lbs.).
10. Install the RH engine mount bracket (1) with six bolts (2) tightened to 25 N.m (18 ft. lbs.).
11. Install the upper timing belt cover (1) with two bolts (2 and 3) tightened to 9 N.m (80 in. lbs.).
12. Install the RH engine mount isolator (3) and support bracket (1) to the engine mount bracket with three bolts. Tighten the isolator to engine bracket bolts in the sequence shown in illustration to 60 N.m (44 ft. lbs.).
13. Install the RH engine mount isolator (3) to the body with three bolts (2). Tighten the isolator to body bolts (2) to 60 N.m (44 ft. lbs.).
14. Install the pressurized coolant bottle (5). Refer to «BOTTLE, PRESSURIZED COOLANT, INSTALLATION»(ref-646235-S22100940262014072800000) .
15. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
16. Install the vibration damper (1). Refer to «DAMPER, VIBRATION, INSTALLATION»(ref-646215-S17405398102014072800000) .
17. Install the accessory drive belt (4). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .
18. Install the frame splash shield (3) with three screws (1).
19. Install two screws (2) to the front wheelhouse splash shield.
20. Install the right vertical brace (5) with two bolts (4) tightened to 45 N.m (33 ft. lbs.).
21. Install the right front wheel and tire assembly. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000) .
22. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
23. Install the tunnel support brace (2) with four bolts (1) tightened to 90 N.m (60 ft. lb.).
24. If equipped with a manual transmission, install the rear engine mount isolator (7) to the transmission with the rear engine mount bracket bolt (3) and nut (6) tightened to 80 N.m (59 ft. lbs.) and tighten the isolator bolt (1) to 130 N.m (96 ft. lbs.).
25. If equipped with an automatic transmission, install the rear engine mount isolator (5) in the bracket (3) with two bolts (4) tighten to 60 N.m (44 ft. lbs.). Install the isolator bolt (1) and tighten to 130 N.m (96 ft. lbs.).
26. Install the belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
27. Lower the vehicle.
28. Connect the fuel vapor purge hose (3) to the intake manifold.
29. Connect the fuel line (2) to the fuel rail and close the hose retainer (1). Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) .
30. Install the vacuum pump (1). Refer to «PUMP, VACUUM, REMOVAL»(ref-646215-S40725219682014072800000) .
31. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 N.m (115 in. lbs.).
32. Connect the vent hose (3) to the oil filler neck.
33. Connect the PCV hose (1) to the intake manifold.
34. Install the air cleaner body (6). Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646215-S04758408592014072800000) .
35. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
36. Install the engine cover (1).
37. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

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. Refer to appropriate Diagnostic Information .