5.7L Engine - Service Information: Overview Dodge Durango III

DESCRIPTION

The 5.7L engine (348 CID) eight-cylinder engine is a 90° V-Type lightweight, deep skirt cast iron block, aluminum heads, single cam, overhead valve engine with hydraulic roller tappets. The heads incorporate splayed valves with a hemispherical style combustion chamber and dual spark plugs. The cylinders are numbered from front to rear; 1, 3, 5, 7 on the left bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2.

OPERATION

The cylinder head closes the combustion chamber allowing the pistons to compress the air fuel mixture to the correct ratio for ignition. The valves located in the cylinder head open and close to either allow clean air into the combustion chamber or to allow the exhaust gases out, depending on the stroke of the engine.

The valve guide seals are made of rubber and incorporate an integral steel valve spring seat. The integral garter spring maintains consistent lubrication control to the valve stems.

The Variable Cam Timing (VCT) assembly is actuated with engine oil pressure. The oil flow to the VCT assemblies are controlled by an Oil Control Valve (OCV). The OCV consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VCT assemblies. The VCT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VCT assembly rotates the rotor with respect to the stator, thus rotating the exhaust camshaft with respect to the timing chain and intake camshaft. An infinitely variable cam timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM.

Scheme 348

1. Remove the timing chain and sprockets. Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL, 5.7L»(ref-465934-S18859631602012042300000) .
2. Remove the camshaft phaser bolt (1).
3. Remove camshaft phaser (2).

Scheme 349

1. Align the slot (2) in the phaser (1) with the dowel on the camshaft. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result.
2. Position the phaser (2) in place and install phaser retaining bolt (1) and tighten to 122 N.m (90 ft. lbs.).
3. Install the timing chain and sprockets. Refer to «CHAIN AND SPROCKETS, TIMING, INSTALLATION, 5.7L»(ref-465934-S15941739012012042300000) .

Scheme 350

With the crankshaft removed from the cylinder block.

Clean the oil off the main bearing journal.

Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal.

The maximum allowable taper is 0.008 mm (0.0004 inch.) and maximum out of round is 0.005 mm (0.0002 inch). Compare the measured diameter with the journal diameter specification (Main Bearing Fitting Chart). Select the inserts required to obtain the specified bearing-to-journal clearance.

Scheme 351

The main bearings are "select fit" to achieve proper oil clearances. For main bearing selection, the crankshaft counterweight has grade identification marks stamped into it. These marks are read from left to right. The left letter (1) refers to the number one main journal and the right letter (2) refers to the number 5 journal.

Note. Service main bearings are coded. These codes identify what size or grade of the bearing.

MAIN BEARING SELECTION CHART - 5.7L

Scheme 352

Wipe the inserts clean and inspect for abnormal wear patterns and for metal or other foreign material imbedded in the lining. Normal main bearing insert wear patterns are illustrated.

Note. If any crankshaft journals are scored, the crankshaft must be repaired or replaced.

Inspect the back of the inserts for fractures, scrapings or irregular wear patterns.

Inspect the upper insert locking tabs for damage.

Replace all damaged or worn bearing inserts.

Scheme 353

Scheme 354

1. Perform the fuel system pressure release procedure. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-465971-S02093746452012042300000) .
2. Remove the transmission. Refer to appropriate Transmission Service Information article.
3. Using the sequence shown in illustration, remove the flexplate retaining bolts.
4. Remove the flexplate. CAUTION: Do not damage the rear surface of the camshaft or the core plug sealing surface, when removing the core plug.
5. Using a suitable sharp punch, place a small hole into the camshaft core hole plug (1).
6. Insert a short sheet metal screw into the small hole in the camshaft core hole plug.
7. Using a suitable slide hammer puller, remove the rear camshaft core hole plug.

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Scheme 360

1. Remove the oil fill cap (1).
2. Remove the engine cover (2).
3. Disconnect and isolate the negative battery cable (2).
4. Remove the engine from the vehicle. Refer to «REMOVAL, 5.7L»(ref-465934-S38665617732012042300000) .
5. Place the engine on a suitable engine stand. NOTE: The oil pump pickup tube, windage tray and oil pan is one assembly. When the oil pan is removed, a new oil pan gasket and pickup tube O-ring must be installed. The old gasket and O-ring cannot be reused.
6. Remove the engine oil dipstick.
7. Using the sequence shown in illustration, remove the oil pan retaining bolts.
8. Remove the oil pan and discard the oil pan gasket and pickup tube O-ring.
9. Clean the sealing surfaces as necessary.
10. Remove the ignition coil retaining bolts (3).
11. Remove the ignition coils (2).
12. Using the sequence shown in illustration, remove the cylinder head cover retaining bolts.
13. Remove the cylinder head cover (2). NOTE: The cylinder head cover gasket (1) may be used again, provided no cuts, tears, or deformation have occurred.
14. Inspect the cylinder head cover gasket (1), replace if necessary. Right cylinder head shown in illustration, left cylinder head similar. NOTE: The rocker arms and push rods must be installed in their original location as removed.
15. Remove the rocker arms and push rods. Note their location to ensure installation in their original locations as removed. Refer to «ROCKER ARM, VALVE, REMOVAL, 5.7L»(ref-465934-S02252868942012042300000) . Right cylinder head shown in illustration, left cylinder head similar.
16. Using the sequence shown in illustration, remove the cylinder head bolts.
17. Remove the cylinder head(s) and discard the cylinder head gasket(s).
18. Remove timing case cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL, 5.7L»(ref-465934-S18607826532012042300000) . NOTE: Identify lifters to ensure installation in original location.
19. Remove the lifters (2) and retainer (1) as an assembly.
20. Remove the oil pump retaining bolts (2) and remove the oil pump (1).
21. Remove timing chain (5). Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL, 5.7L»(ref-465934-S18859631602012042300000) .
22. Remove camshaft thrust plate (1). NOTE: Slowly rotate the camshaft while pulling camshaft out.
23. Install a long bolt (2) into front of camshaft (1) to aid in removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes.

The structural dust cover is made of die cast aluminum and joins the lower half of the transmission bell housing to the engine.

The structural cover provides additional powertrain stiffness and reduces noise and vibration.

The crankshaft damper is used to control the resonance that is produced by the engine. The Noise, Vibration, and Harshness (NVH) created from the crankshaft can be controlled by dissipating the torque energy through the damper.

Scheme 361

The crankshaft damper on the engines is held to the crankshaft by means of a harden steel bolt. The damper is pressed onto a specific machined surface of the crankshaft.

Scheme 362

The HEMI® Engines incorporate various crankshaft vibration dampers depending on the engine application. And can be removed depending on the application used.

Scheme 363

Finding the proper puller for the application will ensure no damage will come to the damper. The flange puller is used by installing 3 bolts into the pre-tapped holes in the damper.

Scheme 364

Some pulleys that do not have bolt holes can be removed with a three jaw style (special tool #1023, Puller).

Scheme 365

Scheme 366

1. Disconnect the negative battery cable.
2. Disconnect the electrical connector at the Intake Air Temperature (IAT) sensor (1).
3. Loosen the clean air hose clamp at the air cleaner housing (2).
4. Remove the resonator retaining bolt (3).
5. Loosen the resonator hose clamp at the throttle body (4) and remove the resonator.
6. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-465940-S34230748332012042300000) .
7. Remove the upper radiator hose clamp (1) at the thermostat housing.
8. Remove the upper radiator hose retainer (2) at the fan shroud and position the radiator hose aside.
9. Remove the serpentine belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-465940-S20367993122012042300000) .
10. Remove the cooling fan module. Refer to «FAN, COOLING, REMOVAL»(ref-465940-S32398312912012042300000) .
11. Remove the crankshaft damper bolt. NOTE: When installing the puller tool, ensure the bolts are fully threaded through the entire crankshaft damper.
12. Install puller tool (2) and remove the crankshaft damper (1).

Scheme 367

Scheme 368

1. Using (special tool #10387, Installer, Vibration Damper). Install the threaded rod (1) into the face of the crankshaft (3) till the face of the rod (4) bottoms out.
2. Position the vibration damper (2) on the crankshaft.
3. Using Damper Installer (1) and a deep well socket, press the damper onto the crankshaft till seated.
4. Remove the Damper Installer tool (1) and install the crankshaft damper bolt. Tighten the bolt to 176 N.m (129 ft. lbs.).
5. Install the cooling fan module. Refer to «FAN, COOLING, INSTALLATION»(ref-465940-S22919138712012042300000) .
6. Install serpentine belt (2). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-465940-S28892887022012042300000) .
7. Position the upper radiator hose and secure retainer (2) at the fan shroud.
8. Install the upper radiator hose at the thermostat housing and secure hose clamp (1).
9. Install the air cleaner resonator support bracket at the water pump.
10. Connect the resonator hose at the throttle body and tighten clamp (4) to 5 N.m (44 in. lbs.).
11. Install the resonator retaining bolt (3) and tighten to 5 N.m (44 in. lbs.).
12. Connect the clean air hose at the air cleaner housing and tighten clamp (2) to 5 N.m (44 in. lbs.).
13. Connect the electrical connector at the Intake Air Temperature (IAT) sensor (1).
14. Refill the cooling system. Refer to «STANDARD PROCEDURE»(ref-465940-S34230748332012042300000) .
15. Connect the negative battery cable.

The pistons are made of a high strength aluminum alloy. Piston skirts are coated with a solid lubricant (Molykote®) to reduce friction and provide scuff resistance. The piston top ring groove and land is anodized. The connecting rods are made of forged powdered metal, with a fractured cap design.

Scheme 369

1. To correctly select the proper size piston, use Cylinder Indicator (special tool #C-119, Cylinder Indicator) (2) to measure the inside diameter of the cylinder bore (3). A cylinder bore gauge capable of reading in 0.003 mm (0.0001 in.) Increments is required. If a bore gauge is not available, do not use an inside micrometer.
2. Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below the top of bore (4). Start perpendicular (across or at 90°) to the axis of the crankshaft at point A (1) and then take an additional bore reading 90° at point B (1).
3. The coated pistons will be serviced with the piston pin and connecting rod pre-assembled. The piston-rod assembly is specific for the left cylinder bank (odd numbered) and the right cylinder bank (even numbered) and must not be interchanged.
4. Measure the piston diameter with a micrometer at points (1, 2).

Scheme 370

Scheme 371

1. Remove the oil fill cap (1).
2. Remove the engine cover (2).
3. Disconnect and isolate the negative battery cable (2).
4. Remove the engine from the vehicle. Refer to «REMOVAL, 5.7L»(ref-465934-S38665617732012042300000) .
5. Place the engine on a suitable engine stand. NOTE: The oil pump pickup tube, windage tray and oil pan is one assembly. When the oil pan is removed, a new oil pan gasket and pickup tube O-ring must be installed. The old gasket and O-ring cannot be reused.
6. Remove the engine oil dipstick.
7. Using the sequence shown in illustration, remove the oil pan retaining bolts.
8. Remove the oil pan and discard the oil pan gasket and pickup tube O-ring.
9. Clean the sealing surfaces as necessary.
10. Remove the ignition coil retaining bolts (3).
11. Remove the ignition coils (2).
12. Using the sequence shown in illustration, remove the cylinder head cover retaining bolts.
13. Remove the cylinder head cover (2). NOTE: The cylinder head cover gasket (1) may be used again, provided no cuts, tears, or deformation have occurred.
14. Inspect the cylinder head cover gasket (1), replace if necessary. Right cylinder head shown in illustration, left cylinder head similar. NOTE: The rocker arms and push rods must be installed in their original location as removed.
15. Remove the rocker arms and push rods. Note their location to ensure installation in their original locations as removed. Refer to «ROCKER ARM, VALVE, REMOVAL, 5.7L»(ref-465934-S02252868942012042300000) . Right cylinder head shown in illustration, left cylinder head similar.
16. Using the sequence shown in illustration, remove the cylinder head bolts.
17. Remove the cylinder head(s) and discard the cylinder head gasket(s).
18. If necessary, remove the ridge on top of the cylinder bores with a reliable ridge reamer before removing the pistons from the cylinder block. Be sure to keep the tops of the pistons covered during this operation. 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 removal to ensure correct reassembly.
19. Mark the connecting rod and bearing cap positions using a permanent ink marker or scribe tool. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur. NOTE: Pistons and connecting rod assemblies must be removed from the top of cylinder block. When removing the piston and connecting rod assemblies from the engine, rotate the crankshaft so each connecting rod is centered in the cylinder bore.
20. Perform the measure bearing clearance procedure. Refer to «Engine/Engine Block - Standard Procedure»(ref-465934-S29460174192012042300000) .
21. Remove the connecting rod cap, install the Connecting Rod Guides (special tool #8507, Guides, Connecting Rod) (1) and carefully remove the piston from the cylinder bore, repeat this procedure for each piston being removed.
22. Immediately after removing the piston and connecting rod, install the bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
23. Perform the piston and connecting rod inspection. Refer to «Engine/Engine Block/ROD, Piston and Connecting - Inspection»(ref-465934-S25898647422012042300000) .
24. Perform the piston fitting procedure. Refer to «Engine/Engine Block/ROD, Piston and Connecting - Standard Procedure»(ref-465934-S08662334442012042300000) .
25. Carefully remove the piston rings from the piston(s), starting from the top ring down.
26. Perform the cylinder bore honing procedure. Refer to «Engine/Engine Block - Standard Procedure»(ref-465934-S29460174192012042300000) .

The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer, for more information. Refer to the following

1. Diagnosis and Testing Refer to «RETAINER, CRANKSHAFT REAR OIL SEAL, DIAGNOSIS AND TESTING, 5.7L»(ref-465934-S11384507422012042300000) .
2. Removal Refer to «RETAINER, CRANKSHAFT REAR OIL SEAL, REMOVAL, 5.7L»(ref-465934-S39485250842012042300000) .
3. Installation Refer to «RETAINER, CRANKSHAFT REAR OIL SEAL, INSTALLATION, 5.7L»(ref-465934-S33914885762012042300000) .

The Multi Displacement System selectively deactivates cylinders 1, 4, 6, and 7, to improve fuel economy. It has two modes of operation

1. 8 cylinders for acceleration and heavy loads.
2. 4 cylinders for cruising and city traffic.

The main components of the Multi Displacement System are

1. Unique MDS camshaft.
2. Deactivating roller tappets.
3. 4 control valves/solenoids.
4. control valve/solenoid wiring harness.
5. oil temp sensor.

Cylinder Deactivation

1. Trap an exhaust charge from a normal combustion event
2. Normal combustion event
3. Don't open the exhaust valve
4. Don't open the intake valve
5. Piston is an air spring
6. Cylinders deactivated in firing sequence

Cylinder Reactivation

1. Open the exhaust valve
2. Empty the cylinder
3. Open the intake valve
4. Normal combustion event
5. Cylinders reactivated in firing sequence

The 5.7L engine is equipped with Variable Valve Timing (VVT). This system uses an oil control valve to direct oil pressure into the camshaft phaser assembly. The camshaft phaser assembly advances and/or retards camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The oil control valve is located under the intake manifold.

The Variable Valve Timing (VVT) assembly is actuated with engine oil pressure. The oil flow to the VVT assemblies are controlled by an Oil Control Valve (OCV). The OCV consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VVT assemblies. The VVT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VVT assembly rotates the rotor with respect to the stator, thus rotating the exhaust camshaft with respect to the timing chain and intake camshaft. An infinitely variable valve timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM.

The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust manifolds are made of high silicon molybdenum cast iron. A multi-layer stainless steel exhaust manifold gasket is used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold, with the exception of the nut, which also secures the oil dipstick tube bracket. That nut should not be backed off.

The exhaust manifolds collect the engine exhaust exiting the combustion chambers, then channels the exhaust gases to the exhaust pipes attached to the manifolds.

The Multiple Displacement System (MDS) selectively deactivates cylinders 1, 4, 6 and 7 during steady speed, low acceleration and shallow grade climbing conditions to increase fuel economy.

The MDS can provide a 5 to 20% fuel economy benefit when operating in four-cylinder mode. Depending on driving habits and vehicle usage. For EPA rating purposes the fuel economy is 8 to 15% higher than if the engine was operating on eight-cylinders at all times.

The MDS deactivating lifter (1) can be distinguished from the non-MDS lifter (2) by the disconnecting pin (3) on the side of the MDS lifter.

MDS is integrated into the basic engine architecture requiring these additional components

1. Unique MDS camshaft
2. 8 deactivating roller lifters
3. 4 MDS control valve solenoids
4. MDS control valve solenoid wiring harness
5. Oil temperature sensor

The Multiple Displacement System (MDS) provides cylinder deactivation during steady speed, low acceleration and shallow grade climbing conditions to increase fuel economy. Both four and eight cylinder configurations have even firing intervals to provide smooth operation. The MDS selectively deactivates cylinders 1, 4, 6, and 7, to improve fuel economy. All deactivated cylinders have unique hydraulic lifters that collapse when deactivated to prevent the valves from opening. Engine oil pressure is used to activate and deactivate the valves. Oil is delivered through special oil passages drilled into the cylinder block. The MDS solenoid valves control the flow. When activated, pressurized oil pushes a latching pin on each MDS lifter which becomes a lost motion link. The base of the MDS lifter follows the camshaft while the top remains stationary. The MDS lifter is held in place against the pushrod by light spring pressure but unable to move because of the much higher force of the valve spring.

Note. It is critical to use the recommended oil viscosity in engines that use MDS.

Deactivation occurs during the compression stroke of each cylinder, after air and fuel enter the cylinder. Ignition occurs, but the combustion products remain trapped in the cylinder under high pressure, because the valves no longer open. No fuel/air enters or leaves during subsequent piston strokes, this high pressure gas is repeatedly compressed and expanded like an air spring.

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1. Disconnect the negative battery cable.
2. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-465940-S34230748332012042300000) . NOTE: It is not necessary to remove water pump for timing chain cover removal.
3. Remove the timing chain cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL, 5.7L»(ref-465934-S18607826532012042300000) .
4. Verify the slide bushings (1) remain installed in the timing chain cover during removal.
5. Remove the oil pump retaining bolts (2) and remove the oil pump (1).
6. Install the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align the timing marks with the timing chain sprockets (1, 2).
7. Retract the chain tensioner arm (1) until the hole in the arm lines up with the hole in the bracket.
8. Install the Tensioner Pin (special tool #8514, Pins, Tensioner) (1) into the chain tensioner holes. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result.
9. Remove the camshaft phaser retaining bolt (1) and remove the timing chain with the camshaft phaser and crankshaft sprocket. NOTE: Inspect the timing chain tensioner and timing chain guide shoes for wear and replace as necessary.
10. If the timing chain tensioner is being replaced, remove the retaining bolts (3) and remove the timing chain tensioner (2).
11. If the timing chain guide (1) is being replaced, remove the retaining bolts (2) and remove the timing chain guide.

Scheme 378

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Scheme 381

1. Install the crankshaft sprocket (1) and position halfway onto the crankshaft.
2. While holding the camshaft phaser in hand, position the timing chain on the camshaft phaser and align the timing marks as shown in illustration.
3. While holding the camshaft phaser and timing chain in hand, position the timing chain on the crankshaft sprocket and align the timing mark as shown in illustration.
4. Align the slot in the camshaft phaser with the dowel on the camshaft and position the camshaft phaser on the camshaft while sliding the crankshaft sprocket into position.
5. Install the camshaft phaser retaining bolt (1) finger tight.
6. If removed, install the timing chain guide (1) and tighten the bolts (2) to 11 N.m (8 ft. lbs.).
7. If removed, install the timing chain tensioner (2) and tighten the bolts (3) to 11 N.m (8 ft. lbs.).
8. Remove the tensioner pin (special tool #8514, Pins, Tensioner) (1).
9. Rotate the crankshaft two revolutions and verify the alignment of the timing marks (1, 2). If the timing marks do not line up, remove the camshaft sprocket and realign.
10. Tighten the camshaft phaser bolt (1) to 85 N.m (63 ft. lbs.).
11. Position the oil pump (1) onto the crankshaft and install the oil pump retaining bolts (2) finger tight.
12. Using the sequence shown in illustration, tighten the oil pump retaining bolts to 28 N.m (21 ft. lbs.).
13. Verify the slide bushings (1) are installed in the timing chain cover.
14. Install the timing chain cover. Refer to «COVER(S), ENGINE TIMING, INSTALLATION, 5.7L»(ref-465934-S35825368412012042300000) .
15. Fill the engine with oil.
16. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-465940-S34230748332012042300000) .
17. Connect the negative battery cable.
18. Start the engine and check for leaks.

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Scheme 383

1. Remove the cooling fan module (1). Refer to «FAN, COOLING, REMOVAL»(ref-465940-S32398312912012042300000) .
2. Remove the serpentine belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-465940-S20367993122012042300000) .
3. Remove the oil pan. Refer to «PAN, OIL, REMOVAL, 5.7L»(ref-465934-S38788101342012042300000) .
4. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-465940-S34230748332012042300000) .
5. Remove the lower radiator hose clamp (1) at the water pump.
6. Remove the lower radiator hose clamp (2) at the radiator and remove the lower radiator hose (3). NOTE: It is not necessary to disconnect the refrigerant lines for A/C compressor removal.
7. Remove the A/C compressor from the engine block and position aside. Refer to «COMPRESSOR, A/C, REMOVAL»(ref-465931-S23974274942012042300000) .
8. Lower the vehicle.
9. Disconnect the CMP sensor electrical connector (4).
10. Remove CMP sensor mounting bolt (3).
11. Using a slight rocking motion, carefully remove the CMP sensor (1) from the timing cover (2).
12. Check the condition of the CMP sensor O-ring, replace as necessary.
13. Remove the upper radiator hose clamp (1) at the thermostat housing.
14. Remove the upper radiator hose retainer (2) at the fan shroud and position the radiator hose aside.
15. Remove the air cleaner resonator support bracket at the water pump.
16. Disconnect the electrical connector to the coolant temperature sensor (3).
17. Remove the heater tube retaining bolt (1).
18. Lift the heater tube (2) out of the water pump.
19. Check condition of heater tube O-ring, replace as necessary. NOTE: It is not necessary to disconnect the hoses from the power steering pump, for power steering pump removal.
20. Remove the power steering pump (1) and position aside. Refer to «PUMP, REMOVAL»(ref-465942-S21726515062012042300000) .
21. Remove the generator. Refer to «GENERATOR, REMOVAL»(ref-465960-S22976153212012042300000) . NOTE: When installing the puller tool, ensure the bolts are fully threaded through the entire crankshaft damper.
22. Remove the crankshaft damper bolt.
23. Install puller tool (2) and remove the crankshaft damper (1). NOTE: It is not necessary to remove the water pump for timing cover removal.
24. Remove the timing cover bolts and remove the timing cover.
25. Verify the timing cover slide bushings (1) remain located in the timing cover.
26. Clean the sealing surfaces as necessary.

The timing chain tension is maintained by routing the timing chain through the tensioner assembly. A nylon shoe presses on the timing chain maintaining the correct chain tension.

Scheme 384

Note. Verify that the tensioner is assembled correctly.

Scheme 385

1. Install the washer (1), spring (2), and plunger (3) inside the tensioner body (4).
2. Squeeze the tensioner body (3) and movable guide shoe (2) together and install Tensioner Pin (special tool #8514, Pins, Tensioner) (1).