5.7L Engine - Service Information: Diagnosis RAM Pickup 2500

DIAGNOSTIC PROCEDURES

The following diagnostic procedures are used to determine the source of excessive internal oil Consumption, these procedures and tests apply to vehicles with 50,000 miles or less.

Note. Engine oil consumption may be greater than normal during engine break-in. Repairs should be delayed until vehicle has been driven at least 7,500 miles.

Severe service (high ambient temperature, short trips, heavy loading, trailer towing, taxi, off-road, or law enforcement use) may result in greater oil consumption than normal.

Sustained high speed driving and high engine RPM operation may result in increased oil consumption.

Failure to comply with the recommended oil type and viscosity rating, as outlined in the owners™ manual, may impact oil economy as well as fuel economy.

Oil consumption may increase with vehicle age and mileage due to normal engine wear.

Note. Because a few drops of external oil leakage per mile can quickly account for the loss of one quart of oil in a few hundred miles, ensure no external engine oil leaks are present.

1. Oil leakage is not the same as oil consumption and all external leakage must be eliminated before any action can be taken to verify and/or correct oil consumption complaints.
2. Verify that the engine has the correct oil level dipstick and dipstick tube installed.
3. Verify that the engine is not being run in an overfilled condition. Check the oil level 15 minutes after a hot shutdown with the vehicle parked on a level surface. In no case should the level be above MAX or the FULL mark on the dipstick.

OIL CONSUMPTION TEST

1. Check the oil level at least 15 minutes after a hot shutdown.
2. If the oil level is low, top off with the proper viscosity and API service level engine oil. Add one bottle of MOPAR® 4-In-1 Leak Detection Dye into the engine oil.
3. Tamper proof the oil pan drain plug, oil filter, dipstick and oil fill cap.
4. Record the vehicle mileage.
5. Instruct the customer to drive the vehicle as usual.
6. Ask the customer to return to the servicing dealer after accumulating 500 miles, Check the oil level at least 15 minutes after a hot shutdown. If the oil level is half way between the "FULL" and "ADD" mark continue with the next step.
7. Using a black light, recheck for any external engine oil leaks, repair as necessary, if no external engine oil leaks are present, continue with oil consumption diagnosis.

OIL CONSUMPTION DIAGNOSIS

1. Check the Positive Crankcase Ventilation (PCV) system. Make sure the system is not restricted and the PCV valve has the correct part number and correct vacuum source (18-20 in. Hg at idle below 3000 ft. above sea level is considered normal).
2. Perform a cylinder compression test and cylinder leak down test using the standard leak down gauge following manufacturers suggested best practices. NOTE: Verify the spark plugs are not oil saturated. If the spark plugs are oil saturated and compression is good it can be assumed the valve seals or valve guides are at fault.
3. If one or more cylinders have more than 15% leak down further engine tear down and inspection will be required.

DIAGNOSIS AND TESTING - CYLINDER HEAD GASKET FAILURE

A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket.

1. Possible indications of the cylinder head gasket leaking between adjacent cylinders are: Loss of engine power Engine misfiring Poor fuel economy
2. Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are: Engine overheating Loss of coolant Excessive steam (white smoke) emitting from exhaust Coolant foaming

CYLINDER-TO-CYLINDER LEAKAGE TEST

To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in the CYLINDER COMPRESSION PRESSURE LEAKAGE . An engine cylinder head gasket leaking between adjacent cylinders will results in approximately a 50 - 70% reduction in compression pressure.

CYLINDER-TO-WATER JACKET LEAKAGE TEST

VISUAL TEST METHOD

With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens.

If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.

CHEMICAL TEST METHOD

Combustion leaks into the cooling system can also be checked by using the Bloc-Chek Kit (special tool #C-3685-A, Bloc-Chek Kit) or equivalent. Perform the test following the procedures supplied with the tool kit.

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1. Remove the cowl grille (4).
2. Remove the engine cover (1). Refer to «COVER, Engine , Installation , 5.7L»(ref-457797-S08167526932012030200000) .
3. Perform the Fuel System Pressure Release procedure. Refer to «STANDARD PROCEDURE»(ref-457834-S04226998202012030200000) .
4. Disconnect the fuel supply line. Refer to «FITTING, QUICK CONNECT»(ref-457834-S36340154892012030200000) .
5. Disconnect and isolate the negative battery cable (2).
6. Drain the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
7. Remove the air cleaner assembly. Refer to «BODY, Air Cleaner , Removal , 5.7L»(ref-457797-S42752377112012030200000) .
8. Remove closed crankcase ventilation system. CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
9. Disconnect the oxygen sensor connectors (2).
10. Saturate all exhaust bolts and nuts with Mopar® Rust Penetrant. Allow 5 minutes for penetration.
11. Remove the exhaust pipe to manifold bolts (3) (left side shown in illustration, right side similar) and disconnect the front exhaust pipe/catalytic converter assembly (4). Refer to «CONVERTER, Catalytic , Removal»(ref-457794-S07022787092012030200000) .
12. Disconnect the evaporation control system.
13. Disconnect the heater hoses (2). CAUTION: Do not let the tensioner arm snap back to the freearm position, sever damage may occur to the tensioner.
14. Insert a suitable square drive ratchet into the square hole on belt tensioner arm (7).
15. Release the belt tension by rotating the tensioner arm (7) clockwise . Rotate the belt tensioner arm (7) until the belt can be removed from the pulleys.
16. Remove the accessory drive belt.
17. Gently release the tensioner arm (7). NOTE: It is not necessary to disconnect the hoses from the power steering pump, for power steering pump removal.
18. Remove the three power steering pump (1) mounting bolts (2) through the access holes in the pulley and secure out of the way.
19. Remove the cylinder head covers and gaskets. Refer to «COVER(S), Cylinder Head , Removal , 5.7L»(ref-457797-S17921459472012030200000) .
20. Remove the intake manifold and throttle body as an assembly. Refer to «MANIFOLD, Intake , Removal , 5.7L»(ref-457797-S09573092392012030200000) . CAUTION: Rocker arm assemblies and pushrods must be installed in their original locations or engine damage could result.
21. Identify the original locations for assembly, remove rocker arm assemblies and pushrods. Refer to «ROCKER ARM, Valve , Removal , 5.7L»(ref-457797-S19173491152012030200000) .
22. Using the sequence shown in illustration, remove the head bolts from each cylinder head. Remove the cylinder head and discard the cylinder head gasket.

INSPECTION

1. Inspect the cylinder head for out-of-flatness using a straightedge and a feeler gauge. If tolerances exceed 0.0508 mm (0.002 in.), replace the cylinder head.
2. Inspect the valve seats for damage. Service the valve seats as necessary.
3. Inspect the valve guides for wear, cracks or looseness. If either condition exist, replace the cylinder head.
4. Inspect the pushrods. Replace worn or bent pushrods.

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1. Clean all surfaces of cylinder block and cylinder heads.
2. Clean cylinder block front and rear gasket surfaces using a suitable solvent. CAUTION: The cylinder head gaskets are not interchangeable between the left and right sides. They are marked with an "L" and "R" to indicate the left or right side and they are marked "TOP" to indicate which side goes up. CAUTION: The head gaskets are marked "TOP" to indicate which side goes up.
3. Position the new cylinder head gasket (5) onto the cylinder block.
4. Position cylinder head (4) onto head gasket (5) and cylinder block.
5. Using the sequence shown in illustration, tighten the cylinder head bolts 1 through 10 to 34 N.m (25 ft. lbs.).
6. Using the sequence shown in illustration, tighten the cylinder head bolts 11 through 15 to 20 N.m (15 ft. lbs.).
7. Using the sequence shown in illustration, tighten the cylinder head bolts 1 through 10 to 54 N.m (40 ft. lbs.).
8. Using the sequence shown in illustration, tighten the cylinder head bolts 11 through 15 to 20 N.m (15 ft. lbs.).
9. Using the sequence shown in illustration, rotate the cylinder head bolts 1 through 10 90°.
10. Using the sequence shown in illustration, tighten the cylinder head bolts 11 through 15 to 34 N.m (25 ft. lbs.).
11. Install the push rods and rocker arm assemblies in their original position, using Pushrod Retainer (special tool #9070, Retainer, Push Rod) (1). Refer to «ROCKER ARM, Valve , Installation , 5.7L»(ref-457797-S15577686302012030200000) .
12. Install the intake manifold. Refer to «MANIFOLD, Intake , Installation , 5.7L»(ref-457797-S13751922512012030200000) .
13. Install the spark plugs.
14. Connect the heater hoses (2).
15. Connect the fuel supply line.
16. Install the three power steering pump mounting bolts (2) through the access holes in the pulley and tighten bolts to 28 N.m (21 ft. lbs.).
17. Install the accessory drive belt. Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .
18. Install the cylinder head cover (1) and hand start all fasteners. Verify that all double ended studs (3) are in the correct location. Refer to «COVER(S), Cylinder Head , Installation , 5.7L»(ref-457797-S24405400242012030200000) .
19. Using the sequence shown in illustration, tighten the cylinder head cover bolts and double ended studs to 8 N.m (70 in. lbs.).
20. Connect the evaporation control system.
21. Install the air cleaner.
22. Install cowl grille (4).
23. Install the engine cover (1). Refer to «COVER, Engine , Installation , 5.7L»(ref-457797-S08167526932012030200000) .
24. Fill the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
25. Drain and fill the engine with new oil.
26. Connect the negative battery cable (2).
27. Start the engine and check for leaks.

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1. Disconnect and isolate the negative battery cable (1).
2. Remove the engine cover (2). Refer to «COVER, Engine , Installation , 5.7L»(ref-457797-S08167526932012030200000) . NOTE: Right side shown in illustration, left side similar.
3. Disconnect the ignition coil electrical connectors (1).
4. Position the electrical harness (2) aside.
5. Remove the ignition coil retaining bolts (3) and remove the ignition coils.
6. Using the sequence shown in illustration, remove the cylinder head cover retaining bolts. CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur.
7. Remove the cylinder head cover (1).
8. Clean the sealing surface of the cylinder head (2) and cover.

Note. The cylinder head cover gasket may be used again, provided no cuts, tears, or deformation have occurred.

The cam bearings are not serviceable. Do not attempt to replace cam bearings for any reason. If the cam bearings are damaged, the cylinder block must be replaced.

DIAGNOSIS AND TESTING - HYDRAULIC TAPPETS

Check the oil pressure before disassembling any part of the engine to correct tappet noise. If vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending-unit. The pressure should be between 207-552 kPa (30-80 psi) at 3,000 RPM.

Check the oil level after the engine reaches normal operating temperature. Allow five minutes for the oil level to stabilize before checking the oil level. The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on the dipstick. Either of these two conditions could be responsible for noisy tappets.

OIL LEVEL

TAPPET NOISE DIAGNOSIS

1. To determine the source of tappet noise, crank the engine over with the cylinder head covers removed.
2. Feel each valve spring or rocker arm to detect the noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation. NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm pushrod sockets and pushrod ends for wear.
3. Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leak-down around the unit plunger, or by the plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is caused by a tappet check valve not seating, or by foreign particles wedged between the plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and cleaning.
4. The valve train generates a noise very much like a light tappet noise during normal operation. Care must be taken to ensure that tappets are making the noise. If more than one tappet seems to be noisy, it's probably not the tappets.

Scheme 362

1. Disconnect and isolate the negative battery cable.
2. Remove the cylinder head. Refer to «Cylinder Head , Removal , 5.7L»(ref-457797-S12195487782012030200000) .
3. Remove the tappet guide holder retaining bolt (1) from the tappet guide holder assembly (2). CAUTION: The lifter and retainer assembly must be installed as a unit. CAUTION: If the lifter and retainer assembly are to be reused, identify the lifters to ensure installation in their original location or engine damage could result.
4. Remove the tappet guide holder (1) and tappets (2) as an assembly.
5. Check the camshaft lobes for abnormal wear.

DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS

The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer and cannot be serviced separately.

Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.

If the leakage occurs at the crankshaft rear oil seal area

1. Raise and support the vehicle.
2. Remove the transmission inspection/torque converter access cover.
3. Inspect the rear of the cylinder block for evidence of oil leakage, note the following: Circular spray pattern generally indicates seal leakage or crankshaft damage. Where leakage tends to run straight down, possible causes are a porous block, camshaft bore cup plugs, oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. See appropriate Engine component service information for proper repair procedures of these items.
4. If no leaks are detected, pressurize the crankcase as outlined in «AIR LEAK DETECTION TEST METHOD»(ref-457797-S39738246492012030200000) . CAUTION: Do not exceed 20.6 kPa (3 psi).
5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out using an emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks or scratches. The crankshaft seal flange is specially machined to complement the function of the rear oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done. Refer to «RETAINER, Crankshaft Rear Oil Seal , Removal , 5.7L»(ref-457797-S32772113992012030200000) .

Check the connecting rod journal for excessive wear, taper and scoring. Refer to STANDARD PROCEDURE - PISTON FITTING .

Check the connecting rod for signs of twist or bending.

Check the piston for taper and elliptical shape before it is fitted into the cylinder bore. Refer to STANDARD PROCEDURE - PISTON FITTING .

Check the piston for scoring or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration.

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

Note. Make sure the piston ring grooves are clean and free of nicks and burrs.

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1. Check piston ring clearance. Refer to «STANDARD PROCEDURE - PISTON RING FITTING»(ref-457797-S01860692602012030200000) .
2. Before installing piston and connecting rod assemblies into the bore, install the piston rings. Refer to «STANDARD PROCEDURE - PISTON RING FITTING»(ref-457797-S01860692602012030200000) .
3. Immerse the piston head and rings in clean engine oil and position a ring compressor over the piston and rings and tighten the ring compressor. Ensure the position of rings do not change during this operation.
4. Position the rod bearing (1) onto the connecting rod and lubricate bearing surface with clean engine oil.
5. Install Connecting Rod Guides (special tool #8507, Guides, Connecting Rod) (1) into the connecting rod bolt threads.
6. The pistons are marked on the piston pin bore surface with an raised "F" or arrow on top of piston indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks.
7. Wipe cylinder bore clean and lubricate with clean engine oil.
8. Rotate the crankshaft until the connecting rod journal is centered with the cylinder bore.
9. Insert the piston and rod assembly into the cylinder bore and carefully position the connecting rod over the crankshaft journal.
10. Tap the piston down into the cylinder bore using a hammer handle while guiding the connecting rod into position on the rod journal.
11. Remove the Connecting Rod Guides (special tool #8507, Guides, Connecting Rod).
12. Wipe the connecting rod cap (1) clean and lubricate with clean engine oil and install the bearing (3). NOTE: The connecting rods and bearing caps are not interchangeable, line up the previously marked bearing caps and connecting rods to ensure assembly to their original location.
13. Lubricate the bearing surfaces with clean engine oil and position the rod cap in place. CAUTION: When installing the connecting rods, make sure the wide side of the connecting rod faces the crankshaft and the narrow sides face each other. CAUTION: Always replace the connecting rod bolts whenever they are loosened or removed.
14. Lubricate the new rod cap bolts with clean engine oil, install and tighten to 21 N.m (15 ft. lbs.) plus 90°.
15. Install the timing chain cover. Refer to «COVER(S), Engine Timing , Installation , 5.7L»(ref-457797-S08343052232012030200000) .
16. Install the new oil pan gasket/windage tray and oil pan. Refer to «PAN, Oil , Installation , 5.7L»(ref-457797-S25274644792012030200000) .
17. Install the engine oil dipstick tube and dipstick.
18. Lower the vehicle.
19. Using the Engine Lift Fixture (special tool #8984B, Fixture, Engine Lifting) (1), Engine Lift Adapter (special tool #8984-UPD, Adapter, Engine Lift) (2) and the Engine Support Fixture (special tool #8534B, Fixture, Driveline Support) (3) lower the engine into position and remove.
20. Raise and support the vehicle.
21. Position the steering gear (2), install mounting bolts (1) and tighten to 95 N.m (70 ft. lbs.).
22. Install the engine mount nuts (1, 2) and tighten to 95 N.m (70 ft. lbs.).
23. Lower the vehicle.
24. Install the cylinder head(s). Refer to «Cylinder Head , Installation , 5.7L»(ref-457797-S30133838482012030200000) .
25. Position the air cleaner housing (2), install the air cleaner housing retaining bolt (3) and securely tighten.
26. Connect the makeup air hose (1).
27. Connect the intake air temperature sensor (4) electrical connector.
28. Connect the air duct to the throttle body and tighten clamp to 3 N.m (30 in. lbs.).
29. Fill the engine with oil. Refer to «STANDARD PROCEDURE - ENGINE OIL SERVICE»(ref-457797-S04567477302012030200000) .
30. Install the engine covers (1).
31. Connect the negative battery cable (3).

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1. Disconnect negative cable from battery.
2. Remove accessory drive belt. Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
3. Drain cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
4. Remove upper radiator hose.
5. Remove radiator shroud attaching fasteners.
6. Remove radiator cooling fan and shroud. Refer to «FAN, Cooling, Electric , Removal»(ref-457792-S13033663812012030200000) and «FAN, Cooling, Viscous , Removal»(ref-457792-S41329399382012030200000) .
7. Remove crankshaft damper bolt.
8. Remove damper using Crankshaft Insert (special tool #8513A, Insert, Crankshaft) (2) and Three Jaw Puller (special tool #1023, Puller) (1). Refer to «DAMPER, Vibration , Removal , 5.7L»(ref-457797-S28530918912012030200000) .
9. Using Seal Remover (special tool #9071, Remover, Seal) (1), remove crankshaft front seal (2).

Scheme 368

1. Using Crankshaft Front Oil Seal Installer (special tool #9072, Installer, Seal) (2) and Damper Installer (special tool #8512A, Installer, Damper) (1), install crankshaft front seal. CAUTION: To prevent severe damage to the crankshaft or damper, thoroughly clean the damper bore and the crankshaft nose before installing damper.
2. Install vibration damper. Refer to «DAMPER, Vibration , Installation , 5.7L»(ref-457797-S32293252722012030200000) .
3. Install radiator cooling fan and shroud. Refer to «FAN, Cooling, Electric , Installation»(ref-457792-S30022413072012030200000) and «FAN, Cooling, Viscous , Installation»(ref-457792-S33156171422012030200000) .
4. Install upper radiator hose.
5. Install accessory drive belt. Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .
6. Refill cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
7. Connect negative cable to battery.

DIAGNOSIS AND TESTING - MDS SOLENOID

The Multi-Displacement System (MDS) has the following detectable issues

1. solenoid circuit
2. fail to deactivate a cylinder(s)
3. fail to reactivate a cylinder(s)
4. low oil pressure

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1. Disconnect and isolate the negative battery cable.
2. Remove the intake manifold. Refer to «MANIFOLD, Intake , Removal , 5.7L»(ref-457797-S09573092392012030200000) .
3. Remove foam insulator pad (1).
4. Remove the Multiple Displacement Solenoid (MDS) (2) electrical connector(s) (1).
5. Remove the MDS solenoid (2) retaining bolt(s) (3). CAUTION: Do not try to pry the solenoid out. This could lead to breakage and contamination of the lubrication system.
6. Lightly tap on the MDS solenoid(s) with a rubber mallet. Rotate the MDS solenoid(s) from side to side to break the seal.
7. Remove the MDS solenoid(s).

AIR LEAK DETECTION TEST METHOD

1. Remove the PCV valve from the IAFM. Cap or plug the PCV valve grommet.
2. Attach an air hose with a pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.
3. Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service information procedures.
4. If the leakage occurs at the rear oil seal area, refer to «INSPECTION FOR REAR SEAL AREA LEAKS»(ref-457797-S18908924652012030200000) .
5. If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve.
6. Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.

INSPECTION FOR REAR SEAL AREA LEAKS

Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.

If the leakage occurs at the crankshaft rear oil seal area

1. Disconnect the battery.
2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak: Circular spray pattern generally indicates seal leakage or crankshaft damage. Where leakage tends to run straight down, possible causes are a porous block, distributor seal, camshaft bore cup plugs oil gallery pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces.
4. If no leaks are detected, pressurize the crankcase as outlined in «AIR LEAK DETECTION TEST METHOD»(ref-457797-S39738246492012030200000) . CAUTION: Do not exceed 20.6 kPa (3 psi).
5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled.

CRANKCASE OIL LEVEL INSPECTION

Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about ten minutes before checking oil level. Checking engine oil level on a cold engine is not accurate.

To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick.

1. Position vehicle on level surface.
2. With engine OFF, allow approximately five minutes for oil to settle to bottom of crankcase, remove engine oil dipstick.
3. Wipe dipstick clean.
4. Install dipstick and verify it is seated in the tube.
5. Remove dipstick, with handle held above the tip, take oil level reading.
6. Add oil only if level is below the ADD mark on dipstick.

Inspect manifold for cracks.

Inspect mating surfaces of manifold for flatness with a straight edge. Gasket surfaces must be flat within 0.2 mm per 300 mm (0.008 inch per foot).

DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKAGE

An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.

1. Start the engine.
2. Spray a small stream of water at the suspected leak area.
3. If a change in RPM is observed the area of the suspected leak has been found.
4. Repair as required.

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1. Disconnect the intake air temperature (IAT) sensor electrical connector (3).
2. Remove the clean air tube (2) from the air cleaner housing (4) and the throttle body.
3. Disconnect the makeup air hose.
4. Remove the air cleaner housing. Refer to «BODY, Air Cleaner , Removal , 5.7L»(ref-457797-S42752377112012030200000) .
5. Lift up the front of the engine cover (1) and separate the engine cover front grommets (2) from the ball studs on the intake manifold.
6. Slightly raise the front of the engine cover and slide forward to remove the rear engine cover pegs (2) from the grommets (1) on the rear of the intake manifold.
7. Perform the fuel pressure release procedure. Refer to «STANDARD PROCEDURE»(ref-457834-S04226998202012030200000) .
8. Disconnect the negative battery cable (1). NOTE: Excessive fuel spillage onto the gaskets can cause gaskets to expand and dislodge from the gasket groove.
9. Disconnect the fuel supply line quick connect fitting at the fuel rail (1) and plug the fuel supply line with a shipping cap to prevent spillage. Refer to «STANDARD PROCEDURE»(ref-457834-S37434674942012030200000) . NOTE: The factory fuel injection electrical harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If the harness was not tagged, note the electrical connector's location during removal.
10. Disconnect the electrical connectors to all fuel injectors and position the fuel injector electrical harness aside.
11. Remove the main engine electrical harness support strap at the rear of the intake manifold and position harness aside.
12. Remove the A/C line P-Clip retaining bolt (1) from the throttle body bracket and remove the P-Clip (2).
13. Secure the A/C line out of the way.
14. Remove the generator. Refer to «GENERATOR , Removal»(ref-457799-S36013499732012030200000) .
15. Remove the throttle body bracket retaining bolt from the intake manifold and remove the bracket.
16. Disconnect the electrical connector at the throttle body and reposition the harness.
17. Disconnect the brake booster vacuum hose, and the vacuum lines.
18. Using the sequence shown in illustration, remove the intake manifold retaining bolts.
19. Slide the intake manifold forward and disconnect both the manifold air pressure (MAP) sensor (1) and the short runner valve (SRV) connectors located at the rear of the intake manifold.
20. Remove the intake manifold and throttle body as an assembly.

1. Inspect the intake manifold sealing surface for cracks, nicks and distortion.
2. Inspect the intake manifold vacuum hose fittings for looseness or blockage.

Scheme 376

Note. If reinstalling the original manifold apply Mopar® Lock & Seal Adhesive to the intake manifold bolts. Not required when installing a new manifold.

1. Apply Mopar® Lock & Seal Adhesive to the intake manifold bolts.
2. Install the intake manifold seals (3) and positive crankcase ventilation (PCV) seals (1).
3. Connect both the manifold air pressure (MAP) sensor (1) and the short runner valve (SRV) electrical connectors located at the rear of the intake manifold as you position the intake manifold in place.
4. Using the sequence shown in illustration, tighten the intake manifold bolts to 12 N.m (9 ft. lbs.).
5. Position the main engine electrical harness at the rear of the intake manifold and install the support strap.
6. Connect the fuel supply line quick connect fitting at the fuel rail (1). NOTE: The factory fuel injection electrical harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If the harness was not tagged, use the noted the electrical connector's location during removal.
7. Position the fuel injector electrical harness and connect the electrical connectors to all fuel injectors.
8. Connect the brake booster vacuum hose, and the vacuum lines.
9. Install the throttle body bracket and securely tighten the retaining bolt.
10. Install the generator. Refer to «GENERATOR , Installation»(ref-457799-S02313752592012030200000) .
11. Position the A/C lines, install the A/C line P-Clip (2) and tighten P-Clip retaining bolt (1) to 4 N.m (35 in. lbs.).
12. Position the wiring harness and connect the electrical connector at the throttle body.
13. Slightly tilt the rear of the engine cover and slide the rear engine cover pegs (2) into the grommets (1) on the rear of the intake manifold until the cover stops. NOTE: Check to make sure the engine cover is installed properly by reaching behind the cover to verify that the pegs (2) are located in the rear grommets (1). NOTE: While installing the engine cover the front ball studs will make a popping or suction sound as the ball studs are inserted into the front grommets.
14. Lower the front of the engine cover (1) and line up the front grommets (2) with the ball studs on the front of the intake manifold and with a downward motion push the engine cover front grommets onto the ball studs. NOTE: Lightly lift the front of the engine cover to insure the front ball studs are seated into the front grommets correctly.
15. Install the air cleaner assembly (4)
16. Connect the clean air tube (2) to the air cleaner assembly (4) and the throttle body.
17. Connect the makeup air hose.
18. Connect the IAT sensor electrical connector (3).
19. Connect the negative battery cable (1).

Scheme 377

Scheme 378

Scheme 379

Scheme 380

Scheme 381

1. Disconnect the negative battery cable.
2. Drain the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) . NOTE: It is not necessary to remove water pump for timing chain cover removal.
3. Remove the timing chain cover. Refer to «COVER(S), Engine Timing , Removal , 5.7L»(ref-457797-S09931747462012030200000) .
4. Verify the slide bushings (1) remain installed in the timing chain cover during removal.
5. Remove the oil pump retaining bolts (2) and remove the oil pump (1).
6. Install the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align the timing marks with the timing chain sprockets (1, 2).
7. Retract the chain tensioner arm (1) until the hole in the arm lines up with the hole in the bracket.
8. Install the Tensioner Pin (special tool #8514, Pins, Tensioner) (1) into the chain tensioner holes. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result.
9. Remove the camshaft phaser retaining bolt (1) and remove the timing chain with the camshaft phaser and crankshaft sprocket. NOTE: Inspect the timing chain tensioner and timing chain guide shoes for wear and replace as necessary.
10. If the timing chain tensioner is being replaced, remove the retaining bolts (3) and remove the timing chain tensioner (2).
11. If the timing chain guide (1) is being replaced, remove the retaining bolts (2) and remove the timing chain guide.

Scheme 382

Scheme 383

Scheme 384

Scheme 385

1. Install the crankshaft sprocket (1) and position halfway onto the crankshaft.
2. While holding the camshaft phaser in hand, position the timing chain on the camshaft phaser and align the timing marks as shown in illustration.
3. While holding the camshaft phaser and timing chain in hand, position the timing chain on the crankshaft sprocket and align the timing mark as shown in illustration.
4. Align the slot in the camshaft phaser with the dowel on the camshaft and position the camshaft phaser on the camshaft while sliding the crankshaft sprocket into position.
5. Install the camshaft phaser retaining bolt (1) finger tight.
6. If removed, install the timing chain guide (1) and tighten the bolts (2) to 11 N.m (8 ft. lbs.).
7. If removed, install the timing chain tensioner (2) and tighten the bolts (3) to 11 N.m (8 ft. lbs.).
8. Remove the tensioner pin (special tool #8514, Pins, Tensioner) (1).
9. Rotate the crankshaft two revolutions and verify the alignment of the timing marks (1, 2). If the timing marks do not line up, remove the camshaft sprocket and realign.
10. Tighten the camshaft phaser bolt (1) to 85 N.m (63 ft. lbs.).
11. Position the oil pump (1) onto the crankshaft and install the oil pump retaining bolts (2) finger tight.
12. Using the sequence shown in illustration, tighten the oil pump retaining bolts to 28 N.m (21 ft. lbs.).
13. Verify the slide bushings (1) are installed in the timing chain cover.
14. Install the timing chain cover. Refer to «COVER(S), Engine Timing , Installation , 5.7L»(ref-457797-S08343052232012030200000) .
15. Fill the engine with oil.
16. Fill the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
17. Connect the negative battery cable.
18. Start the engine and check for leaks.

Scheme 386

1. Disconnect the battery negative cable.
2. Remove the engine cover.
3. Remove air cleaner assembly.
4. Drain cooling system.
5. Remove accessory drive belt.
6. Remove fan and fan drive assembly.
7. Remove coolant bottle and washer bottle.
8. Remove fan shroud. NOTE: It is not necessary to disconnect A/C lines or discharge refrigerant.
9. Remove A/C compressor and set aside.
10. Remove the generator.
11. Remove upper radiator hose.
12. Disconnect both heater hoses at timing cover.
13. Disconnect lower radiator hose at engine.
14. Remove accessory drive belt tensioner and both idler pulleys.
15. Remove crankshaft damper (2). Refer to «DAMPER, Vibration , Removal , 5.7L»(ref-457797-S28530918912012030200000) . NOTE: Do not remove the hoses from the power steering pump.
16. Remove power steering pump and set aside.
17. Remove the dipstick support bolt.
18. Drain the engine oil.
19. Remove the oil pan and pick up tube. Refer to «PAN, Oil , Removal , 5.7L»(ref-457797-S04954463982012030200000) . NOTE: It is not necessary to remove water pump for timing cover removal.
20. Remove timing cover bolts and remove cover.
21. Verify that timing cover slide bushings (1) are located in timing cover.

Scheme 387

1. Clean timing chain cover and block surface. NOTE: Always install a new gasket on timing cover.
2. Verify that the slide bushings (1) are installed in timing cover.
3. Install cover and new gasket. Tighten fasteners to 28 N.m (250 in. lbs.). NOTE: The large lifting stud is tightened to 55 N.m (40 ft. lbs.).
4. Install the oil pan and pick up tube. Refer to «PAN, Oil , Installation , 5.7L»(ref-457797-S25274644792012030200000) .
5. Install the A/C compressor.
6. Install the generator.
7. Install power steering pump.
8. Install the dipstick support bolt.
9. Install the thermostat housing.
10. Install crankshaft damper. Refer to «DAMPER, Vibration , Installation , 5.7L»(ref-457797-S32293252722012030200000) .
11. Install accessory drive belt tensioner assembly and both idler pulleys.
12. Install radiator lower hose.
13. Install both heater hoses.
14. Install the cooling module.
15. Install the accessory drive belt.
16. Install the coolant bottle and washer bottle.
17. Install the upper radiator hose.
18. Install the air cleaner assembly.
19. Fill cooling system.
20. Refill engine oil.
21. Connect the battery negative cable.

Scheme 388

Note. Verify that the tensioner is assembled correctly.

Scheme 389

1. Install the washer (1), spring (2), and plunger (3) inside the tensioner body (4).
2. Squeeze the tensioner body (3) and movable guide shoe (2) together and install the Tensioner Pin (special tool #8514, Pins, Tensioner) (1).