3.5L Engine - Service Information: Other Dodge Journey I

ENGINE PERFORMANCE

MECHANICAL

FORM-IN-PLACE GASKETS AND SEALERS

There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in-place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket. All sealing surfaces that use form-in-place gaskets must be free of grease or oil. Surfaces should be cleaned with Mopar® brake parts cleaner prior to sealer application. After the sealer is applied, the parts should be assembled within 10 minutes.

There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Engine RTV GEN II, Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties and can not be used in place of the other.

MOPAR® ENGINE RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® GASKET MAKER is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.

MOPAR® BED PLATE SEALANT is a unique (green-in-color) anaerobic type gasket material that is specially made to seal the area between the bedplate and cylinder block without disturbing the bearing clearance or alignment of these components. The material cures slowly in the absence of air when torqued between two metallic surfaces, and will rapidly cure when heat is applied.

MOPAR® GASKET SEALANT is a slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.

REPAIR OF DAMAGED OR WORN THREADS

Damaged or worn threads (excluding spark plug and camshaft bearing cap attaching threads) can be repaired. Essentially, this repair consists of drilling out worn or damaged threads, tapping the hole with a special Heli-Coil Tap, (or equivalent) and installing an insert into the tapped hole. This brings the hole back to its original thread size.

Heli-Coil tools and inserts are readily available from automotive parts jobbers.

Scheme 490

When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used.

1. Inspect air cleaner, induction system and intake manifold to insure system is dry and clear of foreign material.
2. Remove negative battery cable.
3. Place a shop towel around the spark plugs when removing them from the engine. This will catch any fluid that may possibly be in the cylinder under pressure.
4. With all spark plugs removed, rotate engine crankshaft using a breaker bar and socket.
5. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other).
6. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting rods, pistons, valves, etc.)
7. Repair engine or components as necessary to prevent this problem from reoccurring. CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart.
8. Install new spark plugs.
9. Drain engine oil and remove oil filter.
10. Install a new oil filter.
11. Fill engine with specified amount of approved oil.
12. Connect negative battery cable.
13. Start engine and check for any leaks.

Scheme 491

Using a blunt tool such as a drift and a hammer, strike the bottom edge of the cup plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug .

Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with Mopar® Stud and Bearing Mount. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 in.) inside the lead-in chamfer.

It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately.

INSTALL

1. Align the front right engine cradle post (2) with the Lift Point Hole in the Engine Block.
2. Align the front left engine cradle post and 8130 support bracket (1) with the lift point hole in the engine block. 1 - 10107-2 ADAPTER 2 - 10107-1 ADAPTER
3. Install 10107-1 Support Bracket (2) in the engine block, and align the left rear engine cradle post with the hole in the support bracket.
4. Install 10107-2 Support Bracket (1) in the engine block, and align the right rear engine cradle post with the hole in the support bracket. 1 - SAFETY STRAPS 2 - SPECIAL TOOL 6135 3 - SPECIAL TOOL 6710
5. Install safety straps (1) so that they securely hold the powertrain assembly in the engine cradle. Tighten the fasteners at the base of each engine cradle post, and verify that the engine cradle posts are fully engaged in the lifting points.
6. Raise the vehicle body on a hoist.
7. Position the engine cradle and powertrain beneath the vehicle.
8. Slowly lower the vehicle body in short length spans. Inspect at each interval for potential engine or transaxle contact to body or suspension components. Move the cradle/dolly fixture as necessary.
9. Install ground strap to the hood and position the hood back.
10. Install 3 right engine mount bolts (1). Tighten bolts to 50 N.m (37 ft. lbs.).
11. Install the left side engine mount bolts (2). Tighten bolts to 98 N.m (72 ft. lbs.).
12. Install the power steering pump (2). Refer to «Steering/Pump - Installation»(ref-353572-S40988039922010011200000) .
13. Install the power steering line retainer bolt (2).
14. Install the fan module. Refer to «Cooling/Engine/FAN, Cooling - Installation»(ref-353584-S41323013652010011200000) .
15. Install the engine oil dipstick tube (2) and the bolt (3).
16. Install the A/C compressor (3). Refer to «Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Installation»(ref-353571-S30446641282010011200000) .
17. Reconnect both A/C lines (1) and (2) and the harness connector to the A/C compressor (3).
18. Reconnect the Upper Radiator hose (1) to the thermostat housing (2) and position aside.
19. Reconnect the coolant reservoir overflow hose (2) to the coolant bottle (4) and position aside.
20. Reconnect the heater core supply hose (1) to the intake manifold outlet (2).
21. Reconnect the positive auxiliary battery post cable (2) and the negative battery cable to the left shock tower and position aside.
22. Reconnect the ground (3) to the front of the transaxle.
23. Reconnect the ground (3) to the side of the transaxle.
24. Reconnect the transaxle cooler lines (1).
25. Reconnect the transaxle shifter cable (1).
26. Reconnect the transaxle harness PCM (1), and 6-way (2) connectors.
27. Reconnect the engine harness PCM (1), 12-way (2), ground (3), 8-way (4) connectors.
28. Raise Vehicle.
29. Install the Left Front Half Shaft. Refer to «Differential and Driveline/Half Shaft - Installation»(ref-353569-S33188263152010011200000) .
30. Reconnect the Lower Coolant Hose (1) from the return tube (2).
31. Install the Front Engine Mount Bracket (2). See «Engine/Engine Mounting/INSULATOR, Engine Mount - Installation»(ref-353585-S23138984702010011200000) . 1 - BRACKET 2 - HEAT SHIELD 3 - BRACKET 4 - BRACE 5 - POWER TRANSFER UNIT
32. If equipped, install the PTU (5). Refer to «Transmission and Transfer Case/Power Transfer Unit - Installation»(ref-353620-S05433498112010011200000) .
33. Install the Left Maniverter (6). See «Engine/Manifolds/MANIFOLD, Exhaust - Installation»(ref-353585-S01866242202010011200000) .
34. Install the Right Maniverter. See «Engine/Manifolds/MANIFOLD, Exhaust - Installation»(ref-353585-S01866242202010011200000) .
35. Install the Right Front Half Shaft assembly. Refer to «Differential and Driveline/Half Shaft - Installation»(ref-353569-S33188263152010011200000) .
36. Install the fore-aft crossmember (1). Refer to «Frame and Bumpers/Frame/CROSSMEMBER - Installation»(ref-353568-S00602877582010011200000) .
37. Install the Cross Under Pipe (3). See «Engine/Manifolds/MANIFOLD, Exhaust - Installation»(ref-353585-S01866242202010011200000) .
38. Install the Exhaust Extension Pipe (1) and gasket (2) to the Crossunder pipe (3). 1 - IDLER PULLEY 2 - P/S PUMP 3 - A/C COMPRESSOR 4 - CRANKSHAFT 5 - TENSIONER 6 - GENERATOR
39. Install the accessory drive belt (6). Refer to «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-353584-S15414070972010011200000) .
40. Install the Front Closeout Panel (2). Refer to «Frame and Bumpers/Bumpers/FASCIA, Front Lower - Installation»(ref-353568-S37931922402010011200000) .
41. Install the Left Forward Splash Shield (2).
42. Install the Right Forward Splash Shield (2). 1 - Belly Pan Fasteners 2 - Belly Pan
43. Install the belly pan (2) and install the 12 belly pan fasteners (1).
44. Install the Upper Intake Manifold (2). See «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353585-S07354684942010011200000) .
45. Install the Air Cleaner Housing (4). See «Engine/Air Intake System/BODY, Air Cleaner - Installation»(ref-353585-S19816332302010011200000) .
46. Reconnect the fuel line (1) to the fuel rail inlet (2).
47. Recharge the air conditioning system. Refer to «Heating and Air Conditioning/Plumbing - Standard Procedure»(ref-353571-S22405082752010011200000) .
48. Fill the cooling system. Refer to «Cooling - Standard Procedure»(ref-353584-S11330501202010011200000) .
49. Reconnect the negative battery cable (1).
50. Start the engine and allow it to reach normal operating temperature. Inspect for leaks, and verify normal operation.
51. Install the engine cover. NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to «DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure»(ref-353603-S03528494482010011200000) .

GENERAL

CYLINDER BLOCK

PISTONS

PISTON PINS

PISTON RINGS

PISTON RING SIDE CLEARANCE

PISTON RING WIDTH

CONNECTING RODS

CRANKSHAFT MAIN BEARING JOURNALS

CONNECTING ROD JOURNALS

CAMSHAFT

VALVE TIMING-INTAKE VALVE

VALVE TIMING-EXHAUST VALVE

CYLINDER HEAD

VALVES

VALVE SPRINGS

OIL PUMP

OIL PRESSURE

CYLINDER HEAD GASKET

A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket.

Possible indications of the cylinder head gasket leaking between adjacent cylinders are

1. Loss of engine power
2. Engine misfiring
3. Poor fuel economy

Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are

1. Engine overheating
2. Loss of coolant
3. Excessive steam (white smoke) emitting from exhaust
4. Coolant foaming

CLEANING

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.

Note. Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Remove all gasket material from cylinder head and block. See Engine - Standard Procedure . Be careful not to gouge or scratch the aluminum head sealing surface.

Clean all engine oil passages.

Scheme 492

1. Before cleaning, check for leaks, damage and cracks.
2. Clean cylinder head and oil passages.
3. Check cylinder head for flatness (1).
4. Cylinder head must be flat within: CAUTION: 0.20 mm (0.008 in.) MAX is a combined total dimension of the stock removal limit from cylinder head and block top surface (Deck) together.

1. Standard dimension = less than 0.05 mm (0.002 inch.)
2. Service Limit = 0.2 mm (0.008 inch.)
3. Grinding Limit = Maximum of 0.2 mm (0.008 inch.) is permitted.

RIGHT CYLINDER HEAD

Scheme 493

Scheme 494

Scheme 495

Scheme 496

1. Clean sealing surfaces of cylinder head and block. See «Engine - Standard Procedure»(ref-353585-S16993374792010011200000) . CAUTION: The cylinder head gaskets are not interchangeable between cylinder heads and are clearly marked right or left.
2. Install head gasket over locating dowels. Ensure the gasket is installed on the correct side of engine. 1 - STRETCHED BOLT 2 - THREADS ARE NOT STRAIGHT ON LINE 3 - THREADS ARE STRAIGHT ON LINE 4 - UNSTRETCHED BOLT CAUTION: Cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced. Failure to replace a damaged bolt may lead to possible engine damage.
3. Inspect the cylinder head bolts (1 and 4) for straightness, head damage, thread damage and necking. Necking can be checked by holding a scale or straight edge against the threads (3). If all the threads do not contact the scale evenly (2) the bolt must be replaced. 1 - INNER TIMING BELT COVER 2 - CYLINDER HEAD BOLTS 3 - RUBBER BANDS 4 - SPARK PLUG TUBE 5 - CAMSHAFT NOTE: Before installing the cylinder head bolts, lubricate the threads with engine oil.
4. Insert the front four cylinder head bolts into the cylinder head. Pull the bolts up to the top of their travel and retain with rubber bands.
5. Install the cylinder head over locating dowels and finger tighten the head bolts.
6. Tighten the cylinder head bolts in the sequence shown in illustration using the following four step torque-turn method: Step 1: All to 61 N.m (45 ft. lbs.) Step 2: All to 88 N.m (65 ft. lbs.) Step 3: All (again) to 88 N.m (65 ft. lbs.) Step 4: + 90° Turn Do not use a torque wrench for this step.
7. Bolt torque after 90° turn should be over 122 N.m (90 ft. lbs.) in the tightening direction. If not, replace the bolt. 1 - M8 FASTENERS (APPLY THREAD SEALANT) 2 - M10 FASTENERS 3 - M6 FASTENERS 4 - REAR TIMING BELT COVER 5 - M10 FASTENERS (STUD/NUT)
8. Install the inner timing cover to cylinder head bolts. Tighten bolts to 54 N.m (40 lbs. ft.). 1 - CAMSHAFT 2 - SPECIAL TOOL 6788 3 - CAMSHAFT SEAL 4 - CYLINDER HEAD
9. Apply light coat of clean engine oil to the lip of the camshaft oil seal (3) and Seal Protector Sleeve 6788 (2). NOTE: When installing the camshaft (1) into the cylinder head (4), you must first insert the Seal Protector Sleeve 6788 (2) through the camshaft seal (3) until the camshaft seats, then remove the Seal Protector Sleeve 6788 (2) from the camshaft.
10. Install the camshaft (1) using Seal Protector Sleeve 6788 (2) into the cylinder head (4).
11. Install camshaft sprocket. Hold the camshaft sprocket gear and tighten the camshaft sprocket bolt to 102 N.m plus a 1/4 turn (75 lbs. ft. plus a 1/4 turn). See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-353585-S01282825562010011200000) .
12. Install the rear camshaft thrust plate (1). 1 - ALIGN CAMSHAFT SPROCKET TIMING MARK BETWEEN MARKS ON REAR TIMING BELT COVER 2 - CRANKSHAFT AT TDC
13. Rotate the camshaft gear to the timing mark (1) and verify the left camshaft gear (1) and crankshaft gear timing marks (2) are aligned.
14. Install the timing belt. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-353585-S01282825562010011200000) .
15. Install the tensioner. See «Engine/Valve Timing/TENSIONER, Engine Timing - Installation»(ref-353585-S04935686572010011200000) . 1 - RIGHT SIDE COVER (STAMPED) 2 - LEFT SIDE COVER (CAST) 3 - LOWER COVER
16. Install the timing belt outer cover. See «Engine/Valve Timing/COVER(S), Engine Timing - Installation»(ref-353585-S10337911082010011200000) .
17. Install the power steering reservoir. 1 - GENERATOR 2 - IDLER PULLEY 3 - POWER STEERING PUMP 4 - A/C COMPRESSOR 5 - CRANKSHAFT PULLEY 6 - TENSIONER
18. Install the vibration damper (5). See «Engine/Engine Block/DAMPER, Vibration - Installation»(ref-353585-S12546785922010011200000) .
19. Install the upper engine mount. See «Engine/Engine Mounting/INSULATOR, Engine Mount - Installation»(ref-353585-S23138984702010011200000) .
20. Install the accessory drive belt tensioner (6).
21. Install the lower accessory drive belt idler pulley (2).
22. Install the right exhaust manifold. See «Engine/Manifolds/MANIFOLD, Exhaust - Installation»(ref-353585-S01866242202010011200000) .
23. Raise the vehicle.
24. Install the exhaust cross over pipe. See «Engine/Manifolds/MANIFOLD, Exhaust - Installation»(ref-353585-S01866242202010011200000) .
25. Install the catalytic converter and exhaust system.
26. Connect both oxygen sensors.
27. Lower the vehicle. 1 - SPARK PLUG TUBE 2 - ROCKER ARM ASSEMBLY 3 - CAMSHAFT 4 - SEAL
28. Install the right rocker arm assembly (2). See «Engine/Cylinder Head/ROCKER ARM, Valve - Installation»(ref-353585-S37836136412010011200000) .
29. Install the right cylinder head cover and ground strap.
30. Install the EGR valve (1) and tube assembly. 1 - LOWER INTAKE MANIFOLD 2 - GASKET
31. Install lower intake manifold (1) and gasket (2). See «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353585-S07354684942010011200000) .
32. Install the fuel rail. Refer to «Fuel System/Fuel Delivery/RAIL, Fuel - Removal»(ref-353596-S39190932472010011200000) .
33. Install the upper intake manifold (2). See «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353585-S07354684942010011200000) .
34. Connect the fuel line (1) to the fuel rail. Refer to «Fuel System/Fuel Delivery/RAIL, Fuel - Installation»(ref-353596-S11810263322010011200000) .
35. Install the air cleaner housing. See «Engine/Air Intake System/BODY, Air Cleaner - Installation»(ref-353585-S19816332302010011200000) .
36. Install the engine cover.
37. Fill the coolant system.
38. Connect the negative battery cable (1).

LEFT CYLINDER HEAD

1. Clean sealing surfaces of cylinder head and block. See «Engine - Standard Procedure»(ref-353585-S16993374792010011200000) . CAUTION: The cylinder head gaskets are not interchangeable between cylinder heads and are clearly marked right or left.
2. Install head gasket over locating dowels. Ensure the gasket is installed on the correct side of engine. CAUTION: Cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced. Failure to replace a damaged bolt may lead to possible engine damage.
3. inspect the cylinder head bolts (1 and 4) for straightness, head damage, thread damage and necking. Necking can be checked by holding a scale or straight edge against the threads (3). If all the threads do not contact the scale evenly (2) the bolt must be replaced.
4. Install the cylinder head over locating dowels. NOTE: Lightly lubricate the threads of the cylinder head bolts with clean engine oil prior to installation.
5. Install the cylinder head bolts finger tight.
6. Tighten the cylinder head bolts in the sequence shown in illustration using the following 4 step torque-turn method: Step 1: All to 61 N.m (45 ft. lbs.) Step 2: All to 88 N.m (65 ft. lbs.) Step 3: All (again) to 88 N.m (65 ft. lbs.) Step 4: + 90° Turn Do not use a torque wrench for this step.
7. Bolt torque after 90° turn should be over 122 N.m (90 ft. lbs.) in the tighten direction. If not, replace the bolt. 1 - M8 FASTENERS (APPLY THREAD SEALANT) 2 - M10 FASTENERS 3 - M6 FASTENERS 4 - REAR TIMING BELT COVER 5 - M10 FASTENERS (STUD/NUT)
8. Install the inner timing cover to cylinder head bolts. Tighten bolts to 54 N.m (40 lbs. ft.).
9. Apply light coat of clean engine oil to the lip of the camshaft oil seal (3) and Seal Protector Sleeve 6788 (2). NOTE: When installing the camshaft into the cylinder head , you must first insert the seal protector through the camshaft seal until the camshaft seats, then remove Seal Protector Sleeve 6788 from the camshaft.
10. Install the oil seal onto the camshaft (1) using Seal Protector Sleeve 6788 and install the camshaft into the cylinder head (4).
11. Install camshaft sprocket. Hold the camshaft sprocket gear and tighten the camshaft sprocket bolt to 115 N.m plus a 1/4 turn (85 lbs. ft. plus a 1/4 turn). See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-353585-S01282825562010011200000) .
12. Install the rear camshaft thrust plate (1).
13. Rotate the left camshaft gear to the alignment mark (1) on rear timing belt cover. Check the right camshaft gear and crankshaft gear timing alignment marks (1 and 2).
14. Install the timing belt. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-353585-S01282825562010011200000) .
15. Install the tensioner. See «Engine/Valve Timing/TENSIONER, Engine Timing - Installation»(ref-353585-S04935686572010011200000) .
16. Install the timing belt front covers (1, 2 and 3). See «Engine/Valve Timing/COVER(S), Engine Timing - Installation»(ref-353585-S10337911082010011200000) .
17. Install the power steering reservoir.
18. Install the vibration damper (5). See «Engine/Engine Block/DAMPER, Vibration - Installation»(ref-353585-S12546785922010011200000) .
19. Install the upper engine mount. See «Engine/Engine Mounting/INSULATOR, Engine Mount - Installation»(ref-353585-S23138984702010011200000) .
20. Install the accessory drive belt tensioner (6).
21. Install the lower accessory drive belt idler pulley (2).
22. Install the left exhaust manifold. See «Engine/Manifolds/MANIFOLD, Exhaust - Installation»(ref-353585-S01866242202010011200000) .
23. Install the exhaust cross over pipe. See «Engine/Manifolds/MANIFOLD, Exhaust - Installation»(ref-353585-S01866242202010011200000) .
24. Install the left rocker arm assembly (2). See «Engine/Cylinder Head/ROCKER ARM, Valve - Installation»(ref-353585-S37836136412010011200000) .
25. Install the left cylinder head cover and ground strap.
26. Install lower intake manifold (1) and gasket (2). See «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353585-S07354684942010011200000) .
27. Install the fuel rail. Refer to «Fuel System/Fuel Delivery/RAIL, Fuel - Installation»(ref-353596-S11810263322010011200000) .
28. Install the upper intake manifold. See «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353585-S07354684942010011200000) .
29. Connect the fuel line (1) to the fuel rail.
30. Install the radiator cooling fan assembly. Refer to «Cooling/Engine/FAN, Cooling - Installation»(ref-353584-S41323013652010011200000) .
31. Install the radiator core support.
32. Install the radiator close out panel.
33. Install the air cleaner housing. See «Engine/Air Intake System/BODY, Air Cleaner - Installation»(ref-353585-S19816332302010011200000) .
34. Install the engine cover.
35. Fill the coolant system.
36. Connect the negative battery cable (1).

Scheme 497

A single overhead camshaft per cylinder head provides valve actuation. The left camshaft accommodates a cam sensor pick-up wheel and is therefore longer. Each camshaft is supported by four bearing journals. A thrust plate attached to the rear of each cylinder head controls camshaft end play. Right and left camshaft driving sprockets support a timing mark, are keyed, and not interchangeable because of the cam sensor pick-up wheel on the left sprocket. Camshaft bearing lubrication is provided via a oil supply passage through each rocker shaft pedestal dowel.

Scheme 498

The camshaft is driven by the crankshaft via drive sprockets and belt. As the crankshaft turns, the timing belt turns the camshaft. The camshaft lobes press the lifters which in turn open the valves at the correct time. The valve spring returns the valve to the closed state.

The camshaft has precisely machined lobes to provide accurate valve timing and duration.

HYDRAULIC LASH ADJUSTER BLEEDING

Note. Use this procedure to manually bleed aerated oil from the lash adjuster and remove sponginess.

Scheme 499

Scheme 500

1. Run the engine, bringing it to operating temperature in order to freshly pressurize and warm the valvetrain system oil supply.
2. Remove cylinder head cover(s).
3. Rotate engine until the rocker arm is positioned on the base circle of the cam (1).
4. For intake rocker arm positions: CAUTION: If probe tip breaks off within the lash adjuster, replace the affected rocker arm. Adjust the gauge pin of Release Probe 8351 (1) to extend approximately 20 mm (0.787 in.). Then, carefully insert the release probe gauge pin into the lash adjuster service access hole (2). Gently unseat lash adjuster's internal check ball (4). While the internal check ball is held unseated, press the rocker arm (3) into the valve tip (5), allowing the hydraulic lash adjuster (6) within the rocker arm to fully collapse. Hold fully collapsed position for at least one second, or longer. Slowly release the rocker arm, thereby allowing the lash adjuster to extend, which in turn refills the high pressure chamber with non-aerated oil. Remove Release Probe 8351 to allow check ball to seat. Recheck for sponginess. If the lash adjuster sponginess is not completely or nearly eliminated, then repeat procedure. If the spongy condition cannot be removed, replace effected rocker arm(s).
5. For exhaust rocker arm positions: CAUTION: If probe tip breaks off within the lash adjuster, replace the affected rocker arm. Adjust the gauge pins of two Release Probes 8351 (1) to extend approximately 20 mm (0.787 in.). Then, using the two release probes, carefully insert gauge pins into the lash adjuster service access holes (2). Gently unseat BOTH lash adjuster's internal check balls (4) at the same time. While the internal check balls are held unseated, press the rocker arm (3) into the valve tip (5), allowing the hydraulic lash adjuster (6) within the rocker arm to fully collapse. Hold fully collapsed position for at least one second, or longer. Slowly release the rocker arm, thereby allowing the lash adjuster to extend, which in turn refills the high pressure chamber with non-aerated oil. Remove the two Release Probes 8351 to allow check balls to seat. Recheck for sponginess. If the lash adjuster sponginess is not completely or nearly eliminated, repeat procedure. If the spongy condition cannot be removed, replace effected rocker arm(s).
6. Install the cylinder head cover(s).

Scheme 501

Scheme 502

1. Remove the cylinder head covers. See «Engine/Cylinder Head/COVER(S), Cylinder Head - Removal»(ref-353585-S28529642522010011200000) . CAUTION: DO NOT use a number stamp or a punch to mark the rocker arms. Damage to the rocker arms could occur.
2. Using a permanent ink or paint marker, identify the location and position on each rocker arm.
3. Remove the rocker arm assembly bolts in the sequence shown in illustration. 1 - SPARK PLUG TUBE 2 - ROCKER ARM ASSEMBLY 3 - CAMSHAFT 4 - SEAL
4. Remove the rocker arm assembly (2). NOTE: To prevent air ingestion into the lash adjusters, avoid turning the rocker arm assembly upside down. CAUTION: Do not allow rocker arm assembly to rest on lash adjusters, as damage may occur to lash adjusters and/or plastic retainers.

1. Position the camshaft seal into the cylinder head (3).
2. Using Camshaft installer MD-998306 (2) tap the seal into place using a mallet (1). 1 - CAMSHAFT 2 - SPECIAL TOOL6788 3 - CAMSHAFT SEAL 4 - CYLINDER HEAD
3. Apply light coat of clean engine oil to the camshaft oil seal lip (3) and Seal Protector Sleeve 6788 (2). NOTE: When installing the camshaft (1) into the cylinder head (4), you must first insert Seal Protector Sleeve 6788 (2) through the camshaft seal (3) until the camshaft seats, then remove Seal Protector Sleeve 6788 (2) from the camshaft.
4. Install the camshaft using Seal Protector Sleeve 6788.
5. Install the left cylinder head. See «Engine/Cylinder Head - Installation»(ref-353585-S38825678362010011200000) .

Scheme 503

1. Remove valve spring. See «Engine/Cylinder Head/SPRING(S), Valve - Removal»(ref-353585-S07894558082010011200000)
2. Remove valve stem seals using a valve stem seal tool.

Scheme 504

1. The valve stem seal/valve spring seat should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. CAUTION: Do not remove garter spring (2) around the seal at the top of the valve stem seal.
2. Install valve spring. See «Engine/Cylinder Head/SPRING(S), Valve - Installation»(ref-353585-S20339828722010011200000)

Scheme 505

The valve springs are made from chrome silicon alloy wire and incorporate a "bee-hive" design. Valve spring retainers and locks are common from valve-to-valve. The valve spring seat is integral with the valve stem oil seal, which incorporates a garter spring to maintain consistent lubrication control to the valve stem.

The valve springs are unique for intake compared to exhaust. Both have different lengths and are wound in opposite directions. The valve springs are color coded, intake spring is right hand coil direction with grey dye on the top coils, and the exhaust spring is left hand coil direction with a blue dye on the top coils.

CYLINDER HEAD OFF

1. Compress valve spring with valve spring compressor C-3422-D and adapter 6526A. See «Engine - Special Tools»(ref-353585-S16939443142010011200000) .
2. Remove valve retaining locks. Release valve spring compressor. Remove valve spring retainer and valve spring.
3. Remove valve stem seal assembly. See «Engine/Cylinder Head/SEAL(S), Valve Guide - Removal»(ref-353585-S09352050062010011200000)

Scheme 506

1. Disconnect negative battery cable.
2. Remove upper intake manifold. See «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353585-S41076526142010011200000) .
3. Remove cylinder head cover(s). See «Engine/Cylinder Head/COVER(S), Cylinder Head - Removal»(ref-353585-S28529642522010011200000) .
4. Remove rocker arm and shaft assembly. See «Engine/Cylinder Head/ROCKER ARM, Valve - Removal»(ref-353585-S29730719562010011200000) .
5. Remove spark plugs.
6. Rotate the crankshaft clockwise, until the number 1 piston is at TDC (Top Dead Center) on the compression stroke.
7. With air hose attached to spark plug adapter installed in number 1 spark plug hole, apply 620.5 to 689 kPa (90 to 100 psi) air pressure. This is to hold valves into place while servicing components. NOTE: It may be necessary to use accessory studs 6886, adapter arm 6887 and 6885 valve adaptor along with MD 998772A, to compress the valve spring on the right cylinder head exhaust valves.
8. Using Tool MD 998772A (1), with adapter 6527 (4) or equivalent, compress valve spring and remove valve locks (5). Release tension on valve spring, remove retainer (5) and valve spring. See «Engine - Special Tools»(ref-353585-S16939443142010011200000) .
9. Remove valve stem seal, if required. See «Engine/Cylinder Head/SEAL(S), Valve Guide - Removal»(ref-353585-S09352050062010011200000)
10. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6. Make sure piston is at TDC in each cylinder of the valve spring that is being removed.
11. Remove spark plug adapter tool.

Scheme 507

When valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. As an example; the compression length of the spring to be tested is 38.00 mm (1.496 in.). Turn table of Tool C-647 until surface is in line with the 38.00 mm (1.496 inches.) mark on the threaded stud and the zero mark on the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to Engine - Specifications to obtain specified height and allowable tensions. Replace springs that do not meet specifications.

Scheme 508

Scheme 509

1. Install valves if removed.
2. Install valve stem seal/spring seat assembly (5) over valve guides on all valve stems. Ensure that the garter spring is intact around the top of the rubber seal.
3. Place valve spring (color-coded end facing up) (4) and valve retainer into position. 1 - SPRING RETAINER 2 - GARTER SPRING 3 - VALVE SPRING SEAT TOP 4 - CYLINDER HEAD SURFACE
4. Compress valve spring with valve spring compressor. Install locks and release tool. If valve and/or seat are reground, measure the installed height of springs (B), make sure measurements are taken from top of spring seat to the bottom surface of spring retainer . If height is greater than 38.75 mm (1.5256 in.), install a 0.762 mm (0.030 in.) spacer in head counterbore under the valve spring seat to bring spring height back within specification.

CYLINDER HEAD ON

1. Install new valve seal(s) if required. See «Engine/Cylinder Head/SEAL(S), Valve Guide - Installation»(ref-353585-S17802690242010011200000) .
2. Place valve spring (color-coded end facing up) and valve retainer into position. NOTE: It may be necessary to use accessory studs 6886, adaptor arm 6887 and 6885 valve adaptor along with MD 998772A, to compress the valve spring on the right cylinder head exhaust valves.
3. Compress valve spring using Special Tool MD 998772A (1) with Adaptor 6527 (4), only enough to install locks (5).
4. After installing locks, release tension on valve spring and verify proper installation.
5. Remove Special Tool MD 998772A (1) and spark plug adapter tool.
6. Install rocker arm and shaft assembly. See «Engine/Cylinder Head/ROCKER ARM, Valve - Installation»(ref-353585-S37836136412010011200000)
7. Install cylinder head cover(s). See «Engine/Cylinder Head/COVER(S), Cylinder Head - Installation»(ref-353585-S25597530122010011200000) .
8. Install spark plugs.
9. Install upper intake manifold. See «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353585-S07354684942010011200000) .
10. Connect negative battery cable.

Scheme 510

1. Remove cylinder head cover(s). See «Engine/Cylinder Head/COVER(S), Cylinder Head - Removal»(ref-353585-S28529642522010011200000) .
2. Using suitable locking pliers, remove the tube (1) from the cylinder head and discard tube.
3. Clean area around spark plug with Mopar® Parts Cleaner or equivalent.

Scheme 511

1. Apply Mopar® Stud and Bearing Mount to a new tube (1) approximately 1 mm (0.039 in.) from the end of tube, in a 3 mm (0.118 in.) wide area.
2. Install sealer end of tube (1) into the cylinder head. Then carefully install the tube (1) using a hardwood block and mallet. Install the tube (1) until it is seated into the bottom of the bore.
3. For spark plug tube (1) seal replacement. See «Engine/Cylinder Head/COVER(S), Cylinder Head - Removal»(ref-353585-S28529642522010011200000) .
4. Install cylinder head cover(s). See «Engine/Cylinder Head/COVER(S), Cylinder Head - Installation»(ref-353585-S25597530122010011200000) .

VALVE AND VALVE SEAT REFACING

Refer to Engine - Specifications for the valve face and valve seat angles.

Scheme 512

1. Inspect the remaining margin after the valves are refaced. See «Engine - Specifications»(ref-353585-S22148766082010011200000) .

Scheme 513

1. When refacing valve seats, it is important that the correct size valve guide pilot be used for re-seating stones. A true and complete surface must be obtained.
2. Measure the concentricity of valve seat using dial indicator. Total runout should not exceed 0.051 mm (0.002 inch.) total indicator reading. 1 - SEAT WIDTH 2 - FACE ANGLE 3 - SEAT ANGLE 4 - SEAT CONTACT AREA
3. Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, then lower valve seat with a 15 degree stone. If the blue is transferred to the bottom edge of valve face, then raise valve seat with a 65 degree stone. NOTE: Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise, the cylinder head must be replaced.
4. When seat is properly positioned, the width of the intake seats should be 0.75 to 1.25 mm (0.0296 to 0.0493 in.) and exhaust seats should be 1.25 to 1.75 mm (0.049 to 0.069 in.).

Scheme 514

Scheme 515

Scheme 516

1. Coat valve stems with clean engine oil and insert the valves into the cylinder head.
2. If valves or seats have been refaced, check valve tip height (A). If valve tip height is greater than 43.65 mm (1.7185 in.) intake or 45.98 mm (1.8102 in.) exhaust, grind valve tip until within specifications. Make sure measurement is taken from cylinder head surface to the top of valve stem. 1 - VALVE 2 - VALVE RETAINING LOCKS 3 - VALVE SPRING RETAINER 4 - VALVE SPRING 5 - VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY
3. Install valve seal/spring seat assembly over valve guides on all valve stems. Ensure that the garter spring is intact around the top of the valve seal.
4. Place valve spring (color-coded end facing up) and valve retainer into position on spring seat.
5. Compress valve springs with valve spring compressor C-3422-D and adapter 6526A. See «Engine - Special Tools»(ref-353585-S16939443142010011200000) , install locks and release tool. 1 - YELLOW OR WHITE DYE 2 - ORANGE DYE
6. If valves and/or seats are refaced, measure the installed height of springs. Measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.5256 in.), install a 0.762 mm (0.030 in.) spacer in head counterbore under the valve spring seat to bring spring height back within specification.

1. Clean all valves thoroughly and discard burned, warped and cracked valves.

Scheme 517

1. Measure valve stems for wear approximately 60 mm (2.36 in.) below the valve lock grooves.
2. Compare measurement to specifications. See «Engine - Specifications»(ref-353585-S22148766082010011200000) . NOTE: Valve stems are chrome plated and should not be polished.

Scheme 518

1. Measure valve stem-to-guide clearance as follows
2. Install valve into cylinder head so it is 15 mm (0.590 inch.) off the valve seat. A small piece of hose may be used to hold valve in place.
3. Attach dial indicator Tool C-3339A to cylinder head and set it at right angle of valve stem being measured.
4. Move valve to and from the indicator.
5. Note dial indicator reading and compare to engine specifications. See «Engine - Specifications»(ref-353585-S22148766082010011200000) NOTE: Replace cylinder head if stem-to-guide clearance exceeds specifications, or if guide is loose in cylinder head.

Scheme 519

1. Coat valve stems with clean engine oil and insert the valves into the cylinder head.
2. If valves or seats have been reground, check valve tip height (A). If valve tip height is greater than 43.65 mm (1.7185 in.) intake or 45.98 mm (1.8102 in.) exhaust, grind valve tip until within specifications. Make sure measurement is taken from cylinder head surface to the top of valve stem.
3. Install new valve stem seals.
4. Install valve springs. See «Engine/Cylinder Head/SPRING(S), Valve - Installation»(ref-353585-S20339828722010011200000) .
5. Install cylinder head(s). See «Engine/Cylinder Head - Installation»(ref-353585-S38825678362010011200000) .

Scheme 520

The cylinder block (5) is made of heat treated aluminum with cast-in-place iron liners. The block is a closed deck design with the right bank forward. To provide high rigidity and improved noise, vibration and harshness (NVH), the block has cast-in contours and ribs, along with powdered metal 6 bolt main caps (4 vertical, 2 horizontal), with a die cast aluminum structural beam windage tray mounted to the main caps.

Clean cylinder block thoroughly using a suitable cleaning solvent.

ENGINE BLOCK

1. Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking.
2. If new core plugs are to be installed. See «Engine - Standard Procedure»(ref-353585-S16993374792010011200000) .
3. Examine block and cylinder bores for cracks or fractures.
4. Check block deck surfaces for flatness. Deck surface must be within service limit of 0.1 mm (0.004 in.).

CYLINDER BORE

Note. The cylinder bores should be measured at normal room temperature, 21°C (70°F).

The cylinder walls should be checked for out-of-round and taper with Tool C119 or equivalent. See Engine - Specifications . If the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted.

Scheme 521

Measure the cylinder bore at three levels in directions A and B. Top measurement should be 10 mm (3/8 in.) down and bottom measurement should be 10 mm (3/8 in.) up from bottom of bore. See Engine - Specifications .

Scheme 522

The bearing caps are not interchangeable and should be marked at removal to insure correct assembly.

The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same side as the rod.

Fit all rods on one bank until complete.

Limits of taper or out-of-round on any crankshaft journals should be held to specification limits. Bearings are available in 0.007 mm oversize (0.0003 in oversize), standard, 0.007 mm (0.0003 in) undersize 0.025 mm (0.001 in) undersize, and 0.254 mm (0.010 in undersize. Install the bearings in pairs. Do not use a new bearing half with an old bearing half. Do not file the rods or bearing caps.

1. For measuring main bearing clearance and connecting rod bearing clearance use plastigage. For more information on using plastigage, see «Engine - Standard Procedure»(ref-353585-S16993374792010011200000) . Refer to «Engine - Specifications»(ref-353585-S22148766082010011200000) for bearing clearance specifications.

Scheme 523

1. Connecting rod bearings use select fit to achieve improved clearance control. On a new engine, the crankshaft journal is gaged to use a specific bearing size. The grade is indicated on the #9 counterweight (2) of the crankshaft and listed from left to right with the recommended size.

SELECT FIT ROD BEARING GRADES

How to Determine Rod Bearing Class

This example shows how to determine the bearing class needed for each rod bearing, assuming that a new crankshaft is being installed in a new or existing engine block. If the code 'B' 'A' 'B' 'B' 'B' 'C' is stamped on the #9 counterweight of the crankshaft (3), then rod #1 would require Class 2 bearings, rod #2 would require Class 1 bearings, rod #3 would require Class 2 bearings, rod #4 would require Class 2 bearings, rod #5 would require Class 2 bearings, and rod #6 would require Class 3 bearings.

EXAMPLE

CONNECTING ROD BOLTS

Note. The rod bearing bolts should be examined before reuse. If the threads are necked down the bolts must be replaced.

Scheme 524

1. Examine connecting rod bolts for stretching. Stretching can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt must be replaced.
2. Before installing the bolts the threads should be cleaned and inspected.
3. Install clean bolts finger tight. Then alternately torque each bolt to assemble the cap properly.
4. Tighten the connecting rod cap bolts to specification. See «Engine - Specifications»(ref-353585-S22148766082010011200000)

Scheme 525

1. Mount a dial indicator to a stationary point on engine. Locate probe perpendicular to and resting against the connecting rod cap being checked. Move connecting rod all the way to rear of its travel (toward flywheel end of crank). Zero the dial indicator. Move connecting rod forward of to limit of travel (toward pulley end of crank) and read the dial indicator. Compare measurement to specification listed in engine specifications. See «Engine - Specifications»(ref-353585-S22148766082010011200000) . Repeat procedure for each connecting rod. Turn crankshaft for connecting rod accessibility.

Scheme 526

The main bearings use a "select fit" system to achieve proper oil clearances between the bearings and the crankshaft. When main bearings are being selected for a new crankshaft, the block and crankshaft grade identification marks must be used to identify the correct main bearings to use.

Scheme 527

The cylinder block main bearing bore grade codes (1) are located on the left side front of the engine block, just below the cylinder head mounting surface. These grade marks (1, 2, 3, or 4) are read left to right, corresponding to main bearing bore 1, 2, 3, or 4.

The grade marks for the crankshaft are located on the rearmost crankshaft counter weight. The crankshaft journal grade marks (A, B, or C) are read left to right, corresponding with journal number 1, 2, 3, 4. For an example, if the main bore grade on the side of the engine block is 3 and the journal grade on the #9 counterweight of the crankshaft is B, the proper select fit bearing would be a (2) +0.003 mm (+0.0001 in.).

Refer to the EXAMPLE CRANKSHAFT MAIN BEARING SELECTION DATA table for a more detailed example of how to properly select the main bearings.

Note. Service main bearings have a number from (1-5) marked in ink on the bearing surface. For verification, refer to the MAIN BEARING SELECTION CHART table for number to size identification.

Scheme 528

The upper main bearing (2) has an oil feed hole and a center groove to allow lubrication of the main journal and must be properly positioned in the block.

MAIN BEARING SELECTION CHART

How to Determine Crankshaft Main Bearing Class

This example shows how to determine the bearing class needed for each crankshaft main journal, assuming that a new crankshaft is being installed in a new or existing engine block. If the code 'B' 'B' 'A' 'C' is stamped on the #9 counterweight of the crankshaft (3), and the code '1' '2' '2' '3' is stamped on the side of the engine block (1), then main #1 would require Class 4 bearings, main #2 would require Class 3 bearings, main #3 would require Class 2 bearings, and main #4 would require Class 3 bearings.

EXAMPLE CRANKSHAFT MAIN BEARING SELECTION DATA

Scheme 529

Bearing caps are not interchangeable and are marked to insure correct assembly. Upper and lower bearing halves are NOT interchangeable.

Scheme 530

1. Remove oil pan. See «Engine/Lubrication/PAN, Oil - Removal»(ref-353585-S23700294392010011200000)
2. Remove oil pick-up tube and windage tray.
3. Identify bearing caps before removal.
4. Remove bearing caps one at a time. Remove upper half of bearing (2 and 4) by inserting Special Main Bearing Tool C-3059A (1 and 3) into the oil hole of crankshaft.
5. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell.

Scheme 531

Bearing caps are not interchangeable and are marked to insure correct assembly. Upper and lower bearing halves are NOT interchangeable.

Note. Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened.

When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side.

Scheme 532

1. Lubricate main bearing with clean engine oil.
2. Start bearing in place, and insert Main Bearing Tool C-3059A into oil hole of crankshaft.
3. Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Special Main Bearing Tool C-3059A. NOTE: Lubricate main bearing cap bolts with engine oil before installation.
4. Lubricate and install lower bearing half and main cap Tighten bolts finger tight.
5. For installing thrust washers (1) at the No. 2 main bearing location, use the following procedure: Move crankshaft forward to limit of travel. Lubricate and install the front thrust washer by rolling the washer (1) onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface. Move crankshaft rearward to limit of travel. Lubricate and install the rear thrust washer by rolling the washer onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface.
6. Install each main bearing cap and tighten inner bolts finger tight.
7. Tighten inner main bearing cap bolts to 20 N.m + 1/4 turn (15 ft. lbs. + 1/4 turn).
8. Measure crankshaft end play. See «Engine/Engine Block/CRANKSHAFT - Standard Procedure»(ref-353585-S09793399852010011200000)
9. Install windage tray. Lubricate bolts with engine oil and tighten to 27 N.m + 1/4 turn (20 ft. lbs. + 1/4 turn).
10. Install the main cap tie (horizontal) bolts and tighten to 28 N.m (250 in. lbs.).
11. Install oil pick-up tube.
12. Install oil pan. See «Engine/Lubrication/PAN, Oil - Installation»(ref-353585-S21699418692010011200000)
13. Fill engine crankcase with proper oil to correct level.

ENGINE OIL AND FILTER CHANGE

Change engine oil at mileage and time intervals described in the Maintenance Schedule. Refer to Vehicle Quick Reference/Maintenance Schedules - Description .

Scheme 533

1. Run engine until achieving normal operating temperature.
2. Position the vehicle on a level surface and turn engine off.
3. Open hood, remove engine oil fill cap (1).
4. Raise vehicle on hoist.
5. Place a suitable drain pan under crankcase drain.
6. Remove oil pan drain plug (1) from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged.
7. Remove oil filter (2).
8. Install drain plug (1) in crankcase. Tighten oil pan drain plug to 27 N.m (20 ft. lbs.).
9. Install new oil filter (2).
10. Lower vehicle. 1 - ENGINE OIL FILL CAP 2 - ENGINE OIL DIPSTICK
11. Fill crankcase with specified type and amount of engine oil. Refer to «Vehicle Quick Reference/Capacities and Recommended Fluids - Description»(ref-353564-S13881188462010011200000) or «Vehicle Quick Reference/Capacities and Recommended Fluids - Specifications»(ref-353564-S22108138092010011200000) .
12. Install oil fill cap (1).
13. Start engine and inspect for leaks.
14. Turn engine off and inspect oil level.

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING above.

Scheme 534

Scheme 535

Scheme 536

1. Disconnect negative battery cable (1).
2. Remove the engine oil indicator (1).
3. Remove the engine oil indicator tube bolt (3).
4. Remove the engine oil indicator tube (2).
5. Raise and support the vehicle.
6. Remove the front crossmember. Refer to «Frame and Bumpers/Frame/CROSSMEMBER - Removal»(ref-353568-S24366143892010011200000) .
7. Remove the crossover pipe. See «Engine/Manifolds/MANIFOLD, Exhaust - Removal»(ref-353585-S14059952682010011200000) .
8. Loosen the front exhaust manifold. See «Engine/Manifolds/MANIFOLD, Exhaust - Removal»(ref-353585-S14059952682010011200000) .
9. Remove the oil pan bell housing bolts (1).
10. Drain the engine oil (1).
11. Remove the engine oil filter (2).
12. Remove the oil pan fasteners. Remove the oil pan. NOTE: A small amount of oil will remain in the oil pan. Use care when removing the oil pan from the engine.
13. Remove oil pan gasket.

Scheme 537

1. Clean oil pan and all gasket surfaces.
2. Apply a 1/8 inch bead of Mopar® Engine RTV GEN II at the parting line of the oil pump housing and the rear seal retainer.
3. Install oil pan gasket to the engine block.
4. Install the oil pan and tighten the oil pan bolts to 28 N.m (21 ft. lbs.).
5. Tighten the oil pan bell housing bolts to 55 N.m (40 ft. lbs.).
6. All engines are equipped with a high quality full-flow, disposable type oil filter (2). When replacing oil filter, use a Mopar® filter or equivalent.
7. Wipe base clean, then inspect gasket contact surface.
8. Lubricate gasket of new filter with clean engine oil.
9. Install and tighten oil filter (2) to 16 N.m (12 ft. lbs.) of torque after gasket contacts base. Use filter wrench if necessary.
10. Install and tighten the oil pan drain bolt (1) to 27 N.m (20 ft. lbs.).
11. Tighten the front maniverter bolts. See «Engine/Manifolds/MANIFOLD, Exhaust - Removal»(ref-353585-S14059952682010011200000) .
12. Install the crossover pipe. See «Engine/Manifolds/MANIFOLD, Exhaust - Removal»(ref-353585-S14059952682010011200000) .
13. Install the front crossmember. Refer to «Frame and Bumpers/Frame/CROSSMEMBER - Removal»(ref-353568-S24366143892010011200000) .
14. Lower vehicle.
15. Install the oil level indicator tube (2).
16. Tighten the oil level indicator tube bolt (3).
17. Install the oil indicator (1).
18. Fill engine crankcase with proper oil to correct level.
19. Connect negative battery cable (1).

1. Clean all parts thoroughly in a suitable solvent.

Scheme 538

Scheme 539

Scheme 540

Scheme 541

Scheme 542

Scheme 543

Scheme 544

1. Disassemble oil pump. See «Engine/Lubrication/PUMP, Engine Oil - Disassembly»(ref-353585-S05108583672010011200000)
2. Clean all parts thoroughly. Mating surface of the oil pump housing should be smooth. Replace pump cover if scratched or grooved. 1 - STRAIGHT EDGE 2 - FEELER GAUGE 3 - OIL PUMP COVER
3. Lay a straightedge (1) across the pump cover surface. If a 0.025 mm (0.001 in.) feeler gauge blade (2) can be inserted between cover and straight edge, cover should be replaced.
4. Measure thickness and diameter of outer rotor. If outer rotor thickness measures 14.299 mm (0.563 in.) or less, or if the diameter is 79.78 mm (3.141 inches.) or less, replace outer rotor.
5. If inner rotor measures 14.299 mm (0.563 in.) or less replace inner rotor. 1 - FEELER GAUGE 2 - OUTER ROTOR
6. Slide outer rotor into body, press to one side with fingers and measure clearance between rotor and body. If measurement is 0.39 mm (0.015 inch.) or more, replace body only if outer rotor is in specifications. 1 - FEELER GAUGE 2 - OUTER ROTOR 3 - INNER ROTOR
7. Install inner rotor into body. If clearance between inner (3) and outer (2) rotors is 0.20 mm (0.008 inch.) or more, replace both rotors. 1 - STRAIGHT EDGE 2 - FEELER GAUGES
8. Place a straightedge across the face of the body, between bolt holes. If a feeler gauge of 0.077 mm (0.003 in.) or more can be inserted between rotors and the straightedge, replace pump assembly ONLY if rotors are in specs.
9. Inspect oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400-grit wet or dry sandpaper. 1 - RELIEF VALVE 2 - SPRING 3 - RETAINER CAP 4 - COTTER PIN
10. The relief valve spring (2) has a free length of approximately 49.5 mm (1.95 in.) it should test between 101-110 N (23-25 lbs.) when compressed to 34 mm (1-11/32 in.). Replace spring that fails to meet specifications.
11. Assemble oil pump. See «Engine/Lubrication/PUMP, Engine Oil - Assembly»(ref-353585-S22323893592010011200000)

Scheme 545

1. Assemble oil pump using new parts as required.
2. Tighten cover screws to 12 N.m (105 in. lbs.).
3. Prime oil pump before installation by filling rotor cavity with engine oil.
4. If oil pressure is low and pump is within specifications, inspect for worn engine bearings or other reasons for oil pressure loss.

TIMING VERIFICATION

Remove the outer timing covers. See Engine/Valve Timing/COVER(S), Engine Timing - Removal Rotate the crankshaft until the pointer on the crankshaft sprocket aligns the TDC mark on the oil pump. Check to determine if the camshaft sprocket timing marks are aligned with the marks on the inner timing cover. It may take an additional full revolution of the crankshaft before the camshaft sprocket marks are aligned.

Scheme 546

1. Perform fuel pressure release procedure. Refer to «Fuel System/Fuel Delivery - Standard Procedure»(ref-353596-S39204571612010011200000) .
2. Disconnect negative battery cable.
3. Remove both cylinder head covers.
4. Remove the front timing belt cover. See «Engine/Valve Timing/COVER(S), Engine Timing - Removal»(ref-353585-S15810965992010011200000) .
5. Mark belt running direction, if timing belt is to be reused. CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.
6. Rotate engine clockwise until crankshaft mark aligns with the TDC mark on oil pump housing and the camshaft sprocket timing marks are aligned with the marks on the rear cover.
7. Remove the timing belt tensioner and remove timing belt. 1 - VISE 2 - LOCKING PIN
8. Inspect the tensioner for fluid leakage.
9. Inspect the pivot and bolt for free movement, bearing grease leakage, and smooth rotation. If not rotating freely, replace the arm and pulley assembly.
10. When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body. CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This ensures proper pin orientation when tensioner is installed on the engine. Place the tensioner into a vise and SLOWLY compress the plunger. Total bleed down of tensioner should take about 5 minutes. When plunger is compressed into the tensioner body install a pin through the body and plunger to retain plunger in place until tensioner is installed.

CAMSHAFT SPROCKETS

Note. The camshaft timing gears are keyed to the camshaft.

1. Perform fuel pressure release procedure. Refer to «Fuel System/Fuel Delivery - Standard Procedure»(ref-353596-S39204571612010011200000) .
2. Remove front timing belt cover. See «Engine/Valve Timing/COVER(S), Engine Timing - Removal»(ref-353585-S15810965992010011200000) .
3. Position crankshaft sprocket to the TDC mark on the oil pump housing by turning crankshaft in the clockwise direction
4. Install a dial indicator in number 1 cylinder to check TDC of the piston. Rotate the crankshaft until the piston is at exactly TDC.
5. Remove camshaft retainer/thrust plate from rear of right cylinder head.
6. Remove the cylinder head covers.
7. Remove rocker arm assemblies.
8. Remove the timing belt tensioner and timing belt.
9. Loosen and remove the left camshaft gear retaining bolt and washer. The left bolt is 255 mm (10.0 in.) long. NOTE: The camshaft timing gears are keyed to the camshaft.
10. Hold the left camshaft sprocket with 36 mm (1 7/16 in.) box end wrench.
11. Remove the left camshaft sprocket. CAUTION: The camshaft must be pushed rearward approximately 3 1/2 inches to remove the camshaft gear retaining bolt and gear. Care must be taken not to scratch or nick the camshaft or cylinder head journals when moving camshaft.
12. Loosen and remove the right camshaft gear retaining bolt and washer. The right bolt is 213 mm (8 3/8 in.) long. NOTE: The camshaft timing gears are keyed to the camshaft.
13. Hold the right camshaft sprocket with 36 mm (1 7/16 in.) box end wrench and loosen the camshaft bolt.
14. Using a floor jack, raise the right side of the engine enough to allow clearance to remove the right camshaft bolt and washer.
15. Remove the right camshaft sprocket.

Scheme 547

1. Remove the timing belt. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) .
2. Remove crankshaft sprocket using Special Tool L-4407A.

Remove the outer timing covers. Rotate the crankshaft until the pointer on the crankshaft sprocket (10) aligns the TDC mark on the oil pump (9). Check to determine if the camshaft sprocket (2, 7) timing marks (1, 8) are aligned with the marks on the inner timing cover. It may take an additional full revolution of the crankshaft before the camshaft sprocket marks are aligned.

Scheme 548

1. Remove front timing belt cover. See «Engine/Valve Timing/COVER(S), Engine Timing - Removal»(ref-353585-S15810965992010011200000) .
2. Inspect both sides of the timing belt. Replace belt if any of the following conditions exist: Hardening of back rubber back side is glossy without resilience and leaves no indent when pressed with fingernail. Cracks on rubber back. Cracks or peeling of canvas. Cracks on rib root. Cracks on belt sides. Missing teeth. Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. Vehicle mileage or time at component maintenance requirement. Refer to «Vehicle Quick Reference/Maintenance Schedules - Description»(ref-353564-S40062438892010011200000) .
3. If none of the above conditions are seen on the belt, the front timing belt cover can be installed. See «Engine/Valve Timing/COVER(S), Engine Timing - Installation»(ref-353585-S10337911082010011200000) .

Scheme 549

1. Install crankshaft sprocket using Special Tools 6641 and C-4685-C1.
2. Install timing belt. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-353585-S01282825562010011200000) .

Scheme 550

1. Install the camshaft sprockets onto the camshafts. Install NEW sprocket attaching bolts into place. The 255 mm (10 in.) bolt is installed in the left camshaft and the 213 mm (8 3/8 in.) bolt is installed into the right camshaft. Do not tighten the bolts at this time, they will be tightened at a later step. Camshaft sprocket timing marks should be aligned with inner cover timing marks at both sprockets.
2. Install the camshaft thrust plates (1) and seals. Tighten the bolts (2) to 28 N.m (250 in. lbs.). 1 - ALIGN CAMSHAFTS WITH TIMING MARKS 2 - INSTALL TENSIONER LOOSE 3 - CRANKSHAFT AT TDC
3. Install the timing belt starting first at the crankshaft sprocket, then to remaining sprockets in a counterclockwise direction.
4. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley. Camshaft sprocket timing marks (1) and crankshaft sprocket timing mark (3) should still be aligned with the inner cover marks. NOTE: It is necessary to compress the plunger into the tensioner body and install a locking pin prior to reinstalling the tensioner. See Timing Belt Removal for tensioner compression procedure. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) .
5. Hold the tensioner pulley against the belt and install the reset (pinned) timing belt tensioner (2) into the housing. Tighten attaching bolts to 28 N.m (250 in. lbs.).
6. Remove tensioner retaining pin to allow the tensioner to extend to the pulley bracket.
7. Hold the right camshaft sprocket hex with a 36 mm (1 7/16 in.) wrench and tighten the right camshaft bolt to 102 N.m (75 ft. lbs.) +90° turn.
8. Hold the left camshaft sprocket hex with a 36 mm (1 7/16 in.) wrench and tighten the left camshaft bolts to 102 N.m (75 ft. lbs.) +90° turn.
9. Install the rocker arm assemblies and cylinder head covers. See «Engine/Cylinder Head/ROCKER ARM, Valve - Installation»(ref-353585-S37836136412010011200000)
10. Install the front timing belt cover. See «Engine/Valve Timing/COVER(S), Engine Timing - Installation»(ref-353585-S10337911082010011200000) NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to «DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure»(ref-353603-S03528494482010011200000) .

TIMING BELT

Scheme 551

1. Align the crankshaft sprocket (10) with the TDC mark (9) on the oil pump cover.
2. Align the camshaft sprockets (2, 7) timing reference marks (1, 8) with the marks on the rear cover.
3. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket and maintain tension on the belt as it is positioned around the tensioner pulley (11). NOTE: It is necessary to compress the plunger into the tensioner body and install a locking pin prior to reinstalling the tensioner. See Timing Belt Removal for tensioner compression procedure. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) .
4. Hold the tensioner pulley (11) against the belt and install the reset (pinned) timing belt tensioner (2) into the housing. Tighten attaching bolts to 28 N.m (250 in. lbs.).
5. When tensioner (12) is in place, pull the retaining pin to allow the tensioner to extend to the pulley bracket.
6. Rotate the crankshaft sprocket (10) two revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. If the marks do not line up, repeat the procedure.
7. Install the front timing belt cover. See «Engine/Valve Timing/COVER(S), Engine Timing - Installation»(ref-353585-S10337911082010011200000) .
8. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to «DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure»(ref-353603-S03528494482010011200000) .

TENSIONER

1. For timing belt tensioner installation procedure. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-353585-S01282825562010011200000) .