3.5L Engine - Service Information: Removal & Installation Dodge Journey I

REMOVAL

Note. Capture and store any residual fluid drainage, or leakage from disconnected components or systems in appropriately marked containers. Dispose of residual fluid in accordance with all applicable environmental regulations.

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1. Remove the engine cover.
2. Disconnect and isolate the negative battery cable (1).
3. Drain the cooling system. Refer to «Cooling - Standard Procedure»(ref-353584-S11330501202010011200000) .
4. Evacuate and recover the air conditioning system. Refer to «Heating and Air Conditioning/Plumbing - Standard Procedure»(ref-353571-S22405082752010011200000) .
5. Perform the fuel pressure release procedure. Refer to «Fuel System/Fuel Delivery - Standard Procedure»(ref-353596-S39204571612010011200000) .
6. Disconnect fuel line (1) from the fuel rail inlet (2) and position aside.
7. Remove the Air Cleaner Housing (4). See «Engine/Air Intake System/BODY, Air Cleaner - Removal»(ref-353585-S33364826632010011200000) .
8. Remove the Upper Intake Manifold (2). See «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353585-S41076526142010011200000) .
9. Raise the vehicle.
10. Remove the 12 belly pan fasteners (1) and remove the belly pan (2).
11. Remove the Right Forward Splash Shield (2). Refer to «Body/Exterior/SHIELD, Splash - Removal»(ref-353577-S07665419552010011200000) .
12. Remove the Left Forward Splash Shield (2). Refer to «Body/Exterior/SHIELD, Splash - Removal»(ref-353577-S07665419552010011200000) .
13. Remove the Front Closeout Panel (2). Refer to «Frame and Bumpers/Bumpers/FASCIA, Front Lower - Removal»(ref-353568-S22545097012010011200000) . 1 - IDLER PULLEY 2 - P/S PUMP 3 - A/C COMPRESSOR 4 - CRANKSHAFT 5 - TENSIONER 6 - GENERATOR
14. Remove the accessory drive belt (6). Refer to «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353584-S03638748182010011200000) .
15. Disconnect the Exhaust Extension Pipe (1) and gasket (2) from the Crossunder pipe (3).
16. Remove the Cross Under Pipe (3). Refer to «Exhaust System/PIPE, Exhaust Crossunder - Removal»(ref-353615-S40083911602010011200000) .
17. Remove the fore-aft crossmember (1). Refer to «Frame and Bumpers/Frame/CROSSMEMBER - Removal»(ref-353568-S24366143892010011200000) .
18. Remove the Right Front Half Shaft assembly. Refer to «Differential and Driveline/Half Shaft - Removal»(ref-353569-S23433654932010011200000) .
19. Remove the Right Maniverter. See «Engine/Manifolds/MANIFOLD, Exhaust - Removal»(ref-353585-S14059952682010011200000) .
20. Remove the Left Maniverter (6). See «Engine/Manifolds/MANIFOLD, Exhaust - Removal»(ref-353585-S14059952682010011200000) . 1 - BRACKET 2 - HEAT SHIELD 3 - BRACKET 4 - BRACE 5 - POWER TRANSFER UNIT
21. If equipped, remove the PTU (5). Refer to «Transmission and Transfer Case/Power Transfer Unit - Removal»(ref-353620-S28539122802010011200000) .
22. Remove the Front Engine Mount Bracket (2). See «Engine/Engine Mounting/INSULATOR, Engine Mount - Removal»(ref-353585-S06981968532010011200000) .
23. Disconnect the Lower Coolant Hose (1) from the return tube (2).
24. Remove the Left Front Half Shaft. Refer to «Differential and Driveline/Half Shaft - Removal»(ref-353569-S23433654932010011200000) .
25. Lower Vehicle.
26. Disconnect the engine harness PCM (1), 12-way (2), ground (3), 8-way (4) connectors.
27. Disconnect the transaxle harness PCM (1), and 6-way (2) connectors.
28. Disconnect the transaxle shifter cable (1).
29. Disconnect the transaxle cooler lines (1).
30. Disconnect the ground (3) from the side of the transaxle.
31. Disconnect the ground (3) from the front of the transaxle.
32. Disconnect the positive auxiliary battery post cable (2) and the negative battery cable from the left shock tower and position aside.
33. Disconnect the heater core supply hose (1) from the intake manifold outlet (2).
34. Disconnect the coolant reservoir overflow hose (2) from the coolant bottle (4) and position aside.
35. Disconnect the Upper Radiator hose (1) from the thermostat housing (2) and position aside.
36. Disconnect both A/C lines (1) and (2) and the harness connector from the A/C compressor (3).
37. Remove the A/C compressor (3). Refer to «Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Removal»(ref-353571-S03338883732010011200000) .
38. Remove the Fan Module. Refer to «Cooling/Engine/FAN, Cooling - Removal»(ref-353584-S40318301502010011200000) .
39. Remove the bolt, and the engine oil dipstick tube (2).
40. Remove the power steering line retainer bolt (2).
41. Position the power steering pump (2) and reservoir aside in the engine compartment. Avoid opening the power steering system by leaving the power steering lines connected. 1 - 8130 ADAPTER 2 - ENGINE CRADLE POST
42. Position vehicle height to allow engine dolly 6135 and cradle 6710A with posts 6848 to be installed under vehicle.
43. Align the front right engine cradle post (2) with the Lift Point Hole in the Engine Block.
44. 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
45. 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.
46. 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
47. 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.
48. Lower vehicle so weight of the engine and transmission ONLY is on the cradle.
49. Remove the left side engine mount bolts (2).
50. Remove the right side engine mount bolts (1).
51. Slowly raise vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for removal clearance.

INSTALLATION

1. Install air filter element into the bottom half of the air filter housing.
2. Slide the air filter housing cover (2) rearward to engage the tabs into the bottom half of the air filter housing.
3. Reengage the air filter housing clips (1).

1. Disconnect the Intake Air Temperature (IAT) sensor wiring harness connector from the IAT (5).
2. Loosen the clamp (1) and disconnect the air inlet hose from the throttle body.
3. Disconnect the makeup air hose from the top half of the air filter housing.
4. Remove the air filter housing retaining bolt (3) and the push pin (2) that secures the air scoop to the top of the radiator core support.
5. Pull the air filter housing up and off of the locating pins.

1. Push the air filter housing onto the locating pins.
2. Install air filter housing (2) straight down on locating pins.
3. Reposition the bracket and install the retainer (1). Tighten the retainer to 5 Nm (44 in. lbs.).
4. Install the push pin that secures the air scoop to the top of the radiator core support.
5. Connect inlet air temperature sensor harness connector (3).
6. Reconnect the air inlet hose to the throttle body, and tighten the clamp (1).
7. Connect negative battery cable.

Scheme 433

The aluminum alloy cylinder heads feature cross- flow type intake and exhaust ports. Valve guides and seat inserts are powdered metal. Valves are arranged in a "V", with each camshaft on center. To improve combustion speed the chambers are a compact spherical design with a squish area of approximately 30 percent of the piston top area. The cylinder heads are common to either cylinder bank by reversing the direction of installation.

Note. Camshafts are removed from the rear of each cylinder head.

Scheme 434

1. Remove the camshaft sprocket. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) .
2. Remove the rocker arm shaft assembly. See «Engine/Cylinder Head/ROCKER ARM, Valve - Disassembly»(ref-353585-S02717135972010011200000)
3. To remove the right camshaft, remove the EGR Valve assembly.
4. Remove the camshaft thrust plate (1) or (2).
5. Carefully remove the camshaft from the rear of the cylinder head.
6. NOTE: It may be necessary to remove the Powertrain Control Module (PCM) in order to remove the camshaft from the right cylinder head.

Scheme 435

1. Inspect camshaft bearing journals for damage and binding. If journals are binding, check the cylinder head for damage. Also check cylinder head oil holes for clogging.
2. Check the cam lobe and bearing surfaces for abnormal wear and damage. Replace camshaft if defective. NOTE: If camshaft is replaced due to lobe wear or damage, always replace the rocker arms.
3. Measure the lobe actual wear and replace camshaft if out of limit. Standard value is 0.0254 mm (0.001 in.), wear limit is 0.254 mm (0.010 in.).

Note. Care must be taken not to scrape or nick the camshaft journals when installing the camshaft into position.

1. Lubricate camshaft bearing journals, camshaft lobes and camshaft seal with clean engine oil and install camshaft into cylinder head.
2. Install the camshaft sprocket. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-353585-S01282825562010011200000)
3. Install the camshaft thrust plate (1) or (2). Clean the mating surfaces and apply the appropriate sealer as necessary. Torque fasteners to 28 N.m (250 in. lbs.).
4. If necessary, install the EGR Valve assembly and Powertrain Control Module (PCM).
5. Install the rocker arm assembly. See «Engine/Cylinder Head/ROCKER ARM, Valve - Installation»(ref-353585-S37836136412010011200000)

Scheme 436

1. Disconnect and isolate the negative battery cable. 1 - Ignition coil ELECTRICAL CONNECTORS 3 - PCV 2 - Engine harness retainer tabs 4 - BRACKET
2. Disconnect and remove the three ignition coils. Refer to «Electrical - Ignition Control/Ignition Control/COIL, Ignition - Removal»(ref-353602-S02693744302010011200000) .
3. Disconnect engine harness retaining clips (2) from cylinder head cover studs. Position the engine harness aside.
4. Disconnect the PCV hose (3) from the valve cover assembly (if required).
5. Completely loosen the eight cylinder head cover retaining bolts (4) and remove the cylinder head cover.

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Scheme 438

1. Clean cylinder head and all gasket sealing surfaces. Inspect and replace gasket and seals as necessary.
2. Using a suitable pry tool, carefully remove spark plug tube seals (2).
3. Position new seal with the part number on seal facing cylinder head cover. 1 - SPECIAL TOOL MD-998306 2 - SPARK PLUG TUBE SEAL
4. Install seals using Camshaft Installer MD-998306 (1). 1 - Ignition coil ELECTRICAL CONNECTORS 3 - PCV 2 - Engine harness retainer tabs 4 - BRACKET
5. Install cylinder head cover and bolts (4). Tighten to 10 N.m (90 in. lbs.).
6. Install the PCV hose (3) (if required).
7. Position the wiring harness on the cylinder head cover.
8. Reinstall the wire harness retainers (2) around the perimeter of the valve cover.
9. Install the ignition coils. Refer to «Electrical - Ignition Control/Ignition Control/COIL, Ignition - Installation»(ref-353602-S13852576352010011200000) .
10. Connect the ignition coil electrical connectors (1).
11. Connect negative battery cable.

Scheme 439

1. Disconnect the negative battery cable.
2. Remove the upper intake manifold from the engine. See «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353585-S41076526142010011200000) .
3. Cover lower intake manifold intake ports with a clean cover to prevent dirt or debris from entering the ports during service. 1 - ELECTRICAL CONNECTORS 2 - IGNITION COILS
4. Disconnect the ignition coil harness connectors (2).
5. Remove ignition coils. Refer to «Electrical - Ignition Control/Ignition Control/COIL, Ignition - Removal»(ref-353602-S02693744302010011200000) .
6. Disconnect the engine wiring harness retainers (1) from the valve cover.
7. Disconnect the makeup air hose (3).
8. Completely loosen the cylinder head cover retaining bolts (4) and remove the cylinder head cover.

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1. Clean cylinder head and cover mating surfaces. Inspect and replace gasket and seals as necessary.
2. Using a suitable pry tool, carefully remove tube seals (2).
3. Position new seal with the part number on seal facing cylinder head cover. 1 - SPECIAL TOOL MD-998306 2 - SPARK PLUG TUBE SEAL
4. Install seals using Camshaft Installer MD-998306 (1). 1 - ELECTRICAL CONNECTORS 2 - IGNITION COILS
5. Install cylinder head cover bolts (4) and tighten to 10 N.m (90 in. lbs.).
6. Reconnect the wire harness retainers (1) to the valve cover.
7. Install the ignition coils. Refer to «Electrical - Ignition Control/Ignition Control/COIL, Ignition - Installation»(ref-353602-S13852576352010011200000) .
8. Connect the ignition coil electrical connectors (2).
9. Reconnect the makeup air hose (3).
10. Install upper intake manifold. See «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353585-S07354684942010011200000) .
11. Connect negative battery cable.

Scheme 442

Rocker arms are made of light weight permanent mold aluminum alloy with a roller type follower operating against the camshaft. The valve actuating end of the rocker arms are machined to retain hydraulic lash adjusters, eliminating the need for manual valve lash adjustment.

Scheme 443

The rocker arm shafts are tubular steel and supported by several forged aluminum alloy pedestals, which are fastened to the cylinder head. Four shafts are used, one for each intake and exhaust rocker arm bank on each cylinder head. The shafts are hollow to provide a duct for lubricating oil flow from the cylinder head to the valve mechanisms. One hollow dowel per pedestal is used to locate the pedestal to the cylinder head, orient the exhaust rocker shaft, and serve as a cam bearing oil feed passage.

1. Perform the fuel pressure release procedure. Refer to «Fuel System/Fuel Delivery - Standard Procedure»(ref-353596-S39204571612010011200000) .
2. Disconnect the negative battery cable (1).
3. Drain cooling system. Refer to «Cooling - Standard Procedure»(ref-353584-S11330501202010011200000) .
4. Remove the engine cover.
5. Remove air cleaner element housing. See «Engine/Air Intake System/BODY, Air Cleaner - Removal»(ref-353585-S33364826632010011200000) .
6. Remove the coolant recovery container (1). Refer to «Cooling/Engine/BOTTLE, Coolant Recovery - Removal»(ref-353584-S00365192622010011200000) .
7. Remove the generator. Refer to «Electrical - Engine Systems/Charging/GENERATOR - Removal»(ref-353587-S16041187092010011200000) .
8. Disconnect the fuel line (1) at the fuel rail (2).
9. Remove the upper intake manifold (2). See «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353585-S41076526142010011200000) .
10. Remove the fuel rail. Refer to «Fuel System/Fuel Delivery/RAIL, Fuel - Removal»(ref-353596-S39190932472010011200000) .
11. Remove the lower intake manifold (1). See «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353585-S41076526142010011200000) .
12. Raise the vehicle.
13. Remove right exhaust manifold. See «Engine/Manifolds/MANIFOLD, Exhaust - Removal»(ref-353585-S14059952682010011200000) .
14. Remove right front tire.
15. Remove right inner splash shield.
16. Remove accessory drive belt (7).
17. Remove vibration damper (5). See «Engine/Engine Block/DAMPER, Vibration - Removal»(ref-353585-S37887033962010011200000) .
18. Remove lower accessory drive belt idler pulley (6).
19. Remove lower outer timing belt cover bolts.
20. Lower vehicle.
21. Remove the upper accessory drive belt idler pulley (2).
22. Remove the belt tensioner.
23. Support the engine with a block of wood and a floor jack.
24. Remove the upper engine mount. See «Engine/Engine Mounting/INSULATOR, Engine Mount - Removal»(ref-353585-S06981968532010011200000) .
25. Remove the power steering reservoir bolts and set reservoir aside.
26. Remove the remaining outer timing belt cover bolts and cover.
27. Remove the timing belt. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) .
28. Remove the right valve cover to cylinder head ground strap.
29. Remove the EGR valve (1) and tube assembly (2).
30. Remove the right cylinder head cover.
31. Remove the right rocker arm and shaft assembly (2). See «Engine/Cylinder Head/ROCKER ARM, Valve - Disassembly»(ref-353585-S02717135972010011200000) .
32. Counterhold the cam gear and loosen the right cam gear retaining bolt.
33. Remove the inner timing cover to right cylinder head retaining bolts.
34. Remove the right rear camshaft thrust plate (1).
35. Carefully push the camshaft out of the back of the cylinder head approximately 3.5 inches. Remove the camshaft sprocket and bolt.
36. NOTE: It may be necessary to raise the engine slightly in order to remove the camshaft sprocket bolt.
37. Remove the cylinder head bolts in REVERSE of tightening sequence. NOTE: Because of clearance restrictions when removing the right cylinder head, the front four cylinder head bolts must be loosened, raised and supported with rubber bands before the cylinder head can be removed.
38. Remove the cylinder head.
39. Clean and inspect all mating surfaces.

Scheme 444

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 right cylinder head. See «Engine/Cylinder Head - Installation»(ref-353585-S38825678362010011200000) .

1. Remove cylinder head(s). See «Engine/Cylinder Head - Removal»(ref-353585-S12478010902010011200000) .
2. Remove rocker arm assembly. See «Engine/Cylinder Head/ROCKER ARM, Valve - Removal»(ref-353585-S29730719562010011200000) .
3. Remove valve spring(s). See «Engine/Cylinder Head/SPRING(S), Valve - Removal»(ref-353585-S07894558082010011200000) .
4. Before removing valve, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location.
5. Remove valve(s) from cylinder head.

1. Position the flex plate (1) with backing plate (3) on the crankshaft.
2. Apply Mopar® Lock AND Seal Adhesive to the eight flex plate bolts (2).
3. Install the flex plate bolts (2). Tighten the bolts to 95 N.m (70 ft. lbs.).
4. Install the transaxle. Refer to «Transmission and Transfer Case/Automatic - 62TE - Installation»(ref-353619-S09372831292010011200000) . 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) .

Scheme 445

1. Remove the engine oil pan. See «Engine/Lubrication/PAN, Oil - Removal»(ref-353585-S23700294392010011200000) .
2. Lower the weight of the engine back onto the engine mounts. NOTE: Before separating the transmission from the engine, use an appropriate support fixture or lifting device to support the weight of the engine.
3. Remove transmission from vehicle.
4. Remove the flex plate.
5. Remove the rear crankshaft oil seal retainer bolts.
6. Remove the crankshaft oil seal and clean all mating surfaces.

Note. The rear crankshaft oil seal and retainer are an assembly. DO NOT separate the seal protector from the rear crankshaft oil seal before installation on engine. Damage to the seal lip will occur if the seal protector is removed and installed prior to installation on engine.

Scheme 446

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Scheme 449

1. Apply engine oil to crankshaft seal surface. 1 - SEAL PROTECTOR 2 - SEAL 3 - RETAINER
2. If the seal protector (1) is missing or was accidentally dislodged, go to step 3 . Otherwise, carefully position the oil seal retainer assembly (3), and seal protector (1) on crankshaft and push firmly into place on engine block (during this step, the seal protector will be pushed from the rear oil seal assembly as a result of installing the rear oil seal). Hand tighten the rear oil seal fasteners, and go to step 4 . NOTE: The seal lip (2) must always uniformly curl inward toward the engine on the crankshaft (1). CAUTION: If for any reason the installation sleeve is missing or dislodged from rear crankshaft oil seal prior to installation, the following procedure must be performed.
3. Using the chamfered seal guide from Special Tool 6926, insert the tapered end (1) into the transmission side of the rear crankshaft oil seal assembly (2), and push the seal guide through the seal assembly. This will ensure the seal lip is positioned toward the engine when the seal assembly is installed. When the seal lip is correctly positioned, go to step 2 . 1 - SEAL RETAINER 2 - SPECIAL TOOLS 8225 NOTE: The following steps must be performed to prevent oil leaks at sealing joints.
4. Attach Special Tools 8225 (1) to pan rail using the oil pan fasteners. NOTE: Special Tools 8225 (1), are use to assist with the fit of the flush mount rear main seal retainer. The notch on tool should be located away the seal retainer.
5. While applying firm pressure to the seal retainer against Special Tools 8225 (1), tighten seal retainer screws to 12 N.m (105 in. lbs.).
6. Remove special tool #8225 (1). NOTE: Make sure that the seal flange is flush with the block oil pan sealing surface.
7. Install oil pan. Tighten the 6 mm fasteners to 12 N.m (105 in. lbs.) and the 8 mm fasteners to 28 N.m (250 in. lbs.).
8. Install the flex plate and transmission.

Scheme 450

The piston rings include a moly-filled top ring with a symmetrical barrel face. The intermediate piston ring (2 and 3) is of the Micro-Napier design. The Micro-Napier design has a reduced "hook" on the running face, removes the need for chroming and improves oil economy. The oil control package consists of two steel rails and an expander spacer.

Scheme 451

Scheme 452

1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 in.) from bottom of cylinder bore. Check gap with feeler gauge (1). For clearance specifications. See «Engine - Specifications»(ref-353585-S22148766082010011200000) . 1 - FEELER GAUGE
2. Check piston ring to groove clearance (1). For clearance specifications. See «Engine - Specifications»(ref-353585-S22148766082010011200000) .

Scheme 453

1. Remove piston and connecting rod. See «Engine/Engine Block/ROD, Piston and Connecting - Removal»(ref-353585-S42560881032010011200000)
2. Remove No. 1 and No. 2 piston rings from piston using a ring expander tool.
3. Remove upper oil ring side rail.
4. Remove lower oil ring side rail.
5. Remove oil ring expander

Scheme 454

1. Measure clearance of piston rings to the cylinder bore and piston. See «Engine/Engine Block/RING(S), Piston - Standard Procedure»(ref-353585-S01385447832010011200000) The No. 1 and No. 2 piston rings have a different cross section. Ensure that which ever design No. 2 ring is installed, it is installed with manufacturers I.D. mark (dot) facing up, towards top of the piston. See «Engine/Engine Block/RING(S), Piston - Description»(ref-353585-S33028670932010011200000) . Do not use a piston ring expander during this step. Oil ring expander. Lower oil ring side rail. Upper oil ring side rail. No. 2 Intermediate piston ring. No. 1 Upper piston ring.
2. Install the side rail (1) by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position.
3. Install upper side rail first and then the lower side rail.
4. Install the No. 2 piston ring and then No. 1 piston ring.
5. Position piston ring end gaps.
6. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control.

1. Position mount isolator (3) in place, install bolts (1, 2) and tighten to 50 N.m (37 ft. lbs.).
2. Raise transaxle into position, install bolts (2) and tighten to 98 N.m (72 ft. lbs.).
3. Remove floor jack and wooden block.
4. Install belly pan (2).
5. Install the air cleaner housing assembly (4). See «Engine/Air Intake System/BODY, Air Cleaner - Removal»(ref-353585-S33364826632010011200000)
6. Connect negative battery cable.

1. Remove the belly pan (2).
2. Lower vehicle. Remove the load on the engine motor mounts by carefully supporting the engine assembly from below.
3. Remove Power Steering Fluid Reservoir and set aside. Refer to «Steering/Pump/RESERVOIR, Power Steering Pump - Removal»(ref-353572-S33306709172010011200000) .
4. Disconnect the ground strap.
5. Remove the right engine support bracket vertical fasteners (1) and (2) and remove support bracket (3).
6. Remove the bolts (5) attaching the right isolator (4) to the frame rail.
7. Remove right isolator (4).

1. Position right isolator (4) and install the isolator to frame rail bolts (5). Tighten bolts to 55 N.m (40 ft. lbs.).
2. Install the engine support bracket (3) and bolts (1). Tighten bolts to 50 N.m (37 ft. lbs).
3. Install the support bracket to isolator nuts (2) and tighten to 30 N.m (22 ft. lbs).
4. Reconnect the ground strap.
5. Raise vehicle on a hoist.
6. Install the belly pan (2).
7. Install power steering reservoir. Refer to «Steering/Pump/RESERVOIR, Power Steering Pump - Installation»(ref-353572-S36247969102010011200000) .

Scheme 455

1. Remove the three top mount bracket bolts (1) and one side mount bracket bolt.
2. Raise the vehicle.
3. Remove the belly pan (2).
4. Remove rear mount bracket through bolt.
5. Remove rear mount bracket from transaxle case.
6. Remove the four rear isolator to suspension crossmember attaching bolts (2).
7. Remove rear isolator (3).

1. Position rear isolator (3).
2. Install the four rear isolator to suspension crossmember attaching bolts (2) and tighten to 50 N.m (37 ft. lbs.).
3. Install the belly pan (2).
4. Lower the vehicle.
5. Position the rear mount bracket on the transaxle case.
6. Install three top mount bracket bolts (1) and one side mount bracket bolt. Tighten bolts to 88 N.m (65 ft. lbs.).
7. Install rear mount bracket through bolt. Tighten to 75 N.m (55 ft. lbs.).

1. Remove the belly pan (2).
2. Remove the Power Transfer Unit (PTU). Refer to «Transmission and Transfer Case/Power Transfer Unit - Removal»(ref-353620-S28539122802010011200000) .
3. Remove the 3 top mount bracket bolts (1).
4. Remove the 4 lower mount to cradle bolts (2).
5. Remove rear mount (3).

1. Position rear mount (3).
2. Install the 4 lower mount to cradle bolts (2) and torque to 50 N.m (37 ft. lbs.).
3. Install 3 top mount bracket bolts and torque 50 N.m (37 ft. lbs.).
4. Install the Power Transfer Unit (PTU). Refer to «Transmission and Transfer Case/Power Transfer Unit - Installation»(ref-353620-S05433498112010011200000) . 1 - belly pan fasteners 2 - belly pan
5. Install the belly pan (2).

1. Raise vehicle. 1 - belly pan fasteners 2 - belly pan
2. Remove the belly pan (2).
3. Remove fore aft member (3) to mount (4) bolts.
4. Remove mount through bolt (1).
5. Remove fore aft member (3) mounting bolts and remove.
6. Remove front mount (4).

Scheme 456

1. Position mount (4) and torque bolts to 47 N.m (35 ft. lbs.).
2. Install fore aft member (3) and torque bolts to 100 N.m (74 ft. lbs.).
3. Install mount through bolt (1) and torque to 47 N.m (35 ft. lbs.). 1 - belly pan fasteners 2 - belly pan
4. Install the belly pan (2).
5. Lower vehicle.

Scheme 457

The oil lubrication system is a full-flow filtration, pressure feed type. The oil pump body (7) is mounted to the engine block. The pump inner rotor (3) is driven by the crankshaft (1). A windage tray, increases engine power by minimizing oil windage at high engine RPM. For increased engine oil cooling, an engine oil-to-engine coolant oil cooler is used.

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.

1. Wipe base clean, then inspect gasket contact surface.
2. Lubricate gasket of new filter with clean engine oil.
3. Install and tighten oil filter (2) to 16 N.m (12 ft. lbs.) of torque after gasket contacts base. Use filter wrench if necessary.
4. Start engine and check for leaks.

It is necessary to remove the oil pump body to service the oil pump rotors.

The oil pump pressure relief valve can be serviced by removing the oil pan. See Engine/Lubrication/VALVE, Oil Pressure Relief - Removal

1. Drain the cooling system. Refer to «Cooling - Standard Procedure»(ref-353584-S11330501202010011200000) .
2. Remove the timing belt. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) .
3. Remove the crankshaft sprocket. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) .
4. Remove the oil pan. See «Engine/Lubrication/PAN, Oil - Removal»(ref-353585-S23700294392010011200000) .
5. Remove the oil pickup tube.
6. Remove the oil pump fasteners. Remove pump and gasket from engine.

Scheme 458

1. To remove the relief valve (1), proceed as follows
2. Drill a 3.175 mm (1/8 inch.) hole into the relief valve retainer cap (3) and insert a self-threading sheet metal screw into cap (3).
3. Clamp screw into a vise and while supporting oil pump body, remove cap by tapping oil pump body using a soft hammer. Discard retainer cap (3) and remove spring (2) and relief valve (1).
4. Remove oil pump cover screws, and lift off cover.
5. Remove pump rotors.
6. Wash all parts in a suitable solvent and inspect carefully for damage or wear.

Note. Thoroughly clean all bolt threads and threaded area in the engine, removing all oil residue, before assembly.

Scheme 459

1. Prime oil pump before installation by filling rotor cavity with clean engine oil.
2. Install oil pump and gasket carefully over the crankshaft and position pump onto block. NOTE: DO NOT apply the thread sealant to the underside of the bolt head.
3. Apply Mopar Thread Sealant as directed on the package to the oil pump cover bolts where indicated. The sealant must be applied from the tip to approximately 10 mm of the thread length. Tighten the oil pump cover bolts to 12 N.m (105 in. lbs.). Tighten oil pump to block bolts to 28 N.m (250 in. lbs.) 1 - SEALANT APPLICATION LOCATION
4. Install new O-ring on oil pickup tube.
5. Install oil pickup tube.
6. Install oil pan. See «Engine/Lubrication/PAN, Oil - Installation»(ref-353585-S21699418692010011200000)
7. Install crankshaft sprocket. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-353585-S01282825562010011200000)
8. Install timing belt. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-353585-S01282825562010011200000) .
9. Install the timing belt covers. See «Engine/Valve Timing/COVER(S), Engine Timing - Installation»(ref-353585-S10337911082010011200000) .
10. Install the crankshaft vibration damper. See «Engine/Engine Block/DAMPER, Vibration - Installation»(ref-353585-S12546785922010011200000)
11. Install the accessory drive belts. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-353584-S15414070972010011200000) .
12. Fill the cooling system. Refer to «Cooling - Standard Procedure»(ref-353584-S11330501202010011200000) .
13. Fill engine crankcase with proper oil to the correct level.

Scheme 460

1. Raise vehicle on hoist.
2. Position an oil collecting container under switch location.
3. Disconnect electrical connector (1).
4. Remove the oil pressure switch (2).

1. Apply Mopar® Thread Sealant to the switch threads.
2. Install oil pressure switch (2).
3. Connect electrical connector (1).
4. Lower vehicle.
5. Start engine and check for leaks.
6. Check engine oil level and adjust as necessary.

Scheme 461

1. Remove the oil pan. See «Engine/Lubrication/PAN, Oil - Removal»(ref-353585-S23700294392010011200000)
2. To remove the relief valve, proceed as follows: Remove the cotter pin that retains the retainer cap. Drill a 3.175 mm (1/8 inch.) hole into the relief valve retainer cap Insert a self-threading sheet metal screw into cap. Using a suitable slide hammer tool, remove retainer cap. Discard retainer cap Remove spring (2) and relief valve (1).

1. Lubricate relief valve (1) with oil. CAUTION: The pressure relief valve must be installed see scheme 379or engine damage may occur.
2. Install valve (1), spring (2) and retainer cap.
3. Install new cotter pin (4).
4. Install the oil pan. See «Engine/Lubrication/PAN, Oil - Installation»(ref-353585-S21699418692010011200000)

Scheme 462

Scheme 463

Scheme 464

1. Disconnect and isolate the negative battery cable.
2. Remove the fasteners (1), and remove the upper heat shield (2).
3. Loosen the oil level indicator tube retaining bolt (3) and position the dipstick tube (2) aside. 1 - belly pan fasteners 2 - belly pan
4. Remove the 12 belly pan fasteners (1) and remove the belly pan (2).
5. Remove the left maniverter-to-crossunder pipe fasteners (1).
6. Disconnect the harness connector (1) and remove the front lower maniverter oxygen sensor (2).
7. Disconnect the harness connector (3) and remove the front upper maniverter oxygen sensor (4).
8. Remove the maniverter retaining bolts (1), the maniverter (2), and gasket (3).

Scheme 465

1. Inspect exhaust maniverters for damage or cracks.
2. Check maniverter mounting surface flatness.
3. Inspect the exhaust manifold gasket for obvious discoloration or distortion.
4. Check distortion of the cylinder head mounting surface with a straightedge and thickness gauge.

INSTALLATION - FRONT EXHAUST MANIVERTER

1. Position the maniverter (2) and gasket (3). Install the retaining bolts (1). Tighten bolts starting at the center working outward to 23 N.m (200 in. lbs.).
2. Install the upper heat shield (2), and torque nuts (1) to 12 Nm (105 in. lbs).
3. Install the oil level indicator tube (2) and the retaining bolt (3).
4. Install the left upstream oxygen sensor (4) and connect the harness connector (3).
5. Install the left downstream oxygen sensor (2) and connect the harness connector (1).
6. Install the left maniverter cross under pipe retaining bolts (1). Tighten bolts to 31 N.m (275 in. lbs.). 1 - belly pan fasteners 2 - belly pan
7. Install the belly pan (2) and the 12 belly pan fasteners (1).
8. Connect the negative battery cable. Refer to «Electrical - Engine Systems/Battery System - Standard Procedure»(ref-353573-S31396964802010011200000) .

Scheme 466

Scheme 467

1. Disconnect and isolate the negative battery cable.
2. Raise and support the vehicle. Refer to «Vehicle Quick Reference/Hoisting - Standard Procedure»(ref-353564-S41400590852010011200000) .
3. Remove twelve belly pan fasteners (1) and remove the belly pan (2).
4. Remove the right front tire and wheel assembly. Refer to «Tires and Wheels - Removal»(ref-353565-S27075249612010011200000) .
5. Remove the exhaust extension pipe (1). Refer to «Exhaust System/PIPE, Exhaust - Removal»(ref-353615-S42767550362010011200000) .
6. Remove the exhaust crossunder pipe (3). Refer to «Exhaust System/PIPE, Exhaust Crossunder - Removal»(ref-353615-S40083911602010011200000) .
7. Disconnect harness connectors (1) and (3). Remove the right maniverter downstream (2) and upstream (4) oxygen sensors. Refer to «Fuel System/Fuel Injection/SENSOR, Oxygen - Removal»(ref-353596-S07107949952010011200000) .
8. Remove heat shield retainers (1), (2), and (3) and remove the upper heat shield (4).
9. Remove the right maniverter retaining bolts (5) and remove the right maniverter (6) and gasket (8).

Scheme 468

Scheme 469

1. Disconnect and isolate the negative battery cable.
2. Raise and support the vehicle. Refer to «Vehicle Quick Reference/Hoisting - Standard Procedure»(ref-353564-S41400590852010011200000) .
3. Remove twelve belly pan fasteners (1) and remove the belly pan (2).
4. Remove the right front tire and wheel assembly. Refer to «Tires and Wheels - Removal»(ref-353565-S27075249612010011200000) .
5. Remove the exhaust extension pipe (1). Refer to «Exhaust System/PIPE, Exhaust - Removal»(ref-353615-S42767550362010011200000) .
6. Remove the exhaust crossunder pipe (3). Refer to «Exhaust System/PIPE, Exhaust Crossunder - Removal»(ref-353615-S40083911602010011200000) .
7. Disconnect harness connectors (1) and (3). Remove the right maniverter downstream (2) and upstream (4) oxygen sensors. Refer to «Fuel System/Fuel Injection/SENSOR, Oxygen - Removal»(ref-353596-S07107949952010011200000) .
8. Remove heat shield retainers (1), (2), and (3) and remove the upper heat shield (4).
9. Remove the right half shaft and intermediate shaft (4). Refer to «Differential and Driveline/Intermediate Shaft - Removal»(ref-353569-S35238813682010011200000) .
10. Remove the maniverter retaining bolts (5).
11. Reposition the maniverter to allow removal of the lower maniverter heatshield (2).
12. Remove the lower maniverter heat shield retainers (1) and remove the lower maniverter heat shield (2).
13. Remove the maniverter and gasket from the vehicle.

INSTALLATION - REAR EXHAUST MANIVERTER, FWD

1. Clean the right maniverter gasket sealing surfaces with an appropriate tool. See «Engine - Standard Procedure»(ref-353585-S16993374792010011200000) .
2. Position the right maniverter (6) and gasket (8). Install the retaining bolts (5) and tighten the bolts starting at the center working outward to 23 N.m (200 in. lbs.).
3. Install the right maniverter upper heat shield (4) with heat shield retainers (1), (2), and (3).
4. Install the right maniverter upstream (4) and downstream (2) oxygen sensors and reconnect the harness connectors (1) and (3). Refer to «Fuel System/Fuel Injection/SENSOR, Oxygen - Installation»(ref-353596-S41267639742010011200000) .
5. Install the exhaust crossunder pipe (3). Refer to «Exhaust System/PIPE, Exhaust Crossunder - Installation»(ref-353615-S30669991642010011200000) .
6. Install the exhaust extension pipe (1). Refer to «Exhaust System/PIPE, Exhaust - Installation»(ref-353615-S06328638972010011200000) .
7. Install the right front tire and wheel assembly. Refer to «Tires and Wheels - Installation»(ref-353565-S19491247132010011200000) .
8. Install the belly pan (2) and the twelve belly pan fasteners (1).
9. Lower the vehicle.
10. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

INSTALLATION - REAR EXHAUST MANIVERTER, AWD

1. Clean the right maniverter gasket sealing surfaces with an appropriate tool. See «Engine - Standard Procedure»(ref-353585-S16993374792010011200000) .
2. Place the right maniverter in the engine compartment and position to allow installation of the maniverter lower heatshield (2).
3. Install the right maniverter lower heat shield (2) with heat shield retainers (1).
4. Install the right maniverter (6) and gasket (8) with retaining bolts (5). Tighten the bolts starting at the center working outward to 23 N.m (200 in. lbs.).
5. Install the right maniverter upper heat shield (4) with heat shield retainers (1), (2), and (3).
6. Install the intermediate shaft (4) and right half shaft. Refer to «Differential and Driveline/Intermediate Shaft - Installation»(ref-353569-S09121150582010011200000) .
7. Install the right maniverter upstream (4) and downstream (2) oxygen sensors and reconnect the harness connectors (1) and (3). Refer to «Fuel System/Fuel Injection/SENSOR, Oxygen - Installation»(ref-353596-S41267639742010011200000) .
8. Install the exhaust crossunder pipe (3). Refer to «Exhaust System/PIPE, Exhaust Crossunder - Installation»(ref-353615-S30669991642010011200000) .
9. Install the exhaust extension pipe (1). Refer to «Exhaust System/PIPE, Exhaust - Installation»(ref-353615-S06328638972010011200000) .
10. Install the right front tire and wheel assembly. Refer to «Tires and Wheels - Installation»(ref-353565-S19491247132010011200000) .
11. Install the belly pan (2) and the twelve belly pan fasteners (1).
12. Lower the vehicle.
13. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 470

Scheme 471

Scheme 472

Scheme 473

1. Remove engine cover.
2. Disconnect negative battery cable.
3. Remove air cleaner housing (4) and inlet hose (1). See «Engine/Air Intake System/BODY, Air Cleaner - Removal»(ref-353585-S33364826632010011200000) .
4. Disconnect the EGR tube. Refer to «Emissions Control/Exhaust Gas Recirculation/VALVE, Exhaust Gas Recirculation (EGR) - Removal»(ref-353616-S04989213572010011200000) .
5. Disconnect the following vacuum hoses from the upper intake manifold: Positive Crankcase Ventilation (PCV) Valve (1) EVAP Purge Solenoid (2) EGR Tube (3) Power Brake Booster (4)
6. Disconnect electrical connectors from the following sensors and actuators: Manifold Tuning Valve (MTV) (1) Short Runner Valve (2) Throttle Position Sensor (TPS) (3) Manifold Absolute Pressure (MAP) (4)
7. Remove the Manifold Tuning Valve (5), then Remove the 2 nuts (1) and (2) from the rear intake manifold brackets.
8. Loosen the 2 bolts (3) and (4) from rear intake manifold brackets and position brackets aside.
9. Remove the 7 upper intake manifold retaining bolts (1) and the upper intake manifold (2). Clean all gasket sealing surfaces.

Scheme 474

Scheme 475

1. Disconnect the negative battery cable (1).
2. Perform fuel pressure release procedure. Refer to «Fuel System/Fuel Delivery - Standard Procedure»(ref-353596-S39204571612010011200000) .
3. Drain the cooling system. Refer to «Cooling - Standard Procedure»(ref-353584-S11330501202010011200000) .
4. Disconnect the upper radiator hose (1) from the thermostat housing (2).
5. Remove the upper intake manifold. See «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353585-S41076526142010011200000) .
6. Disconnect the electrical connectors to fuel injectors and coolant temperature sensor.
7. Disconnect heater supply and return hoses from the thermostat housing.
8. Disconnect the fuel line from the fuel rail.
9. Remove the 4 bolts attaching fuel rail.
10. Remove fuel rail and injectors as an assembly.
11. Remove lower intake 4 bolts and position the ignition coil capacitor aside. 1 - LOWER INTAKE MANIFOLD 2 - GASKET
12. Remove the lower intake manifold (1).

Scheme 476

1. Clean all sealing surfaces.
2. Position new gaskets and intake manifold on cylinder head surfaces.
3. Position the ignition coil capacitor and install the intake manifold bolts. Gradually tighten in sequence shown in illustration until a torque of 28 N.m (250 in. lbs.) is obtained.
4. Install fuel rail and injectors as an assembly.
5. Connect fuel supply hose to fuel rail.
6. Connect heater supply and return hoses to the intake manifold.
7. Connect electrical connectors to fuel injectors and coolant temperature sensor.
8. Install upper intake manifold. See «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353585-S07354684942010011200000) .
9. Connect upper radiator hose to thermostat housing.
10. Fill cooling system. Refer to «Cooling - Standard Procedure»(ref-353584-S11330501202010011200000) .
11. Connect negative battery cable. Refer to «Electrical - Engine Systems/Battery System - Standard Procedure»(ref-353573-S31396964802010011200000) .

INSTALLATION - UPPER INTAKE MANIFOLD

1. Clean and inspect gasket sealing surfaces.
2. Position new gasket.
3. Install the throttle body on the upper intake (if required). Refer to «Fuel System/Fuel Injection/THROTTLE BODY - Installation»(ref-353596-S26476637112010011200000) .
4. Install upper intake manifold (2) and hand start all attaching bolts (1).
5. Tighten bolts gradually starting in the center working outward until a torque of 12 N.m (105 in. lbs.) is obtained.
6. Install the rear intake manifold brackets to the head.
7. Install the 2 intake manifold to bracket nut retainers.
8. Install the EGR tube. Refer to «Emissions Control/Exhaust Gas Recirculation/VALVE, Exhaust Gas Recirculation (EGR) - Installation»(ref-353616-S23642339572010011200000) .
9. Connect electrical connectors to the following sensors and actuators: Manifold Tuning Valve (MTV) (1) Short Runner Valve (2) Throttle Position Sensor (TPS) (3) Manifold Absolute Pressure (MAP) (4)
10. Connect the following vacuum hoses to the upper intake manifold: Positive Crankcase Ventilation (PCV) Valve (1) EVAP Purge Solenoid (2) EGR Tube (3) Power Brake Booster (4)
11. Install air cleaner housing (4) and inlet hose (1). See «Engine/Air Intake System/BODY, Air Cleaner - Installation»(ref-353585-S19816332302010011200000) .
12. Connect negative battery cable. Refer to «Electrical - Engine Systems/Battery System - Standard Procedure»(ref-353573-S31396964802010011200000) .
13. Install the engine cover.

Scheme 477

The timing drive system has been designed to provide quiet performance and reliability to support a NON free-wheeling engine.

The timing drive components include a crankshaft sprocket, camshaft sprockets, tensioner pulley, hydraulic tensioner and a timing belt. The water pump is driven by the back side of the timing belt. The right and left camshaft sprockets are keyed and not interchangeable because of the cam sensor pick-up wheel on the left sprocket.

1. Perform fuel pressure release procedure. Refer to «Fuel System/Fuel Delivery - Standard Procedure»(ref-353596-S39204571612010011200000) .
2. Disconnect negative battery cable.
3. Raise the vehicle.
4. Remove the accessory drive belt. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353584-S03638748182010011200000) .
5. Remove accessory drive belt tensioner.
6. Remove bolts for power steering pump. Reposition power steering pump aside.
7. Remove crankshaft damper. See «Engine/Engine Block/DAMPER, Vibration - Removal»(ref-353585-S37887033962010011200000) . 1 - RIGHT SIDE COVER (STAMPED) 2 - LEFT SIDE COVER (CAST) 3 - LOWER COVER
8. Remove the lower front timing belt cover fasteners.
9. Lower the vehicle.
10. Support the engine with a floor jack.
11. Remove the front engine mount. See «Engine/Engine Mounting/INSULATOR, Engine Mount - Removal»(ref-353585-S06981968532010011200000) .
12. Disconnect the fuel supply line at the fuel rail.
13. Remove the upper timing belt cover bolts and remove front timing belt cover. See «Engine/Air Intake System/BODY, Air Cleaner - Removal»(ref-353585-S33364826632010011200000) .

Note. The timing cover bolts and both holes to the engine block must be thoroughly cleaned and free of oil residue before assembly. IN ADDITION, add thread sealant to the timing cover bolts that mount to the oil pump. See Engine/Lubrication/PUMP, Engine Oil - Installation .

1. Install front timing belt cover.
2. Install the upper engine mount. See «Engine/Engine Mounting/INSULATOR, Engine Mount - Installation»(ref-353585-S23138984702010011200000) .
3. Connect fuel supply line at fuel rail.
4. Raise the vehicle. 1 - GENERATOR 2 - IDLER PULLEY 3 - POWER STEERING PUMP 4 - A/C COMPRESSOR 5 - CRANKSHAFT PULLEY 6 - TENSIONER
5. Install power steering pump fasteners. Tighten bolts to 23 N.m (200 lbs. in.).
6. Install crankshaft damper. See «Engine/Engine Block/DAMPER, Vibration - Installation»(ref-353585-S12546785922010011200000) .
7. Install accessory drive belt tensioner. Torque fastener to 28 N.m (250 in. lbs.).
8. Install accessory drive belt. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-353584-S15414070972010011200000) .
9. Lower the vehicle.
10. Connect negative battery cable.

Scheme 478

Scheme 479

1. Perform fuel pressure release procedure. Refer to «Fuel System/Fuel Delivery - Standard Procedure»(ref-353596-S39204571612010011200000) .
2. Disconnect the negative battery cable.
3. Remove timing belt. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) .
4. Remove camshaft sprockets. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) . 1 - M8 FASTENERS (APPLY THREAD SEALANT) 2 - M10 FASTENERS 3 - M6 FASTENERS 4 - REAR TIMING BELT COVER 5 - M10 FASTENERS (STUD/NUT)
5. Remove rear timing belt cover bolts.
6. Remove the rear cover. NOTE: The rear timing belt cover has O-rings to seal the water pump passages to cylinder block. Do not reuse the O-rings.

Scheme 480

1. Clean rear timing belt cover O-ring sealing surfaces and grooves. Lubricate new O-rings with Mopar® Dielectric Grease or equivalent to facilitate assembly.
2. Position NEW O-rings on cover. 1 - M8 FASTENERS (APPLY THREAD SEALANT) 2 - M10 FASTENERS 3 - M6 FASTENERS 4 - REAR TIMING BELT COVER 5 - M10 FASTENERS (STUD/NUT)
3. Install rear timing belt cover. Tighten bolts to the following specified torque: M10-54 N.m (40 ft. lbs.) M8-28 N.m (20 ft. lbs.) M6-12 N.m (105 in. lbs.)
4. Install camshaft sprockets. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-353585-S01282825562010011200000) .
5. Install timing belt. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-353585-S01282825562010011200000) .

Scheme 481

1. For timing belt tensioner removal procedure. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) .

Scheme 482

1. Remove the timing belt. See «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-353585-S15566303662010011200000) .
2. Remove the timing belt tensioner pulley and bracket assembly by unscrewing the pivot bolt from the oil pump housing.

Scheme 483

1. Inspect hydraulic tensioner for fluid loss around the plunger seal. Replace tensioner if leaking.