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

INSTALLATION

Note. Do not use air tools to install Engine Lift Fixture (special tool #8984B, Engine Lift Fixture) (1).

Scheme 408

Scheme 409

1. Install the Engine Lift Fixture (special tool #8984B, Engine Lift Fixture) (1).
2. Connect a suitable engine lifting devise to the Engine Lift Fixture (special tool #8984B, Engine Lift Fixture) (1).
3. Position the engine in the vehicle.
4. Lower and align the engine (1) with the transmission (3).
5. Continue to lower the engine assembly until the engine mounting brackets lineup with the engine mounts.
6. Install two transmission to engine block mounting bolts (2) finger tight.
7. Remove the engine lifting devise.
8. Raise and support the vehicle. 4x4 rear engine mount isolator shown in illustration, 4x2 rear engine mount isolator similar.
9. Using a suitable transmission hydraulic jack, slightly raise the transmission and remove the block of wood between the transmission and engine cradle crossmember, lower the transmission and remove the jack.
10. Tighten the rear engine mount isolator retaining bolts (1) to 61 N.m (45 ft. lbs.).
11. Install the remaining transmission bell housing-to-engine block retaining bolts (2) and tighten to 68 N.m (50 ft. lbs.).
12. Install all torque converter-to-flexplate bolts (1) finger tight.
13. Verify the torque converter is pulled flush to the flexplate and tighten bolts to 31 N.m (23 ft. lbs.). Left side shown in illustration, right side similar.
14. Install the engine mount retaining nuts (2) and tighten to 95 N.m (70 ft. lbs.). CAUTION: The structural dust cover must be installed as described in the following steps. Failure to do so may cause severe damage to the cover.
15. Position the structural cover (2) in the vehicle.
16. Install the structural dust cover bolts (1) to the engine block finger tight.
17. Install the structural dust cover bolts (1) to the transmission finger tight. CAUTION: The structural dust cover must be held tightly against both the engine and the transmission bell housing during the tightening sequence. Failure to do so may cause severe damage to the cover.
18. Tighten the structural dust cover bolts to the transmission to 9 N.m (80 in. lbs.).
19. Tighten the structural dust cover bolts to the engine block to 9 N.m (80 in. lbs.).
20. Again, tighten the structural dust cover bolts to the transmission to 54 N.m (40 ft. lbs.).
21. Again, tighten the structural dust cover bolts to the engine block to 54 N.m (40 ft. lbs.).
22. Lower the vehicle.
23. Remove the Engine Lift Fixture (special tool #8984B, Engine Lift Fixture) (1).
24. Position the engine harness on both right and left sides of the vehicle. NOTE: Ensure that the O-ring is fully seated into the cylinder block.
25. Position the oil control valve (3) into the cylinder block.
26. Securely tighten the oil control valve retaining bolt (2).
27. Connect the oil control valve electrical connector (1).
28. Install the intake manifold. Refer to «MANIFOLD, INTAKE, REMOVAL, 5.7L»(ref-465934-S15296552422012042300000) .
29. Install the generator. Refer to «GENERATOR, INSTALLATION»(ref-465960-S38649135632012042300000) .
30. Install the cooling fan module (1). Refer to «FAN, COOLING, REMOVAL»(ref-465940-S32398312912012042300000) .
31. Position both heater hoses (2).
32. Install both heater hose clamps (1).
33. Position the upper radiator hose and secure the retainer (2) at the fan shroud.
34. Connect the upper radiator hose to the thermostat housing and install the hose clamp (1).
35. Raise and support the vehicle.
36. Install the starter (1). Refer to «STARTER, REMOVAL»(ref-465961-S35851771622012042300000) .
37. Install the A/C compressor to the engine block. Refer to «COMPRESSOR, A/C, INSTALLATION»(ref-465931-S33917266512012042300000) .
38. Connect the transmission oil cooler lines to their retainer at the oil pan.
39. Install both exhaust pipe/catalytic converters. Refer to «CONVERTER, CATALYTIC, INSTALLATION»(ref-465927-S37313743222012042300000) .
40. Position the left catalytic converter heat shield (2) install the retaining bolts (1) and securely tighten.
41. Connect the lower radiator hose (3) to the radiator and install the hose clamp (2).
42. Connect the lower radiator hose to the water pump and install hose clamp (1).
43. If equipped, position the skid plate, install the four retaining bolts (2) and tighten to 28 N.m (21 ft. lbs.).
44. Lower the vehicle.
45. Connect the left upstream O2 sensor electrical connector (1).
46. Connect the right upstream O2 sensor electrical connector (1).
47. Connect all remaining left and right engine harness electrical connectors.
48. Install the power steering pump (1). Refer to «PUMP, INSTALLATION»(ref-465942-S22978166622012042300000) .
49. Install the serpentine belt. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-465940-S28892887022012042300000) .
50. Install the cowl panel cover (2). Refer to «COVER, COWL PANEL, INSTALLATION»(ref-465921-S30543277132012042300000) .
51. Start the engine and inspect for leaks.
52. Install the air cleaner and resonator assembly. Refer to «BODY, AIR CLEANER, INSTALLATION, 5.7L»(ref-465934-S26716388022012042300000) .
53. Fill the engine with oil. Refer to «CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS»(ref-465919-S34593306932012042300000) .
54. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-465940-S34230748332012042300000) .
55. Connect the negative battery cable (2).
56. Install the engine cover (2).
57. Install the oil fill cap (1).
58. Start the engine and check for leaks.
59. Road test vehicle.

Note. Clean the inside of air cleaner housing before replacing the air filter element.

1. Install the air filter element into the housing assembly.
2. Install the air cleaner cover onto the housing assembly locating tabs.
3. Latch the 2 spring clips (3) and lock the air cleaner cover to the housing assembly.
4. Connect the make up air hose (2) to the air cleaner cover.
5. Connect the clean air hose to the air cleaner cover and tighten clamp (1) to 5 N.m (44 in. lbs.).

Scheme 410

1. Loosen the clean air hose clamp (1) at the air cleaner cover and disconnect the clean air hose.
2. Remove the make up air hose (2) at the air cleaner cover.
3. Release the 2 spring clips (3) from the air cleaner cover.
4. Remove the air cleaner cover from the housing assembly.
5. Remove the air filter element from the housing assembly.
6. Remove the push pin retainer (2) at the air cleaner housing duct.
7. Lift and separate the air cleaner housing rubber grommets (1) from the ball studs and remove the air cleaner housing.

Scheme 411

1. Remove the oil fill cap (1).
2. Lift and separate the engine cover retaining grommets from the ball studs and remove the engine cover (2).
3. Disconnect the electrical connector at the Intake Air Temperature (IAT) sensor (1).
4. Loosen the clean air hose clamp at the air cleaner housing (2).
5. Remove the resonator retaining bolt (3).
6. Loosen the resonator hose clamp at the throttle body (4) and remove the resonator.

REMOVAL - RIGHT CYLINDER HEAD

1. Remove the oil fill cap (1).
2. Remove the engine cover (2).
3. Perform the fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-465971-S02093746452012042300000) .
4. Disconnect and isolate the negative battery cable (2).
5. Remove the cowl cover panel (2). Refer to «COVER, COWL PANEL, REMOVAL»(ref-465921-S01077772762012042300000) .
6. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-465940-S34230748332012042300000) .
7. Remove the air cleaner and resonator assembly. Refer to «BODY, AIR CLEANER, REMOVAL, 5.7L»(ref-465934-S30952154692012042300000) .
8. Remove the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL, 5.7L»(ref-465934-S24753519972012042300000) .
9. Remove the engine oil indicator tube retaining nut at the exhaust manifold and remove the oil indicator tube.
10. Remove the intake manifold. Refer to «MANIFOLD, INTAKE, REMOVAL, 5.7L»(ref-465934-S15296552422012042300000) . NOTE: The rocker arms and push rods must be installed in their original location as removed.
11. Remove the rocker arms and push rods. Note their location to ensure installation in their original locations. Refer to «ROCKER ARM, VALVE, REMOVAL, 5.7L»(ref-465934-S02252868942012042300000) .
12. Using the sequence shown in illustration, remove the cylinder head bolts.
13. Remove the cylinder head and discard the cylinder head gasket.

Note. The cylinder head cover gasket (1) may be used again, provided no cuts, tears, or deformation have occurred.

1. Inspect the cylinder head cover gasket (1), replace if necessary. CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur.
2. Clean the cylinder head cover (2) and the cylinder head sealing surface.
3. Apply Mopar® Lock & Seal Adhesive to the cylinder head cover bolts.
4. Position the cylinder head cover and hand tighten the bolts.
5. Using the sequence shown in illustration, tighten the cylinder head cover bolts to 8 N.m (70 in. lbs.). CAUTION: Do not allow other components including the wire harness to rest on or against the engine cylinder head cover. Prolonged contact with other objects may wear a hole in the cylinder head cover.
6. Position the wiring harness and attach the retainers to the cylinder head cover.
7. Before installing the ignition coils, apply dielectric grease to the inside of the spark plug boots (1).
8. Install the ignition coils (1).
9. Install the ignition coil retaining bolts (3) and tighten to 7 N.m (62 in. lbs.).
10. Connect the ignition coil electrical connectors (1).
11. Connect the make up air hose (3) to the intake manifold.
12. Connect the fuel supply line (2) to the fuel rail.
13. Connect the EVAP vacuum line (1) to the throttle body.
14. Connect the negative battery cable (2).
15. Install the engine cover (2).
16. Install the oil fill cap (1).
17. Start the engine and check for leaks.

Scheme 412

Scheme 413

1. Disconnect the negative battery cable (2).
2. Remove the oil fill cap (1).
3. Remove the engine cover (2).
4. Remove the ignition coils (1). Refer to «COIL, IGNITION, REMOVAL»(ref-465970-S23319521922012042300000) .
5. Using the sequence shown in illustration, remove the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, REMOVAL, 5.7L»(ref-465934-S24753519972012042300000) .
6. Install the pushrod retainer (special tool #9070, Retainer, Push Rod) (1).
7. Using the sequence shown in illustration, loosen the rocker shafts retaining bolts. CAUTION: The rocker shaft assemblies are not interchangeable between the intake and the exhaust, failure to install them in the correct location could result in engine damage. The intake rocker arms (1) are marked with the letter "I" (2). NOTE: The rocker arms and push rods must be installed in their original location as removed. CAUTION: Do not remove the retainers (1) from the rocker shaft (3).
8. Remove the rocker shaft (3). Note the rocker arms and rocker shafts location to ensure installation in their original locations as removed. CAUTION: The longer pushrods are for the exhaust side and the shorter pushrods are for the intake side.
9. Remove the pushrods. Note the pushrods location to ensure installation in their original locations as removed.

1. Install the pushrods in the same order as noted during removal.
2. Install the pushrod retainer (special tool #9070, Retainer, Push Rod) (1). CAUTION: Make sure that the retainers (1) and the rocker arms (2) are not overlapped when tightening bolts or engine damage could result. CAUTION: Verify the pushrod(s) are installed into the rocker arm(s) (2) and the tappet(s) correctly while installing the rocker shaft assembly (3) or engine damage could result. Recheck after the rocker shaft assembly has been tightened to specification. CAUTION: The rocker shaft assemblies are not interchangeable between the intake and the exhaust, failure to install them in the correct location could result in engine damage. The intake rocker arms (1) are marked with the letter "I" (2).
3. Install the rocker shaft assemblies in the same location as noted during removal.
4. Using the sequence shown in illustration, tighten the rocker shaft bolts to 22 N.m (16 ft. lbs.). 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 five minutes).
5. Remove pushrod retainer (special tool #9070, Retainer, Push Rod) (1).
6. Using the sequence shown in illustration, install the cylinder head cover. Refer to «COVER(S), CYLINDER HEAD, INSTALLATION, 5.7L»(ref-465934-S04305016922012042300000) .
7. Install the ignition coils (1). Refer to «COIL, IGNITION, REMOVAL»(ref-465970-S23319521922012042300000) .
8. Install the engine cover (2).
9. Install the oil fill cap (1).
10. Connect the negative battery cable (2).

REMOVAL

The valve stem seal is integral with the valve spring seat, for removal. Refer to SPRING(S), VALVE, REMOVAL, 5.7L .

The valve stem seal is integral with the valve spring seat, for installation. Refer to SPRING(S), VALVE, INSTALLATION, 5.7L .

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Scheme 418

1. Disconnect the negative battery cable.
2. Remove the oil fill cap (1).
3. Lift and separate the engine cover retaining grommets from the ball studs and remove the engine cover (2).
4. Disconnect the electrical connector at the Intake Air Temperature (IAT) sensor (1).
5. Loosen the clean air hose clamp at the air cleaner housing (2).
6. Remove the resonator retaining bolt (3).
7. Loosen the resonator hose clamp at the throttle body (4) and remove the resonator.
8. Remove the ignition coil electrical connectors (1).
9. Remove the ignition coils (2).
10. Remove one spark plug.
11. Using the sequence shown in illustration, remove the cylinder head cover bolts and remove the cylinder head covers. Refer to «COVER(S), CYLINDER HEAD, REMOVAL, 5.7L»(ref-465934-S24753519972012042300000) . CAUTION: The piston must be at TDC, and both valves closed on the cylinder to be serviced. NOTE: The intake push rods can fall into the engine and become lodged in the oil pan, if removing intake rocker arm shaft, install the pushrod retainer (special tool #9070, Retainer, Push Rod) (1) to retain the intake push rods (2).
12. Install the pushrod retainer (special tool #9070, Retainer, Push Rod) (1) on the cylinder head.
13. Clip the pushrods (2) into the pushrod retainer (1).
14. Using the sequence shown in illustration, remove the rocker arm shaft bolts and remove the rocker arm shaft.
15. Install the rocker arm shaft adapter (special tool #9065B, Compressor, Valve Spring) (1).
16. Insert an air hose (2) into the spark plug hole and charge the cylinder with air. NOTE: All valve springs and seals are removed in the same manner. NOTE: Tap the top of the valve spring retainer to loosen the spring retainers locks.
17. Install Valve Spring Compressor (special tool #9065B, Compressor, Valve Spring) (1) and remove the intake valve retainer locks.
18. Release the valve spring compressor and remove the valve springs.
19. Install Valve Spring Compressor (special tool #9065B, Compressor, Valve Spring) (2) and the rocker arm Adapter (special tool #9065B, Compressor, Valve Spring) (1) and remove the exhaust valve retainer locks.
20. Release the valve spring compressor and remove the valve spring. NOTE: The valve springs are interchangeable between the intake and exhaust valves.
21. Remove the valve seal.

Scheme 419

Note. The intake seal has a smaller spring seat diameter compared to the exhaust seal.

Scheme 420

Scheme 421

Scheme 422

1. Install the valve seal. NOTE: The intake spring damper has a longer free length compared to the exhaust spring damper.
2. Install the valve spring.
3. Using the valve spring compressor (special tool #9065B, Compressor, Valve Spring) (1, 3), compress the valve spring and install the valve spring retainer locks.
4. Release the air charge (1) in the cylinder.
5. Remove the valve spring compressor (special tool #9065B, Compressor, Valve Spring) (3). CAUTION: Verify that the pushrods are fully seated into the lifters and the rocker arms. Recheck after rocker arm shaft has been torqued to specification.
6. Install the rocker arm shaft and push rods. Refer to «ROCKER ARM, VALVE, INSTALLATION, 5.7L»(ref-465934-S18923273402012042300000) .
7. Using the sequence shown in illustration, tighten the rocker arm shaft bolts to 22 N.m (16 ft. lbs.).
8. Remove the pushrod retainer (special tool #9070, Retainer, Push Rod) (1).
9. Install the cylinder head. Refer to «CYLINDER HEAD, INSTALLATION, 5.7L»(ref-465934-S32032700812012042300000) .
10. Using the sequence shown in illustration, install the cylinder head cover bolts and tighten to 8 N.m (71 in. lbs.). Refer to «COVER(S), CYLINDER HEAD, INSTALLATION, 5.7L»(ref-465934-S04305016922012042300000) .
11. Install the spark plug.
12. Install the ignition coil (2) and tighten fasteners (3) to 12 N.m (9 ft. lbs.).
13. Connect the ignition coil electrical connectors (1).
14. Connect the resonator hose at the throttle body and tighten clamp (4) to 5 N.m (44 in. lbs.).
15. Install the resonator retaining bolt (3) and tighten to 5 N.m (44 in. lbs.).
16. Connect the clean air hose at the air cleaner housing and tighten clamp (2) to 5 N.m (44 in. lbs.).
17. Connect the electrical connector at the Intake Air Temperature (IAT) sensor (1).
18. Position the engine cover (2) and secure the retaining grommets to the ball studs.
19. Install the oil fill cap (1).
20. Connect the negative battery cable.

1. Raise and support the vehicle.
2. Remove the structural dust cover retaining bolts (1).
3. Remove the structural dust cover (2).

1. Position the structural cover (2) in the vehicle.
2. Install the structural dust cover bolts (1) to the engine block finger tight.
3. Install the structural dust cover bolts (1) to the transmission finger tight. CAUTION: The structural dust cover must be held tightly against both the engine and the transmission bell housing during the tightening sequence. Failure to do so may cause severe damage to the cover.
4. Tighten the structural dust cover bolts to the transmission to 9 N.m (80 in. lbs.).
5. Tighten the structural dust cover bolts to the engine block to 9 N.m (80 in. lbs.).
6. Again, tighten the structural dust cover bolts to the transmission to 54 N.m (40 ft. lbs.).
7. Again, tighten the structural dust cover bolts to the engine block to 54 N.m (40 ft. lbs.).
8. Lower the vehicle.

Scheme 423

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Scheme 428

1. Remove the engine. Refer to «REMOVAL, 5.7L»(ref-465934-S38665617732012042300000) .
2. Secure the engine to a suitable engine stand.
3. Remove the vibration damper (1). Refer to «DAMPER, VIBRATION, REMOVAL, 5.7L»(ref-465934-S30018307852012042300000) .
4. Remove the rear oil seal retainer. Refer to «RETAINER, CRANKSHAFT REAR OIL SEAL, REMOVAL, 5.7L»(ref-465934-S39485250842012042300000) .
5. Remove the oil pan. Refer to «PAN, OIL, REMOVAL, 5.7L»(ref-465934-S38788101342012042300000) .
6. Remove the timing cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL, 5.7L»(ref-465934-S18607826532012042300000) .
7. Remove the oil pump (1). Refer to «PUMP, ENGINE OIL, REMOVAL, 5.7L»(ref-465934-S37812217682012042300000) .
8. Remove the timing chain (5) and sprockets (1, 3). Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL, 5.7L»(ref-465934-S18859631602012042300000) . 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.
9. Mark the connecting rod and bearing cap positions using a permanent ink marker or scribe tool.
10. Remove the rod bearing caps and bearings. CAUTION: Do not use a number stamp or a punch to mark main bearing caps as damage to bearing caps and/or bearings could occur. NOTE: Main bearing caps are not interchangeable and should be marked before removal to ensure correct reassembly.
11. Mark the main bearing caps (1) using a permanent ink marker or scribe tool.
12. Remove the main bearing cap bolts.
13. Remove the main bearing cap crossbolts.
14. Remove main bearing caps (1) and bearings one at a time.
15. Remove the thrust washers.
16. Remove the crankshaft out of the engine block.

Scheme 429

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Scheme 434

Scheme 435

1. Select the proper main bearings. Refer to «Engine/Engine Block/BEARING(S), Crankshaft - Standard Procedure»(ref-465934-S26605586722012042300000) .
2. Install the main bearings in the engine block (1).
3. Install the main bearing shells (2) in the bearing caps (1).
4. Lubricate the main bearing shells with clean engine oil.
5. Position the crankshaft (1) into the cylinder block.
6. Lubricate and install the thrust bearings (1).
7. Install all main bearing caps (1) in the location as noted during removal making sure the arrow (2) faces forward. NOTE: The main cap crossbolts are torqued after final torque of the main cap bolts. Always use a new washer/seal on crossbolts.
8. Clean and oil all cap bolts and install finger tight.
9. Using the sequence shown in illustration, tighten the main bearing cap bolts to 13 N.m (10 ft. lbs.).
10. Again, using the sequence shown in illustration, tighten the main bearing cap bolts to 27 N.m (20 ft. lbs.).
11. Rotate the bearing main cap bolts an additional 90° in the sequence shown in illustration.
12. Install the crossbolts with new seal washer finger tight
13. Using the sequence shown in illustration, tighten the crossbolts to 28 N.m (21 ft. lbs.).
14. Again, using the sequence shown in illustration, repeat the crossbolt tightening procedure.
15. Measure the crankshaft end play. Refer to «Engine/Engine Block/BEARING(S), Crankshaft - Standard Procedure»(ref-465934-S26605586722012042300000) .
16. Wipe the connecting rod caps clean and install the rod bearings. CAUTION: The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.
17. Lubricate the bearing surfaces with clean engine oil and install the bearings and connecting rod caps onto the connecting rod journals in the same location as noted during removal.
18. Lubricate the new connecting rod bolts with clean engine oil and install the bolts finger tight.
19. Tighten the connecting rod bolts to 21 N.m (15 ft. lbs.) plus a 90° turn.
20. If required, measure the connecting rod side clearance. Refer to «Engine - Specifications»(ref-465934-S32251694592012042300000) .
21. Install the timing chain (5) and sprockets (1, 3). Refer to «CHAIN AND SPROCKETS, TIMING, INSTALLATION, 5.7L»(ref-465934-S15941739012012042300000) .
22. Install the oil pump (1). Refer to «PUMP, ENGINE OIL, INSTALLATION, 5.7L»(ref-465934-S10896909402012042300000) .
23. Install the timing chain case cover (1). Refer to «COVER(S), ENGINE TIMING, INSTALLATION, 5.7L»(ref-465934-S35825368412012042300000) .
24. Install the rear main seal and retainer. Refer to «RETAINER, CRANKSHAFT REAR OIL SEAL, INSTALLATION, 5.7L»(ref-465934-S33914885762012042300000) .
25. Install the oil pan. Refer to «PAN, OIL, INSTALLATION, 5.7L»(ref-465934-S04239188692012042300000) .
26. Install the vibration damper. Refer to «DAMPER, VIBRATION, INSTALLATION, 5.7L»(ref-465934-S22535524582012042300000) .
27. Install the engine. Refer to «INSTALLATION, 5.7L»(ref-465934-S22035110552012042300000) .
28. Start the engine and check for leaks.
29. Road test the vehicle.

1. Remove the transmission. Refer to «REMOVAL»(ref-465983-S15667392522012042300000) .
2. Using the sequence shown in illustration, remove the flexplate retaining bolts.
3. Remove the flexplate.

1. Position the flexplate onto the crankshaft and install the retaining bolts hand tight.
2. Using the sequence shown in illustration, tighten the flexplate retaining bolts to 95 N.m (70 ft. lbs.).
3. Install the transmission. Refer to «INSTALLATION»(ref-465983-S05842221462012042300000) .

Scheme 436

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

Scheme 437

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.

The Multiple Displacement System (MDS) provides cylinder deactivation during steady speed, low acceleration and shallow grade climbing conditions to increase fuel economy.

1. Lubricate the lifter guide holder (1) and lifters (2). CAUTION: If the lifters and guide holder assembly are to be reused, they must me installed in their original location.
2. Install the lifter guide holder (2) and lifters.
3. Tighten the lifter guide holder retaining bolt (1) to 12 N.m (9 ft. lbs.).
4. Install the cylinder head. Refer to «CYLINDER HEAD, INSTALLATION, 5.7L»(ref-465934-S32032700812012042300000) .
5. Connect the negative battery cable. CAUTION: To prevent damage to valve assemblies, do not run the engine above fast idle until all hydraulic lifters have filled with oil and have become quiet.
6. Start the engine and check for leaks.
7. Road test the vehicle.

Note. The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer and must be replaced as an assembly.

Note. The crankshaft rear oil seal retainer can not be reused after removal.

Note. This procedure can be performed in vehicle.

1. Disconnect the negative battery cable.
2. Remove the transmission. Refer to appropriate Transmission Service Information article.
3. Remove the flexplate. Refer to «FLEXPLATE, REMOVAL, 5.7L»(ref-465934-S18124248812012042300000) .
4. Remove the oil pan. Refer to «PAN, OIL, REMOVAL, 5.7L»(ref-465934-S38788101342012042300000) .
5. Using the sequence shown in illustration, remove the rear oil seal retainer mounting bolts.
6. Carefully remove the retainer from the engine block.

Note. The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer and must be replaced as an assembly.

Note. The crankshaft rear oil seal retainer can not be reused after removal.

1. Thoroughly clean all gasket residue from the engine block.
2. Position the gasket onto the new crankshaft rear oil seal retainer.
3. Position the crankshaft rear oil seal retainer onto the engine block.
4. Using the sequence shown in illustration, install the crankshaft rear oil seal retainer mounting bolts and tighten to 15 N.m (11 ft. lbs.).
5. Install the oil pan. Refer to «PAN, OIL, INSTALLATION, 5.7L»(ref-465934-S04239188692012042300000) .
6. Install the flexplate. Refer to «FLEXPLATE, INSTALLATION, 5.7L»(ref-465934-S13019159852012042300000) .
7. Install the transmission. Refer to appropriate Transmission Service Information article.
8. Fill the engine with oil.
9. Start the engine and check for leaks.

Scheme 438

Note. Before reinstalling used rings or installing new rings, the ring clearances must be checked.

1. Wipe the cylinder bore clean.
2. Insert the ring in the cylinder bore. NOTE: The ring gap measurement must be made with the ring positioned at least 12 mm (0.50 inch.) from bottom of cylinder bore.
3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder.
4. Using a feeler gauge check the ring end gap. Replace any rings not within specification.

1. Verify the MDS solenoid bores are free of debris before installing the MDS solenoid into the engine block.
2. Install the MDS solenoid(s) (3), ensure the seal is fully seated into the engine block.
3. Install the retaining bolt(s) (2) and tighten to 11 N.m (8 ft. lbs.).
4. Connect the MDS electrical connector to the solenoid(s) (3).
5. Install the foam insulator pad (1).
6. Install the intake manifold. Refer to «MANIFOLD, INTAKE, INSTALLATION, 5.7L»(ref-465934-S40332744012012042300000) .

Scheme 439

Scheme 440

Scheme 441

1. Perform fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-465971-S02093746452012042300000) .
2. Disconnect the negative battery cable (2).
3. Remove the oil fill cap (1).
4. Remove the engine cover (2).
5. Disconnect the electrical connector (1) at the Intake Air Temperature (IAT) sensor.
6. Loosen the hose clamp at the air cleaner housing (2).
7. Remove the resonator retaining bolt (3).
8. Loosen the hose clamp at the throttle body (4) and remove the resonator.
9. Remove the intake manifold. Refer to «MANIFOLD, INTAKE, REMOVAL, 5.7L»(ref-465934-S15296552422012042300000) . NOTE: The engine must be at room temperature for oil control valve removal.
10. Disconnect the oil control valve electrical connector (1).
11. Remove the oil control valve fastener (2).
12. Rotate the oil control valve (3) to break the seal then pull the oil control valve straight out. NOTE: Do not use air tools to install the Engine Lift Fixture (special tool #8984B, Engine Lift Fixture).
13. Install the Engine Lift Fixture (special tool #8984B, Engine Lift Fixture) (1).
14. Securely tighten lifting fixture mounting bolts (2).
15. Position the Engine Support Fixture (special tool #8534B, Support Fixture, Engine) (1).
16. Connect the Engine Support Fixture (special tool #8534B, Support Fixture, Engine) (1) to the Engine Lift Fixture (special tool #8984B, Engine Lift Fixture) (2) and tighten to support the engine.
17. Raise and support vehicle.
18. If equipped, remove the skid plate (1) four retaining bolts (2) and remove the skid plate. Left side shown in illustration, right side similar.
19. Remove both engine mount (1) retaining nuts (2)
20. Lower the vehicle.
21. Using the Engine Support Fixture (special tool #8534B, Support Fixture, Engine), raise the engine enough to gain clearance to remove the engine mount (1). Left side shown in illustration, right side similar.
22. Raise and support the vehicle.
23. Remove the engine mount retaining bolts/nuts (1) and remove the engine mount (2). Left side shown in illustration, right side similar.
24. If necessary, remove the engine mount bracket retaining bolts (1) and remove the engine mount bracket (2).

Left side shown in illustration, right side similar.

Note. Apply Mopar® Lock and Seal Adhesive, Medium Strength Threadlocker to the engine mount bracket to engine block bolts.

1. If removed, position the engine mount bracket (2) to the engine block, install the retaining bolts (1) and tighten to 95 N.m (70 ft. lbs.). Left side shown in illustration, right side similar.
2. Position the engine mount (2), install the retaining bolts/nuts (1) and tighten to 95 N.m (70 ft. lbs.). Left side shown in illustration, right side similar.
3. Lower the vehicle.
4. Using the Engine Support Fixture (special tool #8534B, Support Fixture, Engine), lower the engine onto the engine mounts (1).
5. Raise and support the vehicle.
6. Install both engine mount retaining nuts (2) and tighten to 95 N.m (70 ft. lbs.).
7. If equipped, position the skid plate (1), install the skid plate four retaining bolts (2) and tighten to 28 N.m (21 ft. lbs.).
8. Lower the vehicle.
9. Remove the Engine Support Fixture (special tool #8534B, Support Fixture, Engine) (1).
10. Remove the Engine Lift Fixture (special tool #8984B, Engine Lift Fixture) (2).
11. Install the oil control valve (3) into the cylinder block.
12. Ensure that the O-ring is fully seated into the cylinder block.
13. Securely tighten the oil control valve retaining bolt (2).
14. Connect the oil control valve electrical connector (1).
15. Install the intake manifold. Refer to «MANIFOLD, INTAKE, INSTALLATION, 5.7L»(ref-465934-S40332744012012042300000) .
16. Position the resonator hose onto the throttle body and tighten hose clamp (4) to 5 N.m (45 in. lbs.).
17. Install the resonator retaining bolt (3) and tighten to 5 N.m (45 in. lbs.).
18. Install the fresh air hose onto air cleaner housing and tighten hose clamp (2) to 5 N.m (45 in. lbs.).
19. Connect the electrical connector (1) at the Intake Air Temperature (IAT) sensor.
20. Install the engine cover (2).
21. Install the oil fill cap (1).
22. Connect the negative battery cable (2).
23. Start the engine and check for leaks.

4x4 rear engine mount isolator shown in illustration, 4x2 rear engine mount isolator similar.

Scheme 442

1. Raise and support the vehicle.
2. Using a suitable jack, support transmission.
3. Remove the rear engine mount isolator retaining bolts (1).
4. Using a suitable jack, slightly raise the transmission to relieve the load on the crossmember.
5. Remove the both transmission crossmember support bracket retaining bolts (2, 3) and remove support brackets. Right side crossmember retaining bolts shown in illustration, left side crossmember retaining bolts similar.
6. Remove the transmission crossmember retaining bolts (4) and remove the crossmember. 4x4 rear engine mount isolator shown in illustration, 4x2 rear engine mount isolator similar.
7. Remove the rear engine mount isolator retaining bolts (1)
8. Remove the rear engine mount isolator (2).

4x4 rear engine mount isolator shown in illustration, 4x2 rear engine mount isolator similar.

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

1. Position the rear engine mount isolator, install the retaining bolts and tighten to 61 N.m (45 ft. lbs.). 4x4 rear engine mount isolator shown in illustration, 4x2 rear engine mount isolator similar. Right side crossmember retaining bolts shown in illustration, left side crossmember retaining bolts similar.
2. Position the transmission crossmember, install the retaining bolts (4) and tighten to 54 N.m (40 ft. lbs.).
3. Position both transmission crossmember support brackets, install the retaining bolts (2, 3) and tighten to 54 N.m (40 ft. lbs.).
4. Using a suitable jack, lower the transmission into position, install the rear engine mount isolator retaining bolts (1) finger tight.
5. Remove the jack supporting the transmission.
6. Tighten the rear engine mount isolator retaining bolts (1) to 54 N.m (40 ft. lbs.).

Scheme 443

The 5.7L MDS lubrication system is a full flow filtration pressure feed type.

1. Remove the intake manifold. Refer to «MANIFOLD, INTAKE, REMOVAL, 5.7L»(ref-465934-S15296552422012042300000) . NOTE: To remove the oil control valve, the engine must be at room temperature.
2. Disconnect the oil control valve electrical connector (1).
3. Remove the oil control valve fastener (2).
4. Rotate the oil control valve (3) to break the seal then pull the oil control valve straight out.

Note. Ensure that the O-ring is fully seated into the cylinder block.

1. Position the oil control valve (3) into the cylinder block.
2. Securely tighten the oil control valve retaining bolt (2).
3. Connect the oil control valve electrical connector (1).
4. Install the intake manifold. Refer to «MANIFOLD, INTAKE, INSTALLATION, 5.7L»(ref-465934-S40332744012012042300000) .

All engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler 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 444

1. Lightly lubricate oil filter gasket with engine oil. 1 - SEALING SURFACE 2 - RUBBER GASKET 3 - OIL FILTER
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. see scheme 319
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. NOTE: 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.
2. Install a new oil pan gasket and pickup tube O-ring. NOTE: Mopar® Engine RTV must be applied to the 4 T-joints (1, 2) area where the front cover, rear retainer and oil pan gasket meet. The bead of RTV should cover the bottom of the gasket. This area is approximately 4.5 mm x 25 mm in each of the 4 T-joint locations.
3. Apply Mopar® Engine RTV at the T- joints (1, 2).
4. Position the oil pan, install the mounting bolts and using the sequence shown in illustration, tighten to 12 N.m (9 ft. lbs.).
5. Install the transmission line retaining bracket at the oil pan.
6. Install the engine cradle crossmember. Refer to «CROSSMEMBER, CRADLE, ENGINE AND SUSPENSION, INSTALLATION»(ref-465925-S23508879902012042300000) .
7. Position the steering gear pressure line and Install the retainers (1) to the engine cradle crossmember.
8. Install the return line (2) at the steering gear.
9. Install the pressure line (1) at the steering gear. CAUTION: The structural dust cover must be held tightly against both the engine and the transmission bell housing during the tightening sequence. Failure to do so may cause severe damage to the cover.
10. Position the structural dust cover (2).
11. Install the structural dust cover retaining bolts (1) hand tight.
12. Tighten the structural dust cover-to-transmission bolts to 9 N.m (80 in. lbs.).
13. Tighten the structural dust cover-to-engine bolts to 9 N.m (80 in. lbs.).
14. Retighten the structural dust cover-to-transmission bolts to 54 N.m (40 ft. lbs.).
15. Retighten the structural dust cover-to-engine bolts to 54 N.m (40 ft. lbs.). Left side shown in illustration, right side similar.
16. Install both lower clevis bolts (1) at the lower control arms (2) and tighten to 169 N.m (125 ft. lbs.). Left side shown in illustration, right side similar.
17. If equipped, slide both axle shafts into the hub bearing.
18. Position both steering knuckle assemblies onto the ball joint studs. Left side shown in illustration, right side similar.
19. If equipped, install both half shaft hub bearing nuts (2) and tighten to 135 N.m (100 ft. lbs.).
20. Install both upper ball joint nuts (1) and tighten to 95 N.m (70 ft. lbs.). Left side shown in illustration, right side similar.
21. Position the front brake calipers (2), install the caliper adapter mounting bolts (1) and tighten to 169 N.m (125 ft. lbs.). Left side shown in illustration, right side similar.
22. Position both front wheel speed sensors (3) into the steering knuckle.
23. Install both front wheel speed sensor retaining bolts (2) and tighten to 14 N.m (10 ft. lbs.).
24. Connect both front wheel speed sensor wire harness retainers (1) to the steering knuckles. CAUTION: The steering gear must be centered prior to installing the coupler to prevent clockspring damage.
25. Position the lower steering shaft coupler (2) onto the steering gear.
26. Install the a new lower steering shaft coupler pinch bolt (1) and tighten to 49 N.m (36 ft. lbs.).
27. Position the left catalytic converter heat shield (2), install the retaining bolts (1) and securely tighten bolts.
28. If equipped, position the C/V joint onto the companion flange making sure to align the reference mark (1) made during removal. NOTE: Clean all propeller shaft bolts and apply Mopar® Lock and Seal Adhesive, Medium Strength Thread locker or equivalent to the threads before installation.
29. Install the bolts (2) to the axle flange and tighten to 32 N.m (24 ft. lbs.). Left side shown in illustration, right side similar. NOTE: For engine mount retaining nuts, apply Mopar® Lock and Seal Adhesive, Medium Strength Thread locker or equivalent to the threads before installation.
30. Install both engine mount (1) retaining nuts (2) and tighten to 75 N.m (55 ft. lbs.).
31. If equipped, position the front skid plate (1), install the four retaining bolts (2) and tighten to 28 N.m (21 ft. lbs.).
32. Install both front wheels and tires.
33. Lower the vehicle.
34. Remove the Engine Support Fixture (special tool #8534B, Support Fixture, Engine) (1).
35. Remove the Engine Lift Fixture (special tool #8984B, Engine Lift Fixture) (1).
36. Install the oil control valve (3).
37. Ensure that the O-ring is fully seated into the cylinder block.
38. Securely tighten the oil control valve retaining bolt (2).
39. Connect the oil control valve electrical connector (1).
40. Install the intake manifold. Refer to «MANIFOLD, INTAKE, INSTALLATION, 5.7L»(ref-465934-S40332744012012042300000) .
41. Position the resonator hose onto the throttle body and tighten hose clamp (4) to 5 N.m (45 in. lbs.).
42. Install the resonator retaining bolt (3) and tighten to 5 N.m (45 in. lbs.).
43. Install the fresh air hose to the air cleaner housing and tighten hose clamp (2) to 5 N.m (45 in. lbs.).
44. Connect the electrical connector at the Intake Air Temperature (IAT) sensor (1).
45. Install the engine oil dipstick.
46. Install the engine cover (2).
47. Install the oil fill cap (1).
48. Fill the engine with clean oil.
49. Connect the negative battery cable (2).
50. Start the engine and check for leaks.

1. Remove the oil pan. Refer to «PAN, OIL, REMOVAL, 5.7L»(ref-465934-S38788101342012042300000) .
2. Remove the timing cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL, 5.7L»(ref-465934-S18607826532012042300000) .
3. Remove the four bolts (2) and the oil pump (1).

Note. Always install a new timing cover gasket.

Scheme 445

Scheme 446

1. Clean the timing cover and engine block sealing surfaces.
2. Verify that the slide bushings (1) are installed in the timing cover.
3. Using a new gasket, position the timing cover, install the retaining bolts and tighten to 28 N.m (21 ft. lbs.). NOTE: The large lifting stud is tightened to 55 N.m (40 ft. lbs.). CAUTION: To prevent severe damage to the crankshaft, damper, and damper installer (special tool #8512A, Installer, Damper), thoroughly clean the damper bore and the crankshaft nose before installing damper.
4. Position the damper onto the crankshaft.
5. Assemble the Damper Installer (special tool #8512A, Installer, Damper) (2) and the Pressing Cup (1) from A/C Hub Installer (special tool #6871, Installer, A/C Hub).
6. Using the Damper Installer (special tool #8512A, Installer, Damper) and Hub Install (special tool #6871, Installer, A/C Hub), press the damper (1) onto the crankshaft.
7. Install the crankshaft damper bolt and tighten to 176 N.m (129 ft. lbs.).
8. Install the generator. Refer to «GENERATOR, INSTALLATION»(ref-465960-S38649135632012042300000) .
9. Install the power steering pump (1). Refer to «PUMP, INSTALLATION»(ref-465942-S22978166622012042300000) .
10. Install the heater tube (2) into the water pump.
11. Install the heater tube retaining bolt (1) and tighten to 12 N.m (9 ft. lbs.).
12. Connect the electrical connector to the coolant temperature sensor (3).
13. Position the upper radiator hose and secure retainer (2) at the fan shroud.
14. Install the upper radiator hose at the thermostat housing and secure hose clamp (1).
15. Install the air cleaner resonator support bracket at the water pump.
16. Clean out the machined hole in the timing cover (2).
17. Install the CMP sensor (1) into the timing cover with a slight rocking motion. Do not the twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor retaining bolt, be sure the sensor is completely flush to the timing cover. If the sensor is not flush, damage to the sensor mounting tang may result.
18. Install the CMP sensor retaining bolt (3) and tighten to 12 N.m (9 ft. lbs.).
19. Connect the CMP sensor electrical connector (4).
20. Raise and support the vehicle. Install the oil pan. Refer to «PAN, OIL, INSTALLATION, 5.7L»(ref-465934-S04239188692012042300000) .
21. Install the A/C compressor. Refer to «COMPRESSOR, A/C, INSTALLATION»(ref-465931-S33917266512012042300000) .
22. Connect the lower radiator hose (3) to the radiator and secure the hose clamp (2).
23. Connect the lower radiator hose to the water pump and secure hose clamp (1).
24. Lower the vehicle.
25. Install the cooling fan module (1). Refer to «FAN, COOLING, INSTALLATION»(ref-465940-S22919138712012042300000) .
26. Install the serpentine belt. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-465940-S28892887022012042300000) .
27. Fill the cooling system with the proper coolant. Refer to «STANDARD PROCEDURE»(ref-465940-S34230748332012042300000) .
28. Fill the engine with the proper engine oil. Refer to «CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS»(ref-465919-S34593306932012042300000) .
29. Connect the battery negative cable.
30. Start the engine and check for leaks.

Scheme 447

The timing chain tensioner is a spring loaded design. It consists of two chain guide shoes. One shoe is fixed in place and the other is spring loaded to keep tension on the chain.