ENGINE

6.2L - Service Information - Charger

DESCRIPTION

The supercharged 6.2L HEMI eight-cylinder SRT high performance engine is a 90° V-Type, deep skirt,
lightweight cast iron block with forged aluminum pistons, forged steel crankshaft, aluminum heads, single cam,
overhead valves, and hydraulic roller lifters. The heads incorporate splayed valves with a hemispherical style
combustion chamber and dual spark plugs. The cylinders are numbered from front to rear; 1, 3, 5, 7 on the left
bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2.

DIAGNOSIS AND TESTING

CYLINDER COMBUSTION PRESSURE LEAKAGE

The combustion pressure leakage test provides an accurate means for determining engine condition.

Combustion pressure leakage testing will detect:

Exhaust and intake valve leaks (improper seating)

Leaks between adjacent cylinders or into water jacket
Any causes for combustion pressure loss

1. Check the coolant level and fill as required. DO NOT install the radiator cap.
2. Start and operate the engine until it attains normal operating temperature.
3. Turn the engine OFF.
4. Remove one spark plug per cylinder.
5. Remove the oil filler cap.
6. Remove the air cleaner hose.
7. Calibrate the tester according to the manufacturer's instructions. The shop air source for testing
should maintain a regulated air pressure at 552 kPa (80 psi).
8. Perform the test procedures on each cylinder according to the tester manufacturer's instructions. Set the
piston of the cylinder to be tested at TDC compression.
9. During the testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap

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 opening. Check for bubbles in the radiator coolant.

All gauge pressure indications should be equal, with no more than 25% leakage.

FOR EXAMPLE: Input air at 552 kPa (80 psi), the primary gauge factory set at 207 kPa (30 psi) input
pressure. The secondary gauge should have no more than 176 kPa (25.5 psi) loss, when connected to the
cylinder.

Refer to CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART.

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART

CONDITION POSSIBLE CAUSE CORRECTION
Air escapes through the throttle Intake valve bent, burnt, or not Inspect valve and valve seat. Reface
body seated properly. or replace, as necessary. Inspect
valve springs. Replace as necessary.
Air escapes through the tailpipe Exhaust valve bent, burnt, or not Inspect valve and valve seat. Reface
seated properly. or replace, as necessary. Inspect
valve springs. Replace as necessary.
Air escapes through the radiator Cylinder head gasket leaking or Remove cylinder head and inspect.
cracked in cylinder head or Replace cylinder head gasket,
engine block. cylinder head or engine block as
necessary.
More than 50% leakage from Cylinder head gasket leaking or Remove cylinder head and inspect.
adjacent cylinders crack in cylinder head or engine Replace cylinder head gasket,
block between adjacent cylinder head or engine block as
cylinders. necessary.
More than 25% leakage and air Stuck or broken piston rings; Remove cylinder head and inspect
escapes through the oil filler cap cracked piston; worn rings or for broken rings or piston. Measure
opening only cylinder wall. ring gap and cylinder diameter, taper
and out-of-round. Replace defective
part as necessary.

ENGINE MECHANICAL DIAGNOSIS CHART

CONDITION POSSIBLE CAUSES CORRECTION

1. Check for belt damage and
alignment
1. Worn accessory drive belt
Refer to BELT, SERPENTINE,
DIAGNOSIS AND TESTING .
2. Check for possible coolant
leak. If OK, Check the pulley and
2. Worn coolant pump
ENGINE NOISE input shaft for wear. Replace as
necessary.
3. Check the pulley for wear.
3. Worn generator Spin the armature. Replace as
necessary.
4. Check pulleys. Verify bearing
4. Idler/Tensioner pulley
noise. Replace as necessary.

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 CONDITION POSSIBLE CAUSES CORRECTION
5. Check the pulley and input
5. Power steering pump (if
shaft for wear. Replace as
equipped)
necessary.
6. Check for wear or possible
6. Flywheel/Flexplate cracking. Check bolts. Repair as
necessary.
NOISY VALVES/LIFTERS 1. High or low oil level in 1. Check for correct oil level.
crankcase. Adjust oil level by draining or
adding as needed.
2. Thin or diluted oil. 2. Change oil. Refer to
STANDARD PROCEDURE .
3. Low oil pressure. 3. Check engine oil level. If OK,
perform oil pressure test. Refer to
DIAGNOSIS AND TESTING .
4. Dirt in hydraulic lifters. 4. Clean/replace hydraulic lifters.
5. Bent push rod(s). 5. Install new push rods.
6. Worn rocker arms. 6. Inspect oil supply to rocker
arms and replace worn arms as
needed.
7. Worn hydraulic lifters. 7. Install new hydraulic lifters.
8. Worn valve guides. 8. Inspect all valve guides and
replace as necessary.
9. Excessive runout of valve seats 9. Grind valves and seats.
or valve faces.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. If OK,
perform oil pressure test. Refer to
DIAGNOSIS AND TESTING .
3. Thin or diluted oil. 3. Change oil to correct viscosity.
Refer to STANDARD
PROCEDURE .
4. Excessive connecting rod 4. Measure bearings for correct
bearing clearance. clearance with plasti-gage. Repair
as necessary.
5. Connecting rod journal out of 5. Replace crankshaft or grind
round. journals.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. If OK,
perform oil pressure test. Refer to
DIAGNOSIS AND TESTING .
3. Thin or diluted oil. 3. Change oil to correct viscosity.
Refer to STANDARD
PROCEDURE .
4. Excessive main bearing 4. Measure bearings for correct
clearance. clearance. Repair as necessary.

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 CONDITION POSSIBLE CAUSES CORRECTION
5. Excessive end play. 5. Check crankshaft thrust
bearing for excessive wear on
flanges.
6. Crankshaft main journal out of 6. Grind journals or replace
round or worn. crankshaft.
7. Loose flexplate, flywheel or 7. Inspect crankshaft, flexplate,
torque converter. flywheel and bolts for damage.
Tighten to correct torque.
LOW OIL PRESSURE 1. Low oil level. 1. Check oil level and fill if
necessary.
2. Faulty oil pressure sending unit. 2. Install new sending unit.
3. Clogged oil filter. 3. Install new oil filter.
4. Worn oil pump. 4. Replace oil pump assembly.
5. Thin or diluted oil. 5. Change oil to correct viscosity.
Refer to STANDARD
PROCEDURE .
6. Excessive bearing clearance. 6. Measure bearings for correct
clearance.
7. Oil pump relief valve stuck. 7. Remove valve to inspect, clean
and reinstall.
8. Oil pickup tube loose, broken, 8. Inspect oil pickup tube and
bent or clogged. pump, and clean or replace if
necessary.
9. Oil pump cover warped or 9. Install new oil pump.
cracked.
10. Faulty or missing piston 10. Replace piston cooling jets.
cooling jets.
OIL LEAKS 1. Misaligned or deteriorated 1. Replace gasket.
gaskets.
2. Loose fastener or broken or 2. Tighten, repair or replace the
porous metal part. part.
3. Front or rear crankshaft oil seal 3. Replace seal.
leaking.
4. Leaking oil gallery plug or cup 4. Remove and reseal threaded
plug. plug. Replace cup style plug.
EXCESSIVE OIL 1. PCV System malfunction. 1. Refer to VALVE, POSITIVE
CONSUMPTION OR SPARK CRANKCASE
PLUGS OIL FOULED VENTILATION (PCV),
REMOVAL .
2. Defective valve stem seal(s). 2. Repair or replace seal(s).
3. Worn or broken piston rings. 3. Hone cylinder bores. Install
new rings.
4. Scuffed pistons/cylinder walls. 4. Hone cylinder bores and
replace pistons as required.
5. Carbon in oil control ring 5. Remove rings and de-carbon
groove. piston.

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 CONDITION POSSIBLE CAUSES CORRECTION
6. Worn valve guides. 6. Inspect/replace valve guides as
necessary.
7. Piston rings fitted too tightly in 7. Remove rings and check ring
grooves. end gap and side clearance.
Replace if necessary.

Lifter Purge Guideline

1. Warm engine to standard idle conditions.

NOTE: Engine noise may be in the form of a clicking, chatter, or clattering noise.

2. Listen to the engine for 30 to 60 seconds with the hood up and the engine cover removed.
3. If noise is present, de-aeration of the lifters is required.
4. Run the engine between 2000 and 3000 RPM for three to five minutes.
5. Return the engine to standard idle speed for 30 to 60 seconds.
6. Evaluate noise. If noise is present, repeat the run an additional 4 cycles.

NOTE: The standard drive cycle will be about 10-15 miles of non-stop, combined
highway and city driving.

7. If noise is present, take the vehicle on a standard drive cycle.

8. Evaluate the noise. If noise present, follow standard service procedure for lifter repairs or noise
conditions.
9. Evaluate the lifters for sponginess, check valve defects, and clearance.

ENGINE LUBRICATION DIAGNOSTIC TABLE

CONDITION POSSIBLE CAUSES CORRECTION

OIL LEAKS 1. Gaskets and O-rings 1. Verify condition
Misaligned or damaged Replace as necessary
Loose fasteners, broken or Tighten fasteners, repair or
porous metal parts replace metal parts
2. Crankshaft rear seal 2. Replace as necessary
3. Crankshaft seal flange damaged 3. Polish or replace crankshaft
4. Oil pan flange cracked 4. Replace oil pan
5. Front cover seal 5. Replace seal
damaged/misaligned 6. Polish or replace damper
6. Damaged vibration damper 7. Replace crankshaft
7. Crankshaft rear flange microporosity

OIL PRESSURE 1. Low oil level 1. Check and correct oil level
DROP
2. Faulty oil pressure sending unit 2. Replace sending unit
3. Low oil pressure 3. Check pump and bearing
clearance

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 CONDITION POSSIBLE CAUSES CORRECTION
4. Clogged oil filter 4. Replace oil filter
5. Worn oil pump 5. Replace as necessary
6. Thin or diluted oil 6. Change oil and filter
7. Excessive bearing clearance 7. Replace as necessary
8. Oil pump relief valve stuck 8. Replace oil pump
9. Oil pickup tube loose or damaged 9. Replace as necessary
10. Faulty or missing piston cooling jets 10. Replace piston cooling jets

OIL PUMPING AT 1. Worn or damaged rings 1. Hone cylinder bores and replace
RINGS; rings
2. Carbon in oil ring slots
SPARK PLUGS
3. Incorrect ring size installed 2. Replace rings
FOULING
4. Worn valve guides 3. Replace rings
5. Leaking intake gasket 4. Ream guides and replace valves
6. Leaking valve guide seals 5. Replace intake gaskets
6. Replace valve guide seals

OIL CONSUMPTION TEST AND DIAGNOSIS

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 owner's 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, verify that no external engine oil
leaks are present.

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 correct oil consumption complaints.
Verify that the engine has the correct oil level dipstick and dipstick tube installed.
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

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 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, re-check 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. Refer to DIAGNOSIS AND TESTING.

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.

TOP 18 REASONS THAT MAY LEAD TO ENGINE OIL CONSUMPTION

1. Tapered and Out-of-Round Cylinders

The increased piston clearances permit the pistons to rock in the worn cylinders. While tilted
momentarily, an abnormally large volume of oil is permitted to enter on one side of the piston. The rings,
also tilted in the cylinder, permit oil to enter on one side. Upon reversal of the piston on each stroke, some
of this oil is passed into the combustion chamber.

2. Distorted Cylinders

This may be caused by unequal heat distribution or unequal tightening of cylinder head bolts. This
condition presents a surface which the rings may not be able to follow completely. In this case, there may
be areas where the rings will not remove all of the excess oil. When combustion takes place, this oil will
be burned and cause high oil consumption.

3. Improper operation of the PCV system

The main purpose of the Positive Crankcase Ventilation (PCV) valve is to recirculate blow-by gases back
from the crankcase area through the engine to consume unburned hydrocarbons. The PCV system usually
has a one way check valve and a make up air source. The system uses rubber hoses that route crankcase
blow by gases to the intake manifold. Vacuum within the engine intake manifold pulls the blow by gases
out of the crankcase into the combustion chamber along with the regular intake air and fuel mixture.

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 The PCV system can become clogged with sludge and varnish deposits and trap blow by gases in the
crankcase. This degrades the oil, promoting additional formation of deposit material. If left uncorrected,
the result is plugged oil rings, oil consumption, rapid ring wear due to sludge buildup, ruptured gaskets
and seals due to crankcase pressurization.

4. Worn Piston Ring Grooves

For piston rings to form a good seal, the sides of the ring grooves must be true and flat - not flared or
shouldered. Piston rings in tapered or irregular grooves will not seal properly and, consequently, oil will
pass around behind the rings into the combustion chamber.

5. Worn, Broken or Stuck Piston Rings

When piston rings are broken, worn or stuck to such an extent that the correct tension and clearances are
not maintained, this will allow oil to be drawn into the combustion chamber on the intake stroke and hot
gases of combustion to be blown down the cylinder past the piston on the power stroke. All of these
conditions will result in burning and carbon build up of the oil on the cylinders, pistons and rings.

6. Cracked or Broken Ring Lands

Cracked or broken ring lands prevent the rings from seating completely on their sides and cause oil
pumping. This condition will lead to serious damage to the cylinders as well as complete destruction of
the pistons and rings. Cracked or broken ring lands cannot be corrected by any means other than piston
replacement.

7. Worn Valve Stems and Guides

When wear has taken place on valve stems and valve guides, the vacuum in the intake manifold will draw
oil and oil vapor between the intake valve stems and guides into the intake manifold and then into the
cylinder where it will be burned.

8. Bent or Misaligned Connecting Rods

Bent or misaligned connecting rods will not allow the pistons to ride straight in the cylinders. This will
prevent the pistons and rings from forming a proper seal with the cylinder walls and promote oil
consumption. In addition, it is possible that a bearing in a bent connect rod will not have uniform
clearance on the connecting rod wrist pin. Under these conditions, the bearing will wear rapidly and
throw off an excessive amount of oil into the cylinder.

9. Fuel Dilution

If raw fuel is allowed to enter the lubrication system, the oil will become thinner and more volatile and
will result in higher oil consumption. The following conditions will lead to higher oil consumption;

Excess fuel can enter and mix with the oil via a leaking fuel injector
Gasoline contaminated with diesel fuel
Restricted air intake
Excessive idling
10. Contaminated Cooling Systems

Corrosion, rust, scale, sediment or other formations in the water jacket and radiator will prevent a cooling
system from extracting heat efficiently. This is likely to cause cylinder distortion thus leading to higher

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 oil consumption.

11. Oil Viscosity

The use of oil with a viscosity that is too light may result in high oil consumption. Refer to the vehicle
owner's manual for the proper oil viscosity to be used under specific driving conditions and ambient
temperatures.

12. Dirty Engine Oil

Failure to change the oil and filter at proper intervals may cause the oil to be so dirty that it will promote
accumulation of sludge and varnish and restrict oil passages in the piston rings and pistons. This will
increase oil consumption; dirty oil by nature is also consumed at a higher rate than clean oil.

13. Crankcase Overfull

Due to an error in inserting the oil dip stick so that it does not come to a seat on its shoulder, a low
reading may be obtained. Additional oil may be added to make the reading appear normal with the stick
in this incorrect position which will actually make the oil level too high. If the oil level is so high that the
lower ends of the connecting rods touch the oil in the oil pan excessive quantities of oil will be thrown on
the cylinder walls and some of it will work its way up into the combustion chamber.

14. Excessively High Oil Pressure

A faulty oil pressure relief valve may cause the oil pressure to be too high. The result will be that the
engine will be flooded with an abnormally large amount of oil in a manner similar to that which occurs
with worn bearings. This condition may also cause the oil filter to burst.

15. Aftermarket Performance Chips and Modification

Increasing performance through the use of performance/power enhancement products to a stock or

factory engine will increase the chance of excessive oil consumption.

16. Lugging Engine

Lugging is running the engine at a lower RPM in a condition where a higher RPM (more power/torque)
should be implemented. Especially susceptible on vehicles equipped with a manual transmission. This
driving habit causes more stress loading on the piston and can lead to increases in engine oil
consumption.

17. Turbocharged Engines

There is a possibility for PCV "push-over" due to higher crankcase pressure (as compared to naturally
aspirated engines) which is normal for turbocharged engines. This condition causes varying amounts of
engine oil to enter the intake manifold, charge air cooler and associated plumbing to and from the charge
air cooler, also a leaking turbocharger seal will draw oil into the combustion chamber where it will burn
(blue smoke from the tail pipe may be present) and form carbon deposits which contribute to further oil
consumption as they interfere with proper engine function.

18. Restricted Air Intake

Excessive restriction in the air intake system will increase engine vacuum and can increase oil
consumption. An extremely dirty air filter would be one example of this situation.

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 STANDARD PROCEDURE
DUST COVERS AND CAPS

To avoid the possibility of dust, dirt, moisture and other foreign debris being introduced to the engine during
service, cover or cap all openings when hoses and tubes are removed.

Covers installed over openings will reduce the possibility of foreign materials entering the engine systems.
Using the Universal Protective Cap Set (special tool #10368, Set, Universal Protective Cap), select the
appropriate cover needed for the procedure.

ENGINE GASKET SURFACE PREPARATION

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 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.

Never use the following to clean gasket surfaces:

Metal scraper (1).

Abrasive pad or paper to clean cylinder block and head.
High speed power tool with an abrasive pad or a wire brush (2).

NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Only use the following for cleaning gasket surfaces:

Solvent or a commercially available gasket remover

Plastic or wood scraper (4).
Drill motor with 3M Roloc™ Bristle Disc (3), white is used for the aluminum heads and yellow is used
for the iron block.

CAUTION: Excessive pressure or high RPM (beyond the recommended speed), can
damage the sealing surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80 grit) bristle disc may be
used on cast iron surfaces with care.

REPAIR DAMAGED OR WORN THREADS

CAUTION: Always maintain the original center line when drilling or tapping holes.

Damaged or worn 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

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 Installing a Heli-Coil® insert into the tapped hole to bring the hole back to its original thread size

HYDROSTATIC LOCK

CAUTION: Do not attempt to run engine. Severe damage could occur.

When an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps
below.

1. Disconnect and isolate the negative battery cable.

2. Lift the engine cover retaining grommets off the ball studs and remove the engine cover.
3. Place a shop towel around the fuel supply line quick connect fitting to catch any fuel that may be under
pressure, then disconnect the fuel supply line. Refer to FITTING, QUICK CONNECT, STANDARD
PROCEDURE .
4. Loosen the air duct retaining clamp at the throttle body.
5. Disconnect the intake air temperature sensor electrical connector.
6. Remove the makeup air hose at the air cleaner housing.
7. Remove the air cleaner housing retaining bolt.
8. While lifting up the air cleaner housing, slide the air duct off the throttle body and remove the air cleaner
housing from the vehicle.
9. Inspect the air duct, air cleaner housing and the intake manifold to make sure the system is dry and clear
of any foreign material.
10. Place a shop towel around the spark plugs to catch any fluid that may possibly be under pressure in the
cylinder head.
11. Remove the spark plugs. Refer to SPARK PLUG, REMOVAL .
12. With the spark plugs removed, rotate the crankshaft using a breaker bar and socket.
13. Identify the fluid in the cylinders (coolant, fuel, oil, etc.).
14. Make sure all fluid has been removed from the cylinders.
15. Repair engine or components as necessary to prevent this problem from occurring again.
16. Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will help prevent engine
damage on restart.
17. Install new spark plugs. Refer to SPARK PLUG, INSTALLATION .
18. Perform the Engine Oil Service procedure. Refer to STANDARD PROCEDURE .
19. Connect negative battery cable.
20. Start the engine and check for leaks.

TECHNICAL SPECIFICATIONS
ENGINE SPECIFICATIONS

GENERAL DESCRIPTION
DESCRIPTION SPECIFICATION
Engine Type 90° V-8 OHV
6.2 Liters
Displacement
378 (Cubic Inches)

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 DESCRIPTION SPECIFICATION
Bore 103.9 mm (4.09 in.)
Stroke 90.9 mm (3.58 in.)
Compression Ht. 32.48
Firing Order 1-8-4-3-6-5-7-2
Lubrication Pressure Feed - Full Flow Filtration
Cooling System Liquid Cooled - Forced Circulation
Cylinder Block Cast Iron
Cylinder Head Aluminum
Crankshaft Forged Steel
Camshaft Cast Iron
Pistons Forged Aluminum Alloy
Connecting Rods Forged Powdered Metal

CYLINDER BLOCK
SPECIFICATION
DESCRIPTION
Metric Standard
Cam Bore 1 Diameter 61.71-61.73 mm 2.4295-2.4303 in.
Cam Bore 2 Diameter 57.85-57.87 mm 2.2776-2.2783 in.
Cam Bore 3 Diameter 57.44-57.46 mm 2.2614-2.2622 in.
Cam Bore 4 Diameter 57.05-57.07 mm 2.2461-2.2469 in.
Cam Bore 5 Diameter 43.673-43.693 mm 1.7194-1.7202 in.
Cylinder Bore Diameter 103.9 mm 4.09 in.
Out of Round (MAX) 0.008 mm 0.0003 in.
Taper (MAX) 0.014 mm 0.0006 in.
Lifter Bore Diameter 21.45-21.42 mm 0.8444-0.8433 in.

PISTONS
SPECIFICATION
DESCRIPTION
Metric Standard
Clearance Measured at 38.0 mm 0.0425-0.0675 mm 0.001670-0.00266 in.
(1.5 in.) Below Deck
Ring Groove Diameter
Groove #1 95.3-95.5 mm 3.752-3.760 in.
Groove #2 93.1-93.3 mm 3.665-3.673 in.
Weight 502 grams 17.71 oz.
Piston Length 52.33-52.63 mm 2.060-2.072 in.
Ring Groove Width
No. 1 1.24 mm 0.0488 in
No. 2 1.24 mm 0.0488 in
No. 3 2.05 mm 0.0803 in.

PISTON RINGS
SPECIFICATION
DESCRIPTION
Metric Standard

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 SPECIFICATION
DESCRIPTION
Metric Standard
Ring Gap
Top Compression Ring 0.35 - 0.50 mm 0.0138 - 0.0197 in.
Second Compression Ring 0.50- 0.76 mm 0.0197 - 0.0299 in.
Oil Control (Steel Rails) 0.15 - 0.45 mm 0.0059 - 0.0177 in.
Side Clearance
Top Compression Ring 0.040 - 0.072 mm 0.0016 - 0.0028 in.
Second Compression Ring 0.040 - 0.072 mm 0.0016 - 0.0028 in.
Oil Ring (Steel Ring) 0.061 - 0.210 mm 0.0024 - 0.0083 in.
Ring Width
Top Compression Ring 1.172 - 1.190 mm 0.0461 - 0.0468 in.
Second Compression Ring 1.172 - 1.190 mm 0.0461 - 0.0468 in.
Oil Ring (Steel Rails) 0.387 - 0.413 mm 0.0152 - 0.0163 in.

CONNECTING RODS
SPECIFICATION
DESCRIPTION
Metric Standard
Side Clearance 0.07 - 0.35 mm 0.0028 - 0.0146 in.

CRANKSHAFT
SPECIFICATION
DESCRIPTION
Metric Standard
Main Bearing Journal Diameter 64.978-65.002 mm 2.5582-2.5591 in.
Bearing Clearance 0.014 - 0.050 mm 0.0006 - 0.0020 in.
Out of Round (MAX) 0.005 mm 0.0002 in.
Taper (MAX) 0.003 mm 0.0001 in.
End Play 0.052 - 0.282 mm 0.002 - 0.011 in.
End Play (MAX) 0.282 mm 0.011 in.
Connecting Rod Journal Diameter 53.992-54.008 mm 2.1257-2.1263 in.
Bearing Clearance 0.016-0.056 mm 0.0006-0.0022 in.
Out of Round (MAX) 0.005 mm 0.0002 in.
Taper (MAX) 0.003 mm 0.0001 in.

CAMSHAFT
SPECIFICATION
DESCRIPTION
Metric Standard
Bearing Journal Diameter
No. 1 67.72 mm 2.67 in.
No. 2 57.8 mm 2.27 in.
No. 3 57.4 mm 2.26 in.
No. 4 57.0 mm 2.24 in.
No. 5 43.633 mm 1.72 in.
Bearing To Journal Clearance Standard
No. 1 0.040 - 0.080 mm 0.0015 - 0.003 in.

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 SPECIFICATION
DESCRIPTION
Metric Standard
No. 2 0.050 -0.090 mm 0.0019 - 0.0035 in.
No. 3 0.040 - 0.080 mm 0.0015 - 0.003 in.
No. 4 0.050 - 0.090 mm 0.0019 - 0.0035 in.
No. 5 0.040 - 0.080 mm 0.0015 - 0.003 in.
Camshaft End Play .080 - 0.290 mm 0.0031 - 0.0114 in.
Duration 288.0°
Valve Lift (@ Zero Lash)
Intake 15.0 mm 0.591 in.
Exhaust 14.2 mm 0.559 in.

VALVE TIMING
DESCRIPTION SPECIFICATION
Intake
Opens (BTDC) 25.0°
Closes (ATDC) 253.0°
Duration 278.0°
Exhaust
Opens (BTDC) 278°
Closes (ATDC) 26°
Duration 304°
Valve Overlap 51°

CYLINDER HEAD
SPECIFICATION
DESCRIPTION
Metric Standard
Valve Seat Angle 44.5° - 45.0°
Valve Seat Runout (MAX) 0.04 mm 0.0016 in.
Valve Seat Width
Intake 1.18 - 1.62 mm 0.046 - 0.065 in.
Exhaust 1.48 - 1.92 mm 0.058 - 0.076 in.
Guide Bore Diameter
Intake 7.975 - 7.997 mm 0.314 - 0.315 in.
Exhaust 7.975 - 7.990 mm 0.314 - 0.315 in.

HYDRAULIC TAPPETS
SPECIFICATION
DESCRIPTION
Metric Standard
Body Diameter 21.387 - 21.405 mm 0.8420 - 0.8427 in.
Clearance (To Bore) 0.020 - 0.063 mm 0.0007 - 0.0024 in.
Dry Lash (at the valve) 3.0 mm 0.1181 in.

VALVES
DESCRIPTION SPECIFICATION

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 Metric Standard
Face Angle
Intake 45.5° - 46.0°
Exhaust 45.0° - 45.5°
Head Diameter
Intake 54.3 mm 2.138
Exhaust 42.0 mm 1.654
Length (Overall From Gage Line)
Intake 128.57 5.062
Exhaust 127.165 5.006
Stem Diameter
Intake 7.934 - 7.954 mm 0.312 - 0.313 in.
Exhaust 7.930 - 7.950 mm 0.312 - 0.313 in.
Stem - to - Guide Clearance
Intake 0.021 - 0.063 mm 0.0008 - 0.0025 in.
Exhaust 0.025 - 0.060 mm 0.0010 - 0.0024 in.

VALVE SPRING
SPECIFICATION
DESCRIPTION
Metric Standard
Spring Force - Gage (Valve Open)
Intake 510.0 N ± 26.0 N @ 52.1 mm 114.7 lbs. ± 5.8 lbs. @ 2.051 in.
Exhaust 510.0 N ± 26.0 N @ 52.1 mm 114.7 lbs. ± 5.8 lbs. @ 2.051 in.
Spring Force - Gage (Valve Closed)
Intake 1500.0 N ± 70.0 N @ 37.6 337.2 lbs. ± 15.7 lbs. @ 1.480
mm in.
Exhaust 1500.0 N ± 70.0 N @ 37.6 337.2 lbs. ± 15.7 lbs. @ 1.480
mm in.
Free Length (approx.)
Intake 63.9 mm 2.516 in.
Exhaust 63.9 mm 2.516 in.
Number of Coils
Intake 8.55
Exhaust 8.55
Wire Diameter
Intake and Exhaust 5.65 X 4.51 mm 0.222 - 0.178 in.
Installed Height (Spring Seat to Bottom of Retainer)
Intake 52.1 mm 2.051 in.
Exhaust 51.2 mm 2.016 in.

OIL PUMP
SPECIFICATION
DESCRIPTION
Metric Standard
Clearance Over Rotors (MAX) 0.060 mm 0.002 in.

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 SPECIFICATION
DESCRIPTION
Metric Standard
Outer Rotor to Pump Body Clearance
0.306 mm 0.012 in.
(MAX)
Tip Clearance Between Rotors 0.200 mm
0.008 in.
(MAX)

OIL PRESSURE
SPECIFICATION SPECIFICATION
At Curb Idle Speed (min.)* 90 kPa (13 psi)
@ 3000 RPM 170 - 758 kPa (25 - 110 psi)
* CAUTION: If pressure is zero at curb idle, DO NOT run engine

TORQUE SPECIFICATIONS

ENGINE BLOCK
DESCRIPTION N.m Ft. Lbs. In. Lbs. COMMENT
Camshaft Phaser Bolt 95 70 - Â
Camshaft Thrust Plate
13 - 115 Â
Bolts
Coolant Drain Plugs 1/4 x
34 25 - Â
18 NPT
Do not reuse these
fasteners. If removed, a
40 plus 90° 30 plus 90°
Connecting Rod Cap Bolts - NEW fastener must be
Turn Turn
installed and tightened
to specifications.
Crankshaft Main Bearing Specific torque and fastener pattern required; follow
Â
Cap Bolts installation sequence, refer to INSTALLATION .
Variable Valve Timing
11 - 97 Â
Solenoid Bolt
Lifter Guide Holder 12 9 - Â
Do not reuse these
fasteners. If removed, a
Specific torque and fastener pattern required; follow
Oil Pan Bolts NEW fastener must be
installation sequence, refer to INSTALLATION .
installed and tightened
to specifications.
Oil Dipstick Tube 11 - 97 Â
Oil Filter Adapter-Engine
40 30 - Â
Oil Cooler
Oil Gallery Plugs 1/4 x 18
20 - 177 Â
NPT
Oil Pan Drain Plug 27 20 - Â
Oil Pressure Sensor 14 - 124 Â
Oil Pump to Engine Block
32 23 - Â
Bolts
Oil Pump Cover Bolts. 15 - 133 Â

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 DESCRIPTION N.m Ft. Lbs. In. Lbs. COMMENT
Oil Pump Pickup Tube
28 21 - Â
Bolt
Oil Pump Pickup Tube Nut 12 9 - Â
Oil Temperature Sensor 27 20 - Â
Piston Oil Cooler Jet Bolts 11 8 - Â
Plugs 3/8 x 18 NPT 27 20 - Â
Timing Chain Guide Bolts 11 Â 97 Â
Timing Chain Tensioner
11 - 97 Â
Bolts

CYLINDER HEAD
DESCRIPTION N.m Ft. Lbs. In. Lbs. COMMENT
Specific torque and fastener pattern required. Refer to
Cylinder Head Bolts Â
INSTALLATION .
Cylinder Head Cover
11 - 97 Â
Bolts
Do not reuse these
fasteners. If removed, a
Exhaust Manifold Bolts 25 19 - NEW fastener must be
installed and tightened
to specifications.
Ignition Coil Bolts 7 - 62 Â
Supercharger to Cyl. Head Specific torque and fastener pattern required. Refer to
Â
Bolts SUPERCHARGER, INSTALLATION.
Lifter Guide Holder Bolts 12 9 - Â
Specific torque and fastener pattern required; follow
Rocker Arm Bolts Â
installation sequence, refer to INSTALLATION .

FRONT ENGINE
DESCRIPTION N.m Ft. Lbs. In. Lbs. COMMENT
Do not reuse these
Specific torque and fastener pattern required; follow fasteners. If removed, a
Supercharger Inlet Nose installation sequence, refer to NOSE, INLET, NEW fastener must be
INSTALLATION. installed and tightened
to specifications.
Timing Chain Cover Bolts 28 21 - Â
Lifting Stud 55 41 - Â
Do not reuse these
fasteners. If removed, a
Vibration Damper Bolt 324 239 - NEW fastener must be
installed and tightened
to specifications.
Water Pump-to-Timing
28 21 - Â
Chain Case Cover Bolts

REAR ENGINE
DESCRIPTION N.m Ft. Lbs. In. Lbs. COMMENT

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 DESCRIPTION N.m Ft. Lbs. In. Lbs. COMMENT
Do not reuse these
fasteners. If removed, a
Flexplate Bolts 95 70 - NEW fastener must be
installed and tightened to
specifications.
Inspection Cover to
11 - 97 Â
Transmission Bolt
Rear Crankshaft Oil Seal
13 - 115 Â
Retainer Bolts
Torque Convertor Bolts 42 31 - Â
Transmission to Oil Pan
45 33 - Â
Bolts
Transmission Bell Housing
45 33 - Â
to Engine Bolts
* NEW FASTENERS: Do not reuse these fasteners. If removed, a new fastener must be installed and
tighten to specifications.

ENGINE MOUNTS
DESCRIPTION N.m Ft. Lbs. In. Lbs. COMMENT
Engine Mount Bracket to
61 45 - Â
Block Bolts
Engine Mount to Engine
60 44 - Â
Mount Bracket
Engine Mount to Cradle
48 35 - Â
Bolts
Engine Mount Heat Shield
25 18 - Â
Nuts
Transmission Crossmember
65 48 - Â
Bolts - Automatic
Transmission Crossmember
61 45 - Â
Bolts - Manual
Rear Isolator Bracket to
Transmission Bolts 68 50 - Â
(Automatic)
Rear Isolator to Bracket
31 23 - Â
Bolts (Automatic)
Rear Isolator to
Crossmember Bolts 61 45 - Â
(Automatic)
Rear Isolator to
Transmission Bolts 54 40 - Â
(Manual)
Rear Isolator to
Crossmember Bolts 54 40 - Â
(Manual)

ACCESSORY DRIVE

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 DESCRIPTION N.m Ft. Lbs. In. Lbs. COMMENT
Generator Support Bracket
65 48 - Â
Bolt
Generator Support Bracket
25 18 - Â
to Engine Mount Nut

MISCELLANEOUS COMPONENTS
DESCRIPTION N.m Ft. Lbs. In. Lbs. COMMENT
Air Cleaner Body Bolt 4 - 35 Â
Air Cleaner Cover 3 - 26 Â
Air Cleaner Tube Clamps 4 - 35 Â
Bypass Valve Adapter to
10 7 - Â
Inlet Nose
Specific torque and fastener pattern required; follow
Bypass Valve installation sequence, refer to VALVE, BYPASS, Â
INSTALLATION.
Catalytic Converter to
11 - 97 Â
Exhaust Manifold Nuts
Do not reuse these
fasteners. If removed, a
Supercharger Idler Pulley
50 37 - NEW fastener must be
Bolts
installed and tightened
to specifications.
Oil Control Valve Bolt 11 - 97 Â
Heater Tube Bolt 18 - 159 Â
Strut Tower Support Bolts 38 28 - Â
Specific torque and fastener pattern required; follow
Supercharger Lid installation sequence. Refer to appropriate Â
component installation procedure.

REMOVAL
CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler and lines
must be replaced or damage to the new engine or components could result.

1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .

2. Drain the cooling system. Refer to STANDARD PROCEDURE .
3. Drain the engine oil. Refer to STANDARD PROCEDURE .
4. Remove the supercharger assembly. Refer to SUPERCHARGER, REMOVAL.
5. Remove the cooling fan. Refer to FAN, COOLING, REMOVAL .

NOTE: The power steering lines do not need to be removed from the pump.
Position pump to the side.

6. Remove the power steering pump. Refer to PUMP, REMOVAL .

7. Remove the A/C compressor. Refer to COMPRESSOR, A/C, REMOVAL .

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 NOTE: Left side shown in illustration, right side similar.

8. Remove both left/right engine mount heat shield (4) retaining nuts (3) and remove the heat shields.
9. Remove both left/right engine mount to frame retaining bolts (2).
10. Disconnect the transmission oil cooler lines from their retainers at the oil pan.
11. Remove the lower radiator hose.

NOTE: Two knock sensors are used. Each sensor is bolted to the outside of the
engine block below the exhaust manifold.

NOTE: Left side shown in illustration, right side similar.

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 12. Remove the heat shields from both knock sensors (shield snaps on/off sensor).
13. Disconnect the knock sensor electrical connectors (3).
14. Remove both catalytic converters. Refer to CONVERTER, CATALYTIC, REMOVAL .

NOTE: The Crankshaft Position (CKP) sensor is located at the right-rear side of
the engine block.

15. Remove the CKP sensor wire harness connector (1).

16. Remove the generator support bracket to engine mount retaining nut (1).
17. Remove the generator support bracket retaining bolt (2) and remove the support bracket (3).
18. Lower the vehicle.

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 19. Remove the generator. Refer to GENERATOR, REMOVAL .
20. Remove the A/C liquid line. Refer to LINE, A/C LIQUID, REMOVAL .
21. Remove the A/C suction line. Refer to LINE, A/C SUCTION, REMOVAL .

22. Remove the oil pressure sensor electrical connector (1).

23. Remove the oil temperature wire harness connector (1).

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 24. Use a commercially available low profile 3/4" quick release tool to disconnect the oil filter adapter quick
connectors (1) and then remove the oil cooler hoses (2) from the oil filter adapter.

25. Disconnect the camshaft position sensor (2) wire harness connector (1).

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 26. Remove the heater hoses from the coolant tubes (1).
27. Remove the Variable Valve Timing Solenoid (VVTS). Refer to REMOVAL .
28. Remove the pressurized coolant bottle. Refer to BOTTLE, PRESSURIZED COOLANT, REMOVAL .

29. Remove all ignition coil wire harness connectors (2) and position the harness aside.

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 30. Remove the ignition capacitor (2) wire harness connectors (1).
31. Remove the ground wires from the rear of each cylinder head.
32. For automatic transmission equipped vehicles, follow steps 33-40.
33. Remove the starter. Refer to STARTER, REMOVAL .

34. Remove the transmission to engine structural cover retaining bolts (1) and remove the cover.

NOTE: The left front bolt (2) must be removed with the structural cover.

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 35. Automatic transmission equipped vehicles, rotate the crankshaft in clockwise direction until the torque
converter bolts (1) are accessible and remove the flexplate to torque converter bolts.

36. Remove two engine to transmission bolts (3).

37. Remove remaining transmission to engine bolts (4).

CAUTION: While carefully separating the engine from the transmission and removing
the engine from the vehicle, constant checks must be made to ensure no
damage to other components or wiring harnesses occur throughout the
removal procedure.

38. Lower the vehicle.

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 39. Using a suitable jack, support the transmission.

NOTE: Do not use air tools to install engine lift fixture.

40. Install the (special tool #8984B, Fixture, Engine Lifting) (1) and (special tool #2013800091, Adapter,
Engine Lifting Bracket) (3).
41. Using a suitable engine hoist, separate the engine from the transmission and remove the engine from the
engine compartment.
42. Secure the engine onto a suitable engine stand.

INSTALLATION
CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler and lines
must be replaced or damage to the new engine or components could result.

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 NOTE: Do not use air tools to install the (special tool #8984B, Fixture, Engine Lifting).

1. Install the engine lift fixture (1) (special tool #8984B, Fixture, Engine Lifting) and adapter (special tool
#2013800091, Adapter, Engine Lifting Bracket) (3).
2. Using a suitable engine hoist, lower the engine into the engine compartment.
3. Automatic transmission equipped vehicles, align the engine with the transmission.
4. Install two transmission bell housing to engine block bolts finger tight.
5. Lower the engine assembly until the engine mounts rest in the engine cradle crossmember.

NOTE: Left side shown in illustration, right side similar.

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 6. Align the engine mounts, install both left/right engine mount to frame retaining bolts (2) and tighten to
the proper specification. Refer to TORQUE SPECIFICATIONS .
7. Position both left and right engine mount heat shields (4), install the retaining nuts (3) and tighten to the
proper specification. Refer to TORQUE SPECIFICATIONS .
8. Remove the engine hoist and the jack supporting the transmission.
9. For automatic transmission equipped vehicles, follow steps 10-18.
10. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
11. Carefully engage transmission to engine block dowels until converter hub is seated in crankshaft. Verify
that no wires, or the transmission vent hose, have become trapped between the engine block and the
transmission.
12. Install two bolts to attach the transmission to the engine.

13. Install the remaining torque converter housing to engine bolts (3 and 4). Tighten all torque converter
housing bolts to the proper specification. Refer to TORQUE SPECIFICATIONS .

14. Install all torque converter bolts (1) by hand first. There are 3 sets of two bolts 120° apart.

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 15. Tighten all torque converter bolts to the proper specification. Refer to TORQUE SPECIFICATIONS .

16. Install the engine structural cover and tighten the bolts (1) to the proper specification. Refer to TORQUE
SPECIFICATIONS .

NOTE: The left front structural cover bolt (2) must be installed with the cover.

17. Install the starter. Refer to STARTER, INSTALLATION .

18. Connect the CKP sensor electrical connector (1).

19. Install the catalytic converters. Refer to CONVERTER, CATALYTIC, INSTALLATION .

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 20. Connect the right and left knock sensor (1) electrical connectors (5).
21. Install the heat shields onto both knock sensors (shield snaps on/off sensor).
22. Connect the transmission oil cooler lines to their retainers at the oil pan.
23. Install the lower radiator hose.
24. Lower the vehicle.

25. Remove the engine lift fixture (special tool #8984B, Fixture, Engine Lifting) (1) and adapter (special tool
#8984-UPD, Adapter, Engine Lift) (3).
26. Position the left and right side wiring harness.
27. Install the Variable Valve Timing Solenoid (VVTS). Refer to INSTALLATION .

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 28. Install the heater core tubes (1) and hoses.
29. Install the heater core tube retaining bolts (2) and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .

30. Connect the camshaft position sensor electrical connector (1).

31. Connect the ground wires to the rear of each cylinder head.

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 32. Connect the ignition capacitor (2) electrical connectors (1).

33. Connect the oil cooler lines (2) to the oil filter adapter (1).

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 34. Connect the oil pressure sensor wire harness connector (1).

35. Connect the oil temperature sensor wire harness connector (1).
36. Install the power steering pump. Refer to PUMP, INSTALLATION .
37. Install the generator. Refer to GENERATOR, INSTALLATION .
38. Raise and support the vehicle.

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 39. Position the generator support bracket (3) to the engine mount, install the retaining nut (1) finger tight.
40. Position the generator support bracket (3) to the generator, install the retaining bolt (2) and tighten to the
proper specification. Refer to TORQUE SPECIFICATIONS .
41. Tighten the generator support bracket (3) to engine mount retaining nut to the proper specification. Refer
to TORQUE SPECIFICATIONS .
42. Install the A/C compressor. Refer to INSTALLATION .
43. Install the A/C liquid line. Refer to LINE, A/C LIQUID, INSTALLATION .
44. Install the A/C suction line. Refer to LINE, A/C SUCTION, INSTALLATION .

45. Position the ignition coil electrical harness and connect all ignition wire harness connectors (1).
46. Install the pressurized coolant bottle. Refer to BOTTLE, PRESSURIZED COOLANT,

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 INSTALLATION .
47. Position the wire harness and secure to the right hand inner fender panel.
48. Install the cooling fan. Refer to FAN, COOLING, INSTALLATION .
49. Install the supercharger assembly. Refer to SUPERCHARGER, INSTALLATION.
50. Fill the crankcase with the specified type and amount of engine oil. Refer to CAPACITIES AND
RECOMMENDED FLUIDS, SPECIFICATIONS .
51. Fill the cooling system with the specified type and amount of engine coolant. Refer to STANDARD
PROCEDURE .
52. Connect the negative battery cable.
53. Perform the Refrigerant System Charge procedure. Refer to PLUMBING, STANDARD PROCEDURE
.
54. Start the engine and inspect for leaks.

NOTE: The Cam/Crank Variation Relearn procedure must be performed using the scan
tool anytime there has been a repair/replacement made to a powertrain system,
for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or
components.

SPECIAL TOOLS

1023 - Puller
(Originally Shipped In Kit Number(s)
8678.)

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 10368 - Set, Universal Protective Cap

10386 - Holder, Vibration Damper

6871 - Installer, A/C Hub

(Originally Shipped In Kit Number(s)
6896.)

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 7700 - Tester, Cooling System
(Originally Shipped In Kit Number(s)
7700-A.)

8464 - Adapter, Valve Spring

(Originally Shipped In Kit Number(s)
8664, 8665, 8665CC, 8702, 9577.)

8514 - Pins, Tensioner

(Originally Shipped In Kit Number(s)
8283, 8283CC, 8527, 8527CC, 8575,
8575CC, 9975.)

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 8534C - Fixture, Driveline Support
(Originally Shipped In Kit Number(s)
8534, 8534B, 8849, 9565.)

2013800091 - Adapter, Engine Lifting

Bracket
(Originally Shipped In Kit Number(s).)

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 8984B - Fixture, Engine Lifting
(Originally Shipped In Kit Number(s)
8849CC, 9329, 9515, 9516, 9518, 9519,
9540, 9541, 9577.)

9065-3 - Adapter, Valve Spring

Compressor
(Originally Shipped In Kit Number(s)
9516-CAN, 9517-CAN.)

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 9065C - Compressor, Valve Spring
(Originally Shipped In Kit Number(s).)

9070 - Retainer, Push Rod

(Originally Shipped In Kit Number(s)
8999, 8999CC, 9329, 9515, 9540, 9541,
9577.)

9071 - Remover, Seal

(Originally Shipped In Kit Number(s)
8999, 8999CC, 9329, 9515, 9540, 9541,
9577.)

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 9072 - Installer, Seal
(Originally Shipped In Kit Number(s)
8999, 8999CC, 9329, 9515, 9540, 9541,
9577, 9975, 9976.)

C-119 - Cylinder Indicator

C-3292A - Gauge, Pressure

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 C-3422-D - Compressor, Valve Spring

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 C-3685-A - Bloc-Chek Kit

AIR INTAKE SYSTEM

AIR CLEANER
REMOVAL

1. Disconnect and isolate the negative battery cable.

2. Remove the air cleaner housing cover retaining screws (3).

3. Disconnect the Intake Air Temperature (IAT) sensor wire harness connector (2).
4. Loosen the clamp (1) to remove air cleaner housing cover if necessary.

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 5. Lift the air cleaner housing cover while separating the locating tabs from the housing.

6. Remove the air cleaner element (1) from the housing.

7. Clean the inside of air cleaner housing before replacing element.

INSTALLATION

1. Install the air cleaner element (1) into the housing.

2. Align the air cleaner housing cover locating tabs into the housing while lowering the cover into position.

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 3. If removed, insert air cleaner housing cover into the air inlet tube and tighten the clamp (1) to the proper
specification. Refer to TORQUE SPECIFICATIONS .
4. Install the air cleaner housing cover retaining screws (3) and tighten to the proper specification. Refer to
TORQUE SPECIFICATIONS .
5. Connect the Inlet Air Temperature (IAT) sensor wire harness connector (2).
6. Connect the negative battery cable.

BODY, AIR CLEANER

REMOVAL

1. Disconnect and isolate the negative battery cable.

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 2. Loosen the air inlet tube retaining clamp (1) at the throttle body.
3. Disconnect the make-up air tube (2).
4. Disconnect the Inlet Air Temperature (IAT) sensor wire harness connector (4).
5. Remove the air cleaner housing retaining bolt (5).
6. While lifting up the air cleaner housing, slide the air duct off the throttle body and remove the air cleaner
housing from the vehicle.

NOTE: There is a secondary air inlet duct to the front of the air cleaner housing,
behind the headlamp, this must be disengaged for removal.

7. If necessary, remove the air inlet tube clamp (3) from the air cleaner housing to remove the air inlet tube.

INSTALLATION

1. If removed, insert the air inlet tube onto the air cleaner housing and tighten the clamp (3) to the proper
specification. Refer to TORQUE SPECIFICATIONS .
2. While sliding the air duct onto the throttle body, lower the air cleaner housing into position, then align the
air inlet and the locating pin on the bottom of the housing.
3. Align the secondary air inlet tube behind the headlamp, there are indexing tabs for orientation.
4. Install the air cleaner housing retaining bolt (5) and tighten to the proper specification. Refer to
TORQUE SPECIFICATIONS .
5. Connect the make-up air hose (2) to the air inlet tube.
6. Connect the Inlet Air Temperature (IAT) sensor wire harness connector (4).
7. Position the air inlet tube retaining clamp (1) at the throttle body and tighten to the proper specification.
Refer to TORQUE SPECIFICATIONS .
8. Connect the negative battery cable.

CYLINDER HEAD

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 OPERATION

The cylinder head closes the combustion chamber allowing the pistons to compress the air fuel mixture to the
correct ratio for ignition. The valves located in the cylinder head open and close to either allow clean air into the
combustion chamber or to allow the exhaust gases out, depending on the stroke of the engine.

DIAGNOSIS AND TESTING

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.

Possible indications of the cylinder head gasket leaking between adjacent cylinders are:

Loss of engine power

Engine misfiring
Poor fuel economy

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
Cylinder Compression Pressure Test. An engine cylinder head gasket leaking between adjacent cylinders will
result in approximately a 50-70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST

WARNING: Use extreme caution when the engine is operating with coolant pressure cap
removed. Failure to follow this warning may result in serious or fatal injury.

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.
COOLING SYSTEM TESTER METHOD

WARNING: With cooling system tester in place, pressure will build up fast. Excessive
pressure built up, by continuous engine operation, must be released to a safe
pressure level. Never permit pressure to exceed 138 kpa (20 psi). Failure to
follow this warning may result in serious or fatal injury.

Install Cooling System Tester (special tool #7700, Tester, Cooling System) 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

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 a combustion pressure leak is evident.
CHEMICAL TEST METHOD

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

REMOVAL
REMOVAL

1. Perform the fuel system pressure release procedure. Refer to FUEL DELIVERY, GAS, STANDARD
PROCEDURE .
2. Disconnect and isolate the negative battery cable.
3. Remove the supercharger assembly. Refer to SUPERCHARGER, REMOVAL.
4. Remove the catalytic converters. Refer to CONVERTER, CATALYTIC, REMOVAL .
5. Remove the power steering pump. Refer to PUMP, REMOVAL .

NOTE: It is not necessary to remove the power steering hoses.

6. Remove the rocker arms and push rods. Refer to REMOVAL .

NOTE: It is not necessary to remove the exhaust manifolds to remove the cylinder
heads.

7. Using the sequence shown in illustration, remove the cylinder head bolts and remove the cylinder head(s).

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 8. Discard the cylinder head gasket (1).
9. Inspect and clean the cylinder head (2) mating surface.

10. If necessary, remove the exhaust manifold bolts using the sequence shown in illustration, starting at eight
and going backwards.

CLEANING

Clean all surfaces of the cylinder block and cylinder heads.

Clean the cylinder block front and rear gasket surfaces using a suitable solvent.

INSPECTION

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 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 push rods. Replace worn or bent push rods.
5. Inspect the rocker arm, push rod cups and pallets where they contact the valve tips. Any worn parts
should be replaced with a new rocker shaft assembly.
6. Inspect the cylinder head bolts.

INSTALLATION

NOTE: Left side shown in illustration, right side similar.

1. If removed, using a new exhaust manifold gasket, position the exhaust manifold and install the retaining
bolts finger tight.
2. Using the sequence shown in illustration, tighten the exhaust manifold retaining bolts to the proper
specification. Refer to TORQUE SPECIFICATIONS .

NOTE: The cylinder head gaskets are not interchangeable between left and right
sides. They are marked "T" for top, "B" for bottom, "L" for left side and
"R" for right side.

3. Clean all sealing surfaces of the engine block and the cylinder head(s) (2).

NOTE: Rotate crankshaft 45° so that all pistons are 1/2 the way down the
cylinder bore to avoid piston to valve contact.

4. Position the new cylinder head gasket(s) (1) onto the engine block.
5. Position the cylinder head(s) (2) onto the engine block.

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 6. Install the cylinder head bolts finger tight.

Fig. 1: Cylinder Head Loosening/Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

7. Using the sequence below, tighten the retaining bolts.

a. Using the sequence shown in illustration, tighten bolts 1-10 to 34 N.m (25 ft. lbs.).
b. Using the sequence shown in illustration, tighten bolts 11-15 to 20 N.m (15 ft. lbs.).
c. Using the sequence shown in illustration, tighten bolts 1-10 to 54 N.m (40 ft. lbs.).
d. Using the sequence shown in illustration, verify bolts 11-15 are 20 N.m (15 ft. lbs.).
e. Using the sequence shown in illustration, tighten bolts 1-10 to 61 N.m (45 ft. lbs.).
f. Using the sequence shown in illustration, rotate bolts 1-10 an additional 90 degrees.
g. Using the sequence shown in illustration, tighten bolts 11-15 to 28 N.m (21 ft. lbs.).
8. Install the push rods and rocker arms. Refer to INSTALLATION .
9. Install the power steering pump. Refer to PUMP, INSTALLATION .
10. Install the catalytic converters. Refer to CONVERTER, CATALYTIC, INSTALLATION .
11. Lower the vehicle.
12. Install the supercharger assembly. Refer to SUPERCHARGER, INSTALLATION.
13. Fill cooling system. Refer to STANDARD PROCEDURE .

NOTE: Evacuating or purging air from the charge air cooling system must be
done with the use of a pressurized air operated vacuum generator.

14. Connect the negative battery cable (1).

15. Start engine check for leaks.

COVER(S), CYLINDER HEAD

REMOVAL
LEFT

1. Disconnect and isolate the negative battery cable.

2. Remove the air cleaner body and makeup air hose. Refer to REMOVAL .
3. Remove the power steering pump reservoir and position aside. Refer to RESERVOIR, POWER
STEERING PUMP, REMOVAL .

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 4. Remove the ignition coils. Refer to COIL, IGNITION, REMOVAL .
5. Remove the fuel injector and ignition coil wire harness from the valve cover and position aside.

6. Using the sequence shown in illustration, remove the cylinder head cover retaining bolts.

7. Remove the cylinder head cover (1).

8. Clean the sealing surface of the cylinder head (2).

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

RIGHT

1. Perform Fuel System Pressure Release Procedure. Refer to FUEL DELIVERY, GAS, STANDARD
PROCEDURE .
2. Disconnect and isolate the negative battery cable.

3. Remove the engine covers (1).

4. Disconnect the fuel supply line (1) from fuel rail (2). Refer to FITTING, QUICK CONNECT,

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 STANDARD PROCEDURE .

5. Remove the Positive Crankcase Ventilation (PCV) hose from the right side cylinder head cover (1).

6. Disconnect the wire harness connectors from the camshaft position sensor, oil pressure sending unit, and
oil temperature sensor.
7. Disconnect the bypass valve wire harness connector (3).
8. Disconnect the bank one (1) and throttle outlet (2) Temperature-Manifold Absolute Pressure (TMAP)
sensor wire harness connectors.

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 9. Disconnect the right side fuel injector wire harness connectors (1).
10. Disengage the wire harness from the cylinder head cover and position aside.
11. Remove the ignition coils and position harness aside. Refer to COIL, IGNITION, REMOVAL .

12. Using the sequence shown in illustration, remove the cylinder head cover retaining bolts.

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 13. Remove the cylinder head cover (1).
14. Clean the sealing surface of the cylinder head (2).

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

INSTALLATION
LEFT

CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to
covers may occur.

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 CAUTION: Do not allow other components including the wire harness to rest on or against
the engine cylinder head cover. Prolonged contact with other objects may wear
a hole in the cylinder head cover.

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

1. Clean the cylinder head cover (1) and the sealing surface of the cylinder head (2). Inspect the cylinder
head cover gasket and the coil tower gaskets, replace if necessary.
2. Install the cylinder head cover and hand start all fasteners.

Fig. 2: Cylinder Head Cover Loosening/Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

3. Using the sequence shown in illustration, tighten the cylinder head cover bolts to 11 N.m (97 lbs in.).
4. Install the ignition coils. Refer to COIL, IGNITION, INSTALLATION .
5. Install the fuel injector and ignition coil wire harness.
6. Install the power steering pump reservoir. Refer to RESERVOIR, POWER STEERING PUMP,
INSTALLATION .
7. Install the air cleaner body and fresh air makeup hose. Refer to INSTALLATION .
8. Connect the negative battery cable.
9. Start the engine and inspect for leaks.
RIGHT

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 CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to
covers may occur.

CAUTION: Do not allow other components including the wire harness to rest on or against
the engine cylinder head cover. Prolonged contact with other objects may wear
a hole in the cylinder head cover.

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

1. Clean the cylinder head cover (1) and the sealing surface of the cylinder head (2). Inspect the cylinder
head cover gasket and the coil tower gaskets, replace if necessary.
2. Install the cylinder head cover and hand start all fasteners.

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 3. Using the sequence shown in illustration, tighten the cylinder head cover bolts to 11 N.m (97 lbs in.).
4. Install the ignition coils and ignition coil wire harness. Refer to COIL, IGNITION, INSTALLATION .

5. Connect the left side fuel injector wire harness connectors (1) and fasten wire harness to cylinder head
cover.

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 6. Connect the wire harness connectors to the camshaft position sensor, oil pressure sending unit, and oil
temperature sensor.
7. Connect the bank one (1) and throttle outlet (2) Temperature-Manifold Absolute Pressure (TMAP) sensor
wire harness connectors.
8. Connect the bypass valve wire harness connector (3).

9. Connect the Positive Crankcase Ventilation (PCV) hose to the right side cylinder head cover (1).

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 10. Connect the fuel supply line (1) to the fuel rail (2). Refer to FITTING, QUICK CONNECT,
STANDARD PROCEDURE .

11. Install the engine covers (1).

12. Connect the negative battery cable.
13. Start the engine and inspect for leaks.

ROCKER ARM, VALVE

REMOVAL

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 1. Remove the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL.

2. Install Push Rod Retainer (special tool #9070, Retainer, Push Rod) (1).

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 3. Using the sequence shown in illustration, loosen the rocker shaft assemblies.

CAUTION: The rocker shaft assemblies are not interchangeable between intake and
exhaust. The intake rocker arms are marked with an "I".

4. Remove the rocker shaft assemblies. Note the location for reassembly.

CAUTION: The longer pushrods are for the exhaust side, and the shorter pushrods
are for intake side.

5. Remove the push rods. Note the push rod location for reassembly.

CAUTION: Do not remove the retainers from the rocker shaft assemblies. The assembly
tangs (1) at the bottom of the retainers can be damaged, causing the assembly
tangs to break off and get into the engine.

INSTALLATION

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 CAUTION: The longer pushrods are for the exhaust side, and the shorter pushrods are for
intake side.

1. Install the push rods in the same order as removed.

2. Install the Push Rod Retainer (special tool #9070, Retainer, Push Rod) (1).

CAUTION: Ensure the retainers (1) and rocker arms (3) are not overlapped when
torquing bolts.

CAUTION: Verify the push rods are installed into the rocker arms (3) and lifters
correctly while installing the rocker shaft assembly. Recheck after the
rocker shaft assembly has been torqued to specification.

3. Install the rocker shaft assemblies in the same order as removed.

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 Fig. 3: Rocker Shaft Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

CAUTION: The rocker shaft assemblies are not interchangeable between intake and
exhaust. The intake rocker arms are marked with the letter "I".

4. Verify the rocker arms are installed in the correct location.

NOTE: Repeat torque sequence several times to ensure rocker shaft assembly is
firmly seated.

5. Using the sequence shown in illustration, tighten the rocker shaft bolts as follows:
Snug to 10 N.m (7 ft. lbs.)
Torque to 23 N.m (17 ft. lbs.)
Individually loosen by 1/2 turn and re-torque to 23 N.m (17 ft. lbs.)
Finally, Rotate 30 degrees

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 CAUTION: Do not rotate or crank the engine during or immediately after rocker arm
installation. Allow the hydraulic roller lifters adequate time to bleed down
(about 5 minutes).

6. Remove the Push Rod Retainer (special tool #9070, Retainer, Push Rod) (1).

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 7. Install the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, INSTALLATION.

SEAL(S), VALVE GUIDE

DESCRIPTION

The valve guide seals are made of black rubber and incorporate an integral steel garter spring. The integral
garter spring maintains consistent lubrication control to the valve stems. The intake and exhaust stem seals are
common with each other.

SPRING(S), VALVE
REMOVAL

1. Disconnect and isolate the negative battery cable.

2. Remove the air cleaner body. Refer to REMOVAL .
3. Remove the cylinder head covers. Refer to COVER(S), CYLINDER HEAD, REMOVAL.

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 CAUTION: The piston must be at TDC, and both valves closed on the cylinder to be
serviced.

NOTE: The intake push rods can fall into the engine and become lodged in the oil
pan, if removing intake rocker arm shaft, install the push rod retainer
(special tool #9070, Retainer, Push Rod) (1) to retain the intake push rods
(2).

4. Install the push rod retainer (special tool #9070, Retainer, Push Rod) (1) onto the cylinder head.
5. Clip the push rods (2) into the push rod retainer (1).

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 CAUTION: The rocker shaft assemblies are not interchangeable between intake and
exhaust. The intake rocker arms are marked with an "I".

6. Using the sequence shown in illustration, remove the rocker arm shaft bolts and remove the rocker arm
shaft.

7. Install the rocker arm shaft adapter (special tool #9065C, Compressor, Valve Spring) (1).
8. Insert an air hose (2) into the spark plug hole and charge the cylinder with air.

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 NOTE: A fulcrum assembly (1) must be rotated to the appropriate setting as
marked on the tool for proper valve spring alignment.

NOTE: All valve springs and seals are removed in the same manner.

NOTE: Tap the top of the valve spring retainer to loosen the spring retainer locks.

9. Install the (special tool #9065C, Compressor, Valve Spring) (1) and remove the intake valve retainer
locks.
10. Release the valve spring compressor and remove the valve springs.

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 11. Install the (special tool #9065C, Compressor, Valve Spring) (2) and the (special tool #9065-3, Adapter,
Valve Spring Compressor) (1) and remove the exhaust valve retainer locks.
12. Release the valve spring compressor and remove the valve spring.

NOTE: The valve springs are interchangeable between intake and exhaust.

13. Remove and discard the valve guide seal.

INSTALLATION

NOTE: All valve springs and seals are installed in the same manner.

1. Install a new valve guide seal.

NOTE: The intake spring retainer has a longer free length compared to the
exhaust spring retainer.

2. Install the valve spring.

3. Install the valve spring retainer.

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 4. Using the (special tool #9065C, Compressor, Valve Spring) (2) and the (special tool #9065-3, Adapter,
Valve Spring Compressor) (1), compress the valve spring and install the valve spring retainer locks.

5. Remove the (special tool #9065C, Compressor, Valve Spring) (2) and the (special tool #9065-3, Adapter,
Valve Spring Compressor).
6. Release the air charge (1) in the cylinder.

CAUTION: Verify that the pushrods are fully seated into the lifters and the rocker
arms. Recheck after rocker arm shaft has been torqued to specification.

7. Install the rocker arm shaft and push rods. Refer to INSTALLATION .

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 8. Using the sequence shown in illustration, tighten the rocker shaft bolts as follows:
Snug to 10 N.m (7 ft. lbs.)
Torque to 23 N.m (17 ft. lbs.)
Individually loosen by 1/2 turn and re-torque to 23 N.m (17 ft. lbs.)
Finally, Rotate 30 degrees

9. Remove the (special tool #9070, Retainer, Push Rod) (1).

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 10. Install the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, INSTALLATION.
11. Install the air cleaner body. Refer to INSTALLATION .
12. Connect the negative battery cable.

VALVES, INTAKE AND EXHAUST

DESCRIPTION
VALVES

Both the intake and exhaust valves are made of steel with full chrome plate on valve stems. The intake valve is
54.3 mm (2.14 in.) diameter and the exhaust valve is 42.0 mm (1.65 in.) diameter. All valves use three bead
lock keepers and retainers to retain the springs and promote valve rotation.
VALVE GUIDES

The valve guides are made of powdered metal and are pressed into the cylinder head. The guides are not
replaceable or serviceable, and valve guide reaming is not recommended. If the guides are worn beyond
acceptable limits, replace the cylinder heads.

STANDARD PROCEDURE
STANDARD PROCEDURE - REFACING

NOTE: Valve seats that are worn or burned can be reworked, provided that the correct
angle and seat width are maintained. Otherwise the cylinder head must be
replaced.

NOTE: When refacing valves and valve seats, it is important that the correct size valve
guide pilot be used for reseating stones. A true and complete surface must be
obtained.

1. Measure the concentricity of the valve seat using a dial indicator. Total runout should not exceed 0.051
mm (0.002 inch.) total indicator reading.
2. Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat
the valve seat with Prussian blue then set the valve in place. Rotate the valve using light pressure. If the
blue is transferred to the center of the valve face, contact is satisfactory. If the blue is transferred to the
top edge of the valve face, lower the valve seat with a 15 degree stone. If the blue is transferred to the
bottom edge of the valve face, raise the valve seat with a 65 degree stone.
3. Refer to the below chart for the proper valve seat width, valve seat angle, valve face angle and valve
spring height.

VALVE SEAT, VALVE FACE AND SPRING HEIGHT CHART

DESCRIPTION SPECIFICATION
SEAT WIDTH
INTAKE 0.94 - 1.04 mm 0.037 - 0.041 in.
EXHAUST 1.16 - 1.26 mm 0.046 - 0.050 in.
SEAT ANGLE
(INT. AND EXT.) 44.5° - 45°
FACE ANGLE
INTAKE 45.5° - 46°

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 DESCRIPTION SPECIFICATION
EXHAUST 45° - 45.5°
SPRING HEIGHT
INTAKE 52.1 mm 2.051 in.
EXHAUST 51.2 mm 2.016 in.

4. The valve seat must maintain an angle of 44.5° - 45.0°.

5. The valve face must maintain an angle of 45.5° - 46.0° for the Intake and 45.0° - 45.5° for the
exhaust.

REMOVAL

1. Disconnect and isolate the negative battery cable.

2. Remove the cylinder head. Refer to CYLINDER HEAD, REMOVAL .
3. Compress the valve springs using the valve spring compressor (special tool #C-3422-D, Compressor,
Valve Spring) and adapter (special tool #8464, Adapter, Valve Spring).
4. Remove the valve spring retainer locks, valve spring retainers, valve stem seals and valve springs.
5. Before removing the valves, remove any burrs from the valve spring retainer lock grooves in the valve
stems to prevent damage to the valve guides. Identify the valves to ensure installation in their original
location.
6. Remove the valves.

INSTALLATION

1. Clean the valves thoroughly. Discard burned, warped, and cracked valves.
2. Remove carbon and varnish deposits from inside the valve guides with a reliable guide cleaner.
3. Measure the valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve.
4. Coat the valve stems with clean engine oil and insert them into the cylinder head.
5. If the valves or seats have been reground, check valve stem height. If the valve is too long, replace the
cylinder head.
6. Install new seals on all valve guides. Install the valve springs and valve spring retainers.

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 7. Compress the valve springs with the Valve Spring Compressor (special tool #C-3422-D, Compressor,
Valve Spring) (1) and Adapter (special tool #8464, Adapter, Valve Spring), install the valve spring
retainer locks and release the tool. If the valves and/or seats have been ground, measure the installed
height of the springs. Make sure the measurement is taken from the bottom of spring seat in the cylinder
head to the bottom surface of valve spring retainer.
8. Install the cylinder head. Refer to INSTALLATION .
9. Connect the negative battery cable.

ENGINE BLOCK
CLEANING

Thoroughly clean the oil pan and engine block gasket surfaces.

Use compressed air to clean the following:

Gallery at the oil filter adaptor hole.

Front and rear oil gallery holes.
Feed holes for the crankshaft main bearings.

Once the block has been completely cleaned, apply Loctite PST pipe sealant with Teflon 592 to the threads of
the front and rear oil gallery plugs. Tighten the 1/4 inch NPT plugs, 3/8 inch NPT plugs and the coolant drain
plugs to the proper specification. Refer to TORQUE SPECIFICATIONS .

INSPECTION
ENGINE BLOCK

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 1. Clean the engine block thoroughly and check all core hole plugs for evidence of leaking and repair if
necessary.
2. Examine the engine block and cylinder bores for cracks or fractures.

NOTE: Check the engine block deck surface with a precision straightedge and
feeler gauge. The surface irregularities should not exceed 0.09 mm (0.0035
in.). Check the deck surface from one end to the other with the precision
straightedge positioned across corners and parallel to the block centerline
up and down the deck.

3. Check the engine block deck (1) surfaces for flatness using a precision straightedge (2) and feeler gauge
(3).

CYLINDER BORE

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 1. Use a cylinder bore gauge (2) to correctly measure the inside diameter of the cylinder bore (3). A cylinder
bore gauge capable of reading in 0.003 mm (0.0001 in.) increments is required. If a bore gauge is not
available, do not use an inside micrometer.
2. Measure the inside diameter of the cylinder bore at three levels below the top of the bore (4). Start at the
top of the bore, perpendicular (across or at 90°) to the axis of the crankshaft at point A (1).
3. Repeat the measurement near the middle of the bore then repeat the measurement near the bottom of the
bore.
4. Determine the taper by subtracting the smaller diameter from the larger diameter.
5. Rotate the measuring device 90° to point B (1) and repeat the three measurements. Verify that the
maximum taper is within specifications.
6. Determine out-of-roundness by comparing the difference between each measurement.
7. If the cylinder bore taper does not exceed 0.0127 mm (0.0005 inch) and out-of-roundness does not exceed
0.008 mm (0.0003 inch) then the cylinder bore can be honed. If the cylinder bore taper or out- of-round
condition exceeds the maximum limits, replace the engine block.

NOTE: A slight amount of taper always exists in the cylinder bore after the engine has
been in use for a period of time.

MAIN BEARINGS

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 1. Wipe the main bearing inserts (1, 2) clean.
2. Inspect the inserts for abnormal wear patterns, scoring, grooving, fatigue, pitting and for metal or other
foreign material imbedded in the lining.
3. Inspect the back of the inserts for fractures, scrapes or irregular wear patterns.
4. Inspect the insert locking tabs for damage.
5. Inspect the crankshaft thrust washers for scoring, scratches, bluing, discoloration or signs of wear.
6. Replace any bearing that shows abnormal wear.
7. Inspect the main bearing bores for signs of scoring, nicks and burrs.
8. If the engine block main bearing bores show damage, replace the engine block.

BEARING(S), CRANKSHAFT, MAIN

STANDARD PROCEDURE
STANDARD PROCEDURE - CRANKSHAFT MAIN BEARING - FITTING
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)

CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler and lines
must be replaced or damage to the new engine or components could result.

Crankshaft removed from the cylinder block.

Clean the oil off the main bearing journal.

Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at
each end of the journal.

The maximum allowable taper is 0.003 mm (0.00012 inch). The maximum out-of-round is 0.005 mm (0.0002
inch). Compare the measured diameter with the journal diameter specification (Main Bearing Fitting Chart).
Select inserts required to obtain the specified bearing-to-journal clearance.

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 CRANKSHAFT MAIN BEARING SELECTION

The main bearings are "select fit" to achieve proper oil clearances. For main bearing selection, the crankshaft
counterweight has grade identification marks stamped into it. These marks are read from left to right,
corresponding with journal number 1, 2, 3, 4 and 5.

NOTE: Service main bearings are coded. These codes identify what size (color) the
bearing is.

MAIN BEARING SELECTION CHART

GRADE COLOR mm In FOR USE WITH
JOURNAL SIZE
LOWER AND Â 64.9780-64.9859 mm
 Â
UPPER
A ORANGE 0.008 mm U/S (0.0004 in.) U/S (2.442-2.447 in.)
LOWER AND Â 664.9860-64.9940 mm
 Â
UPPER
B BLACK NOMINAL NOMINAL (2.438-2.443 in.)
LOWER AND Â 64.9941-65.0020 mm
 Â
UPPER
C GREEN 0.008 mm O/S (0.0004 in.) O/S (2.434-2.439 in.)

INSPECTION

CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler and lines
must be replaced or damage to the new engine or components could result.

Wipe the inserts clean and inspect for abnormal wear patterns and for metal or other foreign material imbedded
in the lining. Normal main bearing insert wear patterns are illustrated.

NOTE: If any of the crankshaft journals are scored, the crankshaft must be repaired or
replaced.

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 Inspect the back of the inserts for fractures, scoring or irregular wear patterns.

Inspect the upper insert locking tabs for damage.

Replace all damaged or worn bearing inserts.

CAMSHAFT, ENGINE
REMOVAL
CAMSHAFT CORE HOLE PLUG

1. Perform the fuel system pressure release procedure. Refer to FUEL DELIVERY, GAS, STANDARD
PROCEDURE .
2. Remove the engine from the vehicle. Refer to REMOVAL .
3. On automatic transmission models, remove the flexplate. Refer to REMOVAL .

CAUTION: Do not damage the rear surface of the camshaft or the core plug sealing
surface, when removing the core plug.

4. Using a suitable sharp punch, punch a small hole in the camshaft core hole plug (1).
5. Insert a short sheet metal screw into the small hole in the camshaft core hole plug.
6. Using a suitable slide hammer puller, remove the rear camshaft core hole plug.
CAMSHAFT

1. Remove both cylinder heads. Refer to CYLINDER HEAD, REMOVAL .

CAUTION: Whenever the camshaft is replaced, all lifters must be replaced. If the lifter
and retainer assemblies are to be reused, identify the lifters to ensure
installation in their original location or engine damage could result.

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 CAUTION: The lifter and retainer assembly must be installed as a unit.

2. Remove the lifters (2) and retainer (1) as an assembly. Refer to REMOVAL .
3. Remove the radiator. Refer to RADIATOR, ENGINE COOLING, REMOVAL .
4. Remove the A/C condenser. Refer to CONDENSER, A/C, REMOVAL .
5. Remove the timing chain and camshaft phaser. Refer to REMOVAL .

6. Remove the camshaft thrust plate (1).

CAUTION: Use care when removing the camshaft, do not damage the camshaft
bearings with the camshaft lobes.

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 7. Install a long bolt (2) into the front of the camshaft to aid in removal.
8. Remove the camshaft using care not to damage the camshaft bearings with the camshaft lobes (1).

INSPECTION

NOTE: The cam bearings are not serviceable. Do not attempt to replace cam bearings
for any reason.

INSTALLATION
CAMSHAFT CORE HOLE PLUG

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 1. Clean the core hole in the cylinder block.

NOTE: Do not apply adhesive to the new camshaft core hole plug. A new plug has
adhesive pre-applied.

2. Install a new camshaft core hole plug (1) located at the rear of cylinder block, using a suitable flat faced
tool. The plug must be fully seated on the cylinder block shoulder.
3. On automatic transmission models, install the flexplate. Refer to INSTALLATION .
4. Install the engine. Refer to INSTALLATION .
CAMSHAFT

CAUTION: Use care when installing the camshaft into the engine block, do not damage the
camshaft bearings with the camshaft lobes.

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 1. Lubricate the camshaft lobes (1) and the camshaft bearing journals with clean engine oil.
2. Install a long bolt (2) into the front of the camshaft to aid in the installation, carefully install the camshaft
into the engine block.

3. Install the camshaft thrust plate (1) and tighten retaining bolts to the proper specification. Refer to
TORQUE SPECIFICATIONS .
4. Using a suitable dial indicator, measure the camshaft end play. Refer to ENGINE SPECIFICATIONS .
If not within specification, install a new thrust plate.
5. Install the timing chain and camshaft phaser. Refer to INSTALLATION .

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 6. Install the A/C condenser. Refer to CONDENSER, A/C, INSTALLATION .
7. Install the radiator. Refer to RADIATOR, ENGINE COOLING, INSTALLATION .

CAUTION: Whenever the camshaft is replaced, all lifters must be replaced. If the lifter
and retainer assemblies are to be reused, identify the lifters to ensure
installation in their original location or engine damage could result.

CAUTION: The lifter and retainer assembly must be installed as a unit.

8. Install the lifters (2) and retainer (1) as an assembly into their original location. Refer to
INSTALLATION .
9. Install both cylinder heads. Refer to INSTALLATION .

NOTE: The Cam/Crank Variation Relearn procedure must be performed using the scan
tool anytime there has been a repair/replacement made to a powertrain system,
for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or
components.

CRANKSHAFT
REMOVAL

CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler and lines
must be replaced or damage to the new engine or components could result.

1. Remove the engine. Refer to REMOVAL .

2. Secure the engine onto a suitable engine stand.
3. Remove the crankshaft rear oil seal retainer. Refer to REMOVAL .
4. Remove the oil pan and the oil pump pickup tube. Refer to REMOVAL .
5. Remove the timing chain, camshaft phaser and crankshaft sprocket. Refer to REMOVAL .

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 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 removal to ensure correct reassembly.

6. Mark the connecting rod and bearing cap location using a permanent ink marker or scribe tool.
7. Remove the rod bearing caps and bearings.

CAUTION: Do not use a number stamp or a punch to mark main bearing caps as
damage to bearing caps or bearings could occur.

NOTE: Main bearing caps are not interchangeable and should be marked before
removal to ensure correct reassembly.

8. Mark the main bearing caps using a permanent ink marker or scribe tool.

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 9. Remove the main bearing cap cross-bolts.
10. Remove the main bearing cap bolts.
11. Remove main bearing caps (1) and bearings one at a time.

12. Remove the thrust bearings.

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 13. Remove the crankshaft (1) from the engine block.

INSTALLATION

CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler and lines
must be replaced or damage to the new engine or components could result.

1. Select the proper main bearings (1). Refer to STANDARD PROCEDURE .

2. Lubricate the main bearing shells with clean engine oil.
3. Install the main bearings into the engine block.

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 4. Install the main bearing shells (2) into the bearing caps (1).

5. Position the crankshaft (1) into the engine block.

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 6. Lubricate and install the thrust bearings (1).
7. Install all main bearing caps in the location as noted during removal making sure the arrow faces forward.

Fig. 4: Main Bearing Cap Bolt Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

8. Clean and oil all main cap bolts and install finger tight.
9. Using the sequence shown in illustration, tighten the main bearing cap bolts to 13 N.m (10 ft. lbs.).
10. Again, using the sequence shown in illustration, tighten the main bearing cap bolts to 28 N.m (21 ft. lbs.).
11. Using the sequence shown in illustration, rotate the main bearing cap bolts an additional 90°.

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 Fig. 5: Crossbolt Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

NOTE: The main bearing cap cross-bolts are torqued after the final torque of the
main cap bolts.

12. Install the cross-bolts finger tight.

13. Using the sequence shown in illustration, tighten the cross-bolts to 34 N.m (25 ft. lbs.).
14. Again, using the sequence shown in illustration, repeat the cross-bolt tightening procedure using the same
torque.
15. Measure the crankshaft end play. Refer to STANDARD PROCEDURE .

CAUTION: The connecting rod bolts must not be reused. Always replace the
connecting rod bolts whenever they are loosened or removed.

16. Wipe the connecting rod caps clean and install the rod bearings.
17. Lubricate the bearing surfaces with clean engine oil and install the bearings and connecting rod caps onto
the connecting rod journals in the same location as noted during removal.
18. Install the NEW connecting rod bolts finger tight.
19. Tighten the connecting rod bolts to the proper specification. Refer to TORQUE SPECIFICATIONS .

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 20. If required, measure the connecting rod side clearance (1, 2). Refer to ENGINE SPECIFICATIONS .
21. Install the timing chain, camshaft phaser and crankshaft sprocket. Refer to INSTALLATION .
22. Install the crankshaft rear oil seal retainer. Refer to INSTALLATION .
23. Install the oil pump pickup tube and oil pan. Refer to INSTALLATION .
24. Install the engine. Refer to INSTALLATION .
25. Start the engine and check for leaks.

NOTE: The Cam/Crank Variation Relearn procedure must be performed using the scan
tool anytime there has been a repair/replacement made to a powertrain system,
for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or
components.

DAMPER, VIBRATION
DESCRIPTION

The crankshaft damper is used to control the resonance that is produced by the engine. The Noise, Vibration,
and Harshness (NVH) created from the crankshaft can be controlled by dissipating the torque energy through
the damper.

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 The crankshaft damper is held to the crankshaft by means of a hardened steel bolt. The damper is pressed onto a
specific machined surface of the crankshaft.

REMOVAL

1. Disconnect and isolate the negative battery cable.

2. Allow the engine to cool to room/ambient temperature prior to performing the removal or installation
procedure.

NOTE: The engine must be at room/ambient temperature before installing the

damper.

3. Remove the cooling fan assembly. Refer to FAN, COOLING, REMOVAL .

NOTE: When installing the puller tool, ensure the bolts are fully threaded through
the entire crankshaft damper (2).

4. Remove the vibration damper bolt (1) and discard.

5. Install the crankshaft damper puller, making sure the bolts are fully threaded through the entire crankshaft
damper.
6. Remove the crankshaft damper.

INSTALLATION

NOTE: When installing a new damper after the damper has spun, the timing sprocket
must be replaced.

1. Allow the engine to cool to room/ambient temperature prior to performing the removal or installation
procedure.

NOTE: The engine must be at room/ambient temperature before installing the

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 damper.

2. Using a commercially available damper installer, install the 16mm threaded rod into the crankshaft.
3. Tighten the threaded rod until it is seated to the face of the crankshaft.

4. Position the damper (2) on the crankshaft.

5. Install the press washer, bearing, washer, and the press nut onto the threaded rod.
6. Using Damper Installer and a deep well socket, press the damper onto the crankshaft until seated.
7. Install a New vibration damper bolt (1).
8. Position the (special tool #10386, Holder, Vibration Damper), onto the vibration damper pulley.
9. Tighten the bolt to the proper specification. Refer to TORQUE SPECIFICATIONS .
10. Install the cooling fan. Refer to FAN, COOLING, INSTALLATION .
11. Connect the negative battery cable.

FLEXPLATE
REMOVAL

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 1. Remove the transmission. Refer to REMOVAL .
2. Using the sequence shown in illustration, remove the flexplate (1) retaining bolts.

CAUTION: Do not use an impact socket or a thick walled socket when removing or
installing the flexplate retaining bolts, damage to the crankshaft, internal
engine or the transmission may occur.

3. Remove the flexplate.

INSTALLATION

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 Fig. 6: Flex Plate Loosening/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

1. Position the flexplate (1) onto the crankshaft and install the bolts finger tight.
2. Using the sequence shown in illustration, tighten the flexplate retaining bolts to the proper specification.
Refer to TORQUE SPECIFICATIONS .

CAUTION: Do not use an impact socket or a thick walled socket when removing or
installing the flexplate retaining bolts, damage to the crankshaft, internal
engine or the transmission may occur.

3. Install the transmission. Refer to INSTALLATION .

LIFTER(S), HYDRAULIC, ROLLER

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HYDRAULIC ROLLER LIFTERS

Before disassembling any part of the engine to correct lifter noise, check the oil pressure. If the vehicle has no
oil pressure gauge, install a reliable gauge at the pressure sending-unit. The pressure should be between 207-552
kPa (30-70 psi) at 3, 000 RPM.

Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil level,
check dipstick. 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 lifters.
HIGH

If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine
running, this condition could create foam in the oil pan. Foam in oil pan would be fed to the hydraulic lifters by
the oil pump causing them to lose length and allow valves to seat noisily.

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 LOW

Low oil level may allow oil pump to take in air. When air is fed to the lifters, they lose length, which allows
valves to seat noisily. Any leaks on intake side of oil pump through which air can be drawn will create the same
lifter action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve
retainer cap. When lifter noise is due to aeration, it may be intermittent or constant, and usually more than one
lifter will be noisy. When oil level and leaks have been corrected, operate the engine at fast idle. Run engine for
a sufficient time to allow all of the air inside the lifters to be bled out.
LIFTER NOISE DIAGNOSIS

1. To determine source of lifter noise, crank the engine with cylinder head covers removed.
2. Feel each valve spring or rocker arm to detect noisy lifter. The noisy lifter 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
lifters. If such is the case, noise may be dampened by applying side thrust
on the valve spring. If noise is not noticeably reduced, it can be assumed
the noise is in the lifter. Inspect the rocker arm push rod sockets and push
rod ends for wear.

3. Valve lifter 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 lifter body cylinder. The
lifter should be replaced. A heavy click is caused by a lifter check valve not seating or by foreign particles
wedged between the plunger and the lifter 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
the valve closes. In either case, lifter assembly should be removed for inspection and cleaning.
4. The valve train generates a noise very much like a light lifter noise during normal operation. Care must be
taken to ensure that lifters are making the noise. If more than one lifter seems to be noisy, it's probably
not the lifters.

REMOVAL

1. Disconnect and isolate the negative battery cable.

2. Remove the cylinder head. Refer to CYLINDER HEAD, REMOVAL .

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 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.

CAUTION: The lifter and retainer assembly must be installed as a unit.

3. Remove the lifters (2) and retainer (1) as an assembly.

4. Check the camshaft lobes for abnormal wear.

INSTALLATION

1. Lubricate the lifters (2) and retainer (1) assembly with clean engine oil.

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 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.

CAUTION: The lifter and retainer must be installed as an assembly.

2. Install the lifters (2) and retainer (1) as an assembly into their original location.
3. Tighten the lifter retainer bolt (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
4. Install the cylinder head. Refer to INSTALLATION .
5. Connect the negative battery cable.

CAUTION: To prevent damage to valve assemblies, do not run the engine above fast
idle until all hydraulic lifters have filled with oil and have become quiet.

RETAINER, CRANKSHAFT REAR OIL SEAL

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS

The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer and is serviced as an assembly.

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 and 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

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 plugs, oil gallery pipe plugs, oil filter runoff and main bearing cap to cylinder block mating
surfaces. See appropriate Engine service information, for proper repair procedures of these items.
4. If no leaks are detected, pressurize the crankcase "Engine Oil Leak" . Refer to DIAGNOSIS AND
TESTING .

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
REMOVAL .

REMOVAL

NOTE: The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer
and must be replaced as an assembly.

NOTE: The crankshaft rear oil seal retainer can not be reused after removal.

NOTE: This procedure can be performed in vehicle.

1. Disconnect the negative battery cable.

2. Remove the flexplate or flywheel. Refer to FLEXPLATE .
3. Remove the oil pan. Refer to REMOVAL .

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 4. Using the sequence shown in illustration, remove the rear oil seal retainer mounting bolts.
5. Remove and discard the rear oil seal retainer.

INSTALLATION

NOTE: The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer
and must be replaced as an assembly.

NOTE: The crankshaft rear oil seal retainer can not be reused after removal.

1. Thoroughly clean all gasket residue from the engine block.

2. Position the gasket onto the new crankshaft rear oil seal retainer.
3. Position the crankshaft rear oil seal retainer onto the engine block.

Fig. 7: Rear Oil Seal Retainer Mounting Bolts Loosening/Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

4. Using the sequence shown in illustration, install the crankshaft rear oil seal retainer mounting bolts and
tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
5. Install the oil pan. Refer to INSTALLATION .
6. Install the flexplate or flywheel. Refer to INSTALLATION .

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 7. Install a NEW oil filter and fill the crankcase with the specified type and amount of engine oil. Refer to
STANDARD PROCEDURE .
8. Connect the negative battery cable.
9. Start the engine and check for leaks.

RING(S), PISTON
STANDARD PROCEDURE
PISTON RING FITTING

CAUTION: Before reinstalling used piston rings or installing new piston rings, the piston
ring clearances must be checked or engine damage may result.

1. Wipe the cylinder bore clean.

2. Insert the piston ring into the cylinder bore.

NOTE: The piston ring gap measurement must be made with the piston ring
positioned at least 12 mm (0.50 inch) from bottom of cylinder bore.

3. Using a piston, make sure that the piston ring is squared in the cylinder bore. Slide the piston ring
downward into the cylinder.
4. Using a feeler gauge (1), check the piston ring end gap, replace any rings not within specification.
PISTON RING SIDE CLEARANCE

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

1. Measure the piston ring side clearance with a feeler gauge (1) as shown in illustration. Make sure the
feeler gauge fits snugly between the piston ring land and the piston ring, replace any ring not within
specification.

NOTE: Make sure the marks on the compression rings face upward.

2. Rotate the ring around the piston. The ring must rotate in the groove with out binding.
PISTON RING INSTALLATION

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 1. Install the oil ring expander.
2. Install the lower side rail by placing one end between the piston ring groove and the expander ring (1).
Hold the lower side rail end firmly and press down the portion to be installed until the side rail is in
position. Repeat this step for the upper side rail.

3. Using a piston ring installer, install the No. 2 intermediate piston ring.
4. Using a piston ring installer, install the No. 1 upper piston ring.

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 5. Install the oil ring expander gap at the (5) position.
6. Install the oil ring lower side rail gap at the (4) position.
7. Install the oil ring upper side rail gap at the (1) position.
8. Install the second compression ring gap at the (5) position.
9. Install the top compression ring gap at the (2) position.

ROD, PISTON AND CONNECTING

DESCRIPTION

CAUTION: Do not use a metal stamp to mark connecting rods as damage may result,
instead use ink or a scratch awl.

The pistons are made of a high-strength forged aluminum alloy. Piston skirts are coated with a solid graphite
lubricant to reduce friction and provide scuff resistance. The piston top ring groove and land is anodized. The
connecting rods are made of forged powdered metal with a "fractured cap" design. A floating piston pin is used
to attach the piston and connecting rod.

STANDARD PROCEDURE
STANDARD PROCEDURE - PISTON FITTING

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 1. Use Cylinder Indicator (special tool #C-119, Cylinder Indicator) (2) to correctly measure the inside
diameter of the cylinder bore (3). A cylinder indicator capable of reading in 0.003 mm (0.0001 in.)
increments is required. If a cylinder indicator is not available, do not use an inside micrometer.
2. Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below top of bore (4).
Start perpendicular (across or at 90°) to the axis of the crankshaft at point A and then take an additional
bore reading 90° to that at point B.

NOTE: The coated pistons, piston pins and connecting rods are pre-assembled
and serviced as an assembly.

3. The piston and rod assembly is specific for the left cylinder bank (odd numbered) and the right cylinder

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 bank (even numbered) and must not be interchanged.
4. The coating material (1, 2) is applied to the piston after the final piston machining process. Measuring the
outside diameter of a coated piston will not provide accurate results. Therefore measuring the inside
diameter of the cylinder bore with a cylinder indicator is MANDATORY . To correctly select the proper
size piston, a cylinder indicator capable of reading in 0.003 mm (0.0001 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.

REMOVAL

CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler and lines
must be replaced or damage to the new engine or components could result.

1. Remove the cylinder head(s). Refer to CYLINDER HEAD, REMOVAL .

2. Remove the oil pan. Refer to REMOVAL .
3. If necessary, remove the ridge on top of the cylinder bores with a reliable ridge reamer before removing
pistons from engine block. Be sure to keep the tops of the pistons covered during this operation.

CAUTION: When removing and installing the pistons and connecting rods, do not
damage the piston oil cooler jets. If the jets are bent, engine damage may
occur.

4. Remove the piston oil cooler jet(s) retaining bolt(s) (2) and remove the piston oil cooler jet(s) (1).

CAUTION: Do not use a number stamp or a punch to mark connecting rods or caps,
as damage to connecting rods could occur.

CAUTION: Care must be taken not to damage the fractured rod and cap joint face

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 surfaces as engine damage may occur.

CAUTION: Care must be taken not to nick crankshaft journals as engine damage may
occur.

NOTE: Connecting rods and bearing caps are not interchangeable and should be
marked before removing to ensure correct reassembly.

5. Mark the connecting rod and bearing cap position using a permanent ink marker or scribe tool.

NOTE: Pistons and connecting rod assemblies must be removed from the top of
the engine block. When removing the piston and connecting rod
assemblies from the engine, rotate the crankshaft so each connecting rod
is centered in the cylinder bore.

6. Remove the connecting rod cap and carefully remove the piston from the cylinder bore, repeat this
procedure for each piston being removed.
7. Immediately after removing the piston and connecting rod, install the bearing cap on the mating
connecting rod to prevent damage to the fractured cap and rod surfaces.
8. Carefully remove the piston rings from the piston(s), starting from the top ring down.

CLEANING

NOTE: DO NOT use a wire wheel or other abrasive cleaning devise to clean the pistons
or connecting rods. The pistons have a graphite coating, this coating must not
be damaged.

1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry.
2. Use a wood or plastic scraper to clean the ring land grooves.

INSPECTION

Check the connecting rod journal for excessive wear, taper and scoring.

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

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 PROCEDURE .

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

INSTALLATION

CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler and lines
must be replaced or damage to the new engine or components could result.

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.

1. Check piston ring clearance. Refer to STANDARD PROCEDURE .

2. Before installing piston and connecting rod assemblies into the bore, install the piston rings. Refer to
STANDARD PROCEDURE .
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. Make sure the position of rings do not change during this
operation.

4. The pistons are marked on the piston pin bore surface with an etched arrow on top of piston indicating
installation position. This mark must be pointing toward the front of the engine on both cylinder banks.
5. Wipe the cylinder bore clean and lubricate with clean engine oil.
6. Rotate the crankshaft until the connecting rod journal is centered with the cylinder bore.

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 7. Insert the piston and rod assembly into the cylinder bore and carefully position the connecting rod over
the crankshaft journal.
8. Push the piston down in cylinder bore using a hammer handle. While at the same time, guide the
connecting rod into position on crankshaft rod journal.
9. Perform the measure bearing clearance procedure. Refer to appropriate service information.

10. 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.

11. Lubricate the bearing surfaces with clean engine oil and position the rod cap onto the connecting rod.

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.

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 12. Verify the connecting rods are properly installed, the wide side (1) of the connecting rod is facing towards
the crankshaft and the narrow sides (2) of the connecting rods face each other.
13. Lubricate the new rod cap bolts with clean engine oil, install and tighten to the proper specification. Refer
to TORQUE SPECIFICATIONS .

CAUTION: When removing and installing the pistons and connecting rods, do not
damage the piston oil cooler jets. If the jets are bent, engine damage may
occur.

14. Position the piston oil cooler jet(s) (1).

15. Install the piston oil cooler jet retaining bolt(s) (2) and tighten to proper specification. Refer to TORQUE
SPECIFICATIONS .
16. Install the oil pan and oil pump pickup tube and oil pan. Refer to INSTALLATION .

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 17. Install the cylinder head(s). Refer to INSTALLATION .
18. Connect the negative battery cable.
19. Start the engine and check for leaks.

SEAL, CRANKSHAFT OIL, FRONT

REMOVAL

1. Remove the vibration damper. Refer to REMOVAL .

2. Using the Seal Remover (special tool #9071, Remover, Seal) (1), remove the crankshaft front seal (2).

INSTALLATION

CAUTION: The front crankshaft seal must be installed dry. Do not apply lubricant to
sealing lip or to outer edge.

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 1. Install the threaded rod (1) from the (special tool #10387, Installer, Vibration Damper) into the crankshaft
(2) till seated.

2. Using Seal Installer (special tool #9072, Installer, Seal) and (special tool #10387, Installer, Vibration
Damper) (2), install the crankshaft front oil seal.
3. Install the vibration damper. Refer to INSTALLATION .

SEAL, CRANKSHAFT OIL, REAR

DESCRIPTION

The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer, for more information refer to the
following;

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 Diagnosis and Testing Refer to DIAGNOSIS AND TESTING .
Removal Refer to REMOVAL .
Installation Refer to INSTALLATION .

ENGINE MOUNTING
INSULATOR, ENGINE MOUNT, FRONT
REMOVAL

1. Disconnect and isolate the negative battery cable.

2. Remove the supercharger assembly. Refer to SUPERCHARGER, REMOVAL.
3. Remove the engine oil dipstick tube retaining nut at the right exhaust manifold.
4. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .

5. Remove the belly pan retainers (1) and remove the belly pan.

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 6. Remove both left/right engine mount heat shield (4) retaining nuts (3) and remove the heat shields
7. Remove both left/right engine mount lower retaining bolts (2).
8. Lower the vehicle.
9. Remove the Variable Valve Timing Solenoid (VVTS). Refer to REMOVAL .

NOTE: Do not use air tools to install the engine lift fixture.

10. Install the Engine Lift Fixture (special tool #8984B, Fixture, Engine Lifting) (1), Engine Lift Adapter
(special tool #8984-UPD, Adapter, Engine Lift) (3) and the Engine Support Fixture (special tool #8534C,
Fixture, Driveline Support) (2).
11. Raise the engine to provide clearance to remove the engine mounts.

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 12. Raise and support the vehicle.

13. Remove the generator support bracket to engine mount retaining nut (1).
14. Remove the generator support bracket retaining bolt (2) and remove the support bracket (3).

15. Remove both left/right engine mount retaining bolts (1) and remove the engine mounts (2).

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 16. If necessary, remove both engine mount to engine block mounting bracket retaining bolts (1) and remove
the mounting brackets (2).

INSTALLATION

1. If removed, position the engine mount to engine block mounting brackets, install the retaining bolts and
tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .

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 2. Position the engine mounts (2), Install the retainers (1) and tighten to the proper specification. Refer to
TORQUE SPECIFICATIONS .

3. Position the generator support bracket (3) to the engine mount, install the retaining nut (1) and tighten
finger tight.
4. Position the generator support bracket to the generator, install the retaining bolt (2) and tighten to the
proper specification. Refer to TORQUE SPECIFICATIONS .
5. Tighten the generator support bracket to engine mount retaining nut to the proper specification. Refer to
TORQUE SPECIFICATIONS .
6. Lower the vehicle.

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 7. Lower the Engine Support Fixture (special tool #8534C, Fixture, Driveline Support) (3) until the engine
mounts are seated in the engine cradle.
8. Remove 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 #8534C,
Fixture, Driveline Support) (3).
9. Install the Variable Valve Timing Solenoid (VVTS). Refer to INSTALLATION .
10. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .

NOTE: Left side shown in illustration, right side similar.

11. Install both left/right engine mount lower retaining bolts (2) and tighten to the proper specification. Refer
to TORQUE SPECIFICATIONS .

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 12. Position both left/right engine mount heat shields (4), install the retaining nuts (3) and tighten to the
proper specification. Refer to TORQUE SPECIFICATIONS .

13. Position the belly pan and install the belly pan retainers (1).
14. Lower the vehicle.
15. Position the engine oil dipstick tube, install the retaining nut at the right exhaust manifold.
16. Install the supercharger assembly. Refer to SUPERCHARGER, INSTALLATION.
17. Connect the negative battery cable.

INSULATOR, ENGINE MOUNT, REAR

REMOVAL
AUTOMATIC TRANSMISSION

1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .

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 2. Using a suitable jack, support the transmission.
3. Remove the rear transmission mount isolator bolts (2).
4. Remove the rear cross member retaining bolts (1, 3) and remove the cross member.

5. Remove the rear transmission mount isolator retaining bolts (1) and remove the isolator.

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 6. If required, remove the rear transmission mount bracket retaining bolts (1) from the transmission and
remove the bracket.
MANUAL TRANSMISSION

1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .

2. Using a suitable jack, support the transmission.

3. Remove the rear transmission mount isolator nuts (2).
4. Remove the rear cross member retaining bolts (1) and remove the cross member.

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 5. Remove bolts (1) and the rear transmission mount isolator (2).

INSTALLATION
AUTOMATIC TRANSMISSION

1. If removed, position the rear transmission mount bracket to the transmission and tighten the retaining
bolts (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .

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 2. Position the rear transmission mount isolator to the rear transmission mount bracket, install the retaining
bolts (1) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .

3. Position the transmission crossmember, install the retaining bolts (1, 3) finger tight.
4. Install the rear transmission mount isolator retaining bolts (2) finger tight.
5. Tighten the transmission crossmember retaining bolts (1, 3) to the proper specification. Refer to
TORQUE SPECIFICATIONS .
6. Lower the transmission and remove the jack.
7. Tighten the rear transmission mount isolator retaining bolts (2) to the proper specification. Refer to
TORQUE SPECIFICATIONS .
MANUAL TRANSMISSION

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 1. Install the rear transmission mount isolator (2). Tighten the bolts (1) to the proper specification. Refer to
TORQUE SPECIFICATIONS .

2. Install the rear cross member and tighten bolts (1) finger tight.
3. Install the rear transmission mount isolator nuts (2) and tighten finger tight.
4. Tighten the transmission crossmember bolts to the proper specification. Refer to TORQUE
SPECIFICATIONS .
5. Lower the transmission and remove the jack.
6. Tighten the rear transmission mount isolator retaining nuts to the proper specification. Refer to TORQUE
SPECIFICATIONS .

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 LUBRICATION
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE

1. Remove oil pressure sending unit and install gauge assembly (special tool #C-3292A, Gauge, Pressure).
2. Run engine until thermostat opens.
3. Check oil pressure gauge:
Curb Idle - 90 kPa (13 psi) minimum
3000 RPM - 170 - 758 kPa (25 - 110 psi)
4. If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief
valve stuck open.

ENGINE OIL LEAK

Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil
leak source is not readily identifiable, the following steps should be followed:

1. Do not clean or degrease the engine at this time because some solvents may cause rubber to swell thus
temporarily stopping the leak.
2. Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil
leak. If the oil leak is found and identified, repair per service information procedures.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat
inspection.

NOTE: If the oil indicator tube is located in the engine oil pan. A plug (1) is

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 inserted into the hole on the engine block (2). Validation of the plug is
required when the engine block has been replaced.

AIR LEAK DETECTION TEST METHOD

1. Remove the PCV valve, cap or plug the PCV valve port at the intake manifold.
2. Attach an air hose with a pressure gauge and regulator onto 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, proceed with the Inspection For Rear Seal Area Leaks
below.
5. If no leaks are detected, turn off the air supply and remove the air hose from the dipstick tube.
6. Remove the PCV port plug or cap at the intake manifold and install the PCV valve.
7. 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. If the
oil leak is found and identified, repair per service information procedures.
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 and isolate the negative battery cable.

2. Raise and support the vehicle.
3. Remove torque converter or clutch housing inspection cover.
4. Using a black light and inspect the rear of the engine block for evidence of oil.

Circular spray pattern on the rear of the engine block generally indicates:

Rear crankshaft oil seal

Damaged crankshaft

Oil running straight down the back of the engine block generally indicates:

Porous engine block

Camshaft core hole plug
Oil gallery pipe plug
Oil pan gasket
5. If no leaks are detected, pressurize the crankcase as outlined in the Air Leak Detection Test Method .

CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test
pressure.

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 6. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected
between the crankshaft and crankshaft oil 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 machined
specifically to complement the function of the rear oil seal.

7. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled.

SOLENOID, VARIABLE VALVE TIMING (VVTS), EXHAUST

DESCRIPTION

The 6.2L engine is equipped with Variable Valve Timing (VVT). This system uses a Variable Valve Timing
Solenoid (VVTS) to control the oil pressure to direct oil pressure to the camshaft phaser assembly. The
camshaft phaser assembly advances and/or retards camshaft timing to improve engine performance, mid-range
torque, idle quality, fuel economy and reduce emissions. The VVTS (2) is located under the supercharger
assembly.

OPERATION

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 The Variable Cam Timing (VCT) assembly is actuated with engine oil pressure. The oil flow to the VCT
assembly is controlled by an Variable Valve Timing Solenoid (VVTS). The VVTS consists of a Pulse Width
Modulated (PWM) solenoid and a spool valve. The Powertrain Control Module (PCM) actuates the VVTS to
control oil flow through the spool valve into the VCT assembly. The VCT assembly consists of a rotor and a
stator/sprocket. The stator/sprocket is connected to the timing chain. The rotor is connected to the camshaft. Oil
flow into the VCT assembly rotates the rotor with respect to the stator, thus rotating the camshaft with respect to
the stator/sprocket. This will rotate both the intake and exhaust lobes on the camshaft by the same amount. The
intake and exhaust lobes can not be individually controlled with this VCT system. An infinitely variable valve
timing position can be achieved within the limits of the hardware. The camshaft position sensor monitors the
position of the camshaft with respect to the crankshaft and provides feedback to the PCM.

REMOVAL

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 NOTE: The Variable Valve Timing Solenoid (VVTS) (2) is located under the
supercharger assembly.

1. Remove the supercharger. Refer to SUPERCHARGER, INSTALLATION.

2. Disconnect VVTS electrical connector (1).
3. Remove VVTS retaining bolt (3).

NOTE: To remove the VVTS, the engine must be at room temperature.

4. Rotate the VVTS to break the seal and remove.

INSTALLATION

1. Lubricate the Variable Valve Timing Solenoid (VVTS) rubber O-ring seal with clean engine oil.

2. Install the VVTS (2) and rotate into position.

3. Install the VVTS retaining bolt (3) and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
4. Connect VVTS electrical connector (1).
5. Install the supercharger. Refer to SUPERCHARGER, INSTALLATION.

COOLER, OIL
DESCRIPTION

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 The engine oil cooler (2) is engineered for maximum cooling efficiency with no restriction in oil flow. The oil
cooler is mounted (1) behind the front fascia, on the right side of the vehicle.

The engine oil cooler uses the external air flow across cooling fins, to maintain a consistent engine oil
temperature.

NOTE: The engine oil cooler contains an additional drain plug that must be removed
when changing engine oil.

REMOVAL

CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler and lines
must be replaced or damage to the new engine or components could result.

1. Remove the front fascia. Refer to FASCIA, FRONT, REMOVAL .

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 2. Drain the engine oil from the oil cooler, using the drain plug located on the bottom of the oil cooler.
3. Use a commercially available low profile 3/4" quick release tool to disconnect the lines (2) from the oil
cooler.
4. If replacing the oil cooler lines, use a commercially available low profile 3/4" quick release tool to
disconnect the lines (1) from the oil filter adapter.

5. Remove the fasteners (2) from the oil cooler shroud (1) and remove the shroud.

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 6. Remove the oil cooler retaining bolts (1) and remove the oil cooler (2).

7. If replacing the oil filter adapter (2), remove the oil filter (1) from the oil filter adapter.
8. Remove the oil filter adapter retaining screw.

NOTE: Whenever the oil filter adapter is serviced, the rubber O-ring seal must be
replaced.

INSTALLATION

CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler and lines
must be replaced or damage to the new engine or components could result.

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 NOTE: Whenever the oil filter adapter is serviced, the rubber O-ring seal must be
replaced.

1. Clean the sealing surface of the oil cooler and install a new rubber O-ring seal.
2. Lightly lubricate the oil cooler rubber O-ring seal with clean engine oil.

3. Install the oil filter adapter retaining screw and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
4. Lightly lubricate the oil filter gasket with clean engine oil.

NOTE: Do not over tighten the oil filter.

5. Thread the oil filter (1) onto the oil filter adapter (2) oil filter boss.
6. When the oil filter gasket makes contact with the oil cooler sealing surface, hand tighten the oil filter one
half turn, or 180°.

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 7. Install the oil cooler (2) retaining bolts (1) and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .

8. Position the oil cooler shroud (1) to the oil cooler and install the retainers (2).

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 9. Connect the oil cooler lines to the quick connect fittings on the oil filter adapter (1) and the oil cooler (2).

NOTE: Gently pull outward on each line after connected to verify a secure
connection.

10. Install the front fascia. Refer to FASCIA, FRONT, INSTALLATION .

11. Fill the engine oil. Refer to STANDARD PROCEDURE .
12. Start the engine and check for leaks.
13. Turn the engine off and check the oil level.

FILTER, ENGINE OIL

REMOVAL

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 1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
2. Remove the belly pan retainers (1) and remove the belly pan.
3. Position a drain pan under the oil filter.

4. Using a suitable oil filter wrench, rotate the oil filter (2) counterclockwise to remove it from the oil filter
adapter.
5. When the oil filter separates from the oil filter adapter, keep the gasket end upward to minimize oil spill
and remove the oil filter from vehicle.

NOTE: Make sure the oil filter gasket was removed with the oil filter.

6. Using a wiping cloth, clean the oil cooler gasket sealing surface of oil and grime.

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 INSTALLATION

1. Lightly lubricate the oil filter gasket with clean engine oil.

NOTE: Do not over tighten the oil filter.

2. Thread the oil filter (2) onto the oil filter adapter.
3. When the oil filter gasket makes contact with the oil filter adapter sealing surface, hand tighten the oil
filter one half turn, or 180°.

4. Position the belly pan to the under side of the vehicle and install the retainers (1).
5. Remove the support and lower the vehicle.

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 6. Fill the crankcase with the specified type and amount of engine oil. Refer to STANDARD
PROCEDURE .
7. Install the oil fill cap.
8. Start the engine and check for leaks.
9. Turn the engine off and check the oil level.

JET, PISTON OIL COOLER

DESCRIPTION

Four dual-nozzle oil jets are bolted to the cylinder block underneath the main oil gallery. The jets connect with
an oil-tight fit to the main gallery through lubrication passages. Each oil jet helps cool the two opposing pistons.

REMOVAL

1. Remove the oil pan and oil pump pickup tube. Refer to REMOVAL .

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 NOTE: It may be necessary to rotate the engine crankshaft to access the piston
oil cooler jet retaining bolts.

2. Remove the piston oil cooler jet retaining bolt (2).

3. Remove the piston oil cooler jet (1).

INSTALLATION

1. Position the piston oil cooler jet (1).

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 2. Install the piston oil cooler jet retaining bolt 2) and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
3. Install the engine oil pump pickup tube and oil pan. Refer to INSTALLATION .

OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL SERVICE
CRANKCASE OIL LEVEL INSPECTION

The oil level indicator is located on the right side of the engine.

CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can
result.

Inspect the 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 the oil level. Checking the 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 level indicator.

1. Position the vehicle on the level surface.

2. With the engine off, allow approximately five minutes for the oil to settle to the bottom of the crankcase
and then remove the engine oil level indicator.
3. Wipe the oil level indicator clean.
4. Install the oil level indicator and verify it is seated in the tube.
5. Remove the oil level indicator, with the handle held above the tip, observe the oil level reading.
6. Add oil only if the level is below the ADD mark on the oil level indicator.
ENGINE OIL CHANGE

Change the engine oil at the mileage and time intervals described in the Maintenance Schedules. Refer to
MAINTENANCE SCHEDULES, DESCRIPTION .

1. Run the engine until it reaches normal operating temperature, then shut off the engine.
2. Remove the oil fill cap.
3. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
4. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
5. Place a suitable drain pan under the oil pan drain.

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 6. Remove the drain plug (1) from the oil pan and allow the oil to drain.
7. Remove the oil filter (2).

8. Place a suitable drain pan under the engine oil cooler.

9. Remove the drain plug (1) from the engine oil cooler and allow the oil to drain.

NOTE: Allow oil to drain until there is only one drip every second, approximately
five minutes.

10. Lightly lubricate the NEW oil filter gasket with clean engine oil.
11. Fill the NEW oil filter with fresh engine oil.

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 12. Thread the oil filter onto the oil filter adapter.

NOTE: Do not over tighten the oil filter.

13. When the oil filter gasket makes contact with the oil filter adapter sealing surface, hand tighten the oil
filter one half turn, or 180°.
14. Clean any residual oil that may have dripped onto the oil cooler hoses (3, 4)

15. Inspect the drain plug threads for stretching or other damage and replace if necessary.
16. Install both drain plugs and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
17. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
18. Lower the vehicle and fill the crankcase with the specified type and amount of engine oil. Refer to
CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
19. Install the oil fill cap.
20. Start the engine and check for leaks.
21. Stop the engine and after five minutes, check the oil level.

NOTE: Care should be exercised when disposing of used engine oil.

PAN, OIL
REMOVAL

1. Disconnect and isolate the negative battery cable.

2. Remove the supercharger assembly. Refer to SUPERCHARGER, REMOVAL.

3. Remove the engine oil tube fastener (1) from the exhaust manifold.
4. Remove the engine oil dipstick and tube (2) from the oil pan.

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 5. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .

6. Remove the belly pan retainers (1) and remove the belly pan.

7. Drain the engine oil (1) and remove the oil filter (2).

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 NOTE: Do not remove the tie rod ends or disconnect the steering column coupler.

8. Remove the steering gear mounting bolts (1) and lower the steering gear (2) to provide clearance to
remove the oil pan.

9. Remove both left/right front engine mount heat shield retaining nuts (3) and remove the heat shields (4).
10. Remove both left/right front engine mount lower retaining bolts (2).
11. Lower the vehicle.

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 NOTE: Do not use air tools to install engine lift fixture.

12. Install the Engine Lift Fixture (special tool #8984B, Fixture, Engine Lifting) (1), Engine Lift Adapter
(special tool #8984-UPD, Adapter, Engine Lift) (3) and the Engine Support Fixture (special tool #8534C,
Fixture, Driveline Support) (2).
13. Raise the engine to provide clearance to remove the oil pan.

NOTE: Do not pry on the oil pan or oil pan gasket. The oil pan gasket is integral to
the engine windage tray and does not come out with the oil pan.

NOTE: The horizontal M10 retaining bolts (11, 12, 15, 18) are 5 mm longer in
length then the vertical M10 retaining bolts (20, 21, 22, 23) and must be
reinstalled in their original locations.

14. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
15. Remove the M10 retaining bolts (horizontal 11, 12, 15, 18 and vertical 20, 21, 22, 23) from the rear of the

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 oil pan to the transmission.
16. Remove the M6 retaining bolts and remove the oil pan.

NOTE: When the oil pan is removed, a new oil pan gasket and the integral
windage tray assembly must be installed, the old gasket cannot be reused.

17. Remove the oil pump pickup tube retaining bolt and nut.
18. Remove the oil pump pickup tube.
19. Remove and discard the oil pan gasket/windage tray.

INSTALLATION

NOTE: Mopar® Engine RTV must be applied to the 4 T-joints, the area where the front
cover, rear retainer and oil pan gasket meet. The bead of RTV should cover the
bottom of the gasket. This area is approximately 4.5 mm x 25 mm in each of the
4 T-joint locations.

1. Clean the oil pan gasket mating surface of the engine block and oil pan.
2. Apply Mopar® Engine RTV at the 4 T- joints (1, 2).

NOTE: When the oil pan is removed a NEW oil pan gasket and the integral
windage tray assembly must be installed, the old gasket cannot be reused.

3. Install a NEW oil pan gasket/windage tray.

4. Using a NEW O-ring, position the oil pump pickup tube into the oil pump.
5. Install the oil pump pickup tube retaining bolt and nut and tighten to the proper specification. Refer to
TORQUE SPECIFICATIONS .

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 Fig. 8: Oil Pan Bolts Loosening/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

NOTE: The horizontal M10 retaining bolts (11, 12, 15, 18) are 5 mm longer in
length then the vertical M10 retaining bolts (20, 21, 22, 23) and must be
reinstalled in their original locations.

NOTE: NEW M6 retaining bolts must be used when reinstalling the oil pan. Do not
reuse the old M6 retaining bolts.

6. Align the rear of the oil pan with the rear face of the engine block and install the M10 and M6 retaining
bolts finger tight.
7. Using the sequence shown in illustration, tighten the M6 retaining bolts to 5 N.m (44 in. lbs.).
8. Using the sequence shown in illustration, tighten the M10 retaining bolts to 54 N.m (40 ft. lbs.).
9. Using the sequence shown in illustration, tighten the M6 retaining bolts to 12 N.m (9 ft. lbs.).
10. Lower the vehicle.

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 11. Using the Engine Lift Fixture (special tool #8984B, Fixture, Engine Lifting) (1), Engine Lift Adapter
(special tool #8984-UPD, Adapter, Engine Lift) (3) and the Engine Support Fixture (special tool #8534C,
Fixture, Driveline Support) (2) lower the engine into position and remove.
12. Install the engine oil dipstick tube and dipstick.
13. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .

14. Install both engine mount lower retaining bolts (2) and tighten to the proper specification. Refer to
TORQUE SPECIFICATIONS .
15. Position both engine mount heat shields (4) and install retaining nuts (3).

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 16. Position the steering gear (2), install mounting bolts (1) and tighten to the proper specification. Refer to
TECHNICAL SPECIFICATIONS .

17. Lightly lubricate the oil filter gasket with clean engine oil.

NOTE: Do not over tighten the oil filter.

18. Install the oil pan drain plug (1) and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
19. Thread the oil filter (2) onto the oil filter adapter.
20. When the oil filter gasket makes contact with the oil cooler sealing surface, hand tighten the oil filter one

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 half turn, or 180°.

21. Install the oil dipstick and tube (2) into the oil pan and tighten the fastener to the proper specification.
Refer to TORQUE SPECIFICATIONS .

22. Position the belly pan to the under side of the vehicle and install the belly pan retainers (1).
23. Lower the vehicle.
24. Install the supercharger assembly. Refer to SUPERCHARGER, INSTALLATION.
25. Fill the engine with oil. Refer to STANDARD PROCEDURE .
26. Connect the negative battery cable.
27. Start the engine and check for leaks.

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 PUMP, ENGINE OIL
REMOVAL

1. Remove the engine timing cover. Refer to REMOVAL .

2. Remove the oil pan and oil pump pickup tube. Refer to REMOVAL .

3. Remove the oil pump retaining bolts (2) and remove the oil pump (1).

INSPECTION

1 - FEELER GAUGE

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 2 - OUTER ROTOR

CAUTION: Oil pump pressure relief valve and spring should not be removed from the oil
pump. If these components are disassembled and or removed from the pump
the entire oil pump assembly must be replaced.

1. Remove the pump cover.

2. Clean all parts thoroughly. The mating surface of the oil pump housing should be smooth. If the oil pump
cover is scratched or grooved the oil pump assembly should be replaced.
3. Slide the outer rotor into the body of the oil pump. Press the outer rotor to one side of the oil pump body
and measure the clearance between the outer rotor (2) and the body. If the measurement is 0.306 mm
(0.012 in.) or greater the oil pump assembly must be replaced.

1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR

4. Install the inner rotor into the oil pump body. Measure the clearance between the inner (3) and outer (1)
rotors. If the clearance between the rotors is 0.200 mm (0.008 in.) or greater the oil pump assembly must
be replaced.

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 1 - STRAIGHT EDGE
2 - FEELER GAUGE

5. Place a straight edge (1) across the body of the oil pump (between the bolt holes), using a feeler gauge
(2), measure the clearance between the straightedge and the rotors. If the clearance is 0.060 mm (0.002
in.) or greater the oil pump must be replaced.
6. Install the pump cover and tighten retainers to the proper specification. Refer to TORQUE
SPECIFICATIONS .

NOTE: The oil pump is serviced as an assembly. In the event the oil pump is not
functioning or out of specification it must be replaced as an assembly.

INSTALLATION

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 1. Gently push the oil pump (1) upwards and press firmly against the block. finger tighten all of the
retaining bolts (2) to ensure that the pump is fixed in it's position.

Fig. 9: Oil Pump Retaining Bolt Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

2. Using the sequence shown in illustration, tighten the oil pump retaining bolts to the proper specification.
Refer to TORQUE SPECIFICATIONS .
3. Install the timing chain cover. Refer to INSTALLATION .
4. Install the oil pump pickup tube and oil pan. Refer to INSTALLATION .

SENSOR, OIL PRESSURE

DESCRIPTION

The oil pressure sensor uses the following three circuits:

Signal circuit to the PCM

Sensor ground circuit through the PCM
5 volt reference circuit from the PCM

The oil pressure sensor returns a voltage signal back to the PCM with reference to oil pressure. Ground for the
sensor is supplied by the PCM.

The oil pressure sensor is located on the right side of the engine block. The sensor screws into the engines main
oil gallery.

REMOVAL

1. Remove the generator. Refer to GENERATOR, REMOVAL .

2. Position the generator aside to gain access to the oil pressure sensor.

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 3. Disconnect the oil pressure sensor wire harness connector (1).

4. Remove the oil pressure sensor (1).

INSTALLATION

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 NOTE: Apply Mopar® Thread Sealant with PTFE to the sensor threads before
installing into the engine block.

1. Install the oil pressure sensor (1) and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .

2. Connect the oil pressure sensor wire harness connector (1).

3. Install the generator. Refer to GENERATOR, INSTALLATION .

SENSOR, OIL TEMPERATURE

DESCRIPTION

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 The oil temperature sensor uses the following two circuits:

Signal circuit to the PCM

Ground circuit from the PCM

The oil temperature sensor is a Negative Thermal Coefficient sensor. The resistance of the sensor changes as oil
temperature changes. This results in different output voltages back to the PCM.

The oil temperature sensor is located on the right side of the engine block.

REMOVAL

1. Remove the generator. Refer to GENERATOR, REMOVAL .

2. Position the generator aside to gain access to the oil temperature sensor.

3. Disconnect the oil temperature sensor wire harness connector (1).

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 4. Remove the oil temperature sensor (1).

INSTALLATION

NOTE: Apply Mopar® Thread Sealant with PTFE to the sensor threads before
installing into the engine block.

1. Install the oil temperature sensor (1) and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .

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 2. Connect the oil temperature sensor wire harness connector (1).
3. Install the generator. Refer to GENERATOR, INSTALLATION .

MANIFOLDS
MANIFOLD, EXHAUST
DESCRIPTION

The exhaust manifolds are tube in shell air gap design to maximize durability and performance. The exhaust
manifolds are made of stainless steel stamped shells and stainless steel tubes with a powdered metal outlet. A
layered graphite over perforated steel manifold gasket is used to provide sealing to the cylinder head.

OPERATION

The exhaust manifolds collect the engine exhaust gases exiting the combustion chambers and then channels the
exhaust gases to the exhaust pipes/catalytic converters.

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 REMOVAL

NOTE: The left side shown in illustration. Right side similar.

1. Disconnect and isolate the negative battery cable.

2. Remove cylinder head. Refer to CYLINDER HEAD, REMOVAL .

3. Remove the exhaust manifold bolts using the sequence shown in illustration, starting at eight and going
backwards.

INSPECTION

Inspect the exhaust manifold for cracks.

Inspect the mating surface of the exhaust manifold for flatness with a straight edge. The exhaust manifold
gasket surface must be flat and within 0.67 mm (0.0264 in.) overall.

INSTALLATION

NOTE: Left side shown in illustration. Right side similar.

1. Clean the sealing surfaces of the exhaust manifold and cylinder head.
2. Using a new exhaust manifold gasket, position the exhaust manifold to the cylinder head.

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 Fig. 10: Exhaust Manifold Loosening/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

3. First install the NEW exhaust manifold retaining bolts finger tight.
4. Using the sequence shown in illustration, tighten the retaining bolts to the proper specification. Refer to
TORQUE SPECIFICATIONS .
5. Install the cylinder head. Refer to INSTALLATION .
6. Connect the negative battery cable.
7. Start the engine and check for leaks.

SUPERCHARGER SYSTEM
BELT, DRIVE
DESCRIPTION

The supercharger drive belt is a serpentine type belt. The supercharger drive belt is separate from the accessory
drive belt. Satisfactory performance of these belts depends on belt condition and proper belt tension.

REMOVAL

1. Remove the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL .

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 2. Release the belt tension by rotating the tensioner (1) clockwise . Rotate the belt tensioner until the belt (2)
can be removed from pulleys.
3. Remove the belt.
4. Gently release the tensioner.

INSTALLATION

1. Position the drive belt (2) over all pulleys, except for the idler pulley.
2. Rotate the tensioner (1) clockwise and slip the belt over the idler pulley.
3. Gently release tensioner.

DECOUPLER

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 DESCRIPTION

The decoupler is the drive pulley assembly for the supercharger. It contains a one way clutch, engaged in the
drive direction. Load impulses are isolated by driving through a heavy coil spring.

REMOVAL

The decoupler is serviced as an assembly with the supercharger inlet nose. For removal, refer to NOSE,
INLET, REMOVAL.

INSTALLATION

The decoupler is serviced as an assembly with the supercharger inlet nose. For installation, refer to NOSE,
INLET, INSTALLATION.

NOSE, INLET
REMOVAL

1. Remove the supercharger. Refer to SUPERCHARGER, REMOVAL.

NOTE: Wipe down the lid, rotor case, inlet nose, fuel rail and water manifold
before removing the lid.

2. Remove the four throttle body retaining screws and remove the throttle body from the inlet nose.
3. Remove and discard the throttle body inlet seal.

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 4. Remove the five long lid retaining screws (1).

5. Remove the sixteen short lid retaining screws (1).

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 6. Remove the lid, using the tab on the rear of the supercharger (1) and discard the lid gasket.

NOTE: The six cooler retention seals must remain with the lid.

7. Remove and discard the three lid tower O-ring seals from the supercharger.

8. Remove the three bypass throttle body adapter retaining screws and remove the adapter from the inlet
nose.
9. Inspect the seals for damage and discard if necessary.
10. Remove the TMAP sensor from the inlet nose and discard the fastener.

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 11. Remove the six inlet nose retaining screws (1-6).
12. Remove the inlet nose from the supercharger and discard the gasket and retaining screws.

13. Thread a M6 tap into the inlet nose to supercharger bushing approximately 1/4 inch deep (1).
14. Pull outward to remove the bushing from the rotor side coupler.
15. Repeat this step for the seven remaining bushings and discard the bushings.

INSTALLATION

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 1. Press the NEW supercharger to inlet nose bushings into the coupler bore.

NOTE: It may be necessary to gently tap the bushing into the bore using a small
plastic or rubber mallet.

NOTE: Caution must be used to not make contact with the aluminum inlet bearing
housing, or damage may occur.

Fig. 11: Supercharger Inlet Nose Loosening/Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

2. Using a NEW inlet nose gasket, install the inlet nose to the supercharger.
3. Using the sequence shown in illustration, tighten the NEW inlet nose retaining screws to 35 N.m (26 ft.

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 lbs.).

4. Install the bypass adapter onto the inlet nose, using a NEW gasket if necessary.
5. Tighten the bypass adapter retaining screws to the proper specification. Refer to TORQUE
SPECIFICATIONS .
6. Lubricate the bypass adapter cuff (1) using clean engine oil.
7. Install the three NEW lid tower O-rings to the supercharger.
8. Lubricate the TMAP sensor O-ring seal with clean engine oil.
9. Install the TMAP sensor into the inlet nose and tighten the NEW fastener to the proper specification.
Refer to FUEL INJECTION, GAS, TECHNICAL SPECIFICATIONS .

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 10. Install a NEW lid gasket (1) onto the supercharger.

11. Verify that the six cooler retention seals (1) are assembled in the lid.
12. Align the lid onto the supercharger.
13. Press the lid, above the bypass throttle body, into the cuff. The bypass throttle body will be partially
seated in the cuff.

14. Using the sequence shown in illustration, tighten the retaining screws to 10 N.m (7 ft. lbs.).
15. Using the sequence shown in illustration, torque the five long lid fasteners (1-5) again, to 10 N.m (7 ft.
lbs.).
16. Using a NEW seal, install the throttle body onto the inlet nose and torque the four retaining screws to the
proper specification. Refer to FUEL INJECTION, GAS, TECHNICAL SPECIFICATIONS .
17. Install the supercharger. Refer to SUPERCHARGER, INSTALLATION.

PULLEY, IDLER
REMOVAL
LOWER

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 1. Remove accessory drive belt. Refer to TENSIONER, BELT, REMOVAL .

2. Remove the supercharger drive belt (2). Refer to BELT, DRIVE, REMOVAL.
3. Remove the retaining bolt (1) and idler pulley.
UPPER

1. Remove accessory drive belt. Refer to TENSIONER, BELT, REMOVAL .

2. Remove the supercharger drive belt (1). Refer to BELT, DRIVE, REMOVAL.
3. Remove the retaining bolt (2) and idler pulley.

INSTALLATION

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 LOWER

1. Using a NEW bolt (1) coated with red loctite®, install the idler pulley and tighten the bolt (1) to the
proper specification. Refer to TORQUE SPECIFICATIONS .
2. Install the supercharger drive belt (2). Refer to BELT, DRIVE, INSTALLATION.
3. Install accessory drive belt. Refer to BELT, SERPENTINE, INSTALLATION .
UPPER

1. Using a NEW bolt (1) coated with red loctite®, install the idler pulley and tighten the retaining bolt (2)
to the proper specification. Refer to TORQUE SPECIFICATIONS .
2. Install the supercharger drive belt (1). Refer to BELT, DRIVE, INSTALLATION.

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 3. Install the accessory drive belt. Refer to BELT, SERPENTINE, INSTALLATION .

SUPERCHARGER
DESCRIPTION
DESCRIPTION AND OPERATION

A supercharger is an air compressor that increases the pressure or density of air supplied to the engine. This
gives each intake cycle of the engine more oxygen, letting it burn more fuel and do more work, increasing
power.

The twin-screw supercharger has integral charge air coolers and an integrated 64 mm electronic bypass valve to
regulate boost pressure. The supercharger has a drive ratio of 2.36:1 and a maximum speed of 14, 600 RPM.
The one-way clutch de-coupler improves refinement without detracting from the engine noise. The supercharger
intakes air through a 92 mm throttle body.

REMOVAL

1. Perform the fuel system pressure release procedure. Refer to FUEL DELIVERY, GAS, STANDARD
PROCEDURE .
2. Disconnect and isolate the negative battery cable.
3. Remove the cowl cover panel. Refer to COVER, COWL PANEL, REMOVAL .
4. Drain the low temperature cooling system. Refer to STANDARD PROCEDURE .
5. Remove the air cleaner body. Refer to REMOVAL .

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 6. Remove the engine covers (1).
7. Remove the supercharger belt. Refer to BELT, DRIVE, REMOVAL.

8. Remove the fuel purge hose (2) from the top of the supercharger nose (1).
9. Remove the brake booster vacuum supply hose, located under the nose of the supercharger.

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 10. Remove the Positive Crankcase Ventilation (PCV) hose (1) from the right side of the supercharger nose
(2).

11. Disconnect the throttle body wire harness connector at the nose of the supercharger.
12. Disconnect the bypass valve wire harness connector (3).
13. Disconnect the bank one (1) and throttle outlet (2) Temperature-Manifold Absolute Pressure (TMAP)
sensor wire harness connectors.

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 14. Disconnect the wire harness connector (2) from the bank two TMAP sensor (3).

15. Disconnect the wire harness connector (2) from the intermediate TMAP sensor (1).

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 16. Disconnect the wire harness connect from the charge air cooler temperature sensor, located on the
crossover tube.
17. Remove Low Temp Radiator (LTR) circuit hoses from coolant crossover (1).

NOTE: Mark which hose connects to top and bottom of coolant crossover.

18. Disconnect the fuel supply line (1) from the fuel rail (2). Refer to FITTING, QUICK CONNECT,
STANDARD PROCEDURE .

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 19. Disconnect the fuel injector connectors (1) from both sides of supercharger.

20. Remove the supercharger to cylinder head retaining bolts, starting with number ten, going backwards to
number one.

NOTE: The supercharger assembly will require the help of an assistant(s) to lift
from the engine compartment.

21. Lift the supercharger upward to disengage the dowels which align the supercharger to the right cylinder
head.

NOTE: Take care not to damage supercharger to cylinder head intake gaskets

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 during removal.

INSTALLATION
INSTALLATION

NOTE: The supercharger assembly will require the help of an assistant(s) to install the
assembly into the engine compartment.

1. Inspect the seals and replace if necessary.

2. Position the supercharger assembly onto the cylinder heads, aligning the dowels in the supercharger with
the holes cylinder head.

Fig. 12: Supercharger Loosening/Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

3. Using the sequence shown in illustration, Install the supercharger retaining bolts and tighten all retaining
bolts as follows:
First tighten all bolts, using the sequence, to 5 N.m (4 ft. lbs.).
Next tighten all bolts, using the sequence, to 15 N.m (11 ft. lbs.).
Finally tighten all bolts, using the sequence, to 30 N.m (22 ft. lbs.).

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 4. Connect the fuel supply line (1) to the fuel rail (2). Refer to FITTING, QUICK CONNECT,
STANDARD PROCEDURE .

5. Install the Low Temperature Radiator (LTR) circuit hoses to coolant crossover (1).

NOTE: Use previous markings to determine hose location.

6. Connect the wire harness connector to the charger air cooler temperature sensor, located on the crossover
tube.

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 7. Connect the fuel injector wire harness connectors (1) on both sides of supercharger.

8. Connect the wire harness connector (2) to the intermediate Temperature-Manifold Absolute Pressure
(TMAP) sensor (1).

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 9. Connect the wire harness connector (2) to the bank two TMAP sensor (3).

10. Connect bank one (1) and throttle outlet (2) TMAP sensor wire harness connectors.
11. Connect the wire harness connector to the throttle body at nose of supercharger.
12. Connect the bypass valve wire harness connector (3).

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 13. Install the Positive Crankcase Ventilation (PCV) hose (1) to the right side of supercharger nose (2).

14. Install the fuel purge hose (2) to the top of the supercharger nose (1).
15. Install the brake booster hose, located under the nose of the supercharger.
16. Install the supercharger belt. Refer to BELT, DRIVE, INSTALLATION.

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 17. Install the engine covers.
18. Install the air cleaner body. Refer to INSTALLATION .
19. Install the cowl cover panel. Refer to COVER, COWL PANEL, INSTALLATION .
20. Fill the cooling system. Refer to STANDARD PROCEDURE .

NOTE: Evacuating or purging air from the charge air cooling system must be
done with the use of a pressurized air operated vacuum generator.

21. Connect the negative battery cable.

TENSIONER, DRIVE BELT

REMOVAL

1. Remove the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL .

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 2. Remove the supercharger drive belt (2). Refer to BELT, DRIVE, REMOVAL.
3. Remove belt tensioner retaining bolt (3) and the belt tensioner.
4. If necessary, remove the three mounting bracket bolts (1) and remove the bracket.

INSTALLATION

1. If removed, install the mounting bracket and tighten the retaining bolts (1) to the proper specification.
Refer to TECHNICAL SPECIFICATIONS .
2. Install the belt tensioner retaining bolt (3) and tighten to the proper specification. Refer to TECHNICAL
SPECIFICATIONS .
3. Install the supercharger drive belt (2). Refer to BELT, DRIVE, INSTALLATION.

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 4. Install the accessory drive belt. Refer to BELT, SERPENTINE, INSTALLATION .

VALVE, BYPASS
REMOVAL

1. Disconnect and isolate the negative battery cable.

2. Remove the cowl cover panel. Refer to COVER, COWL PANEL, REMOVAL .

3. Remove the engine covers (1).

4. Remove the fuel purge hose (2) from the top of the supercharger nose (1).

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 5. Disconnect the bypass valve wire harness connector (3).

6. Disconnect the wire harness connector (2) from the intermediate TMAP sensor (1).

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 7. Wipe down the lid, rotor case, inlet nose, fuel rail and water manifold before removing the lid.
8. Remove the supercharger to cylinder head retaining bolts, starting with number ten, going backwards to
number one.

9. Remove the five long lid retaining screws (1).

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 10. Remove the sixteen short lid retaining screws (1).

11. Remove the lid, using the tab on the rear of the supercharger (1) and discard the lid gasket.

NOTE: The six cooler retention seals must remain with the lid.

12. Place the lid, upside down on a clean a dry surface.

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 13. Remove the bypass retaining screws (1).

14. Remove and discard the bypass seal.

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 15. Inspect the cooler retention seals (1) for damage and discard if necessary.

INSTALLATION

1. Install a NEW bypass seal.

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 Fig. 13: Bypass Valve Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

2. Position the bypass to the lid and torque the retaining screws, using the sequence shown in illustration, to
10 N.m (7 ft. lbs.).

3. Inspect the bypass adapter cuff, and replace if necessary.

4. Lubricate the bypass adapter cuff (1) using clean engine oil.

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 5. Install a NEW lid gasket (1) onto the supercharger.

6. Inspect the cooler retention seals and replace if necessary.

7. Verify that the cooler retention seals (1) are assembled in the lid.
8. Align the lid onto the supercharger.
9. Press the lid, above the bypass throttle body, into the cuff. The bypass throttle body will be partially
seated in the cuff.

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 Fig. 14: Supercharger Long Lid Fasteners Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

10. Using the sequence shown in illustration, tighten the retaining screws to 10 N.m (7 ft. lbs.).
11. Using the sequence shown in illustration, torque the five long lid fasteners 1-5 again, to 10 N.m (7 ft.
lbs.).

12. Using the sequence shown in illustration, Install the supercharger to cylinder head retaining bolts and
tighten as follows:
First tighten all bolts, using the sequence, to 5 N.m (4 ft. lbs.).
Next tighten all bolts, using the sequence, to 15 N.m (11 ft. lbs.).
Finally tighten all bolts, using the sequence, to 30 N.m (22 ft. lbs.).

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 13. Connect the wire harness connector (2) to the intermediate TMAP sensor (1).

14. Connect the bypass valve wire harness connector (3).

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 15. Install the fuel purge hose (2) to the top of the supercharger nose (1).

16. Install the engine covers (1).

17. Install the cowl cover panel. Refer to COVER, COWL PANEL, INSTALLATION .
18. Connect the negative battery cable.

VALVE TIMING
CHAIN AND SPROCKETS, TIMING
REMOVAL

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 1. Remove the engine oil pump. Refer to PUMP, ENGINE OIL, REMOVAL .

2. 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).

3. Retract the chain tensioner arm (1) until the hole in the arm lines up with the hole in the bracket.

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 4. 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.

5. Remove the camshaft phaser retaining bolt (1) and remove the timing chain with the camshaft phaser and
crankshaft sprocket.

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 NOTE: Inspect the timing chain tensioner and timing chain guide shoes for wear
and replace as necessary.

6. If the timing chain tensioner is to be replaced, remove the retaining bolts (3) and remove the timing chain
tensioner (2).

7. If the timing chain guide (1) is to be replaced, remove the retaining bolts (2) and remove the timing chain
guide (1).

INSTALLATION

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 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.

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 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.

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 6. If removed, install the timing chain guide (1) and tighten the bolts (2) to the proper specification. Refer to
TORQUE SPECIFICATIONS .

7. If removed, install the timing chain tensioner (2) and tighten the bolts to the proper specification. Refer to
TORQUE SPECIFICATIONS .
8. If required, retract the chain tensioner arm and install the Tensioner Pin (special tool #8514, Pins,
Tensioner) (1) into the holes of the chain tensioner arm.

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 9. Using care, rotate the crankshaft to 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) and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
11. Install the engine oil pump. Refer to INSTALLATION .
12. Start the engine and check for leaks.

COVER(S), ENGINE TIMING

REMOVAL

1. Remove the oil pan. Refer to REMOVAL .

2. Remove the support and lower the vehicle.
3. Remove the water pump. Refer to PUMP, WATER, REMOVAL .

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 4. Disconnect the camshaft position sensor wire harness connector (1).
5. Remove A/C compressor from the front timing chain cover and position aside. Refer to COMPRESSOR,
A/C, REMOVAL .
6. Remove the generator from the front timing chain cover and position aside. Refer to GENERATOR,
REMOVAL .
7. Remove the vibration damper. Refer to REMOVAL .

8. Remove the engine timing cover retaining bolts (1) and remove the engine timing cover (1).

INSTALLATION

1. Clean the engine timing cover and engine block surface.

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 NOTE: Always install a NEW gasket when servicing the engine timing cover.

2. Using a NEW gasket, install the engine timing cover (1) and tighten the retaining bolts (2) to the proper
specification. Refer to TORQUE SPECIFICATIONS .
3. Install the vibration damper onto the crankshaft. Refer to INSTALLATION .
4. Install the water pump. Refer to PUMP, WATER, INSTALLATION .
5. Install the oil pump pickup tube (2) and the oil pan. Refer to INSTALLATION .
6. Install the generator. Refer to GENERATOR, INSTALLATION .
7. Install the A/C compressor. Refer to COMPRESSOR, A/C, INSTALLATION .

8. Connect the camshaft position sensor (2) wire harness connector (1).

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 9. Fill the cooling system with the specified type and amount of engine coolant. Refer to STANDARD
PROCEDURE .
10. Change the engine oil filter and fill the crankcase with the specified type and amount of engine oil. Refer
to STANDARD PROCEDURE .
11. Connect the negative battery cable.
12. Perform the Refrigerant System Charge procedure. Refer to PLUMBING, STANDARD PROCEDURE
.
13. Start the engine and check for leaks.

TENSIONER, ENGINE TIMING

DESCRIPTION

The timing chain tensioner is a spring loaded design. It consists of two chain guide shoes. One shoe is fixed in
place and the other is spring loaded to keep tension on the chain.

OPERATION

The timing chain tension is maintained by routing the timing chain through the tensioner assembly. The
tensioner assembly consists of two chain guide shoes. One shoe is fixed in place and the other is spring loaded
to maintain the correct timing chain tension.

For the removal procedure, refer to REMOVAL .

For the installation procedure. Refer to INSTALLATION .

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 Article GUID: A00910351

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