4.0L Engine - Service Information: Other Dodge Nitro I

ENGINE MECHANICAL

ENGINE PERFORMANCE

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.

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 is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.

HYDROSTATIC LOCKED ENGINE

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.

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 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

1. Perform the fuel pressure release procedure. Refer to «STANDARD PROCEDURE»(ref-306144-S17322326742008120900000).
2. Disconnect negative battery cable (2).
3. Evacuate the air conditioning system. Refer to «STANDARD PROCEDURE»(ref-306135-S14322548632008120900000).
4. Remove the hood.
5. Drain the cooling system (Refer to «STANDARD PROCEDURE»(ref-306154-S25259837052008120900000) ).
6. Disconnect the lower radiator hose.
7. Disconnect the generator electrical connectors (2) (Refer to «REMOVAL»(ref-306161-S35576092952008120900000) ).
8. Remove the starter wiring (2).
9. Remove the starter (1) and spacer plate (Refer to «REMOVAL»(ref-306163-S04724120662008120900000) ).
10. Remove the A/C lines (1,3).
11. Disconnect the oil cooler hose (3) at the oil cooler.
12. Disconnect the oil cooler hose (2) at the oil cooler.
13. Disconnect the ground strap (1) at the right transmission housing.
14. Disconnect the engine block heater wiring connector and set aside (if equipped).
15. Remove the crankshaft position sensor (2) (Refer to «REMOVAL»(ref-306144-S01067994792008120900000) )
16. Disconnect the left oxygen sensor electrical connector and separate the exhaust manifold from the left exhaust pipe (1).
17. Disconnect the right oxygen senor electrical connector and separate the exhaust manifold from the right exhaust pipe (2).
18. Remove the flex plate access plate (1).
19. Remove the P/S pump (2).
20. Remove the torque converter bolts (2).
21. Remove the transmission housing to engine mounting bolts (2).
22. Remove the engine mounting to frame fasteners (1).
23. Remove the upper intake manifold (Refer to «REMOVAL»(ref-306143-S33795118172008120900000) ).
24. Disconnect the heater hose.
25. Disconnect the coolant temperature, cam position (1), oil pressure sensor electrical connectors. 1 - Electrical Connector 2 - Mounting Bolt 3 - Coil
26. Disconnect the left ignition coil (1) and fuel injector harness connectors and position the wiring harness aside.
27. Remove the right intake manifold support braces.
28. Disconnect the capacitor and ground strap from the right cylinder head cover. 1 - Electrical Connector 2 - Mounting Bolt 3 - Coil
29. Disconnect the oxygen sensor, knock, EGR, injector and ignition coil harness connectors (1) and position the wiring harness aside.
30. Disconnect the engine wiring harness from the transmission housing and remove the remaining transmission housing bolts. 1 - LIFTING CHAIN 2 - ENGINE LIFTING BRACKET #8534 3 - CAM POSITION SENSOR 4 - EGR VALVE 5 - BOLTS 6 - COOLANT PIPE
31. Connect the engine lifting bracket (2) from special tool kit 8534B to the right rear of the cylinder head outer most bolt access hole (5). (Scheme 242)
32. Install a bolt into the inner most bolt access hole (5) next to the engine lift bracket to assure lifting bracket positioning. 1 - LIFTING CHAIN 2 - UPPER TIMING CHAIN COVER 3 - POWER STEERING PUMP 4 - THERMOSTAT HOUSING
33. Connect a engine hoisting chain (1) to the left timing chain cover (2) engine lifting point and engine lift bracket. (Scheme 243) CAUTION: While slowly separating the engine from the vehicle, constant checks must be made to assure proper positioning and that no damage to other components or wiring harnesses occur during separation.
34. Carefully remove the engine from the engine bay area.

CYLINDER HEAD

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.

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

COOLING SYSTEM TESTER METHOD

Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester's pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.

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 STANDARD PROCEDURE . Be careful not to gouge or scratch the aluminum head sealing surface.

Clean all engine oil passages.

Scheme 244

1. Before cleaning, check for leaks, damage and cracks.
2. Clean cylinder head and oil passages.
3. Check cylinder head for flatness. (Scheme 244)
4. Cylinder head must be flat within: Standard dimension = less than 0.05 mm (0.002 inch.) Service Limit = 0.2 mm (0.008 inch.) Grinding Limit = Maximum of 0.2 mm (0.008 inch.) is permitted.

Scheme 245

Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

1. Check cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced. CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper.
2. Clean sealing surfaces of cylinder head and block. See «STANDARD PROCEDURE»(ref-306143-S18889717392008120900000) .
3. Install camshaft (5) in cylinder head. CAUTION: THE CYLINDER HEAD GASKETS ARE NOT INTERCHANGEABLE BETWEEN CYLINDER HEADS AND ARE CLEARLY MARKED RIGHT OR LEFT. CAUTION: Ensure that the correct head gaskets are used and are oriented correctly on cylinder block.
4. Push camshaft (5) out of the back of the cylinder head approximately 3.5 inches. Install head gasket and cylinder head over locating dowels. NOTE: Before installing the cylinder head bolts, lubricate the threads with clean engine oil.
5. Install and finger tighten eight head bolts (2).
6. Tighten the cylinder head bolts in the following sequence, using the 4 step torque-turn method. Tighten according to the following torque values: 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.
8. Install three inner timing cover to cylinder head bolts (1). Tighten bolts to 54 N.m (40 ft. lbs.). CAUTION: The camshaft sprockets are keyed and not interchangeable from side to side because of the camshaft position sensor pick-up.
9. Push the camshaft back into the cylinder head and install the camshaft sprocket (2).
10. Install NEW sprocket attaching bolt into place. The 255 mm (10 in.) bolt is to be installed in the left camshaft and the 213 mm (8 3/8 in.) bolt is to be installed into the right camshaft. Counterhold the camshaft sprocket (2) and tighten the camshaft sprocket bolt to 102 N.m (75 ft. lbs.) plus a 90° turn.
11. Install the camshaft thrust plate (1) and gasket (3). Tighten three bolts (2) to 28 N.m (250 in. lbs.).
12. Install new gasket between EGR solenoid/valve (2) and rear of cylinder head (1).
13. Position EGR solenoid/valve assembly to rear of cylinder head. Install and tighten two mounting bolts (6) to 8 N.m (80 in. lbs.).
14. Rotate the right camshaft gear (2) to align its timing mark (1). Verify that the left camshaft gear (7) timing mark (8) and crankshaft gear (10) timing mark (9) are still aligned.
15. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley (11).
16. Holding the tensioner pulley (11) against the belt, install the tensioner (12) into the housing and tighten two bolts to 28 N.m (250 in. lbs.). Each camshaft sprocket mark should remain aligned with the cover marks.
17. When tensioner is in place pull retaining pin to allow the tensioner to extend to the tensioner pulley bracket.
18. Rotate crankshaft sprocket two revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. If marks do not line up, repeat procedure. NOTE: With the camshaft gears in these positions the lobes are in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it.
19. Install the rocker arm and shaft assembly (2) and ten bolts making sure that the identification marks face toward the front of engine for left head and toward the rear of the engine for right head.
20. Tighten the ten rocker arm/shaft assembly bolts in sequence to 31 N.m (275 in. lbs.).
21. Clean cylinder head and cover mating surfaces. Inspect and replace gasket (1) and seals (2) as necessary. See «INSTALLATION»(ref-306143-S37027035352008120900000) .
22. Install cylinder head cover and eight bolts. Tighten bolts to 12 N.m (105 in. lbs.).
23. Install the spark plugs. Tighten to 28 N.m (20 ft. lbs.). Refer to «INSTALLATION»(ref-306179-S30660777572008120900000) .
24. Install ignition coils (3) into cylinder head.
25. Install and tighten coil mounting bolts (2) to 6.7 N.m (60 in. lbs.).
26. Reposition engine wire harness and install retainers to cylinder head cover. Connect and lock electrical connectors to ignition coils (1), capacitor and EGR valve.
27. Reposition engine wire harness, connect and lock electrical connectors to PCM (1), body harness (3), A/C high pressure switch (2) and A/C compressor clutch.
28. Connect the front exhaust pipe to exhaust manifold (2). Tighten the fasteners (3) to 34 N.m (300 in. lbs.).
29. Reposition oil cooler hose retainer bracket (1) near timing belt tensioner and install bolt (2).
30. Install the front timing belt outer cover (1) and 14 bolts.
31. Tighten the timing cover bolts as follows: M6 bolts - 12 N.m (105 in. lbs.) M8 bolts - 28 N.m (250 in. lbs.) M10 bolts - 54 N.m (40 ft. lbs.)
32. Install crankshaft damper using Special Tools C-4685-C1 (5.9 in.) Bolt (2), with Nut and Thrust Bearing from 6792, and 6792-1 Installer (1).
33. Install crankshaft damper bolt (3). Tighten bolt to 95 N.m (70 ft. lbs.) while holding damper (1) with Special Tool 9365 (2).
34. Install the accessory drive bracket (2). Tighten four bolts (1) and nut (3) to 54 N.m (40 ft. lbs.).
35. Install the lower stud (3) and upper stud (5) that secures the front of the A/C compressor to the accessory drive bracket. Tighten studs securely.
36. Install the lower nut (4) and upper nut (6) that secures the front of the A/C compressor to the accessory drive bracket. Tighten nuts to 28 N.m (21 ft. lbs.).
37. Position generator (1) to engine and install two mounting bolts (2) and (3). Tighten both bolts to 57 N.m (42 ft. lbs.).
38. Snap field wire connector into rear of generator.
39. Install B+ terminal and nut to generator mounting stud. Tighten nut to 13 N.m (115 in. lbs.)
40. Snap plastic protective cover to B+ terminal.
41. Install the power steering belt (1). Refer to «INSTALLATION»(ref-306154-S38527570572008120900000) .
42. Install the accessory drive belt (7). Refer to «INSTALLATION»(ref-306154-S38527570572008120900000) .
43. Using Tool 6958, install the fan blade/viscous fan drive assembly. Tighten mounting nut to 50 N.m (37 ft. lbs.).
44. Install electric fan shroud with two screws (1). Tighten screws to 6 N.m (50 in. lbs.).
45. Connect and lock the electric fan connector (2).
46. Install transmission cooler line retainer to electric fan shroud with one screw (2).
47. Install radiator hose retainer (3) to electric fan shroud.
48. Install the coolant recovery/washer fluid reservoir assembly (1) with five screws. Connect two washer pump hoses, coolant recovery hose, and washer pump electrical connector.
49. Install lower intake manifold (3) and fuel rail (1). See «INSTALLATION»(ref-306143-S05495232132008120900000) .
50. Install the upper intake manifold, EGR tube, PCV, Purge and power brake booster vacuum hoses. See «INSTALLATION»(ref-306143-S05495232132008120900000) .
51. Install and connect the air cleaner element housing (1). See «INSTALLATION»(ref-306143-S35312860342008120900000) .
52. Fill the coolant system. Refer to «STANDARD PROCEDURE»(ref-306154-S25259837052008120900000) .
53. Connect the negative battery cable. Tighten nut to 4.5 N.m (40 in. lbs.).

LEFT CYLINDER HEAD

Scheme 258

1. Check cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced. CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper.
2. Clean sealing surfaces of cylinder head and block. See «STANDARD PROCEDURE»(ref-306143-S18889717392008120900000) .
3. Install camshaft (5) in cylinder head. CAUTION: THE CYLINDER HEAD GASKETS ARE NOT INTERCHANGEABLE BETWEEN CYLINDER HEADS AND ARE CLEARLY MARKED RIGHT OR LEFT. CAUTION: Ensure that the correct head gaskets are used and are oriented correctly on cylinder block.
4. Push camshaft (5) out of the back of the cylinder head approximately 3.5 inches. Install head gasket and cylinder head over locating dowels. NOTE: Before installing the cylinder head bolts, lubricate the threads with clean engine oil.
5. Install and finger tighten eight head bolts (2).
6. Tighten the cylinder head bolts in the following sequence, using the 4 step torque-turn method. Tighten according to the following torque values: 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.
8. Install four inner timing cover to cylinder head bolts (1) and (2). Tighten bolts to 54 N.m (40 ft. lbs.). CAUTION: The camshaft sprockets are keyed and not interchangeable from side to side because of the camshaft position sensor pick-up.
9. Push the camshaft back into the cylinder head and install the camshaft sprocket.
10. Install NEW sprocket attaching bolt into place. The 255 mm (10 in.) bolt is to be installed in the left camshaft and the 213 mm (8 3/8 in.) bolt is to be installed into the right camshaft. Counterhold the camshaft sprocket and tighten the camshaft sprocket bolt to 102 N.m (75 ft. lbs.) plus a 90° turn.
11. Install the camshaft thrust plate (1) and gasket (3). Tighten three bolts (2) to 28 N.m (250 in. lbs.).
12. Rotate the left camshaft gear (7) to align its timing mark (8). Verify that the right camshaft gear (2) timing mark (1) and crankshaft gear (10) timing mark (9) are still aligned.
13. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley (11).
14. Holding the tensioner pulley (11) against the belt, install the tensioner into the housing and tighten two bolts to 28 N.m (250 in. lbs.). Each camshaft sprocket mark should remain aligned with the cover marks.
15. When tensioner is in place pull retaining pin to allow the tensioner to extend to the tensioner pulley bracket.
16. Rotate crankshaft sprocket two revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. If marks do not line up, repeat procedure. NOTE: With the camshaft gears in these positions the lobes are in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it.
17. Install the rocker arm and shaft assembly (2) and ten bolts making sure that the identification marks face toward the front of engine for left head and toward the rear of the engine for right head.
18. Tighten the ten rocker arm/shaft assembly bolts in sequence to 31 N.m (275 in. lbs.).
19. Clean cylinder head and cover mating surfaces. Inspect and replace gasket (1) and seals (2) as necessary. See «INSTALLATION»(ref-306143-S37027035352008120900000) .
20. Install cylinder head cover and eight bolts. Tighten bolts to 12 N.m (105 in. lbs.).
21. Install the spark plugs. Tighten to 28 N.m (20 ft. lbs.). Refer to «INSTALLATION»(ref-306179-S30660777572008120900000) .
22. Install ignition coil (3) into cylinder head.
23. Install and tighten coil mounting bolt (2) to 6.7 N.m (60 in. lbs.).
24. Reposition engine wire harness and install retainers to cylinder head cover. Connect and lock electrical connectors to ignition coils (1) and knock sensor.
25. Install dipstick tube and bolt.
26. Connect the front exhaust pipe to exhaust manifold (1). Tighten the fasteners (5) to 34 N.m (300 in. lbs.).
27. Reposition oil cooler hose retainer bracket (1) near timing belt tensioner and install bolt (2).
28. Install the front timing belt outer cover (1) and 14 bolts.
29. Tighten the timing cover bolts as follows: M6 bolts - 12 N.m (105 in. lbs.) M8 bolts - 28 N.m (250 in. lbs.) M10 bolts - 54 N.m (40 ft. lbs.)
30. Install crankshaft damper using Special Tools C-4685-C1 (5.9 in.) Bolt (2), with Nut and Thrust Bearing from 6792, and 6792-1 Installer (1).
31. Install crankshaft damper bolt (3). Tighten bolt to 95 N.m (70 ft. lbs.) while holding damper (1) with Special Tool 9365 (2).
32. Install the accessory drive bracket (2). Tighten four bolts (1) and nut (3) to 54 N.m (40 ft. lbs.).
33. Install the lower stud (3) and upper stud (5) that secures the front of the A/C compressor to the accessory drive bracket. Tighten studs securely.
34. Install the lower nut (4) and upper nut (6) that secures the front of the A/C compressor to the accessory drive bracket. Tighten nuts to 28 N.m (21 ft. lbs.).
35. Position generator (1) to engine and install two mounting bolts (2) and (3). Tighten both bolts to 57 N.m (42 ft. lbs.).
36. Snap field wire connector into rear of generator.
37. Install B+ terminal and nut to generator mounting stud. Tighten nut to 13 N.m (115 in. lbs.)
38. Snap plastic protective cover to B+ terminal.
39. Install the power steering belt (1). Refer to «INSTALLATION»(ref-306154-S38527570572008120900000) .
40. Install the accessory drive belt (7). Refer to «INSTALLATION»(ref-306154-S38527570572008120900000) .
41. Using Tool 6958, install the fan blade/viscous fan drive assembly. Tighten mounting nut to 50 N.m (37 ft. lbs.).
42. Install electric fan shroud with two screws (1). Tighten screws to 6 N.m (50 in. lbs.).
43. Connect and lock the electric fan connector (2).
44. Install transmission cooler line retainer to electric fan shroud with one screw (2).
45. Install radiator hose retainer (3) to electric fan shroud.
46. Install the coolant recovery/washer fluid reservoir assembly (1) with five screws. Connect two washer pump hoses, coolant recovery hose, and washer pump connector.
47. Install lower intake manifold (3) and fuel rail (1). See «INSTALLATION»(ref-306143-S05495232132008120900000) .
48. Install the upper intake manifold, support brackets, EGR tube, PCV, Purge and power brake booster vacuum hoses. See «INSTALLATION»(ref-306143-S05495232132008120900000) .
49. Install and connect the air cleaner element housing (1). See «INSTALLATION»(ref-306143-S35312860342008120900000) .
50. Fill the coolant system. Refer to «STANDARD PROCEDURE»(ref-306154-S25259837052008120900000) .
51. Connect the negative battery cable. Tighten nut to 4.5 N.m (40 in. lbs.).

Scheme 259

Scheme 260

1. Disconnect the negative battery cable.
2. Remove front timing cover and align the camshaft gear (1,8) and crankshaft gear timing mark (9) to TDC. See «REMOVAL»(ref-306143-S37847068952008120900000).
3. Remove timing belt (4).
4. Remove the right camshaft sprocket. see scheme 191 See «REMOVAL»(ref-306143-S05505308212008120900000). 1 - CAMSHAFT THRUST PLATE 2 - BOLT 3 - O-RING
5. Remove the EGR valve and camshaft thrust plate (1) from the rear of the cylinder head.
6. Remove the cylinder head cover. See «REMOVAL»(ref-306143-S09043848162008120900000).
7. Remove the rocker arm assembly. See «REMOVAL»(ref-306143-S41312733922008120900000).
8. Maneuver the camshaft rearward and out of the cylinder head approximately 3.5 inches. NOTE: Care must be taken not to damage the cylinder head to seal or camshaft journal surfaces when removing the camshaft seal. 1 - CYLINDER HEAD 2 - DRIFT 3 - CAMSHAFT
9. Using an appropriate driver carefully remove camshaft oil seal. (Scheme 260)

Scheme 261

1. Disconnect the negative battery cable.
2. Drain cooling system.
3. Remove front timing cover and align the camshaft gear and crankshaft gear timing marks to TDC. See «REMOVAL»(ref-306143-S37847068952008120900000) .
4. Remove the rear timing cover. See «REMOVAL»(ref-306143-S37847068952008120900000) .
5. Remove the cylinder head cover. See «REMOVAL»(ref-306143-S09043848162008120900000) .
6. Remove the rocker arm assembly. See «REMOVAL»(ref-306143-S41312733922008120900000) . 1 - CAMSHAFT THRUST PLATE 2 - BOLT 3 - O-RING
7. Remove the camshaft thrust plate (1) from the rear of the cylinder head.
8. Maneuver the camshaft rearward and out of the cylinder head approximately 3.5 inches. NOTE: Care must be taken not to damage the cylinder head to seal or camshaft journal surfaces when removing the camshaft seal. 1 - DRIFT 2 - CAMSHAFT 3 - CYLINDER HEAD
9. Using an appropriate driver (1) carefully remove camshaft oil seal.

Scheme 262

Scheme 263

Scheme 264

1. Position the camshaft seal into the cylinder head. (Scheme 262)
2. Using MD-998306 (2) tap the seal into place. (Scheme 262) 1 - REAR TIMING COVER 2 - SPECIAL TOOL 6788 3 - CAMSHAFT
3. Apply light coat of clean engine oil to the camshaft oil seal lip and 6788 Seal Protector Sleeve (2).
4. Install oil seal 6788 Seal Protector Sleeve (2) onto the camshaft. (Scheme 263)
5. Slide the camshaft (3) forward, inserting the seal protector (2) through the camshaft seal until the camshaft (3) seats. (Scheme 263)
6. Remove Special Tool (2) from the camshaft. 1 - CAMSHAFT THRUST PLATE 2 - BOLT 3 - O-RING
7. Install the camshaft thrust plate (1), and new seal (3) to the rear of the cylinder head. see scheme 199 1 - TUBE 2 - EGR VALVE
8. Install the EGR valve (2). (Scheme 264)
9. Install camshaft sprocket (2) and tighten the camshaft sprocket bolt to 102 N.m (75 ft. lbs.).
10. Install the timing belt (4). see scheme 202 See «INSTALLATION»(ref-306143-S40647239562008120900000).
11. Install rocker assembly (1). See «INSTALLATION»(ref-306143-S12715012362008120900000).
12. Install cylinder head cover. See «INSTALLATION»(ref-306143-S37027035352008120900000).
13. Install the front timing belt cover. See «INSTALLATION»(ref-306143-S21750707092008120900000).
14. Install the vibration damper (4). See «INSTALLATION»(ref-306143-S03609820182008120900000).
15. Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-306154-S25259837052008120900000).
16. Connect the negative battery cable.

Scheme 265

Scheme 266

1. Position the camshaft seal into the cylinder head (3)
2. Using MD-998306 (2) tap the seal into place. (Scheme 265) 1 - CAMSHAFT 2 - SPECIAL TOOL 6788 3 - CAMSHAFT SEAL 4 - CYLINDER HEAD
3. Apply light coat of engine oil to the camshaft oil seal lip (3) and 6788 (2) Seal Protector Sleeve.
4. Install oil seal (3) 6788 Seal Protector Sleeve (2) onto the camshaft (1). (Scheme 266)
5. Slide the camshaft (1) forward, inserting the seal protector (2) through the camshaft seal (3) until the camshaft seats. (Scheme 266)
6. Remove 6788 (2) from the camshaft (1). 1 - CAMSHAFT THRUST PLATE 2 - BOLT 3 - O-RING
7. Install the camshaft thrust plate (1) and new seal (3) to the rear of the cylinder head. see scheme 206
8. Install rear timing belt cover. See «INSTALLATION»(ref-306143-S21750707092008120900000).
9. Install the camshaft gear (7) and align the timing marks (1,8,9). see scheme 207 See «INSTALLATION»(ref-306143-S40647239562008120900000).
10. Install the timing belt (4). See «INSTALLATION»(ref-306143-S40647239562008120900000).
11. Install the rocker arm assembly. See «INSTALLATION»(ref-306143-S12715012362008120900000).
12. Install the cylinder head cover.
13. Install the front timing belt cover. See «INSTALLATION»(ref-306143-S21750707092008120900000).
14. Install the vibration damper (4). See «INSTALLATION»(ref-306143-S03609820182008120900000).
15. Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-306154-S25259837052008120900000).
16. Connect the negative battery cable.

CAMSHAFT

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.

The camshaft is driven by the crankshaft via drive sprockets and belt. The camshaft has precisely machined lobes to provide accurate valve timing and duration.

Scheme 267

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

1. Remove the cylinder head. See «REMOVAL»(ref-306143-S11948561452008120900000). CAUTION: Care must be taken not to nick or scratch the journals when removing the camshaft.
2. Carefully remove the camshaft (3) from the rear of the cylinder head. (Scheme 267)

Scheme 268

1. Inspect camshaft bearing journals (4) 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 (5) 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 (5) 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.). (Scheme 268)

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

1. Lubricate camshaft (3) bearing journals, camshaft lobes and camshaft seal (4) with clean engine oil and install camshaft (3) into cylinder head. see scheme 211
2. Install the cylinder head. See «INSTALLATION»(ref-306143-S17621396012008120900000).

CYLINDER HEAD COVER - LEFT

1. Disconnect and isolate the negative battery cable.
2. Remove the upper intake manifold from the engine. See «REMOVAL»(ref-306143-S33795118172008120900000) .
3. Cover lower intake manifold with a suitable cover during service.
4. Disconnect and remove the three ignition coils. Refer to «REMOVAL»(ref-306179-S22107179072008120900000) .
5. Lift up on the wire harness track retaining tabs and reposition wire harness.
6. Completely loosen eight cylinder head cover retaining bolts (2) and remove the cylinder head cover (1).

Scheme 269

Scheme 270

1. Clean cylinder head and cover mating surfaces. Inspect and replace gasket (1) and seals (2) as necessary. (Scheme 269) 1 - SPECIAL TOOL MD-998306 2 - SPARK PLUG TUBE SEAL
2. To replace spark plug tube seals (2): Using a suitable pry tool, carefully remove tube seals (2). Position new seal (2) with the part number on seal facing cylinder head cover. Install seals using MD-998306 (1). (Scheme 270)
3. Install cylinder head cover (1) and eight bolts (2). Tighten to 12 N.m (105 in. lbs.).
4. Position the wiring harness on the cylinder head cover.
5. Reclip the wire harness track retaining tabs into the cover.
6. Install the ignition coils. Tighten mounting screws to 6.7 N.m (60 in. lbs.)
7. Connect the ignition coil electrical connectors.
8. Install upper intake manifold. See «INSTALLATION»(ref-306143-S05495232132008120900000).
9. Connect negative battery cable. Tighten nut to 4.5 N.m (40 in. lbs.)

CYLINDER HEAD COVER - RIGHT

1. Disconnect and isolate the negative battery cable.
2. Remove the upper intake manifold. See «REMOVAL»(ref-306143-S33795118172008120900000) .
3. Cover lower intake manifold openings during service.
4. Disconnect and remove the three ignition coils. Refer to «REMOVAL»(ref-306179-S22107179072008120900000) .
5. Lift up on the wire harness track retaining tabs and reposition wire harness.
6. Completely loosen the eight cylinder head cover retaining bolts and remove the cylinder head cover (1).

Scheme 271

1. Clean cylinder head and cover mating surfaces. Inspect and replace gasket (1) and seals (2) as necessary. (Scheme 251) 1 - SPECIAL TOOL MD-998306 2 - SPARK PLUG TUBE SEAL
2. To replace spark plug tube seals (2): Using a suitable pry tool, carefully remove tube seals (2). Position new seal (2) with the part number on seal facing cylinder head cover. Install seals using MD-99830 (1).
3. Install cylinder head cover and eight bolts. Tighten bolts to 12 N.m (105 in. lbs.).
4. Position the wire harness on the cylinder head cover.
5. Reclip the wire harness track retaining tabs into the cover.
6. Install the ignition coils. Tighten mounting screws to 6.7 N.m (60 in. lbs.).
7. Connect the ignition coil electrical connectors.
8. Install upper intake manifold. See «INSTALLATION»(ref-306143-S05495232132008120900000).
9. Connect negative battery cable. Tighten the nut to 4.5 N.m (40 in. lbs.)

VALVES

Valves are made of highly heat-resistant steel and are chrome plated to prevent stem scuffing. The intake valve is a one-piece forging, while the exhaust valve has a forged head with a welded stem for lock groove hardness. The four valves (two intake and two exhaust) employ a three-groove lock design to help facilitate valve rotation.

The intake valve allows the air/fuel mixture to enter the combustion chamber. The exhaust valve allows the burned air/fuel mixture to exit the combustion chamber. Also, the intake and exhaust valves seal the combustion chamber during the compression and power strokes.

Scheme 272

1. Inspect the remaining margin (1) after the valves are refaced. See «SPECIFICATIONS»(ref-306143-S10827893482008120900000) .

Scheme 273

1. When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating 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.
3. Inspect the valve seat (3) with Prussian blue to determine where the valve (1) contacts the seat. To do this, coat valve seat (1) 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 (2), contact is satisfactory. If the blue is transferred to top edge of valve face (2), then lower valve seat (3) with a 15° stone. If the blue is transferred to the bottom edge of valve face (2), then raise valve seat (3) with a 65° stone. NOTE: Valve seats (1) which are worn or burned can be reworked, provided that correct angle and seat width (1) are maintained. Otherwise 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 273)

Scheme 274

Scheme 275

Scheme 276

1. Coat valve stems with clean engine oil and insert them in cylinder head.
2. If valves or seats have been refaced, check valve tip height (A). (Scheme 274) If valve tip height is greater than 43.65 mm (1.7185 in.) intake or 46.48 mm (1.8299 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 valve seal/spring seat assembly over valve guides on all valve stem. (Scheme 276) Ensure that the garter spring is intact around the top of the rubber seal. 1 - YELLOW OR WHITE DYE 2 - ORANGE DYE
4. Place valve spring (color-coded end facing up) and valve retainer into position on spring seat. (Scheme 274)and (Scheme 275). 1 - VALVE 2 - VALVE RETAINING LOCKS 3 - VALVE SPRING RETAINER 4 - VALVE SPRING 5 - VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY
5. Compress valve springs (4) with valve spring compressor C-3422-D and adapter 6526 (see «SPECIAL TOOLS»(ref-306143-S36634217892008120900000) ), install locks (2) and release tool.
6. If valves (1) and/or seats are refaced, measure the installed height of springs. (Scheme 274) Measurements are taken from top of spring (4) 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. Remove cylinder head(s). See «REMOVAL»(ref-306143-S11948561452008120900000) .
2. Remove rocker arm assembly. See «REMOVAL»(ref-306143-S41312733922008120900000) .
3. Remove valve spring(s). See «REMOVAL»(ref-306143-S30763988192008120900000) .
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.

VALVE AND VALVE SPRING

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

Scheme 277

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-3339 to cylinder head and set it at right angle of valve stem being measured. (Scheme 277)
4. Move valve to and from the indicator.
5. Note dial indicator reading and compare to engine specifications. See «SPECIFICATIONS»(ref-306143-S10827893482008120900000).

Note. Replace cylinder head if stem-to-guide clearance exceeds specifications, or if guide is loose in cylinder head.

Scheme 278

1. Measure valve stems for wear approximately 60 mm (2.36 in.) below the valve lock grooves. (Scheme 278)
2. Compare measurement to specifications. See «SPECIFICATIONS»(ref-306143-S10827893482008120900000).

Note. Valve stems are chrome plated and should not be polished. (Scheme 278)

Scheme 279

1. Coat valve stems with clean engine oil and insert them in cylinder head.
2. If valves or seats have been reground, check valve tip height (A). (Scheme 279) If valve tip height is greater than 43.65 mm (1.7185 in.) intake or 46.48 mm (1.8299 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 «INSTALLATION»(ref-306143-S21755227922008120900000).
5. Install cylinder head(s). See «INSTALLATION»(ref-306143-S17621396012008120900000).

Scheme 280

The rocker arm shafts are tubular steel and are 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. (Scheme 280)

Scheme 281

Rocker arms are made of light weight permanent mold aluminum alloy with a roller (3) type follower operating against the camshaft. (Scheme 281) The valve actuating end of the rocker arms are machined to retain hydraulic lash adjusters, eliminating the need for manual valve lash adjustment.

ROCKER ARMS

The rocker arm is the pivot point between the camshaft lobe and the valve.

SHAFT - ROCKER ARM

Note. Rocker arm and shaft assembly can be installed either prior to or after (preferred) cylinder head installation.

1. Rotate camshaft gears to the position shown in (1,8,9). see scheme 236 With the camshaft gears in these positions the lobes are in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it.
2. Install the rocker arm and shaft assembly making sure that the identification marks face toward the front of engine for left head and toward the rear of the engine for right head.
3. Tighten rocker arm/shaft assembly bolts in sequence to 31 N.m (275 in. lbs.). (Scheme 250)
4. Install cylinder head covers. See «INSTALLATION»(ref-306143-S37027035352008120900000).

Scheme 282

1. Remove cylinder head cover(s). See «REMOVAL»(ref-306143-S09043848162008120900000).
2. Using suitable locking pliers, remove the tube from the cylinder head and discard tube. (Scheme 282)
3. Clean area around spark plug with Mopar® Parts Cleaner or equivalent.

TUBE - SPARK PLUG

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. see scheme 239
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 «REMOVAL»(ref-306143-S09043848162008120900000).
4. Install cylinder head cover(s). See «INSTALLATION»(ref-306143-S37027035352008120900000).

Scheme 283

1. Remove valve spring. See «REMOVAL»(ref-306143-S30763988192008120900000).
2. Remove valve stem seals by using a valve stem seal tool. (Scheme 283)

Scheme 284

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. (Scheme 284)
2. Install valve spring. See «INSTALLATION»(ref-306143-S21755227922008120900000).

Scheme 285

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 orange dye on the top coils, and the exhaust spring is left hand coil direction with a yellow or white dye on the top coils. (Scheme 285)

The exhaust spring with the white dye on the top of the coils has an increased open and closed load when compared to the exhaust spring with the yellow dye. A yellow and a white exhaust valve spring should never be used on a single forked rocker arm. Color coated exhaust springs should always be used in pairs for a forked exhaust rocker springs.

VALVE SPRING

The valve spring returns the valve against its seat for a positive seal of the combustion chamber.

VALVE SPRING - CYLINDER HEAD OFF

1. Compress valve spring with valve spring compressor C-3422-D and adapter 6526. See «SPECIAL TOOLS»(ref-306143-S36634217892008120900000) .
2. Remove valve retaining locks. Release valve spring compressor. Remove valve spring retainer and valve spring.
3. Remove valve stem seal assembly. See «REMOVAL»(ref-306143-S03276419802008120900000) .

Scheme 286

1. Disconnect negative battery cable.
2. Remove upper intake manifold. See «REMOVAL»(ref-306143-S33795118172008120900000).
3. Remove cylinder head cover(s). See «REMOVAL»(ref-306143-S09043848162008120900000).
4. Remove rocker arm and shaft assembly. See «REMOVAL»(ref-306143-S41312733922008120900000).
5. Remove spark plugs.
6. Rotate the crankshaft clockwise, until the number 1 piston is at Top Dead Center (TDC) 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.
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 «SPECIAL TOOLS»(ref-306143-S36634217892008120900000). (Scheme 286)
9. Remove valve stem seal, if required. See «REMOVAL»(ref-306143-S03276419802008120900000).
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 287

When valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. (Scheme 287) 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 SPECIFICATIONS to obtain specified height and allowable tensions. Replace springs that do not meet specifications.

SPRING - VALVE - CYLINDER HEAD ON

1. Install new valve seal(s) if required. See «INSTALLATION»(ref-306143-S15620552202008120900000).
2. Place valve spring (color-coded end facing up) and valve retainer into position.
3. Compress valve spring using Special Tool MD 998772A (1) with Adapter 6527 (4) only enough to install locks (5). see scheme 245
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 «INSTALLATION»(ref-306143-S12715012362008120900000).
7. Install cylinder head cover(s). See «INSTALLATION»(ref-306143-S37027035352008120900000).
8. Install spark plugs.
9. Install upper intake manifold. See «INSTALLATION»(ref-306143-S05495232132008120900000).
10. Connect negative battery cable.

Scheme 288

Scheme 289

1. Install valves if removed.
2. Install valve stem seal/spring seat assembly (5) over valve guides on all valve stems. (Scheme 288) 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. (Scheme 289)

Scheme 290

The cylinder block 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. (Scheme 290)

BLOCK-CYLINDER

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 «STANDARD PROCEDURE»(ref-306143-S18889717392008120900000) .
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.).

Scheme 291

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 cylinder bore gauge, or equivalent. (Scheme 291) See SPECIFICATIONS. If the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted.

Measure the cylinder bore at three levels in directions A and B. (Scheme 291) 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 SPECIFICATIONS.

Scheme 292

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 «STANDARD PROCEDURE»(ref-306143-S18889717392008120900000) . Refer to «SPECIFICATIONS»(ref-306143-S10827893482008120900000) for bearing clearance specifications.

Scheme 293

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 ROD BEARING SELECTION DATA

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 294

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 «SPECIFICATIONS»(ref-306143-S10827893482008120900000) .

Scheme 295

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 «SPECIFICATIONS»(ref-306143-S10827893482008120900000) . Repeat procedure for each connecting rod. Turn crankshaft for connecting rod accessibility.

CRANKSHAFT

The crankshaft is constructed of a forged micro alloy steel. A six throw, nine counterweight crankshaft is supported by four select fit main bearings with number two serving as the thrust washer location. The six separate connecting rod throws are an even-firing design which reduces torque fluctuations while a torsional vibration damper is used to control torsion caused vibration of the crankshaft. Rubber lipped seals are used at front and rear. The front seal is retained in the oil pump case and the rear seal is retained in a block-mounted housing.

The crankshaft transfers force generated by combustion within the cylinder to the flywheel or flexplate.

Scheme 296

Scheme 297

1. Remove engine from vehicle. See «REMOVAL»(ref-306143-S20513227792008120900000).
2. Remove oil pan. See «REMOVAL»(ref-306143-S12798993982008120900000).
3. Remove oil pickup tube.
4. Remove front timing belt cover. See «REMOVAL»(ref-306143-S37847068952008120900000).
5. Remove timing belt and tensioner. See «REMOVAL»(ref-306143-S05505308212008120900000).
6. Remove crankshaft sprocket. See «REMOVAL»(ref-306143-S05505308212008120900000).
7. Tap dowel pin out of crankshaft.
8. Remove oil pump assembly. See «REMOVAL»(ref-306143-S12967298572008120900000).
9. Remove crankshaft rear oil seal retainer (Refer to «REMOVAL»(ref-306143-S00280118942008120900000) ). CAUTION: Connecting rod bearing caps are not interchangeable and should be paint marked or scribed before removal to insure correct assembly. DO NOT use a metal stamp to mark the bearing caps.
10. Remove connecting rod bearing caps. (Scheme 296) WARNING: Main bearing caps are not interchangeable and should be paint marked or scribed before removal to insure correct assembly. DO NOT use a metal stamp to mark the bearing caps.
11. Remove main bearing caps (1). Main bearing caps (1) are not interchangeable and are marked to insure correct assembly. (Scheme 297)and see scheme 257. 1 - MAIN CAPS 2 - BOLTS 3 - MAIN BEARING-LOWER 4 - CRANKSHAFT 5 - THRUST WASHERS 6 - MAIN BEARING-UPPER 7 - ENGINE BLOCK
12. Remove crankshaft (4) from cylinder block (7). see scheme 257

Note. Before installing crankshaft, refer to CRANKSHAFT MAIN BEARING FITTING and BEARING - CONNECTING ROD . See STANDARD PROCEDURE for crankshaft main bearing. See STANDARD PROCEDURE for connecting rod bearing.

The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper on any crankshaft journals should be held to 0.010 mm (0.0004 in.). Limits for journal roundness should be 0.008 mm (0.0003 in.). Journal grinding should not exceed 0.254 mm (0.010 in.) under the standard journal diameter. DO NOT grind thrust faces of Number 2 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages. Crank journals must be polished smooth 0.10 micron ra.

Scheme 298

Scheme 299

1. Install crankshaft upper main bearings in cylinder block. Ensure oil holes in bearings line up with oil holes in cylinder block. (Scheme 298)and «STANDARD PROCEDURE»(ref-306143-S22315068822008120900000). 1 - MAIN CAPS 2 - BOLTS 3 - MAIN BEARING-LOWER 4 - CRANKSHAFT 5 - THRUST WASHERS 6 - MAIN BEARING-UPPER 7 - ENGINE BLOCK NOTE: Care must be taken not to damage the journals or bearings during crankshaft installation.
2. Install the crankshaft (4) to cylinder block (7). see scheme 259 1 - FRONT THRUST WASHER
3. Move crankshaft forward to limit of travel. Lubricate and install the front thrust washer (1) by rolling the washer (1) onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface. (Scheme 299)
4. 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. (Scheme 299) 1 - MAIN CAPS 2 - BOLTS 3 - MAIN BEARING-LOWER 4 - CRANKSHAFT 5 - THRUST WASHERS 6 - MAIN BEARING-UPPER 7 - ENGINE BLOCK
5. Install lower main bearings (3) into main bearing caps (1). see scheme 261
6. Lubricate lower main bearings (3) with clean engine oil. NOTE: Lubricate main bearing cap bolts (2) with engine oil before installation.
7. Install each main cap (1) and tighten bolts finger tight. The main bearing cap bolts (2) must be tightened in the proper sequence. First the inner main cap bolts (2), secondly the windage tray bolts, lastly the main cap tie (horizontal) bolts (6).
8. Install the inside main bearing cap bolts (2) and tighten to 20 N.m + 1/4 turn (15 ft. lbs. + 1/4 turn).
9. Measure crankshaft end play (Refer to «CRANKSHAFT»(ref-306143-S14723573232008120900000) )
10. Install connecting rods and measure side clearance. See «STANDARD PROCEDURE»(ref-306143-S16769652082008120900000).
11. Install windage tray. Lubricate bolts with engine oil and tighten to 27 N.m + 1/4 turn (20 ft. lbs. + 1/4 turn).
12. Install the main cap tie (horizontal) bolts and tighten to 28 N.m (250 in. lbs.). see scheme 262
13. Install rear crankshaft oil seal retainer and oil seal (Refer to «INSTALLATION»(ref-306143-S07088088692008120900000) ).
14. Install oil pump assembly. See «INSTALLATION»(ref-306143-S29951389632008120900000).
15. Install dowel pin in crankshaft. See «INSTALLATION»(ref-306143-S23872412052008120900000).
16. Install crankshaft sprocket. See «INSTALLATION»(ref-306143-S40647239562008120900000).
17. Install timing belt and tensioner. See «INSTALLATION»(ref-306143-S40647239562008120900000).
18. Install front timing belt cover. See «INSTALLATION»(ref-306143-S21750707092008120900000).
19. Install oil pickup tube and tighten bolt to 28 N.m (250 in. lbs.).
20. Install oil pan. See «INSTALLATION»(ref-306143-S29257593452008120900000).
21. Install engine assembly. See «INSTALLATION»(ref-306143-S05654550102008120900000).
22. Fill engine crankcase with proper amount of oil.

Scheme 300

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 301

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 EXAMPLE ROD 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 MAIN BEARING SELECTION CHART for number to size identification.

Scheme 302

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 303

Bearing caps are not interchangeable and are marked to insure correct assembly. (Scheme 303) Upper and lower bearing halves are NOT interchangeable.

Scheme 304

1. Remove oil pan. See «REMOVAL»(ref-306143-S12798993982008120900000).
2. Remove oil pick-up tube and windage tray.
3. Identify bearing caps before removal. (Scheme 303) 1 - SPECIAL TOOL C-3059 2 - BEARING 3 - SPECIAL TOOL C-3059 4 - BEARING
4. Remove bearing caps one at a time. Remove upper half of bearing by inserting Main Bearing Tool C-3059 into the oil hole of crankshaft. (Scheme 304)
5. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell.

Scheme 305

Bearing caps are not interchangeable and are marked to insure correct assembly. Upper and lower bearing halves are NOT interchangeable. (Scheme 305)

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 chamber the sharp edges from the plain side.

Scheme 306

1. Lubricate main bearing (4) with clean engine oil.
2. Start bearing (4) in place, and insert Main Bearing Tool C-3059 (3) into oil hole of crankshaft. see scheme 270
3. Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Main Bearing Tool C-3059. 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. 1 - FRONT THRUST WASHER
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 (1) by rolling the washer onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface. (Scheme 306) 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. 1 - MAIN CAPS 2 - BOLTS 3 - MAIN BEARING-LOWER 4 - CRANKSHAFT 5 - THRUST WASHERS 6 - MAIN BEARING-UPPER 7 - ENGINE BLOCK The main bearing cap bolts (2) must be tightened in the proper sequence. First the inner main cap bolts, secondly the windage tray bolts, lastly the main cap tie (horizontal) bolts.
6. Install each main bearing cap (1) and tighten inner bolts finger tight.
7. Tighten inner main bearing cap bolts (2) to 20 N.m + 1/4 turn (15 ft. lbs. + 1/4 turn).
8. Measure crankshaft end play (Refer to «CRANKSHAFT»(ref-306143-S14723573232008120900000) )
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.). see scheme 272and see scheme 273.
11. Install oil pick-up tube.
12. Install oil pan. See «INSTALLATION»(ref-306143-S29257593452008120900000).
13. Fill engine crankcase with proper oil to correct level.

Scheme 307

Scheme 308

1. Remove the crankshaft sprocket. See «REMOVAL»(ref-306143-S05505308212008120900000).
2. Tap the dowel pin (2) out of the crankshaft. (Scheme 307) 1 - SPECIAL TOOL 6341A
3. Remove crankshaft seal using Tool 6341A (1). (Scheme 308) CAUTION: Do not nick shaft seal surface or seal bore.
4. Shaft seal lip surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary.

Scheme 309

1. Install crankshaft seal using Special Tool 6342 (1). (Scheme 309)
2. Install the dowel pin into the crankshaft to 1.2 mm (0.047 in.) protrusion.
3. Install the crankshaft sprocket. See «INSTALLATION»(ref-306143-S40647239562008120900000).

Scheme 310

The rear crankshaft oil seal (2) and retainer (3) are molded and serviced as an assembly. This assembly also includes a separate rear crankshaft seal protector (1) that should not be removed before the seal is installed on the engine block. Once the seal protector (1) is separated from the assembly it can not be reinstalled on the assembly or reused.

Scheme 311

1. Remove the engine oil pan. See «REMOVAL»(ref-306143-S12798993982008120900000) .
2. Lower the weight of the engine back onto the engine mounts.
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.

SEAL-CRANKSHAFT OIL REAR

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 312

Scheme 313

Scheme 314

Scheme 315

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. 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. 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 8mm fasteners to 28 N.m (250 in. lbs.).
8. Install the flex plate and transmission.

Scheme 316

1. Remove the transmission.
2. Remove flex plate attaching bolts (2).
3. Remove the flex plate (1). (Scheme 316)

PLATE-FLEX

1. Position flex plate (1) with backing plate (3) on the crankshaft. see scheme 284
2. Apply Mopar® Lock & Seal Adhesive to the flex plate bolts (2).
3. Install flex plate bolts (2). see scheme 284 Tighten bolts to 95 N.m (70 ft. lbs.).
4. Install the transmission.

ROD-PISTON & CONNECTING

The pistons are made of a high strength aluminum alloy. Top land height has been decreased to reduce emissions. Piston skirts are coated with a solid lubricant for scuff resistance. Connecting rod is forged steel with a fractured connecting rod cap design. The connecting rod is also equipped with a squirt hole and attaches to the piston with a full floating pin retained by lock rings.

The piston and connecting rod assembly is the link between the combustion force and the crankshaft.

Scheme 317

The pistons are machined to two different weight specifications and matched to rods based on weight. All piston and rod assemblies weigh the same to maintain engine balance.

Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90° to piston pin at size location (Scheme 317) Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line. See SPECIFICATIONS. Pistons and cylinder bores should be measured at normal room temperature, 70°F (21°C).

Scheme 318

1. Remove the cylinder heads. See «REMOVAL»(ref-306143-S11948561452008120900000).
2. Remove the oil pan. See «REMOVAL»(ref-306143-S12798993982008120900000).
3. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore. CAUTION: DO NOT stamp the connecting rods for cylinder identification
4. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them with a paint mark or scribe, if necessary. see scheme 286
5. Remove connecting rod cap. Install protectors, tool 8189, on connecting rod. (Scheme 318) Guide each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals.
6. After removal, install bearing cap on the mating rod.

Scheme 319

Scheme 320

Scheme 321

Scheme 322

1. Install the piston rings. See «INSTALLATION»(ref-306143-S33852502922008120900000). NOTE: The connecting rod bearing cap bolts must be examined before reuse. If the threads are necked down, the bolts must be replaced.
2. Check connecting rod bolts for necking by holding a scale or straight edge against the threads. If all threads do not contact the scale, the bolt must be replaced. (Scheme 319) 1 - SIDE RAIL UPPER 2 - NO. 1 RING GAP 3 - PISTON PIN 4 - SIDE RAIL LOWER 5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
3. Before installing pistons and connecting rod assemblies into the bore, ensure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. (Scheme 320)
4. Immerse the piston head and rings in clean engine oil, slide the ring compressor over the piston and tighten with the special wrench. see scheme 290 Ensure position of rings does not change during this operation.
5. Install connecting rod bolt protectors, special tool # 8189. see scheme 290
6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert the rod and piston into cylinder bore and guide the rod over the crankshaft journal. CAUTION: Do Not interchange piston assemblies cylinder-to-cylinder or bank-to-bank. 1 - ARROW FACES FRONT OF ENGINE
7. The arrow on top of piston must be pointing toward front of engine. (Scheme 321) 1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SQUIRT HOLE CAUTION: View of connecting rod oil squirt hole is from the front of the engine.
8. The oil squirt hole on connecting rod faces the major thrust side of the cylinder bore. (Scheme 322) NOTE: Make sure the rod bearings are seated with the oil squirt hole aligned.
9. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. NOTE: Connecting rod bolts must be lubricated with clean engine oil.
10. Install the rod caps. Install cleaned and inspected connecting rod bolts and tighten to 27 N.m (20 ft. lbs.) Plus 1/4 turn.
11. Install the cylinder head(s). See «INSTALLATION»(ref-306143-S17621396012008120900000).
12. Install the oil pan. See «INSTALLATION»(ref-306143-S29257593452008120900000).

Scheme 323

The piston rings include a moly-filled top ring with a symmetric barrel face. The intermediate piston ring is of the standard chrome design OR 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 323)

Scheme 324

Scheme 325

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. (Scheme 324) For clearance specifications, see «SPECIFICATIONS»(ref-306143-S10827893482008120900000). 1 - FEELER GAUGE
2. Check piston ring to groove clearance: (Scheme 325) For clearance specifications, see «SPECIFICATIONS»(ref-306143-S10827893482008120900000).

Scheme 326

Scheme 327

1. Remove piston and connecting rod. See «REMOVAL»(ref-306143-S01669159892008120900000).
2. Remove No. 1 and No. 2 piston rings from piston using a ring expander tool. (Scheme 326) 1 - TOP PISTON RING 2 - CHROME INTERMEDIATE PISTON RING 3 - MICRO-NAPIER INTERMEDIATE PISTON RING 4 - OIL CONTROL RINGS 5 - SPACER
3. Remove upper oil control ring side rail. (Scheme 327)
4. Remove lower oil control ring side rail. (Scheme 327)
5. Remove oil control ring expander. (Scheme 327)

RING - PISTON

Scheme 328

Scheme 329

1. Measure clearance of piston rings to the cylinder bore and piston. See «STANDARD PROCEDURE»(ref-306143-S24775276722008120900000). The No. 1 and No. 2 piston rings have a different cross section. see scheme 298 Insure 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 «DESCRIPTION»(ref-306143-S20738412242008120900000). 1 - SIDE RAIL END CAUTION: Install piston rings in the following order: Oil ring expander. Lower oil control ring side rail. Upper oil control ring side rail. No. 2 Intermediate piston ring. No. 1 Upper piston ring.
2. Install the side rail by placing one end between the piston ring groove and the spacer. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander tool during this step. (Scheme 328)
3. Install lower side rail first and then the upper side rail. The No. 1 and No. 2 piston rings have a different cross section. see scheme 300 Insure 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 «DESCRIPTION»(ref-306143-S20738412242008120900000).
4. Install No. 2 piston ring and then No. 1 piston ring. see scheme 300 1 - SIDE RAIL UPPER 2 - NO. 1 RING GAP 3 - PISTON PIN 4 - SIDE RAIL LOWER 5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
5. Position piston ring end gaps (Scheme 329)
6. Position oil control 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.

DAMPER-CRANKSHAFT

1. Disconnect and isolate the negative battery cable.
2. Remove the air cleaner element housing. See «REMOVAL»(ref-306143-S23132016952008120900000) .
3. Disconnect two washer pump hoses, coolant recovery hose and washer pump electrical connector from the coolant recovery/washer fluid reservoir assembly (1).
4. Remove 5 screws and remove the coolant recovery/washer fluid reservoir assembly (1).
5. Disengage the radiator hose retainer (3) from the electric fan shroud.
6. Remove transmission cooling line retainer bolt (2) from the electric fan shroud.
7. Disconnect the electric fan connector (2) from the electric fan shroud.
8. Remove two bolts (1) and lift the electric fan shroud from vehicle.
9. Using Tool 6958 and adapter pins 8346 (1), remove fan/viscous fan drive assembly. Refer to «REMOVAL»(ref-306154-S21887878352008120900000) .
10. Remove accessory drive belt (7). Refer to «REMOVAL»(ref-306154-S30160988302008120900000) . Remove the power steering belt (1). Refer to «REMOVAL»(ref-306154-S30160988302008120900000) .
11. Remove crankshaft damper bolt.
12. Using puller 1023 (1) and insert 9020-R (2), remove crankshaft damper.

Scheme 330

Scheme 331

1. Install crankshaft damper using Special Tools C-4685-C1 (5.9 in.) Bolt (2), with Nut and Thrust Bearing from 6792, and 6792-1 Installer (1).
2. Install crankshaft damper bolt (3). Tighten bolt to 95 N.m (70 ft. lbs.) while holding damper (1) with Special Tool 9365 (2).
3. Install the power steering belt (1). Refer to «INSTALLATION»(ref-306154-S38527570572008120900000) .
4. Install the accessory drive belt (7). Refer to «INSTALLATION»(ref-306154-S38527570572008120900000) .
5. Using Tool 6958, install the fan blade/viscous fan drive assembly. Tighten mounting nut to 50 N.m (37 ft. lbs.).
6. Install electric fan shroud with two screws (1). Tighten screws to 6 N.m (50 in. lbs.).
7. Connect and lock the electric fan connector (2).
8. Install transmission cooler line retainer to electric fan shroud with one screw (2).
9. Install radiator hose retainer (3) to electric fan shroud.
10. Install the coolant recovery/washer fluid reservoir assembly (1) with five screws. Connect two washer pump hoses, coolant recovery hose, and washer pump electrical connector.
11. Install and connect the air cleaner element housing (1). See «INSTALLATION»(ref-306143-S35312860342008120900000) .
12. Connect the negative battery cable. Tighten nut to 4.5 N.m (40 in. lbs.).

ENGINE MOUNTS

The engine mounting system are of molded rubber material and consist of two mounts; right and a left side support the powertrain, and control powertrain torque.

Scheme 332

1. Disconnect the negative battery cable.
2. Raise and support the vehicle.
3. Remove both engine mount to frame nuts and remove the left engine mount bolts (2).
4. Using a suitable jack and a block of wood under the oil pan, raise the engine until the weight is off of the mounts (approximately 5 mm).
5. Remove the engine mount bolts and remove the mount.

MOUNT-LEFT

1. Install the left mount (1) to the engine mounting bracket. Hand tighten fasteners.
2. Tighten the engine mount to mounting bracket fasteners (2) to 75 N.m (55 ft. lbs.).
3. Lower the engine and remove lifting device.
4. Install the left engine mount to frame fasteners and tighten both to 75 N.m (55 ft. lbs.).
5. Connect the negative battery cable.

Scheme 333

1. Disconnect the negative battery cable.
2. Raise and support the vehicle.
3. Remove both of the engine mount to frame fasteners.
4. Using a suitable jack stand and a block of wood positioned under the oil pan, raise the engine until the weight is off of the mounts (approximately 5 mm.).
5. Remove both of the engine mount to bracket bolts (2).
6. Remove the engine mount (1).

ENGINE MOUNT - RIGHT

1. Install the engine mount (1) to the engine bracket. Tighten bolts (2) to 54 N.m (40 lbs. ft.).
2. Lower the engine and remove the lifting devise.
3. Install the right engine mount to frame fasteners and tighten both to 75 N.m (55 lbs. ft.).
4. Connect the negative battery cable.

ENGINE MOUNT - REAR

Note. A resilient rubber cushion supports the transmission at the rear between the transmission extension housing and the rear support crossmember or skid plate.

1. Disconnect negative cable from battery.
2. Raise the vehicle and support the transmission.
3. Remove the nuts holding the support cushion to the crossmember. Remove the crossmember.

MANUAL TRANSMISSION

1. Remove the support cushion nuts and remove the cushion.
2. Remove the transmission support bracket bolts and remove the bracket from the transmission.

AUTOMATIC TRANSMISSION

1. Remove the support cushion bolts and remove the cushion and the support bracket from the transmission (4WD) or from the Adapter bracket (2WD).
2. On 2WD vehicles, remove the bolts holding the transmission support Adapter bracket to the transmission. Remove the Adapter bracket.

Scheme 334

Scheme 335

1. Install the transmission mount (1) to the transmission. Install the bolts (2) and tighten.
2. Position the crossmember in the vehicle. Install the crossmember to mount through bolt and nut.
3. Install crossmember-to-sill bolts and tighten to 41 N.m (30 ft. lbs.)
4. Remove the transmission support.
5. Lower the vehicle.
6. Connect negative cable to battery.

Scheme 336

Scheme 337

1. Install the transmission mount to transmission and install the bolts. (Scheme 336)and (Scheme 337).
2. Position the crossmember in the vehicle. Install the crossmember to mount through bolt and nut.
3. Remove the transmission support.
4. Lower the vehicle.
5. Connect negative cable to battery.

Scheme 338

The oil lubrication system is a full-flow filtration, pressure feed type. The oil pump body is mounted to the engine block. The pump inner rotor is driven by the crankshaft. A windage tray, increases power by minimizing oil windage at high engine RPM. For increased oil cooling, an oil pan mounted, oil-to-coolant oil cooler is used. (Scheme 338)

CHECKING ENGINE OIL PRESSURE

Check oil pressure using a gauge at oil pressure switch location.

1. Remove the oil pressure switch (1) (Refer to «REMOVAL»(ref-306143-S27902215792008120900000) ).
2. Install oil pressure test gauge, C-3292 with Adapter 8406. For Special Tool identification, (Refer to «SPECIAL TOOLS»(ref-306143-S36634217892008120900000) ). CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM.
3. Warm engine to normal operating temperature.
4. Monitor gauge readings at idle and 3000 RPM. For specifications (Refer to «SPECIFICATIONS»(ref-306143-S10827893482008120900000) ).

ENGINE OIL

For engine oil type and capacity. refer to DESCRIPTION .

ENGINE OIL AND FILTER CHANGE

Change engine oil at mileage and time intervals described in the Maintenance Schedule. Refer to DESCRIPTION .

TO CHANGE ENGINE OIL

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. see scheme 329
4. Raise vehicle on hoist.
5. Place a suitable drain pan under crankcase drain.
6. Remove oil pan drain plug 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). see scheme 330
8. Install drain plug in crankcase. Torque oil pan drain plug to 27 N.m (20 ft. lbs.).
9. Install new oil filter (2). see scheme 330
10. Lower vehicle.
11. Fill crankcase with specified amount and type of engine oil. (Refer to «ENGINE OIL»(ref-306134-S33874522762008120900000) and «FLUID TYPES»(ref-306134-S38415165652008120900000) ).
12. Install oil fill cap. see scheme 331
13. Start engine and inspect for leaks.
14. Stop engine 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.

OIL LEVEL CHECK

The best time to check engine oil level is after the engine has sat overnight, or if the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level.

Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is at, or below, the ADD mark on the indicator.

COOLER-ENGINE OIL

The engine oil cooler (1) is a oil-to-coolant type and is mounted between the oil filter and the oil pan.

Engine oil travels from the oil cooler and into the oil filter. Engine oil then exits the filter into the main gallery. Engine coolant flows into the cooler from the heater return tube and exits into the water inlet tube.

FILTER-OIL

Note. When servicing the oil filter, avoid deforming the filter can. Install the remove/install tool band strap against the base lock seam. The lock seam joining the can to the base is reinforced by the base plate.

1. Using a suitable oil filter wrench, unscrew filter (2) from base and discard.

1. Wipe base clean, then inspect gasket contact surface.
2. Lubricate gasket of new filter (2) with clean engine oil.
3. Install and tighten filter to 12 N.m (106 in. lbs.) of torque after gasket contacts base. Use filter wrench if necessary.
4. Start engine and check for leaks.

Scheme 339

Scheme 340

1. Disconnect negative battery cable.
2. Remove engine oil indicator.
3. Raise and support the vehicle.
4. Drain engine oil and remove the oil filter (Refer to «STANDARD PROCEDURE»(ref-306143-S11904722932008120900000) ).
5. Remove the oil filter, oil cooler mounting stud and set oil cooler aside (Refer to «REMOVAL»(ref-306143-S06270517002008120900000) ).
6. Remove the flex plate access cover (1). 1 - REAR MAIN SEAL RETAINER 2 - OIL PAN 3 - BOLT
7. Remove the two rear oil pan bolts (3). 1 - OIL PAN 2 - BOLT 3 - FASTENER 4 - GASKET 5 - ENGINE BLOCK
8. Remove the remaining oil pan bolts and nuts.
9. Loosen the engine mount bolts at the cradle.
10. Raise and support the engine using a suitable floor jack with a block of wood at the transmission housing.
11. Remove the oil pan (1). NOTE: A small amount of oil will remain in the oil pan. Use care when removing the oil pan from the engine.
12. Clean all mating surfaces.

Scheme 341

Scheme 342

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. (Scheme 341) 1 - OIL PAN 2 - BOLT 3 - FASTENER 4 - GASKET 5 - ENGINE BLOCK
3. Install oil pan gasket to the engine block. see scheme 344
4. Install the oil pan while aligning the oil level indicator tube and attach fasteners finger tight. 1 - TIGHTEN FIRST 2 - TIGHTEN SECOND 3 - TIGHTEN LAST NOTE: Assure that the rear face of the oil pan is flush to the transmission bell housing when installing the oil pan.
5. Pre-torque the horizontal rear oil pan to transmission bolts to 1.4 N.m (12 in. lbs.).
6. First tighten the M8 (1) oil pan alignment bolt to 28 N.m (250 lbs. in.), then tighten bolt (2) to 28 N.m (250 lbs. in.). (Scheme 342)
7. Tighten the remaining M8 bolts and M8 nuts to 28 N.m (250 in. lbs.), and the M6 bolts to 12 N.m (105 in. lbs.). (Scheme 342)
8. Tighten the four M10 oil pan to transmission bolts to 55 N.m (40 ft. lbs.).
9. Lower the engine and remove the lifting fixture. Tighten the engine mount to cradle fasteners to 75 N.m (55 lbs. ft.).
10. Install the flex plate inspection cover (1) and tighten the fastener (2) to 11 N.m (97 in. lbs.). see scheme 346
11. Install the oil cooler (align the oil cooler notch to oil pan tab (Refer to «INSTALLATION»(ref-306143-S36881239992008120900000) ).
12. Install the engine oil filter. Tighten filter to 12 N.m (106 in. lbs.).
13. Fill engine crankcase with proper oil to correct level.
14. Connect negative battery cable.

SWITCH-OIL PRESSURE SENSOR

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

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

Scheme 343

Scheme 344

Scheme 345

1. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-306154-S25259837052008120900000).
2. Remove the timing belt. See «REMOVAL»(ref-306143-S05505308212008120900000).
3. Remove the crankshaft sprocket. See «REMOVAL»(ref-306143-S05505308212008120900000).
4. Remove the oil pan. See «REMOVAL»(ref-306143-S12798993982008120900000). 1 - OIL PICK UP TUBE WITH STRAINER 2 - BOLT 3 - O-RING 4 - OIL PUMP 5 - WINDAGE TRAY
5. Remove the oil pickup tube. (Scheme 344) 1 - CRANKSHAFT 2 - DOWEL 3 - GASKET 4 - OIL PUMP 5 - FRONT CRANKSHAFT SEAL 6 - CRANKSHAFT GEAR 7 - PIN
6. Remove the oil pump fasteners. Remove the oil pump and gasket from engine. (Scheme 345)

Scheme 346

1. Remove oil pump cover screws (3) and lift off cover (4). (Scheme 346)
2. Remove pump rotors (2, 5).
3. Wash all parts in a suitable solvent and inspect carefully for damage or wear.

PUMP-OIL

1. Clean all parts thoroughly in a suitable solvent.

Note. DO NOT inspect the oil relief valve assembly. If the oil relief valve is suspect, replace the oil pump.

Scheme 347

Scheme 348

Scheme 349

Scheme 350

Scheme 351

Scheme 352

1. Disassemble oil pump. See «DISASSEMBLY»(ref-306143-S20475725032008120900000).
2. Clean all parts thoroughly. Mating surface of the oil pump housing should be smooth. Replace pump cover if scratched or grooved.
3. Lay a straightedge (1) across the pump cover (3) surface. If a 0.025 mm (0.001 in.) feeler gauge can be inserted between cover and straight edge, cover should be replaced. (Scheme 347)
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. (Scheme 348)
5. If inner rotor measures 14.299 mm (0.563 in.) or less replace inner rotor. (Scheme 349) 1 - FEELER GAUGE 2 - OUTER ROTOR
6. Slide outer rotor (2) 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. (Scheme 350) 1 - FEELER GAUGE 2 - OUTER ROTOR 3 - INNER ROTOR
7. Install inner rotor into body. If clearance between inner (3) and outer rotors (2) is 0.20 mm (0.008 inch.) or more, replace both rotors. (Scheme 351) 1 - STRAIGHT EDGE 2 - FEELER GAUGES
8. Place a straightedge (1) 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. (Scheme 352)
9. Assemble oil pump. See «ASSEMBLY»(ref-306143-S36608038112008120900000).

1. Assemble oil pump using new parts as required.
2. Tighten cover screws (3) to 12 N.m (105 in. lbs.). see scheme 357
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.

1. Prime oil pump (4) before installation by filling rotor cavity with clean engine oil.
2. Install oil pump (4) and gasket (3) carefully over the crankshaft. Position pump onto block and tighten bolts to 28 N.m (250 in. lbs.). 1 - OIL PICK UP TUBE WITH STRAINER 2 - BOLT 3 - O-RING 4 - OIL PUMP 5 - WINDAGE TRAY
3. Install new O-ring (3) on oil pickup tube (1).
4. Install oil pickup tube (1).
5. Install oil pan. (Refer to «INSTALLATION»(ref-306143-S29257593452008120900000) )
6. Install crankshaft sprocket. (Refer to «INSTALLATION»(ref-306143-S40647239562008120900000) )
7. Install timing belt. (Refer to «INSTALLATION»(ref-306143-S40647239562008120900000) )
8. Install the timing belt covers. (Refer to «INSTALLATION»(ref-306143-S21750707092008120900000) ) 1 - GENERATOR 2 - IDLER PULLEY 3 - WATER PUMP PULLEY 4 - CRANKSHAFT PULLEY 5 - ACCESSORY DRIVE BELT TENSIONER 6 - A/C COMPRESSOR 7 - ACCESSORY DRIVE BELT
9. Install the crankshaft vibration damper (4). (Refer to «INSTALLATION»(ref-306143-S03609820182008120900000) ).
10. Install the accessory drive belt (7). (Refer to «INSTALLATION»(ref-306154-S38527570572008120900000) ).
11. Fill the cooling system. (Refer to «STANDARD PROCEDURE»(ref-306154-S25259837052008120900000) ).
12. Fill engine crankcase with proper oil to the correct level.

INTAKE MANIFOLD-LOWER

Scheme 353

Scheme 354

Scheme 355

1. Perform fuel pressure release procedure. Refer to «STANDARD PROCEDURE»(ref-306144-S17322326742008120900000) .
2. Remove and isolate negative battery cable at battery.
3. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-306154-S25259837052008120900000) .
4. Remove the upper intake manifold including EGR tube, PCV, purge and power brake booster vacuum hoses. See «REMOVAL»(ref-306143-S33795118172008120900000) .
5. Disconnect the fuel supply hose (1) from fuel rail. Refer to «STANDARD PROCEDURE»(ref-306144-S00241737712008120900000) .
6. Disconnect electrical connectors (3) at all six fuel injectors. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
7. Remove four fuel rail mounting bolts (2).
8. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.
9. Remove fuel rail (with injectors attached) from engine.
10. Disconnect the coolant temperature sensor (2) and knock sensor (4) electrical connectors.
11. Disconnect the coolant hose (5) from the thermostat housing.
12. Disconnect heater hose (1) from the rear of the lower intake manifold (3).
13. Remove the four remaining bolts attaching lower intake and remove intake manifold (1) and gaskets (2).

Scheme 356

Scheme 357

Scheme 358

1. Disconnect and isolate the negative battery cable.
2. Disconnect the IAT sensor (5), MAP sensor (3), electronic throttle control (2) and manifold tuning valve (4) electrical connectors.
3. Loosen clamps (1) and remove air inlet hose (6) from the throttle body.
4. Disconnect the PCV (3), purge (2) and power brake booster vacuum (1) hoses from the upper intake manifold.
5. Remove two EGR tube mounting flange bolts (3) at the intake manifold.
6. Remove two EGR tube mounting flange bolts (3) at the EGR solenoid/valve (2).
7. Separate the EGR tube (4) and gasket (5) from the EGR solenoid/valve (2). Slip opposite end of tube (4) from intake manifold.
8. Remove two nuts (2) from studs on left intake manifold support brackets (1).
9. Remove the upper intake manifold retaining bolts and manifold. Clean all gasket sealing surfaces.

Scheme 359

1. Clean all sealing surfaces.
2. Position new gaskets (2) and intake manifold (1) on cylinder head surfaces.
3. Install four of the eight manifold bolts. Do not tighten at this time.
4. Install fuel rail and injectors (1) as an assembly. Refer to «INSTALLATION»(ref-306144-S13941710522008120900000) .
5. Install the four remaining intake manifold bolts and gradually tighten in sequence shown in illustration until a torque of 28 N.m (250 in. lbs.) is obtained.
6. Connect fuel supply hose (1) to fuel rail (4). Refer to «STANDARD PROCEDURE»(ref-306144-S00241737712008120900000) .
7. Connect fuel injector electrical connectors (3).
8. Connect heater hose (1) to rear lower intake manifold (3).
9. Connect coolant hose (5) to thermostat housing.
10. Connect coolant temperature sensor (2) and knock sensor (4) electrical connectors.
11. Install upper intake manifold, EGR tube, PCV, purge and power brake booster vacuum hoses. See «INSTALLATION»(ref-306143-S05495232132008120900000) .
12. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-306154-S25259837052008120900000) .
13. Connect the negative battery cable. Tighten nut to 4.5 N.m (40 in. lbs.).

Scheme 360

1. Clean and inspect gasket sealing surfaces.
2. Position new upper intake manifold gasket.
3. Install the upper intake manifold. Tighten bolts to 12 N.m (105 in. lbs.) starting in the center working outward in a cross sequence pattern.
4. Install two nuts (2) to the left manifold support brackets (1). Tighten nuts to 12 N.m (105 in. lbs.).
5. Install new O-ring to intake manifold end of EGR tube (5).
6. Install two flange mounting bolts (3) at the intake manifold. Do not tighten at this time.
7. Install new gasket (5) between EGR solenoid/valve and tube flange.
8. Position tube (4) to solenoid/valve (2). Install and tighten two flange bolts (3) at solenoid/valve to 8 N.m (80 in. lbs.).
9. Tighten two flange bolts (3) at intake manifold to 4 N.m (35 in. lbs.).
10. Connect the PVC (3), purge (2) and power brake booster (1) vacuum hoses to the intake manifold.
11. Connect the manifold tuning valve (4), electronic throttle control (2), MAP sensor (3) and IAT sensor (5) electrical connectors.
12. Install the inlet hose (6) tighten clamps (1).
13. Connect negative battery cable. Tighten nut to 5 N.m (45 in. lbs.).

Scheme 361

1. Disconnect and isolate the negative battery cable.
2. Raise and support the vehicle.
3. Separate the front exhaust pipe to manifold union (2). 1 - GASKET 2 - STUD 3 - NUT 4 - BOLT 5 - UPPER HEAT SHIELD 6 - LOWER HEAT SHIELD 7 - EXHAUST MANIFOLD
4. Lower the vehicle.
5. Disconnect and remove the oxygen sensor from the exhaust manifold (7)
6. Remove the exhaust manifold shield (5) retaining bolts, exhaust manifold (7) , and discard gasket (1).

EXHAUST MANIFOLD

1. Inspect exhaust manifolds for damage or cracks.
2. Check manifold 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.

MANIFOLD-EXHAUST LEFT

Note. If replacing the exhaust manifold, tighten the exhaust outlet studs to manifold to 40 N.m (350 in. lbs.).

1. Position the exhaust manifold (7) and gasket (1). Install the retaining bolts (2). Tighten 4 bolts starting at the center working outward to 23 N.m (200 in. lbs.).
2. Install the exhaust manifold heat shields (5,6). Tighten the bolts to 12 N.m (105 in. lbs.).
3. Tighten the out most stud nuts to 8 N.m (73 in. lbs.).
4. Connect the oxygen sensor.
5. Raise and support the vehicle.
6. Connect the exhaust pipe to manifold union (2). Tighten the exhaust stud nuts to 34 N.m (300 in. lbs.).
7. Connect the negative battery cable.

Scheme 362

1. Disconnect the negative battery cable.
2. Disconnect the upstream oxygen sensor electrical connector.
3. Raise and support the vehicle.
4. Remove the exhaust manifold to exhaust pipe flange retaining bolts (2). 1 - GASKET 2 - MANIFOLD 3 - LOWER SHIELD 4 - UPPER SHIELD 5 - BOLT
5. Lower the vehicle.
6. Remove the exhaust manifold heat shield and manifold.
7. Remove the oxygen sensor from the exhaust manifold.

MANIFOLD-EXHAUST RIGHT

1. Clean gasket surfaces. NOTE: If replacing the exhaust manifold, tighten the exhaust outlet studs to 39 N.m (350 in. lbs.).
2. Position the exhaust manifold and gasket. Install the retaining bolts. Tighten 4 bolts starting at the center working outward to 23 N.m (200 in. lbs.). see scheme 388
3. Install the heat shields. Tighten the heat shield fasteners to 12 N.m (105 in. lbs.).
4. Tighten the 2 out most nuts to 8 N.m (73 in. lbs.).
5. Connect the oxygen sensor.
6. Raise and support the vehicle.
7. Connect the front exhaust pipe to exhaust manifold (2). Tighten the fasteners to 34 N.m (300 in. lbs.).
8. Connect the negative battery cable.

Scheme 363

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 (4), camshaft sprockets, tensioner pulley, hydraulic tensioner and a timing belt (3). The water pump (2) is driven by the back side of the timing belt (3). The right and left camshaft sprockets are keyed and not interchangeable because of the cam sensor pick-up wheel on the left sprocket. (Scheme 363)

Scheme 364

1. Disconnect and isolate the negative battery cable.
2. Remove the air cleaner element housing. See «REMOVAL»(ref-306143-S23132016952008120900000) .
3. Disconnect two washer pump hoses, coolant recovery hose and washer pump electrical connector from the coolant recovery/washer fluid reservoir assembly (1).
4. Remove 5 screws and remove the coolant recovery/washer fluid reservoir assembly (1).
5. Disengage the radiator hose retainer (3) from the electric fan shroud.
6. Remove transmission cooling line retainer bolt (2) from the electric fan shroud.
7. Disconnect the electric fan connector (2) from the electric fan shroud.
8. Remove two bolts (1) and lift the electric fan shroud from vehicle.
9. Using Tool 6958 and adapter pins 8346 (1), remove fan/viscous fan drive assembly. Refer to «REMOVAL»(ref-306154-S21887878352008120900000) . Remove accessory drive belt (7). Refer to «REMOVAL»(ref-306154-S30160988302008120900000) .
10. Remove the power steering belt (1). Refer to «REMOVAL»(ref-306154-S30160988302008120900000) .
11. Remove two nuts (4) and (6) that secure the front of the A/C compressor (1).
12. Back out the two A/C compressor mounting studs (3) and (5) from the accessory drive bracket.
13. Remove four bolts (1) and nut (3) and remove the accessory drive bracket (2).
14. Remove crankshaft damper bolt.
15. Using puller 1023 (1) and insert 9020-R (2), remove crankshaft damper.
16. Remove the fourteen outer timing belt cover bolts and cover (1).

COVER-FRONT TIMING BELT

1. Install the front timing belt outer cover (1) and 14 bolts.
2. Tighten the timing cover bolts as follows: M6 bolts - 12 N.m (105 in. lbs.) M8 bolts - 28 N.m (250 in. lbs.) M10 bolts - 54 N.m (40 ft. lbs.)
3. Install crankshaft damper using Special Tools C-4685-C1 (5.9 in.) Bolt (2), with Nut and Thrust Bearing from 6792, and 6792-1 Installer (1).
4. Install crankshaft damper bolt (3). Tighten bolt to 95 N.m (70 ft. lbs.) while holding damper (1) with Special Tool 9365 (2).
5. Install the accessory drive bracket (2). Tighten four bolts (1) and nut (3) to 54 N.m (40 ft. lbs.).
6. Install the lower stud (3) and upper stud (5) that secures the front of the A/C compressor to the accessory drive bracket. Tighten studs securely.
7. Install the lower nut (4) and upper nut (6) that secures the front of the A/C compressor to the accessory drive bracket. Tighten nuts to 28 N.m (21 ft. lbs.).
8. Install the power steering belt (1). Refer to «INSTALLATION»(ref-306154-S38527570572008120900000) .
9. Install the accessory drive belt (7). Refer to «INSTALLATION»(ref-306154-S38527570572008120900000) .
10. Using Tool 6958, install the fan blade/viscous fan drive assembly. Tighten mounting nut to 50 N.m (37 ft. lbs.).
11. Install electric fan shroud with two screws (1). Tighten screws to 6 N.m (50 in. lbs.).
12. Connect and lock the electric fan connector (2).
13. Install transmission cooler line retainer to electric fan shroud with one screw (2).
14. Install radiator hose retainer (3) to electric fan shroud.
15. Install the coolant recovery/washer fluid reservoir assembly (1) with five screws. Connect two washer pump hoses, coolant recovery hose, and washer pump connector.
16. Install and connect the air cleaner element housing (1). See «INSTALLATION»(ref-306143-S35312860342008120900000) .
17. Connect the negative battery cable. Tighten nut to 4.5 N.m (40 in. lbs.).

Scheme 365

Note. The rear timing belt cover has O-rings to seal the water pump passages to cylinder block. Do not reuse the O-rings.

1. Perform fuel pressure release procedure. Refer to «STANDARD PROCEDURE»(ref-306144-S17322326742008120900000).
2. Disconnect the negative battery cable.
3. Remove timing belt. See «REMOVAL»(ref-306143-S05505308212008120900000).
4. Remove camshaft sprockets. See «REMOVAL»(ref-306143-S05505308212008120900000).
5. Remove rear timing belt cover bolts (1, 2, 3). (Scheme 365)
6. Remove the rear cover.

Scheme 366

1. Clean rear timing belt cover O-ring (1) sealing surfaces and grooves. Lubricate new O-rings with Mopar® Dielectric Grease or equivalent to facilitate assembly. (Scheme 366)
2. Position NEW O-rings on cover (2). 1 - M8 FASTENERS (APPLY THREAD SEALANT) 2 - M10 FASTENERS 3 - M6 FASTENERS 4 - M10 FASTENERS (STUD/NUT)
3. Install rear timing belt cover (4). see scheme 416 Tighten bolts to the following specified torque: M10 (2, 5) - 54 N.m (40 ft. lbs.) M8 (1) - 28 N.m (20 ft. lbs.) M6 (3) - 12 N.m (105 in. lbs.)
4. Install camshaft sprockets. See «INSTALLATION»(ref-306143-S40647239562008120900000).
5. Install timing belt. See «INSTALLATION»(ref-306143-S40647239562008120900000).

CAMSHAFT SPROCKETS

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

1. Remove timing belt. See «REMOVAL»(ref-306143-S05505308212008120900000) .
2. Hold the left camshaft sprocket with a 36 mm (1 7/16 in.) box end wrench so that the timing mark (1) does not move while removing the retaining bolt.
3. Loosen and remove the 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.
4. Remove the camshaft sprocket.
5. Hold the right camshaft sprocket with a 36 mm (1 7/16 in.) box end wrench so that the timing mark (2) does not move while removing the retaining bolt.
6. Loosen and remove the 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.
7. Remove the camshaft sprocket.

Scheme 367

1. Remove the timing belt. See «REMOVAL»(ref-306143-S05505308212008120900000) .
2. Remove crankshaft sprocket using Special Tool L-4407-A (1).

TIMING BELT

Scheme 368

1. Disconnect and isolate the negative battery cable.
2. Remove the front timing belt cover. See «REMOVAL»(ref-306143-S37847068952008120900000) .
3. 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.
4. Rotate engine clockwise until crankshaft (10) mark aligns with the TDC mark on oil pump housing (9) and the camshaft sprocket (2, 7) timing marks (1, 8) are aligned with the marks on the rear cover.
5. Raise and support the vehicle.
6. Remove bolt (2) and reposition oil cooler hose (1).
7. Remove the timing belt tensioner (12).
8. Lower vehicle.
9. Remove the timing belt (4).
10. Inspect the tensioner for fluid leakage.
11. Inspect the pivot and bolt for free movement, bearing grease leakage, and smooth rotation. If not rotating freely, replace the arm and pulley assembly. 1 - VISE 2 - LOCKING PIN
12. 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 (1) and SLOWLY compress the plunger. Total bleed down of tensioner should take approximately two minutes. When plunger is compressed into the tensioner body install a pin (2) through the body and plunger to retain plunger in place until tensioner is installed.

Scheme 369

1. Remove front timing belt cover. See «REMOVAL»(ref-306143-S37847068952008120900000).
2. Inspect both sides of the timing belt. Replace belt if any of the following conditions exist. (Scheme 369): Hardening of back rubber back side is glossy without resilience and leaves no indent when pressed with fingernail. Cracks (4) on rubber back. Cracks or peeling (1) of canvas. Cracks on rib root. Cracks on belt sides. Missing teeth (2). Abnormal wear (7) 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 «DESCRIPTION»(ref-306134-S12882877512008120900000).
3. If none of the above conditions are seen on the belt, the front timing belt cover can be installed. See «INSTALLATION»(ref-306143-S21750707092008120900000).

TIMING VERIFICATION

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. see scheme 425

1. Install the left camshaft sprocket onto the camshaft.
2. Install NEW sprocket attaching bolt into place. The 255 mm (10 in.) bolt is to be installed into the left camshaft and the 213 mm (8 3/8 in.) bolt is to be installed into the right camshaft.
3. Hold the left camshaft sprocket with a 36 mm (1 7/16 in.) box end wrench so that the timing mark (1) does not move while tightening the retaining bolt. Tighten the bolt to 102 N.m (75 ft. lbs.) +90° turn.
4. Install the right camshaft sprocket onto the camshaft.
5. Install NEW sprocket attaching bolt into place. The 255 mm (10 in.) bolt is to be installed into the left camshaft and the 213 mm (8 3/8 in.) bolt is to be installed into the right camshaft.
6. Hold the right camshaft sprocket with a 36 mm (1 7/16 in.) box end wrench so that the timing mark (2) does not move while tightening the retaining bolt. Tighten the bolt to 102 N.m (75 ft. lbs.) +90° turn.
7. Install the timing belt. See «INSTALLATION»(ref-306143-S40647239562008120900000) .

Scheme 370

1. Install crankshaft sprocket using Special Tool 6641 (1), 12 mm screw C-4685-C1, thrust bearing and washer.
2. Install timing belt. See «INSTALLATION»(ref-306143-S40647239562008120900000) .

1. Align the crankshaft sprocket (10) with the TDC mark (9) on 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. Maintain tension on the belt as it is positioned around the tensioner pulley (11).
4. Holding the tensioner pulley (11) against the belt, install the tensioner (12) into the housing and tighten two bolts to 28 N.m (250 in. lbs.). Each camshaft sprocket mark should remain aligned the cover marks.
5. When tensioner is in place pull retaining pin to allow the tensioner to extend to the pulley bracket.
6. Rotate crankshaft sprocket two revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. If marks do not line up, repeat procedure.
7. Reposition oil cooler hose retainer bracket (1) near timing belt tensioner and install bolt (2).
8. Install the front timing belt cover. See «INSTALLATION»(ref-306143-S21750707092008120900000) .
9. Connect negative battery cable. Tighten nut to 4.5 N.m (40 in. lbs.).

TIMING BELT TENSIONER

1. For timing belt tensioner removal procedure, see «REMOVAL»(ref-306143-S05505308212008120900000) .

Scheme 371

1. Remove the timing belt. See «REMOVAL»(ref-306143-S05505308212008120900000).
2. Remove the timing belt tensioner pulley (1) and bracket (3) assembly by unscrewing the pivot bolt (2) from the oil pump housing. (Scheme 371)

Scheme 372

1. Inspect hydraulic tensioner (2) for fluid loss around the plunger (1) seal. Replace tensioner if leaking. (Scheme 372)

1. For timing belt tensioner installation procedure, see «INSTALLATION»(ref-306143-S40647239562008120900000) .