3.7L Engine - Service Information: Removal & Installation RAM Pickup 2500

INSTALLATION

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

1. Install filter element into housing.
2. Position housing cover (3) into housing locating tabs.
3. Pry up 4 spring clips (5) and lock cover to housing.
4. Install air duct (2) to air cleaner cover (3) and tighten hose clamp (1) to 3 N.m (30 in. lbs.).

Scheme 67

Scheme 68

1. Loosen clamp (1) and disconnect air duct (2) at air cleaner cover (3).
2. Lift entire housing (1) assembly from 4 locating pins (2).

Scheme 69

Scheme 70

1. Position housing assembly (1) into 4 locating pins (2).
2. Connect air duct (2) at air cleaner cover (3) and tighten clamp (1).

REMOVAL

Scheme 71

Scheme 72

1. Remove cylinder head cover. Refer to «COVER(S), Cylinder Head, Removal, 3.7L»(ref-457795-S38087059622012030200000) for left cover and «COVER(S), Cylinder Head, Removal, 3.7L»(ref-457795-S11243807712012030200000) for right cover.
2. Set engine cylinder #1 to TDC, camshaft sprocket V6 marks at the 12 o'clock position.
3. Mark one link on the secondary timing chain on both sides of the V6 mark on the camshaft sprocket to aid in installation. CAUTION: Do not hold or pry on the camshaft target wheel (Located on the right side camshaft sprocket) for any reason, Severe damage will occur to the target wheel resulting in a vehicle no start condition.
4. Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave the bolt snug against the sprocket. NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners. CAUTION: Do not force Locking Wedge (special tool #9867, Wedge, Locking) past the narrowest point between the chain strands. Damage to the tensioners may occur.
5. Position the Wedge Locking Tool (special tool #8379, Locking Tool, Wedge) (1) between the timing chain strands, tap the tool to securely wedge the timing chain against the tensioner arm and guide.
6. Hold the camshaft with the Camshaft Holder (special tool #8428A, Holder, Camshaft), while removing the camshaft sprocket bolt and sprocket. see scheme 35
7. Using the Camshaft Holder (special tool #8428A, Holder, Camshaft), gently allow the camshaft to rotate 5° clockwise until the camshaft is in the neutral position (no valve load).
8. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps. CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS. NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
9. Remove the camshaft bearing caps and the camshaft.

Scheme 73

Scheme 74

1. Lubricate camshaft journals with clean engine oil. NOTE: Position the left side camshaft so that the camshaft sprocket dowel is near the 1 o'clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
2. Position the camshaft into the cylinder head.
3. Install the camshaft bearing caps, hand tighten the retaining bolts. NOTE: Caps should be installed so that the stamped numbers on the caps are in numerical order, (1 through 4) from the front to the rear of the engine. All caps should be installed so that the stamped arrows on the caps point toward the front of the engine.
4. Working in 1/2 turn increments, tighten the bearing cap retaining bolts in the sequence shown in illustration.
5. Tighten the camshaft bearing cap retaining bolts to 11 N.m (100 in. lbs.). see scheme 36
6. Position the camshaft drive gear into the timing chain aligning the V6 mark between the two marked chain links (Two links marked during removal).
7. Using the Camshaft Holder (special tool #8428A, Holder, Camshaft) (2), rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft. CAUTION: Remove excess oil from the camshaft sprocket retaining bolt, failure to do so can cause bolt over-torque resulting in bolt failure.
8. Remove excess oil from bolt, then install the camshaft sprocket retaining bolt and hand tighten.
9. Remove Wedge Locking Tool (special tool #8379, Locking Tool, Wedge).
10. Using the Spanner Wrench (special tool #6958, Wrench, Spanner) (4) with adapter pins (special tool #8346, Pins, Adapter), tighten the camshaft sprocket retaining bolt to 122 N.m (90 ft. lbs.).
11. Install the cylinder head cover. Refer to «COVER(S), Cylinder Head, Installation, 3.7L»(ref-457795-S18626148182012030200000) for left cover and «COVER(S), Cylinder Head, Installation, 3.7L»(ref-457795-S10268980662012030200000) for right cover.

Scheme 75

The cylinder head covers (1,.2) are made of glass re-enforced thermoset plastic, and are not interchangeable from side-to-side. see scheme 39

Scheme 76

1. Disconnect negative cable from battery.
2. Remove the resonator assemble and air inlet hose.
3. Disconnect injector connectors and unclip the injector harness.
4. Route injector harness in front of cylinder head cover.
5. Disconnect the left side breather tube and remove the breather tube.
6. Remove the cylinder head cover mounting bolts (1).
7. Remove cylinder head cover (1) and gasket. (Scheme 67)

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

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

1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary.
2. Install cylinder head cover (2). (Scheme 68)
3. Tighten cylinder head cover bolts (1) and double ended studs to 12 N.m (105 in. lbs.).
4. Install left side breather and connect breather tube.
5. Connect injector electrical connectors and injector harness retaining clips.
6. Install the resonator and air inlet hose.
7. Connect negative cable to battery.

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

1. For rocker arm installation on cylinders No. 4, Rotate the crankshaft until cylinder No. 1 is at BDC intake stroke.
2. For rocker arm installation on cylinder No. 1, Rotate the crankshaft until cylinder No. 1 is at BDC combustion stroke.
3. For rocker arm installation on cylinders No. 3 and No. 5, Rotate the crankshaft until cylinder No. 1 is at TDC exhaust stroke.
4. For rocker arm installation on cylinders No. 2 and No. 6, Rotate the crankshaft until cylinder No. 1 is at TDC ignition stroke.
5. Using the Rocker Arm Remover/Installer (special tool #8516A, Remover/Installer) (2) press downward on the valve spring, install rocker arm. (Scheme 70)
6. Install the cylinder head cover. Refer to «COVER(S), Cylinder Head, Installation, 3.7L»(ref-457795-S18626148182012030200000) for left cover and «COVER(S), Cylinder Head, Installation, 3.7L»(ref-457795-S10268980662012030200000) for right cover.

The valve stem seal is integral with the valve spring seat. For removal, refer to SPRING(S), Valve , Removal , 3.7L for left head and SPRING(S), Valve , Removal , 3.7L for right head.

The valve stem seal is integral with the valve spring seat. For installation, refer to SPRING(S), Valve , Installation , 3.7L for left head and SPRING(S), Valve , Installation , 3.7L for right head.

1. Remove the cylinder head cover. Refer to «COVER(S), Cylinder Head , Removal , 3.7L»(ref-457795-S38087059622012030200000) for left cover and «COVER(S), Cylinder Head , Removal , 3.7L»(ref-457795-S11243807712012030200000) for right cover.
2. Using the Valve Spring Remover/Installer (special tool #8516A, Remover/Installer), remove the rocker arms and the hydraulic lash adjusters.
3. Remove the spark plug for the cylinder the valve spring and seal are to be removed from.
4. Apply shop air to the cylinder to hold the valves in place when the spring is removed. NOTE: All six valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.
5. Using the Valve Spring Compressor (special tool #8387, Compressor, Valve Spring), compress the valve spring. NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
6. Remove the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
7. Remove the valve spring compressor. NOTE: The valve springs are NOT common between intake and exhaust.
8. Remove the spring retainer, and the spring. NOTE: The valve stem seals are common between intake and exhaust.
9. Remove the valve stem seal.

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

1. Apply shop air to the cylinder to hold the valves in place while the spring is installed. NOTE: The valve stem seals are common between intake and exhaust.
2. Install the valve stem seal. NOTE: The valve springs are NOT common between intake and exhaust.
3. Install the spring retainer, and the spring.
4. Using the Valve Spring Compressor (special tool #8387, Compressor, Valve Spring), compress the valve spring.
5. Install the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
6. Remove the valve spring compressor.
7. Disconnect the shop air to the cylinder.
8. Install the spark plug for the cylinder the valve spring and seal was installed on.
9. Using Valve Spring Remover/Installer (special tool #8516A, Remover/Installer), install the rocker arms and the hydraulic lash adjusters.
10. Install the cylinder head cover. Refer to «COVER(S), Cylinder Head , Installation , 3.7L»(ref-457795-S18626148182012030200000) for left cover and «COVER(S), Cylinder Head , Installation , 3.7L»(ref-457795-S10268980662012030200000) for right cover.

Note. The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down (2) the bolts should be replaced.

Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced. see scheme 54

1. Clean the cylinder head and cylinder block mating surfaces. (Scheme 74) * - INDICATES SEALANT ON THREADS
2. Position the new cylinder head gasket on the locating dowels. CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm.
3. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels. NOTE: The four M8 cylinder head mounting bolts (1) require sealant to be added to them before installing. Failure to do so may cause leaks.
4. Lubricate the cylinder head bolt threads with clean engine oil and install the eight M10 bolts.
5. Coat the four M8 cylinder head bolts with Mopar Lock and Seal Adhesive then install the bolts. NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.
6. Tighten the bolts in sequence using the following steps and torque values: (Scheme 75) Step 1: Tighten bolts 1-8, 27 N.m (20 ft. lbs.). Step 2: Verify that bolts 1-8, all reached 27 N.m (20 ft. lbs.), by repeating step 1 without loosening the bolts. Tighten bolts 9 thru 12 to 14 N.m (10 ft. lbs.). Step 3: Tighten bolts 1-8, 90°. Step 4: Tighten bolts 1-8, 90°, again. Tighten bolts 9-12, 26 N.m (19 ft. lbs.) 1 - SPECIAL TOOL 8429 2 - CAMSHAFT CHAIN 3 - CRANKSHAFT TIMING GEAR
7. Position the secondary chain (2) onto the camshaft drive gear, making sure one marked chain link is on either side of the V6 mark (1) on the gear, then using Special Tool (special tool #8428A, Holder, Camshaft) Camshaft Wrench, position the gear onto the camshaft. (Scheme 76)and see scheme 58. CAUTION: Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt. Failure to do so may cause over-torquing of bolt resulting in bolt failure.
8. Install the camshaft drive gear retaining bolt.
9. Install the right side secondary chain guide. Refer to «CHAIN and SPROCKETS, Timing, Installation, 3.7L»(ref-457795-S27896854792012030200000). 1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
10. Install the cylinder head access plug (1, 2). see scheme 59
11. Reset and install the right side secondary chain tensioner. Refer to «CHAIN and SPROCKETS, Timing, Installation, 3.7L»(ref-457795-S27896854792012030200000). 1 - SPECIAL TOOL 8429 2 - CAMSHAFT CHAIN 3 - CRANKSHAFT TIMING GEAR
12. Remove Special Tool (special tool #8429, Holder, Secondary Camshaft Chain)(1). see scheme 60
13. Install the timing chain cover. Refer to «COVER(S), Engine Timing, Removal, 3.7L»(ref-457795-S00384933232012030200000).
14. Install the crankshaft damper. Refer to «DAMPER, Vibration, Installation, 3.7L»(ref-457795-S23438291102012030200000). Tighten damper bolt 175 N.m (130 Ft. Lbs.).
15. Install accessory drive belt. Refer to «BELT, Serpentine, Installation»(ref-457792-S21966014282012030200000).
16. Install the fan shroud. Refer to «FAN, Cooling, Electric, Installation»(ref-457792-S30022413072012030200000) and «FAN, Cooling, Viscous, Installation»(ref-457792-S33156171422012030200000).
17. Install the cylinder head cover. Refer to «COVER(S), Cylinder Head, Installation, 3.7L»(ref-457795-S18626148182012030200000) for left head cover and «COVER(S), Cylinder Head, Installation, 3.7L»(ref-457795-S10268980662012030200000) for right head cover.
18. Install the intake manifold. Refer to «MANIFOLD, Intake, Installation, 3.7L»(ref-457795-S26066281302012030200000).
19. Install oil fill housing onto cylinder head.
20. Refill the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000).
21. Raise the vehicle.
22. Install the exhaust pipe onto the right exhaust manifold.
23. Lower the vehicle.
24. Reconnect battery negative cable.
25. Start the engine and check for leaks.

1. Remove the cylinder head cover. Refer to «COVER(S), Cylinder Head, Removal, 3.7L»(ref-457795-S38087059622012030200000) for left head cover and «COVER(S), Cylinder Head, Removal, 3.7L»(ref-457795-S11243807712012030200000) for right head cover.
2. Set engine to TDC cylinder No. 1, camshaft sprocket V6 marks at the 12 o'clock position (1). see scheme 61
3. Mark one link on the secondary timing chain on both sides of the V6 mark on the camshaft sprocket to aid in installation. 1 - Camshaft hole 2 - Special Tool 8428 CAUTION: Do not hold or pry on the camshaft target wheel for any reason, severe damage will occur to the target wheel resulting in a vehicle no start condition.
4. Loosen but DO NOT remove the camshaft sprocket retaining bolt. see scheme 63 Leave bolt snug against sprocket. 1 - SPECIAL TOOL 8379 2 - CAMSHAFT SPROCKET 3 - CAMSHAFT SPROCKET BOLT 4 - CYLINDER HEAD NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners. CAUTION: Do not force Locking Wedge (special tool #9867, Wedge, Locking) past the narrowest point between the chain strands. Damage to the tensioners may occur.
5. Position the Wedge Locking Tool (special tool #8379, Locking Tool, Wedge)(1) between the timing chain strands. see scheme 63 Tap the tool to securely wedge the timing chain against the tensioner arm and guide. 1 - Camshaft hole 2 - Special Tool 8428
6. Remove the camshaft position sensor.
7. Hold the camshaft with Camshaft Holder (special tool #8428A, Holder, Camshaft)(2), while removing the camshaft sprocket bolt and sprocket. see scheme 64
8. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. see scheme 65 Repeat until all load is off the bearing caps. CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS. NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
9. Remove the camshaft bearing caps and the camshaft.

1. Lubricate camshaft journals with clean engine oil. NOTE: Position the right side camshaft so that the camshaft sprocket dowel is near the 10 o'clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
2. Position the camshaft into the cylinder head.
3. Install the camshaft bearing caps, hand tighten the retaining bolts. NOTE: Caps should be installed so that the stamped numbers on the caps are in numerical order, (1 through 4) from the front to the rear of the engine. All caps should be installed so that the stamped arrows on the caps point toward the front of the engine.
4. Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward.
5. Tighten the camshaft bearing cap retaining bolts to 11 N.m (100 in. lbs.). see scheme 66
6. Position the camshaft drive gear into the timing chain aligning the V6 mark between the two marked chain links (Two links marked during removal). see scheme 67 1 - Camshaft hole 2 - Special Tool 8428
7. Using the Camshaft Holder (special tool #8428A, Holder, Camshaft) (2), rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. see scheme 68 Install the sprocket onto the camshaft. CAUTION: Remove excess oil from the camshaft sprocket retaining bolt, failure to do so can cause bolt over-torque resulting in bolt failure.
8. Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and hand tighten. 1 - SPECIAL TOOL 8379 2 - CAMSHAFT SPROCKET 3 - CAMSHAFT SPROCKET BOLT 4 - CYLINDER HEAD
9. Remove timing chain wedge special tool (special tool #8379, Locking Tool, Wedge) (1). see scheme 69
10. Using Spanner Wrench (special tool #6958, Wrench, Spanner) with adapter pins (special tool #8346, Pins, Adapter), tighten the camshaft sprocket retaining bolt to 122 N.m (90 ft. lbs.)
11. Install the camshaft position sensor.
12. Install the cylinder head cover. Refer to «COVER(S), Cylinder Head, Installation, 3.7L»(ref-457795-S18626148182012030200000) for left head cover and «COVER(S), Cylinder Head, Installation, 3.7L»(ref-457795-S10268980662012030200000) for right head cover.

1. Disconnect battery negative cable.
2. Remove air cleaner assembly, resonator assembly and air inlet hose.
3. Drain cooling system, below the level of the heater hoses. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
4. Remove accessory drive belt. Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
5. Remove air conditioning compressor retaining bolts and move compressor to the left.
6. Remove heater hoses.
7. Disconnect injector and ignition coil connectors.
8. Disconnect and remove positive crankcase ventilation (PCV) hose.
9. Remove oil fill tube.
10. Unclip injector and ignition coil harness and move away from cylinder head cover.
11. Remove right rear breather tube and filter assembly.
12. Remove cylinder head cover retaining bolts.
13. Remove cylinder head cover.

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

1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary.
2. Tighten cylinder head cover bolts and double ended studs to 12 N.m (105 in. lbs).
3. Install right rear breather tube and filter assembly.
4. Connect injector, ignition coil electrical connectors and harness retaining clips.
5. Install the oil fill tube.
6. Install PCV hose.
7. Install heater hoses.
8. Install air conditioning compressor retaining bolts.
9. Install accessory drive belt. Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .
10. Fill Cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
11. Install air cleaner assembly, resonator assembly and air inlet hose.
12. Connect battery negative cable.

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

1. Remove the cylinder head cover. Refer to «COVER(S), Cylinder Head, Removal, 3.7L»(ref-457795-S38087059622012030200000) for left head cover and «COVER(S), Cylinder Head, Removal, 3.7L»(ref-457795-S11243807712012030200000) for right head cover.
2. For rocker arm removal on cylinder No. 4, Rotate the crankshaft until cylinder No. 1 is at BDC intake stroke.
3. For rocker arm removal on cylinder No. 1, Rotate the crankshaft until cylinder No. 1 is at BDC combustion stroke.
4. For rocker arm removal on cylinders No. 3 and No. 5, Rotate the crankshaft until cylinder No. 1 is at TDC exhaust stroke.
5. For rocker arm removal on cylinders No. 2 and No. 6, Rotate the crankshaft until cylinder No. 1 is at TDC ignition stroke.
6. Using the Rocker Arm Remover/Installer (special tool #8516A, Remover/Installer)(2), press downward on the valve spring, remove rocker arm. see scheme 70

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

1. For rocker arm installation on cylinders No. 4, Rotate the crankshaft until cylinder No. 1 is at BDC intake stroke.
2. For rocker arm installation on cylinder No. 1, Rotate the crankshaft until cylinder No. 1 is at BDC combustion stroke.
3. For rocker arm installation on cylinders No. 3 and No. 5, Rotate the crankshaft until cylinder No. 1 is at TDC exhaust stroke.
4. For rocker arm installation on cylinders No. 2 and No. 6, Rotate the crankshaft until cylinder No. 1 is at TDC ignition stroke.
5. Using the Rocker Arm Remover/Installer (special tool #8516A, Remover/Installer) (2) press downward on the valve spring, install rocker arm. see scheme 71
6. Install the cylinder head cover. Refer to «COVER(S), Cylinder Head, Installation, 3.7L»(ref-457795-S18626148182012030200000) for left head cover and «COVER(S), Cylinder Head, Installation, 3.7L»(ref-457795-S10268980662012030200000) for right head cover.

The valve stem seal is integral with the valve spring seat. For removal, refer to SPRING(S), Valve , Removal , 3.7L for left head and SPRING(S), Valve , Removal , 3.7L for right head.

The valve stem seal is integral with the valve spring seat. For installation, refer to SPRING(S), Valve , Installation , 3.7L for left head and SPRING(S), Valve , Installation , 3.7L for right head.

1. Remove the cylinder head cover. Refer to «COVER(S), Cylinder Head , Removal , 3.7L»(ref-457795-S38087059622012030200000) for left head cover and «COVER(S), Cylinder Head , Removal , 3.7L»(ref-457795-S11243807712012030200000) for right head cover.
2. Using the Valve Spring Remover/Installer (special tool #8516A, Remover/Installer), remove the rocker arms and the hydraulic lash adjusters.
3. Remove the spark plug for the cylinder the valve spring and seal are to be removed from.
4. Apply shop air to the cylinder to hold the valves in place when the spring is removed. NOTE: All six valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.
5. Using the Valve Spring Compressor (special tool #8387, Compressor, Valve Spring), compress the valve spring. NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
6. Remove the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
7. Remove the valve spring compressor. NOTE: The valve springs are NOT common between intake and exhaust.
8. Remove the spring retainer, and the spring.
9. Remove the valve stem seal.

Note. The valve stem seals are common between intake and exhaust.

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

1. Apply shop air to the cylinder to hold the valves in place while the spring is installed. NOTE: The valve stem seals are common between intake and exhaust.
2. Install the valve stem seal. NOTE: The valve springs are NOT common between intake and exhaust.
3. Install the spring retainer, and the spring.
4. Using Valve Spring Compressor (special tool #8387, Compressor, Valve Spring), compress the valve spring.
5. Install the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
6. Remove the valve spring compressor.
7. Disconnect the shop air to the cylinder.
8. Install the spark plug for the cylinder the valve spring and seal was installed on.
9. Using the Valve Spring Remover/Installer Special Tool (special tool #8516A, Remover/Installer), install the rocker arms and the hydraulic lash adjusters.
10. Install the cylinder head cover. Refer to «COVER(S), Cylinder Head , Installation , 3.7L»(ref-457795-S18626148182012030200000) for left head cover and «COVER(S), Cylinder Head , Installation , 3.7L»(ref-457795-S10268980662012030200000) for right head cover.

1. Raise vehicle on hoist.
2. Remove the left hand exhaust pipe from exhaust manifold.
3. Loosen the right hand exhaust manifold-to-exhaust pipe retaining bolts.
4. Remove the eight bolts (1,2,3) retaining structural cover in the sequence shown in illustration.
5. Pivot the exhaust pipe downward and remove the structural cover.

1. Position the structural cover in the vehicle.
2. Install all four bolts (1, 2, 3) retaining the cover-to-engine. see scheme 77 DO NOT tighten the bolts at this time.
3. Install the four cover-to-transmission bolts (1, 2, 3). Do NOT tighten at this time. CAUTION: The structural dust cover must be held tightly against both the engine and the transmission bell housing during the tightening sequence. Failure to do so may cause severe damage to the cover.
4. Starting with the two rear cover-to-engine bolts, tighten bolts (1) to 54 N.m (40 ft. lbs.), then tighten bolts (2) and (3) to 54 N.m (40 ft. lbs.) in the sequence shown in illustration.
5. Install the exhaust pipe on left hand exhaust manifold.
6. Tighten exhaust manifold-to-exhaust pipe retaining bolts to 20 - 26 N.m (15 - 20 ft. lbs.).

Scheme 77

The crankshaft (1) is constructed of nodular cast iron. see scheme 78 The crankshaft is a three throw split pin design with six counterweights for balancing purposes. The crankshaft is supported by four select fit main bearings with the No. 2 serving as the thrust washer location. The main journals of the crankshaft are cross drilled to improve rod bearing lubrication. The No. 6 counterweight has provisions for crankshaft position sensor target wheel (2) mounting. The select fit main bearing markings are located on the rear side of the target wheel. The crankshaft oil seals are one piece design. The front oil seal is retained in the timing chain cover, and the rear seal is pressed in to a bore formed by the cylinder block and the bedplate assembly.

Scheme 78

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

1. Remove the engine. Refer to «Removal, 3.7L»(ref-457795-S00631650232012030200000).
2. Remove the engine oil pump. Refer to «PUMP, Engine Oil, Removal, 3.7L»(ref-457795-S37118821752012030200000). CAUTION: DO NOT pry on the oil pan gasket when removing the oil pan, The oil pan gasket is mounted to the cylinder block in three locations and will remain attached to block when removing oil pan. Gasket can not be removed with oil pan.
3. Remove the bedplate mounting bolts. Note the location of the two stud bolts for installation.
4. Remove the connecting rods from the crankshaft. CAUTION: The bedplate to cylinder block mating surface is a critical sealing surface. Do not pry on or damage this surface in anyway. NOTE: The bedplate contains the lower main bearing halves. Use care when handling bedplate as not to drop or damage bearing halves. Installing main bearing halves in the wrong position will cause severe damage to the crankshaft. NOTE: The bedplate has pry points cast into it. Use these points only. The pry points are shown in illustration below.
5. Carefully pry on the pry points to loosen the bedplate then remove the bedplate. see scheme 79 CAUTION: When removing the crankshaft, use care not to damage bearing surfaces on the crankshaft.
6. Remove the crankshaft.
7. Remove the crankshaft tone wheel.

1. Position the flexplate onto the crankshaft and install the bolts hand tight.
2. Tighten the flexplate (1) retaining bolts to 95 N.m (70 ft. lbs.) in the sequence shown in illustration. see scheme 90
3. Install the transmission.

Scheme 79

Scheme 80

1. Remove the primary and secondary timing chains. Refer to «CHAIN and SPROCKETS, Timing , Removal , 3.7L»(ref-457795-S04678736542012030200000) . NOTE: The balance shaft and gear are serviced as an assembly. Do not attempt to remove the gear from the balance shaft. Remove the retaining bolt (4) from the counterbalance shaft thrust plate (2).
2. Using the Counterbalance Shaft Remover/Installer (special tool #8641, Remover/Installer) (1), remove the counterbalance shaft from the engine.

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

1. Coat counterbalance shaft bearing journals with clean engine oil. NOTE: The balance shaft is heavy, and care should be used when installing shaft, so bearings are not damaged.
2. Using the Counterbalance Shaft Remover/Installer (special tool #8641, Remover/Installer) (1), carefully install counterbalance shaft into engine. see scheme 93 1 - IDLER SHAFT 2 - COUNTERBALANCE SHAFT THRUST PLATE 3 - COUNTERBALANCE SHAFT DRIVE GEAR 4 - RETAINING BOLT
3. Install Counterbalance shaft thrust plate retaining bolt (4) finger tight. Do not tighten bolt at this time.
4. Position the right side of the thrust plate with the right chain guide bolt, install bolt finger tight.
5. Tighten the thrust plate retaining bolt (4) to 28 N.m (250 in. lbs.). see scheme 94
6. Remove the chain guide bolt so that guide can be installed.

Scheme 81

Before reinstalling used rings or installing new rings, the ring clearances must be checked.

Scheme 82

Scheme 83

Scheme 84

Scheme 85

1. Wipe the cylinder bore clean.
2. Insert the ring in the cylinder bore. NOTE: The ring gap measurement must be made with the ring positioned at least 12mm (0.50 inch.) from bottom of cylinder bore.
3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder.
4. Using a feeler gauge (1) check the ring end gap. Replace any rings not within specification. 1 - FEELER GAUGE PISTON RING SIDE CLEARANCE NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs.
5. Measure the ring side clearance as shown in illustration, making sure the feeler gauge (1) fits snugly between the ring land and the ring. Replace any ring not within specification.
6. Rotate the ring around the piston, the ring must rotate in the groove with out binding. PISTON RING SPECIFICATION CHART (1 OF 2) Ring Position Groove Clearance Maximum Clearance Upper Ring 0.051 - 0.094 mm 0.11 mm - (0.0020 - 0.0037 in.) (0.004 in.) Intermediate Ring 0.04 - 0.08 mm 0.10 mm - (0.0016 - 0.0031 in.) (0.004 in.) Oil Control Ring 0.019 - 0.229 mm 0.25 mm (Steel Rails) (0.0007-.0090 in.) (0.010 in.) PISTON RING SPECIFICATION CHART (2 OF 2) Ring Position Ring Gap Wear Limit Upper Ring 0.20 - 0.36 mm 0.43 mm - (0.0079 - 0.0142 in.) (0.0017 in.) Intermediate Ring 0.37 - 0.63 mm 0.74 mm - (0.0146 - 0.0249 in.) (0.029 in.) Oil Control Ring 0.025 - 0.76 mm 1.55 mm (Steel Rail) (0.0099 - 0.03 in.) (0.061 in.) 1 - SIDE RAIL END
7. The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston. NOTE: Piston rings are installed in the following order: Oil ring expander. Upper oil ring side rail. Lower oil ring side rail. No. 2 Intermediate piston ring. No. 1 Upper piston ring.
8. Install the oil ring expander.
9. Install upper side rail (1) by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail.
10. Install No. 2 intermediate piston ring using a piston ring installer.
11. Install No. 1 upper piston ring using a piston ring installer. 1 - SIDE RAIL UPPER 2 - NO. 1 RING GAP 3 - PISTON PIN 4 - SIDE RAIL LOWER 5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
12. Position piston ring end gaps as shown in illustration. It is important that expander ring gap (5) is at least 45° from the side rail gaps, but not on the piston pin center or on the thrust direction.

Scheme 86

The pistons (2) are made of a high strength aluminum alloy. see scheme 100 The connecting rods (1) are made of forged powdered metal, with a "fractured cap" design. A full floating piston pin is used to attach the piston to the connecting rod.

Scheme 87

Inspect the connecting rod bearings for scoring. Check the bearings for normal wear patterns, scoring, grooving, fatigue and pitting. Replace any bearing that shows abnormal wear.

Inspect the connecting rod journals for signs of scoring, nicks and burrs.

Misaligned or bent connecting rods can cause abnormal wear on pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft connecting rod journals. If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod, inspect it for correct rod alignment. Replace misaligned, bent or twisted connecting rods.

Scheme 88

Scheme 89

Scheme 90

1. Wipe the oil from the connecting rod journal.
2. Lubricate the upper bearing insert and position in connecting rod. Center bearing insert (2) in connecting rod (1)
3. Use piston ring compressor (3) and Connecting Rod Guides (special tool #8507, Guides, Connecting Rod) to install the rod and piston assemblies. The oil slinger slots in the rods must face front of the engine. The "F"s near the piston wrist pin bore (1) should point to the front of the engine.
4. Install the lower bearing insert in the bearing cap. Center bearing insert in connecting rod. . The lower insert must be dry. Place strip of Plastigage across full width of the lower insert at the center of bearing cap. Plastigage must not crumble in use. If brittle, obtain fresh stock.
5. Install bearing cap and connecting rod on the journal and tighten bolts to 27 N.m (20 ft. lbs.) plus a 90° turn. DO NOT rotate crankshaft. Plastigage will smear, resulting in inaccurate indication.
6. Remove the bearing cap and determine amount of bearing-to-journal clearance by measuring the width of compressed Plastigage (2). Refer to Engine «Specifications»(ref-457795-S32849896692012030200000) for the proper clearance. Plastigage should indicate the same clearance across the entire width of the insert. If the clearance varies, it may be caused by either a tapered journal, bent connecting rod or foreign material trapped between the insert and cap or rod.
7. If the correct clearance is indicated, replacement of the bearing inserts is not necessary. Remove the Plastigage from crankshaft journal and bearing insert. Proceed with installation. BEARING & JOURNAL SIZE Bearing Mark SIZE USED WITH JOURNAL SIZE 0.025 OS 0.025 mm 0.001 in. 57.883 - 57.867 mm 2.2788 - 2.2783 in. STD STANDARD STANDARD 57.908 - 57.892 mm 2.2798 - 2.2792 in. 0.250 US 0.250 mm 0.010 in. 57.658 - 57.646 mm 2.2700 - 2.2695 in.
8. If bearing-to-journal clearance exceeds the specification, determine which services bearing set to use the bearing sizes are as follows: CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed.
9. Repeat the Plastigage measurement to verify your bearing selection prior to final assembly.
10. Once you have selected the proper insert, install the insert and cap. Tighten the connecting rod bolts to 27 N.m (20 ft. lbs.) plus a 90° turn.

Scheme 91

Slide snug-fitting feeler gauge between the connecting rod and crankshaft journal flange. Refer to Engine Specifications for the proper clearance. Replace the connecting rod if the side clearance is not within specification.

Scheme 92

Scheme 93

1. To correctly select the proper size piston, a cylinder bore gauge (2), capable of reading in 0.003 mm (.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer. see scheme 106
2. Measure the inside diameter of the cylinder bore (3) at a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B. 1 - MOLY COATED 2 - MOLY COATED
3. The coated pistons (1, 2) will be serviced with the piston pin and connecting rod pre-assembled. see scheme 107
4. The coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston (1, 2) will not provide accurate results. Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY. To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (.0001 in.) increments is required.
5. Piston installation into the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.

1. Disconnect negative cable from battery.
2. Remove the following components: Oil pan and gasket/windage tray. Refer to «PAN, Oil , Removal , 3.7L»(ref-457795-S31280788402012030200000) . Cylinder head covers. Refer to «COVER(S), Cylinder Head , Removal , 3.7L»(ref-457795-S38087059622012030200000) for left cover or «COVER(S), Cylinder Head , Removal , 3.7L»(ref-457795-S11243807712012030200000) for right cover. Timing chain cover. Refer to «COVER(S), Engine Timing , Removal , 3.7L»(ref-457795-S00384933232012030200000) . Cylinder head(s). Refer to «Cylinder Head, Left , Removal , 3.7L»(ref-457795-S33882215162012030200000) and «Cylinder Head, Right , Removal , 3.7L»(ref-457795-S13300154642012030200000) . .
3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
5. Remove connecting rod cap. Install the Connecting Rod Guides (special tool #8507, Guides, Connecting Rod) into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur.
6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.

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

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

1. Clean the oil pan gasket mating surface of the bedplate and oil pan. see scheme 129
2. Inspect integrated oil pan gasket (2), and replace as necessary.
3. Position the integrated oil pan gasket/windage tray assembly (2).
4. Install the oil pickup tube to the engine. Tighten nuts to 28 N.m (20 ft. lbs.).
5. If removed, install stud at position No. 9.
6. Position the oil pan and install the mounting bolts and nut (1-17). Tighten the mounting bolts and nut to 15 N.m (11 ft. lbs.) in the sequence shown in illustration. see scheme 130
7. Lower the engine into mounts using special tool (special tool #8534B, Fixture, Driveline Support).
8. Install both the left and right side engine mount through bolts. Tighten the nuts to 68 N.m (50 ft. lbs.).
9. Remove special tool (special tool #8534B, Fixture, Driveline Support).
10. Connect cooler lines to radiator, transmission and clips. NOTE: When connecting the transmission oil cooler lines, it is necessary to replace the line clip that is located on the oil pan stud. The retention force of the clip is severely degraded upon removal.
11. Install structural dust cover, if equipped.
12. Install the front crossmember. Refer to «CROSSMEMBER, Lower Control Arm, Installation»(ref-457829-S30643828682012030200000) or «CROSSMEMBER, Transmission, Installation»(ref-457829-S11579147072012030200000).
13. Fill engine oil.
14. Reconnect the negative battery cable.
15. Start engine and check for leaks.

1. Remove the oil pan and pick-up tube. Refer to «PAN, Oil , Removal , 3.7L»(ref-457795-S31280788402012030200000) .
2. Remove the timing chain cover. Refer to «COVER(S), Engine Timing , Removal , 3.7L»(ref-457795-S00384933232012030200000) .
3. Remove the timing chains and tensioners. Refer to «CHAIN and SPROCKETS, Timing , Removal , 3.7L»(ref-457795-S04678736542012030200000) .
4. Remove the four bolts, primary timing chain tensioner and the oil pump.

1. Disconnect the negative cable from the battery.
2. Raise vehicle on hoist.
3. Remove front splash shield.
4. Disconnect oil pressure sender wire (4).
5. Remove the pressure sender (2). see scheme 139

Scheme 94

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

Scheme 95

The exhaust manifolds (1,2) are log style with a patented flow enhancing design to maximize performance. The exhaust manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is used to improve sealing to the cylinder head.

Scheme 96

The exhaust manifolds are covered by a three layer laminated heat shield (3) for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold.

Scheme 97

1. Disconnect the negative cable from the battery.
2. Raise and support the vehicle.
3. Remove the bolts and nuts attaching the exhaust pipe to the engine exhaust manifold.
4. Lower the vehicle.
5. Remove the exhaust heat shield (1).
6. Remove bolts, nuts and washers attaching manifold to cylinder head.
7. Remove manifold and gasket from the cylinder head. see scheme 143

Scheme 98

1. Disconnect the negative cable from the battery.
2. Raise and support the vehicle.
3. Remove the bolts and nuts attaching the exhaust pipe to the engine exhaust manifold.
4. Lower the vehicle.
5. Remove the exhaust heat shields (1).
6. Remove bolts, nuts and washers attaching manifold to cylinder head.
7. Remove manifold and gasket from the cylinder head. see scheme 144

1. Remove the primary and secondary timing chains and sprockets. Refer to «CHAIN and SPROCKETS, Timing , Removal , 3.7L»(ref-457795-S04678736542012030200000) . NOTE: To remove the idler shaft, it is necessary to tap threads into the shaft, to install the removal tool.
2. Using a 12 mm X 1.75 tap, cut threads in the idler shaft center bore.
3. Cover the radiator core with a suitable cover. CAUTION: Use care when removing the idler shaft, Do not strike the radiator cooling fins with the slide hammer.
4. Using Slide Hammer (special tool #8517, Remover) remove the idler shaft.

1. Thoroughly clean the idler shaft bore.
2. Position the idler shaft in the bore. NOTE: The two lubrication holes in the idler shaft do not require any special alignment. NOTE: Before using the retaining bolt to install the idler shaft, coat the threads and the pilot on the idler shaft, with clean engine oil.
3. Using the primary idler sprocket retaining bolt and washer, carefully draw the idler shaft into the bore until fully seated.
4. Coat the idler shaft with clean engine oil.
5. Install the timing chains and sprockets. Refer to «CHAIN and SPROCKETS, Timing , Installation , 3.7L»(ref-457795-S27896854792012030200000) .