5.9L V8 Engine: Removal & Installation Dodge Pickup R2500

REMOVAL

1. Disconnect the battery negative cable.
2. Drain cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000) .
3. Recover refrigerant from a/c system, if equipped. Refer to «PLUMBING»(ref-189725-S02400897692005091100000) .
4. Remove the a/c condenser, if equipped. Refer to «A/C CONDENSER»(ref-189725-S37314472812005091100000) .
5. Remove the transmission oil cooler. Refer to «TRANSMISSION COOLING»(ref-189657) .
6. Remove the washer bottle from the fan shroud.
7. Remove the viscous fan/drive. Refer to «RADIATOR FAN»(ref-167132-S19937825632004100600000) .
8. Remove radiator. Refer to «RADIATOR REMOVAL»(ref-189656-S22402735342005091200000) .
9. Remove the upper crossmember and top core support.
10. Remove the accessory drive belt. Refer to «ACCESSORY DRIVE»(ref-189655) .
11. Remove the A/C compressor with the lines attached. Secure compressor out of the way.
12. Remove generator assembly. Refer to «GENERATORS & REGULATORS»(ref-165616) .
13. Remove the air cleaner resonator and duct work as an assembly.
14. Disconnect the throttle linkage. Refer to «FUEL RAIL & INJECTORS»(ref-158737-S06750985542003101600000) .
15. Remove throttle body. Refer to «FUEL RAIL & INJECTORS»(ref-158737-S06750985542003101600000) .
16. Remove the intake manifold. Refer to «INTAKE MANIFOLD REMOVAL»(ref-189682-S28571244112005091100000) .
17. Remove the distributor cap and wiring.
18. Disconnect the heater hoses.
19. Disconnect the power steering hoses, if equipped.
20. Perform the Fuel System Pressure Release procedure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-157772-S14853159042003082600000) .
21. Disconnect the fuel supply line. Refer to «FUEL LINE DISCONNECT FITTINGS»(ref-158737-S30612821652003101600000) .
22. On Manual Transmission vehicles, remove the shift lever.
23. Raise and support the vehicle on a hoist and drain the engine oil.
24. Remove engine front mount thru-bolt nuts.
25. Disconnect the transmission oil cooler lines from their retainers at the oil pan bolts.
26. Disconnect exhaust pipe at manifolds.
27. Disconnect the starter wires. Remove starter motor. Refer to «STARTER MOTOR»(ref-164936-S21331940332004081900000) .
28. Remove the dust shield and transmission inspection cover.
29. Remove drive plate to converter bolts (Automatic transmission equipped vehicles).
30. Remove transmission bell housing to engine block bolts.
31. Lower the vehicle.
32. Install an engine lifting fixture.
33. Separate engine from transmission, remove engine from vehicle, and install engine assembly on a repair stand.

INSTALLATION

1. Remove engine from the repair stand and position in the engine compartment. Position the thru-bolt into the support cushion brackets.
2. Install engine lifting device.
3. Lower engine into compartment and align engine with transmission: Manual Transmission: Align clutch disc assembly (if disturbed). Install transmission input shaft into clutch disc while mating engine and transmission surfaces. Install two transmission to engine block mounting bolts finger tight. Automatic Transmission: Mate engine and transmission and install two transmission to engine block mounting bolts finger tight.
4. Lower engine assembly until engine mount through bolts rest in mount perches.
5. Install remaining transmission to engine block mounting bolts and tighten.
6. Tighten engine mount through bolts.
7. Install drive plate to torque converter bolts. (Automatic transmission models)
8. Install the dust shield and transmission cover.
9. Install the starter and connect the starter wires. Refer to «STARTER MOTOR»(ref-164936-S21331940332004081900000) .
10. Install exhaust pipe to manifold.
11. Install the transmission cooler line brackets to the oil pan.
12. Install the drain plug and tighten to 34 N.m (25 ft. lbs.) torque.
13. Lower the vehicle.
14. Remove engine lifting fixture.
15. On Manual Transmission vehicles, install the shift lever.
16. Connect the fuel supply line. Refer to «FUEL LINE DISCONNECT FITTINGS»(ref-158737-S30612821652003101600000) .
17. Connect the power steering hoses, if equipped.
18. Connect the heater hoses.
19. Install the distributor cap and wiring.
20. Install the intake manifold. Refer to «INTAKE MANIFOLD INSTALLATION»(ref-189682-S42701317292005091100000) .
21. Using a new gasket, install throttle body. Refer to «FUEL RAIL & INJECTORS»(ref-158737-S06750985542003101600000) .
22. Connect the throttle linkage. Refer to «FUEL RAIL & INJECTORS»(ref-158737-S06750985542003101600000) .
23. Install the air cleaner resonator and duct work..
24. Install the generator and wire connections. Refer to «GENERATORS & REGULATORS»(ref-165616) .
25. Install a/c compressor and lines. Refer to «A/C COMPRESSOR»(ref-189725-S01920583182005091100000) .
26. Install the accessory drive belt. Refer to «ACCESSORY DRIVE»(ref-189655) .
27. Install upper radiator support crossmember.
28. Install radiator. Refer to «RADIATOR INSTALLATION»(ref-189656-S22676704102005091200000) .
29. Connect the radiator lower hose.
30. Connect the transmission oil cooler lines to the radiator.
31. Install the fan shroud.
32. Install the fan. Refer to «RADIATOR FAN»(ref-167132-S19937825632004100600000) .
33. Connect the radiator upper hose.
34. Install the washer bottle.
35. Install the transmission oil cooler. Refer to «TRANSMISSION COOLING»(ref-189657) .
36. Connect the transmission cooler lines.
37. If equipped, install the condenser. Refer to «A/C CONDENSER»(ref-189725-S37314472812005091100000) .
38. Evacuate and charge the air conditioning system, if equipped. Refer to «STANDARD PROCEDURE»(ref-189725-S18587694352005091100000) .
39. Add engine oil to crankcase. Refer to «OIL - STANDARD PROCEDURE»(ref-189682-S18220277132005091100000) .
40. Fill cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000) .
41. Connect battery negative cable.
42. Start engine and inspect for leaks.
43. Road test vehicle.

Scheme 535

Scheme 536

Scheme 537

Scheme 538

Scheme 539

Scheme 540

Scheme 541

Scheme 542

Scheme 543

Scheme 544

Scheme 545

Scheme 546

Scheme 547

Scheme 548

Scheme 549

Scheme 550

Scheme 551

Scheme 552

Scheme 553

Scheme 554

Scheme 555

Scheme 556

Scheme 557

Scheme 558

Scheme 559

Scheme 560

Scheme 561

Scheme 562

Scheme 563

Scheme 564

Scheme 565

Scheme 566

1. Install filter element into housing.
2. Position housing cover into housing locating tabs see scheme 41
3. Pry up 4 spring clips see scheme 41 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.

1. Disconnect the battery negative cable.
2. Drain cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000) .
3. Remove the air cleaner resonator and duct work.
4. Remove the intake manifold-to-generator bracket support rod. Remove the generator.
5. Remove closed crankcase ventilation system.
6. Disconnect the evaporation control system.
7. Perform the Fuel System Pressure Release procedure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-157772-S14853159042003082600000) . Disconnect the fuel supply line. Refer to «FUEL LINE DISCONNECT FITTINGS»(ref-158737-S30612821652003101600000) .
8. Disconnect accelerator linkage and if so equipped, the speed control and transmission kick-down cables.
9. Remove distributor cap and wires.
10. Disconnect the coil wires.
11. Disconnect heat indicator sending unit wire.
12. Disconnect heater hoses and bypass hose.
13. Remove the master cylinder and booster assembly. Refer to «MASTER CYLINDER»(ref-162777-S32457471392004061000000) and «POWER BRAKE BOOSTER»(ref-162777-S14668905622004061000000) .
14. Remove cylinder head covers and gaskets. Refer to «CYLINDER HEAD COVER(S) REMOVAL»(ref-189682-S30376610152005091100000) .
15. Remove intake manifold. Refer to «INTAKE MANIFOLD REMOVAL»(ref-189682-S28571244112005091100000) and throttle body as an assembly. Discard the flange side gaskets and the front and rear cross-over gaskets.
16. Remove exhaust manifolds. Refer to «EXHAUST MANIFOLD REMOVAL»(ref-189682-S42914277392005091100000) .
17. Remove rocker arm assemblies and push rods. Identify to ensure installation in original locations.
18. Remove the head bolts from each cylinder head and remove cylinder heads. Discard the cylinder head gasket.
19. Remove spark plugs.

Note. A steel backed silicon gasket is used with the cylinder head cover (Scheme 567) This gasket can be used again.

Scheme 567

1. Disconnect the negative cable from the battery.
2. Disconnect the spark plug wires form the spark plugs and set aside.
3. Disconnect closed ventilation system and evaporation control system from cylinder head cover.
4. Remove cylinder head cover and gasket.

1. The cylinder head cover gasket can be used again. Install the gasket onto the head rail.
2. Position the cylinder head cover onto the gasket. Tighten the bolts to 11 N.m (95 in. lbs.) torque.
3. Install closed crankcase ventilation system and evaporation control system.
4. Connect the spark plug wires to the spark plugs.
5. Connect the negative cable to the battery.

1. Remove the cylinder head. Refer to «CYLINDER HEAD - REMOVAL»(ref-189682-S33122456722005091100000) .
2. Compress valve springs using Valve Spring Compressor Tool MD- 998772A and adapter 6716A.
3. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs.
4. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location.

1. Clean valves thoroughly. Discard burned, warped and cracked valves.
2. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
3. Measure valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve.
4. Coat valve stems with lubrication oil and insert them in cylinder head.
5. If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head.
6. Install new seals on all valve guides. Install valve springs and valve retainers.
7. Compress valve springs with Valve Spring Compressor Tool MD-998772A and adapter 6716A, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer. If height is greater than 42.86 mm (1-11/16 inches), install a 1.587 mm (1/16 inch) spacer in head counterbore. This should bring spring height back to normal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
8. Install cylinder head. Refer to «CYLINDER HEAD - INSTALLATION»(ref-189682-S09516615642005091100000) .

Scheme 568

1. Remove cylinder head cover and gasket. Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189682-S30376610152005091100000).
2. Remove the rocker arm bolts and pivots (Scheme 568) Place them on a bench in the same order as removed.
3. Remove the push rods and place them on a bench in the same order as removed.

1. Rotate the crankshaft until the "V8" mark lines up with the TDC mark on the timing chain case cover. This mark is located 147° ATDC from the No. l firing position.
2. Install the push rods in the same order as removed.
3. Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 N.m (21 ft. lbs.) torque. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes)
4. Install cylinder head cover. Refer to «CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189682-S21505435482005091100000) .

Note. The camshaft has an integral oil pump and distributor drive gear (Scheme 569)

Scheme 569

1. Remove the radiator. Refer to «RADIATOR REMOVAL»(ref-189656-S22402735342005091200000).
2. Remove the A/C Condenser (if equipped)
3. Remove the engine cover.
4. Remove intake manifold. Refer to «INTAKE MANIFOLD - REMOVAL»(ref-189682-S28571244112005091100000).
5. Remove cylinder head covers. Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189682-S30376610152005091100000).
6. Remove timing case cover. Refer to «CHAIN COVER(S) - REMOVAL»(ref-189682-S19950526722005091100000), and timing chain. Refer to «CHAIN AND SPROCKETS - REMOVAL»(ref-189682-S26163343512005091100000).
7. Remove rocker arms.
8. Remove push rods and tappets. Identify each part so it can be installed in its original location.
9. Remove distributor and lift out the oil pump and distributor drive shaft.
10. Remove camshaft thrust plate, note location of oil tab (Scheme 570)
11. Install a long bolt into front of camshaft to aid in removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes.

Scheme 570

1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 51 mm (2 inches) of its final position in cylinder block.
2. Install Camshaft Holder Tool C-3509 with tongue back of distributor drive gear see scheme 60
3. Hold tool in position with a distributor lock-plate bolt. This tool will restrict camshaft from being pushed in too far and prevent knocking out the welch plug in rear of cylinder block. Tool should remain installed until the camshaft and crankshaft sprockets and timing chain have been installed.
4. Install camshaft thrust plate and chain oil tab. Make sure tang enters lower right hole in thrust plate. Tighten bolts to 24 N.m (210 in. lbs.) torque. Top edge of tab should be flat against thrust plate in order to catch oil for chain lubrication.
5. Install timing chain and gears. Refer to «CHAIN AND SPROCKETS - INSTALLATION»(ref-189682-S35500361942005091100000).
6. Measure camshaft end play. Refer to «ENGINE SPECIFICATIONS»(ref-189682-S32426383512005091100000). If not within limits install a new thrust plate.
7. Each tappet reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the tappets must be replaced.
8. Install distributor and distributor drive shaft.
9. Install push rods and tappets.
10. Install rocker arms.
11. Install timing case cover. Refer to «CHAIN COVER(S) - INSTALLATION»(ref-189682-S27364514462005091100000).
12. Install cylinder head covers. Refer to «CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189682-S21505435482005091100000).
13. Install intake manifold. Refer to «INTAKE MANIFOLD - INSTALLATION»(ref-189682-S42701317292005091100000).
14. Install the engine cover.
15. Install the A/C Condenser (if equipped)
16. Install the radiator. Refer to «RADIATOR INSTALLATION»(ref-189656-S22676704102005091200000).
17. Start engine check for leaks.

Note. This procedure can be done in vehicle. However the transmission must be removed first.

1. If crankshaft is to be removed while engine is in vehicle, remove the transmission. Refer to appropriate TRANSMISSION article.
2. Remove the oil pan. Refer to «OIL PAN - REMOVAL»(ref-189682-S03515524672005091100000) .
3. Remove the oil pump from the rear main bearing cap. Refer to «OIL PUMP - REMOVAL»(ref-189682-S14300052802005091100000) .
4. Remove the vibration damper. Refer to «VIBRATION DAMPER - REMOVAL»(ref-189682-S09260815872005091100000) .
5. Remove the timing chain cover. Refer to «CHAIN COVER(S) - REMOVAL»(ref-189682-S19950526722005091100000) .
6. Identify rod bearing caps before removal. Remove rod bearing caps with bearings. CAUTION: Support crankshaft before removing main bearing caps, failure to do so will allow the crankshaft to fall damaging the crankshaft
7. Using a suitable jack, support the crankshaft.
8. Identify main bearing caps before removal. Remove main bearing caps and bearings one at a time.
9. Lower the crankshaft out of the block.
10. Remove and discard the crankshaft rear oil seals.
11. Remove and discard the front crankshaft oil seal.

Scheme 571

Scheme 572

1. Clean Gasket Maker residue and sealant from the cylinder block and rear cap mating surface. Do this before applying the Mopar(R) Gasket Maker and the installation of rear cap.
2. Lightly oil the new upper seal lips with engine oil.
3. Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine.
4. Position the crankshaft into the cylinder block.
5. Lightly oil the new lower seal lips with engine oil.
6. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine.
7. Apply 5 mm (0.20 in) drop of Mopar(R) Gasket Maker, or equivalent, on each side of the rear main bearing cap (Scheme 572) DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application.
8. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement.
9. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 N.m (85 ft. lbs.) torque.
10. Install oil pump. Refer to «OIL PUMP - INSTALLATION»(ref-189682-S33015858352005091100000).
11. Install the timing chain cover. Refer to «CHAIN COVER(S) - INSTALLATION»(ref-189682-S27364514462005091100000).
12. Install the vibration damper. Refer to «VIBRATION DAMPER - INSTALLATION»(ref-189682-S14911789762005091100000).
13. Position the connecting rods onto the crankshaft and install the rod bearing caps. Tighten the nuts to 61 N.m (45 ft. lbs.).
14. Apply Mopar(R) Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing see scheme 63 Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove.
15. Install new front crankshaft oil seal. Refer to «CRANKSHAFT OIL SEAL - FRONT - INSTALLATION»(ref-189682-S13917442072005091100000).
16. Immediately install the oil pan. Refer to «OIL PAN - INSTALLATION»(ref-189682-S19365031812005091100000).
17. If the transmission was removed, install the transmission. Refer to appropriate TRANSMISSION article.

1. Remove the oil pan. Refer to «OIL PAN - REMOVAL»(ref-189682-S03515524672005091100000).
2. Remove the oil pump from the rear main bearing cap. Refer to «OIL PUMP - REMOVAL»(ref-189682-S14300052802005091100000).
3. Identify bearing caps before removal. Remove bearing caps one at a time.
4. Remove upper half of bearing by inserting Crankshaft Main Bearing Remover/Installer Tool C-3059 into the oil hole of crankshaft (Scheme 574)
5. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell.

Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened. All bearing capbolts removed during service procedures are to be cleaned and oiled before installation.

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

1. Start bearing in place, and insert Crankshaft Main Bearing Remover/Installer Tool C-3059 into oil hole of crankshaft (Scheme 574)
2. Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Tool C-3059.
3. Install the bearing caps. Clean and oil the bolts. Tighten the capbolts to 115 N.m (85 ft. lbs.) torque.
4. Install the oil pump. Refer to «OIL PUMP - INSTALLATION»(ref-189682-S33015858352005091100000).

The oil seal can be replaced without removing the timing chain cover, provided that the cover is not misaligned.

1. Disconnect the negative cable from the battery.
2. Remove vibration damper. Refer to «VIBRATION DAMPER - REMOVAL»(ref-189682-S09260815872005091100000) .
3. If front seal is suspected of leaking, check front oil seal alignment to crankshaft. The seal installation/alignment Tool 6635, should fit with minimum interference. If tool does not fit, the cover must be removed and installed properly.
4. Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal bore of cover.

1. Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635 see scheme 67 Seat the oil seal in the groove of the tool.
2. Position the seal and tool onto the crankshaft see scheme 68
3. Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft see scheme 69
4. Remove the vibration damper bolt and seal installation tool.
5. Inspect the seal flange on the vibration damper.
6. Install the vibration damper. Refer to «VIBRATION DAMPER -INSTALLATION»(ref-189682-S14911789762005091100000).
7. Connect the negative cable to the battery.

The service seal is a two piece, Viton seal. The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed. When a new upper seal is installed, install a new lower seal. The lower seal half can be installed only with the rear main bearing cap removed.

The service seal is a two piece, Viton seal. The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed. When a new upper seal is installed, install a new lower seal. The lower seal half can be installed only with the rear main bearing cap removed.

Scheme 573

Scheme 574

1. Clean the cylinder block rear cap mating surface. Be sure the seal groove is free of debris. Check for burrs at the oil hole on the cylinder block mating surface to rear cap.
2. Lightly oil the new upper seal lips with engine oil.
3. Install the new upper rear bearing oil seal with the white paint facing toward the rear of the engine.
4. Position the crankshaft into the cylinder block.
5. Lightly oil the new lower seal lips with engine oil.
6. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine.
7. Apply 5 mm (0.20 in.) drop of Mopar(R) Gasket Maker, or equivalent, on each side of the rear main bearing cap see scheme 70 DO NOT over-apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application.
8. To align the bearing cap, use cap slot, alignment dowel, and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than two times for proper engagement.
9. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 N.m (85 ft. lbs.) torque.
10. Install oil pump. Refer to «OIL PUMP - INSTALLATION»(ref-189682-S33015858352005091100000).
11. Apply Mopar(R) GEN II Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap-to-block joint to provide cap to block and oil pan sealing see scheme 71 Apply enough sealant so that a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove.
12. Install new front crankshaft oil seal. Refer to «CRANKSHAFT OIL SEAL - FRONT - INSTALLATION»(ref-189682-S13917442072005091100000).
13. Immediately install the oil pan. Refer to «OIL PAN - INSTALLATION»(ref-189682-S19365031812005091100000).

1. Remove the air cleaner assembly and air in-let hose.
2. Remove cylinder head cover. Refer to «CYLINDER HEAD COVER(S) - REMOVAL»(ref-189682-S30376610152005091100000) .
3. Remove rocker assembly and push rods. Refer to «ROCKER ARM/ADJUSTER ASSEMBLY»(ref-189682-S10887765452005091100000) . Identify push rods to ensure installation in original locations.
4. Remove intake manifold. Refer to «INTAKE MANIFOLD - REMOVAL»(ref-189682-S28571244112005091100000) .
5. Remove yoke retainer and aligning yokes.
6. Slide Hydraulic Tappet Remover/Installer Tool C-4129-A through opening in cylinder head and seat tool firmly in the head of tappet.
7. Pull tappet out of bore with a twisting motion. If all tappets are to be removed, identify tappets to ensure installation in original location.
8. If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize. Replace with oversize tappet.

1. Lubricate tappets with Mopar(R) Engine Oil Supplement or equivalent.
2. Install tappets and push rods in their original positions. Ensure that the oil feed hole in the side of the tappet body faces up (away from the crankshaft).
3. Install aligning yokes with ARROW toward camshaft.
4. Install yoke retainer. Tighten the bolts to 23 N.m (200 in. lbs.) torque. Install intake manifold. Refer to «INTAKE MANIFOLD - INSTALLATION»(ref-189682-S42701317292005091100000) .
5. Install rocker arms. Refer to «ROCKER ARM/ADJUSTER ASSEMBLY»(ref-189682-S33890192062005091100000) .
6. Install cylinder head cover. Refer to «CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189682-S21505435482005091100000) .
7. Install air cleaner assembly and air in-let hose.
8. Start and operate engine. Warm up to normal operating temperature.

1. Remove the engine from the vehicle. Refer to «ENGINE - REMOVAL»(ref-189682-S19185086672005091100000) .
2. Remove the cylinder head. Refer to «CYLINDER HEAD - REMOVAL»(ref-189682-S33122456722005091100000) .
3. Remove the oil pan. Refer to «OIL PAN - REMOVAL»(ref-189682-S03515524672005091100000) .
4. 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.
5. Be sure each connecting rod and connecting rod cap is identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts.
6. Pistons and connecting rods must be removed from top of cylinder block. When removing the assemblies from the engine, rotate crankshaft so that the connecting rod is centered in cylinder bore and at BDC. Be careful not to nick crankshaft journals.
7. After removal, install bearing cap on the mating rod.

Scheme 575

1. Position the vibration damper onto the crankshaft.
2. Place installing tool, part of Puller Tool Set C-3688 in position and press the vibration damper onto the crankshaft see scheme 84
3. Install the crankshaft bolt and washer. Tighten the bolt to 244 N.m (180 ft. lbs.) torque.
4. Install the accessory drive belt. Refer to «ACCESSORY DRIVE»(ref-189655).
5. Position the fan shroud and install the bolts. Tighten the retainer bolts to 11 N.m (95 in. lbs.) torque.
6. Install the cooling fan. Refer to «FAN DRIVE VISCOUS CLUTCH»(ref-189656-S33852084192005091200000).
7. Connect the battery negative cable.

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.).

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

Scheme 576

Scheme 577

1. Position a drain pan under the oil filter.
2. Using a suitable oil filter wrench loosen filter.
3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss (Scheme 579)
4. When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from vehicle.
5. With a wiping cloth, clean the gasket sealing surface see scheme 94 of oil and grime.
6. Install new filter. Refer to «OIL FILTER - INSTALLATION»(ref-189682-S19365031812005091100000).

1. Lightly lubricate oil filter gasket with engine oil or chassis grease.
2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, see scheme 94 hand tighten filter one full turn, do not over tighten.
3. Add oil. Refer to «OIL - STANDARD PROCEDURE»(ref-189682-S18220277132005091100000).

1. Disconnect the negative cable from the battery.
2. Remove engine oil dipstick.
3. Raise vehicle.
4. Drain engine oil.
5. Remove exhaust pipe.
6. Remove left engine to transmission strut.
7. Loosen the right side engine support bracket cushion thru-bolt nut and raise the engine slightly. Remove oil pan by sliding backward and out.
8. Remove the one-piece gasket.

1. Remove the oil pan. Refer to «OIL PAN - REMOVAL»(ref-189682-S03515524672005091100000) .
2. Remove the oil pump from rear main bearing cap.

Scheme 578

Scheme 579

1. Remove the relief valve as follows: Remove cotter pin. Drill a 3.175 mm (1/8 inch) hole into the relief valve retainer cap and insert a self-threading sheet metal screw. Clamp screw into a vise and while supporting oil pump, remove cap by tapping pump body using a soft hammer. Discard retainer cap and remove spring and relief valve see scheme 97
2. Remove oil pump cover see scheme 98
3. Remove pump outer rotor and inner rotor with shaft see scheme 98
4. Wash all parts in a suitable solvent and inspect carefully for damage or wear.

1. Install oil pump. During installation slowly rotate pump body to ensure driveshaft-to-pump rotor shaft engagement.
2. Hold the oil pump base flush against mating surface on No.5 main bearing cap. Finger tighten pump attaching bolts. Tighten attaching bolts to 41 N.m (30 ft. lbs.) torque.
3. Install the oil pan. Refer to «OIL PAN - INSTALLATION»(ref-189682-S19365031812005091100000) .

1. Disconnect the negative cable from the battery.
2. Drain the cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000).
3. Remove the A/C compressor. Refer to «A/C COMPRESSOR»(ref-189725-S01920583182005091100000).
4. Remove the generator. Refer to «GENERATORS & REGULATORS»(ref-165616).
5. Remove the accessory drive bracket.
6. Remove the air cleaner.
7. Perform the Fuel System Pressure release procedure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-157772-S14853159042003082600000). Disconnect the fuel lines. Refer to «FUEL LINE DISCONNECT FITTINGS»(ref-158737-S30612821652003101600000).
8. Disconnect the accelerator linkage. Refer to «FUEL RAIL & INJECTORS»(ref-158737-S06750985542003101600000) and if so equipped, the speed control and transmission kickdown cables.
9. Remove the return spring.
10. Remove the distributor cap and wires.
11. Disconnect the coil wires.
12. Disconnect the heat indicator sending unit wire.
13. Disconnect the heater hoses and bypass hose.
14. Remove the closed crankcase ventilation and evaporation control systems.
15. Remove intake manifold bolts.
16. Lift the intake manifold and throttle body out of the engine compartment as an assembly.
17. Remove and discard the flange side gaskets and the front and rear end seals.
18. Remove the throttle body bolts and lift the throttle body off the intake manifold (Scheme 580) Discard the gasket.
19. If required, remove the plenum pan and gasket. Discard gasket.

1. Disconnect the negative cable from the battery.
2. Raise and support the vehicle.
3. Remove the bolts and nuts attaching the exhaust pipe to the engine exhaust manifold.
4. Lower the vehicle.
5. Remove the exhaust heat shields.
6. Remove bolts, nuts and washers attaching manifold to cylinder head.
7. Remove manifold from the cylinder head.

Scheme 580

1. Position the engine exhaust manifolds on the two studs located on the cylinder head. Install conical washers and nuts on these studs see scheme 113
2. Install two bolts and conical washers at the inner ends of the engine exhaust manifold outboard arms. Install two bolts WITHOUT washers on the center arm of engine exhaust manifold see scheme 113 Starting at the center arm and working outward, tighten the bolts and nuts to 34 N.m (25 ft. lbs.) torque.
3. Install the exhaust heat shields.
4. Raise and support the vehicle.
5. Assemble exhaust pipe to manifold and secure with bolts, nuts and retainers. Tighten the bolts and nuts to 34 N.m (25 ft. lbs.) torque.
6. Lower the vehicle.
7. Connect the negative cable to the battery.

1. Disconnect the negative cable from the battery.
2. Remove water pump. Refer to «COOLING»(ref-189654-S13811322982005091200000) .
3. Remove power steering pump. Refer to «STEERING PUMP»(ref-189696) .
4. Remove vibration damper. Refer to «VIBRATION DAMPER - REMOVAL»(ref-189682-S09260815872005091100000) .
5. Loosen oil pan bolts and remove the front bolt at each side.
6. Remove the cover bolts.
7. Remove chain case cover and gasket using extreme caution to avoid damaging oil pan gasket.

Scheme 581

1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs.
2. The water pump mounting surface must be cleaned.
3. Using a new cover gasket, carefully install chain case cover to avoid damaging oil pan gasket. Use a small amount of Mopar(R) Silicone Rubber Adhesive Sealant, or equivalent, at the joint between timing chain cover gasket and the oil pan gasket. Finger tighten the timing chain cover bolts at this time. NOTE: Special Tool 6635 must be used to align the front cover and seal with the crankshaft.
4. Position the special tool 6635 onto the crankshaft see scheme 114
5. Tighten chain case cover bolts to 41 N.m (30 ft. lbs.) torque. Tighten oil pan bolts to 24 N.m (215 in. lbs.) torque.
6. Remove special tool 6635.
7. Inspect the seal flange on the vibration damper.
8. Install vibration damper. Refer to «VIBRATION DAMPER - INSTALLATION»(ref-189682-S14911789762005091100000).
9. Install water pump and housing assembly using new gaskets. Refer to «COOLING»(ref-189654-S13811322982005091200000).
10. Install power steering pump. Refer to «STEERING PUMP»(ref-189696).
11. Install the serpentine belt. Refer to «ACCESSORY DRIVE»(ref-189655).
12. Install the cooling system fan. Refer to «RADIATOR FAN»(ref-167132-S19937825632004100600000).
13. Position the fan shroud and install the bolts. Tighten the bolts to 11 N.m (95 in. lbs.) torque.
14. Fill cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000).
15. Connect the negative cable to the battery.
16. Start engine check for leaks.

Scheme 582

1. Disconnect battery negative cable.
2. Remove Timing Chain Cover. Refer to «CHAIN COVER(S) - REMOVAL»(ref-189682-S19950526722005091100000).
3. Re-install the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align timing marks as shown in see scheme 115
4. Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets.