2.0L Engine - Service Information: Other Jeep Compass I

FORM-IN-PLACE GASKETS AND SEALERS

Note. All of the sealants mentioned below are not used on every engine, they are listed as a general reference guide. See service information for specific sealer usage.

There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in-place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket. All sealing surfaces that use form-in-place gaskets and sealers must free of grease or oil. Surfaces should be cleaned with Mopar® brake parts cleaner prior to sealer application. After the sealer is applied, the parts should be assembled in no more than 10 minutes.

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

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

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

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

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

MOPAR® GASKET SEALANT is a slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 4 oz./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 re-occurring. CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart.
8. Install new spark plugs.
9. Drain engine oil and remove oil filter.
10. Install a new oil filter.
11. Fill engine with specified amount of approved oil.
12. Connect negative battery cable.
13. Start engine and check for any leaks.

Scheme 58

Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage

1. Remove oil film from surface to be checked. Plastigage is soluble in oil.
2. Place a piece of Plastigage (1) across the entire width of the journal. (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Tighten the bearing cap bolts of the bearing being checked to the proper specifications.
3. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Compare clearance measurements to specs found in engine specifications. See «SPECIFICATIONS»(ref-304329-S08975828942008110700000) . Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking.
4. Install the proper crankshaft bearings to achieve the specified bearing clearances.

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.

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1. Remove hood.
2. Remove engine cover (1).
3. Perform fuel pressure release procedure. Refer to «STANDARD PROCEDURE»(ref-304342-S34730499872008110700000) .
4. Remove retainers (5) and remove air inlet (2).
5. Remove air cleaner housing assembly (1) and clean air hose. See «REMOVAL»(ref-304329-S37258294512008110700000) .
6. Disconnect both cables from battery (3).
7. Remove battery (3).
8. Remove battery tray (1).
9. Drain cooling system. Refer to «STANDARD PROCEDURE»(ref-304343-S02124729692008110700000) .
10. Remove coolant reservoir (3).
11. Remove power steering reservoir (2).
12. Remove windshield washer reservoir (1).
13. Remove coolant hoses from coolant adapter (3).
14. Remove grill closure panel.
15. Remove upper radiator hose support (1).
16. Disconnect engine electrical connectors and reposition harness.
17. Remove air intake tube from throttle body.
18. Disconnect fuel line (3) from fuel rail.
19. Remove vacuum lines from throttle body and intake manifold.
20. Remove harness from intake (2).
21. Remove throttle body support bracket (1).
22. Disconnect electronic throttle control and manifold flow control valve electrical connectors.
23. Remove PCV hose (5), and make-up air hose (2) from valve cover.
24. Remove dipstick.
25. Remove intake bolts (1-5) and remove intake.
26. Disconnect electrical connectors and reposition harness.
27. Remove accessory drive belt.
28. Remove power steering line support at engine mount (1) and exhaust manifold.
29. Remove power steering pump and set aside.
30. Remove upper idler pulley.
31. Remove ground strap near right tower.
32. Raise vehicle.
33. Remove right front tire.
34. Remove splash shield.
35. Drain oil (2).
36. Remove inspection cover (1) and mark torque converter to flywheel.
37. Remove torque converter bolts (1).
38. Remove lower bellhousing bolts (2).
39. Remove A/C compressor (1) mounting bolts.
40. Remove generator and lower idler pulley.
41. Disconnect crankshaft position sensor electrical connector and remove crankshaft position sensor (2).
42. Remove exhaust variable valve timing solenoid.
43. Install engine lift chain (1) as shown in illustration to cylinder head.
44. Connect the chain to the rear engine lift hook.
45. Install engine lifting crane.
46. Remove right engine mount through bolt (4).
47. Remove engine mount adapter retaining bolts (3) and mount adapter (2).
48. Lift engine from engine compartment.

Scheme 78

1. Remove engine cover (1) by pulling upwards.

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1. Position engine assembly over vehicle and slowly lower the engine into place.
2. Continue lowering engine until engine and transaxle are aligned. to mounting locations.
3. Install engine mount adapter (2) and tighten bolts (3). Install mount through bolt (4) and tighten to 118 N.m (87 ft. lbs.).
4. Remove engine lift chain (1).
5. Install oil control valve.
6. Raise vehicle.
7. Install A/C compressor (1).
8. Install exhaust manifold and heat shields (2). See «INSTALLATION»(ref-304329-S23079465502008110700000) .
9. Install oxygen sensor and connect electrical connector (3).
10. Install crankshaft position sensor (2) and connect connector.
11. Install manifold to exhaust pipe bolts (1) and tighten bolts.
12. Install generator.
13. Install lower bell housing bolts (2) and tighten bolts.
14. Align torque converter and flex plate mark. Install torque converter bolts (1) and tighten.
15. Install inspection cover (1).
16. Install crankshaft damper
17. Install Damper holder 9707 (1).
18. Apply clean engine oil crankshaft damper bolt threads and between bolt head and washer. Tighten bolt to 210 N.m (155 ft. lbs.).
19. Install right splash shield.
20. Install tire.
21. Install coolant hose to oil cooler (2).
22. Install new oil filter (3).
23. Lower vehicle.
24. Install upper idler pulley.
25. Install coolant adapter assembly (3).
26. Install Ground strap (1) near right strut tower.
27. Install power steering line support bracket (1).
28. Install power steering pump.
29. Install accessory drive belt.
30. Connect electrical connectors at block ground, starter, A/C compressor, knock sensor, Oil pressure sensor, generator, Coolant temperature sensor at block, and block heater (if equipped).
31. Install intake manifold and tighten bolts as shown in illustration.
32. Install throttle body support bracket (1).
33. Install harness retainer (2).
34. Install engine oil level indicator.
35. Install PCV hose (5) to valve cover.
36. Install make-up air hose (2).
37. Connect manifold flow control valve and electronic throttle control electrical connectors.
38. Install vacuum lines at throttle body and intake manifold.
39. Install intake air tube to throttle body.
40. Connect coil electrical connectors (1).
41. Connect injector electrical connectors (4).
42. Connect fuel line (3) to rail.
43. Connect intake and exhaust oil control valve electrical connectors.
44. Install grill trim panel.
45. Install upper radiator support bracket (1).
46. Connect coolant temperature sensor (1).
47. Connect capacitor electrical connector (2).
48. Install coolant hoses at coolant adapter (3).
49. Install coolant reservoir (3) and connect hose.
50. Install battery tray (1).
51. Install battery (3).
52. Connect battery cables.
53. Install air cleaner housing (1) and connect inlet air hose.
54. Install clean air hose (5).
55. Fill with coolant.
56. Fill with oil.
57. Start engine and check for leaks.
58. Install engine cover (1).
59. Install hood.

Scheme 99

1. Position engine cover (1) over mounting studs.
2. Seat the cover on the rear studs by pushing downwards.
3. Push downward on the front of the cover to seat the front studs.

GENERAL SPECIFICATIONS

CYLINDER BLOCK

PISTONS

PISTON RINGS

CONNECTING ROD

CRANKSHAFT

CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER

CAMSHAFT

CYLINDER HEAD

VALVE SEAT

VALVE GUIDE

VALVES

VALVE MARGIN

VALVE STEM TIP

VALVE STEM TO GUIDE CLEARANCE

VALVE SPRINGS

OIL PRESSURE

CYLINDER HEAD

The cross flow designed, aluminum cylinder head contains dual over-head camshafts with four valves per cylinder. The valves are arranged in two in-line banks. The intake valves face toward the front of the vehicle. The exhaust valves face the dash panel. The cylinder head incorporates powdered metal valve guides and seats. The cylinder head is sealed to the block using a multi-layer steel head gasket and retaining bolts.

Integral oil galleries provide lubrication passages to the variable camshaft timing phasers, camshafts, and valve mechanisms.

Note. Replacement cylinder heads will come complete with valves, seals, springs, retainers, keepers, lash buckets, and camshafts.

CYLINDER HEAD GASKET

A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent water jacket or from an oil passage to the exterior of the engine.

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.

Note. Replacement cylinder heads will come complete with valves, seals, springs, retainers, keepers, tappets, and camshafts.

Scheme 100

1. Cylinder head must be flat within 0.1 mm (0.004 in.).
2. Inspect camshaft bearing journals for scoring.
3. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
4. Verify the valve tappets move freely in theirs bores, and that they have been rotating.
5. Check valve guide height.
6. Prior to installing cylinder head, the cylinder block should be checked for flatness. See «INSPECTION»(ref-304329-S22168196732008110700000) .

Scheme 101

Note. Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.

Note. The Cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced.

Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2), the bolt should be replaced.

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1. Replace the variable valve timing filter screen (3). NOTE: When using RTV, the sealing surfaces must be clean and free from grease and oil. NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes.
2. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder block as shown in illustration.
3. Position the new cylinder head gasket on engine block with the part number facing up. Ensure gasket is seated over the locating dowels in block.
4. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder head gasket as shown in illustration. NOTE: The head must be installed within 15 minutes before the RTV skins.
5. Position cylinder head onto engine block. CAUTION: This engine was built with 2 different style cylinder head bolts. Each style bolt requires a different torque value. The bolts can be identified by the short bolt head (1) and the long bolt head (2).
6. Measure the bolt head from the washer to the top of the bolt head. The short bolt head (1) measures 8 mm (5/16") and the long bolt head (2) measures 13 mm (1/2").
7. Identify whether your engine has the short head design (1) or the long head design (2). NOTE: The front two cylinder head bolts do not have captured washers. The washers must be installed with the bevel up towards the bolt head.
8. Install washers (1) for the front two cylinder head bolts.
9. Before installing the bolts, the threads should be lightly coated with engine oil.
10. Install the cylinder head bolts and tighten in the sequence shown in illustration.
11. If your bolt has the short head (1), use the following torque specifications: First: All to 30 N.m (25 ft. lbs.) Second: All to 61 N.m (45 ft. lbs.) Third: All to 61 N.m (45 ft. lbs.) Fourth: All an additional 90° CAUTION: Do not use a torque wrench for the Fourth step.
12. If your bolt has the long head (2), use the following torque specifications: First: All to 30 N.m (25 ft. lbs.) Second: All to 73 N.m (54 ft. lbs.) Third: All to 73 N.m (54 ft. lbs.) Fourth: All an additional 90° CAUTION: Do not use a torque wrench for the Fourth step.
13. Clean excess RTV from timing chain cover sealing surface.
14. Install camshafts. See «INSTALLATION»(ref-304329-S11114030262008110700000) .
15. Install cylinder head cover. See «INSTALLATION»(ref-304329-S15488240462008110700000) .
16. On AWD vehicles, install maniverter. See «INSTALLATION»(ref-304329-S23079465502008110700000) .
17. On FWD vehicles, install exhaust manifold. See «INSTALLATION»(ref-304329-S23079465502008110700000) .
18. Install ground strap (1) at right rear of cylinder head.
19. Install coolant adapter (3) with new seals.
20. Connect coolant hoses.
21. Connect purge hose (4).
22. Install intake manifold.
23. Install intake manifold bolts and tighten to 24 N.m (18 ft. lbs.).
24. Install upper radiator hose retaining bracket bolt (1).
25. Install timing chain (2). See «INSTALLATION»(ref-304329-S29298268142008110700000) .
26. Install timing chain cover. See «INSTALLATION»(ref-304329-S38724498342008110700000) .
27. Remove coils from cylinder head cover.
28. Install cylinder head cover. See «INSTALLATION»(ref-304329-S15488240462008110700000) .
29. Connect cam sensor wiring connector.
30. Install spark plugs and tighten to 27 N.m (20 ft. lbs.).
31. Install ignition coils (1) and tighten to 8 N.m (70 in. lbs.).
32. Install power steering pump reservoir (2).
33. Install windshield washer reservoir (1).
34. Install coolant recovery reservoir (3)
35. Install accessory drive belts. Refer to «INSTALLATION»(ref-304343-S25877668642008110700000) .
36. Connect engine coolant temperature sensor connector.
37. Connect coolant hoses to coolant adapter (3). Connect heater hoses to coolant adapter (1).
38. Connect coolant temperature sensor (1) and capacitor (2) electrical connectors.
39. Install heater tube support bracket to cylinder head.
40. Install fastener attaching dipstick tube to lower intake manifold.
41. Connect coil (1) and injector (4) electrical connectors.
42. Install fuel rail.
43. Connect fuel supply line quick-connect (3) at the fuel rail assembly. Refer to «STANDARD PROCEDURE»(ref-304342-S34560691312008110700000) .
44. Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-304343-S02124729692008110700000) .
45. Connect negative cable to battery (3).
46. Install clean air hose (5) and air cleaner housing (1). See «INSTALLATION»(ref-304329-S20848631162008110700000) .
47. Install new oil filter and fill engine with oil.
48. Start engine and check for leaks.
49. Install engine cover.

CAMSHAFT BEARING CAPS

The front cam bearing cap spans both camshafts, and includes dowels for precise alignment. The front exhaust journal has a select fit bearing insert. This bearing is required to seal the oil passage to the camshaft phaser, because a portion of the lower bearing saddle is machined away for head bolt access. The select fit is required to minimize bearing clearance and oil leakage. An exhaust bearing grade (1,2,or 3) is stamped into the front bearing cap adjacent to the exhaust cam journal. The bearings are also marked with the corresponding grade markings. If the bearing is replaced, the same grade must be used. Due to unique purpose of this bearing, it may appear to have uneven wear patterns. Unless the wear is excessive it is no cause for concern.

The front intake journal has a full lower bearing saddle, and therefore, no bearing insert is required.

All small bearing caps have a formed in arrow to assist in assembly. All small bearing cap arrows must point towards the center of the cylinder head. The small bearing caps are marked for position during the manufacturing process, and must be reinstalled in their original position.

The #1 small cap includes a passage to direct oil from the cylinder head oil gallery to the #1 small bearing journal; and into the camshaft as well. The hollow camshaft then distributes oil to the remainder of the small journals. Oil flowing out of each cam journal lubricates the valve tappets.

The #3 small cap is machined at the front and rear face to control camshaft end-play. This cap has dowels for precise alignment.

CAMSHAFT(S)

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

Scheme 117

1. Using a suitable tool, move camshaft as far rearward as it will go.
2. Zero dial indicator.
3. Move camshaft as far forward as it will go.
4. Record reading on dial indicator. For end play specification, see «SPECIFICATIONS»(ref-304329-S08975828942008110700000) .
5. If end play is excessive, check cylinder head and camshaft for wear; replace as necessary.

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1. Remove engine cover by pulling upward.
2. Disconnect negative battery (3) cable.
3. Disconnect coil electrical connectors (1).
4. Remove cylinder head cover. See «REMOVAL»(ref-304329-S10843827882008110700000) .
5. Raise vehicle.
6. Remove right splash shield.
7. Rotate engine to TDC (1).
8. Make sure camshaft timing marks (3) are aligned.
9. Mark the chain link corresponding to timing marks (1) with a paint marker.
10. Remove timing tensioner plug (1) from front cover.
11. Insert small Allen wrench through timing tensioner plug hole and lift ratchet (2) upward to release the tensioner and push Allen wrench inward. Leave the Allen wrench installed during the remainder of this procedure.
12. Verify that camshaft timing marks (3) are facing each other as shown in illustration.
13. Mark the camshaft sprocket timing marks and the corresponding chain links (1) with a paint marker.
14. Insert Locking Wedge 9701 (1) between camshaft phasers.
15. Lightly tap Locking Wedge 9701 (2) into place with a suitable (1) tool until it will no longer sink down.
16. Remove the front camshaft bearing cap.
17. Slowly remove the remaining intake and exhaust camshaft bearing cap bolts one turn at a time.
18. Remove intake camshaft (1) by lifting the rear of the camshaft upward.
19. Rotate the camshaft while lifting out of the front bearing cradle.
20. Lift the timing chain (2) off the sprocket (1).
21. Remove exhaust camshaft.
22. Secure timing chain with wire so that it does fall into the timing chain cover.

CAMSHAFT

Clean camshafts with a suitable solvent.

1. Inspect camshaft bearing journals for damage. If journals are damaged, check the cylinder head for damage. Also check cylinder head oil holes for clogging.
2. Check the cam lobe and bearing surfaces for abnormal wear and damage. Replace camshaft if defective.

Note. If camshaft is replaced due to lobe wear or damage, always replace the lash buckets.

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1. The cam cap (1) is numbered (2) either one, two, or three, this corresponds to the select fit bearing to use.
2. Install the corresponding select fit bearing (1).
3. Oil all of the camshaft journals with clean engine oil.
4. Install camshaft phasers on camshafts if removed. Install camshaft phaser making sure that the dowel is in the correct hole. Install camshaft phaser bolt and hand tighten.
5. Install timing chain onto exhaust cam sprocket making sure that the timing marks (1) on the sprocket and the painted chain link are aligned.
6. Position exhaust camshaft on bearing journals in the cylinder head.
7. Align exhaust cam timing mark (3) so it is parallel to the cylinder head as shown in illustration.
8. Install intake camshaft by raising the rear of the camshaft upward and roll the sprocket into the chain.
9. Align the timing marks (1) on the intake cam sprocket with the painted chain link.
10. Position the intake camshaft into the bearing journals in the cylinder head.
11. Verify that the timing marks (1) are aligned on both camshafts and that the timing marks (3) are parallel with the cylinder head. CAUTION: Install the front intake and exhaust camshaft bearing cap last. Ensure that the dowels are seated and follow torque sequence or damage to engine could result. NOTE: If the front camshaft bearing cap is broken, the cylinder head MUST be replaced.
12. Install intake and exhaust camshaft bearing caps and slowly tighten bolts to 11 N.m (100 in. lbs.) in the sequence shown in illustration. NOTE: Verify that the exhaust bearing shells are correctly installed, and the dowels are seated in the head, prior to tightening bolts.
13. Install the front intake and exhaust bearing cap and tighten bolts to 25 N.m (18 ft. lbs.) in the sequence shown in illustration.
14. Verify that all timing marks (1,3) are aligned.
15. Remove Allen wrench from timing chain tensioner.
16. Remove Locking Wedge 9701 (1) by pulling straight upward on pull rope.
17. Apply MOPAR® thread sealant to timing tensioner plug (1) and Install.
18. Install right splash shield.
19. Clean RTV from cylinder head cover gasket (1).
20. Inspect cylinder head cover gaskets (1,2) for damage. If no damage is present, gaskets can be reinstalled.
21. Install cylinder head cover. See «INSTALLATION»(ref-304329-S15488240462008110700000) .
22. Connect negative battery (3) cable.
23. Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-304343-S02124729692008110700000) .
24. Fill with oil.
25. Start engine and check for leaks.
26. Install engine cover (1).

Scheme 143

1. Remove engine cover.
2. Disconnect ignition coil electrical connectors.
3. Disconnect PCV and make-up air hoses from cylinder head cover.
4. Use compressed air to blow dirt and debris off the cylinder head cover prior to removal.
5. Remove cylinder head cover bolts.
6. Remove cylinder head cover from cylinder head.

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1. Install new cylinder head cover gaskets (1,2).
2. Install studs in cover as shown in illustration.
3. Clean all RTV from cylinder head. NOTE: When using RTV, the sealing surfaces must be clean and free from grease and oil. NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes.
4. Apply a dot of Mopar® engine sealant RTV or equivalent to cylinder head/front cover T-joints (1).
5. Install cylinder head cover assembly to cylinder head and install all bolts, ensuring the studs are located as shown in illustration.
6. Tighten bolts in sequence shown in illustration using a 2 step torque method as follows: Tighten all bolts to 5 N.m (44 in. lbs.) Tighten all bolts to 10 N.m (90 in. lbs.).
7. Install ignition coils. Tighten fasteners to 8 N.m (70 in. lbs.).
8. If the PCV valve was removed, tighten PCV valve to 5 N.m (44 in. lbs.).
9. Connect PCV and make-up air hoses to cylinder head cover.
10. Install engine cover.

CLEARANCE TOO LARGE

1. Remove camshafts. See «REMOVAL»(ref-304329-S15893420982008110700000) .
2. Clearance - specification = change.
3. Increase tappet thickness by change figure.
4. Install camshafts. See «INSTALLATION»(ref-304329-S11114030262008110700000) .
5. Verify that valve lash is correct.

Scheme 148

Note. This procedure is for in-vehicle service with camshafts installed.

Note. Camshaft tappets must be replaced if cylinder head or camshafts are replaced.

Scheme 149

1. Remove cylinder head cover. See «REMOVAL»(ref-304329-S10843827882008110700000) .
2. Remove camshafts. See «REMOVAL»(ref-304329-S15893420982008110700000) .
3. Remove camshaft tappets (1).
4. Repeat removal procedure for each camshaft tappet (1).
5. If reusing, mark each camshaft tappet for reassembly in it's original position.

Scheme 150

Note. If reinstalling original tappets they must go back in their original location or engine damage could result.

Scheme 151

1. Apply a light coat of clean engine oil to camshaft tappets (1) prior to assembly.
2. Install camshaft tappets (1) into cylinder head.
3. Repeat installation procedure for each camshaft tappet.
4. Install camshafts. See «INSTALLATION»(ref-304329-S11114030262008110700000) . NOTE: If installing new tappets, the valve lash procedure must be performed.
5. Install cylinder head cover. See «INSTALLATION»(ref-304329-S15488240462008110700000) .

VALVE AND VALVE SPRING

The valves are made of heat resistant steel. They have nitrided stems to prevent scuffing. Viton rubber valve stem seals are integral with the spring seats. The valves have single bead lock keepers to retain the springs.

The four valves per cylinder (two intake and two exhaust) are opened by using direct acting tappets which are actuated by the camshaft.

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

Scheme 152

1. With cylinder head removed from cylinder block, place a ball of rags in the combustion chamber. CAUTION: Care must be taken not to damage the tappet bore or engine damage may result.
2. Mark valve tappet location for assembly.
3. Remove valve tappets.
4. Using metric valve keeper tool such as Snap-on® GA317 (or equivalent) remover (1) , remove valve keepers with a downward push.
5. Remove retainer and springs.
6. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves, locks and retainers to insure installation in original location.
7. Inspect the valves. See «INSPECTION»(ref-304329-S14232039082008110700000) .

Scheme 153

Scheme 154

Scheme 155

1. Rotate crankshaft until piston is at TDC on compression.
2. Remove cylinder head cover. See «REMOVAL»(ref-304329-S10843827882008110700000) .
3. Remove camshafts. See «REMOVAL»(ref-304329-S15893420982008110700000) .
4. Mark valve tappet location for assembly.
5. Remove valve tappets.
6. With air hose attached to adapter tool installed in spark plug hole, apply 90-120 psi air pressure. CAUTION: Care must be taken not to damage the tappet bore or engine damage may result.
7. Using metric valve keeper tool (1) such as Snap-on® GA317 (or equivalent), and remove valve spring keepers and retainer.
8. Remove valve spring(s).
9. Remove valve stem seal(s) by a using valve stem seal tool.

1. Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested for correct load. Discard the springs that do not meet specifications. The following specifications apply to both intake and exhaust valves springs: Valve closed nominal load - 179.5 N ± 9 N @ 35.0 mm (40.35 lbs. ± 2 lbs. @ 1.38 in.). Valve open nominal load - 364.8 N ± 17 N @ 29.25 mm (82 lbs. ± 3.8 lbs. @ 1.152 in.).
2. Inspect each valve spring for squareness with a steel square and surface plate, test springs from both ends. If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring.

Scheme 156

Scheme 157

Scheme 158

1. Coat valve stems with clean engine oil and insert in cylinder head.
2. Install new valve stem seals (3) on all valves using an appropriate sized socket to seat the seal/spring seat. The valve stem seals should be pushed firmly and squarely over valve guide.
3. Install valve springs (2).
4. Install keepers in retainer and place on valve spring.
5. Using metric valve keeper tool such as Snap-on® GA317 (or equivalent) installer (2) and remover (1) as a handle, push downward to install keepers. 1 - GARTER SPRING 2 - VALVE SPRING SEAT 3 - CYLINDER HEAD SURFACE
6. Check the valve spring installed height B after refacing the valve and seat. 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 (1.525 in.), install a 0.762 mm (0.030 in.) spacer under the valve spring seat to bring spring height back within specification.
7. Install valve tappets.

VALVE SPRINGS AND VALVE SEALS IN VEHICLE

Scheme 159

Scheme 160

1. Install valve seal/valve spring seat (3) assembly. Push the assembly down with appropriate size socket to seat it onto the valve guide.
2. Install valve spring (2) and retainer (4) with keepers (1).
3. Place the valve keepers in the retainer. Using metric valve keeper tool such as Snap-on® GA317 (or equivalent) installer (2) and remover (1) as a handle, install valve keepers with a downward push.
4. Remove air hose and install spark plugs.
5. Install valve tappets.
6. Install camshafts. See «INSTALLATION»(ref-304329-S11114030262008110700000) .
7. Install cylinder head cover. See «INSTALLATION»(ref-304329-S15488240462008110700000) .

CAMSHAFT PHASERS

Note. Camshaft phaser and camshaft sprocket are supplied as an assembly, do not attempt to disassemble.

Scheme 161

1. Remove camshafts. See «REMOVAL»(ref-304329-S15893420982008110700000) .
2. Remove camshaft phaser (2) retaining bolt while holding the camshaft in place with a wrench (1) on the camshaft flats.
3. Remove phaser (2) assembly from camshaft.

Scheme 162

1. Install phaser (2) assembly on camshaft. NOTE: Make sure the dowel is seated in the dowel hole and not in an oil feed hole. The dowel hole is larger than the 4 oil feed holes.
2. Install phaser retaining bolt and tighten while holding camshaft in place with a wrench (1).
3. Install camshafts. See «INSTALLATION»(ref-304329-S11114030262008110700000) .

CYLINDER BLOCK AND LADDER FRAME

The die cast aluminum cylinder block is a two-piece assembly, consisting of the cylinder block and ladder frame. The block is an open deck design with cast in place cast iron cylinder liners. The cast iron cylinder liners are recessed below the aluminum deck surface. The ladder frame bolts to the cylinder block and does not incorporate the main bearing caps. This design offers a much stronger lower end and increased cylinder block and transaxle rigidity. The rear oil seal retainer is integral with the block and ladder frame. The ladder frame and block are serviced as an assembly.

Scheme 163

The engine serial number is located on the bottom of the ladder frame just behind the oil pan. The date can be seen with the oil pan in place.

Scheme 164

1. Deglazing of the cylinder walls may be done using a quality commercially available flex hone, if the cylinder bore is straight and round. 20-60 strokes depending on the bore condition, will be sufficient to provide a satisfactory surface. Use a light honing oil. Do not use engine or transmission oil, mineral spirits or kerosene. Inspect cylinder walls after each 20 strokes.
2. Honing should be done by moving the hone up and down fast enough to get a cross-hatch pattern. When hone marks intersect at 30-50 degrees, the cross hatch angle is most satisfactory for proper seating of rings. (Scheme 164)
3. A controlled hone motor speed between 200-300 RPM is necessary to obtain the proper cross-hatch angle. The number of up and down strokes per minute can be regulated to get the desired 30-50 degree angle. Faster up and down strokes increase the cross-hatch angle.
4. After honing, it is necessary that the block be cleaned again to remove all traces of abrasive.

ENGINE BLOCK

Clean cylinder block thoroughly using a suitable cleaning solvent.

1. Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking.
2. Examine block and cylinder bores for cracks or fractures.
3. Check block deck surfaces for flatness. Deck surface must be within service limit of 0.050 mm (0.002 in.).

Scheme 165

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 Cylinder Indicator C119 or equivalent. 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. 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 166

1. Mount a dial indicator (2) to front of engine with the locating probe on nose of crankshaft (1). (Scheme 166)
2. Move crankshaft all the way to the rear of its travel.
3. Zero the dial indicator.
4. Move crankshaft all the way to the front and read the dial indicator for end play specification. See «SPECIFICATIONS»(ref-304329-S08975828942008110700000).

Scheme 167

Note. Crankshaft can not be removed when engine is in vehicle.

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

1. Remove engine assembly from vehicle. See «REMOVAL»(ref-304329-S27147758722008110700000) .
2. Separate transaxle from engine.
3. Remove flex plate/flywheel (1).
4. Remove crankshaft rear oil seal. See «REMOVAL»(ref-304329-S15993774722008110700000) .
5. Remove engine from lift chain (1) and mount engine on a suitable repair stand.
6. Drain engine oil (2).
7. Remove oil filter (1).
8. Remove crankshaft vibration damper (2). See «REMOVAL»(ref-304329-S31668286012008110700000) .
9. Remove water pump pulley (3).
10. Remove engine mount support bracket (1).
11. Remove the oil pan (2). See «REMOVAL»(ref-304329-S23187716552008110700000) .
12. Remove timing chain cover. See «REMOVAL»(ref-304329-S38855027942008110700000) .
13. Remove the timing chain. See «REMOVAL»(ref-304329-S28290244522008110700000) .
14. Remove balance shaft module.
15. Remove the crankshaft sprocket (1).
16. Remove crankshaft position sensor retaining bolt (1) and remove sensor (2).
17. Remove ladder frame. See «REMOVAL»(ref-304329-S12788253062008110700000) . NOTE: If piston/connecting rod replacement is necessary, remove cylinder head. See «REMOVAL»(ref-304329-S19954444682008110700000) . CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.
18. Using a permanent ink or paint marker, identify cylinder number on each connecting rod and cap.
19. Remove all connecting rod bolts and caps. Care should be taken not to damage the fracture rod and cap surfaces. NOTE: Do not reuse connecting rod bolts.
20. Remove main bearing caps. CAUTION: Use extreme care when handling crankshaft. Tone wheel damage can occur if crankshaft is mishandled.
21. Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the crankshaft.

Scheme 177

The crankshaft main journals should be checked for excessive wear, taper and scoring. Limits of taper on any crankshaft main journals should be held to 0.006 mm (0.00024 in.). Limits of taper on any crankshaft rod journals should be held to 0.005 mm (0.0002 in.). DO NOT nick crank pin or bearing fillets. Limits of out of round on any crankshaft journals should be held to 0.005 mm (0.0002 in). DO NOT nick crank pin or bearing fillets.

Scheme 178

The crankshaft is supported in five main bearings. All upper bearing shells (2) in the crankcase have oil grooves and holes. All lower bearing shells (1) are smooth. Crankshaft end play is controlled by a two piece thrust bearing (3) on the number three main bearing journal.

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

1. Clean main bearing cap bolt holes with Mopar® brake parts cleaner or equivalent and blow out with compressed air.
2. Install the main bearing upper (2) shells with the lubrication groove and oil hole in the engine block.
3. Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots. NOTE: If the crankshaft is sent out for machine work, it must be balanced as an assembly with the target ring installed.
4. Clean crankshaft and target ring with MOPAR® Brake Parts cleaner and dry with compressed air to ensure that the crankshaft mating surface and target ring mounting holes are free from oil and lock patch debris. NOTE: Always use NEW mounting screws whether installing original or new target ring.
5. Install NEW mounting screws finger tight starting with the #1 location. Make sure engagement occurs with the shoulder of the screws and mounting hole before starting all other screws.
6. Tighten all mounting screws to 13 N.m (110 in-lbs) in the sequence shown in illustration. NOTE: Lightly apply trans gel to thrust bearings to hold bearings in block. NOTE: The thrust bearings must be installed the notches facing the crankshaft.
7. Install thrust bearings (2) in block (1). CAUTION: Do not get oil on the ladder frame mating surface. It will affect the ability of the RTV to seal the ladder frame to cylinder block. NOTE: Ensure main bearing cap bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.
8. Oil the bearings and journals. Install crankshaft in engine block.
9. Install lower main bearings (1) into main bearing cap. Make certain the bearing tabs are seated into the bearing cap slots. NOTE: Main bearing caps are stamped 1 - 5 front to rear. Arrows on the caps must point towards the front of the engine.
10. Install main bearing caps to engine block.
11. Before installing the bolts the threads should be clean and dry.
12. Loosely install main bearing cap bolts.
13. To ensure correct thrust bearing alignment, perform the following steps: Step 1: Rotate crankshaft until number 4 piston is at TDC. Step 2: Move crankshaft rearward to limits of travel. Step 3: Then, move crankshaft forward to limits of travel. Step 4: Wedge an appropriate tool between the rear of the cylinder block and the rear crankshaft counterweight. This will hold the crankshaft in its furthest forward position. CAUTION: There are different sets main bolts supplied with this engine. Each bolt set has a different torque value and engine damage could result if bolts are not torqued correctly. The bolts are not interchangeable.
14. If your bolt heads look like this (1,2), go to step 15 . If your bolt heads do not look like this (1,2), go to step 16 . CAUTION: Before tightening bolts, you must identify the bolt head to obtain the correct torque value. Failure to identify the bolts correctly, could result in improperly tightened bolts which could result in engine damage.
15. Tighten bolts using a three step method, in the sequence shown in illustration. Tighten bolts to 15 N.m (11 ft. lbs.) Tighten bolts to 27 N.m (20 ft. lbs.) Rotate an additional 45°.
16. Tighten bolts using a three step method, in the sequence shown in illustration. Tighten bolts to 15 N.m (11 ft. lbs.) Tighten bolts to 45 N.m (33 ft. lbs.) Rotate an additional 45°.
17. Remove wedge tool used to hold crankshaft.
18. Check the crankshaft turning torque, it should not exceed 5.6 N.m (50 in. lbs.).
19. Check crankshaft end play. See «STANDARD PROCEDURE»(ref-304329-S33274587152008110700000) .
20. Install connecting rod bearings and caps. Do Not Reuse Connecting Rod Bolts. Tighten connecting rod bolts to 20 N.m + 90° (15 ft. lbs.) + 90°. See «INSTALLATION»(ref-304329-S05109861862008110700000) .
21. Install the ladder frame assembly. See «INSTALLATION»(ref-304329-S13056612862008110700000) .
22. Install the balance shaft module. See «INSTALLATION»(ref-304329-S27260761992008110700000) .
23. Install crankshaft position sensor (2) and tighten bolt (1).
24. Install cylinder head if it was removed. See «INSTALLATION»(ref-304329-S19292371512008110700000) .
25. Install front crankshaft sprocket (1).
26. Install the timing chain. See «INSTALLATION»(ref-304329-S29298268142008110700000) .
27. Install the timing chain front cover. See «INSTALLATION»(ref-304329-S38724498342008110700000) .
28. Install the oil pan. See «INSTALLATION»(ref-304329-S34519148672008110700000) .
29. Install rear crankshaft oil seal. See «INSTALLATION»(ref-304329-S15115023492008110700000) .
30. Install front crankshaft oil seal. See «INSTALLATION»(ref-304329-S23013764732008110700000) .
31. Install engine mount support bracket (1).
32. Install crankshaft vibration damper (2). See «INSTALLATION»(ref-304329-S39521080112008110700000) .
33. Install water pump pulley (3).
34. Remove engine from repair stand and install engine lift chain (1).
35. Install crankshaft rear oil seal. See «INSTALLATION»(ref-304329-S15115023492008110700000) .
36. Install drive plate/flex plate using new bolts. Tighten bolts to 95 N.m (70 ft. lbs.).
37. Attach transaxle to engine. Tighten bellhousing bolts to 101 N.m (75 ft. lbs.).
38. Install the engine assembly. See «INSTALLATION»(ref-304329-S01070925352008110700000) .
39. Install new oil filter (1) and fill with oil.
40. Fill with coolant. Refer to «STANDARD PROCEDURE»(ref-304343-S02124729692008110700000) .
41. Start engine and check for leaks.
42. Install engine cover.

Scheme 188

Scheme 189

1. Remove accessory drive belt.
2. Install Damper Holder 9707 (1) and remove damper retaining bolt.
3. Pull damper off crankshaft.
4. Remove front crankshaft oil seal (1) by prying out with a screw driver (2). Be careful not to damage the cover seal surface.

Scheme 190

Scheme 191

Scheme 192

Scheme 193

1. Place seal (1) onto Front Crankshaft Seal Installer 9506 (2) with seal spring towards the inside of engine.
2. Install new seal (1) by using Front Crankshaft Seal Installer 9506 (2) and crankshaft damper bolt (3).
3. Press seal into front cover until Front Crankshaft Seal Installer 9506 (1) seats against timing chain cover (3).
4. Remove Front Crankshaft Seal Installer 9506 (1).
5. Install crankshaft vibration damper.
6. Oil the bolt threads and between the bolt head and washer.
7. Install damper retaining bolt and Damper Holder 9707 (1). Tighten bolt to 210 N.m (155 ft. lbs.).

Scheme 194

Scheme 195

1. Remove transaxle
2. Remove flex plate bolts and discard.
3. Remove flex plate (1).
4. Insert a 3/16 flat bladed screwdriver (7) between the dust lip (8) and the metal case (4) of the crankshaft seal (1). Angle the screwdriver through the dust lip against metal case of the seal. Pry out seal. CAUTION: Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of the screwdriver blade against crankshaft edge (chamfer) is permitted.
5. Check to make sure the seal's garter spring is not on the crankshaft.

Scheme 196

Note. When installing seal, lubricate Seal Guide 9509 with clean engine oil.

Scheme 197

1. Place Rear Crankshaft Seal Guide 9509 (3) on crankshaft.
2. Position seal (2) over Rear Crankshaft Seal Guide 9509 (3). Guide tool should remain on crankshaft during installation of seal. Ensure that the lip of the seal is facing towards the crankcase during installation.
3. Drive the seal into the block using Seal Driver 9706 (1) and Driver Handle C-4171 (4) until Seal Driver 9706 bottoms out against the block.
4. Install flex plate (1).
5. Install washer (2).
6. Install new flex plate bolts (3) and tighten to 95 N.m (70 ft. lbs.).
7. Install transaxle. Refer to appropriate Automatic Transmission SERVICE INFORMATION article for procedure.

PISTON AND CONNECTING ROD

The pistons are made of a cast aluminum alloy. The pistons have pressed-in pins attached to forged connecting rods. The piston pin is offset 0.8 mm (0.0314 in.) towards the thrust side of the piston. The connecting rods are a cracked cap design and are not repairable. The piston with rings, connecting rod and piston pin are serviced as an assembly.

Scheme 198

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

Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin (1).

Scheme 199

1. Measurement should be taken approximately 16 mm (0.629 in.) from the bottom of the skirt (2) as shown in illustration. NOTE: Correct piston to bore clearance must be established in order to assure quiet and economical operation.
2. Cylinder bores should be measured halfway down the cylinder bore and transverse (measurement location B) to the engine crankshaft center line shown in illustration. See «SPECIFICATIONS»(ref-304329-S08975828942008110700000) .

Scheme 200

Note. Pistons, rings, and rods are serviced as an assembly.

Scheme 201

Scheme 202

1. Remove engine. See «REMOVAL»(ref-304329-S27147758722008110700000) .
2. Remove cylinder head. See «REMOVAL»(ref-304329-S19954444682008110700000) .
3. Drain engine oil (2).
4. Remove oil pan (1). See «REMOVAL»(ref-304329-S23187716552008110700000) .
5. Remove oil filter (1).
6. Remove balance shaft assembly.
7. Remove ladder frame. NOTE: Remove any carbon build up and clean debris from cylinder prior to piston removal to avoid scratching piston skirts.
8. 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 .
9. Rotate crankshaft so that each connecting rod is centered in cylinder bore.
10. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods, as damage to connecting rod may occur. CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage may occur.
11. Remove connecting rod bolts and cap. NOTE: Do not reuse connecting rod bolts.
12. Carefully push each piston and rod assembly out of cylinder bore. Reinstall bearing cap on the mating rod.
13. Repeat procedure for each piston and connecting rod assembly.

Scheme 203

Scheme 204

1. Install piston rings on piston. See «INSTALLATION»(ref-304329-S01084404492008110700000) .
2. Before installing pistons and connecting rod assemblies into the bore, be sure that top compression ring gap (1) and the second compression ring gap (3) are staggered so that neither is in line with oil ring rail gap.
3. Before installing the ring compressor, make sure the oil ring expander ends are butted (1) and the rail gaps (2,4) are located as shown in illustration. As viewed from the top of the piston.
4. Immerse the piston head and rings in clean engine oil and slide the ring compressor over the piston. Be sure position of rings does not change during this operation .
5. The directional arrow stamped on the piston should face toward the front of the engine.
6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate connecting rod journal with clean engine oil. NOTE: There are three different size rod bearings, perform rod bearing selection procedure.
7. The rod bearing sizes are indicated on the nose of the crankshaft.
8. Install connecting rod upper bearing half into connecting rod.
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: The connecting rod cap bolts should NOT be reused.
10. Before installing the NEW bolts, the threads should be coated with clean engine oil.
11. Install connecting rod lower bearing half into connecting rod cap. Install connecting rod cap.
12. Install each bolt finger tight then alternately tighten each bolt to assemble the cap properly.
13. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values: CAUTION: Do not use a torque wrench for the second step. Tighten the bolts to 20 N.m (15 ft. lbs.). Tighten the connecting rod bolts an additional 90°
14. Using a feeler gauge, check connecting rod side clearance. See «SPECIFICATIONS»(ref-304329-S08975828942008110700000) for connecting rod side clearance.
15. Install the ladder frame.
16. Install balance shaft module. See «INSTALLATION»(ref-304329-S27260761992008110700000) .
17. Install oil pan. See «INSTALLATION»(ref-304329-S34519148672008110700000) .
18. Install cylinder head. See «INSTALLATION»(ref-304329-S19292371512008110700000) .
19. Install engine. See «INSTALLATION»(ref-304329-S01070925352008110700000) .

STANDARD PROCEDURE

Note. There are three different possibilities for the upper main bearings and five different lower main bearings. The upper and lower bearing shells are not interchangeable.

Scheme 205

The lower main bearing identification (2) is stamped in the nose of the crankshaft (3). There are 5 different bearing sizes available 0 through 4.

LOWER MAIN BEARING SELECTION

Scheme 206

The upper main bearing shell identification (1) is located in the middle of cylinder block on the right side of the engine. There are three different size bearings available. The bearing class is read downward from top and corresponds to the front journal to the rear journal on the bottom.

UPPER MAIN BEARING SELECTION

Scheme 207

There are three different sizes of rod bearings available. Connecting rod bearing identification (4) can be found on the nose of the crankshaft (3). Use the table below for proper bearing selection.

CONNECTING ROD BEARING SELECTION

Scheme 208

Scheme 209

1. For measuring connecting rod bearing clearance procedure and use of Plastigage. See «STANDARD PROCEDURE»(ref-304329-S05314424972008110700000) . For bearing clearance, see «SPECIFICATIONS»(ref-304329-S08975828942008110700000) . NOTE: The rod bolts should not be reused.
2. Before installing the NEW rod bolts the threads and under the bolt head should be oiled with clean engine oil.
3. Install each bolt finger tight then alternately tighten each bolt to assemble the cap properly.
4. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values: CAUTION: Do not use a torque wrench for the second step. Tighten the bolts to 20 N.m (15 ft. lbs.). Tighten the connecting rod bolts an additional 90°.
5. Using a feeler gauge, check connecting rod side clearance. For clearance specifications, see «SPECIFICATIONS»(ref-304329-S08975828942008110700000) .

Scheme 210

Scheme 211

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 13 mm (0.50 inch) from bottom of cylinder bore and below the bottom of the oil ring travel where cylinder bore has minimal wear. Check gap with feeler gauge. Refer to «SPECIFICATIONS»(ref-304329-S08975828942008110700000) . NOTE: Ring end gap measurements are sensitive to the ring being square in the bore. Care must be used to avoid tilting the rings in cylinder bores when taking measurements.
2. Check piston ring to groove side clearance. Refer to «SPECIFICATIONS»(ref-304329-S08975828942008110700000) .

Scheme 212

1. Using a suitable ring expander, remove upper and intermediate piston rings.
2. Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston.
3. Clean ring grooves of any carbon deposits.

Scheme 213

Note. The identification mark on face of upper and intermediate piston rings must point toward top of piston.

1. Oil ring expander.
2. Upper oil ring side rail.
3. Lower oil ring side rail.
4. No. 2 Intermediate piston ring.
5. No. 1 Upper piston ring.

Scheme 214

1. Install oil ring expander.
2. Install upper side rail first and then the lower side rail. Install the side rails by placing one end between the piston ring groove and the oil ring expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander. NOTE: The compression rings are marked Y1 for the upper compression ring and Y2 for the second compression ring. These markings must face upward.
3. Install No. 2 piston ring and then No. 1 piston ring.
4. Position piston ring end gaps as shown in illustration.
5. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control.

Scheme 215

1. Remove accessory drive belts. Refer to «REMOVAL»(ref-304343-S05780822912008110700000) .
2. Install Damper holder 9707 (1).
3. Remove crankshaft damper bolt.
4. Pull damper off crankshaft.

Scheme 216

1. Install crankshaft damper.
2. Apply clean engine oil crankshaft damper bolt threads and between bolt head and washer. Tighten bolt to 210 N.m (155 ft. lbs.).
3. Install accessory drive belts. Refer to «INSTALLATION»(ref-304343-S25877668642008110700000) .

Scheme 217

Scheme 218

1. Remove oil pan. See «REMOVAL»(ref-304329-S23187716552008110700000) .
2. Remove balance shaft assembly. See «REMOVAL»(ref-304329-S24666377072008110700000) .
3. Remove ladder frame retaining bolts.
4. Remove ladder frame using pry point cast in the rear of the block (1).
5. To assist in removing the ladder frame another (1) pry point cast in the right side of the block.

CLEANING

Clean ladder frame with a plastic or wooden scraper and a suitable solvent. See STANDARD PROCEDURE .

Scheme 219

Note. When using RTV, the sealing surfaces must be clean and free from grease and oil.

Note. When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes.

Scheme 220

1. Apply a 2 mm bead of Mopar® engine sealant RTV or equivalent as shown in illustration.
2. Install bolts and tighten as shown in illustration following a two step method. First: All to 10 N.m (89 in. lbs.). Second: All to 26 N.m (19 ft. lbs.).
3. Install balance shaft module. See «INSTALLATION»(ref-304329-S27260761992008110700000) .
4. Install oil pan. See «INSTALLATION»(ref-304329-S34519148672008110700000) .

ENGINE MOUNTING

The engine mounting system consists of a four-point system utilizing two load-carrying mounts and two torque controlling mounts. The load-carrying mounts are located on each frame rail. The right and left mounts are hydro-elastic mounts. The two torque controlling mounts are attached to a fore/aft member and the front and rear of the engine.

ENGINE MOUNT

The four-point engine mounting system minimizes the transmission of structure-borne engine noise to the passenger compartment. The load-carrying right and left mounts dampen and isolate vertical motion and vibration. The front and rear mount absorb torque reaction forces and torsional vibrations.

Scheme 221

Scheme 222

Scheme 223

1. Remove air cleaner inlet (2) and air cleaner housing (1).
2. Remove PCM (1).
3. Remove PCM mounting bracket.
4. Disconnect negative cable from battery (3).
5. Support transaxle with a suitable jack.
6. Remove left mount through bolt (3).
7. Remove left mount bracket to body frame rail fasteners (1).
8. Remove mount.

Scheme 224

Scheme 225

Scheme 226

1. Position mount (2) in place.
2. Install left mount to frame rail bolts (1) and torque to 75 N.m (55 ft. lbs.).
3. Install mount through bolt (3) and torque to 100 N.m (74 ft.lbs.).
4. Remove jack.
5. Install PCM mounting bracket.
6. Install PCM (1).
7. Connect negative cable to battery (3).
8. Install air cleaner housing (1) and air cleaner inlet (2).

Scheme 227

Scheme 228

Scheme 229

1. Remove coolant reservoir (3) and set aside.
2. Remove power steering reservoir (2) and set aside.
3. Remove windshield washer bottle (1).
4. Remove power steering line support bracket (1) from engine mount.
5. Support transaxle with a block of wood and a suitable jack.
6. Remove engine mount through bolt (4).
7. Remove engine mount bracket bolts (3).
8. Remove engine mount retaining bolts.
9. Remove engine mount.

Scheme 230

Scheme 231

Scheme 232

1. Position right engine mount (1).
2. Install engine mount retaining bolts and tighten to 75 N.m (55 ft. lbs.).
3. Install engine mount adapter (2) and tighten bolts (3) to 68 N.m (50 ft. lbs.).
4. Install engine mount through bolt (4) and tighten to 88 N.m (65 ft. lbs.).
5. Remove jack.
6. Install power steering line support bracket (1) at engine mount.
7. Install windshield washer bottle (1).
8. Install power steering reservoir (2).
9. Install coolant reservoir (3).
10. Install engine cover.

Scheme 233

1. Raise vehicle.
2. Remove fore aft member (3) to mount (4) bolts.
3. Remove mount through bolt (1).
4. Remove fore aft member (3) mounting bolts and remove.
5. Remove front mount (4).

Scheme 234

1. Position mount (4) and tighten bolts to 47 N.m (35 ft. lbs.).
2. Install fore aft member (3) and tighten bolts to 100 N.m (74 ft. lbs.).
3. Install mount through bolt (1) and tighten to 47 N.m (35 ft. lbs.).
4. Lower vehicle.

Scheme 235

1. Remove rear mount retaining bolts (4).
2. Remove rear mount through bolt (1).
3. Remove oxygen sensor connector (2) from mount.
4. Remove rear mount (3).

Scheme 236

1. Position rear mount (3).
2. Install rear mount retaining bolts (4) and tighten to 50 N.m (37 ft. lbs.).
3. Install rear mount through bolt (1) and tighten to 47 N.m (35 ft. lbs.).
4. Install oxygen sensor connector (2) retainer to mount (3).

Scheme 237

The lubrication system is a full-flow filtration, pressure feed type. The balance shaft module (BSM) is mounted below the ladder frame and chain driven by the crankshaft. The BSM consists of a non-serviceable pump, oil pressure relief valve, and a non-serviceable balance assembly.

ENGINE OIL AND FILTER CHANGE

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

Scheme 238

Scheme 239

1. Run engine until achieving normal operating temperature.
2. Position the vehicle on a level surface and turn engine off.
3. Remove oil fill cap.
4. Raise vehicle on hoist.
5. Place a suitable oil collecting container under oil pan drain plug (2).
6. Remove oil pan drain plug (2) or and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged.
7. Remove oil filter (1). See «REMOVAL»(ref-304329-S35364062342008110700000) .
8. Install oil pan drain plug (2) and tighten drain plug to 40 N.m (30 ft. lbs.).
9. Install new oil filter (1). See «INSTALLATION»(ref-304329-S23257786962008110700000) .
10. Lower vehicle and fill crankcase with specified type and amount of engine oil. Refer to «SPECIFICATIONS»(ref-304322-S27173260482008110700000) and «DESCRIPTION»(ref-304322-S14876863772008110700000) .
11. Install oil fill cap.
12. Start engine and inspect for leaks.
13. 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.

Scheme 240

Note. The engine must be HOT when checking oil level.

The best time to check engine oil level is after the engine is at operating temperature. Allow the engine to be shut off for at least 5 minutes before checking oil level.

Scheme 241

Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick (1), and observe oil level. Add oil only when the level is at or below the SAFE mark. If the oil level is in the safe (2) range, do not add oil.

Scheme 242

1. Using a suitable filter wrench, turn oil filter (1) counterclockwise to remove.

Scheme 243

1. Clean and check filter mounting surface. The surface must be smooth, flat and free of debris or pieces of gasket.
2. Lubricate new oil filter gasket.
3. Screw oil filter (1) on until the gasket contacts base. Tighten to 14 N.m (124 in. lbs.).

Scheme 244

Scheme 245

Scheme 246

1. Raise vehicle on hoist.
2. Remove oil drain plug (2) and drain the engine oil.
3. Remove accessory drive belt splash shield.
4. Remove lower A/C compressor mounting bolt (if equipped).
5. Remove A/C mounting bracket (2). NOTE: Do not use pry points in block to remove oil pan.
6. Remove oil pan retaining bolts.
7. Using a putty knife (1), loosen seal around oil pan (2).
8. Remove oil pan (2).

Scheme 247

Note. Oil pan sealing surfaces must be free of grease or oil.

Note. Parts must be assembled within 10 minutes of applying RTV.

Scheme 248

Scheme 249

1. Apply Mopar® Engine RTV GEN II at the front cover to engine block parting lines (1).
2. Apply a 2 mm bead of Mopar® Engine RTV GEN II around the oil pan as shown in illustration.
3. Position oil pan and install bolts. Tighten bolts to 12 N.m (105 in. lbs.). NOTE: The 2 long bolts must be tightened to 22 N.m (195 in. lbs.).
4. Install oil drain plug (2).
5. Lower vehicle and fill engine crankcase with proper oil to correct level.
6. Start engine and check for leaks.

Scheme 250

Scheme 251

Variable valve timing solenoid assembly. The solenoid receives pulse width modulation signal and the current is controlled within 0 ma to 1000 ma. The spool position is controllable at any position to control supply of oil between the advance and retard ports.

SOLENOID-VARIABLE VALVE TIMING

There is both an Intake and an exhaust camshaft sensor on vehicles equipped with a World Engine. The variable valve timing system used on World Engines requires the exact position of both the intake and exhaust camshaft. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshafts. Intake and exhaust phaser oil control valves are required on World Engine vehicles using variable valve timing. The oil valves direct oil to the Intake and exhaust phasers. Oil pressure in the phasers moves the camshafts to an advanced or retarded position.

To resolve this inherent conflict between optimum high and low speed valve timing, the GPEC1 controlled engine uses a variable valve timing system. The variable valve timing system advances and retards valve timing by rotating the position of both the intake and exhaust camshafts. With this system, the intake valve opening can range from 80 to 120 crankshaft degrees after Top Dead Center. Likewise, the exhaust valve opening can range from 85 to 120 crankshaft degrees before Top Dead Center. This degree of flexibility provides many benefits, including: Improved Engine Performance, Increased Fuel Economy, Improved Idle Stability and Decreased Engine Emissions. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft.

The variable valve timing system is electronically controlled and hydraulically operated. The GPEC1 receives information from many sensors to determine the optimum valve timing. It then pulse-width modulates oil control valves which direct oil to the cam phasers. The cam phasers use oil pressure to rotate the intake and exhaust camshafts. The rotation of the camshafts is referred to as cam phasing. Before the GPEC1 can begin commanding the camshaft phasing, several enabling conditions must be met

1. The engine oil temperature must be at least -6.6°C (20°F)
2. The oil control valve coil temperature must be less than 140°C (284°F)
3. Engine speed must be at least 600 to 1000 rpm to achieve minimum oil pressure.
4. Battery voltage must be at least 10 volts
5. And there must be no camshaft or crankshaft sensor faults, engine timing faults, or oil control valve faults

First we will examine variable valve timing enabling conditions, and then we will take a closer look at the inputs and outputs of the system

1. Accelerator pedal position sensor
2. Oil temperature sensor
3. Map sensor
4. Intake cam sensor
5. Exhaust cam sensor
6. Crankshaft sensor
7. GPEC1
8. Exhaust phaser oil control valve
9. Intake phaser oil control valve
10. Inputs
11. Engine control module
12. Outputs
13. Sensed battery voltage

A minimum oil temperature is required to enable variable valve timing operation. Oil temperature and viscosity also have an impact on the operation of variable valve timing after start-up. Oil is used to control the movement of the camshafts. An incorrect oil viscosity could adversely affect the operation of the system or even render the system inoperative. It may even set a fault code.

The accelerator pedal position sensor indicates how far the driver wants to open the throttle plate. The GPEC1 calculates an initial camshaft set point based on whether the accelerator pedal is at part throttle or wide open throttle.

The MAP sensor provides information regarding engine load.

Sensed battery voltage provides information regarding current system voltage. Sensed battery voltage must be at least 10 volts in order for the oil control valves to function properly.

This information allows the GPEC1 to adjust camshaft timing to achieve the best fuel economy, the best engine performance or a combination of both. The hall-effect crankshaft sensor provides RPM information and determines when the number one piston is approaching Top Dead Center. The sensor generates a signal as the tone wheel, attached to the crankshaft, rotates. The tone wheel has 60 teeth minus two. When the gap, created by the missing teeth passes by the sensor, a signal is produced that indicates the number one piston is at Top Dead Center. The GPEC1 uses crankshaft sensor data along with camshaft data to determine the actual position of the camshaft. There are two hall-effect camshaft sensors on engines equipped with variable valve timing. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshaft.

The GPEC1 individually controls each valve. It sends a pulse width modulated signal to move a spool within the outer casing of the valve. Depending upon spool movement, oil is directed through the passages to advance or retard cam timing. The oil control valve also has a special cleaning strategy at key-on. The cleaning strategy is known as "debris crush mode". At key-on the GPEC1 cycles the oil control valve on and off several (5) times to crush any debris in the oil control valve and prevent the spool valve from sticking. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft.

There are two oil control valves. One valve directs oil to the intake cam phaser, the other valve directs oil to the exhaust cam phaser. The valves are designed and function in the same manner. The outer casing of each oil valve has five oil passages. A passage for pressurized supply oil. A passage to the advance chamber of the cam phaser. A passage to the retard chamber of the cam phaser. A passage for oil return from the advance chamber of the cam phaser. A passage for oil return from the retard chamber of the cam phaser. Oil flows through the passages and applies pressure to the cam phasers to change cam timing.

There are two cam phasers. One phaser controls the position of the intake camshaft. The other phaser controls the position of the exhaust camshaft. The phasers consist of a sprocket, a rotor vane, and a housing or stator. The exhaust cam phaser also consists of a front bushing and spring. We will discuss the purpose and function of the bushing and spring later. The housing is bolted and permanently fixed to the camshaft sprocket, while the rotor vane is bolted and permanently fixed to the camshaft. With this design, any movement of the rotor vane in relation to the housing will also move the camshaft. The phaser and sprocket are serviced as an assembly.

Camshaft and crankshaft sensors provide feedback to the GPEC1 regarding the actual position of the camshafts. The GPEC1 then compares the actual camshaft positioning with desired positioning. If the desired positioning is not achieved within a specified time, during the second key cycle a trouble code is set.

There are six new diagnostic trouble codes available to help you determine if the control circuit from the GPEC1 to the oil control valve is intact and operating properly. The codes identify whether the control circuit is open, shorted to ground, or shorted to power. Three trouble codes are related to intake camshaft positioning, the other three codes are specific to exhaust camshaft positioning.

The oil control valve contains both electrical and mechanical components. It is electrically controlled by the GPEC1. The electrical current that energizes the coil results in mechanical motion of the spool valve. It is possible to verify both the electrical and mechanical operation of the valve. The oil control valve consists of a coil that is energized to move a spool within an outer casing. The condition of the coil can be tested with a Digital Volt Ohmmeter or DVOM. With the DVOM set to measure resistance, check the coil for an open, a short to ground, or excessive resistance. The correct resistance value of the coil is between 6 and 8 ohms. The mechanical operation of the oil control valve can be tested using actuator commands on the scan tool. Remove the oil control valve, then navigate to the actuator menu and select the oil control valve. Use commands to activate the valve and watch as the spool valve moves back and forth inside the casing.

Because the cam phasers are hydraulically operated by engine oil, the condition of the oil is very important. The oil must be of the correct viscosity, not obstructed by debris, to maintain correct pressure. Maintaining the correct oil viscosity is critical to the operation of the variable valve timing system. The wrong oil viscosity may cause the variable valve timing to malfunction and trouble codes to set. The correct oil viscosity for this system is 5W20. Oil must be clean, unobstructed and free to flow through the variable valve timing system. Oil could become obstructed in oil passages located in the cylinder head, cylinder block, or even in the oil screen. In the event oil flow is obstructed, further diagnosis or disassembly may be required to pin point the source of the obstruction. The variable valve timing system relies on oil pressure to advance or retard the position of the camshaft. Insufficient oil pressure will adversely affect the operation of variable valve timing. The minimum oil pressure for this system is 15 psi at normal operating temperature.

Though not directly used to change camshaft positioning, the oil screen is an important component of the variable valve timing system. It helps to remove debris going to the variable valve timing components. The oil screen is located in the cylinder block, immediately below the cylinder head. Oil must pass through the oil screen before entering the oil control valve. The cylinder head must be removed to service the oil screen. The intention is not to service the oil screen during vehicle life.

How the cam phaser works. The cam phaser assembly has eight separate chambers; four advance chambers and four retard chambers. When camshaft advance is requested, oil enters all four advance chambers and exerts force on the rotor vane. Because the rotor vane is bolted to the camshaft, the entire camshaft profile moves along with the rotor vane. At the same time, oil is forced out of the retard chambers. When camshaft retard is requested oil enters the retard chambers to move the camshaft in the opposite direction. There is a lock pin on one side of the rotor vane that fits inside a recessed area in the housing. The lock pin ensures that the default position of the intake cam phaser is 120 crankshaft degrees full retard and the default position of the exhaust cam phaser is 120 crankshaft degrees full advance. When the engine is turned off, rotational force and inertia move the intake camshaft and rotor vane toward the retard position. The exhaust cam phaser includes a spring and bushing to work against the rotational force of the engine, allowing the exhaust cam phaser to lock in the fully advanced position. Under most conditions the cam phasers are returned to lock pin position when the engine is turned off. In the unique condition of an engine stall, which abruptly shuts off the engine, the cam phasers may not return to the lock pin position. In this case, the phasers will return to the lock pin position at the next start-up. Lock pin position is the most ideal cam timing for idle stability. When engine rpm exceeds approximately 600 to 1000 rpm, oil pressure unlocks the pins and variable valve timing resumes. Once enabling conditions are met, the GPEC1 uses input from sensors to calculate optimum valve timing.

There are four preprogrammed modes from which the GPEC1 bases initial valve timing.

1. Starting
2. Idle or Part throttle
3. Wide open throttle
4. Limp-in or Default

From each preprogrammed mode, the GPEC1 adjusts valve timing based on operating conditions.

GPEC1 has calculated optimum intake valve timing of 112 degrees after Top Dead Center and optimum exhaust valve timing of 97 degrees before Top Dead Center. The GPEC1 pulse width modulates the oil control valves to advance or retard the camshaft to their desired location. The spool valve inside the intake oil control valve is energized and moves to allow pressurized oil into the advance chambers of the intake cam phaser. At the same time, the spool valve inside the exhaust oil control valve is energized and moves to allow pressurized oil into the retard chambers of the exhaust cam phaser. Oil enters the advance chambers of the intake phaser and the retard chambers of the exhaust phaser. Oil pressure releases the lock pin from its locked position and pushes against the rotor vane. Both the rotor vanes are moved, advancing the intake camshaft and retarding the exhaust camshaft.

Scheme 252

Scheme 253

1. Disconnect negative battery cable.
2. Remove engine cover.
3. Disconnect variable valve timing solenoid electrical connector.
4. Remove variable valve timing solenoid mounting bolt.
5. Pull solenoid straight out of cylinder head.

Scheme 254

Scheme 255

Scheme 256

1. Disconnect negative battery cable.
2. Remove engine cover.
3. Rotate hose clamp out of way.
4. Disconnect oil pressure sensor electrical connector.
5. Remove oil pressure sensor.
6. Disconnect variable valve timing solenoid electrical connector.
7. Remove variable valve timing solenoid mounting bolt.
8. Pull solenoid straight out of cylinder head.

Scheme 257

Scheme 258

Scheme 259

1. Solenoid for front location 1/1. Note mounting tab location is different between front and rear solenoids.
2. Install solenoid into cylinder head.
3. Install mounting bolt and tighten to 12 N.m (9 ft. lbs.).
4. Install oil pressure sensor.
5. Connect electrical connector to oil pressure sensor.
6. Connect electrical connector to Variable valve timing solenoid.
7. Connect negative battery cable.
8. Install engine cover.

Scheme 260

Scheme 261

1. Rear variable valve timing solenoid. Note mounting tab location is different between front and rear solenoids.
2. Install solenoid into cylinder head.
3. Install mounting bolt and tighten to 12 N.m (9 ft. lbs.).
4. Connect electrical connector to Variable valve timing solenoid.
5. Connect negative battery cable.
6. Install engine cover.

Scheme 262

1. Remove oil pan. See «REMOVAL»(ref-304329-S23187716552008110700000) .
2. Remove pressure regulating valve cap (2).
3. Remove pressure regulating valve spring (3) and valve (4).

Scheme 263

Note. Pressure regulating valve (4) can be serviced separately from the oil pump assembly.

1. Inspect pressure relief valve (4) scoring, gouging, or debris. Replace as needed.
2. Inspect the pressure relief valve bore in the pump for scoring, gouging, or debris.
3. If pump bore is damaged, replace balance shaft module.

Scheme 264

1. Lightly coat pressure regulating valve with clean engine oil and install valve (4).
2. Install spring (3) and cap (2).
3. Tighten cap to 44 N.m (32 lbs. ft.).

Scheme 265

The oil pump is integral to the balance shaft module (BSM) (2). The oil pump cannot be disassembled for inspection. The pressure relief valve is serviceable and can be removed and inspected. The BSM can be identified by the plastic end caps (1).

Scheme 266

Scheme 267

Scheme 268

1. Rotate engine to TDC (1,2) on #1 compression stroke.
2. Remove oil pan. See «REMOVAL»(ref-304329-S23187716552008110700000) .
3. Mark the chain (6) and the sprocket (5) for reassembly.
4. Push tensioner piston back into the tensioner body.
5. With piston held back insert tensioner pin 9703 (4) into the tensioner body to hold the piston in the retracted position. NOTE: Do not remove sprocket from BSM.
6. Remove BSM mounting bolts and discard.
7. Lower the back of the BSM and remove the chain (6) from the sprocket (5).
8. Remove BSM from the engine.

Scheme 269

1. Remove timing chain cover. See «REMOVAL»(ref-304329-S38855027942008110700000) .
2. Remove oil pan. See «REMOVAL»(ref-304329-S23187716552008110700000) .
3. Measure the distance between the tensioner body and the guide shoe as shown in illustration.
4. If the distance is 10.1 mm (0.397 in.) or greater, replace the chain.

Scheme 270

Scheme 271

Scheme 272

1. Clean BSM mounting holes Mopar® brake parts cleaner.
2. If the chain was removed, align marks on crankshaft sprocket (2) and chain (1).
3. Align marks on oil pump sprocket (5) and chain (4).
4. Install chain on sprocket.
5. Pivot BSM assembly upwards and position on ladder frame.
6. Start new BSM mounting bolts by hand. NOTE: Use a three step procedure when torquing BSM mounting bolts.
7. Tighten BSM mounting bolts to 15 N.m (11 ft. lbs.) as shown in illustration.
8. Tighten BSM mounting bolts to 29 N.m (22 ft. lbs.) as shown in illustration.
9. Rotate bolts an additional 90° as shown in illustration.
10. Remove tensioner pin 9703 (4).
11. Install oil pan. See «INSTALLATION»(ref-304329-S34519148672008110700000) .
12. Fill with oil.
13. Start engine and check for leaks.

OIL PRESSURE SWITCH

The oil pressure switch is located on the left front side of the engine block. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block).

The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig.

Scheme 273

1. Raise vehicle.
2. Disconnect electrical connector.
3. Remove oil pressure sensor using oil pressure socket C-4597 (1) and discard sensor.

Scheme 274

Note. If the oil pressure sensor is removed, it must be replaced with a new sensor.

1. Install oil pressure sensor using oil pressure socket C-4597 (1) and tighten to 8 N.m (71 in. lbs.).
2. Connect electrical connector.

Scheme 275

1. Disconnect oil temperature sensor (1) electrical connector.
2. Remove sensor (1).

Scheme 276

1. If re-using the oil temperature sensor, coat the threads with Mopar® thread sealant.
2. Install oil temperature sensor (1). Tighten to 18 N.m (160 in. lbs.).
3. Connect electrical connector.

OIL COOLER & LINES

An engine oil cooler is used on some engine packages. The cooler is a coolant-to-oil type and mounted between the oil filter and oil filter adapter.

Note. The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, the oil cooler should be replaced.

Scheme 277

Scheme 278

1. Raise vehicle on hoist.
2. Drain cooling system. Refer to «STANDARD PROCEDURE»(ref-304343-S02124729692008110700000) .
3. Disconnect oil cooler coolant hoses.
4. Remove oil filter (3).
5. Remove oil cooler connector bolt (2).
6. Remove oil cooler (1).

Scheme 279

Scheme 280

1. Replace oil cooler seal (1).
2. Lubricate seal and position oil cooler to oil filter adapter, aligning notch to tab.
3. Install oil cooler connector bolt (2). Tighten connector bolt to 49 N.m (36 ft. lbs.).
4. Install oil filter (3).
5. Connect oil cooler coolant hose.
6. Lower vehicle.
7. Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-304343-S02124729692008110700000) .

Scheme 281

Scheme 282

Scheme 283

Scheme 284

1. Remove engine cover (1).
2. Disconnect negative cable from battery.
3. Remove bolts attaching upper heat shield.
4. Remove upper heat shield (1).
5. Disconnect exhaust pipe from manifold.
6. Remove manifold support bracket (2).
7. Disconnect oxygen sensor electrical connector.
8. Remove exhaust manifold retaining fasteners.
9. Remove and discard manifold gasket.

EXHAUST MANIFOLD

1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head.

1. Inspect manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 in. per foot) of manifold length.
2. Inspect manifolds for cracks or distortion. Replace manifold as necessary.

Scheme 285

Scheme 286

Scheme 287

Scheme 288

Scheme 289

1. Install a new exhaust manifold gasket. DO NOT APPLY SEALER .
2. Tighten the exhaust manifold bolts to 34 N.m (25 ft. lbs.).
3. Install exhaust manifold heat shields. Tighten bolts to 12 N.m (105 in. lbs.).
4. Install exhaust manifold support bracket (2).
5. Install new catalytic converter gasket.
6. Install exhaust pipe to manifold (1). Tighten fasteners to 28 N.m (250 in. lbs.).
7. Connect oxygen sensor electrical connector (3).
8. Connect negative cable to battery (3).
9. Install engine cover.

INTAKE MANIFOLD

1. Discard gasket(s).
2. Clean all sealing surfaces.

1. Inspect manifold for cracks, distortion, or mounting surface warpage. Replace manifold if necessary.
2. Inspect manifold gasket for surface damage or excessive swelling. Replace gaskets as necessary.

Scheme 290

Scheme 291

Scheme 292

1. Clean all gasket surfaces.
2. Replace intake manifold gasket.
3. Install intake manifold, tighten bolts to 25 N.m (220 in. lbs.) as shown in illustration.
4. Install the fuel rail assembly to intake manifold. Tighten bolts to 23 N.m (200 in. lbs.).
5. Connect fuel injector electrical connectors (4).
6. Inspect quick connect fittings for damage, replace if necessary. Refer to «STANDARD PROCEDURE»(ref-304342-S34560691312008110700000) .
7. Connect fuel line (3).
8. Connect negative cable to battery (3).
9. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-304343-S02124729692008110700000) .
10. Install air cleaner housing (1).
11. Install clean air hose (5).
12. Start engine and check for leaks.
13. Install engine cover (1).

Scheme 293

The timing drive system consists of the following

1. Timing Chain (2)
2. Camshaft Sprockets (1,3)
3. Crankshaft Sprocket
4. Right Timing Chain Guide (Moveable) (6)
5. Left Timing Chain Guide (Fixed) (4)
6. Timing Chain Tensioner (5)

The camshaft sprockets are attached to the cam phasers which are attached to the front of the camshafts and are used with the timing chain and crankshaft sprocket to turn the camshafts. The camshaft position sensors target is part of the camshafts and is used with the camshaft position sensors to provide the PCM with valvetrain position information.

The timing chain tensioner is installed in the right side of the engine block. Using engine oil pressure, the tensioner applies constant pressure to the right side (movable) timing chain guide, which in turn applies pressure to the timing chain. Also as the tensioner extends, it rachet locks in position to provide constant timing chain tension.

Scheme 294

Scheme 295

1. Remove engine cover.
2. Remove cylinder head cover. See «REMOVAL»(ref-304329-S10843827882008110700000) .
3. Set engine to TDC (1,2).
4. The mark on the camshaft sprocket should be in line with the cylinder head cover sealing surface (2).
5. Verify that the painted or colored chain links (1,3) aligns with marks on camshaft sprockets.
6. Verify that the painted or colored chain link aligns with mark on crankshaft sprocket.
7. Install cylinder head cover. See «INSTALLATION»(ref-304329-S15488240462008110700000) .

Scheme 296

Scheme 297

Scheme 298

Scheme 299

Scheme 300

Scheme 301

Scheme 302

Scheme 303

Scheme 304

Scheme 305

Scheme 306

Scheme 307

1. Remove engine cover (1) by pulling upward.
2. Perform fuel pressure bleed procedure. Refer to «STANDARD PROCEDURE»(ref-304342-S34730499872008110700000) .
3. Disconnect negative cable at battery (3).
4. Remove coolant recovery bottle (3).
5. Remove power steering reservoir (2) and set aside.
6. Disconnect fuel line (3).
7. Remove make up air hose (2).
8. Remove PCV hose (5).
9. Disconnect ignition coil electrical connectors (1).
10. Remove cylinder head cover. See «REMOVAL»(ref-304329-S10843827882008110700000) .
11. Raise vehicle.
12. Remove right lower splash shield.
13. Set engine to TDC (1).
14. Remove accessory drive belt. Refer to «REMOVAL»(ref-304343-S05780822912008110700000) .
15. Remove lower A/C compressor (1) retaining bolts.
16. Remove A/C compressor lower bracket (2).
17. Remove accessory drive belt lower idler pulley.
18. Remove crankshaft damper (2).
19. Remove front crankshaft oil seal. See «REMOVAL»(ref-304329-S36857708032008110700000) .
20. Remove water pump pulley (4).
21. Remove engine mount bracket (1) lower bolt.
22. Remove timing chain cover lower bolts (1).
23. Lower vehicle.
24. Remove power steering line support (1).
25. Remove power steering pump and set aside.
26. Support engine with a suitable jack and a block of wood under the oil pan.
27. Remove right engine mount to mount bracket bolts (3).
28. Remove accessory drive belt upper idler pulley.
29. Remove right engine mount bracket (1).
30. Remove accessory drive belt tensioner.
31. Remove timing chain cover retaining bolts.
32. Remove timing chain cover using pry points (1,2,3).
33. Remove timing chain cover (1) out through the bottom of the vehicle.

Scheme 308

Note. When using RTV, the sealing surfaces must be clean and free from grease and oil.

Note. When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes.

Scheme 309

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Scheme 311

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Scheme 321

Scheme 322

1. Clean all sealing surfaces.
2. Apply Mopar® engine sealant RTV or equivalent as shown in illustration at the cylinder head to block parting line (1,2).
3. Apply Mopar® engine sealant RTV or equivalent as shown in illustration at the ladder frame to block parting line (1,2).
4. Apply Mopar® engine sealant RTV or equivalent as shown in illustration in the corner of the oil pan and block.
5. Apply 2 mm bead of Mopar® engine sealant RTV or equivalent to the oil pan as shown in illustration.
6. Apply 2 mm bead of Mopar® engine sealant RTV or equivalent to the engine block (1,2) as shown in illustration.
7. Install timing chain cover (1) upwards from under the vehicle.
8. Install timing chain cover upper retaining bolts and tighten M6 bolts to 9 N.m (80 in lbs) and M8 bolts to 26 N.m (230 in lbs).
9. Install accessory drive belt tensioner.
10. Install right engine mount bracket (1).
11. Install accessory drive belt upper idler pulley.
12. Install right engine mount (1).
13. Remove jack from under engine.
14. Install power steering pump.
15. Raise vehicle.
16. Install oil pan to timing chain cover lower retaining bolts (1) and tighten bolts.
17. Install timing chain cover retaining bolts and tighten bolts.
18. Install water pump pulley (4).
19. Install crankshaft pulley (2) and tighten bolt.
20. Install accessory drive belt lower idler pulley.
21. Install lower A/C compressor mounting bracket (2).
22. Install A/C compressor (1).
23. Install accessory drive belt. Refer to «INSTALLATION»(ref-304343-S25877668642008110700000) .
24. Install right lower splash shield.
25. Lower vehicle.
26. Install cylinder head cover. See «INSTALLATION»(ref-304329-S15488240462008110700000) .
27. Connect coil electrical connectors (1).
28. Connect PCV hose (5) to PCV valve.
29. Connect make up air hose (2).
30. Install power steering reservoir (2).
31. Install windshield washer bottle (1).
32. Install coolant recovery bottle (3).
33. Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-304343-S02124729692008110700000) .
34. Connect negative cable to battery (3).
35. Install air cleaner housing (3). See «INSTALLATION»(ref-304329-S20848631162008110700000) .
36. Fill with fluids.
37. Start engine and check for leaks.
38. Install engine cover (1) by pressing the rear of the cover down first.

CAMSHAFT SPROCKET(S)

Note. Camshaft phasers and camshaft sprockets are supplied as an assembly, do not attempt to disassemble.

Refer to camshaft phaser removal. See REMOVAL .

Scheme 323

1. Remove timing chain. See «REMOVAL»(ref-304329-S28290244522008110700000) .
2. Remove oil pan. See «REMOVAL»(ref-304329-S23187716552008110700000) .
3. Remove oil pump drive chain tensioner.
4. Remove oil pump drive chain.
5. Remove crankshaft sprocket (1).

Scheme 324

Scheme 325

Scheme 326

Scheme 327

1. Set engine to TDC.
2. Remove timing chain cover. See «REMOVAL»(ref-304329-S38855027942008110700000) . NOTE: If the timing chain plated links can no longer be seen, the timing chain links corresponding to the timing marks must be marked prior to removal if the chain is to be reused.
3. Mark chain link (1) corresponding to camshaft timing mark.
4. Mark chain link (3) corresponding to crankshaft timing mark (2).
5. Remove timing chain tensioner (5). See «REMOVAL»(ref-304329-S28900201212008110700000) .
6. Remove timing chain (2).

Scheme 328

Inspect timing chain for stretching prior to removal.

1. Rotate engine while watching timing chain tensioner plunger. When the plunger reaches its maximum travel stop rotating engine.
2. Measure the distance from the tensioner body and the edge of the chain guide as shown in illustration.
3. If the distance is greater than 20.5 mm (0.81 in.) inspect guide shoes for excessive wear.
4. If guides are okay, replace timing chain.

Scheme 329

Note. The camshaft sprockets and the camshaft phasers are an assembly and cannot be serviced separately.

1. Refer to Camshaft phaser (2) installation. See «INSTALLATION»(ref-304329-S11114030262008110700000)

Scheme 330

Scheme 331

Scheme 332

1. Install crankshaft sprocket (1) onto crankshaft.
2. Install oil pump drive chain. Verify that Oil pump is correctly timed (1,2,5,6).
3. Reset oil pump drive chain tensioner by pushing plunger inward and install tensioner pin 8514.
4. Install oil pump drive chain tensioner (3) and remove Tensioner Pin 8514 (4).
5. Install timing chain. See «INSTALLATION»(ref-304329-S29298268142008110700000) .
6. Install oil pan. See «INSTALLATION»(ref-304329-S34519148672008110700000) .
7. Fill engine with oil. See «STANDARD PROCEDURE»(ref-304329-S34487595182008110700000) .
8. Start engine and check for leaks.

Scheme 333

Scheme 334

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Scheme 336

Scheme 337

Scheme 338

Scheme 339

1. Verify that the crankshaft sprocket keyway is at the 9 o'clock position.
2. Align camshaft timing marks (3) so they are parallel to the cylinder head and aligned each other as shown in illustration.
3. Install timing chain guide (4) and tighten bolts to 12 N.m (105 in. lbs.).
4. Install timing chain so plated links on chain align with timing marks on camshaft sprockets (1).
5. Align timing mark on the crankshaft sprocket (2) with the plated link (3) on the timing chain. Position chain so slack will be on the tensioner side. NOTE: Keep the slack in the timing chain on the tensioner side.
6. Install the moveable timing chain pivot guide (6) and tighten bolt to 12 N.m (105 in. lbs.).
7. Reset timing chain tensioner (4) by lifting up on ratchet (2) and pushing plunger (3) inward towards the tensioner body (4). Insert Tensioner Pin 8514 into slot (1) to hold tensioner plunger in the retracted position.
8. Install timing chain tensioner (1) and tighten bolts to 12 N.m (105 in. lbs.).
9. Remove timing Tensioner Pin 8514 (2). Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned at the TDC position with the key way at the 9 o'clock position.
10. Verify that the camshafts timing marks (3) are in the proper position.
11. Install front timing chain cover. See «INSTALLATION»(ref-304329-S38724498342008110700000) .
12. Install the balancer and verify that balancer mark (2) and cover mark (1) are aligned.
13. Connect negative battery cable.
14. Fill with oil, start engine and check for leaks.

Scheme 340

1. Remove timing chain. See «REMOVAL»(ref-304329-S28290244522008110700000) . NOTE: Tensioner will not come apart during removal.
2. Remove timing chain tensioner retaining bolts and remove tensioner.

Scheme 341

1. Reset tensioner.
2. Install timing chain. See «INSTALLATION»(ref-304329-S29298268142008110700000) .