2.4L Engine - Service Information: Removal & Installation Dodge Dart PF

REMOVAL

Scheme 599

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Scheme 613

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-646217-S00479151812014072800000) .
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-646217-S07411960972014072800000) .
65. Remove the right engine mount (Refer to «ENGINE MOUNTING»(ref-646217-S11966356822014072800000) , Right/Removal).
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 614

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

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

Scheme 615

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

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

Scheme 616

Scheme 617

1. Remove the engine cover.
2. Disconnect the electrical connector (2) from the Inlet Air Temperature (IAT) sensor.
3. Loosen the clamp (2) that secures the resonator (1) to the throttle body inlet.
4. Loosen the clamp (1) and remove the air inlet hose from the resonator (3).
5. Remove the bolt (2) that secures the resonator to the cylinder head cover.
6. Pull the resonator (3) up while tipping the top edge of the resonator slightly forward and remove from the vehicle.

1. Position the resonator (3) between the forward edge of the cowl and the cylinder head cover. Align the openings with the throttle body intake and the airbox flex hose.
2. Install the bolt. Tighten the bolt to 9 N.m (81 in. lbs.).
3. Tighten the hose clamp (1).
4. Tighten the clamp (2) at the resonator outlet (1).
5. Connect the IAT connector (3).
6. Install the engine cover. Push downward to make sure all four rubber mounts are secure.

Scheme 618

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

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

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

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

Scheme 619

Scheme 620

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

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

Scheme 621

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

Scheme 622

Scheme 623

1. Remove the engine cover assembly.
2. Disconnect and isolate the battery negative cable.
3. Remove the make up air hose from the cylinder head cover fitting.
4. Remove the positive crankcase ventilation (PCV) hose.
5. Disconnect and remove the ignition coils. Refer to «COIL, IGNITION, REMOVAL»(ref-646264-S36315389822014072800000) .
6. Use compressed air to blow dirt and debris off of the cylinder head cover prior to removal.
7. Remove the push pins that secure the coil harness to the cover. NOTE: If any of the push pins break off in the cover, use a pick to rotate the lodged portion counterclockwise to back the portion out of the hole.
8. Loosen twelve cylinder head cover mounting bolts and six stud bolts (1).
9. Remove the cylinder head cover from the cylinder head. NOTE: With the help of an assistant, hold the coil harness up and spread open as the cover is removed through the area between the left and right harness runs.
10. Remove and discard the cylinder head cover gaskets (1 and 2).
11. Remove all residual sealant (1) from the cylinder head, timing chain cover, rear exhaust camshaft bearing cap and cylinder head cover mating surfaces. Refer to «ENGINE - STANDARD PROCEDURE»(ref-646217-S05151393892014082600000) .

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

1. Disconnect and isolate the negative battery cable.
2. Remove the cylinder head cover assembly bolts (1) and remove the cover from the cylinder head.
3. Install special (1) tool to the cylinder head. With the spring compressors lined up in the 2.4L position of the bridge (3), rotate the screw jacks counterclockwise to compress the springs enough to allow slight movement of the rockers.
4. Remove the camshaft(s). Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-646217-S15123378442014072800000) . NOTE: If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.
5. Remove the rocker arm(s). Refer to «ROCKER ARM, VALVE, REMOVAL»(ref-646217-S36729380132014072800000) . NOTE: If the hydraulic lifters are to be reused, identify their positions so that they can be reassembled into their original locations.
6. Remove the hydraulic lifter(s).

1. Verify that the hydraulic lifters are at least partially full of oil. There should be little or no plunger travel when the hydraulic lifter is depressed. NOTE: If the hydraulic lifters are being reused, reassemble them into their original locations.
2. Install the hydraulic lifter(s) NOTE: If the rocker arms are being reused, reassemble them into their original locations.
3. Install the rocker arm(s). Refer to «ROCKER ARM, VALVE, INSTALLATION»(ref-646217-S02234497982014072800000) .
4. Install the camshaft. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-646217-S40821436342014072800000) .
5. Install the VVAA. Refer to «ASSEMBLY, VARIABLE VALVE ACTUATION, INSTALLATION»(ref-646217-S02413844502014072800000) .
6. Install the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION»(ref-646217-S10697975412014072800000) .
7. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 624

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

1. Disconnect and isolate the battery negative cable.
2. If the exhaust rockers are to be serviced, remove the exhaust camshaft. Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-646217-S15123378442014072800000) . NOTE: If the rocker arms are to be reused, identify their positions so that they can be reassembled into their original locations.
3. If the intake rockers are to be serviced, remove the Variable Valve Actuator Assembly (VVAA). Refer to «ASSEMBLY, VARIABLE VALVE ACTUATION, REMOVAL»(ref-646217-S27444429722014072800000) .
4. Remove the rocker arm(s).

1. Lubricate the rocker arms with clean engine oil before installation. NOTE: If the rocker arms are being reused, reassemble them into their original locations.
2. Install the rocker arm(s).
3. If the intake rockers were serviced, install the VVAA Refer to «ASSEMBLY, VARIABLE VALVE ACTUATION, INSTALLATION»(ref-646217-S02413844502014072800000) .
4. If the exhaust rockers were serviced, Install the camshaft and cylinder head cover. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-646217-S40821436342014072800000) .
5. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 625

Note. Typical valve configuration shown in illustration.

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

Scheme 626

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

Scheme 627

Scheme 628

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

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

Scheme 629

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

Scheme 630

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

Scheme 631

Scheme 632

Scheme 633

Scheme 634

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

Scheme 635

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

Scheme 636

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

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

Scheme 637

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

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

Scheme 638

Scheme 639

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

Scheme 640

1. If removed, install the valve(s). Refer to «VALVES, INTAKE AND EXHAUST, INSTALLATION»(ref-646217-S21890509752014072800000) . NOTE: Reassemble the valves into their original locations. If the valves or valve seats have been refinished, verify that the valve stem tip height (5) is within specification. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) .
2. If removed, install the valve guide seal (2) over the valve guide (3). Refer to «SEAL(S), VALVE GUIDE, INSTALLATION»(ref-646217-S25894898622014072800000) . NOTE: Make sure that the garter spring (1) is intact around the top of the valve guide seal (2). Number 2 cylinder exhaust valve guide seal shown in illustration, all other valves similar. NOTE: If the valve springs are being reused, reassemble them into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valves similar.
3. Install the valve spring (2) and valve spring retainer (1).
4. Install the (special tool #10224, Adapter, Valve Spring) (2) on the (special tool #MD998772A, Compressor, Valve Spring) (1). NOTE: Number 3 intake valve spring compression shown in illustration, all other valves similar.
5. Install the (special tool #MD998772A, Compressor, Valve Spring) (1) onto the cylinder head.
6. Place a ball of rags in the combustion chamber to hold the valves in place. NOTE: Number 3 cylinder exhaust valve spring compression shown in illustration, all other valves similar.
7. Using the (special tool #10224, Adapter, Valve Spring) (2) with the (special tool #MD998772A, Compressor, Valve Spring) (1), compress the valve spring (4) only enough to install the valve retaining locks (3).
8. If the valves or valve seats have been refinished, verify that the installed height of the valve springs (4) are within specification. Make sure the measurement is taken from the top of spring seat (6) to the bottom surface of spring retainer (1). Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) .
9. Install the cylinder head. Refer to «CYLINDER HEAD, INSTALLATION»(ref-646217-S06655855062014072800000) .

1. Remove the cylinder head. Refer to «CYLINDER HEAD, REMOVAL»(ref-646217-S25199295112014072800000) . NOTE: If the springs are to be reused, identify their positions so that they can be reassembled into their original locations. Number 2 cylinder exhaust valve spring shown in illustration, all other valve springs similar.
2. Remove the valve spring(s) (2). Refer to «SPRING(S), VALVE, REMOVAL»(ref-646217-S13625247992014072800000) . CAUTION: Before removing the valves, remove any burrs from the valve stem retainer lock grooves (2) and stem tip (1) to prevent damage to the valve guides.
3. Remove the valve(s). Identify each valve to ensure installation in the original location.
4. If required, remove the valve guide seal (2) and spring seat (3). Refer to «SEAL(S), VALVE GUIDE, REMOVAL»(ref-646217-S28446605692014072800000) .

1. Coat the valve stems (2) with clean engine oil and install the valves into the cylinder head. NOTE: If the valves are being reused, reassemble them into their original locations.
2. If the valves or valve seats have been refinished, check the valve tip height (5). If the valve tip height (5) exceeds the specification, grind the valve tip until it is within specification. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) . Make sure the measurement is taken from the cylinder head surface (7) to the top of the valve stem (2).
3. If removed, install the spring seat (3) and valve guide seal (2) over the valve guide. Refer to «SEAL(S), VALVE GUIDE, INSTALLATION»(ref-646217-S25894898622014072800000) . NOTE: Make sure that the garter spring (1) is intact around the top of the valve guide seal (2). Number 2 cylinder exhaust valve guide seal shown in illustration, all other valves similar.
4. Install the valve spring(s) (2). Refer to «SPRING(S), VALVE, INSTALLATION»(ref-646217-S15163833812014072800000) . NOTE: Reassemble the valves springs into their original locations. If the valves or valve seats have been refinished, verify that the valve spring installed height is within specification. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) . Number 2 cylinder exhaust valve spring shown in illustration, all other valves springs similar.
5. Install the cylinder head. Refer to «CYLINDER HEAD, INSTALLATION»(ref-646217-S06655855062014072800000) .

Scheme 641

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

Scheme 642

Scheme 643

Scheme 644

Scheme 645

1. Remove the engine cover. Refer to «RESONATOR, AIR CLEANER, REMOVAL»(ref-646217-S01497312852014072800000) .
2. Remove the battery. Refer to «BATTERY, REMOVAL»(ref-646227-S35480669362014072800000) . NOTE: Oil may leak from the vacuum pump drive when the pump is removed. Place a shop towel under the pump to prevent oil leakage onto the engine or transmission assembly.
3. Disconnect the vacuum line at the pump (1).
4. Remove the vacuum pump mounting bolts (2) and the vacuum pump.
5. Remove and discard the vacuum pump gasket (1). Note the location of the pump drive tab.
6. If required, remove the screw (1) and the vacuum fitting (2).
7. The vacuum fitting O-ring seal (1) can be reused if not damaged.

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

Scheme 646

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

Scheme 647

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

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

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

Scheme 648

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

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

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

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

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

Scheme 649

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

Scheme 650

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

Scheme 651

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

Scheme 652

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

Scheme 653

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

Scheme 654

Scheme 655

Scheme 656

Scheme 657

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

Scheme 658

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

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

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

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 "A00646217.vid1" into the "Search Channel" box

Scheme 659

Scheme 660

Scheme 661

Scheme 662

Scheme 663

Scheme 664

Scheme 665

Scheme 666

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

CONNECTING ROD BEARING REPLACEMENT

The connecting rod bearings (1) are serviced in-vehicle. They must be replaced one-at-a-time in order to prevent the pistons from contacting the valves. The connecting rod bearings are "select fit" to achieve proper oil clearances. Refer to BEARING(S), CONNECTING ROD - STANDARD PROCEDURE .

1. Disconnect and isolate the battery negative cable.
2. Remove the spark plugs. Refer to «SPARK PLUG, REMOVAL»(ref-646264-S20945443012014072800000) .
3. Remove the oil pan, oil pump pick-up and engine oil pump. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-646217-S41540061932014072800000) .
4. Remove the eight main bearing cap bolts in the sequence shown in illustration. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
5. Mark connecting rod and bearing cap positions (1) using a permanent ink marker or scribe tool. NOTE: Typical V6 engine configuration shown in illustration. CAUTION: Replace only one connecting rod bearing at a time while all other connecting rod bearing caps remain properly tightened. If all connecting rod bearing caps are removed, crankshaft rotation will result in valve and/or piston damage. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
6. Remove the connecting rod cap bolts (5) and the connecting rod cap (4). Discard the cap bolts.
7. 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: Care must be taken not to nick crankshaft journals, as engine damage may occur.
8. Rotate the crankshaft away from the connecting rod and remove the bearing shell.
9. If required, select and fit new bearings to the connecting rod. Refer to «BEARING(S), CONNECTING ROD - STANDARD PROCEDURE»(ref-646217-S06019193492014072800000) .
10. Install the bearing shell (8) on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
11. Rotate the crankshaft while guiding the connecting rod into position over the rod journal. CAUTION: The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.
12. Install the bearing shell (6) on the connecting rod cap (4) with the tang inserted into the machined groove in the cap. Lubricate the bearing surface with clean engine oil. NOTE: Do not lubricate the threads of the connecting rod cap bolts (5).
13. Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten the NEW connecting rod cap bolts (5) to 20 N.m (15 ft. lbs.) plus 90°.
14. If required, check the connecting rod side clearance. Refer to «ROD, PISTON AND CONNECTING - STANDARD PROCEDURE»(ref-646217-S08681735612014072800000) .
15. Repeat the previous steps for each connecting rod bearing being replaced. CAUTION: The main bearing cap bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.
16. Check the main bearing cap bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
17. Install the eight main bearing cap bolts. Tighten the bolts in the sequence shown in illustration to 21 N.m (16 ft. lbs.) plus 90°.
18. Install the engine oil pump, oil pump pick-up and oil pan. Refer to «PUMP, ENGINE OIL, INSTALLATION»(ref-646217-S42937032902014072800000) .
19. Install the spark plugs and ignition coils. Refer to «SPARK PLUG, INSTALLATION»(ref-646264-S27190124152014072800000) .
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. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
22. Operate the engine until it reaches normal operating temperature.

Scheme 667

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

Scheme 668

1. Mount a dial indicator (2) to front of engine with the locating probe on nose of crankshaft (1).
2. Move crankshaft all the way to the rear of its travel.
3. Zero the dial indicator.
4. Move crankshaft all the way to the front and read the dial indicator. for end play specification. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) .

Scheme 669

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

Scheme 670

Scheme 671

Scheme 672

Scheme 673

Scheme 674

Scheme 675

Scheme 676

1. Remove engine assembly from vehicle. Refer to «ENGINE - REMOVAL»(ref-646217-S06099343112014072800000) .
2. Remove flex plate/flywheel (1).
3. Remove crankshaft rear oil seal. Refer to «SEAL, CRANKSHAFT OIL, REAR, REMOVAL»(ref-646217-S15129442612014072800000) .
4. Install engine on suitable stand.
5. Drain engine oil (2).
6. Remove oil filter (1).
7. Remove crankshaft vibration damper. Refer to «DAMPER, VIBRATION, REMOVAL»(ref-646217-S34674813762014072800000) .
8. Remove water pump pulley.
9. Remove the oil pan (2). Refer to «PAN, OIL, REMOVAL»(ref-646217-S42351844612014072800000) .
10. Remove timing chain cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-646217-S12456726232014072800000) .
11. Remove the timing chain. Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL»(ref-646217-S11520093992014072800000) .
12. Remove balance shaft module.
13. Remove the crankshaft sprocket (1).
14. Remove crankshaft position sensor retaining bolt (1) and remove sensor (2).
15. Remove ladder frame. Refer to «FRAME, LADDER, REMOVAL»(ref-646217-S31507162472014072800000) . NOTE: If piston/connecting rod replacement is necessary, remove cylinder head. Refer to «CYLINDER HEAD, REMOVAL»(ref-646217-S25199295112014072800000) . CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.
16. Using a permanent ink or paint marker, identify cylinder number on each connecting rod and cap.
17. Remove all connecting rod bolts and caps. Care should be taken not to damage the fracture rod and cap surfaces. NOTE: Do not reuse connecting rod bolts.
18. Remove main bearing caps. CAUTION: Use extreme care when handling crankshaft. Tone wheel damage can occur if crankshaft is mis-handled.
19. Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the crankshaft.

Scheme 677

Note. Typical crankshaft journal measurements shown in illustration.

1. Clean the oil off the bearing journals.
2. Determine the maximum diameter of the journals with a micrometer. Measure at two locations 90° apart at each end of the journals.
3. Compare the measured rod journal diameter to the crankshaft connecting rod bearing journal diameter grade marking chart. Refer to «BEARING(S), CONNECTING ROD - STANDARD PROCEDURE»(ref-646217-S06019193492014072800000) . Select the bearing size that corresponds to the crankshaft markings for each rod bearing journal that will provide the proper oil clearance.
4. Compare the measured main bearing journal diameter to the crankshaft main bearing journal diameter grade marking chart. Refer to «BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE»(ref-646217-S33625823892014072800000) . Obtain the main bearing journal grade identification marks from the engine block and select the upper and lower main bearing sizes that will provide the proper oil clearance.
5. For connecting rod journals, verify that the maximum taper and maximum out of round are within specifications. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) .
6. For main bearing journals, verify that the maximum taper and maximum out of round are within specifications. Refer to «ENGINE SPECIFICATIONS»(ref-646217-S08719865132014072800000) .

Scheme 678

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

Scheme 679

Scheme 680

Scheme 681

Scheme 682

Scheme 683

Scheme 684

1. Clean main bearing cap bolt holes with Mopar® brake parts cleaner or equivalent and blow out with compressed air.
2. Install the main bearing upper (2) shells with the lubrication groove and oil hole in the engine block.
3. Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots. NOTE: If the crankshaft is sent out for machine work, it must be balanced as an assembly with the target ring installed.
4. Clean crankshaft and target ring with Mopar® brake parts cleaner or equivalent and dry with compressed air to ensure that the crankshaft mating surface and target ring mounting holes are free from oil and lock patch debris. NOTE: Always use NEW mounting screws whether installing original or new target ring.
5. Install NEW mounting screws finger tight starting with the #1 location. Make sure engagement occurs with the shoulder of the screws and mounting hole before starting all other screws.
6. Tighten all mounting screws to 13 N.m (110 in. lbs.) in the sequence shown in illustration. NOTE: Lightly apply trans gel to thrust bearings to hold bearings in block. NOTE: The thrust bearings must be installed with the notches facing the crankshaft.
7. Install thrust bearings (2) in block (1). CAUTION: Do not get oil on the ladder frame mating surface. It will affect the ability of the RTV to seal the ladder frame to cylinder block. NOTE: Ensure main bearing cap bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.
8. Oil the bearings and journals. Install crankshaft in engine block.
9. Install lower main bearings (1) into main bearing cap. Make certain the bearing tabs are seated into the bearing cap slots. NOTE: Main bearing caps are stamped 1 - 5 front to rear. Arrows on the caps must point towards the front of the engine.
10. Install main bearing caps to engine block.
11. Before installing the bolts the threads should be clean and dry.
12. Loosely install main bearing cap bolts.
13. To ensure correct thrust bearing alignment, perform the following steps: Step 1: Rotate crankshaft until number 4 piston is at TDC. Step 2: Move crankshaft rearward to limits of travel. Step 3: Then, move crankshaft forward to limits of travel. Step 4: Wedge an appropriate tool between the rear of the cylinder block and the rear crankshaft counterweight. This will hold the crankshaft in its furthest forward position. CAUTION: There are different sets main bolts supplied with this engine. Each bolt set has a different torque value and engine damage could result if bolts are not torqued correctly. The bolts are not interchangeable.
14. If your bolt heads are marked with b (1) or 6 (2), go to step 15. If your bolt heads are marked with M (3) or any other marking, go to step 16 . CAUTION: Before tightening bolts, you must identify the bolt head to obtain the correct torque value. Failure to identify the bolts correctly, could result in improperly tightened bolts which could result in engine damage.
15. Tighten bolts marked with b or 6 using the following three step method, in the sequence shown in illustration: Tighten all bolts to 15 N.m (11 ft. lbs.) Tighten all bolts to 27 N.m (20 ft. lbs.) Tighten all bolts an additional 45°.
16. Tighten bolts marked with M using the following three step method, in the sequence shown in illustration: Tighten all bolts to 15 N.m (11 ft. lbs.) Tighten all bolts to 45 N.m (33 ft. lbs.) Tighten all bolts an additional 45°.
17. Remove wedge tool used to hold crankshaft.
18. Check the crankshaft turning torque, it should not exceed 5.6 N.m (50 in. lbs.).
19. Check crankshaft end play. Refer to «CRANKSHAFT - STANDARD PROCEDURE»(ref-646217-S40895728312014072800000) .
20. Install connecting rod bearings and caps. Do Not Reuse Connecting Rod Bolts. Tighten connecting rod bolts to 20 N.m + 90° (15 ft. lbs.) + 90°. Refer to «ROD, PISTON AND CONNECTING, INSTALLATION»(ref-646217-S19872350382014072800000) .
21. Install the ladder frame assembly. Refer to «FRAME, LADDER, INSTALLATION»(ref-646217-S19930080782014072800000) .
22. Install the balance shaft module. Refer to «PUMP, ENGINE OIL, INSTALLATION»(ref-646217-S42937032902014072800000) .
23. Install crankshaft position sensor (2) and bolt (1). Tighten the bolt to 9 N.m (80 in. lbs.)
24. Install cylinder head if it was removed. Refer to «CYLINDER HEAD, INSTALLATION»(ref-646217-S06655855062014072800000) .
25. Install front crankshaft sprocket (1).
26. Install the timing chain. Refer to «CHAIN AND SPROCKETS, TIMING, INSTALLATION»(ref-646217-S38825218802014072800000) .
27. Install the timing chain front cover . Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-646217-S31374882382014072800000) .
28. Install the oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-646217-S25505509172014072800000) .
29. Install rear crankshaft oil seal. Refer to «SEAL, CRANKSHAFT OIL, REAR, INSTALLATION»(ref-646217-S23034431832014072800000) .
30. Install front crankshaft oil seal. Refer to «SEAL, CRANKSHAFT OIL, FRONT, INSTALLATION»(ref-646217-S35584390902014072800000) .
31. Install crankshaft vibration damper. Refer to «DAMPER, VIBRATION, INSTALLATION»(ref-646217-S16897361002014072800000) .
32. Install water pump pulley. Refer to «PUMP, WATER, INSTALLATION»(ref-646235-S33718727012014072800000) .
33. Install crankshaft rear oil seal. Refer to «SEAL, CRANKSHAFT OIL, REAR, INSTALLATION»(ref-646217-S23034431832014072800000) .
34. Install drive plate/flex plate using new bolts. Tighten bolts to 95 N.m (70 ft. lbs.).
35. Attach transaxle to engine. Tighten bellhousing bolts to 101 N.m (75 ft. lbs.).
36. Install the engine assembly into the vehicle. Refer to «ENGINE - INSTALLATION»(ref-646217-S02800983112014072800000) .
37. Install new oil filter (1) and fill with oil.
38. Fill with coolant. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
39. Start engine and check for leaks.
40. Install engine cover.

Scheme 685

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

Scheme 686

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

Scheme 687

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

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 688

Scheme 689

1. Remove oil pan. Refer to «PAN, OIL, REMOVAL»(ref-646217-S42351844612014072800000) .
2. Remove balance shaft assembly. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-646217-S41540061932014072800000) .
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 690

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 691

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-646217-S42937032902014072800000) .
4. Install oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-646217-S25505509172014072800000) .

Scheme 692

Scheme 693

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 694

Note. Typical piston shown in illustration.

Scheme 695

Scheme 696

1. Remove the piston and connecting rod(s). Refer to «ROD, PISTON AND CONNECTING, REMOVAL»(ref-646217-S10549414842014072800000) . 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 697

Scheme 698

1. If required, fit new rings to the piston. Refer to «RING(S), PISTON - STANDARD PROCEDURE»(ref-646217-S02152739552014072800000) . 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-646217-S19872350382014072800000) .

Scheme 699

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 700

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 701

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 702

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 703

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-646217-S08719865132014072800000) .
5. Repeat this procedure for each connecting rod. Rotate the crankshaft for connecting rod accessibility.

Scheme 704

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-646217-S08719865132014072800000) .
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-646217-S25199295112014072800000) .
3. Remove the engine oil pump. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-646217-S41540061932014072800000) .
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-646217-S05936337732014072800000) .
13. Repeat the previous steps for each piston being removed.

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

Scheme 705

Scheme 706

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

Scheme 707

Scheme 708

Scheme 709

Scheme 710

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

Scheme 711

1. Remove transmission and flexplate (1). Refer to «FLEXPLATE, REMOVAL»(ref-646217-S03410204032014072800000) .
2. Insert a 3/16 flat bladed screwdriver (7) between the dust lip (8) and the metal case (4) of the crankshaft seal (1). Angle the screwdriver through the dust lip against metal case of the seal. Pry out seal. CAUTION: Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of the screwdriver blade against crankshaft edge (chamfer) is permitted.
3. Check to make sure the seals garter spring is not on the crankshaft.

Scheme 712

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

1. Place Seal Guide (special tool #9509, Installer, Oil Seal) (3) on crankshaft.
2. Position seal (2) over guide tool. Guide tool should remain on crankshaft during installation of seal. Ensure that the lip of the seal is facing towards the crankcase during installation.
3. Drive the seal into the block using Seal Driver (special tool #9706, Installer, Crankshaft Rear Oil Seal) (1) and Driver Handle (special tool #C-4171, Driver Handle, Universal) (4) until Seal Driver (special tool #9706, Installer, Crankshaft Rear Oil Seal) bottoms out against the block.
4. Install the flexplate (1) and transmission. Refer to «FLEXPLATE, INSTALLATION»(ref-646217-S37925319822014072800000) .

Scheme 713

Scheme 714

1. Raise and support the vehicle. Refer to «HOISTING - STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
2. Remove the belly pan. Refer to «BELLY PAN, REMOVAL»(ref-646214-S24731623582014072800000) .
3. Lower the vehicle.
4. Remove the engine cover to prevent contact with the cowl.
5. Remove the battery and tray. Refer to «TRAY, BATTERY, REMOVAL»(ref-646227-S29548343982014072800000) .
6. Remove the wire harness retainer from the top of the left engine mount.
7. Support transaxle with a suitable jack.
8. Remove the coolant tube bracket bolt (1).
9. Remove the three mount to transaxle bracket bolts (2).
10. Remove the two mount to frame rail bolts (3).
11. Loosen, but do not remove the bolt (2) for the trans mount (3) to strut tower (1) attachment.
12. Remove the mount.

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 715

Scheme 716

1. Remove the engine cover.
2. Remove the air cleaner assembly. Refer to «BODY, AIR CLEANER, REMOVAL»(ref-646217-S11826178562014072800000) .
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-646217-S00793981562014072800000) .
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 717

Scheme 718

Scheme 719

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 720

Scheme 721

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-646217-S01497312852014072800000) .
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.

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 722

Scheme 723

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 724

Scheme 725

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 726

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

Scheme 727

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 728

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 729

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 730

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 "A00646217.vid2" into the "Search Channel" box

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 731

Scheme 732

Scheme 733

1. Remove the oil pan. Refer to «PAN, OIL, REMOVAL»(ref-646217-S42351844612014072800000) .
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 734

1. Remove timing chain cover . Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-646217-S12456726232014072800000) .
2. Remove oil pan. Refer to «PAN, OIL, REMOVAL»(ref-646217-S42351844612014072800000) .
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 "A00646217.vid3" into the "Search Channel" box

Scheme 735

Scheme 736

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-646217-S25505509172014072800000) .
14. Fill engine with oil.
15. Start engine and check for leaks.

Scheme 737

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

Scheme 738

Scheme 739

1. Disconnect the battery negative cable.
2. Remove the engine cover (1). Loosen the intake clamp (1), remove the resonator bolt (2) and resonator (3).
3. Remove the engine cover (1).
4. Remove the wiring harness fastener from the intake manifold.
5. Disconnect oil temperature sensor electrical connector.
6. Remove sensor (1).

1. If re-using the oil temperature sensor, coat the threads with Mopar® thread sealant.
2. Install oil temperature sensor (1). Tighten to 18 N.m (160 in. lbs.).
3. Install the resonator (3), bolt (2) and clamp (1). Tighten the bolt to 5 N.m (81 in. lbs.). Tighten the clamp.
4. Connect electrical connector.
5. Install the engine cover (1).

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) .

Scheme 740

1. Remove oil pan. Refer to «PAN, OIL, REMOVAL»(ref-646217-S42351844612014072800000) .
2. Remove pressure regulating valve cap (2).
3. Remove pressure regulating valve spring (3) and valve (4).

Scheme 741

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 742

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.).

1. 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.
2. Install timing chain tensioner (6) 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-646217-S01066670532014072800000) .
5. Install the engine timing cover. Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-646217-S31374882382014072800000) .
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-646217-S18080092152014072800000) .
7. Connect the battery negative cable and tighten nut to 5 N.m (45 in. lbs.).
8. Install the resonator. Refer to «RESONATOR, AIR CLEANER, INSTALLATION»(ref-646217-S37132917522014072800000) .
9. Install the engine cover.
10. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

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