2.4L Engine - Service Information: Other Dodge Dart PF

CYLINDER COMPRESSION PRESSURE LEAKAGE

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

Note. Ensure 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-646217-S20767186452014082600000) .

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.

Scheme 762

Scheme 763

Scheme 764

Scheme 765

Scheme 766

Scheme 767

Scheme 768

Scheme 769

Scheme 770

Scheme 771

Scheme 772

Scheme 773

Scheme 774

1. Perform the fuel system pressure release procedure. Refer to «FUEL DELIVERY, GAS , STANDARD PROCEDURE»(ref-646230-S42658421212014072800000) .
2. Disconnect and isolate the battery negative cable.
3. Remove the engine cover.
4. Remove the resonator (3). Refer to «RESONATOR, AIR CLEANER, REMOVAL»(ref-646217-S01497312852014072800000) .
5. Remove the air cleaner body. Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646217-S11826178562014072800000) .
6. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
7. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
8. Remove the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-646217-S03078198452014072800000) .
9. Remove the maniverter. Refer to «MANIFOLD, EXHAUST, REMOVAL»(ref-646217-S00479151812014072800000) .
10. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
11. Drain the coolant.
12. Remove the two nuts (1), the bolt (2) and the intake manifold lower bracket (3).
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-646217-S12456726232014072800000) .
16. Remove the tensioner (6) and timing chain (7). Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL»(ref-646217-S11520093992014072800000) .
17. Remove the timing chain guides (3).
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. Loosen the camshaft bearing cap bolts and remove the camshaft bearing caps.
28. 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.
29. Remove the rocker arm(s). NOTE: If the hydraulic lifters are to be reused, identify their positions so that they can be reassembled into their original locations.
30. Remove the hydraulic lifter(s). NOTE: All of the cylinder head bolts have captured washers EXCEPT the front two (1).
31. Remove the cylinder head bolts and two uncaptured washers (1).
32. Remove the cylinder head from the engine block. NOTE: There is a foam insulator that is sandwiched between the intake manifold and the engine black that may fall off when the cylinder head is removed. The foam pad must be reinstalled during assembly.
33. Disconnect the fuel injector electrical connectors (1). Remove the two bolts at the fuel rail (2).
34. Remove the throttle body bracket bolts (3), loosen the nuts (2). Allow the throttle body bracket bolts to remain with the intake manifold.
35. Remove the four screws that secure the intake manifold silencer to the manifold (1).
36. Remove wiring harness retainer from the intake manifold eyelets (1)
37. Unplug the MAP sensor connector (2).
38. Remove intake manifold retaining bolts (2) and nuts (1).
39. Remove the intake manifold from the cylinder head.
40. Inspect the cylinder head and cylinder head components. Refer to «CYLINDER HEAD - INSPECTION»(ref-646217-S13125298082014072800000) .

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-646217-S05151393892014082600000) . 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.

Scheme 775

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-646217-S08719865132014072800000) .
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-646217-S08719865132014072800000) . Springs Valve Seats Valve Guides Valves

Scheme 776

Scheme 777

Scheme 778

Scheme 779

Scheme 780

Scheme 781

Scheme 782

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. 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 exhaust hydraulic lifters. NOTE: If the rocker arms are being reused, reassemble them into their original locations.
21. Install the exhaust rocker arms.
22. Oil all of the camshaft journals with clean engine oil.
23. Install the camshaft Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-646217-S40821436342014072800000) .
24. Install the VVAA. Refer to «ASSEMBLY, VARIABLE VALVE ACTUATION, INSTALLATION»(ref-646217-S02413844502014072800000) .
25. Install timing chain and tensioner. Refer to «CHAIN AND SPROCKETS, TIMING, INSTALLATION»(ref-646217-S38825218802014072800000) .
26. Install timing chain cover, engine mount, pulleys and accessory drive belt. Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-646217-S31374882382014072800000) .
27. Install the cylinder head cover and ignition coils. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-646217-S10697975412014072800000) .
28. Install the exhaust manifold. Refer to «MANIFOLD, EXHAUST, INSTALLATION»(ref-646217-S20689673422014072800000) .
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 VVAA solenoids.
37. Connect the MAP sensor connector (2).
38. Inspect quick connect fittings for damage, replace if necessary. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) .
39. Install the air cleaner body (1). Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646217-S00793981562014072800000) .
40. 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-646217-S18080092152014072800000) .
41. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
42. Recharge the air conditioning system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-646220-S33335783492014072800000) .
43. Install the resonator. Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-646217-S37132917522014072800000) .
44. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
45. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
46. The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to appropriate Diagnostic Information .

Scheme 783

The 2.4L engine uses a Single Over Head Camshaft (SOHC) to provide valve actuation but the camshaft is in the standard position of an exhaust camshaft in a Dual Over Head Camshaft (DOHC) engine. The camshaft has five bearing journal surfaces and three cam lobes per cylinder. The camshaft is built up on a hollow tube with cam lobes, bearing journals and end caps pressed into position. The front end cap includes the camshaft sprocket mounting. The middle (number three) bearing surface has thrust walls machined into it to control end play. The rear has a camshaft position sensor pick-up wheel and also drives the vacuum pump.

STANDARD PROCEDURE - CAMSHAFT ENDPLAY

1. Remove the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-646217-S03078198452014072800000) .
2. Mount Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) (1) to a stationary point at the front of the engine. Locate the probe perpendicular against the nose of the camshaft.
3. Move the camshaft all the way to the rear of its travel.
4. Zero the dial indicator.
5. Move the camshaft forward to the limit of travel and read the dial indicator. Compare the measured end play to the specification. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) .

Scheme 784

Scheme 785

Scheme 786

Scheme 787

Scheme 788

1. Disconnect and isolate the battery negative cable.
2. Remove the cylinder head cover . Refer to «COVER(S), CYLINDER HEAD, REMOVAL»(ref-646217-S03078198452014072800000) .
3. Remove the spark plugs. Refer to «SPARK PLUG, REMOVAL»(ref-646263-S33174100562014072800000) .
4. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
5. Remove the frame cover portion of the right splash shield. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL»(ref-646233-S05943217422014072800000) .
6. 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.
7. Verify that the camshaft timing is correct as viewed above. The vertical center line of the camshaft (1) and the horizontal surface of the top of the cylinder head (3) MUST be 90° from each other. NOTE: The camshaft dowel (2) is slightly visible above the camshaft center bolt and should be at 12 o'clock when set.
8. Lower the vehicle and support the engine with a jack stand.
9. Using a paint pen or equivalent, mark both camshaft sprockets and corresponding chain links (1 and 2) to aid in reassembly. 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.
10. Remove the vacuum pump.
11. Remove the right engine mount. Refer to «INSULATOR, ENGINE MOUNT, REAR, REMOVAL»(ref-646217-S04677741592014072800000) and/or «INSULATOR, ENGINE MOUNT, RIGHT, REMOVAL»(ref-646217-S11995298642014072800000) .
12. Remove the timing cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-646217-S12456726232014072800000) .
13. Using a permanent ink or paint marker, identify the location and position on each camshaft bearing cap.
14. Using special tool 10259A (1), loosen the spring compressors (2) to fit over the valve and spring assemblies. Adjust the tool to align with the 2.4L indicators (3).
15. Install the (special tool #10259B, Compressor, MultiAir® Spring) spring compressor
16. Rotate the spring compressors counterclockwise until the springs are fully seated.
17. Slowly remove the exhaust camshaft bearing cap bolts (1) one turn at a time. Remove the camshaft bearing caps.
18. Lift the timing chain (2) off of the sprocket (1).
19. Remove the camshaft.
20. Remove the sprocket from the camshaft.

Scheme 789

1. Inspect the camshaft bearing journals (4) for damage and binding. If the journals are binding, check the camshaft bearing housing for damage. Also check the oil supply holes for clogging.
2. Check the surface of the cam lobes (5) for abnormal wear (1). Measure and compare the unworn area (3) to the worn area (2). Replace the camshaft if it is not within specification. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) .

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-646217-S08719865132014072800000) .
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-646217-S08719865132014072800000) .

Scheme 790

Scheme 791

1. Coat the valve stems (2) with clean engine oil and install the valves into the cylinder head. NOTE: If the valves are being reused, reassemble them into their original locations.
2. If the valves or valve seats have been refinished, check the valve tip height (5). If the valve tip height (5) exceeds the specification, grind the valve tip until it is within specification. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) . Make sure the measurement is taken from the cylinder head surface (7) to the top of the valve stem (2).
3. If removed, install the spring seat (3) and valve guide seal (2) over the valve guide. Refer to «SEAL(S), VALVE GUIDE, INSTALLATION»(ref-646217-S25894898622014072800000) . NOTE: 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) (1) mounted in the Valve Spring Compressor (special tool #C-3422-D, Compressor, Valve Spring) (2). 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-646217-S08719865132014072800000) .

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-646217-S08719865132014072800000) .

Scheme 792

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-646217-S08719865132014072800000) .

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 - CONNECTING ROD - FITTING

There are three different sizes of rod bearings available. Connecting rod bearing identification (4) can be found on the nose of the crankshaft (3). Use the table below for proper bearing selection.

CONNECTING ROD BEARING SELECTION

1. For measuring connecting rod bearing clearance procedure and use of Plastigage. Refer to «ENGINE - STANDARD PROCEDURE»(ref-646217-S05151393892014082600000) . For bearing clearance. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) . NOTE: The rod bolts should not be reused.
2. Before installing the NEW rod bolts the threads and under the bolt head should be oiled with clean engine oil.
3. Install each bolt finger tight then alternately tighten each bolt to assemble the cap properly.
4. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values: CAUTION: Do not use a torque wrench for the second step. Tighten the bolts to 20 N.m (15 ft. lbs.). Tighten the connecting rod bolts an additional 90°.
5. Using a feeler gauge, check connecting rod side clearance. For clearance specifications. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) .

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 793

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-646217-S06019193492014072800000) .
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-646217-S08681735612014072800000) . 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.

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

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

Scheme 794

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-646217-S37132917522014072800000) .

Scheme 795

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 796

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.

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-646217-S08570901242014072800000) .

CHECKING VVT OIL PRESSURE

This test can be used to help diagnose VVT faults.

Scheme 797

Scheme 798

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-646217-S42351844612014072800000) .
7. Remove oil pressure relief valve and inspect, if damaged replace pressure relief valve. Refer to «VALVE, OIL PRESSURE RELIEF, REMOVAL»(ref-646217-S12467847622014072800000) .
8. If pressure relief valve is ok, replace balance shaft module assembly. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-646217-S41540061932014072800000) .
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 799

Scheme 800

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-646217-S41613752412014072800000) .
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-646217-S36138704552014072800000) .
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 801

Scheme 802

Scheme 803

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 804

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

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

Scheme 805

Scheme 806

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 807

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 808

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.

STANDARD PROCEDURE - VALVE TIMING VERIFICATION

Correct timing is critical for the NON free-wheeling designed 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-646217-S03078198452014072800000) .
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 dowel window (2) on the camshaft sprocket point toward 12 o'clock.
5. Using a straightedge tool (1), place the tool vertically at the center of the cam gear. Using the top edge of the cylinder head (3) as a reference point, the angle between the straightedge and the cylinder head needs to be 90°.
6. If the engine timing is not correct, proceed to Timing Chain and Sprockets for service procedures. Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL»(ref-646217-S11520093992014072800000) .

Scheme 809

1. Remove the timing chain cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-646217-S12456726232014072800000) .
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 camshaft dowel (2) is at the 12 o'clock position. The dowel center line (1) will be 90° from the horizontal surface line at the top of the cylinder head (3).
5. Mark the chain links corresponding to camshaft and crankshaft timing marks.
6. Remove timing chain tensioner (6). Refer to «TENSIONER, ENGINE TIMING, REMOVAL»(ref-646217-S15651968162014072800000) .
7. Rotate the tensioner guide (3) away from the chain.
8. Remove timing chain (7).

Scheme 810

Scheme 811

1. Set the timing at TDC. Refer to «VALVE TIMING - STANDARD PROCEDURE»(ref-646217-S01066670532014072800000) .
2. Remove the timing cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-646217-S12456726232014072800000) .
3. Hold the camshaft stationary by the wrench flats (1).
4. Remove the camshaft center bolt (1) from the sprocket (2).
5. Once the sprocket is clear of the alignment dowel, lower the sprocket to allow chain to slacken, then remove the chain from the sprocket.
6. Remove the sprocket from the engine.

Scheme 812

Scheme 813

1. Remove the timing chain. Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL»(ref-646217-S11520093992014072800000) .
2. Remove the oil pan. Refer to «PAN, OIL, REMOVAL»(ref-646217-S42351844612014072800000) .
3. Remove the oil pump drive chain tensioner (3).
4. Remove the oil pump drive chain.
5. Remove the crankshaft sprocket (1).

Scheme 814

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 815

1. Align the timing chain onto the crank sprocket mark (1) using the painted link (2) as a guide.
2. Align the timing chain onto the camshaft sprocket mark (2) using the painted link (1) as a guide.
3. Reset the cam chain tensioner. Refer to «VALVE TIMING - STANDARD PROCEDURE»(ref-646217-S01066670532014072800000) . NOTE: Keep the slack in the timing chain on the tensioner side.
4. Install timing chain tensioner (6) and tighten bolts to 12 N.m (105 in. lbs.).
5. Remove the pin (1/8 in. drill bit) from the timing chain tensioner.
6. Verify that the valve timing is correct. Refer to «VALVE TIMING - STANDARD PROCEDURE»(ref-646217-S01066670532014072800000) .
7. Install the engine timing cover. Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-646217-S31374882382014072800000) .
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-646217-S18080092152014072800000) .
9. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
10. Install the resonator. Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-646217-S37132917522014072800000) .
11. Install the engine cover.
12. 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.

CAMSHAFT SPROCKET(S)

Note. Do not use an impact wrench to tighten the camshaft sprocket bolt. Damage to the camshaft dowel pin and camshaft may occur.

1. Install the chain onto the sprocket (2), insert the bolt (1).
2. Using a wrench to hold the camshaft flats (1) tighten the sprocket bolt to 10 N.m + 65° (88 in. lbs. + 65°).
3. Verify correct timing. Refer to «VALVE TIMING - STANDARD PROCEDURE»(ref-646217-S01066670532014072800000) .
4. Install the timing cover. Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-646217-S31374882382014072800000) .
5. Install the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-646217-S10697975412014072800000) .
6. Install engine cover.

Scheme 816

Scheme 817

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-646217-S38825218802014072800000) .
6. Install the oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-646217-S25505509172014072800000) .
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-646217-S18080092152014072800000) .
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.

Scheme 818

Scheme 819

Scheme 820

Scheme 821

1. Perform the fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS , STANDARD PROCEDURE»(ref-646230-S42658421212014072800000) .
2. Disconnect and isolate the battery negative cable.
3. Remove the resonator. Refer to «RESONATOR, AIR CLEANER, REMOVAL»(ref-646217-S01497312852014072800000) .
4. Remove the air cleaner body. Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646217-S11826178562014072800000) .
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-646217-S03078198452014072800000) .
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-646217-S34674813762014072800000) .
14. Remove three bolts (6) and the water pump pulley (5) from the water pump. NOTE: The oil pan will need to be removed and immediately reinstalled. This procedure is necessary because the oil pan sealant must be broken to allow the timing cover to be removed without damage to the oil pan. The reason the pan is to be reinstalled is to allow for a support surface when the timing cover is removed.
15. Remove the oil pan. Refer to «PAN, OIL, REMOVAL»(ref-646217-S42351844612014072800000) .
16. Temporarily reinstall the oil pan.
17. Install the oil pan bolts finger tight. Do not install the four oil pan to timing cover bolts (1) at this time.
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-646217-S11995298642014072800000) .
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 822

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 823

Scheme 824

Scheme 825

1. Install a new crankshaft seal if necessary.
2. Clean all sealing surfaces. Refer to «ENGINE - STANDARD PROCEDURE»(ref-646217-S05151393892014082600000) .
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® MS-GF-46 (or equivalent) to the engine block and cylinder head to timing cover mating surfaces as shown in illustration. Be sure to apply a bead at the two center bolt lands that are between the timing chain.
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. Install the right engine mount. Refer to «INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION»(ref-646217-S05475237812014072800000) .
9. Install the coolant reservoir bottle. Tighten bolt to 9 N.m (80 in. lbs.).
10. Install the water pump pulley (5) and tighten three bolts (6) to 9 N.m (80 in. lbs.).
11. Install the crankshaft damper (4). Refer to «DAMPER, VIBRATION, INSTALLATION»(ref-646217-S16897361002014072800000) .
12. Install the accessory drive belt tensioner (2).
13. Install the accessory drive belt idler pulley (3). Tighten bolt to 25 N.m (18 ft. lbs.).
14. Install the accessory drive belt (1). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .
15. Reseal the oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-646217-S25505509172014072800000) .
16. Install the right lower splash shield. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE - INSTALLATION»(ref-646233-S24910490662014072800000) .
17. Install the cylinder head cover and ignition coils . Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-646217-S10697975412014072800000) .
18. Install the air cleaner body. Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-646217-S00793981562014072800000) .
19. Install the engine cover (1).
20. 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-646217-S18080092152014072800000) .
21. Install the resonator (1). Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-646217-S37132917522014072800000) .
22. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
23. Run the engine until it reaches normal operating temperature. Check cooling system for possible leaks and 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 826

1. Remove the engine timing cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-646217-S12456726232014072800000) .
2. Remove timing chain tensioner retaining bolts (3).
3. Remove the tensioner.