3.7L V6 Engine: Removal & Installation Dodge Pickup R2500

REMOVAL

1. Disconnect the battery negative cable.
2. Remove hood. Mark hood hinge location for reinstallation.
3. Remove air cleaner assembly.
4. Remove radiator core support bracket.
5. Remove fan shroud with viscous fan assembly.
6. Remove drive belt.
7. Remove A/C compressor and secure away from engine.
8. Remove generator and secure away from engine. NOTE: Do NOT remove the phenolic pulley from the P/S pump. It is not required for P/S pump removal.
9. Remove power steering pump with lines attached and secure away from engine.
10. Drain cooling system.
11. Disconnect the heater hoses from the engine.
12. Disconnect heater hoses from heater core and remove hose assembly.
13. Disconnect throttle and speed control cables.
14. Remove upper radiator hose from engine.
15. Remove lower radiator hose from engine.
16. Remove radiator/cooling module assembly.
17. Disconnect the engine to body ground straps at the left side of cowl.
18. Disconnect the engine wiring harness at the following points: Intake air temperature (IAT) sensor Fuel Injectors Throttle Position (TPS) Switch Idle Air Control (IAC) Motor Engine Oil Pressure Switch Engine Coolant Temperature (ECT) Sensor Manifold Absolute Pressure MAP) Sensor Camshaft Position (CMP) Sensor Coil Over Plugs Crankshaft Position Sensor
19. Remove coil over plugs.
20. Release fuel rail pressure.
21. Remove fuel rail and secure away from engine. NOTE: It is not necessary to release the quick connect fitting from the fuel supply line for engine removal.
22. Remove the PCV hose.
23. Remove the breather hoses.
24. Remove the vacuum hose for the power brake booster.
25. Disconnect knock sensors.
26. Remove engine oil dipstick tube.
27. Remove intake manifold.
28. Install engine lifting fixture, special tool#8247, using original fasteners from the removed intake manifold, and fuel rail. Torque to factory specifications. NOTE: Recheck bolt torque for engine lift plate before removing engine.
29. Secure the left and right engine wiring harnesses away from engine.
30. Raise vehicle.
31. Disconnect oxygen sensor wiring.
32. Disconnect crankshaft position sensor.
33. Disconnect the engine block heater power cable, if equipped.
34. Disconnect the front propshaft at the front differential and secure out of way. NOTE: It is necessary to disconnect the front prop-shaft for access to the starter and left side exhaust flange.
35. Remove the starter.
36. Remove the ground straps from the left and right side of the block.
37. Disconnect the right and left exhaust pipes at the manifolds and from the crossover, and remove from the vehicle. NOTE: The exhaust clamps at the manifolds cannot be reused. New clamps must be used or leaks may occur.
38. Remove the structural cover.
39. Remove torque convertor bolts, and mark location for reassembly.
40. Remove transmission bellhousing to engine bolts.
41. Remove left and right engine mount thru bolts.
42. Lower the vehicle.
43. Support the transmission with a suitable jack.
44. Connect a suitable engine hoist to the engine lift plate.
45. Remove engine from vehicle.

INSTALLATION

1. Position the engine in the vehicle.
2. Install both left and right side engine mounts onto engine.
3. Raise the vehicle.
4. Install the transmission bellhousing to engine mounting bolts. Tighten the bolts to 41 N.m (30ft. lbs.).
5. Tighten the engine mount thru bolts.
6. Install the torque convertor bolts.
7. Connect the ground straps on the left and right side of the engine.
8. Install the starter.
9. Connect the crankshaft position sensor.
10. Install the engine block heater power cable, if equipped. CAUTION: The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover
11. Install the structural cover. NOTE: New clamps must be used on exhaust manifold flanges. Failure to use new clamps may result in exhaust leaks.
12. Install the left and right exhaust pipes.
13. Connect the left and right oxygen sensors.
14. Lower vehicle.
15. Remove the engine lift plate.
16. Connect the knock sensors.
17. Connect the engine to body ground straps at the left side of the cowl.
18. Install the intake manifold.
19. Install the engine oil dipstick tube.
20. Install the power brake booster vacuum hose.
21. Install the breather hoses.
22. Install the PCV hose.
23. Install the fuel rail.
24. Install the coil over plugs.
25. Connect the engine wiring harness at the following points: Intake air temperature (IAT) sensor Fuel Injectors Throttle Position (TPS) Switch Idle Air Control (IAC) Motor Engine Oil Pressure Switch Engine Coolant Temperature (ECT) Sensor Manifold Absolute Pressure MAP) Sensor Camshaft Position (CMP) Sensor Coil Over Plugs Crankshaft Position Sensor
26. Reinstall the radiator/cooling module assembly.
27. Connect lower radiator hose.
28. Connect upper radiator hose.
29. Connect throttle and speed control cables.
30. Install the heater hose assembly.
31. Install coolant recovery bottle.
32. Install the power steering pump.
33. Install the generator.
34. Install the A/C compressor.
35. Install the drive belt.
36. Install the fan shroud with the viscous fan assembly.
37. Install the radiator core support bracket.
38. Install the air cleaner assembly.
39. Refill the engine cooling system.
40. Recharge the air conditioning.
41. Install the hood.
42. Check and fill engine oil.
43. Connect the battery negative cable.
44. Start the engine and check for leaks.

1. Install filter element into housing.
2. Position housing cover into housing locating tabs see scheme 38
3. Pry up 4 spring clips see scheme 38 and lock cover to housing.
4. Install air duct to air cleaner cover and tighten hose clamp to 3 N.m (30 in. lbs.) torque.
5. If any other hose clamps were removed from air intake system, tighten them to 3.4 N.m (30 in. lbs.) torque.
6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 N.m (40 in. lbs.) torque.

Note. The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced.

Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced (Scheme 190)

Scheme 188

Scheme 189

Scheme 190

1. Clean the cylinder head and cylinder block mating surfaces (Scheme 191)
2. Position the new cylinder head gasket on the locating dowels. CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm
3. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels. NOTE: The four smaller cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.
4. Lubricate the cylinder head bolt threads with clean engine oil and install the eight Mil bolts.
5. Coat the four M8 cylinder head bolts with Mopar® Lock and Seal Adhesive then install the bolts. NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.
6. Tighten the bolts in sequence using the following steps and torque values: Step 1: Tighten bolts 1-8, 27 N.m (20 ft. lbs.). Step 2: Verify that bolts 1-8, all reached 27 N.m (20 ft. lbs.), by repeating step-1 without loosening the bolts. Tighten bolts 9 thru 12 to 14 N.m (10 ft. lbs.). Step 3: Tighten bolts 1-8, 90 degrees (Scheme 192) Step 4: Tighten bolts 1-8, 90 degrees, again. Tighten bolts 9-12, 26 N.m (19 ft. lbs.)
7. Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V6 mark on the gear then using Special Tool 8428 Camshaft Wrench, position the gear onto the camshaft. CAUTION: Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt. Failure to do so may cause over-torqueing of bolt resulting in bolt failure
8. Install the camshaft drive gear retaining bolt.
9. Install the left side secondary chain guide (Refer to «CHAIN AND SPROCKETS - INSTALLATION»(ref-189679-S04374630932005091100000) ).
10. Install the cylinder head access plug.
11. Re-set and Install the left side secondary chain tensioner (Refer to «CHAIN AND SPROCKETS - INSTALLATION»(ref-189679-S04374630932005091100000) ).
12. Remove Special Tool 8429.
13. Install the timing chain cover (Refer to «CHAIN COVER(S) - INSTALLATION»(ref-189679-S33473021302005091100000) ).
14. Install the crankshaft damper (Refer to «VIBRATION DAMPER - INSTALLATION»(ref-189679-S14701575192005091100000) ). Tighten damper bolt 175 N.m (130 Ft. Lbs.).
15. Install the power steering pump.
16. Install the fan blade assembly and fan shroud (Refer to «RADIATOR FAN»(ref-167132-S19937825632004100600000) ).
17. Install the cylinder head cover (Refer to «CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189679-S37619184992005091100000) ).
18. Reinstall the master cylinder and booster assembly (Refer to «POWER BRAKE BOOSTER»(ref-162777-S14668905622004061000000) ).
19. Install the intake manifold (Refer to «INTAKE MANIFOLD - INSTALLATION»(ref-189679-S10804188112005091100000) ).
20. Refill the cooling system (Refer to «COOLING»(ref-189654-S13811322982005091200000) ).
21. Raise the vehicle.
22. Install the exhaust pipe onto the left exhaust manifold.
23. Lower the vehicle.
24. Connect the negative cable to the battery.
25. Start the engine and check for leaks.

Scheme 191

Scheme 192

1. Remove cylinder head cover (Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189679-S17596840832005091100000) ).
2. Set engine to TDC cylinder #1, camshaft sprocket V6 marks at the 12 o'clock position.
3. Mark one link on the secondary timing chain on both sides of the V6 mark on the camshaft sprocket to aid in installation. CAUTION: Do not hold or pry on the camshaft target wheel (Located on the right side camshaft sprocket) for any reason, Severe damage will occur to the target wheel resulting in a vehicle no start condition
4. Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave the bolt snug against the sprocket. NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners. CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur
5. Position Special Tool 8379 timing chain wedge between the timing chain strands, tap the tool to securely wedge the timing chain against the tensioner arm and guide (Scheme 193)
6. Hold the camshaft with Special Tool 8428 Camshaft Wrench, while removing the camshaft sprocket bolt and sprocket see scheme 48
7. Using Special Tool 8428 Camshaft Wrench, gently allow the camshaft to rotate 5° clockwise until the camshaft is in the neutral position (no valve load).
8. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps. CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
9. Remove the camshaft bearing caps and the camshaft.

Scheme 193

1. Lubricate camshaft journals with clean engine oil. NOTE: Position the left side camshaft so that the camshaft sprocket dowel is near the 1 o'clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
2. Position the camshaft into the cylinder head.
3. Install the camshaft bearing caps, hand tighten the retaining bolts. NOTE: Caps should be installed so that the stamped numbers on the caps are in numerical order, (1 thru 4) from the front to the rear of the engine. All caps should be installed so that the stamped arrows on the caps point toward the front of the engine.
4. Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward see scheme 49
5. Torque the camshaft bearing cap retaining bolts to 11 N.m (100 in. lbs.).
6. Position the camshaft drive gear into the timing chain aligning the V6 mark between the two marked chain links (Two links marked during removal).
7. Using Special Tool 8428 Camshaft Wrench, rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft. CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over-torque resulting in bolt failure
8. Remove excess oil from bolt, then install the camshaft sprocket retaining bolt and hand tighten.
9. Remove Special Tool 8379 timing chain wedge.
10. Using Special Tool 6958 spanner wrench with adapter pins 8346, torque the camshaft sprocket retaining bolt to 122 N.m (90 ft. lbs.).
11. Install the cylinder head cover (Refer to «CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189679-S37619184992005091100000) ).

Note. The gasket may be used again, provided no cuts, tears, or deformation has occurred.

1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary.
2. Tighten cylinder head cover bolts and double ended studs to 12 N.m (105 in. lbs.).
3. Install left side breather and connect breather tube.
4. Connect injector electrical connectors and injector harness retaining clips.
5. Install the resonator and air inlet hose.
6. Connect negative cable to battery.

Note. The cylinder heads must be removed in order to perform this procedure.

1. Remove rocker arms and lash adjusters (Refer to «ADJUSTER ASSY - REMOVAL»(ref-189679-S07802122002005091100000) ). see scheme 53
2. Remove the camshaft bearing caps and the camshaft. NOTE: All six valve springs and valves are removed in the same manner; this procedure only covers one valve and valve spring.
3. Using Special Tool C-3422-B or C-3422-C Valve Spring Compressor and Special tool 8519 Adapter, compress the valve spring. NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
4. Remove the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
5. Remove the valve spring compressor.
6. Remove the spring retainer, and the spring. NOTE: Check for sharp edges on the keeper grooves. Remove any burrs from the valve stem before removing the valve from the cylinder head.
7. Remove the valve from the cylinder head. NOTE: The valve stem seals are common between intake and exhaust.
8. Remove the valve stem seal. Mark the valve for proper installation.

Note. Disconnect the battery negative cable to prevent accidental starter engagement.

1. Remove the cylinder head cover (Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189679-S17596840832005091100000) ).
2. For rocker arm removal on cylinder #4, Rotate the crankshaft until cylinder #1 is at BDC intake stroke.
3. For rocker arm removal on cylinder #1, Rotate the crankshaft until cylinder #1 is at BDC combustion stroke.
4. For rocker arm removal on cylinders #3 and #5, Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke.
5. For rocker arm removal on cylinders #2 and #6, Rotate the crankshaft until cylinder #1 is at TDC ignition stroke.
6. Using special tool 8516 Rocker Arm Remover, press downward on the valve spring, remove rocker arm (Scheme 197)

Note. Coat the rocker arms with clean engine oil prior to installation.

Scheme 194

1. For rocker arm installation on cylinders #4, Rotate the crankshaft until cylinder #1 is at BDC intake stroke.
2. For rocker arm installation on cylinder #1, Rotate the crankshaft until cylinder #1 is at BDC combustion stroke.
3. For rocker arm installation on cylinders #3 and #5, Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke.
4. For rocker arm installation on cylinders #2 and #6, Rotate the crankshaft until cylinder #1 is at TDC ignition stroke.
5. Using special tool 8516 press downward on the valve spring, install rocker arm (Scheme 198)
6. Install the cylinder head cover (Refer to «CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189679-S37619184992005091100000) ).

1. Remove the cylinder head cover (Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189679-S17596840832005091100000) ).
2. Using Special Tool 8516 Valve Spring Compressor, remove the rocker arms and the hydraulic lash adjusters.
3. Remove the spark plug for the cylinder the valve spring and seal are to be removed from.
4. Apply shop air to the cylinder to hold the valves in place when the spring is removed. NOTE: All six valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.
5. Using Special Tool 8387 Valve Spring Compressor, compress the valve spring. NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
6. Remove the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
7. Remove the valve spring compressor. NOTE: The valve springs are NOT common between intake and exhaust.
8. Remove the spring retainer, and the spring.
9. Remove the valve stem seal. NOTE: The valve stem seals are common between intake and exhaust.

Note. All six valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.

1. Apply shop air to the cylinder to hold the valves in place while the spring is installed. NOTE: The valve stem seals are common between intake and exhaust.
2. Install the valve stem seal. NOTE: The valve springs are NOT common between intake and exhaust.
3. Install the spring retainer, and the spring.
4. Using Special Tool 8387 Valve Spring Compressor, compress the valve spring.
5. Install the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
6. Remove the valve spring compressor.
7. Disconnect the shop air to the cylinder.
8. Install the spark plug for the cylinder the valve spring and seal was installed on.
9. Using Special Tool 8516 Valve Spring Compressor, install the rocker arms and the hydraulic lash adjusters.
10. Install the cylinder head cover (Refer to «CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189679-S37619184992005091100000) ).

1. Disconnect battery negative cable.
2. Raise the vehicle on a hoist.
3. Disconnect the exhaust pipe at the right side exhaust manifold.
4. Drain the engine coolant (Refer to «COOLING»(ref-189654-S13811322982005091200000) ).
5. Lower the vehicle.
6. Remove the intake manifold (Refer to «INTAKE MANIFOLD - REMOVAL»(ref-189679-S17262764292005091100000) ).
7. Remove the cylinder head cover (Refer to «CYLINDER HEAD - REMOVAL»(ref-189679-S25752946602005091100000) ).
8. Remove the fan shroud (Refer to «RADIATOR FAN»(ref-167132-S19937825632004100600000) ).
9. Remove oil fill housing from cylinder head.
10. Remove accessory drive belt (Refer to «ACCESSORY DRIVE»(ref-189655) ).
11. Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark.
12. Verify the V6 mark on the camshaft sprocket is at the 12 o'clock position. Rotate the crankshaft one turn if necessary.
13. Remove the crankshaft damper (Refer to «VIBRATION DAMPER - REMOVAL»(ref-189679-S30564636212005091100000) ).
14. Remove the timing chain cover (Refer to «CHAIN COVER(S) - REMOVAL»(ref-189679-S31783398672005091100000) ).
15. Lock the secondary timing chains to the idler sprocket using Special Tool 8429 Timing Chain Holding Fixture. NOTE: Mark the secondary timing chain prior to removal to aid in installation.
16. Mark the secondary timing chain, one link on each side of the V6 mark on the camshaft drive gear.
17. Remove the right side secondary chain tensioner (Refer to «CHAIN AND SPROCKETS - REMOVAL»(ref-189679-S18035227532005091100000) ).
18. Remove the cylinder head access plug.
19. Remove the right side secondary chain guide (Refer to «CHAIN AND SPROCKETS - REMOVAL»(ref-189679-S18035227532005091100000) ). CAUTION: The nut on the right side camshaft sprocket should not be removed for any reason, as the sprocket and camshaft sensor target wheel is serviced as an assembly. If the nut was removed re-torque nut to 5 N m (44 in. lbs.)
20. Remove the retaining bolt and the camshaft drive gear. CAUTION: Do not allow the engine to rotate, severe damage to the valve train can occur CAUTION: Do not overlook the four smaller bolts at the front of the cylinder head. Do not attempt to remove the cylinder head without removing these four bolts CAUTION: Do not hold or pry on the camshaft target wheel for any reason. A damaged target wheel can result in a vehicle no start condition NOTE: The cylinder head is attached to the cylinder block with twelve bolts.
21. Remove the cylinder head retaining bolts.
22. Remove the cylinder head and gasket. Discard the gasket. CAUTION: Do not lay the cylinder head on its gasket sealing surface, do to the design of the cylinder head gasket any distortion to the cylinder head sealing surface may prevent the gasket from properly sealing resulting in leaks

Note. The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced.

Necking can be checked by holding a straight edge against the threads (Scheme 199) If all the threads do not contact the scale, the bolt should be replaced.

Scheme 195

Scheme 196

Scheme 197

1. Clean the cylinder head and cylinder block mating surfaces see scheme 60
2. Position the new cylinder head gasket on the locating dowels. CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm
3. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels. NOTE: The four M8 cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.
4. Lubricate the cylinder head bolt threads with clean engine oil and install the eight M10 bolts.
5. Coat the four M8 cylinder head bolts with Mopar Lock and Seal Adhesive then install the bolts. NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.
6. Tighten the bolts in sequence using the following steps and torque values: Step 1: Tighten bolts 1-8, 27 N.m (20 ft. lbs.). Step 2: Verify that bolts 1-8, all reached 27 N.m (20 ft. lbs.), by repeating step-1 without loosening the bolts. Tighten bolts 9 thru 12 to 14 N.m (10 ft. lbs.). Step 3: Tighten bolts 1-8, 90 degrees see scheme 61 Step 4: Tighten bolts 1-8, 90 degrees, again. Tighten bolts 9-12, 26 N.m (19 ft. lbs.) CAUTION: The nut on the right side camshaft sprocket should not be removed for any reason, as the sprocket and camshaft sensor target wheel is serviced as an assembly. If the nut was removed re-torque nut to 5 ft. lbs.(60 in. lbs.)
7. Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V6 mark on the gear then using Special Tool 8428 Camshaft Wrench, position the gear onto the camshaft. CAUTION: Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt. Failure to do so may cause over-torquing of bolt resulting in bolt failure
8. Install the camshaft drive gear retaining bolt.
9. Install the right side secondary chain guide (Refer to «CHAIN AND SPROCKETS - INSTALLATION»(ref-189679-S04374630932005091100000) ).
10. Install the cylinder head access plug.
11. Re-set and install the right side secondary chain tensioner (Refer to «CHAIN AND SPROCKETS - INSTALLATION»(ref-189679-S04374630932005091100000) ).
12. Remove Special Tool 8429.
13. Install the timing chain cover (Refer to «CHAIN COVER(S) - REMOVAL»(ref-189679-S31783398672005091100000) ).
14. Install the crankshaft damper (Refer to «VIBRATION DAMPER - INSTALLATION»(ref-189679-S14701575192005091100000) ). Tighten damper bolt 175 N.m (130 Ft. Lbs.).
15. Install accessory drive belt (Refer to «ACCESSORY DRIVE»(ref-189655) ).
16. Install the fan shroud (Refer to «RADIATOR FAN»(ref-167132-S19937825632004100600000) ).
17. Install the cylinder head cover (Refer to «CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189679-S37619184992005091100000) ).
18. Install the intake manifold (Refer to «INTAKE MANIFOLD INSTALLATION»(ref-189679-S10804188112005091100000) ).
19. Install oil fill housing onto cylinder head.
20. Refill the cooling system (Refer to «COOLING»(ref-189654-S13811322982005091200000) ).
21. Raise the vehicle.
22. Install the exhaust pipe onto the right exhaust manifold.
23. Lower the vehicle.
24. Reconnect battery negative cable.
25. Start the engine and check for leaks.

1. Remove the cylinder head cover (Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189679-S17596840832005091100000) ).
2. Set engine to TDC cylinder #1, camshaft sprocket V6 marks at the 12 o'clock position.
3. Mark one link on the secondary timing chain on both sides of the V6 mark on the camshaft sprocket to aid in installation. CAUTION: Do not hold or pry on the camshaft target wheel for any reason, Severe damage will occur to the target wheel. A damaged target wheel could cause a vehicle no start condition
4. Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave bolt snug against sprocket. NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners. CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur
5. Position Special Tool 8379 timing chain wedge between the timing chain strands. Tap the tool to securely wedge the timing chain against the tensioner arm and guide.
6. Remove the camshaft position sensor.
7. Hold the camshaft with Special Tool 8428 Camshaft Wrench, while removing the camshaft sprocket bolt and sprocket.
8. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps. CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
9. Remove the camshaft bearing caps and the camshaft.

Scheme 198

1. Lubricate camshaft journals with clean engine oil. NOTE: Position the right side camshaft so that the camshaft sprocket dowel is near the 10 o'clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
2. Position the camshaft into the cylinder head.
3. Install the camshaft bearing caps, hand tighten the retaining bolts. NOTE: Caps should be installed so that the stamped numbers on the caps are in numerical order, (1 thru 4) from the front to the rear of the engine. All caps should be installed so that the stamped arrows on the caps point toward the front of the engine.
4. Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward see scheme 62
5. Torque the camshaft bearing cap retaining bolts to 11 N.m (100 in. lbs.).
6. Position the camshaft drive gear into the timing chain aligning the V6 mark between the two marked chain links (Two links marked during removal).
7. Using Special Tool 8428 Camshaft Wrench, rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft. CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over-torque resulting in bolt failure
8. Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and hand tighten.
9. Remove timing chain wedge special tool 8379.
10. Using Special Tool 6958 spanner wrench with adapter pins 8346, torque the camshaft sprocket retaining bolt to 122 N.m (90 ft. lbs.).
11. Install the camshaft position sensor.
12. Install the cylinder head cover (Refer to «CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189679-S37619184992005091100000) ).

1. Disconnect battery negative cable.
2. Remove air cleaner assembly, resonator assembly and air inlet hose.
3. Drain cooling system, below the level of the heater hoses (Refer to «COOLING»(ref-189654-S13811322982005091200000) ).
4. Remove accessory drive belt (Refer to «ACCESSORY DRIVE»(ref-189655) ).
5. Remove air conditioning compressor retaining bolts and move compressor to the left.
6. Remove heater hoses.
7. Disconnect injector and ignition coil connectors.
8. Disconnect and remove positive crankcase ventilation (PCV) hose.
9. Remove oil fill tube.
10. Un-clip injector and ignition coil harness and move away from cylinder head cover.
11. Remove right rear breather tube and filter assembly.
12. Remove cylinder head cover retaining bolts.
13. Remove cylinder head cover.

Note. The gasket may be used again, provided no cuts, tears, or deformation has occurred.

1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary.
2. Tighten cylinder head cover bolts and double ended studs to 12 N.m (105 in. lbs).
3. Install right rear breather tube and filter assembly.
4. Connect injector, ignition coil electrical connectors and harness retaining clips.
5. Install the oil fill tube.
6. Install PCV hose.
7. Install heater hoses.
8. Install air conditioning compressor retaining bolts.
9. Install accessory drive belt (Refer to «ACCESSORY DRIVE»(ref-189655) ).
10. Fill Cooling system (Refer to «COOLING»(ref-189654-S13811322982005091200000) ).
11. Install air cleaner assembly, resonator assembly and air inlet hose.
12. Connect battery negative cable.

Note. Disconnect the battery negative cable to prevent accidental starter engagement.

Scheme 199

1. Remove the cylinder head cover (Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189679-S17596840832005091100000) ).
2. For rocker arm removal on cylinder #4, Rotate the crankshaft until cylinder #1 is at BDC intake stroke.
3. For rocker arm removal on cylinder #1, Rotate the crankshaft until cylinder #1 is at BDC combustion stroke.
4. For rocker arm removal on cylinders #3 and #5, Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke.
5. For rocker arm removal on cylinders #2 and #6, Rotate the crankshaft until cylinder #1 is at TDC ignition stroke.
6. Using special tool 8516 Rocker Arm Remover, press downward on the valve spring, remove rocker arm (Scheme 200)

1. Remove the cylinder head cover (Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189679-S17596840832005091100000) ).
2. Using Special Tool 8516 Valve Spring Compressor, remove the rocker arms and the hydraulic lash adjusters.
3. Remove the spark plug for the cylinder the valve spring and seal are to be removed from.
4. Apply shop air to the cylinder to hold the valves in place when the spring is removed. NOTE: All six valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.
5. Using Special Tool 8387 Valve Spring Compressor, compress the valve spring. NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
6. Remove the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
7. Remove the valve spring compressor. NOTE: The valve springs are NOT common between intake and exhaust.
8. Remove the spring retainer, and the spring.
9. Remove the valve stem seal. NOTE: The valve stem seals are common between intake and exhaust.

Note. All six valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.

1. Apply shop air to the cylinder to hold the valves in place while the spring is installed. NOTE: The valve stem seals are common between intake and exhaust.
2. Install the valve stem seal. NOTE: The valve springs are NOT common between intake and exhaust.
3. Install the spring retainer, and the spring.
4. Using Special Tool 8387 Valve Spring Compressor, compress the valve spring.
5. Install the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
6. Remove the valve spring compressor.
7. Disconnect the shop air to the cylinder.
8. Install the spark plug for the cylinder the valve spring and seal was installed on.
9. Using Special Tool 8516 Valve Spring Compressor, install the rocker arms and the hydraulic lash adjusters.
10. Install the cylinder head cover (Refer to «CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189679-S37619184992005091100000) ).

Note. To remove the crankshaft from the engine, the engine must be removed from the vehicle.

Scheme 200

1. Remove the engine (Refer to «ENGINE - REMOVAL»(ref-189679-S07697268472005091100000) ).
2. Remove the engine oil pump (Refer to «OIL PUMP - REMOVAL»(ref-189679-S02637780752005091100000) ). CAUTION: DO NOT pry on the oil pan gasket when removing the oil pan, The oil pan gasket is mounted to the cylinder block in three locations and will remain attached to block when removing oil pan. Gasket can not be removed with oil pan
3. Remove the bedplate mounting bolts. Note the location of the two stud bolts for installation.
4. Remove the connecting rods from the crankshaft. CAUTION: The bedplate to cylinder block mating surface is a critical sealing surface. Do not pry on or damage this surface in anyway NOTE: The bedplate contains the lower main bearing halves. Use care when handling bedplate as not to drop or damage bearing halves. Installing main bearing halves in the wrong position will cause severe damage to the crankshaft. NOTE: The bedplate has pry points cast into it. Use these points only. The pry points are shown below.
5. Carefully pry on the pry points see scheme 67 to loosen the bedplate then remove the bedplate. CAUTION: When removing the crankshaft, use care not to damage bearing surfaces on the crankshaft
6. Remove the crankshaft.
7. Remove the crankshaft tone wheel.

Note. Apply sealant to the tone wheel retaining screws prior to installation.

Scheme 201

Scheme 202

Scheme 203

1. Lubricate upper main bearing halves with clean engine oil.
2. Install the crankshaft tone wheel. Torque the mounting screws to 15 N.m (11 ft. lbs.).
3. Position crankshaft in cylinder block.
4. Install the thrust washers see scheme 68 CAUTION: The bedplate to cylinder block mating surface must be coated with Mopar® Engine RTV sealant prior to installation. Failure to do so will cause severe oil leaks NOTE: Make sure that the bedplate and cylinder block sealing surfaces are clean and free of oil or other contaminants. Contaminants on the sealing surfaces may cause main bearing distortion and/or oil leaks.
5. Apply a 2.5mm (0.100 inch) bead of Mopar® Engine RTV sealant to the cylinder block-to-bedplate mating surface as shown see scheme 69
6. Coat the crankshaft main bearing journals with clean engine oil and position the bedplate onto the cylinder block. NOTE: Lubricate the bedplate retaining bolts with clean engine oil prior to installation.
7. Install the bedplate retaining bolts, making sure to place the stud bolts in the correct location, Torque the bolts in the sequence shown see scheme 70 Hand tighten bolts 1D,1G and 1F until the bedplate contacts the block. Tighten bolts 1A-1J to 54 N.m (40 ft. lbs.) Tighten bolts 1-8 to 7 N.m (5 ft. lbs.) Turn bolts 1-8 an additional 90°. Tighten bolts A-E 27 N.m (20 ft. lbs.).
8. Measure crankshaft end play.
9. Install the connecting rods and measure side clearance (Refer to «PISTON & CONNECTING ROD - STANDARD PROCEDURE»(ref-189679-S31049557472005091100000) ).
10. Install oil pump (Refer to «OIL PUMP - INSTALLATION»(ref-189679-S11084593392005091100000) ).
11. Install the engine (Refer to «ENGINE - INSTALLATION»(ref-189679-S24840388002005091100000) ).

Scheme 204

1. Using Special Tool 8348 and 8512, install crankshaft front seal (Scheme 208)
2. Install vibration damper (Refer to «VIBRATION DAMPER - INSTALLATION»(ref-189679-S14701575192005091100000) ).
3. Install radiator cooling fan and shroud (Refer to «RADIATOR FAN»(ref-167132-S19937825632004100600000) ).
4. Install upper radiator hose.
5. Install A/C compressor and tighten fasteners to 54 N.m (40 ft. lbs.).
6. Install accessory drive belt refer (Refer to «ACCESSORY DRIVE»(ref-189655) ).
7. Refill cooling system (Refer to «COOLING»(ref-189654-S13811322982005091200000) ).
8. Connect negative cable to battery.

Note. This procedure can be performed in vehicle.

Scheme 205

1. If being preformed in vehicle, remove the transmission.
2. Remove the flexplate (Refer to «FLEX PLATE - REMOVAL»(ref-189679-S08274542472005091100000) ). NOTE: The crankshaft oil seal CAN NOT be reused after removal. NOTE: The crankshaft rear oil seal remover Special Tool 8506 must be installed deeply into the seal. Continue to tighten the removal tool into the seal until the tool can not be turned farther. Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine.
3. Using Special Tool 8506 see scheme 77, remove the crankshaft rear oil seal.

Scheme 206

Scheme 207

1. Lubricate the crankshaft flange with engine oil.
2. Position the magnetic seal guide Special Tool 8349-2 see scheme 78 onto the crankshaft rear face. Then position the crankshaft rear oil seal onto the guide.
3. Using Special Tools 8349 Crankshaft Rear Oil Seal Installer and C-4171 Driver Handle see scheme 79, with a hammer, tap the seal into place. Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore.
4. Install the flexplate.
5. Install the transmission.

1. Remove the transmission.
2. Remove the bolts and flexplate.

Scheme 208

1. Position the flexplate onto the crankshaft and install the bolts hand tight.
2. Tighten the flexplate retaining bolts to 95 N.m (70 ft. lbs.) in the sequence shown see scheme 80
3. Install the transmission.

1. Disconnect negative cable from battery.
2. Remove the following components: Oil pan and gasket/windage tray (Refer to «OIL PAN - REMOVAL»(ref-189679-S35036542072005091100000) ). Cylinder head covers (Refer to «CYLINDER HEAD COVER(S) - REMOVAL)»(ref-189679-S17596840832005091100000) . Timing chain cover (Refer to «CHAIN COVER(S) - REMOVAL»(ref-189679-S31783398672005091100000) ). Cylinder head(s) (Refer to «CYLINDER HEAD - REMOVAL»(ref-189679-S25752946602005091100000) ).
3. If necessary, 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 the each connecting rod is centered in cylinder bore. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur
5. Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur
6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.

Scheme 209

Scheme 210

1. Align crankshaft damper slot with key in crankshaft. Slide damper onto crankshaft slightly. CAUTION: Special Tool 8512-A, is assembled in a specific sequence. Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft
2. Assemble Special Tool 8512-A as follows, The nut is threaded onto the shaft first. Then the roller bearing is placed onto the threaded rod (The hardened bearing surface of the bearing MUST face the nut). Then the hardened washer slides onto the threaded rod see scheme 99 Once assembled coat the threaded rod's threads with Mopar® Nickel Anti-Seize or (Loctite No. 771).
3. Using Special Tool 8512-A, press damper onto crankshaft see scheme 100
4. Install then tighten crankshaft damper bolt to 175 N.m (130 ft. lbs.).
5. Install fan blade assembly (Refer to «FAN DRIVE VISCOUS CLUTCH»(ref-189656-S33852084192005091200000) ).
6. Install radiator upper shroud and tighten fasteners to 11 N.m (95 in. lbs.).
7. Connect electrical connector for shroud fan.
8. Install radiator upper hose.
9. Install accessory drive belt (Refer to «ACCESSORY DRIVE»(ref-189655) ).
10. Refill cooling system (Refer to «COOLING»(ref-189654-S13811322982005091200000) ).
11. Connect negative cable to battery.

Scheme 211

1. Position the structural cover in the vehicle.
2. Install all four bolts retaining the cover-to-engine. DO NOT tighten the bolts at this time.
3. Install the four cover-to-transmission bolts. Do NOT tighten at this time. CAUTION: The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence. Failure to do so may cause damage to the cover
4. Starting with the two rear cover-to-engine bolts, tighten bolts (1) to 54 N.m (40 ft. lbs.), then tighten bolts (2) and (3) to 54 N.m (40 ft. lbs.) in the sequence shownsee scheme 102
5. Install the exhaust pipe on left hand exhaust manifold.
6. Tighten exhaust manifold-to-exhaust pipe retaining bolts to 20-26 N.m (15-20 ft. lbs.).

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

1. Install the two bolts that attach the transmission mount to the transmission bracket.
2. Torque the bolts to 61 N.m (45 ft. lbs.) torque.
3. Lower the transmission so the transmission mount rests on the crossmember, and the studs of the transmission mount are aligned in the slots in the crossmember.
4. Install the nuts onto the transmission mount studs through the crossmember access slot.
5. Torque the nuts to 54 N.m (40 ft. lbs.).

1. Install oil pressure sender.
2. Connect oil pressure sender wire.
3. Install front splash shield.
4. Lower vehicle.
5. Connect the negative battery cable.

1. Remove the oil pan and pick-up tube (Refer to «OIL PAN - REMOVAL»(ref-189679-S35036542072005091100000) ).
2. Remove the timing chain cover (Refer to «CHAIN COVER(S) - REMOVAL»(ref-189679-S31783398672005091100000) ).
3. Remove the timing chains and tensioners (Refer to «CHAIN AND SPROCKETS - REMOVAL»(ref-189679-S18035227532005091100000) ).
4. Remove the four bolts, primary timing chain tensioner and the oil pump.

All engines are equipped with a high quality full-flow, disposable type oil filter. DaimlerChrysler Corporation recommends a Mopar® or equivalent oil filter be used.

Scheme 212

1. Position a drain pan under the oil filter.
2. Using a suitable oil filter wrench loosen filter.
3. Rotate the oil filter counterclockwise see scheme 123 remove it from the cylinder block oil filter boss.
4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter.
5. With a wiping cloth, clean the gasket sealing surface of oil and grime.

Scheme 213

1. Lightly lubricate oil filter gasket with engine oil.
2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, see scheme 124 hand tighten filter one full turn, do not over tighten.
3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks.

1. Disconnect negative cable from battery.
2. Remove resonator assembly and air inlet hose.
3. Disconnect throttle and speed control cables.
4. Disconnect electrical connectors for the following components: Refer to «FUEL SYSTEMS»(ref-157773-S21691392952003082600000) for component locations. Manifold Absolute Pressure (MAP) Sensor Intake Air Temperature (LAT) Sensor Throttle Position (TPS) Sensor Coolant Temperature (CTS) Sensor Idle Air Control (IAC) Motor
5. Disconnect vapor purge hose, brake booster hose, speed control servo hose, positive crankcase ventilation (PCV) hose.
6. Disconnect generator electrical connections.
7. Disconnect air conditioning compressor electrical connections.
8. Disconnect left and right radio suppressor straps.
9. Disconnect and remove ignition coil towers.
10. Remove top oil dipstick tube retaining bolt and ground strap.
11. Bleed fuel system. Refer to «FUEL SYSTEMS»(ref-157773-S21691392952003082600000) .
12. Remove fuel rail.
13. Remove throttle body assembly and mounting bracket.
14. Drain cooling system below coolant temperature level. Refer to «COOLING»(ref-189654-S13811322982005091200000) .
15. Remove the heater hoses from the engine front cover and the heater core.
16. Unclip and remove heater hoses and tubes from intake manifold.
17. Remove coolant temperature sensor. Refer to «FUEL SYSTEM»(ref-157773-S21691392952003082600000) .
18. Remove intake manifold retaining fasteners in reverse order of tightening sequence.
19. Remove intake manifold.

Scheme 214

1. Install intake manifold gaskets.
2. Install intake manifold.
3. Install intake manifold retaining bolts and tighten in sequence shown in to 12 N.m (105 in. lbs.) see scheme 129
4. Install left and right radio suppressor straps.
5. Install throttle body assembly.
6. Connect throttle cable and speed control cable to throttle body.
7. Install fuel rail.
8. Install ignition coil towers.
9. Position and install heater hoses and tubes onto intake manifold.
10. Install the heater hoses to the heater core and engine front cover.
11. Connect electrical connectors for the following components: Manifold Absolute Pressure (MAP) Sensor Intake Air Temperature (LAT) Sensor Throttle Position (TPS) Sensor Coolant Temperature (CTS) Sensor Idle Air Control (IAC) Motor Ignition coil towers Fuel injectors
12. Install top oil dipstick tube retaining bolt and ground strap.
13. Connect generator electrical connections.
14. Connect Vapor purge hose, Brake booster hose, Speed control servo hose, Positive crankcase ventilation (PCV) hose.
15. Fill cooling system.
16. Install resonator assembly and air inlet hose.
17. Connect negative cable to battery.

Note. The balance shaft and gear are serviced as an assembly. Do not attempt to remove the gear from the balance shaft.

1. Coat counterbalance shaft bearing journals with clean engine oil. NOTE: The balance shaft is heavy, and care should be used when installing shaft, so bearings are not damaged.
2. Using Special Tool 8641 Counterbalance shaft remover/installer tool, carefully install counterbalance shaft into engine.
3. Install Counterbalance shaft thrust plate retaining bolt finger tight. Do not tighten bolt at this time.
4. Position the right side of the thrust plate with the right chain guide bolt, install bolt finger tight.
5. Torque the thrust plate retaining bolt to 28 N.m (250 in. lbs.).
6. Remove the chain guide bolt so that guide can be installed.

1. Remove the primary and secondary timing chains and sprockets. Refer to «TIMING BELT/CHAIN AND SPROCKETS»(ref-189679-S24956491102005091100000) . NOTE: To remove the idler shaft, it is necessary to tap threads into the shaft, to install the removal tool.
2. Using a 12 mm X 1.75 tap, cut threads in the idler shaft center bore.
3. Cover the radiator core with a suitable cover. CAUTION: Use care when removing the idler shaft, Do not strike the radiator cooling fins with the slide hammer
4. Using Special Tool 8517 Slide Hammer, remove the idler shaft.

1. Thoroughly clean the idler shaft bore.
2. Position the idler shaft in the bore. NOTE: The two lubrication holes in the idler shaft do not require any special alignment. NOTE: Before using the retaining bolt to install the idler shaft, coat the threads and the pilot on the idler shaft, with clean engine oil.
3. Using the primary idler sprocket retaining bolt and washer, carefully draw the idler shaft into the bore until fully seated.
4. Coat the idler shaft with clean engine oil.
5. Install the timing chains and sprockets. Refer to «TIMING BELT/CHAIN AND SPROCKETS»(ref-189679-S24956491102005091100000) .

Scheme 215

Scheme 216

1. Disconnect the battery negative cable.
2. Drain cooling system (Refer to «COOLING»(ref-189654-S13811322982005091200000) ).
3. Remove electric cooling fan and fan shroud assembly.
4. Remove fan and fan drive assembly (Refer to «FAN DRIVE VISCOUS CLUTCH»(ref-189656-S33852084192005091200000) ).
5. Disconnect both heater hoses at timing cover.
6. Disconnect lower radiator hose at engine.
7. Remove accessory drive belt tensioner assembly (Scheme 221)
8. Remove crankshaft damper (Refer to «VIBRATION DAMPER - REMOVAL»(ref-189679-S30564636212005091100000) ).
9. Remove the generator (Refer to «GENERATORS & REGULATORS»(ref-165616) ).
10. Remove A/C compressor (Refer to «A/C COMPRESSOR»(ref-189725-S01920583182005091100000) ). CAUTION: The 3.7L engine uses an anaerobic sealer instead of a gasket to seal the front cover to the engine block, from the factory. For service, Mopar® Engine RTV sealant must be substituted NOTE: It is not necessary to remove the water pump for timing cover removal.
11. Remove the bolts holding the timing cover to engine block (Scheme 222)
12. Remove the timing cover.

Scheme 217

Scheme 218

1. Clean timing chain cover and block surface using rubbing alcohol. CAUTION: The 3.7L uses a special anaerobic sealer instead of a gasket to seal the timing cover to the engine block, from the factory. For service repairs, Mopar® Engine RTV must be used as a substitute.
2. Inspect the water passage o-rings for any damage, and replace as necessary.
3. Apply Mopar® Engine RTV sealer to front cover following the path below using a 3 to 4mm thick bead see scheme 144
4. Install cover. Tighten fasteners in sequence as shown in to 58 N.m (43 ft. lbs.) see scheme 145
5. Install crankshaft damper (Refer to «VIBRATION DAMPER - INSTALLATION»(ref-189679-S14701575192005091100000) ).
6. Install the A/C compressor (Refer to «A/C COMPRESSOR»(ref-189725-S01920583182005091100000) ).
7. Install the generator (Refer to «GENERATORS & REGULATORS»(ref-165616) ).
8. Install accessory drive belt tensioner assembly (Refer to «ACCESSORY DRIVE»(ref-189655) ).
9. Install radiator upper and lower hoses.
10. Install both heater hoses.
11. Install electric fan shroud and viscous fan drive assembly (Refer to «FAN DRIVE VISCOUS CLUTCH»(ref-189656-S33852084192005091200000) ).
12. Fill cooling system (Refer to «COOLING»(ref-189654-S13811322982005091200000) ).
13. Connect the battery negative cable.

Scheme 219

Scheme 220

Scheme 221

Scheme 222

1. Disconnect negative cable from battery.
2. Drain cooling system (Refer to «COOLING»(ref-189654-S13811322982005091200000) ).
3. Remove right and left cylinder head covers (Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189679-S17596840832005091100000) ).
4. Remove radiator fan shroud (Refer to «RADIATOR FAN»(ref-167132-S19937825632004100600000) ).
5. Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover see scheme 146 and the camshaft sprocket "V6" marks are at the 12 o'clock position (#1 TDC exhaust stroke) see scheme 147
6. Remove power steering pump (Refer to «STEERING PUMP»(ref-189696) ).
7. Remove access plug from left and right cylinder heads for access to chain guide fasteners see scheme 148
8. Remove the oil fill housing to gain access to the right side tensioner arm fastener.
9. Remove crankshaft damper (Refer to «VIBRATION DAMPER - REMOVAL»(ref-189679-S30564636212005091100000) ) and timing chain cover (Refer to «CHAIN COVER(S) - REMOVAL»(ref-189679-S31783398672005091100000) ).
10. Collapse and pin primary chain tensioner. CAUTION: Plate behind left secondary chain tensioner could fall into oil pan. Therefore, cover pan opening
11. Remove secondary chain tensioners.
12. Remove camshaft position sensor see scheme 149 CAUTION: Care should be taken not to damage camshaft target wheel. Do not hold target wheel while loosening or tightening camshaft sprocket. Do not place the target wheel near a magnetic source of any kind. A damaged or magnetized target wheel could cause a vehicle no start condition CAUTION: Do not forcefully rotate the camshafts or crankshaft independently of each other. Damaging intake valve to piston contact will occur. Ensure negative battery cable is disconnected to guard against accidental starter engagement
13. Remove left and right camshaft sprocket bolts.
14. While holding the left camshaft steel tube with Special Tool 8428 Camshaft Wrench, remove the left camshaft sprocket. Slowly rotate the camshaft approximately 5 degrees clockwise to a neutral position.
15. While holding the right camshaft steel tube with Special Tool 8428 Camshaft Wrench, remove the right camshaft sprocket.
16. Remove idler sprocket assembly bolt.
17. Slide the idler sprocket assembly and crank sprocket forward simultaneously to remove the primary and secondary chains.
18. Remove both pivoting tensioner arms and chain guides.
19. Remove primary chain tensioner.