5.7L Engine - Service Information: Removal & Installation Dodge Durango II

REMOVAL

1. Perform the Fuel System Pressure Release procedure. Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(ref-564649-S02344868012013070500000) .
2. Disconnect the battery negative cable.
3. Remove the air cleaner resonator and duct work as an assembly.
4. Remove the wiper module (Refer to «MODULE-WINDSHIELD WIPER»(ref-212806-S16497299482005122700000) ).
5. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
6. Remove the accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
7. Remove the viscous fan/drive (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
8. Remove the upper crossmember and top core support.
9. Remove the condenser (Refer to «CONDENSER-A/C»(ref-212855-S07394227692005122700000) ).
10. Remove radiator (Refer to «RADIATOR»(ref-212747-S10591844532006072400000) ).
11. Evacuate the refrigerant (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-212855-S22954270352005122700000) ).
12. Remove the A/C compressor with the lines attached. Secure compressor out of the way.
13. Remove generator assembly (Refer to «GENERATOR»(ref-166557-S21300542562004092300000) ).
14. Remove the intake manifold and IAFM as an assembly (Refer to «REMOVAL»(ref-212816-S07415221622005122700000) ).
15. Disconnect the heater hoses. NOTE: It is not necessary to disconnect P/S hoses from pump, for P/S pump removal.
16. Remove the power steering pump and set aside.
17. Disconnect the fuel supply line. Refer to «FITTING, QUICK CONNECT»(ref-564649-S03316152772013070500000) .
18. Raise and support the vehicle on a hoist and drain the engine oil.
19. Remove engine front mount thru-bolt nuts.
20. Disconnect the transmission oil cooler lines from their retainers at the oil pan bolts.
21. Disconnect exhaust pipe at manifolds.
22. Disconnect the starter wires. Remove starter motor (Refer to «STARTERS»(ref-164418) ).
23. Remove the structural dust cover and transmission inspection cover, (Refer to «REMOVAL»(ref-212816-S10854357262005122700000) ).
24. Remove drive plate to converter bolts (Automatic transmission equipped vehicles).
25. Remove transmission bell housing to engine block bolts.
26. Lower the vehicle.
27. Install engine lift fixture, special tool # 8984.
28. Separate engine from transmission, remove engine from vehicle, and install engine assembly on a repair stand.

INSTALLATION

1. Install engine lift fixture Special tool # 8984.
2. Position the engine in the engine compartment.
3. Lower engine into compartment and align engine with transmission: Manual Transmission: Align clutch disc assembly (if disturbed). Install transmission input shaft into clutch disc while mating engine and transmission surfaces. Install two transmission to engine block mounting bolts finger tight. Automatic Transmission: Mate engine and transmission and install two transmission to engine block mounting bolts finger tight.
4. Position the thru-bolt into the support cushion brackets.
5. Lower engine assembly until engine mount through bolts rest in mount perches.
6. Install remaining transmission to engine block mounting bolts and tighten.
7. Tighten engine mount through bolts.
8. Install drive plate to torque converter bolts. (Automatic transmission models)
9. Install the structural dust cover and transmission dust cover, (Refer to «INSTALLATION»(ref-212816-S09224397912005122700000) ).
10. Install the starter and connect the starter wires (Refer to «STARTERS»(ref-164418) ).
11. Install exhaust pipe to manifold.
12. Lower the vehicle.
13. Remove engine lift fixture, special tool # 8984.
14. Connect the fuel supply line. Refer to «FITTING, QUICK CONNECT»(ref-564649-S03316152772013070500000) .
15. Reinstall the power steering pump.
16. Connect the heater hoses.
17. Install the intake manifold.
18. Using a new gasket, install throttle body (Refer to «THROTTLE BODY»(ref-212820-S24883851382005122700000) ).
19. Install the generator and wire connections (Refer to «GENERATOR»(ref-166557-S21300542562004092300000) ).
20. Install a/c compressor and lines (Refer to «COMPRESSOR-A/C»(ref-212855-S21919888982005122700000) ).
21. Install the accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
22. Install radiator (Refer to «RADIATOR»(ref-212747-S10591844532006072400000) ).
23. Connect the radiator lower hose.
24. Connect the transmission oil cooler lines to the radiator.
25. Install the fan shroud.
26. Install the fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
27. Connect the radiator upper hose.
28. Install the condenser (Refer to «CONDENSER-A/C»(ref-212855-S07394227692005122700000) ).
29. Install upper radiator support crossmember.
30. Install the washer bottle.
31. Charge the refrigerant (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-212855-S42838088152005122700000) ).
32. Install the air cleaner resonator and duct work.
33. Add engine oil to crankcase (Refer to «LUBRICATION»(ref-212816-S26295309092005122700000) ).
34. Fill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
35. Install the wiper module (Refer to «MODULE-WINDSHIELD WIPER»(ref-212806-S16497299482005122700000) ).
36. Connect battery negative cable.
37. Start engine and inspect for leaks.
38. Road test vehicle.

1. Perform the Fuel System Pressure Release procedure. Disconnect the fuel supply line. «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(ref-564649-S02344868012013070500000) and «FITTING, QUICK CONNECT»(ref-564649-S03316152772013070500000)
2. Disconnect the battery negative cable.
3. Remove the wiper module (Refer to «MODULE-WINDSHIELD WIPER»(ref-212806-S16497299482005122700000) ).
4. Drain cooling system.
5. Remove the air cleaner resonator and duct work.
6. Remove the generator.
7. Remove closed crankcase ventilation system.
8. Disconnect the evaporation control system.
9. Disconnect heater hoses.
10. Remove cylinder head covers and gaskets.
11. Remove intake manifold and throttle body as an assembly.
12. Remove rocker arm assemblies and push rods. Identify to ensure installation in original locations.
13. Remove the head bolts from each cylinder head and remove cylinder heads. Discard the cylinder head gasket.

1. Disconnect battery negative cable.
2. Disconnect coil on plug connectors. CAUTION: The ground straps must be installed in the same location as removed. The covers are machined to accept the ground straps in those locations only.
3. Remove cylinder head cover retaining bolts, and ground straps.
4. Remove cylinder head cover.

Note. The gasket may be used again, provided no cuts, tears, or deformation has occurred.

1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary.
2. Install cylinder head cover and hand start all fasteners. Verify that all double ended studs are in the correct location and install left and right ground straps. CAUTION: The ground straps must be installed in the same location as removed. The covers are machined to accept the ground straps in those locations only. NOTE: The right hand ground strap is located on the front inboard stud. The left hand ground strap is located on the rear inboard stud.
3. Tighten cylinder head cover bolts and double ended studs to 8 N.m (70 in. lbs). Begin torque sequence in the middle of head cover and torque bolts moving outward in a crisscross pattern from top to bottom.
4. Install ignition coil on plug, and torque fasteners to 12 N.m (105 in. lbs)
5. Connect, ignition coil electrical connectors.
6. Install PCV hose.
7. Connect battery negative cable.

1. Remove the cylinder head (Refer to «REMOVAL»(ref-212816-S21954729302005122700000) ).
2. Compress valve springs using Valve Spring Compressor Tool special tool # C-3422 and adapter 8464.
3. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs.
4. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location.

1. Clean valves thoroughly. Discard burned, warped and cracked valves.
2. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
3. Measure valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve.
4. Coat valve stems with lubrication oil and insert them in cylinder head.
5. If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head.
6. Install new seals on all valve guides. Install valve springs and valve retainers.
7. Compress valve springs with Valve Spring Compressor Tool special tool # C- 3422 and adapter 8464, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer.
8. Install cylinder head (Refer to «INSTALLATION»(ref-212816-S07814174022005122700000) ).

1. Remove cylinder head cover. (Refer to «REMOVAL»(ref-212816-S23194616392005122700000) )
2. Loosen the rocker shafts using the following sequence: Center, center-left, center-right, left, right. CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with an "I".
3. Remove the rocker shafts. Note location for reassembly. CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side.
4. Remove the pushrods. Note pushrod location for reassembly.

1. Install the push rods in the same order as removed. CAUTION: Verify that pushrod is installed into rocker arm and lifter correctly while installing rocker shaft assembly. Recheck after rocker shaft has been torqued to specification. CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with the letter "I".
2. Install rocker shaft assemblies in the same order as removed. CAUTION: Ensure that hold downs and rocker arms are not overlapped when torquing bolts.
3. Tighten the rocker shaft bolts to 22 N.m (195 in. lbs.) torque, using the following sequence: Center, center-right, center-left, right, left. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes).
4. Install cylinder head cover (Refer to «INSTALLATION»(ref-212816-S04550456792005122700000) ).

1. Install valve seal.
2. Install valve spring.
3. Using special tool #9065, compress valve spring and install valve spring retainer and locks.
4. Release air charge in cylinder.
5. Remove spring compressor tool # 9065. CAUTION: Verify that the pushrods are fully seated into lifter and rocker arm. Recheck after rocker arm shaft has been torqued to specification.
6. Install rocker arm shaft and pushrods (Refer to «ROCKER ARM»(ref-212816-S03855292522005122700000) ).
7. Tighten the rocker shaft bolts to 22 N.m (195 in. lbs.) torque, using the following sequence: Center, center-right, center-left, right, left.
8. Remove special tool #9070, pushrod retaining plate, if used.
9. Install cylinder head cover.
10. Tighten cylinder head cover bolts and double ended studs (Refer to «INSTALLATION»(ref-212816-S04550456792005122700000) ).
11. Install spark plugs.
12. Install ignition coil on plug, and torque fasteners to 12 N.m (105 in. lbs)
13. Install ignition coil connectors.
14. Install spark plug cables.
15. Install air intake resonator.
16. Install air cleaner assembly.
17. Connect negative battery cable.

REMOVAL - CAMSHAFT CORE HOLE PLUG

1. Remove the rear cam bearing core plug.

REMOVAL - CAMSHAFT

1. Remove the battery negative cable.
2. Remove the air cleaner assembly.
3. Drain coolant.
4. Remove the accessory drive belt.
5. Remove the generator.
6. Remove the A/C compressor, and set aside
7. Remove the radiator (Refer to «RADIATOR»(ref-212747-S10591844532006072400000) ).
8. Remove intake manifold (Refer to «REMOVAL»(ref-212816-S07415221622005122700000) ).
9. Remove cylinder head covers (Refer to «REMOVAL»(ref-212816-S23194616392005122700000) ).
10. Remove both left and right cylinder heads (Refer to «REMOVAL»(ref-212816-S21954729302005122700000) ).
11. Remove the oil pan (Refer to «REMOVAL»(ref-212816-S04343475892005122700000) ).
12. Remove timing case cover (Refer to «COVER-TIMING CASE»(ref-212816-S38582651762005122700000) ).
13. Remove the oil pick up tube.
14. Remove the oil pump (Refer to «REMOVAL»(ref-212816-S19228472532005122700000) ).
15. Remove timing chain (Refer to «REMOVAL»(ref-212816-S33264127652005122700000) ).
16. Remove camshaft tensioner/thrust plate assembly. NOTE: Identify lifters to ensure installation in original location.
17. Remove the lifters and retainer assembly.
18. Install a long bolt into front of camshaft to aid in removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes.

INSTALLATION - CAMSHAFT CORE HOLE PLUG

1. Install a new core hole plug at the rear of camshaft, using special tool # 9048. Clean plug and apply Mopar® lock and seal adhesive to the edge of the plug, before installing. The plug must be installed to a depth of +/- 0.25mm from the end of the machined bevel, that is the end of the bevel that is closest to the cam bearing.

INSTALLATION - CAMSHAFT

1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft
2. Install camshaft Tensioner plate assembly. Tighten bolts to 28 N.m (250 in. lbs.) torque.
3. Install timing chain and sprockets (Refer to «INSTALLATION»(ref-212816-S09170502262005122700000) ).
4. Measure camshaft end play (Refer to «SPECIFICATIONS»(ref-212816-S32984530442005122700000) ). If not within limits install a new thrust plate.
5. Install the oil pump (Refer to «INSTALLATION»(ref-212816-S35656199152005122700000) ).
6. Install the oil pick up tube.
7. Each lifter reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the lifters must be replaced.
8. Install lifters and retainer assembly.
9. Install both left and right cylinder heads (Refer to «INSTALLATION»(ref-212816-S07814174022005122700000) ).
10. Install pushrods
11. Install rocker arms (Refer to «ROCKER ARM»(ref-212816-S03855292522005122700000) ).
12. Install timing case cover (Refer to «COVER-TIMING CASE»(ref-212816-S38582651762005122700000) ).
13. Install the oil pan (Refer to «INSTALLATION»(ref-212816-S40524003202005122700000) ).
14. Install cylinder head covers (Refer to «INSTALLATION»(ref-212816-S04550456792005122700000) ).
15. Install intake manifold (Refer to «INSTALLATION»(ref-212816-S37046619332005122700000) ).
16. Install the A/C compressor, and set aside
17. Install the generator.
18. Install the accessory drive belt.
19. Install the radiator (Refer to «RADIATOR»(ref-212747-S10591844532006072400000) ).
20. Install the air cleaner assembly.
21. Install the battery negative cable.
22. Refill coolant.
23. Refill engine oil.
24. Start engine and check for leaks.

1. Remove the vibration damper (Refer to «DAMPER-CRANKSHAFT»(ref-212816-S32407700202005122700000) ).
2. Remove the oil pan (Refer to «REMOVAL»(ref-212816-S04343475892005122700000) ).
3. Remove the oil pump pickup.
4. Remove the windage tray/oil pan gasket.
5. Remove the timing chain cover (Refer to «COVER-TIMING CASE»(ref-212816-S38582651762005122700000) ).
6. Remove the oil pump (Refer to «REMOVAL»(ref-212816-S19228472532005122700000) ).
7. Remove the timing drive (Refer to «REMOVAL»(ref-212816-S33264127652005122700000) ).
8. Identify rod bearing caps before removal. Remove rod bearing caps with bearings.
9. Identify main bearing caps before removal. Remove main bearing caps and bearings one at a time.
10. Remove the thrust washers.
11. Remove the rear oil seal retainer (Refer to «REMOVAL»(ref-212816-S11914019492005122700000) ).
12. Remove the crankshaft out of the block.
13. Remove and discard the crankshaft rear oil seal.
14. Remove and discard the front crankshaft oil seal.

Scheme 343

1. Select the proper main bearings (Refer to «STANDARD PROCEDURE»(ref-212816-S37538770032005122700000) ).
2. Install main bearings in block and caps, and lubricate bearings.
3. Position the crankshaft into the cylinder block.
4. Install the thrust washers. NOTE: The main cap crossbolts are torqued after final torque of the main cap bolts. Always use a new washer/seal on crossbolts.
5. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten in two steps using the following sequence. Step 1 - 27 N.m ( 20ft. lbs.) torque. Step 2 - Turn main cap bolts an additional 90°.
6. Install the crossbolts with new washer/gasket. Starting with crossbolt A torque each crossbolt to 28 N.m (21 ft.lbs.)torque.
7. Repeat crossbolt torque procedure.
8. Measure crankshaft end play (Refer to «STANDARD PROCEDURE»(ref-212816-S37538770032005122700000) ).
9. Position the connecting rods onto the crankshaft and install the rod bearing caps (Refer to «INSTALLATION»(ref-212816-S31029830012005122700000) ).
10. Install timing drive (Refer to «INSTALLATION»(ref-212816-S09170502262005122700000) ).
11. Install oil pump (Refer to «INSTALLATION»(ref-212816-S35656199152005122700000) ).
12. Install the timing chain cover (Refer to «COVER-TIMING CASE»(ref-212816-S38582651762005122700000) ).
13. Install the rear main seal and retainer (Refer to «INSTALLATION»(ref-212816-S37545717062005122700000) ).
14. Install the windage tray/oil pan gasket.
15. Install the oil pick up tube.
16. Install the oil pan (Refer to «INSTALLATION»(ref-212816-S40524003202005122700000) ).
17. Install the vibration damper (Refer to «DAMPER-CRANKSHAFT»(ref-212816-S32407700202005122700000) ).
18. Install the engine (Refer to «INSTALLATION»(ref-212816-S32115406612005122700000) ).

1. Disconnect negative cable from battery.
2. Remove accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
3. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
4. Remove upper radiator hose.
5. Remove radiator shroud attaching fasteners.
6. Remove radiator cooling fan and shroud (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
7. Remove crankshaft damper bolt.
8. Remove damper using Special Tools 8513A Insert and 8454 Three Jaw Puller.
9. Using Special Tool 9071, remove crankshaft front seal.

1. Using Special Tool 8348 and 8512A, install crankshaft front seal. CAUTION: To prevent severe damage to the Crankshaft or Damper, thoroughly clean the damper bore and the crankshaft nose before installing Damper.
2. Install vibration damper (Refer to «DAMPER-CRANKSHAFT»(ref-212816-S32407700202005122700000) ).
3. Install radiator cooling fan and shroud (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
4. Install upper radiator hose.
5. Install accessory drive belt refer (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
6. Refill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
7. Connect negative cable to battery.

Note. This procedure can be performed in vehicle.

1. If being preformed in vehicle, remove the transmission.
2. Remove the flexplate (Refer to «PLATE-TORQUE CONVERTER DRIVE»(ref-212816-S36533056522005122700000) ). NOTE: The crankshaft oil seal CAN NOT be reused after removal. NOTE: The crankshaft rear oil seal remover Special Tool 8506 must be installed deeply into the seal. Continue to tighten the removal tool into the seal until the tool can not be turned farther. Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine.
3. Using Special Tool 8506, remove the crankshaft rear oil seal.

1. Position the plastic seal guide onto the crankshaft rear face. Then position the crankshaft rear oil seal onto the guide.
2. Using Special Tools 8349 Crankshaft Rear Oil Seal Installer and C-4171 Driver Handle, with a hammer, tap the seal into place. Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore.
3. Install the flexplate.
4. Install the transmission.

1. Disconnect negative cable from battery.
2. Remove the transmission.
3. Remove the drive plate/flywheel.
4. Remove the oil pan (Refer to «REMOVAL»(ref-212816-S04343475892005122700000) ).
5. Remove the rear oil seal retainer mounting bolts.
6. Carefully remove the retainer from the engine block.

1. Thoroughly clean all gasket residue from the engine block.
2. Use extreme care and clean all gasket residue from the retainer.
3. Position the gasket onto the retainer.
4. Position the retainer onto the engine block.
5. Install the retainer mounting bolts. Tighten the bolts to 15 N.m (132 in. lbs.) using a crisscross pattern, starting with the bolt on the lower right.
6. Install a new rear seal (Refer to «INSTALLATION»(ref-212816-S42837120602005122700000) ).
7. Install the oil pan (Refer to «INSTALLATION»(ref-212816-S40524003202005122700000) ).
8. Install the drive plate/flywheel.
9. Install the transmission.
10. Check and verify engine oil level.
11. Start engine and check for leaks.

1. Remove the transmission.
2. Remove the bolts and flexplate.

1. Position the flexplate or flywheel onto the crankshaft and install the bolts hand tight.
2. For automatic transmissions: Tighten the flexplate retaining bolts to 95 N.m (70 ft. lbs.).
3. For manual transmissions: Tighten the flywheel retaining bolts to 75 N.m (55 ft. lbs.).
4. Install the transmission.

1. Disconnect the negative cable from the battery.
2. Remove the air cleaner (Refer to «REMOVAL»(ref-212816-S12811131522005122700000) ).
3. Remove intake manifold (Refer to «REMOVAL»(ref-212816-S07415221622005122700000) ).
4. Remove cylinder head cover (Refer to «REMOVAL»(ref-212816-S23194616392005122700000) ).
5. Remove rocker arm assembly and push rods (Refer to «ROCKER ARM»(ref-212816-S03855292522005122700000) ). Identify push rods to ensure installation in original location.
6. Remove the cylinder head (Refer to «REMOVAL»(ref-212816-S21954729302005122700000) ).
7. Remove bolt from tappet guide holder.
8. Remove tappet guide holder.
9. Pull tappet out of bore with a twisting motion. If all tappets are to be removed and reused, identify tappets to ensure installation in original location.
10. Check camshaft lobes for abnormal wear.

1. Lubricate tappets.
2. Install tappets in their original positions.
3. Install tappet guide holder. Install the tappet guide holder bolt and tighten to 12 N.m (106 in. lbs.) torque.
4. Install cylinder head (Refer to «INSTALLATION»(ref-212816-S07814174022005122700000) ).
5. Install pushrods and rocker arm assembly (Refer to «ROCKER ARM»(ref-212816-S03855292522005122700000) ).
6. Install cylinder head cover (Refer to «INSTALLATION»(ref-212816-S04550456792005122700000) ).
7. Install intake manifold (Refer to «INSTALLATION»(ref-212816-S37046619332005122700000) ).
8. Install the air cleaner (Refer to «INSTALLATION»(ref-212816-S31029830012005122700000) ).
9. Connect the negative cable to the battery. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet.
10. Road test vehicle and check for leaks.

1. Before installing piston and connecting rod assemblies into the bore, install the piston rings (Refer to «STANDARD PROCEDURE»(ref-212816-S38415193892005122700000) ).
2. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation.
3. Position bearing onto connecting rod. Lubricate bearing surface with clean engine oil.
4. Install Special Tool 8507 Connecting Rod Guides into connecting rod bolt threads.
5. The pistons are marked on the piston pin bore surface with an raised "F" or arrow on top of piston indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks.
6. Wipe cylinder bore clean and lubricate with engine oil.
7. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully, position connecting rod guides over crankshaft journal.
8. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal. CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed.
9. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 21 N.m (15 ft. lbs.) plus a 90° turn.
10. Install the following components: Cylinder head(s). (Refer to «INSTALLATION»(ref-212816-S07814174022005122700000) ). Cylinder head covers (Refer to «INSTALLATION»(ref-212816-S04550456792005122700000) ). Install the intake manifold. Oil pan and gasket/windage tray. (Refer to «INSTALLATION»(ref-212816-S40524003202005122700000) ).
11. Fill crankcase with proper engine oil to correct level.
12. Connect negative cable to battery.

1. Disconnect negative cable from battery.
2. Remove accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
3. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
4. Remove radiator upper hose.
5. Remove upper fan shroud.
6. Using Special Tools 6958 Spanner with Adapter Pins 8346, loosen fan and viscous assembly from water pump.
7. Remove fan and viscous assembly.
8. Remove crankshaft damper bolt.
9. Remove damper using Special Tools 8513A Insert and 8454 Three Jaw Puller.

Scheme 344

1. Slide damper onto crankshaft slightly. CAUTION: Special Tool 8512-A, is assembled in a specific sequence. Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft.
2. Assemble Special Tool 8512-A as follows, The nut is threaded onto the shaft first. Then the roller bearing is placed onto the threaded rod (The hardened bearing surface of the bearing MUST face the nut). Then the hardened washer slides onto the threaded rod. Once assembled coat the threaded rod's threads with Mopar® Nickel Anti-Seize or (Loctite No. 771).
3. Using Special Tool 8512-A, press damper onto crankshaft.
4. Install then tighten crankshaft damper bolt to 176 N.m (129 ft. lbs.).
5. Install fan blade assembly (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
6. Install radiator upper shroud and tighten fasteners to 11 N.m (95 in. lbs.).
7. Install radiator upper hose.
8. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
9. Refill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
10. Connect negative cable to battery.

1. Raise vehicle on hoist. CAUTION: On manual transmission vehicles, the 7/16 inch engine block to clutch housing bolts must be loosened before removal of the structural dust cover. Clutch housing distortion will occur if this procedure is not followed.
2. Remove the bolts retaining structural cover.
3. Remove the structural cover.

Note. Threadlocking compound must be applied to the bolts before installation.

1. Install the two bolts that attach the transmission mount to the transmission bracket.
2. Torque the bolts to 61N.m (45 ft.lbs.) torque.
3. Lower the transmission so the transmission mount rests on the crossmember, and the studs of the transmission mount are aligned in the slots in the crossmember.
4. Install the nuts onto the transmission mount studs through the crossmember access slot.
5. Torque the nuts to 54N.m (40 ft. lbs.).

Scheme 345

The lubrication system is a full flow filtration pressure feed type.

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

1. Position a drain pan under the oil filter.
2. Using a suitable oil filter wrench loosen filter.
3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss.
4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter.
5. With a wiping cloth, clean the gasket sealing surface of oil and grime.

Scheme 346

1. Lightly lubricate oil filter gasket with engine oil.
2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one half turn, or 180°,do not over tighten.
3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks.

1. Clean the oil pan gasket mating surface of the block and oil pan.
2. Inspect the integral windage tray and gasket and replace as needed.
3. Reinstall the oil pump pickup tube with new o-ring. Tighten tube to pump fasteners to 28 N.m (250 in. lbs.). NOTE: The double ended oil pan studs must be installed in the same location that they were removed from.
4. Position the oil pan and install the mounting bolts and studs. Tighten the mounting bolts to 12 N.m (105 in.lbs.).
5. Lower the engine into mounts using special tool # 8534.
6. Install both the left and right side engine mount through bolts. Tighten the nuts to 68 N.m (50 ft. lbs.).
7. Reinstall the front axle, if removed.
8. Install the steering rack, if removed.
9. Install the rear transmission mount, if removed.
10. Remove special tool # 8534.
11. Install the front crossmember .
12. Install the fan shroud and fan.
13. Fill engine oil.
14. Reconnect the negative battery cable.
15. Start engine and check for leaks.

1. Remove the oil pan and pick-up tube (Refer to «REMOVAL»(ref-212816-S04343475892005122700000) ).
2. Remove the timing chain cover (Refer to «COVER-TIMING CASE»(ref-212816-S38582651762005122700000) ).
3. Remove the four bolts, and the oil pump.

1. Position the oil pump onto the crankshaft and install the 4 oil pump retaining bolts.
2. Tighten the oil pump retaining bolts to 28 N.m (250 in. lbs.).
3. Install the timing chain cover (Refer to «COVER-TIMING CASE»(ref-212816-S38582651762005122700000) ).
4. Install the pick-up tube and oil pan (Refer to «INSTALLATION»(ref-212816-S40524003202005122700000) ).

1. Disconnect negative cable from battery.
2. Remove the wiper module (Refer to «MODULE-WINDSHIELD WIPER»(ref-212806-S16497299482005122700000) ).
3. Remove resonator assembly and air inlet hose.
4. Disconnect electrical connectors for the following components: Manifold Absolute Pressure (MAP) Sensor Intake Air Temperature (IAT) Sensor Throttle Position (TPS) Sensor Coolant Temperature (CTS) Sensor
5. Disconnect brake booster hose and positive crankcase ventilation (PCV) hose.
6. Remove generator and set aside. NOTE: It is not necessary to remove lines or remove freon from A/C compressor.
7. Remove air conditioning compressor and set aside.
8. Bleed fuel system. Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(ref-564649-S02344868012013070500000) .
9. Remove intake manifold retaining fasteners in a crisscross pattern starting from the outside bolts and ending a the middle bolts.
10. Remove intake manifold and IAFM as an assembly.

1. Install intake manifold seals.
2. Position intake manifold and IAFM.
3. Install intake manifold retaining bolts, and tighten in sequence from the middle bolts towards the outside in a crisscross pattern. Torque fasteners to 12 N.m (105 in. lbs.).
4. Connect electrical connectors for the following components: Manifold Absolute Pressure (MAP) Sensor Intake Air Temperature (IAT) Sensor Throttle Position (TPS) Sensor Coolant Temperature (CTS) Sensor Idle Air Control (IAC) Motor
5. Install generator.
6. Install A/C compressor.
7. Connect Brake booster hose and Positive crankcase ventilation (PCV) hose.
8. Install the wiper module (Refer to «MODULE-WINDSHIELD WIPER»(ref-212806-S16497299482005122700000) ).
9. Install resonator assembly and air inlet hose.
10. Connect negative cable to battery.

1. Disconnect the battery negative cable.
2. Remove air cleaner assembly.
3. Drain cooling system.
4. Remove accessory drive belt.
5. Remove fan and fan drive assembly (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
6. Remove coolant bottle and washer bottle.
7. Remove fan shroud. NOTE: It is not necessary to disconnect A/C lines or discharge freon.
8. Remove A/C compressor and set aside.
9. Remove the generator.
10. Remove upper radiator hose.
11. Disconnect both heater hoses at timing cover.
12. Disconnect lower radiator hose at engine.
13. Remove accessory drive belt tensioner and both idler pulleys.
14. Remove crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(ref-212816-S32407700202005122700000) ). NOTE: Do not remove the hoses from the power steering pump.
15. Remove power steering pump and set aside.
16. Remove the dipstick support bolt.
17. Drain the engine oil.
18. Remove the oil pan and pick up tube (Refer to «REMOVAL»(ref-212816-S04343475892005122700000) ). NOTE: It is not necessary to remove water pump for timing cover removal.
19. Remove timing cover bolts and remove cover.

1. Clean timing chain cover and block surface. NOTE: Always install a new gasket on timing cover.
2. Install cover and new gasket. Tighten fasteners to 28 N.m (250 in. lbs.). NOTE: The large lifting stud is torqued to 55 N.m (40 ft. lbs.).
3. Install the oil pan and pick up tube (Refer to «INSTALLATION»(ref-212816-S40524003202005122700000) ).
4. Install the A/C compressor.
5. Install the generator.
6. Install power steering pump.
7. Install the dipstick support bolt.
8. Install the thermostat housing.
9. Install crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(ref-212816-S32407700202005122700000) ).
10. Install accessory drive belt tensioner assembly and both idler pulleys.
11. Install radiator lower hose.
12. Install both heater hoses.
13. Install radiator fan shroud.
14. Install the fan and fan drive assembly
15. Install the accessory drive belt.
16. Install the coolant bottle and washer bottle.
17. Install the upper radiator hose.
18. Install the air cleaner assembly.
19. Fill cooling system.
20. Refill engine oil.
21. Connect the battery negative cable.

Scheme 347

1. Disconnect battery negative cable.
2. Drain cooling system.
3. Remove Timing Chain Cover. CAUTION: The camshaft pin and the slot in the cam sprocket must be clocked at 12:00. The crankshaft keyway must be clocked at 2:00. The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00.
4. Re-install the vibration clamber bolt finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align timing chain sprockets and key-ways as shown.
5. Retract tensioner shoe until hole in shoe lines up with hole in bracket. Slide a suitable pin into the holes.
6. Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets.
7. If tensioner assembly is to be replaced, remove the tensioner to block bolts and remove tensioner assembly.

Scheme 348

1. If tensioner assembly is being replaced, install tensioner and mounting bolts. Torque bolts to 28 N.m (250 in. lbs.).
2. Retract tensioner if required. CAUTION: The camshaft pin and the slot in the cam sprocket must be clocked at 12:00. The crankshaft keyway must be clocked at 2:00. The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00.
3. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. CAUTION: The timing chain must be installed with the single plated link aligned with the dot and or paint marking on the camshaft sprocket. The crankshaft sprocket is aligned with the dot and or paint marking on the sprocket between two plated timing chain links.
4. Place timing chain around both sprockets.
5. Lift sprockets and chain (keep sprockets tight against the chain in position as shown).
6. Slide both sprockets evenly over their respective shafts and check alignment of timing marks.
7. Install the camshaft bolt. Tighten the bolt to 122 N.m (90 ft. lbs.) torque.
8. Remove tensioner pin. Again, verify alignment of timing marks.
9. Install the oil pump (Refer to «INSTALLATION»(ref-212816-S35656199152005122700000) ).
10. Install the oil pan and pick up (Refer to «INSTALLATION»(ref-212816-S40524003202005122700000) ).
11. Install the timing chain cover (Refer to «COVER-TIMING CASE»(ref-212816-S38582651762005122700000) ).
12. Fill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
13. Connect battery negative cable.
14. Start engine and check for oil and coolant leaks.