2.0L Engine - Service Information: Removal & Installation Dodge Dart PF

REMOVAL

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Scheme 374

1. Release the fuel pressure. Refer to «FUEL DELIVERY, GAS , STANDARD PROCEDURE»(ref-646230-S42658421212014072800000) .
2. Disconnect the battery negative cable.
3. Secure the steering wheel.
4. Remove the steering coupler bolt. Position the shaft out of the way.
5. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
6. Drain the coolant.
7. Remove the battery. Refer to «BATTERY, REMOVAL»(ref-646227-S35480669362014072800000) .
8. Remove the PCM. Refer to «MODULE, POWERTRAIN CONTROL, REMOVAL»(ref-646224-S21304088122014072800000) .
9. Disconnect the heater core supply and return hoses at the fittings nearest the thermostat housing.
10. Remove the bolt securing the heater supply pipe at the left engine mount bracket.
11. Disconnect the heater hose at the thermostat outlet connector.
12. Separate the wire harness retainers at the transmission bell housing.
13. Loosen the upper starter bolt completely. NOTE: The upper bolt will not back out completely due to lack of clearance. Leave the bolt in the bell housing.
14. Release the PDC locking tabs. Position the PDC aside and secure the assembly with an elastic strap to prevent dame during repairs.
15. Remove the engine cover.
16. Disconnect the fuel line (1) and the purge line (2) quick connects.
17. Disconnect the positive and negative battery cables.
18. Remove the three bolts (1) that secure the PDC.
19. Remove the starter connector (1) at the power block.
20. Disconnect the intermediate connector (1), the generator feed connector (2) and the PCM connector (3).
21. Remove the battery. Refer to «BATTERY, REMOVAL»(ref-646227-S35480669362014072800000) .
22. Recover the air conditioning system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-646220-S33335783492014072800000) .
23. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
24. Remove the bolt holding the windshield washer reservoir to the battery tray.
25. Release the retainer from the harness at the bottom of the battery tray.
26. Remove the battery tray. Refer to «TRAY, BATTERY, REMOVAL»(ref-646227-S29548343982014072800000) .
27. Remove the fresh air hose from valve cover.
28. Raise and support the vehicle.
29. Remove the front tire and wheel assemblies.
30. Remove the left and right axle shafts. Refer to «REMOVAL»(ref-646219-S30341200882014072800000) .
31. Separate the lower control arm from the knuckle by prying down with the pry bar.
32. Remove the left and right wheel well liners.
33. Remove the Belly pan. Refer to «BELLY PAN, REMOVAL»(ref-646214-S24731623582014072800000) .
34. Remove the front closeout panel.
35. Remove the upper radiator hose.
36. Remove the radiator hoses at the crossover pipe.
37. Remove the crossover pipe bolts. Remove crossover pipe.
38. Remove the lower radiator hose.
39. Remove the radiator fan assembly. Refer to «FAN, COOLING, REMOVAL»(ref-646235-S02837375212014072800000) .
40. Remove the four bracket retaining bolts (1) from the cross member to fascia support beams bracket, then remove the bracket.
41. Remove the fasteners (2) securing the lower bumper reinforcement (1) and front fascia support beams to the frame/front end module.
42. Remove the front fascia support beams (1).
43. Remove the rear engine mount to bracket through bolt (4) and nut (2).
44. Remove the rear engine mount to crossmember through bolt (1).
45. Reposition the engine forward to allow the mount to be removed from the pocket past the engine bracket (3).
46. Remove the bolts holding the intermediate shaft to the engine support cradle.
47. Remove the exhaust cross-under pipe assembly. Refer to «PIPE, EXHAUST CROSSUNDER, REMOVAL»(ref-646259-S35977026882014072800000) .
48. Remove the bolt holding the ground cable (2) to transaxle and separate cable from transaxle (1).
49. Disconnect the reverse lamp sensor (1).
50. Lower the vehicle.
51. Remove the hot bottle return pipe bolts (1).
52. Disconnect the fitting at the thermostat housing and position the hose assembly to the side (2).
53. Remove the bolt holding the ground strap to left frame rail.
54. Pry up on the cable connector (1) to disengage both the cables from the levers and separate cables end from the shift levers.
55. Disconnect the gear shift selector cables (1) at the manual levers (2).
56. Disconnect the hydraulic supply pipe for the concentric slave cylinder.
57. Remove the exhaust manifold assembly Refer to «MANIFOLD, EXHAUST, REMOVAL»(ref-646216-S29333726532014072800000) .
58. Disconnect the heater hose quick connects at the heater core inlet and outlet tubes.
59. Disconnect the AC lines at the compressor. Discard the seals. Refer to «COMPRESSOR, A/C, REMOVAL»(ref-646220-S17088941942014072800000) .
60. Disconnect the shifter cables from the transmission. Refer to «CABLE, GEARSHIFT CONTROL, REMOVAL»(ref-646222-S40924175722014072800000) .
61. Reposition the main wire harness away from the engine.
62. Raise and position the 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.
63. 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).
64. Remove the left engine mount. Refer to «INSULATOR, ENGINE MOUNT, LEFT, REMOVAL»(ref-646216-S41351235492014072800000) .
65. Remove the right engine mount (Refer to «INSULATOR, ENGINE MOUNT, RIGHT, REMOVAL»(ref-646216-S16552545632014072800000) ).
66. Slowly raise the vehicle to allow the it to clear the powertrain assembly. CAUTION: Make sure that all components are clear of obstructions while raising the vehicle off of the powertrain assembly.
67. On vehicles equipped with an automatic transaxle, remove torque converter bolts. On vehicles equipped with an manual transaxle, remove modular clutch bolts. Refer to «DISASSEMBLY»(ref-646222-S34277140452014072800000) .
68. Remove lower bellhousing bolts.
69. Separate engine and transmission.

INSTALLATION

Scheme 375

1. Attach the transmission to the engine. Refer to «INSTALLATION»(ref-646222-S24966917122014072800000) .
2. With the engine and the transmission bolted together and on the engine cradle, slowly and carefully lower the vehicle down to a point that the engine assembly can be verified that it is in the proper alignment with the engine bay. NOTE: An assistant may be needed to help align the assembly.
3. Slowly lower engine assembly in to position.
4. Install the right engine mount. Refer to «INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION»(ref-646216-S27557929332014072800000) .
5. Install the left engine mount. Refer to «INSULATOR, ENGINE MOUNT, LEFT, INSTALLATION»(ref-646216-S38752139742014072800000) .
6. Remove the Engine Support Cradle straps and remove the cradle from below the engine/transmission assembly.
7. Connect the shifter cables to the transmission. Refer to «CABLE, GEARSHIFT CONTROL, INSTALLATION»(ref-646222-S17760027552014072800000) .
8. Connect the AC lines at the compressor. Refer to «LINE, A/C DISCHARGE, INSTALLATION»(ref-646220-S03179606782014072800000) .
9. Connect the heater hose quick connects at the heater core inlet and outlet tubes.
10. Install the exhaust manifold assembly. Refer to «MANIFOLD, EXHAUST, INSTALLATION»(ref-646216-S27928656742014072800000) .
11. Connect the hydraulic supply pipe (1) for the concentric slave cylinder (2). Refer to «CYLINDER, CLUTCH SLAVE, INSTALLATION»(ref-646231-S21266678342014072800000) .
12. Connect the gear shift selector cables (1) at the manual levers (2).
13. Install the bolt holding the ground strap to left frame rail. Tighten the bolt to 9 N.m (80 in. lbs.).
14. Attach the hot bottle hose (2) quick connect to the thermostat housing. Install the bolts (1). Tighten the bolts to 9 N.m (80 in. lbs.).
15. Raise and support the vehicle.
16. Connect the reverse lamp sensor (1).
17. Install the ground cable (2) to the transaxle (1). Install the bolt and tighten to 24 N.m (18 ft. lbs.).
18. Install the exhaust crossunder pipe with new flange gaskets.
19. Install the intermediate shaft bracket bolts. Tighten bolts to 65 N.m (48 ft. lbs.)
20. Reposition the engine forward to allow the mount to be inserted into the pocket past the engine bracket (3).
21. Install the rear engine mount to crossmember through bolt (1). Tighten the bolt to 87 N.m (64 ft. lbs)
22. Install the rear engine mount to engine bracket (3) through bolt (4) and nut (2). Tighten the bolt to 87 N.m (64 ft. lbs)
23. Install new oil filter.
24. Install the front fascia beams (1).
25. Install the fasteners (2) securing the lower bumper reinforcement (1) to the frame/front end module. Tighten the fasteners to 45 N.m (33 ft. lbs.).
26. Install the crossmember to fascia support beam bracket and install the four retaining bolts (1) and tighten to 95 N.m (70 ft. lbs.).
27. Insert the lower ball joint into the knuckle and install the pinch bolt and nut and tighten to 70 N.m (52 ft. lbs.).
28. Install the radiator. Refer to «RADIATOR, ENGINE COOLING, INSTALLATION»(ref-646235-S26734770022014072800000) .
29. Install accessory drive belt.
30. Install the coolant crossover pipe. Install bolts, tighten to 9 N.m (80 in. lbs.)
31. Install the hoses at the crossover tube.
32. Install the upper radiator hose.
33. Fill with coolant. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
34. Install the front closeout panel.
35. Install the bellypan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
36. Install the left and right wheel well liners.
37. Install the left and right axle shafts. Refer to «INSTALLATION»(ref-646219-S37404040972014072800000) .
38. Install the front wheel and tire assemblies.
39. Lower the vehicle.
40. Install the radiator fan assembly. Refer to «FAN, COOLING, INSTALLATION»(ref-646235-S19645703512014072800000) .
41. Install the fresh air hose to the valve cover.
42. Install the battery tray. Refer to «TRAY, BATTERY, INSTALLATION»(ref-646227-S37644486382014072800000) .
43. Lock the harness retainer at the bottom of the battery tray.
44. Install the windshield washer reservoir to the battery tray. Install the retainer bolt and tighten to 9 N.m (80 in. lbs.).
45. Install the battery. Refer to «BATTERY, INSTALLATION»(ref-646227-S21166870622014072800000) .
46. Evacuate and recharge the AC system. Refer to «STANDARD PROCEDURE»(ref-646220-S32937035862014072800000) . .
47. Connect the intermediate connector (1), the generator feed connector (2) and the PCM connector (3).
48. Install the starter connector (1) at the power block. Tighten the nut to 7 N.m (62 in. lbs.).
49. Install the three bolts (1) that secure the PDC. Tighten to 9 N.m (80 in. lbs.).
50. Install the battery cables.
51. Connect the fuel line (1) and the purge line (2) quick connects.
52. Connect the brake booster vacuum hose to intake manifold fitting.
53. Install the air box (1), the resonator (2) and the bolt (3). Tighten to 9 N.m (80 in. lbs.).
54. Connect the IAT sensor connector.
55. Tighten the snorkel clamp at the throttle body inlet.

1. Install the air filter element (2) into the air cleaner housing.
2. Install the cover (1) so that the rear tabs insert into the lower air box.
3. Seat the cover onto the housing and tighten the two housing cover screws (1).

Scheme 376

1. Loosen the clamp (2) and disengage the hose from the resonator.
2. Remove the make up air hose (3) from the air cleaner body.
3. Disengage the coolant line retainer (4) from the air cleaner body.
4. Remove air cleaner housing retaining bolt (5).
5. Lift the air cleaner body (1) straight up off of the locating pins.

1. Install the air cleaner body (1) straight down on the locating pins.
2. Install the retaining bolt (5).
3. Install the hose to the resonator and tighten the clamp (2) to 4 N.m (35 in. lbs.).
4. Engage the coolant line retainer (4) to the air cleaner body.
5. Install the make up air hose (3).

Scheme 377

Scheme 378

1. Disconnect and isolate the negative battery cable.
2. Disconnect the electrical connector (1) from the Inlet Air Temperature (IAT) sensor.
3. Loosen the throttle body clamp (2).
4. Loosen the clamp (2) and remove the air inlet hose from the resonator (1).
5. Pull the resonator (1) straight up off of the four locating pins on the cylinder head cover. Disengage and remove the resonator from the throttle body inlet.

1. Lubricate the four rubber mount sockets on the resonator with Mopar® Rubber Bushing Installation Lube.
2. Install the resonator to the throttle body inlet. Push the resonator down onto the four locating pins on the cylinder head cover until the rubber mount sockets are fully seated.
3. Install the air inlet hose to the resonator (1) and tighten the clamp (2) to 4 N.m (35 in. lbs.).
4. Tighten the throttle body clamp (2) to 4 N.m (35 in. lbs.).
5. Connect the electrical connector (1) to the Inlet Air Temperature (IAT) sensor.
6. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 379

The cross flow designed, aluminum cylinder head contains dual over-head camshafts (DOHC) with four valves per cylinder. The valves are arranged in two in-line banks. The exhaust valves face toward the front of the vehicle. The intake valves face the dash panel. The DOHC valvetrain uses roller rocker arms with hydraulic lifters. The cylinder head incorporates pressed in powdered metal valve guides. The valve guides are not serviceable. The cylinder head is sealed to the block using a multi-layer steel head gasket and retaining bolts.

Integral oil galleries provide lubrication passages to the variable camshaft timing phasers, camshafts, and valve mechanisms.

Note. Intake camshaft shown in illustration, exhaust cam similar.

1. Install the phaser assembly (2) on the camshaft. NOTE: Make sure the dowel is seated in the dowel hole and not in an oil feed hole. The dowel hole is larger than the 4 oil feed holes.
2. Install the phaser retaining bolt. Hold the camshaft in place with a wrench (3) and tighten the bolt to 59 N.m (44 ft. lbs.).
3. Install the camshafts . Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-646216-S23969339752014072800000) .

1. Install new cylinder head cover gaskets (1 and 2). NOTE: When using RTV, the sealing surfaces must be clean and free from grease and oil. NOTE: When using RTV, components should be assembled within 10 minutes and tighten to specification within 45 minutes.
2. Apply a 2 to 3 mm wide bead of Mopar® engine sealant RTV or equivalent to the cylinder head/front cover T-joint (1) and the rear exhaust camshaft bearing cap/cylinder head T-joint (2).
3. Install the cylinder head cover to the cylinder head with twelve bolts (2) and six stud bolts (1). Tighten all eighteen fasteners to 10 N.m (90 in. lbs.).
4. Install the cylinder cover ground strap and nut. Tighten the nut to 10 N.m (90 in. lbs.)
5. Install and connect the ignition coils. Refer to «COIL, IGNITION, INSTALLATION»(ref-646264-S09640927192014072800000) .
6. If removed, install the positive crankcase ventilation (PCV) valve and tighten to 4 N.m (37 in. lbs.). NOTE: Make sure the O-ring is seated on the shoulder of the opening prior to reading the torque.
7. Connect the PCV hose to the PCV valve.
8. Connect the make up air hose.
9. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
10. Install the engine cover assembly. Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-646216-S21595726612014072800000) .

1. Disconnect and isolate the negative battery cable.
2. Remove the camshaft(s). Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-646216-S01449161842014072800000) . NOTE: If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.
3. Remove the rocker arm(s). Refer to «ROCKER ARM, VALVE, REMOVAL»(ref-646216-S19668306372014072800000) . NOTE: If the hydraulic lifters are to be reused, identify their positions so that they can be reassembled into their original locations.
4. Remove the hydraulic lifter(s) (1).

1. Verify that the hydraulic lifters are at least partially full of oil. There should be little or no plunger travel when the hydraulic lifter is depressed. NOTE: If the hydraulic lifters are being reused, reassemble them into their original locations.
2. Install the hydraulic lifter(s) (1). NOTE: If the rocker arms are being reused, reassemble them into their original locations.
3. Install the rocker arm(s). Refer to «ROCKER ARM, VALVE, INSTALLATION»(ref-646216-S15707358262014072800000) .
4. Install the camshaft(s) with phasers and cylinder head cover. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-646216-S23969339752014072800000) .
5. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 380

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.

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Scheme 384

1. Remove the engine cover (2). Refer to «RESONATOR, AIR CLEANER, REMOVAL»(ref-646216-S00754484562014072800000) .
2. Remove the battery. Refer to «BATTERY, REMOVAL»(ref-646227-S35480669362014072800000) . NOTE: Oil may leak from the vacuum pump drive when the pump is removed. Place a shop towel under the pump to prevent oil leakage onto the engine or transmission assembly.
3. Disconnect the vacuum line at the pump (1).
4. Remove the vacuum pump mounting bolts (2) and the vacuum pump.
5. Remove and discard the vacuum pump gasket (1). Note the location of the pump drive tab.
6. If required, remove the screw (1) and the vacuum fitting (2).
7. The vacuum fitting O-ring seal (1) can be reused if not damaged.

1. The vacuum fitting O-ring seal (1) can be reused if not damaged. If removed, lightly lubricate the O-ring seal (1) with clean engine oil and install on the vacuum fitting.
2. If removed, install the vacuum fitting (2) to the vacuum pump with the screw (1) tightened to 8 N.m (71 in. lbs.).
3. Clean the mating surfaces of the cylinder head and the vacuum pump. Install a new vacuum pump gasket.
4. Align the pump drive tab with the pump drive slot located on the cam shaft.
5. Install the vacuum pump mounting bolts. Tighten the bolts to 20 N.m (15 ft. lbs.).
6. Connect the vacuum supply line to the pump. CAUTION: When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.
7. Install the battery (4). Refer to «BATTERY, INSTALLATION»(ref-646227-S21166870622014072800000) .
8. Install the engine cover. Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-646216-S21595726612014072800000) .
9. Run the engine a check the vacuum pump for proper operation.

Scheme 385

The rocker arms are steel stampings with an integral roller bearing. The rocker arms incorporate a 0.5 mm oil hole in the lash adjuster socket for roller and camshaft lubrication.

1. Disconnect and isolate the negative battery cable.
2. Remove the camshaft(s). Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-646216-S01449161842014072800000) . NOTE: If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.
3. Remove the rocker arm(s) (1).

Scheme 386

Inspect the cam follower assembly for wear or damage. Replace as necessary.

1. Lubricate the rocker arms with clean engine oil before installation. NOTE: If the rocker arms are being reused, reassemble them into their original locations.
2. Install the rocker arm(s) (1).
3. Install the camshaft(s) with phasers and cylinder head cover. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-646216-S23969339752014072800000) .
4. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 387

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

Scheme 388

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 389

1. Remove the valve spring(s) (2). Refer to «SPRING(S), VALVE, REMOVAL»(ref-646216-S41122961142014072800000) . 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.
3. If required, remove the valve(s). Refer to «VALVES, INTAKE AND EXHAUST, REMOVAL»(ref-646216-S20802634572014072800000) .

Scheme 390

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 .

1. If removed, install the valve(s). Refer to «VALVES, INTAKE AND EXHAUST, INSTALLATION»(ref-646216-S00387810962014072800000) .
2. Apply engine oil to the lip of the valve guide seal (2). Install the valve guide seal (2) over the valve stem (3). 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(s) (2). Refer to «SPRING(S), VALVE, INSTALLATION»(ref-646216-S28549638702014072800000) .

Scheme 391

The valve springs (2) are made from high strength chrome silicon steel. The springs are common for intake and exhaust applications. Valve guide seals (3) are rubber overmolded on a steel support cylinder with a garter spring at the seal lip. The seals are integrated with the valve spring seat. The steel valve spring retainers (4) and the valve spring retainer locks (1) are a three bead Butt type design to promote valve rotation.

Scheme 392

Scheme 393

Scheme 394

1. Remove the camshaft(s). Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-646216-S01449161842014072800000) . NOTE: If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.
2. Remove the rocker arm(s). Refer to «ROCKER ARM, VALVE, REMOVAL»(ref-646216-S19668306372014072800000) .
3. Install the (special tool #10224, Adapter, Valve Spring) (2) on the (special tool #MD998772A, Compressor, Valve Spring) (1). NOTE: Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.
4. Remove the spark plug. Refer to «SPARK PLUG, REMOVAL»(ref-646264-S20945443012014072800000) .
5. Install the (special tool #MD998772A, Compressor, Valve Spring) (1) onto the cylinder head.
6. Install a spark plug adapter attached to a regulated shop air supply (2). Pressurize the cylinder being serviced to 620.5 - 689 kPa (90 - 100 psi) to hold the valves in place. NOTE: Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar. CAUTION: Air pressure must be maintained as long as the valve springs are removed to prevent the valves from dropping into the cylinders.
7. Using the (special tool #10224, Adapter, Valve Spring) (2), compress valve spring (4) and remove valve retaining locks (3). NOTE: If the springs are to be reused, identify their positions so that they can be reassembled into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valve springs similar.
8. Release the valve spring compression and remove the valve spring retainer (1) and valve spring (2).
9. If required, remove the valve guide seal. Refer to «SEAL(S), VALVE GUIDE, REMOVAL»(ref-646216-S10556063262014072800000) .

Scheme 395

1. Install the (special tool #10224, Adapter, Valve Spring) (2) on the (special tool #MD998772A, Compressor, Valve Spring) (1). NOTE: Number 3 intake valve spring compression shown in illustration, all other valves similar.
2. Install the (special tool #MD998772A, Compressor, Valve Spring) (1) onto the cylinder head.
3. Place a ball of rags in the combustion chamber to hold the valves in place. NOTE: Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.
4. Using the (special tool #10224, Adapter, Valve Spring) (2), compress valve spring (4) and remove valve retaining locks (3). NOTE: If the springs are to be reused, identify their positions so that they can be reassembled into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valve springs similar.
5. Release the valve spring compression and remove the valve spring retainer (1) and valve spring (2).
6. If required, remove the valve guide seal. Refer to «SEAL(S), VALVE GUIDE, REMOVAL»(ref-646216-S10556063262014072800000) .

Scheme 396

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 397

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 .

1. Remove the cylinder head. Refer to «CYLINDER HEAD, REMOVAL»(ref-646216-S18344550582014072800000) . 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-646216-S41122961142014072800000) . 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(s) (1). Refer to «SEAL(S), VALVE GUIDE, REMOVAL»(ref-646216-S10556063262014072800000) .

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. 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.
4. Install the valve spring(s) (2). Refer to «SPRING(S), VALVE, INSTALLATION»(ref-646216-S28549638702014072800000) . 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-646216-S00174117082014072800000) . 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-646216-S07426475732014072800000) .

1. Install flex plate (1).
2. Install washer (2).
3. Install new flex plate bolts (3) and tighten in a criss-cross pattern to 95 N.m (70 ft. lbs.).
4. Install transaxle.

Scheme 398

Scheme 399

1. Remove oil pan. Refer to «PAN, OIL, REMOVAL»(ref-646216-S04723550562014072800000) .
2. Remove balance shaft assembly. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-646216-S32370746852014072800000) .
3. Remove ladder frame retaining bolts.
4. Remove ladder frame using pry point cast in the rear of the block (1).
5. To assist in removing the ladder frame another (1) pry point cast in the right side of the block.

Scheme 400

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 401

1. Apply a 2 mm bead of Mopar® engine sealant RTV or equivalent as shown in illustration.
2. Install bolts and tighten as shown in illustration following a two-step method. First: All to 10 N.m (89 in. lbs.). Second: All to 26 N.m (19 ft. lbs.).
3. Install balance shaft module. Refer to «PUMP, ENGINE OIL, INSTALLATION»(ref-646216-S42682464182014072800000) .
4. Install oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-646216-S06493741972014072800000) .

Scheme 402

Scheme 403

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 (top) Ring 0.25 - 0.40 mm (0.010 - 0.016 in.) No. 2 (center) Ring 0.30 - 0.45 mm (0.012 - 0.018 in.) Oil Control Ring (Steel Rail) 0.15 - 0.66 mm (0.006- 0.26 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 404

Note. Typical piston shown in illustration.

Scheme 405

Scheme 406

1. Remove the piston and connecting rod(s). Refer to «ROD, PISTON AND CONNECTING, REMOVAL»(ref-646216-S26323103992014072800000) . 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 ring upper side rail (3) Oil ring lower side rail (4) Oil ring expander (5) 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 ring side rails.
4. Remove the oil ring upper side rail.
5. Remove the oil ring lower side rail.
6. Remove the oil ring expander (1).

Note. Typical piston shown in illustration.

Scheme 407

Scheme 408

1. If required, fit new rings to the piston. Refer to «RING(S), PISTON - STANDARD PROCEDURE»(ref-646216-S14623562242014072800000) . CAUTION: To avoid damage to the piston rings, they must be installed in the following order: Oil ring expander (5) Oil ring lower side rail (4) Oil ring upper side rail (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 ring side rails.
2. Install the oil ring expander (1).
3. Install the oil ring lower side rail by placing one end between the piston ring groove and the oil ring expander. Hold this end firmly and press down the portion to be installed until the side rail is in position.
4. Install the oil ring upper side rail in the same manner as the lower side rail. NOTE: The No. 1 (upper) piston ring (1) and No. 2 (intermediate) piston ring (3) have a different cross section. Install the rings with manufacturers I.D. mark (dot) (2) facing up, towards the top of the piston. NOTE: Typical piston shown in illustration.
5. Install the No. 2 (intermediate) piston ring using a ring expander tool.
6. Install the No. 1 (upper) piston ring using a ring expander tool.
7. Rotate the rings around the piston, the rings must rotate in the grooves with out binding.
8. 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)
9. Install the piston and connecting rod(s). Refer to «ROD, PISTON AND CONNECTING, INSTALLATION»(ref-646216-S23172826442014072800000) .

Scheme 409

The pistons are a lightweight design with ultra low tension piston rings for improved fuel economy. The pistons are made of a high strength aluminum alloy and the piston skirt has a Moly® coating. The top piston ring land has an anodized coating for improved wear. The piston is connected to the rod using a full floating pin with two locking clips. The connecting rod is forged steel with a bolted cracked cap design. The connecting rod bolts are not reusable. Pistons are available in two different diameters with grade markings for each bore indicated on the side of the cylinder block. The upper compression ring is a 1.2 mm steel ring with a spray coating. The intermediate compression ring is 1.2 mm micro napier design. Both compression rings have a dot or a mark on the piston ring. The marked side of the ring must face the top of the piston. The 2 mm three piece oil control ring is very thin. These are chrome plated rings and have a stainless steel expander.

Scheme 410

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 411

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 412

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 413

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-646216-S00174117082014072800000) .
5. Repeat this procedure for each connecting rod. Rotate the crankshaft for connecting rod accessibility.

Scheme 414

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-646216-S00174117082014072800000) .
2. Repeat this procedure for each connecting rod. Rotate the crankshaft for connecting rod accessibility.

1. Disconnect and isolate the negative battery cable.
2. Remove the oil pans, engine timing cover and cylinder heads. Refer to «CYLINDER HEAD, REMOVAL»(ref-646216-S18344550582014072800000) .
3. Remove the engine oil pump. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-646216-S32370746852014072800000) .
4. Remove the eight main bearing cap bolts from the windage tray in the sequence shown in illustration and remove the windage tray (1).
5. If necessary, remove the top ridge of the cylinder bores with a reliable ridge reamer before removing the pistons from the engine block. Be 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.
6. Mark connecting rod and bearing cap positions (1) using a permanent ink marker or scribe tool. NOTE: Typical V6 engine configuration shown in illustration. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
7. Remove the connecting rod cap bolts (5) and the connecting rod cap (4). Discard the cap bolts. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur.
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 removed. CAUTION: Avoid contact with the piston oil cooler jet(s). Positioning of the oil cooler jet(s) is critical for proper engine operation.
9. Remove the piston and connecting rod (1) from cylinder bore.
10. Repeat the previous steps for each piston being removed.
11. Immediately after piston and connecting rod removal, reinstall the bearing cap (4) on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
12. If required, remove the piston rings. Refer to «RING(S), PISTON, REMOVAL»(ref-646216-S13886903262014072800000) .
13. 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 415

Scheme 416

1. Remove the engine cover.
2. Remove the air cleaner assembly. Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646216-S37540781882014072800000) .
3. Remove the coolant reservoir bolts (3) 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 (1).
7. Remove the two mount to frame bolts (2).
8. Loosen, but do not remove the mount (1) to strut tower (3) bolt (2).
9. Remove the engine mount.

1. Set the mount into position.
2. Tighten the right mount to strut tower bolt (2) finger tight.
3. Install engine mount to frame retaining bolts (2). Finger tighten the bolts.
4. Install the right mount to timing cover bolts (1). 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 (2) to 63 N.m (46 ft lbs.).
7. Tighten the engine mount to timing cover bolts (1). Tighten to 63 N.m (46 ft. lbs.).
8. Install the coolant reservoir bottle. Install and tighten the bolts (3) to 9 N.m (80 in. lbs.).
9. Install the air box assembly. Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646216-S26351878182014072800000) .
10. Install the engine cover.
11. Remove the jack stand.
12. Install the belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
13. Start the engine and check for vibrations.

Scheme 417

The lubrication system is a full-flow filtration, pressure feed type. The balance shaft module (BSM) is mounted below the ladder frame and chain driven by the crankshaft. The BSM consists of a non-serviceable pump, oil pressure relief valve, and a non-serviceable balance assembly.

Scheme 418

Note. Not all blocks have the bolt on timing chain oil squirter. Engine blocks either have a bolt-on oil squirter or a 1.0 mm hole (1) drilled into the oil gallery passage. Engine blocks with the 1.0 mm hole no longer use an oil squirter even though the threaded mounting hole may still be present.

Note. The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, the oil cooler should be replaced.

Scheme 419

Scheme 420

1. Raise vehicle on hoist.
2. Drain cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
3. Disconnect oil cooler coolant hoses.
4. Remove oil filter (3).
5. Remove oil cooler connector bolt (2).
6. Remove oil cooler (1).

Scheme 421

Scheme 422

1. Replace oil cooler seal (1).
2. Lubricate seal and position oil cooler to oil filter adapter, aligning notch to tab.
3. Install oil cooler connector bolt (2). Tighten connector bolt to 49 N.m (36 ft. lbs.).
4. Install oil filter (3).
5. Connect oil cooler coolant hose.
6. Lower vehicle.
7. Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

Scheme 423

1. Using a suitable filter wrench, turn oil filter (1) counterclockwise to remove.

Scheme 424

1. Clean and check filter mounting surface. The surface must be smooth, flat and free of debris or pieces of gasket.
2. Lubricate new oil filter gasket.
3. Screw oil filter (1) on until the gasket contacts base. Tighten to 14 N.m (124 in. lbs.).

Scheme 425

Note. The engine must be HOT when checking oil level.

The best time to check engine oil level is after the engine is at operating temperature. Allow the engine to be shut off for at least 5 minutes before checking oil level.

Scheme 426

Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick (1), and observe oil level. Add oil only when the level is at or below the SAFE mark. If the oil level is in the safe (2) range, do not add oil.

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

1. Use Mopar® Brake Parts Cleaner (or equivalent) sparingly to clean the block.
2. Install the plug (2) flush with the block boss face (1). The plug (2) is correctly installed when it is flush or protruding no more than 1 mm from the block boss face (1).

Scheme 427

The oil pump is integral to the balance shaft module (BSM) (2). The oil pump cannot be disassembled for inspection. The pressure relief valve is serviceable and can be removed and inspected. The BSM can be identified by the plastic end caps (1).

A multimedia supplement to the instructions contained in this article is available. To the multimedia example of the condition described go to; http://www.youtube.com/user/Mitchell1Tips then type "A00646216.vid1" into the "Search Channel" box

Scheme 428

When removing and installing the Balance Shaft/Oil Pump assembly in the vehicle, it is not necessary to align the plated links on the drive chain as long as the reference marks are created during the procedure.

Scheme 429

Scheme 430

Scheme 431

1. Remove the oil pan Refer to «PAN, OIL, REMOVAL»(ref-646216-S04723550562014072800000) .
2. Rotate the engine clockwise until the balance shaft/oil pump drive gear and the housing indicator are aligned. NOTE: IT IS VERY IMPORTANT THAT THE CRANKSHAFT STAYS STATIONARY DURING THE FOLLOWING STEPS. DO NOT MOVE THE CRANKSHAFT UNTIL THE INSTALLATION PROCEDURE IS COMPLETED.
3. Clean the balance shaft/oil pump assembly drive gear with Mopar® brake cleaner or similar. NOTE: Make sure the gear is clear of any oil to allow for marking.
4. If the balance shaft/oil pump assembly is being reused, mark the oil pump chain and the sprocket (1) to the module body (2) for reassembly.
5. Install one air-conditioning compressor bracket bolt into the left forward corner thread boss. NOTE: The bolt will provide a sturdy point to secure a tie strap to hold the tensioner in the compressed position.
6. Position a plastic tie strap (3) around the chain, tensioner (4) and bolt (2) that was previously installed.
7. Push the chain, guide and tensioner (1) to the compressed position.
8. Tighten the tie strap to hold the components together. NOTE: The tighter the strap, the more room for removal and installation.
9. Remove the balance shaft/oil pump assembly mounting bolts.
10. Remove assembly from the engine by tilting the rear of the balance shaft/oil pump assembly downward while lifting the drive gear out of the chain links.

Scheme 432

1. Remove timing chain cover . Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-646216-S30183277652014072800000) .
2. Remove oil pan. Refer to «PAN, OIL, REMOVAL»(ref-646216-S04723550562014072800000) .
3. Measure the distance between the tensioner body and the guide shoe as shown in illustration.
4. If the distance is 10.1 mm (0.397 in.) or greater, replace the chain.

A multimedia supplement to the instructions contained in this article is available. To the multimedia example of the condition described go to; http://www.youtube.com/user/Mitchell1Tips then type "A00646216.vid2" into the "Search Channel" box

Scheme 433

Scheme 434

1. The 185 mm (7.283 in.) length bolts must be checked for stretching. Check the bolts with a straight edge for necking (2). If the bolts are necked down, they must be replaced.
2. Clean the balance shaft/oil pump assembly mounting holes with Mopar® brake parts cleaner.
3. Align the marks on the balance shaft/oil pump assembly and drive sprocket.
4. With the rear of the balance shaft/oil pump assembly on a slight downward angle, position the gear into the chain links. Make sure the paint marks are aligned.
5. Pivot balance shaft/oil pump assembly upwards and position on ladder frame.
6. Start balance shaft/oil pump assembly mounting bolts by hand. NOTE: Use a three step procedure when tightening balance shaft/oil pump assembly mounting bolts. For new 180 mm bolts, go to step 7. For 185 mm bolts, go to step 8 .
7. Tighten new 180 mm balance shaft/oil pump assembly mounting bolts as follows: Tighten to 15 N.m (11 ft. lbs.) in the sequence shown in illustration. Tighten to 33 N.m (24 ft. lbs.) in the sequence shown in illustration. Rotate bolts an additional 90° in the sequence shown in illustration.
8. Tighten 185 mm balance shaft/oil pump assembly mounting bolts as follows: Tighten to 15 N.m (11 ft. lbs.) in the sequence shown in illustration. Tighten to 29 N.m (22 ft. lbs.) in the sequence shown in illustration. Rotate bolts an additional 90° in the sequence shown in illustration.
9. Double check the alignment marks to ensure the gear (1) and balance shaft/oil pump assembly indicator (2) is aligned.
10. Remove the tie strap (3).
11. Remove the bracket bolt (2).
12. Inspect that the tensioner (1) has fully extended and applied pressure to the guide and chain (4).
13. Install the oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-646216-S06493741972014072800000) .
14. Fill engine with oil.
15. Start engine and check for leaks.

Scheme 435

1. Raise and support the vehicle.
2. Remove the belly pan. Refer to «BELLY PAN, REMOVAL»(ref-646214-S24731623582014072800000) .
3. Disengage the sensor harness at the block (5).
4. Unlock the connector (3).
5. Disconnect oil temperature sensor electrical connector (4).
6. Unscrew the sensor (2) from the cylinder block.
7. Remove sensor.

1. Screw the sensor (2) into the block.
2. Tighten the sensor to 48 N.m (35 ft. lbs.).
3. Install the connector (4).
4. Lock the connector (3).
5. Engage the harness retainer (5) into the block.
6. Install the belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .

1. Screw the sensor (1) into the block.
2. Tighten the sensor to 48 N.m (35 ft. lbs.).
3. Install the connector (3).
4. Lock the connector (2).
5. Install the belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .

Scheme 436

1. Remove oil pan. Refer to «PAN, OIL, REMOVAL»(ref-646216-S04723550562014072800000) .
2. Remove pressure regulating valve cap (2).
3. Remove pressure regulating valve spring (3) and valve (4).

Scheme 437

Note. Pressure regulating valve (4) can be serviced separately from the oil pump assembly.

1. Inspect pressure relief valve (4) scoring, gouging, or debris. Replace as needed.
2. Inspect the pressure relief valve bore in the pump for scoring, gouging, or debris.
3. If pump bore is damaged, replace balance shaft module.

Scheme 438

1. Lightly coat pressure regulating valve with clean engine oil and install valve (4).
2. Install spring (3) and cap (2).
3. Tighten cap to 44 N.m (32 lbs. ft.).

Scheme 439

Scheme 440

Scheme 441

1. Remove engine cover.
2. Disconnect battery negative cable.
3. Disconnect the upstream and downstream oxygen sensors.
4. Raise and support the vehicle.
5. Remove the belly pan.
6. Remove the two nuts from the converter outlet. Discard the gasket .
7. Lower the vehicle.
8. Remove the four bolts from the upper shield (2) .
9. Remove the upper shield (2).
10. Remove the exhaust manifold bolts (1).
11. Remove the manifold out the top of the vehicle.
12. Remove and discard manifold gasket.

1. Install a new exhaust manifold gasket DO NOT APPLY SEALER .
2. Set the manifold into position. Install the manifold bolts.
3. Following the torque sequence, tighten the exhaust manifold bolts to 34 N.m (25 ft. lbs.).
4. Install the four shields in the proper sequence. Tighten bolts to 12 N.m (105 in. lbs.).
5. Install a new manifold lower gasket.
6. Install flange nuts. Tighten nuts to 28 N.m (21 ft. lbs.)
7. Install exhaust pipe to manifold (1). Tighten fasteners to (250 in. lbs.).
8. Install the oxygen sensors. Tighten to 50 N.m (37 ft. lbs.).
9. Connect the oxygen sensor connectors.
10. Install belly pan.
11. Lower vehicle.
12. Connect oxygen sensor electrical connector (3).
13. Connect negative cable to battery.
14. Install the engine cover.

Scheme 442

Scheme 443

Scheme 444

Scheme 445

1. Perform fuel system pressure release procedure before attempting any repairs. Refer to «FUEL DELIVERY, GAS , STANDARD PROCEDURE»(ref-646230-S42658421212014072800000) .
2. Disconnect and isolate the battery negative cable.
3. Remove the resonator assembly. Refer to «RESONATOR, AIR CLEANER, REMOVAL»(ref-646216-S00754484562014072800000) .
4. Using a steering wheel holder, lock the steering wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation.
5. Remove the steering column lower coupler pinch bolt (3) and separate the column (2) from the steering gear (4).
6. Disconnect the vapor line (2) at the purge vapor solenoid end of the line.
7. Remove the NVH foam pad (3) prior to disconnecting the fuel line (1).
8. 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.
9. Unplug the Electronic Throttle Control (ETC) connector.
10. Unplug the purge solenoid.
11. Remove the throttle body bracket bolts (3), loosen the nuts (2). Allow the throttle body bracket bolts to remain with the intake manifold.
12. Disconnect the fuel injector electrical connectors (1).
13. Disconnect fuel line at rail (3).
14. Remove the two bolts at the fuel rail (2).
15. Remove the throttle body bolts (1) and nut (2) then remove the throttle body assembly (3).
16. Raise and support the vehicle.
17. Remove the front suspension crossmember. Refer to «CROSSMEMBER, FRONT SUSPENSION, REMOVAL»(ref-646214-S00037398332014072800000) .
18. Remove the four screws that secure the intake manifold silencer to the manifold (1).
19. Remove the intake manifold silencer assembly.
20. Remove the two nuts (1), the bolt (2) and the intake manifold lower bracket (3).
21. Remove wiring harness retainer from the intake manifold eyelets (1).
22. Unplug the three hose connectors (3).
23. Unplug the MAP sensor connector (2).
24. Remove intake manifold retaining bolts (2) and nuts (1).
25. Remove intake manifold through the bottom of the vehicle.

1. Reset the cam chain tensioner. Refer to «VALVE TIMING - STANDARD PROCEDURE»(ref-646216-S42090997302014072800000) . NOTE: Keep the slack in the timing chain on the tensioner side.
2. Install timing chain tensioner (1) and tighten bolts to 12 N.m (105 in. lbs.).
3. Remove the pin (1/8 in. drill bit) from the timing chain tensioner.
4. Verify that the valve timing is correct. Refer to «VALVE TIMING - STANDARD PROCEDURE»(ref-646216-S42090997302014072800000) .
5. Install the engine timing cover. Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-646216-S12032062052014072800000) .
6. 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) .
7. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
8. 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.