2.0L Engine - Service Information: Other Dodge Dart PF

CYLINDER COMPRESSION PRESSURE LEAKAGE

Note. To perform a compression test on a MULTI-AIR equipped engine, the ignition MUST remain in the "key on" position. If the ignition is in the "off" position, the intake valves will not actuate and the result will be no compression.

Note. The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.

Note. Be certain the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.

1. Clean the spark plug recesses with compressed air.
2. Remove the spark plugs and record the cylinder number of each spark plug for future reference.
3. Inspect the spark plug electrodes for abnormal firing indicators such as fouled, hot, oily, etc.
4. Disable the fuel system and perform the fuel system pressure release procedure. Refer to «FUEL DELIVERY, GAS , STANDARD PROCEDURE»(ref-646230-S42658421212014072800000) .
5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present.
7. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder.
8. If one or more cylinders have abnormally low compression pressures, repeat the compression test. NOTE: If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question.
9. If one or more cylinders continue to have abnormally low compression pressures, perform the cylinder combustion pressure leakage test. Refer to «CYLINDER COMBUSTION PRESSURE LEAKAGE»(ref-646216-S33438942572014072800000) .

CYLINDER COMBUSTION PRESSURE LEAKAGE

The combustion pressure leakage test provides an accurate means for determining engine condition.

Combustion pressure leakage testing will detect

1. Exhaust and intake valve leaks (improper seating).
2. Leaks between adjacent cylinders or into water jacket.
3. Any causes for combustion/compression pressure loss.

1. Check the coolant level and fill as required. DO NOT install the radiator cap.
2. Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.
3. Remove the spark plugs.
4. Remove the oil filler cap.
5. Remove the air cleaner hose.
6. Calibrate the tester according to the manufacturer's instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1, 379 kPa (200 psi) maximum and 552 kPa (80 psi) recommended.
7. Perform the test procedures on each cylinder according to the tester manufacturer's instructions. Set piston of cylinder to be tested at TDC compression. While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the radiator coolant.

All gauge pressure indications should be equal, with no more than 25% leakage. FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the cylinder.

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART

TOP 19 REASONS THAT MAY LEAD TO ENGINE OIL CONSUMPTION

1. Tapered and Out-of-Round Cylinders The increased piston clearances permit the pistons to rock in the worn cylinders. While tilted momentarily, an abnormally large volume of oil is permitted to enter on one side of the piston. The rings, also tilted in the cylinder, permit oil to enter on one side. Upon reversal of the piston on each stroke, some of this oil is passed into the combustion chamber.
2. Distorted Cylinders This may be caused by unequal heat distribution or unequal tightening of cylinder head bolts. This condition presents a surface which the rings may not be able to follow completely. In this case, there may be areas where the rings will not remove all of the excess oil. When combustion takes place, this oil will be burned and cause high oil consumption.
3. Improper operation of "PCV" system The main purpose of the Positive Crankcase Ventilation (PCV) valve is to recirculate blow-by gases back from the crankcase area through the engine to consume unburned hydrocarbons. The PCV system usually has a one way check valve and a make up air source. The system uses rubber hoses that route crankcase blow by gases to the intake manifold. Vacuum within the engine intake manifold pulls the blow by gases out of the crankcase into the combustion chamber along with the regular intake air and fuel mixture. The PCV system can become clogged with sludge and varnish deposits and trap blow by gases in the crankcase. This degrades the oil, promoting additional formation of deposit material. If left uncorrected, the result is plugged oil rings, oil consumption, rapid ring wear due to sludge buildup, ruptured gaskets and seals due to crankcase pressurization. If equipped with an engine driven vacuum pump, high oil consumption can be caused by unchecked airflow into the pump. This can be caused by anything that opens the vacuum pump intake port up to the atmosphere such as a faulty vacuum pump, hose fitting, hose and brake booster. If there is not a restriction (normally caused by the pump pulling vacuum on the brake booster), then the vacuum pump will pump a high volume of air. This high volume of air will pressurize the crankcase and cause excessive oil burning and oil flow through the PCV system.
4. Worn Piston Ring Grooves For piston rings to form a good seal, the sides of the ring grooves must be true and flat - not flared or shouldered. Piston rings in tapered or irregular grooves will not seal properly and, consequently, oil will pass around behind the rings into the combustion chamber.
5. Worn, Broken or Stuck Piston Rings When piston rings are broken, worn or stuck to such an extent that the correct tension and clearances are not maintained, this will allow oil to be drawn into the combustion chamber on the intake stroke and hot gases of combustion to be blown down the cylinder past the piston on the power stroke. All of these conditions will result in burning and carbon build up of the oil on the cylinders, pistons and rings.
6. Cracked or Broken Ring Lands Cracked or broken ring lands prevent the rings from seating completely on their sides and cause oil pumping. This condition will lead to serious damage to the cylinders as well as complete destruction of the pistons and rings. Cracked or broken ring lands cannot be corrected by any means other than piston replacement.
7. Worn Valve Stems and Guides When wear has taken place on valve stems and valve guides, the vacuum in the intake manifold will draw oil and oil vapor between the intake valve stems and guides into the intake manifold and then into the cylinder where it will be burned.
8. Bent or Misaligned Connecting Rods Bent or misaligned connecting rods will not allow the pistons to ride straight in the cylinders. This will prevent the pistons and rings from forming a proper seal with the cylinder walls and promote oil consumption. In addition, it is possible that a bearing in a bent connect rod will not have uniform clearance on the connecting rod wrist pin. Under these conditions, the bearing will wear rapidly and throw off an excessive amount of oil into the cylinder.
9. Fuel Dilution If raw fuel is allowed to enter the lubrication system, the oil will become thinner and more volatile and will result in higher oil consumption. The following conditions will lead to higher oil consumption; Excess fuel can enter and mix with the oil via a leaking fuel injector Gasoline contaminated with diesel fuel Restricted air intake Excessive idling
10. Contaminated Cooling Systems Corrosion, rust, scale, sediment or other formations in the water jacket and radiator will prevent a cooling system from extracting heat efficiently. This is likely to cause cylinder distortion thus leading to higher oil consumption.
11. Oil Viscosity The use of oil with a viscosity that is too light may result in high oil consumption. Refer to the vehicle Owner's Manual for the proper oil viscosity to be used under specific driving conditions and/or ambient temperatures.
12. Dirty Engine Oil Failure to change the oil and filter at proper intervals may cause the oil to be so dirty that it will promote accumulation of sludge and varnish and restrict oil passages in the piston rings and pistons. This will increase oil consumption; dirty oil by nature is also consumed at a higher rate than clean oil.
13. Crankcase Overfull Due to an error in inserting the oil dip stick so that it does not come to a seat on its shoulder, a low reading may be obtained. Additional oil may be added to make the reading appear normal with the stick in this incorrect position which will actually make the oil level too high. If the oil level is so high that the lower ends of the connecting rods touch the oil in the oil pan excessive quantities of oil will be thrown on the cylinder walls and some of it will work its way up into the combustion chamber.
14. Excessively High Oil Pressure A faulty oil pressure relief valve may cause the oil pressure to be too high. The result will be that the engine will be flooded with an abnormally large amount of oil in a manner similar to that which occurs with worn bearings. This condition may also cause the oil filter to burst.
15. Aftermarket Performance Chips and Modification Increasing performance through the use of performance/power enhancement products to a stock or factory engine will increase the chance of excessive oil consumption.
16. Lugging Engine Lugging is running the engine at a lower RPM in a condition where a higher RPM (more power/torque) should be implemented. Especially susceptible on vehicles equipped with a manual transmission. This driving habit causes more stress loading on the piston and can lead to increases in engine oil consumption.
17. Turbocharged Engines There is a possibility for PCV "push-over" due to higher crankcase pressure (as compared to naturally aspirated engines) which is normal for turbocharged engines. This condition causes varying amounts of engine oil to enter the intake manifold, charge air cooler and associated plumbing to and from the charge air cooler, also a leaking turbocharger seal will draw oil into the combustion chamber where it will burn (blue smoke from tail pipe may be present) and form carbon deposits which contribute to further oil consumption as they interfere with proper engine function.
18. Restricted Air Intake Excessive restriction in the air intake system will increase engine vacuum and can increase oil consumption, an extremely dirty air filter would be one example of this situation.
19. Intake Manifold port seals Engines that have a "V" configuration and a "wet valley" (3.3/3.8L) could draw oil into the intake ports due to improper sealing between the intake manifold ports and cylinder head. Causes may include improper torque of intake manifold bolts, corrosion (aluminum intake manifold) and or warped sealing surface.

REPAIR DAMAGED OR WORN THREADS

Damaged or worn threads can be repaired. Essentially, this repair consists of

1. Drilling out worn or damaged threads.
2. Tapping the hole with a special Heli-Coil Tap, or equivalent.
3. Installing an insert into the tapped hole to bring the hole back to its original thread size.

FORM-IN-PLACE GASKETS AND SEALERS

Note. All of the sealants mentioned below are not used on every engine, they are listed as a general reference guide. See appropriate Service Information for specific sealer usage.

There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in-place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket. All sealing surfaces that use form-in-place gaskets and sealers must be free of grease or oil. Surfaces should be cleaned with Mopar® brake parts cleaner prior to sealer application. After the sealer is applied, the parts should be assembled within 10 minutes.

There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Engine RTV GEN II, Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties and can not be used in place of the other.

MOPAR® ENGINE RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® GASKET MAKER is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.

MOPAR® BED PLATE SEALANT is a unique (green-in-color) anaerobic type gasket material that is specially made to seal the area between the bed plate and cylinder block without disturbing the bearing clearance or alignment of these components. The material cures slowly in the absence of air when torqued between two metallic surfaces, and will rapidly cure when heat is applied.

MOPAR® THREEBOND ENGINE RTV SEALANT is a unique gasket material that is specially made to retain adhesion and sealing properties when used to seal components exposed to engine oil.

CYLINDER HEAD GASKET

A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket.

Possible indications of the cylinder head gasket leaking between adjacent cylinders are

1. Loss of engine power
2. Engine misfiring
3. Poor fuel economy

Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are

1. Engine overheating
2. Loss of coolant
3. Excessive steam (white smoke) emitting from exhaust
4. Coolant foaming

HYDRAULIC LASH ADJUSTER

A tappet-like noise may be produced from several items. Check the following items.

1. Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy.
2. Insufficient running time after rebuilding the cylinder head. Low speed running up to one hour may be required.
3. Turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature.
4. Low oil pressure.
5. The oil screen in cylinder head or the oil passage to the cylinder head is plugged with debris.
6. Air ingested into oil due to broken or cracked oil pump pick-up.
7. Worn valve guides.
8. Rocker arm ears contacting valve spring retainer.
9. Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system.
10. Oil leak or excessive cam bore wear in the cylinder head.
11. Faulty lash adjuster.

1. Check lash adjusters for "sponginess" while installed in the cylinder head and cam lobe at base circle. Depress part of rocker arm over the adjuster. Normal adjusters should feel firm when pressed quickly. When pressed very slowly, lash adjusters should collapse.
2. Remove suspected lash adjusters, and replace.
3. Before installation, make sure adjusters are full of oil. This can be verified by little plunger travel when lash adjuster is depressed quickly.

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1. Perform the fuel system pressure release procedure. Refer to «FUEL DELIVERY, GAS , STANDARD PROCEDURE»(ref-646230-S42658421212014072800000) .
2. Disconnect and isolate the negative battery cable.
3. Remove the resonator (1). Refer to «RESONATOR, AIR CLEANER, REMOVAL»(ref-646216-S00754484562014072800000) .
4. Remove the air cleaner body (1). Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646216-S37540781882014072800000) .
5. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
6. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
7. Remove the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-646216-S10550530762014072800000) .
8. Remove the maniverter. Refer to «MANIFOLD, EXHAUST, REMOVAL»(ref-646216-S29333726532014072800000) .
9. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
10. Drain the coolant.
11. Remove the two nuts (1), the bolt (2) and the intake manifold lower bracket (3).
12. Remove the frame cover portion of the right splash shield. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL»(ref-646233-S05943217422014072800000) . CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.
13. Remove the frame cover portion of the right splash shield. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL»(ref-646233-S05943217422014072800000) . CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.
14. Rotate the crankshaft clockwise (as viewed from the front) to align the timing cover mark (1) with the damper notch (2) to place the number one cylinder piston at top-dead-center on the compression stroke.
15. Remove the engine timing cover (1). Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-646216-S30183277652014072800000) .
16. Remove the tensioner (5) and timing chain (2). Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL»(ref-646216-S30073282402014072800000) .
17. Remove the timing chain guide (4) and the timing chain pivot guide (6).
18. Disconnect the vapor line (2) at the purge vapor solenoid end of the line.
19. Remove the NVH foam pad (3) prior to disconnecting the fuel line (1).
20. To remove the foam pad, cut the pad along the score line (1). Make sure care is taken to not make contact with any other components while cutting the pad. Do not cut beyond the line . Remove the pad from the fuel rail once split.
21. Disconnect the fuel line from the fuel rail. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) .
22. Unplug the Electronic Throttle Control (ETC) connector.
23. Disconnect the VVAA solenoids.
24. Unplug the purge solenoid.
25. Disconnect the three hoses from the intake manifold fittings (3).
26. Using a permanent ink or paint marker, identify the location and position on each camshaft bearing cap. CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS.
27. Remove the bolt (3) and cam chain guide (1).
28. Remove four bolts (1) and the front camshaft bearing cap (2). NOTE: Camshaft bearing caps should have been marked during engine manufacturing. For example, number one exhaust camshaft bearing is marked "E1>". CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS.
29. Using a permanent ink or paint marker, identify the location and position on each camshaft bearing cap.
30. Loosen the camshaft bearing cap bolts (1) and remove the camshaft bearing caps.
31. Remove the camshafts. NOTE: If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.
32. Remove the rocker arm(s) (1). NOTE: If the hydraulic lifters are to be reused, identify their positions so that they can be reassembled into their original locations.
33. Remove the hydraulic lifter(s) (1). NOTE: All of the cylinder head bolts have captured washers EXCEPT the front two (1).
34. Remove the cylinder head bolts and two uncaptured washers.
35. Remove the cylinder head from the engine block.
36. Inspect the cylinder head and cylinder head components. Refer to «CYLINDER HEAD, INSPECTION»(ref-646216-S00653239252014072800000) .

Note. Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.

CLEANING

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.

Note. Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

1. Remove all gasket material from cylinder head and block. Refer to «ENGINE - STANDARD PROCEDURE»(ref-646216-S32430634582014072800000) . Be careful not to gouge or scratch the aluminum head sealing surface.
2. Clean all engine oil passages.
3. Clean out the cylinder head bolt holes in the engine block.

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Note. Typical Cylinder Head shown in illustration.

1. Check for cylinder head warping with a straight edge (2) and feeler gauge (1).
2. Cylinder head must be flat within specification. Refer to «ENGINE SPECIFICATIONS»(ref-646216-S00174117082014072800000) .
3. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
4. Inspect the following components and verify that they are within specification. Refer to «ENGINE SPECIFICATIONS»(ref-646216-S00174117082014072800000) . Springs Valve Seats Valve Guides Valves

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1. Check the cylinder head 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. NOTE: Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged. CAUTION: Always replace the variable valve timing filter screen (3) when servicing the head gasket or engine damage could result. NOTE: Prior to installing the cylinder head to the block, the intake manifold must installed onto the cylinder head.
2. Replace the variable valve timing filter screen (3).
3. Clean all gasket surfaces.
4. Replace intake manifold gasket seals.
5. Position the foam pad over the coolant transfer tube.
6. Apply 3-5 dabs of RTV to the foam pad where it makes contact with the coolant transfer tube prior to setting the foam pad in position. This will aid in holding the pad in the proper position while setting the head on the block.
7. Position the intake manifold onto the cylinder head.
8. Install the three bolts and two nuts. Using the torque sequence pattern as a guide, tighten the bolts and nuts to 25 N.m (18 ft. lbs.).
9. Install the manifold to head bracket (1). Tighten the nuts (2) and bolts to 9 N.m (81 in. lbs.)
10. Install the fuel rail assembly. Refer to «RAIL, FUEL, INSTALLATION»(ref-646230-S39143070532014072800000) .
11. Install the intake manifold silencer pad and screws. Tighten the screws to 2.5 N.m (22 in. lbs.).
12. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on the cylinder block as shown in illustration.
13. Position the new cylinder head gasket on the engine block with the part number facing up. Ensure gasket is seated over the locating dowels in the block.
14. Route the knock sensor wiring harness between the coolant transfer tube and the engine block. Insert the harness retainer into the holder.
15. Position the cylinder head onto the engine block. NOTE: Make sure the foam pad is not out of position. Inspect the positioning of the pad from below to make sure that no part of the pad is between the cylinder head and the engine block surface. NOTE: The front two cylinder head bolts do not have captured washers. The washers must be installed with the bevel edge (1) up towards the bolt head.
16. Install washers (1) for the front two cylinder head bolts with the beveled edge facing up. NOTE: DOHC shown in illustration, SOHC same sequence. NOTE: Before installing the cylinder head bolts, lubricate the threads with clean engine oil.
17. Install the ten cylinder head bolts finger tight.
18. Tighten the cylinder head bolts in the sequence shown in illustration, following this 4 step torque plus angle method. Tighten according to the following torque values: Step 1: All to 30 N.m (22 ft. lbs.) Step 2: All to 73 N.m (54 ft. lbs.) Step 3: All again to 73 N.m (54 ft. lbs.) Step 4: All an additional 90° Turn Do not use a torque wrench for this step.
19. If the hydraulic lifters are being reused, reassemble them into their original locations.
20. Install the hydraulic lifters. NOTE: If the rocker arms are being reused, reassemble them into their original locations.
21. Install the rocker arms.
22. Oil all of the camshaft journals with clean engine oil.
23. Install the camshaft. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-646216-S23969339752014072800000) .
24. Install the VVAA.
25. Install timing chain and tensioner. Refer to «CHAIN AND SPROCKETS, TIMING, INSTALLATION»(ref-646216-S09171916332014072800000) .
26. Install timing chain cover, engine mount, pulleys and accessory drive belt. Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-646216-S12032062052014072800000) .
27. Install the cylinder head cover and ignition coils. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-646216-S20861717392014072800000) .
28. Install the exhaust manifold. Refer to «MANIFOLD, EXHAUST, INSTALLATION»(ref-646216-S27928656742014072800000) .
29. Connect the electrical connectors to the ignition coils and fuel injectors.
30. Insert the foam insulator (3) over the fuel rail.
31. Connect fuel line (1).
32. Connect the purge vapor line (2). Remove wiring harness retainer from the intake manifold eyelets (1).
33. Connect the three hose connectors (3).
34. Connect the knock sensor connector.
35. Install the intake manifold lower bracket (3). Install the nuts (1) and bolt (2). Tighten to 9 N.m (81 in. lbs.)
36. Connect the MAP sensor connector (2).
37. Inspect quick connect fittings for damage, replace if necessary. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) .
38. Install the air cleaner body (1). Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646216-S26351878182014072800000) .
39. Install the resonator (3), bolt (2), and clamp (1). Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-646216-S21595726612014072800000) .
40. Install the engine cover (1).
41. 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-646216-S42585434202014072800000) .
42. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
43. Recharge the air conditioning system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-646220-S33335783492014072800000) .
44. Install the resonator. Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-646216-S21595726612014072800000) .
45. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
46. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
47. 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 «POWERTRAIN CONTROL MODULE (PCM) - STANDARD PROCEDURE»(ref-646316-S36714730782014072800000) .

ON VEHICLE

1. If removed, install the valve guide seal (2) over the valve guide (3). Refer to «SEAL(S), VALVE GUIDE, INSTALLATION»(ref-646216-S12112320312014072800000) . NOTE: Make sure that the garter spring (1) is intact around the top of the valve guide seal (2). Number 2 cylinder exhaust valve guide seal shown in illustration, all other valves similar. NOTE: If the valve springs are being reused, reassemble them into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valves similar.
2. Install the valve spring (2) and valve spring retainer (1). NOTE: Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.
3. Using the (special tool #10224, Adapter, Valve Spring) (2) with the (special tool #MD998772A, Compressor, Valve Spring) (1), compress the valve spring (4) only enough to install the valve retaining locks (3).
4. Relieve the air pressure and remove the spark plug adapter.
5. Install the spark plug and tighten to 19 N.m (14 ft. lbs.). Refer to «SPARK PLUG, INSTALLATION»(ref-646264-S27190124152014072800000) . NOTE: If the rocker arms are being reused, reassemble them into their original locations.
6. Install the rocker arm(s) (1). Refer to «ROCKER ARM, VALVE, INSTALLATION»(ref-646216-S15707358262014072800000) .
7. Install the camshaft(s) and cylinder head cover. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-646216-S23969339752014072800000) .
8. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

OFF VEHICLE

1. If removed, install the valve(s). Refer to «VALVES, INTAKE AND EXHAUST, INSTALLATION»(ref-646216-S00387810962014072800000) . NOTE: Reassemble the valves into their original locations. If the valves or valve seats have been refinished, verify that the valve stem tip height (5) is within specification. Refer to «ENGINE SPECIFICATIONS»(ref-646216-S00174117082014072800000) .
2. If removed, install the valve guide seal (2) over the valve guide (3). Refer to «SEAL(S), VALVE GUIDE, INSTALLATION»(ref-646216-S12112320312014072800000) . NOTE: Make sure that the garter spring (1) is intact around the top of the valve guide seal (2). Number 2 cylinder exhaust valve guide seal shown in illustration, all other valves similar. NOTE: If the valve springs are being reused, reassemble them into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valves similar.
3. Install the valve spring (2) and valve spring retainer (1).
4. Install the (special tool #10224, Adapter, Valve Spring) (2) on the (special tool #MD998772A, Compressor, Valve Spring) (1). NOTE: Number 3 intake valve spring compression shown in illustration, all other valves similar.
5. Install the (special tool #MD998772A, Compressor, Valve Spring) (1) onto the cylinder head.
6. Place a ball of rags in the combustion chamber to hold the valves in place. NOTE: Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.
7. Using the (special tool #10224, Adapter, Valve Spring) (2) with the (special tool #MD998772A, Compressor, Valve Spring) (1), compress the valve spring (4) only enough to install the valve retaining locks (3).
8. If the valves or valve seats have been refinished, verify that the installed height of the valve springs (4) are within specification. Make sure the measurement is taken from the top of spring seat (6) to the bottom surface of spring retainer (1). Refer to «ENGINE SPECIFICATIONS»(ref-646216-S00174117082014072800000) .
9. Install the cylinder head. Refer to «CYLINDER HEAD, INSTALLATION»(ref-646216-S07426475732014072800000) .

Scheme 492

Each of the four combustion chambers contains four valves, two intake and two exhaust, for a total of 16 valves. The valves are made of heat resistant steel. They have nitrided stems to prevent scuffing. Viton rubber valve stem seals are integral with the spring seats. All valves use three bead lock keepers (1) to retain springs (3) and to promote valve rotation.

Scheme 493

The intake and exhaust valves have a 44.5 to 45 degree face angle (1). The valve seats (2) have a 45 to 45.5 degree face angle.

Scheme 494

Inspect the remaining margin (5) after the valves are refaced. Refer to ENGINE SPECIFICATIONS .

VALVE SEATS

Note. When refacing the valve seats, it is important that the correct size valve guide pilot be used for the reseating stones. A true and complete surface must be obtained.

1. Measure the concentricity of the valve seat using a dial indicator. Refer to «ENGINE SPECIFICATIONS»(ref-646216-S00174117082014072800000) .
2. Inspect the valve seat (3) with Prussian blue to determine where the valve contacts the seat. To do this, coat the valve seat (3) LIGHTLY with Prussian blue then set the valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of the valve face (4), contact is satisfactory. If the blue is transferred to the top edge of the valve face, then lower the valve seat with a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, then raise the valve seat with a 65 degree stone. NOTE: Valve seats which are worn or burned can be reworked, provided that the correct angle and seat width are maintained. Otherwise the cylinder head must be replaced.
3. When the seat is properly positioned the width of the intake and exhaust seats should be within specification. Refer to «ENGINE SPECIFICATIONS»(ref-646216-S00174117082014072800000) .

VALVE AND SPRING INSTALLED HEIGHT

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-646216-S00174117082014072800000) . Make sure the measurement is taken from the cylinder head surface (7) to the top of the valve stem (2).
3. Install the valve guide seal (2) over the valve guide (3). Refer to «SEAL(S), VALVE GUIDE, INSTALLATION»(ref-646216-S12112320312014072800000) . NOTE: Ensure 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.
4. 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.
5. Compress valve springs (4) with the Valve Spring Compressor Adapter (special tool #10224, Adapter, Valve Spring) (2) mounted in the Valve Spring Compressor (special tool #MD998772A, Compressor, Valve Spring) (1). Install the retaining locks (3) and release the valve spring compression.
6. 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»(ref-646216-S00174117082014072800000) .

VALVES

1. Clean and inspect the valves thoroughly. Replace burned, warped and cracked valves.
2. Inspect the retainer lock grooves for wear or damage (2).
3. Inspect the valve face (4) for wear and pitting.
4. Measure the valve stems (3) and margins (5) for wear. Refer to «ENGINE SPECIFICATIONS»(ref-646216-S00174117082014072800000) .

Scheme 495

Note. Typical cylinder head shown in illustration.

1. Remove carbon and varnish deposits from inside of the valve guides with a reliable guide cleaner.
2. Measure valve stem-to-guide clearance as follows
3. Install the valve (2) into the cylinder head so that it is 15 mm (0.590 inch.) off of the valve seat. A small piece of hose may be used to hold the valve in place.
4. Attach the Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) (1) to the cylinder head and set it at a right angle to the valve stem being measured.
5. Move the valve to and from the indicator. Compare this reading to the specification. Refer to «ENGINE SPECIFICATIONS»(ref-646216-S00174117082014072800000) .

Note. If stem-to-guide clearance exceeds specifications, you must measure the valve stem. If the valve stem is within specification or if the valve guide is loose in the cylinder head, replace the cylinder head.

STANDARD PROCEDURE - MAIN BEARING SELECTION

Note. There are three different possibilities for the upper main bearings and five different lower main bearings. The upper and lower bearing shells are not interchangeable.

Scheme 496

The lower main bearing identification (2) is stamped in the nose of the crankshaft (3). There are 5 different bearing sizes available 0 through 4.

Scheme 497

The upper main bearing shell identification (1) is located in the middle of cylinder block on the right side of the engine. There are three different size bearings available. The bearing class is read downward from top and corresponds to the front journal to the rear journal on the bottom.

UPPER MAIN BEARING SELECTION

Scheme 498

The main bearings are serviced in-vehicle. They must be replaced one-at-a-time in order to properly support the crankshaft. The upper and lower main bearing shells are NOT interchangeable. The upper and lower main bearings are "select fit" to achieve proper oil clearances. Refer to BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE .

Scheme 499

Note. Late production vehicles are equipped with Electro-Hydraulic Power Steering (EHPS) and do not have an engine mounted power steering pump.

Scheme 500

Scheme 501

Scheme 502

Scheme 503

1. Disconnect and isolate the negative battery cable.
2. Remove the spark plugs. Refer to «SPARK PLUG, REMOVAL»(ref-646264-S20945443012014072800000) .
3. If equipped with an engine mounted power steering pump, remove the serpentine drive belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-646235-S33730159442014072800000) . NOTE: Only two power steering pump mounting bolts are shown in illustration. Another bolt is on the lower end of the pump near the pulley.
4. Remove the three power steering pump mounting bolts (1) and reposition the power steering pump, if equipped.
5. Remove the oil pan, oil pump pick-up and engine oil pump. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-646216-S32370746852014072800000) .
6. Remove the eight main bearing cap bolts from the windage tray in the sequence shown in illustration and remove the windage tray (1). NOTE: Typical V6 engine configuration shown in illustration.
7. Remove the eight main bearing tie bolts in the sequence shown in illustration. CAUTION: DO NOT use a number stamp or a punch to mark main bearing caps, as damage to main bearings could occur. NOTE: Main bearing caps are not interchangeable and are marked to insure correct assembly.
8. Mark the main bearing cap positions using a permanent ink marker or a scribe tool. NOTE: Typical V6 engine configuration shown in illustration. CAUTION: Replace only one main bearing at a time while all other main bearing caps remain properly tightened. If all main bearing caps are removed, the weight of the unsupported crankshaft will damage the crankshaft oil seals. NOTE: Replace the main bearings in the following order; 2, 3, 1, 4.
9. Remove the two cap bolts (2) and remove the main bearing cap (1).
10. When removing the No. 2 bearing cap, also remove the thrust washers (5).
11. Slide the upper main bearing half (6) out from between the crankshaft and the engine block.
12. If required, select fit new main bearings to the engine block. Refer to «BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE»(ref-646216-S10380825622014072800000) .
13. Lubricate the upper main bearing half (6) with clean engine oil and slide the bearing into position. NOTE: Typical V6 engine configuration shown in illustration.
14. When installing thrust washers (1) at the No. 2 main bearing location, use the following procedure: Move the crankshaft forward to the limit of travel. Lubricate and install the front thrust washer (1) by rolling the washer onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface. Move the crankshaft rearward to the limit of travel. Lubricate and install the rear thrust washer by rolling the washer onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface. CAUTION: The main bearing cap 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.
15. Check the main bearing cap 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. NOTE: Typical V6 engine configuration shown in illustration.
16. Lubricate and install the lower bearing half (3) onto the main cap (1).
17. Install the main bearing cap (1) with two inner main bearing cap bolts (2) tightened to 20 N.m (15 ft. lbs.) plus 90°.
18. Repeat the previous steps for main bearings 3, 1 and 4.
19. Measure crankshaft end play. Refer to «CRANKSHAFT - STANDARD PROCEDURE»(ref-646216-S27351840892014072800000) .
20. Install the windage tray with eight main bearing cap bolts. Tighten the bolts in the sequence shown in illustration to 21 N.m (16 ft. lbs.) plus 90°. NOTE: Typical V6 engine configuration shown in illustration.
21. Install the eight main bearing tie bolts. Tighten the bolts in the sequence shown in illustration to 28 N.m (21 ft. lbs.).
22. Install the engine oil pump, oil pump pick-up and oil pan. Refer to «PUMP, ENGINE OIL, INSTALLATION»(ref-646216-S42682464182014072800000) . NOTE: Only two power steering pump mounting bolts are shown in illustration. Another bolt is on the lower end of the pump near the pulley.
23. If removed, position the power steering pump (4) to the engine block. Install the three pump mounting bolts (1) and tighten to 25 N.m (18 ft. lbs.).
24. If removed, install the accessory drive belt. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .
25. Install the spark plugs and ignition coils. Refer to «SPARK PLUG, INSTALLATION»(ref-646264-S27190124152014072800000) .
26. 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-646216-S42585434202014072800000) .
27. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
28. Operate the engine until it reaches normal operating temperature.

Scheme 504

The crankshaft is made from induction hardened forged steel. Eight counterweights at 180° balance the crankshaft rotary mass. The main journals are crossed drilled for rod bearing lubrication. The crankshaft is supported by five select fit main bearings with the center bearing serving as the thrust washer location. Both the front and rear seals are a single piece design and are mounted to the oil pump and cylinder block.

Scheme 505

1. Mount a dial indicator (2) to front of engine with the locating probe on nose of crankshaft (1).
2. Move crankshaft all the way to the rear of its travel.
3. Zero the dial indicator.
4. Move crankshaft all the way to the front and read the dial indicator. for end play specification. Refer to «ENGINE SPECIFICATIONS»(ref-646216-S00174117082014072800000) .

Scheme 506

Note. Crankshaft can not be removed when engine is in vehicle.

Scheme 507

Scheme 508

Scheme 509

Scheme 510

Scheme 511

Scheme 512

Scheme 513

1. Remove engine assembly from vehicle. Refer to «REMOVAL»(ref-646216-S08977644302014072800000) .
2. Remove flex plate/flywheel (1).
3. Remove crankshaft rear oil seal. Refer to «SEAL, CRANKSHAFT OIL, REAR, REMOVAL»(ref-646216-S08919409772014072800000) .
4. Install engine on suitable stand.
5. Drain engine oil (2).
6. Remove oil filter (1).
7. Remove crankshaft vibration damper. Refer to «DAMPER, VIBRATION, REMOVAL»(ref-646216-S28557353782014072800000) .
8. Remove water pump pulley.
9. Remove the oil pan (2). Refer to «PAN, OIL, REMOVAL»(ref-646216-S04723550562014072800000) .
10. Remove timing chain cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-646216-S30183277652014072800000) .
11. Remove the timing chain. Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL»(ref-646216-S30073282402014072800000) .
12. Remove balance shaft module.
13. Remove the crankshaft sprocket (1).
14. Remove crankshaft position sensor retaining bolt (1) and remove sensor (2).
15. Remove ladder frame. Refer to «FRAME, LADDER, REMOVAL»(ref-646216-S39062448252014072800000) . NOTE: If piston/connecting rod replacement is necessary, remove cylinder head. Refer to «CYLINDER HEAD, REMOVAL»(ref-646216-S18344550582014072800000) . CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.
16. Using a permanent ink or paint marker, identify cylinder number on each connecting rod and cap.
17. Remove all connecting rod bolts and caps. Care should be taken not to damage the fracture rod and cap surfaces. NOTE: Do not reuse connecting rod bolts.
18. Remove main bearing caps. CAUTION: Use extreme care when handling crankshaft. Tone wheel damage can occur if crankshaft is mis-handled.
19. Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the crankshaft.

Scheme 514

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 rod journal diameter to the crankshaft connecting rod bearing journal diameter grade marking chart. Refer to «BEARING(S), CONNECTING ROD - STANDARD PROCEDURE»(ref-646216-S19245603512014072800000) . Select the bearing size that corresponds to the crankshaft markings for each rod bearing journal that will provide the proper oil clearance.
4. Compare the measured main bearing journal diameter to the crankshaft main bearing journal diameter grade marking chart. Refer to «BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE»(ref-646216-S10380825622014072800000) . 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.
5. For connecting rod journals, verify that the maximum taper and maximum out of round are within specifications. Refer to «ENGINE SPECIFICATIONS»(ref-646216-S00174117082014072800000) .
6. For main bearing journals, verify that the maximum taper and maximum out of round are within specifications. Refer to «ENGINE SPECIFICATIONS»(ref-646216-S00174117082014072800000) .

Scheme 515

The crankshaft is supported in five main bearings. All upper bearing shells (2) in the crankcase have oil grooves and holes. All lower bearing shells (1) are smooth. Crankshaft end play is controlled by a two piece thrust bearing (3) on the number three main bearing journal.

Scheme 516

Scheme 517

Scheme 518

Scheme 519

Scheme 520

Scheme 521

1. Clean main bearing cap bolt holes with Mopar® brake parts cleaner or equivalent and blow out with compressed air.
2. Install the main bearing upper (2) shells with the lubrication groove and oil hole in the engine block.
3. Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots. NOTE: If the crankshaft is sent out for machine work, it must be balanced as an assembly with the target ring installed.
4. Clean crankshaft and target ring with Mopar® brake parts cleaner or equivalent and dry with compressed air to ensure that the crankshaft mating surface and target ring mounting holes are free from oil and lock patch debris. NOTE: Always use NEW mounting screws whether installing original or new target ring.
5. Install NEW mounting screws finger tight starting with the #1 location. Make sure engagement occurs with the shoulder of the screws and mounting hole before starting all other screws.
6. Tighten all mounting screws to 13 N.m (110 in. lbs.) in the sequence shown in illustration. NOTE: Lightly apply trans gel to thrust bearings to hold bearings in block. NOTE: The thrust bearings must be installed with the notches facing the crankshaft.
7. Install thrust bearings (2) in block (1). CAUTION: Do not get oil on the ladder frame mating surface. It will affect the ability of the RTV to seal the ladder frame to cylinder block. NOTE: Ensure main bearing cap bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.
8. Oil the bearings and journals. Install crankshaft in engine block.
9. Install lower main bearings (1) into main bearing cap. Make certain the bearing tabs are seated into the bearing cap slots. NOTE: Main bearing caps are stamped 1 - 5 front to rear. Arrows on the caps must point towards the front of the engine.
10. Install main bearing caps to engine block.
11. Before installing the bolts the threads should be clean and dry.
12. Loosely install main bearing cap bolts.
13. To ensure correct thrust bearing alignment, perform the following steps: Step 1: Rotate crankshaft until number 4 piston is at TDC. Step 2: Move crankshaft rearward to limits of travel. Step 3: Then, move crankshaft forward to limits of travel. Step 4: Wedge an appropriate tool between the rear of the cylinder block and the rear crankshaft counterweight. This will hold the crankshaft in its furthest forward position. CAUTION: There are different sets main bolts supplied with this engine. Each bolt set has a different torque value and engine damage could result if bolts are not torqued correctly. The bolts are not interchangeable.
14. If your bolt heads are marked with b (1) or 6 (2), go to step 15. If your bolt heads are marked with M (3) or any other marking, go to step 16 . CAUTION: Before tightening bolts, you must identify the bolt head to obtain the correct torque value. Failure to identify the bolts correctly, could result in improperly tightened bolts which could result in engine damage.
15. Tighten bolts marked with b or 6 using the following three-step method, in the sequence shown in illustration: Tighten all bolts to 15 N.m (11 ft. lbs.) Tighten all bolts to 27 N.m (20 ft. lbs.) Tighten all bolts an additional 45°.
16. Tighten bolts marked with M using the following three-step method, in the sequence shown in illustration: Tighten all bolts to 15 N.m (11 ft. lbs.) Tighten all bolts to 45 N.m (33 ft. lbs.) Tighten all bolts an additional 45°.
17. Remove wedge tool used to hold crankshaft.
18. Check the crankshaft turning torque, it should not exceed 5.6 N.m (50 in. lbs.).
19. Check crankshaft end play. Refer to «CRANKSHAFT - STANDARD PROCEDURE»(ref-646216-S27351840892014072800000) .
20. Install connecting rod bearings and caps. Do Not Reuse Connecting Rod Bolts. Tighten connecting rod bolts to 20 N.m + 90° (15 ft. lbs.) + 90°. Refer to «ROD, PISTON AND CONNECTING, INSTALLATION»(ref-646216-S23172826442014072800000) .
21. Install the ladder frame assembly. Refer to «FRAME, LADDER, INSTALLATION»(ref-646216-S09248322442014072800000) .
22. Install the balance shaft module. Refer to «PUMP, ENGINE OIL, INSTALLATION»(ref-646216-S42682464182014072800000) .
23. Install crankshaft position sensor (2) and bolt (1). Tighten the bolt to 9 N.m (80 in. lbs.)
24. Install cylinder head if it was removed. Refer to «CYLINDER HEAD, INSTALLATION»(ref-646216-S07426475732014072800000) .
25. Install front crankshaft sprocket (1).
26. Install the timing chain. Refer to «CHAIN AND SPROCKETS, TIMING, INSTALLATION»(ref-646216-S09171916332014072800000) .
27. Install the timing chain front cover . Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-646216-S12032062052014072800000) .
28. Install the oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-646216-S06493741972014072800000) .
29. Install rear crankshaft oil seal. Refer to «SEAL, CRANKSHAFT OIL, REAR, INSTALLATION»(ref-646216-S38766701362014072800000) .
30. Install front crankshaft oil seal. Refer to «SEAL, CRANKSHAFT OIL, FRONT, INSTALLATION»(ref-646216-S18343493382014072800000) .
31. Install crankshaft vibration damper. Refer to «DAMPER, VIBRATION, INSTALLATION»(ref-646216-S35203769822014072800000) .
32. Install water pump pulley. Refer to «PUMP, WATER, INSTALLATION»(ref-646235-S33718727012014072800000) .
33. Install crankshaft rear oil seal. Refer to «SEAL, CRANKSHAFT OIL, REAR, INSTALLATION»(ref-646216-S38766701362014072800000) .
34. Install drive plate/flex plate using new bolts. Tighten bolts to 95 N.m (70 ft. lbs.).
35. Attach transaxle to engine. Tighten bellhousing bolts to 50 N.m (36 ft. lbs.).
36. Install the engine assembly into the vehicle. Refer to «INSTALLATION»(ref-646216-S00395411002014072800000) .
37. Install new oil filter (1) and fill with oil.
38. Fill with coolant. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
39. Start engine and check for leaks.
40. Install engine cover.

Scheme 522

1. Remove accessory drive belts. Refer to «BELT, SERPENTINE, REMOVAL»(ref-646235-S33730159442014072800000) .
2. Install Damper holder (special tool #9707, Holder, Vibration Damper) (1).
3. Remove crankshaft damper bolt.
4. Pull damper off crankshaft.

Scheme 523

1. Install crankshaft damper.
2. Apply clean engine oil crankshaft damper bolt threads and between bolt head and washer. Tighten bolt to 210 N.m (155 ft. lbs.).
3. Install accessory drive belts. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .

Scheme 524

1. Remove transmission.
2. Remove flex plate bolts (3) and discard.
3. Remove washer (2).
4. Remove flex plate (1).

1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry.
2. Use a wood or plastic scraper to clean the ring land grooves.

Scheme 525

1. Wipe the 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. Replace any bearing that shows abnormal wear. Refer to «BEARING(S), CONNECTING ROD - STANDARD PROCEDURE»(ref-646216-S19245603512014072800000) .
6. Inspect the connecting rod bearing bores for signs of scoring, nicks and burrs. NOTE: Misaligned or bent connecting rods can cause abnormal wear on pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft connecting rod journals. If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod, inspect it for correct rod alignment.
7. Replace misaligned, bent or twisted connecting rods. NOTE: Connecting rods are serviced with the piston pre-assembled. The pistons are "select fit" to achieve proper oil clearance. Refer to «ROD, PISTON AND CONNECTING - STANDARD PROCEDURE»(ref-646216-S39483599652014072800000) . NOTE: Typical coated piston shown in illustration.
8. Inspect the piston for scoring or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration. NOTE: The coating material (1 and 2) is applied to the piston after the final piston machining process. This coating may affect the outside diameter measurement of a coated piston may not provide accurate results.
9. Check the piston for taper and out of round shape.

Note. Piston installation into the cylinder bore may require 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.

Note. The coated pistons will be serviced with the piston pin and connecting rod pre-assembled.

Scheme 526

1. If required, select and fit new piston and connecting rod assemblies to the engine block. Refer to «ROD, PISTON AND CONNECTING - STANDARD PROCEDURE»(ref-646216-S39483599652014072800000) .
2. If required, select and fit new bearings to the connecting rod. Refer to «BEARING(S), CONNECTING ROD - STANDARD PROCEDURE»(ref-646216-S19245603512014072800000) .
3. If required, hone the cylinder bores. Refer to «ENGINE BLOCK - STANDARD PROCEDURE»(ref-646216-S04839885642014072800000) .
4. If removed, install the piston rings. Refer to «RING(S), PISTON, INSTALLATION»(ref-646216-S00603071432014072800000) .
5. Position the piston ring end gaps as follows: Oil ring expander gap (5) Oil ring lower side rail end gap (4) Oil ring upper side rail end gap (1) No. 2 (intermediate) ring end gap (5) No. 1 (upper) ring end gap (2) NOTE: Typical V6 engine configuration shown in illustration. NOTE: Ensure the position of the ring end gaps does not change when installing the ring compressor.
6. Lubricate the piston rings with clean engine oil. Position Piston Compressor (special tool #C-385, Compressor, Piston) (2) over the piston and rings. Tighten the compressor (2). NOTE: Install the rod bearings in pairs. Do not mix sizes or use a new bearing half with an old bearing half.
7. Install the bearing shell (8) on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
8. Remove the plastic guide plates (3) from the Guide Pins (special tool #8189, Guide Pins) (7) and install the Guide Pins to the connecting rod being installed. NOTE: View similar.
9. The pistons crowns are stamped with a mark (1) indicating installation position. This mark must be positioned toward the front of engine.
10. Wipe the cylinder bore clean and lubricate with clean engine oil.
11. Rotate the crankshaft until the connecting rod journal is on the center of cylinder bore. CAUTION: Avoid contact with the piston oil cooler jet(s). Positioning of the oil cooler jet(s) is critical for proper engine operation.
12. Insert the piston and connecting rod into the cylinder bore and carefully position the guide pins over the crankshaft journal.
13. Tap the piston down in the cylinder bore using a hammer handle while guiding the connecting rod into position over the rod journal. NOTE: Typical V6 engine configuration shown in illustration. CAUTION: The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.
14. Install the bearing shell (6) on the connecting rod cap (4) 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).
15. 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 90°.
16. If required, check the connecting rod side clearance. Refer to «ROD, PISTON AND CONNECTING - STANDARD PROCEDURE»(ref-646216-S39483599652014072800000) .
17. Repeat the previous steps for each piston being installed. CAUTION: The main bearing cap 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.
18. Check the main bearing cap 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.
19. Install the windage tray with eight main bearing cap bolts. Tighten the bolts in the sequence shown in illustration to 21 N.m (16 ft. lbs.) plus 90°.
20. Install the engine oil pump and oil pump pick-up. Refer to «PUMP, ENGINE OIL, INSTALLATION»(ref-646216-S42682464182014072800000) .
21. Install the cylinder heads, engine timing cover and oil pans. Refer to «CYLINDER HEAD, INSTALLATION»(ref-646216-S07426475732014072800000) .
22. 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-646216-S42585434202014072800000) .
23. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
24. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
25. Operate the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

Scheme 527

Scheme 528

1. Remove accessory drive belt.
2. Install Damper Holder (special tool #9707, Holder, Vibration Damper) (1) and remove damper retaining bolt.
3. Pull damper off crankshaft.
4. Remove front crankshaft oil seal (1) by prying out with a screw driver (2). Be careful not to damage the cover seal surface.

Scheme 529

Scheme 530

Scheme 531

Scheme 532

1. Place seal (1) onto Front Crankshaft Seal Installer (special tool #9506, Installer, Oil Seal) (2) with seal spring towards the inside of engine.
2. Install new seal (1) by using Front Crankshaft Seal Installer (special tool #9506, Installer, Oil Seal) (2) and crankshaft damper bolt (3).
3. Press seal into front cover until Front Crankshaft Seal Installer (special tool #9506, Installer, Oil Seal) (1) seats against timing chain cover (3).
4. Remove Front Crankshaft Seal Installer (special tool #9506, Installer, Oil Seal) (1).
5. Install crankshaft vibration damper.
6. Oil the bolt threads and between the bolt head and washer.
7. Install damper retaining bolt and Damper Holder (special tool #9707, Holder, Vibration Damper) (1). Tighten bolt to 210 N.m (155 ft. lbs.).

Scheme 533

1. Remove transmission and flexplate (1). Refer to «FLEXPLATE, REMOVAL»(ref-646216-S36205906802014072800000) .
2. Insert a 3/16 flat bladed screwdriver (7) between the dust lip (8) and the metal case (4) of the crankshaft seal (1). Angle the screwdriver through the dust lip against metal case of the seal. Pry out seal. CAUTION: Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of the screwdriver blade against crankshaft edge (chamfer) is permitted.
3. Check to make sure the seals garter spring is not on the crankshaft.

Scheme 534

Note. When installing seal, lubricate Seal Guide (special tool #9509, Installer, Oil Seal) with clean engine oil.

1. Place Seal Guide (special tool #9509, Installer, Oil Seal) (3) on crankshaft.
2. Position seal (2) over guide tool. Guide tool should remain on crankshaft during installation of seal. Ensure that the lip of the seal is facing towards the crankcase during installation.
3. Drive the seal into the block using Seal Driver (special tool #9706, Installer, Crankshaft Rear Oil Seal) (1) and Driver Handle (special tool #C-4171, Driver Handle, Universal) (4) until Seal Driver (special tool #9706, Installer, Crankshaft Rear Oil Seal) bottoms out against the block.
4. Install the flexplate (1) and transmission. Refer to «FLEXPLATE, INSTALLATION»(ref-646216-S33256097172014072800000) .

Scheme 535

Scheme 536

1. Raise and support the vehicle
2. Remove the belly pan. Refer to «BELLY PAN, REMOVAL»(ref-646214-S24731623582014072800000) .
3. Lower the vehicle.
4. Remove the engine cover to prevent contact with the cowl.
5. Remove the battery and tray. Refer to «TRAY, BATTERY, REMOVAL»(ref-646227-S29548343982014072800000) .
6. Remove the wire harness retainer from the top of the left engine mount.
7. Support transaxle with a suitable jack.
8. Remove the coolant tube bracket bolt (1).
9. Remove the three mount to transaxle bracket bolts (2).
10. Remove the two mount to frame rail bolts (3).
11. Loosen, but do not remove the bolt (2) for the trans mount (3) to strut tower (1) attachment.
12. Remove the mount.

ENGINE OIL LEAK

Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed

1. Do not clean or de-grease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak.
2. Add an oil soluble dye (use as recommended by the manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light.
3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of the oil leak. If the oil leak is found and identified, repair per Service Information instructions.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat the inspection. If the oil leak source is not positively identified at this time, proceed with the «AIR LEAK DETECTION TEST METHOD»(ref-646216-S05937583162014072800000) .

CHECKING VVT OIL PRESSURE

This test can be used to help diagnose VVT faults.

Scheme 537

Scheme 538

1. Disconnect and remove oil pressure sensor (1). CAUTION: Threads in block are 1/8"-28 British Standard Pipe (BSP). Do not install a National Pipe Thread (NPT) threaded adapter, this could crack the cylinder block.
2. Install an 1/8-28 BSP male to 1/8-27 female threaded adapter (2).
3. Install oil pressure gauge (1).
4. Start engine and record oil pressure. CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test
5. If oil pressure is 0 at idle, shut off engine. Check for pressure relief valve stuck open or a clogged oil pick-up screen.
6. Remove oil pan and inspect for debris. Refer to «PAN, OIL, REMOVAL»(ref-646216-S04723550562014072800000) .
7. Remove oil pressure relief valve and inspect, if damaged replace pressure relief valve. Refer to «VALVE, OIL PRESSURE RELIEF, REMOVAL»(ref-646216-S33008497842014072800000) .
8. If pressure relief valve is ok, replace balance shaft module assembly. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-646216-S32370746852014072800000) .
9. After test is complete, remove test gauge (1) and fitting (2).
10. Install oil pressure sensor and electrical connector.

ENGINE OIL AND FILTER CHANGE

Change engine oil at mileage and time intervals described in the Maintenance Schedule. Refer to MAINTENANCE SCHEDULES, DESCRIPTION .

Scheme 539

Scheme 540

1. Run engine until achieving normal operating temperature.
2. Position the vehicle on a level surface and turn engine off.
3. Remove oil fill cap.
4. Raise vehicle on hoist.
5. Place a suitable oil collecting container under oil pan drain plug (2).
6. Remove oil pan drain plug (2) or and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged.
7. Remove oil filter (1). Refer to «FILTER, ENGINE OIL, REMOVAL»(ref-646216-S37737728712014072800000) .
8. Install oil pan drain plug (2) and tighten drain plug to 40 N.m (30 ft. lbs.).
9. Install new oil filter (1). Refer to «FILTER, ENGINE OIL, INSTALLATION»(ref-646216-S24750309002014072800000) .
10. Lower vehicle and fill crankcase with specified type and amount of engine oil . Refer to «CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS»(ref-646211-S35411413522014072800000) and «CAPACITIES AND RECOMMENDED FLUIDS, DESCRIPTION»(ref-646211-S40621448392014072800000) .
11. Install oil fill cap.
12. Start engine and inspect for leaks.
13. Stop engine and inspect oil level.

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING under ENGINE OIL AND FILTER CHANGE .

Scheme 541

Scheme 542

Scheme 543

1. Raise vehicle on hoist.
2. Remove oil drain plug (2) and drain the engine oil.
3. Remove accessory drive belt splash shield.
4. Remove lower A/C compressor mounting bolt (if equipped).
5. Remove A/C mounting bracket (2). NOTE: Do not use pry points in block to remove oil pan.
6. Remove oil pan retaining bolts.
7. Using a putty knife (1), loosen seal around oil pan (2).
8. Remove oil pan (2).

Scheme 544

Note. Oil pan sealing surfaces must be free of grease or oil.

Note. Parts must be assembled within 10 minutes of applying RTV.

Scheme 545

Scheme 546

1. Apply Mopar® Engine RTV GEN II at the front cover to engine block parting lines (1).
2. Apply a 2 mm bead of Mopar® Engine RTV GEN II around the oil pan as shown in illustration.
3. Position oil pan and install bolts. Tighten bolts to 12 N.m (105 in. lbs.). NOTE: The 2 long bolts must be tightened to 22 N.m (195 in. lbs.).
4. Install oil drain plug (2).
5. Lower vehicle and fill engine crankcase with proper oil to correct level.
6. Start engine and check for leaks.

Scheme 547

The engine block has three tapered plugs sealing the high pressure oil gallery. These threaded plugs do not have a torque specification but instead are installed to a specific depth. Do not attempt to further tighten these plugs, damage to the engine block could result. Whenever these plugs are removed they must be replaced. Service plugs have a lock patch and do not require the application of additional sealant.

Scheme 548

Note. Rear plug shown in illustration, other plugs are similar.

1. Remove the plug (2) from the engine block.
2. Use Mopar® Brake Parts Cleaner (or equivalent) sparingly to clean the block.

1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head.

1. Discard gasket(s).
2. Clean all sealing surfaces.

Scheme 549

1. Clean all gasket surfaces.
2. Replace intake manifold gasket seals.
3. Position the foam pad over the coolant transfer tube.
4. Install intake manifold, tighten bolts to 12 N.m (9 ft. lbs.). NOTE: Install the upper fasteners (1) from the top of the engine and the remaining (2) from below.
5. Install the intake manifold silencer cover and screws. Tighten the screws to 2.5 N.m (22 in. lbs.).
6. Install the intake manifold lower bracket (3). Install the two nuts (1) and one bolt (2). Tighten to 9 N.m (80 in. lbs.).
7. Install new fuel injector O-rings and insert the fuel rail into the intake manifold. Tighten bolts
8. Install the fuel rail assembly to intake manifold. Tighten bolts to 8 N.m (71 in. lbs.).
9. Connect fuel injector electrical connectors (4).
10. Inspect quick connect fittings for damage, replace if necessary. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) .
11. Connect the purge solenoid vapor line and electrical connector.
12. Insert the foam insulator over the fuel rail (3).
13. Connect fuel line (1).
14. Connect the purge vapor line (2). Remove wiring harness retainer from the intake manifold eyelets (1).
15. Connect the three hose connectors (3).
16. Connect the MAP sensor connector (2).
17. Install the front suspension crossmember. Refer to «CROSSMEMBER, FRONT SUSPENSION, INSTALLATION»(ref-646214-S18817399002014072800000) .
18. Lower the vehicle.
19. Install intermediate shaft (2) to steering rack pinion shaft. Install a NEW pinch bolt and tighten to 55 N.m (40 ft. lbs.).
20. Remove the steering wheel lock.
21. Install throttle body (3) onto the intake manifold.
22. Install the three throttle body screws (1) and one throttle body bolt (2). Tighten to 8 N.m (71 in. lbs.).
23. Install the intake manifold upper bracket (1). Install bolts (3) and nuts (2). Tighten to 9 N.m (80 in. lbs.).
24. Install the throttle body upper support (2). Tighten the bolts to 8 N.m (71 in. lbs.).
25. Connect the PCV valve hose.
26. Connect negative cable to battery.
27. Install the resonator assembly. Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-646216-S21595726612014072800000) .

Scheme 550

The timing drive system consists of the following

1. Timing Chain (2)
2. Camshaft Sprockets (1, 3)
3. Crankshaft Sprocket
4. Right Timing Chain Guide (Moveable) (6)
5. Left Timing Chain Guide (Fixed) (4)
6. Timing Chain Tensioner (5)

The camshaft sprockets are attached to the cam phasers which are attached to the front of the camshafts and are used with the timing chain and crankshaft sprocket to turn the camshafts. The camshaft position sensors target is part of the camshafts and is used with the camshaft position sensors to provide the PCM with valvetrain position information.

The timing chain tensioner is installed in the right side of the engine block. Using engine oil pressure, the tensioner applies constant pressure to the right side (movable) timing chain guide, which in turn applies pressure to the timing chain. Also as the tensioner extends, it rachet locks in position to provide constant timing chain tension.

STANDARD PROCEDURE - VALVE TIMING VERIFICATION

Correct timing is critical for the NON free-wheeling designed, 2.0L engine. Engine timing can be verified by using the following procedures

1. Remove the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-646216-S10550530762014072800000) .
2. Remove the spark plugs. Refer to «SPARK PLUG, REMOVAL»(ref-646264-S20945443012014072800000) . CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.
3. Rotate the crankshaft clockwise (as viewed from the front) to align the timing cover mark (1) with the damper notch (2) to place the number one cylinder piston at top-dead-center on the compression stroke.
4. While maintaining this alignment, verify that the SCRIBE LINES (3) on the camshaft sprockets point toward each other and are parallel to the cylinder head cover mounting surface and that there are twenty-four chain pins (1) BETWEEN the exhaust camshaft sprocket marking (2) and the intake camshaft sprocket marking (4) as viewed from either the front or rear of the camshaft sprockets.
5. If the engine timing is not correct, proceed to Timing Chain and Sprockets for service procedures. Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL»(ref-646216-S30073282402014072800000) .

Scheme 551

Scheme 552

1. Remove the timing chain cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-646216-S30183277652014072800000) .
2. Verify that the number one cylinder piston is still set to top-dead-center on the compression stroke. NOTE: If the timing chain plated links can no longer be seen, the timing chain links corresponding to the timing marks must be marked prior to removal if the chain is to be reused.
3. Mark chain link (2) corresponding to crankshaft timing mark (1).
4. While maintaining this alignment, verify that the SCRIBE LINES (3) on the camshaft sprockets point toward each other and are parallel to the cylinder head cover mounting surface and that there are twenty-four chain pins (1) BETWEEN the exhaust camshaft sprocket marking (2) and the intake camshaft sprocket marking (4) as viewed from the front of the camshaft sprockets. If the marks do not line up, the timing chain is not correctly installed.
5. Mark the chain links corresponding to camshaft timing marks (2 and 4).
6. Remove timing chain tensioner (5). Refer to «TENSIONER, ENGINE TIMING, REMOVAL»(ref-646216-S26606444482014072800000) .
7. Remove timing chain (2).

CAMSHAFT SPROCKET(S)

Note. Camshaft phasers and camshaft sprockets are supplied as an assembly, do not attempt to disassemble.

Refer to camshaft phaser removal. Refer to CAMSHAFT, ENGINE, REMOVAL .

Scheme 553

Scheme 554

1. Remove the timing chain. Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL»(ref-646216-S30073282402014072800000) .
2. Remove the oil pan. Refer to «PAN, OIL, REMOVAL»(ref-646216-S04723550562014072800000) .
3. Remove the oil pump drive chain tensioner (3).
4. Remove the oil pump drive chain.
5. Remove the crankshaft sprocket (1).

Scheme 555

Inspect timing chain for stretching prior to removal.

1. Rotate engine while watching timing chain tensioner plunger. When the plunger reaches its maximum travel stop rotating engine.
2. Measure the distance from the tensioner body and the edge of the chain guide as shown in illustration.
3. If the distance is greater than 20.5 mm (0.81 in.) inspect guide shoes for excessive wear.
4. If guides are okay, replace timing chain.

Scheme 556

Scheme 557

1. Install the crankshaft sprocket (1) onto the crankshaft.
2. Install the oil pump drive chain. Verify that the oil pump is correctly timed (1, 2, 5, 6).
3. Reset the oil pump drive chain tensioner by pushing the plunger inward and installing (special tool #9703, Pin, Tensioner).
4. Install the oil pump drive chain tensioner (3) and remove (special tool #9703, Pin, Tensioner) (4).
5. Install the timing chain and timing chain cover. Refer to «CHAIN AND SPROCKETS, TIMING, INSTALLATION»(ref-646216-S09171916332014072800000) .
6. Install the oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-646216-S06493741972014072800000) .
7. 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-646216-S42585434202014072800000) .
8. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
9. 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.

Note. The camshaft sprockets and the camshaft phasers are an assembly and cannot be serviced separately.

1. Refer to Camshaft phaser (2) installation. Refer to «ASSEMBLY, VARIABLE VALVE TIMING, INSTALLATION»(ref-646216-S35855167842014072800000) .

Scheme 558

1. Verify that the number one cylinder piston is still set to top-dead-center on the compression stroke.
2. Align camshaft timing marks (3) so they are facing each other and in line with the cylinder head cover sealing surface.
3. Install timing chain so plated (or marked) links on chain align with timing marks (2 and 4) on camshaft sprockets. There should be twenty-four chain pins (1) BETWEEN the exhaust camshaft sprocket marking (2) and the intake camshaft sprocket marking (4).
4. Align timing mark on the crankshaft sprocket (1) with the plated (or marked) link (2) on the timing chain. Position chain so slack will be on the tensioner side. NOTE: Keep the slack in the timing chain on the tensioner side.
5. Install the timing chain tensioner (5). Refer to «TENSIONER, ENGINE TIMING, INSTALLATION»(ref-646216-S31399301062014072800000) . Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned at top-dead-center on the compression stroke with the key way at the 9 o'clock position.
6. While maintaining this alignment, verify that the SCRIBE LINES (3) on the camshaft sprockets point toward each other and are parallel to the cylinder head cover mounting surface and that there are twenty-four chain pins (1) BETWEEN the exhaust camshaft sprocket marking (2) and the intake camshaft sprocket marking (4). If the marks do not line up, the timing chain is not correctly installed.
7. Install front timing chain cover . Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-646216-S12032062052014072800000) .
8. 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-646216-S42585434202014072800000) .
9. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
10. 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.

Scheme 559

Scheme 560

Scheme 561

Scheme 562

Scheme 563

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 resonator (1). Refer to «RESONATOR, AIR CLEANER, REMOVAL»(ref-646216-S00754484562014072800000) .
4. Remove the air cleaner body (1). Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646216-S37540781882014072800000) .
5. Remove the coolant recovery bottle. Refer to «BOTTLE, PRESSURIZED COOLANT, REMOVAL»(ref-646235-S12438365052014072800000) .
6. Remove the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-646216-S10550530762014072800000) .
7. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
8. Remove the frame cover portion of the right splash shield. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL»(ref-646233-S05943217422014072800000) . CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.
9. Rotate the crankshaft clockwise (as viewed from the front) to align the timing cover mark (1) with the damper notch (2) to place the number one cylinder piston at top-dead-center on the compression stroke.
10. Remove the accessory drive belt (1). Refer to «BELT, SERPENTINE, REMOVAL»(ref-646235-S33730159442014072800000) .
11. Remove the accessory drive belt idler pulley (3).
12. Remove the accessory drive belt tensioner (2).
13. Remove the crankshaft damper (4). Refer to «DAMPER, VIBRATION, REMOVAL»(ref-646216-S28557353782014072800000) .
14. Remove three bolts (6) and the water pump pulley (5) from the water pump.
15. Remove the lower A/C compressor mounting bolt.
16. Remove the lower A/C compressor mount (2).
17. Remove four timing chain cover lower bolts (1).
18. Lower the vehicle.
19. Support the engine with a suitable jack.
20. Remove the right engine mount insulator. Refer to «INSULATOR, ENGINE MOUNT, RIGHT, REMOVAL»(ref-646216-S16552545632014072800000) .
21. Remove one M8 studbolt (1), six M6 bolts (2), two M8 bolts (3) and five M10 bolts (4).
22. Remove the engine timing cover using pry points (1, 2 and 3).
23. Remove the engine timing cover (1) out through the bottom of the vehicle.

Scheme 564

Note. When using RTV, the sealing surfaces must be clean and free from grease and oil.

Note. When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes.

Scheme 565

Scheme 566

Scheme 567

Scheme 568

Scheme 569

1. Install a new crankshaft seal if necessary.
2. Clean all sealing surfaces. Refer to «ENGINE - STANDARD PROCEDURE»(ref-646216-S32430634582014072800000) .
3. Apply Mopar® engine sealant RTV (or equivalent) as shown in illustration at the cylinder head to block parting line (1 and 2).
4. Apply Mopar® engine sealant RTV (or equivalent) as shown in illustration at the ladder frame to block parting line (1 and 2).
5. Apply 2 mm bead of Mopar® engine sealant RTV (or equivalent) to the engine block (1 and 2) as shown in illustration.
6. Install timing chain cover (1) upwards from under the vehicle.
7. Install the timing chain cover retaining bolts. Tighten six M6 bolts (2) to 9 N.m (80 in. lbs.), two M8 bolts (3) and one studbolt (1) to 26 N.m (19 ft. lbs.) and five M10 bolts (4) to 65 N.m (48 ft. lbs.).
8. Position right engine mount over the strut tower bolt (1).
9. Install engine mount to frame retaining bolts (1 and 3). Tighten to 75 N.m (55 ft. lbs.).
10. Install engine mount to timing cover bolts (2) Tighten to 68 N.m (50 ft. lbs.).
11. Tighten the strut tower bolt to 88 N.m (65 ft. lbs.).
12. Install the coolant reservoir bottle. Tighten bolt to 9 N.m (80 in. lbs.).
13. Install the water pump pulley (5) and tighten three bolts (6) to 9 N.m (80 in. lbs.).
14. Install the crankshaft damper (4). Refer to «DAMPER, VIBRATION, INSTALLATION»(ref-646216-S35203769822014072800000) .
15. Install the accessory drive belt tensioner (2).
16. Install the accessory drive belt idler pulley (3). Tighten bolt to 25 N.m (18 ft. lbs.).
17. Install the accessory drive belt (1). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .
18. Reseal the oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-646216-S06493741972014072800000) .
19. Install the right lower splash shield. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION»(ref-646233-S24910490662014072800000) .
20. Install the cylinder head cover and ignition coils . Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-646216-S20861717392014072800000) .
21. Install the air cleaner body (1). Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646216-S26351878182014072800000) .
22. 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-646216-S42585434202014072800000) .
23. Install the resonator (1). Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-646216-S21595726612014072800000) .
24. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
25. 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.

Scheme 570

1. Remove the engine timing cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-646216-S30183277652014072800000) . NOTE: Tensioner will not come apart during removal.
2. Remove timing chain tensioner retaining bolts and remove tensioner (5).