ENGINE

6.4L - Service Information - Chrysler 300

DESCRIPTION
DESCRIPTION

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Fig. 1: 6.4L HEMI V-8 Engine
Courtesy of CHRYSLER GROUP, LLC

The 6.4L HEMI eight-cylinder SRT high performance engine is a 90° V-Type, deep skirt, lightweight
cast iron block with 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. The 6.4L HEMI engine is a bored and stroked version
of the 5.7L HEMI engine developed for SRT high performance vehicles. This engine shares the same
architecture as the 2009 5.7L HEMI with the following Performance Upgrades:

Increased Bore
Increased Stoke
Increased Valve Sizing

The 6.4L HEMI engine also has improved horsepower, torque and fuel economy as compared with
the 6.1L HEMI engine. This is achieved with the larger displacement and the following Technical
Improvements:

Variable Cam Timing (VCT) Cam Phasing System

Multi-Displacement System (MDS)
High Flow Ports
Increased Maximum RPM
Combustion Chamber Shape
Higher Compression Ratio

DIAGNOSIS AND TESTING

ENGINE DIAGNOSIS - INTRODUCTION

Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by

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routine maintenance.

These malfunctions may be classified as either performance e.g., (engine idles rough and stalls) or
mechanical e.g., (a strange noise). For possible causes and corrections of malfunctions, refer to
ENGINE MECHANICAL DIAGNOSIS CHART.

Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that
can not be isolated with the Service Diagnosis charts. For additional Information on diagnosis and
testing, refer to the following tests:

Cylinder Compression Pressure Leakage. Refer to CYLINDER COMPRESSION PRESSURE

LEAKAGE.
Cylinder Combustion Pressure Leakage. Refer to CYLINDER COMBUSTION PRESSURE
LEAKAGE.
Checking Engine Oil Pressure. Refer to CHECKING ENGINE OIL PRESSURE.
Cylinder Head Gasket Failure. Refer to DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET FAILURE.
Intake Manifold Leakage. Refer to DIAGNOSIS AND TESTING - INTAKE MANIFOLD
LEAKAGE.

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 and/or compression 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 reaches normal operating temperature, then turn the engine
OFF.
3. Remove the spark plugs.
4. Remove the oil filler cap.
5. Remove the air cleaner hose.
6. Calibrate the tester according to the manufacturer's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1, 379 kPa (200 psi) maximum and 552 kPa (80 psi)
recommended.
7. Perform the test procedures on each cylinder according to the tester manufacturer's
instructions. Position the piston of cylinder to be tested at TDC compression. While testing,
listen for pressurized air escaping through the throttle body, tailpipe, and oil filler cap opening.
Check for bubbles in the radiator coolant.

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

FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be
maintained in 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.
body seated properly. Reface or replace, as
necessary. Inspect valve
springs. Replace as necessary.
Air escapes through the tailpipe Exhaust valve bent, burnt, or Inspect valve and valve seat.
not seated properly. Reface or replace, as
necessary. Inspect valve
springs. Replace as necessary.
Air escapes through the Cylinder head gasket leaking or Remove cylinder head and
radiator cracked in cylinder head or inspect. Replace cylinder head
engine block. gasket, cylinder head or engine
block as necessary.
More than 50% leakage from Cylinder head gasket leaking or Remove cylinder head and
adjacent cylinders crack in cylinder head or inspect. Replace cylinder head
engine block between adjacent gasket, cylinder head or engine
cylinders. block as necessary.
More than 25% leakage and air Stuck or broken piston rings; Remove cylinder head and
escapes through the oil filler cracked piston; worn rings inspect for broken rings or
cap opening only and/or cylinder wall. piston. Measure ring gap and
cylinder diameter, taper and
out-of-round. Replace defective
part as necessary.
CYLINDER COMPRESSION PRESSURE LEAKAGE

NOTE: The results of a cylinder compression pressure test can be utilized to diagnose
several engine malfunctions.

NOTE: Ensure the battery is completely charged and the engine starter motor is in
good operating condition. Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.

1. Clean the spark plug recesses with compressed air.

2. Remove the spark plugs and record the cylinder number of each spark plug for future reference.
3. Inspect the spark plug electrodes for abnormal firing indicators such as fouled, hot, oily, etc.
4. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE
RELEASE .

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5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for
three revolutions.
6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining
cylinders.

NOTE: The recommended compression pressures are to be used only as a guide

to diagnosing engine problems. An engine should not be disassembled to
determine the cause of low compression unless some malfunction is
present.

7. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from
cylinder to cylinder.
8. If one or more cylinders have abnormally low compression pressures, repeat the compression
test.

NOTE: If the same cylinder or cylinders repeat an abnormally low reading on the
second compression test, it could indicate the existence of a problem in
the cylinder in question.

9. If one or more cylinders continue to have abnormally low compression pressures, perform the
cylinder combustion pressure leakage test. Refer to CYLINDER COMBUSTION PRESSURE
LEAKAGE.

ENGINE MECHANICAL DIAGNOSIS CHART

CONDITION POSSIBLE CAUSES CORRECTION

NOISY VALVES/LIFTERS 1. High or low oil level in 1. Check for correct oil level. Adjust
crankcase. oil level by draining or adding as
needed.
2. Thin or diluted oil. 2. Change oil. Refer to
 Engine/Lubrication/OIL - Standard
Procedure.
3. Low oil pressure. 3. Check engine oil level. If OK,
perform oil pressure test. Refer to
Engine/Lubrication - 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 9. Grind valves and seats.
seats or valve faces.

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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
Engine/Lubrication - Diagnosis
and Testing.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
Refer to Engine/Lubrication/OIL -
Standard Procedure.
4. Excessive connecting rod 4. Measure bearings for correct
bearing clearance. clearance with plasti-gage. Repair as
necessary.
5. Connecting rod journal 5. Replace crankshaft or grind
out of round. journals.
6. Misaligned connecting 6. Replace bent connecting rods.
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
Engine/Lubrication - Diagnosis
and Testing.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
Refer to Engine/Lubrication/OIL -
Standard Procedure.
4. Excessive main bearing 4. Measure bearings for correct
clearance. clearance. Repair as necessary.
5. Excessive end play. 5. Check crankshaft thrust bearing for
excessive wear on flanges.
6. Crankshaft main journal 6. Grind journals or replace
out of round or worn. crankshaft.
 7. Loose flexplate, flywheel 7. Inspect crankshaft, flexplate,
or 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 2. Install new sending unit.
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 Engine/Lubrication/OIL -
Standard Procedure.
6. Excessive bearing 6. Measure bearings for correct
clearance. clearance.
7. Oil pump relief valve 7. Remove valve to inspect, clean
stuck. and reinstall.

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8. Oil pickup tube loose, 8. Inspect oil pickup tube and pump,
broken, bent or clogged. 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 1. Replace gasket.
deteriorated gaskets.
2. Loose fastener or broken 2. Tighten, repair or replace the part.
or porous metal part.
3. Front or rear crankshaft 3. Replace seal.
oil seal leaking.
4. Leaking oil gallery plug or 4. Remove and reseal threaded plug.
cup plug. Replace cup style plug.
EXCESSIVE OIL 1. PCV System malfunction. 1. Refer to VALVE, POSITIVE
CONSUMPTION OR CRANKCASE VENTILATION (PCV),
SPARK PLUGS OIL REMOVAL .
FOULED 2. Defective valve stem seal 2. Repair or replace seal(s).
(s).
3. Worn or broken piston 3. Hone cylinder bores. Install new
rings. rings.
4. Scuffed pistons/cylinder 4. Hone cylinder bores and replace
walls. pistons as required.
5. Carbon in oil control ring 5. Remove rings and de-carbon
groove. piston.
6. Worn valve guides. 6. Inspect/replace valve guides as
necessary.
7. Piston rings fitted too 7. Remove rings and check ring end
tightly in grooves. gap and side clearance. Replace if
 necessary.

ENGINE LUBRICATION DIAGNOSTIC TABLE

CONDITION POSSIBLE CAUSES CORRECTION

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

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4. Replace oil pan
6. Damaged vibration damper
5. Replace seal
7. Crankshaft rear flange
microporosity 6. Polish or replace damper
7. Replace crankshaft
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
4. Clogged oil filter clearance
5. Worn oil pump 4. Replace oil filter
6. Thin or diluted oil 5. Replace as necessary
7. Excessive bearing clearance 6. Change oil and filter
8. Oil pump relief valve stuck 7. Replace as necessary
9. Oil pickup tube loose or damaged 8. Replace oil pump
10. Faulty or missing piston cooling 9. Replace as necessary
jets 10. Replace piston cooling jets
OIL PUMPING AT 1. Worn or damaged rings 1. Hone cylinder bores and
RINGS; replace rings
SPARK PLUGS 2. Carbon in oil ring slots
FOULING 3. Incorrect ring size installed 2. Replace rings
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

LUBRICATION
 CONDITION POSSIBLE CAUSES CORRECTION
OIL LEAKS 1. Gaskets and O-rings. 1. Replace as necessary.
a. Misaligned or a. Replace as necessary.
damaged.
b. Loose fasteners, b. Tighten fasteners,
broken or porous metal Repair or replace metal
parts. parts.
2. Crankshaft rear seal. 2. Replace as necessary.
3. Crankshaft seal flange. 3. Polish or replace crankshaft.
Scratched, nicked or grooved.
4. Oil pan flange cracked. 4. Replace oil pan.
5. Front cover seal, damaged 5. Replace seal.
or misaligned.
6. Scratched or damaged 6. Polish or replace damper.

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vibration damper hub.
7. Crankshaft Rear Flange 7. Replace Crankshaft.
Microporosity.
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.
2. Faulty oil pressure sending 2. Replace sending unit.
unit.
3. Low oil pressure. 3. Check pump and bearing
clearance.
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 7. Replace as necessary.
clearance.
8. Oil pump relief valve stuck. 8. Replace oil pump.
9. Oil pickup tube loose or 9. Replace as necessary.
damaged.
OIL PUMPING AT RINGS; 1. Worn or damaged rings. 1. Hone cylinder bores and
SPARK PLUGS FOULING replace rings.
2. Carbon in oil ring slots. 2. Replace rings.
3. Incorrect ring size installed. 3. Replace rings.
4. Worn valve guides. 4. Ream guides and replace
valves.
5. Leaking intake gasket(s). 5. Replace intake gasket(s).
6. Leaking valve guide seals. 6. Replace valve guide seals.

OIL CONSUMPTION TEST AND DIAGNOSIS

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

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

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

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

Failure to comply with the recommended oil type and viscosity rating, as outlined in the
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.

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

Oil leakage is not the same as oil consumption and all external leakage must be
eliminated before any action can be taken to verify and/or correct oil consumption
complaints.
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

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 PRESSURE LEAKAGE test and CYLINDER-TO-
CYLINDER LEAKAGE TEST using the standard leak down gauge following manufacturers
suggested best practices.

NOTE: Verify the spark plugs are not oil saturated. If the spark plugs are oil
saturated and compression is good it can be assumed the valve seals or
valve guides are at fault.

3. If one or more cylinders have more than 15% leak down further engine tear down and
inspection will be required.

TOP 19 REASONS THAT MAY LEAD TO ENGINE OIL CONSUMPTION

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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 "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.

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

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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 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/or 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

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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 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.

STANDARD PROCEDURE
ENGINE GASKET SURFACE PREPARATION

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Fig. 2: Proper Tool Usage For Surface Preparation
Courtesy of CHRYSLER GROUP, LLC

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).
Fig. 3: Proper Tool Usage For Surface Preparation

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Courtesy of CHRYSLER GROUP, LLC

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).
High speed power tool with a plastic bristle brush style disc.

Sealing surfaces must be free of grease or oil residue. Clean surfaces with Mopar® brake parts
cleaner (or equivalent).

DUST COVERS AND CAPS

Fig. 4: Covers/Caps
Courtesy of CHRYSLER GROUP, LLC

Due to the high amounts of failures cased by dust, dirt, moisture and other foreign debris being
introduced to the engine during service. Covers or caps are needed to reduce the possible damage
that can be caused or created.

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Fig. 5: Opening Cover
Courtesy of CHRYSLER GROUP, LLC

Covers over openings will reduce any possibilities for foreign materials to enter the engine systems.
Using miller tool (special tool #10368, Set, Universal Protective Cap), Select the appropriated cover
needed to the procedure.

REPAIR DAMAGED OR WORN THREADS

CAUTION: Always maintain the original center line when drilling and/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
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.

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Fig. 6: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect and isolate the negative battery cable (1).

Fig. 7: Engine Covers

Courtesy of CHRYSLER GROUP, LLC

2. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (2).
3. Place a shop towel around the fuel supply line Quick Connect Fitting to catch any fuel that may
be under pressure and disconnect the fuel supply line. Refer to FITTING, QUICK CONNECT .
 Fig. 8: Air Duct Retaining Clamp, Intake Air Temperature Sensor Electrical Connector,

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Makeup Air Hose, Bolt & Air Cleaner Housing
Courtesy of CHRYSLER GROUP, LLC

4. Loosen the air duct retaining clamp (1) at the throttle body.
5. Disconnect the intake air temperature sensor electrical connector (2).
6. Remove the makeup air hose (3) at the air cleaner housing.
7. Remove the air cleaner housing retaining bolt (4).
8. While lifting up the air cleaner housing (5), 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 Engine/Lubrication/OIL - Standard
Procedure.
19. Connect negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
20. Start the engine and check for leaks.
SPECIFICATIONS
SPECIFICATIONS

GENERAL DESCRIPTION
DESCRIPTION SPECIFICATION
Engine Type 90° V-8 OHV
Displacement 6.4 Liters
392 (Cubic Inches)
Bore 103.9 mm (4.09 in.)
Stroke 94.6 mm (3.72 in.)
Compression Ratio 10.9:1
Firing Order 1-8-4-3-6-5-7-2
Lubrication Pressure Feed - Full Flow Filtration

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Cooling System Liquid Cooled - Forced Circulation
Cylinder Block Cast Iron
Cylinder Head Aluminum
Crankshaft Forged Steel
Camshaft Cast Iron
Pistons Aluminum Alloy
Connecting Rods Powdered Metal

CYLINDER BLOCK
DESCRIPTION SPECIFICATION
Metric Standard
Cylinder Bore Diameter 103.9 mm 4.09 in.
Out of Round (MAX) 0.008 mm 0.0003 in.
Taper (MAX) 0.0127 mm 0.0005 in.
Lifter Bore Diameter 21.45 - 21.425 mm 0.8444 - 0.8435 in.

PISTONS
DESCRIPTION SPECIFICATION
Metric Standard
Clearance Measured at 38.0 0.0245 - 0.0515 mm 0.00096 - 0.0020 in.
mm (1.5 in.) Below Deck
Ring Groove Diameter
Groove #1 93.1 - 93.4 mm 3.665 - 3.677 in.
Groove #2 91.6 - 91.8 mm 3.606 - 3.614 in.
Weight 435 grams 15.34 oz.
Piston Length 54.70 - 55.30 mm 2.153 - 2.177 in.
Ring Groove Width
No. 1 1.2 mm 0.0472 in
 No. 2 1.2 mm 0.0472 in
No. 3 2.0 mm 0.0787 in.

PISTON RINGS
DESCRIPTION SPECIFICATION
Metric Standard
Ring Gap
Top Compression Ring 0.30 - 0.40 mm 0.0118 - 0.0157 in.
Second Compression Ring 0.35 - 0.60 mm 0.0137 - 0.0236 in.
Oil Control (Steel Rails) 0.20 - 0.71 mm 0.0079 - 0.028 in.
Side Clearance
Top Compression Ring 0.02 - 0.068 mm 0.0007 - 0.0026 in.
Second Compression Ring 0.02 - 0.058 mm 0.0007 - 0.0022 in.
Oil Ring (Steel Ring) 0.019 - 0.229 mm 0.0007 - 0.0091 in.

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Ring Width
Top Compression Ring 1.472 - 1.490 mm 0.0579 - 0.0586 in.
Second Compression Ring 1.472 - 1.490 mm 0.0579 - 0.0586 in.
Oil Ring (Steel Rails) 0.447 - 0.473 mm 0.0175 - 0.0186 in.

CONNECTING RODS
DESCRIPTION SPECIFICATION
Metric Standard
Side Clearance 0.10 - 0.35 mm 0.003 - 0.0137 in.

CRANKSHAFT
DESCRIPTION SPECIFICATION
Metric Standard
Main Bearing Journal Diameter 65 mm 2.6 in.
Bearing Clearance 0.023 - 0.051 mm 0.0009 - 0.002 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 54 mm 2.126 in.
Diameter
Bearing Clearance 0.020 - 0.074 mm 0.0007 - 0.0029 in.
Out of Round (MAX) 0.005 mm 0.0002 in.
Taper (MAX) 0.003 mm 0.0001 in.

CAMSHAFT
DESCRIPTION SPECIFICATION
 Metric Standard
Bearing Journal Diameter
No. 1 58.2 mm 2.29 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.
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.

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Camshaft End Play .080 - 0.290 mm 0.0031 - 0.0114 in.

VALVE TIMING
DESCRIPTION SPECIFICATION
Intake
Opens (BTDC) 36.0°
Closes (ATDC) 250.0°
Duration 286.0°
Exhaust
Opens (BTDC) 278°
Closes (ATDC) 10°
Duration 288.0°
Valve Overlap 46°

CYLINDER HEAD
DESCRIPTION SPECIFICATION
Metric Standard
Valve Seat Angle 44.5° - 45.0°
Valve Seat Runout (MAX) 0.04 mm 0.0016 in.
Valve Seat Width
Intake 0.94 - 1.04 mm 0.037 - 0.041 in.
Exhaust 1.16 - 1.26 mm 0.046 - 0.050 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
 DESCRIPTION SPECIFICATION
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
Metric Standard
Face Angle
Intake 45.5° - 46.0°
Exhaust 45.0° - 45.5°
Head Diameter
Intake 54.14 - 54.46 mm 2.131 - 2.144 in.

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Exhaust 41.87 - 42.13 mm 1.648 - 1.659 in.
Length (Overall From Gage
Line)
Intake 128.38 - 128.76 mm 5.054 - 5.069 in.
Exhaust 126.975 - 127.355 mm 4.999 - 5.014 in.
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 - 0.066 mm 0.0008 - 0.0025 in.
Exhaust 0.025 - 0.070 mm 0.0010 - 0.0028 in.
Valve Lift (@ Zero Lash)
Intake 14.65 mm 0.577 in.
Exhaust 13.65 mm 0.537 in.

VALVE SPRING
DESCRIPTION SPECIFICATION
Metric Standard
Spring Force (Valve Closed)
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 (Valve Open)
Intake 1500.0 N ± 70.0 N @ 37.6 mm 337.2 lbs. ± 15.7 lbs. @ 1.480
in.
Exhaust 1500.0 N ± 70.0 N @ 37.6 mm 337.2 lbs. ± 15.7 lbs. @ 1.480
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

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DESCRIPTION SPECIFICATION
Metric Standard
Clearance Over Rotors (MAX) 0.095 mm 0.0038 in.
Outer Rotor to Pump Body
0.235 mm 0.009 in.
Clearance (MAX)
Tip Clearance Between Rotors 0.150 mm
0.006 in.
(MAX)

OIL PRESSURE
SPECIFICATION SPECIFICATION
At Curb Idle Speed (min.)* 25 kPa (4 psi)
@ 3000 rpm 170 - 758 kPa (25 - 110 psi)
* CAUTION: If pressure is zero at curb idle, DO NOT run engine

TORQUE SPECIFICATIONS

6.4L ENGINE
DESCRIPTION N.m Ft. Lbs. In. Lbs.
Air Cleaner Housing - Bolt 5 - 44
Block Pipe Plugs
(1/4 NPT) 20 15 -
(3/8 NPT) 27 20 -
Water Drain Plugs 34 25 -
Camshaft Sprocket - Bolt 122 90 -
Camshaft Thrust Plate - Bolts 12 - 106
Lifting Stud 55 40 -
Connecting Rod Cap - Bolts 45 33
Plus 60° Plus 60° -
 Turn Turn
Main Bearing Cap - Bolts
28 21
Plus 90° Plus 90° -
M-12 Bolts Turn Turn
M-8 Bolts (Crossbolts) 31 23 -
Specific torque and fastener pattern
required; follow installation sequence.
Cylinder Head - Bolts (M-12)
Refer to CYLINDER HEAD,
INSTALLATION.
Cylinder Head Cover - Bolts 8 - 70
Engine Mount Bracket to Engine Block - Bolts 61 45 -
Engine Mount Heat Shield - Nuts 27 20 -
Engine Timing Cover - Bolts 28 21 -
Exhaust Manifold to Cylinder Head - Bolts 31 23 -

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Flexplate to Crankshaft - Bolts 95 70 -
Flywheel to Crankshaft - Bolts 75 55 -
Front Isolator to Engine Mount Bracket- Bolts 60 44 -
Front Isolator to Engine Cradle Crossmember - Bolts 61 45 -
Generator to Engine Block - Bolts 65 48 -
Generator Support Bracket-to-Engine Mount Nut 28 21 -
Heater Tube - Bolt 11 8 -
Specific torque and fastener pattern
required; follow installation sequence.
Intake Manifold - Bolts
Refer to MANIFOLD, INTAKE,
INSTALLATION.
Lifter Guide Holder - Bolts 12 9 -
MDS Solenoid - Bolts 11 8 -
Oil Control Valve - Bolt 11 8 -
Piston Oil Cooler Jet - Bolts 13 10 -
Power Steering Pump to Engine Block - Bolts 28 21 -
Oil Dipstick Tube - Nut 31 23 -
Oil Pan - Drain Plug 27 20 -
Specific torque and fastener pattern
Oil Pan - Bolts required; follow installation sequence.
Refer to PAN, OIL, INSTALLATION.
Oil Pump - Bolts 28 21 -
Oil Pump Pickup Tube - Bolt and Nut 28 21 -
Rear Seal Retainer - Bolts 15 11 -
Rear Isolator Bracket to Transmission - Bolts 33 24 -
(Automatic)
Rear Isolator to Bracket - Bolts (Automatic) 54 40 -
Rear Isolator to Crossmember - Bolts (Automatic) 61 45 -
Rear Isolator to Transmission - Bolts (Manual) 56 41 -
Rear Isolator to Crossmember - Bolts (Manual) 54 40 -
Rocker Arm - Bolts 22 16 -
Strut Tower Support - Bolts 32 28 -
Thermostat Housing - Bolts 28 21 -
Throttle Body - Bolts 12 9 -
Torque Converter to Flexplate - Bolts 68 50 -
Transmission to Engine Block - Bolts 68 50 -
Vibration Damper - Bolt 250 184 -
Water Pump to Engine Timing Cover - Bolts 28 21 -

REMOVAL

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REMOVAL

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

Fig. 9: Cowl Panel, Push-Pins & Fasteners

Courtesy of CHRYSLER GROUP, LLC

1. Remove the hood. Refer to HOOD, REMOVAL .

2. Remove the cowl panel cover (1). Refer to COVER, COWL PANEL, REMOVAL .
3. Remove the strut tower support (6).
 Fig. 10: Engine Covers

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Courtesy of CHRYSLER GROUP, LLC

4. Lift the engine cover retaining grommets off the ball studs and remove the engine covers (1).
5. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE
RELEASE .

Fig. 11: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

6. Disconnect and isolate the negative battery cable (1).

 Fig. 12: Intake Manifold Removal/Tightening Sequence

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Remove the intake manifold and throttle body as an assembly.

7. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL.

Fig. 13: Oil Control Valve, Electrical Connector & Retaining Bolt
Courtesy of CHRYSLER GROUP, LLC

NOTE: The engine must be at room temperature before removing the oil control
valve.

8. Disconnect the oil control valve electrical connector (1).

9. Remove the oil control valve retaining bolt (2).
10. Rotate the oil control valve (3) to break the seal then pull the oil control valve straight out.

CAUTION: Do not let the tensioner arm snap back to the freearm position, sever
damage may occur to the tensioner.

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Fig. 14: Accessory Drive Belt Routing, Tensioner & Pulleys
Courtesy of CHRYSLER GROUP, LLC

11. Rotate the accessory drive belt tensioner (8) clockwise until it contacts the stop and remove the
accessory drive belt (2), then slowly rotate the tensioner into the freearm position.

Fig. 15: Cooling Fan Module Components

Courtesy of CHRYSLER GROUP, LLC
12. Remove the cooling fan (1). Refer to FAN, COOLING, REMOVAL .
13. Raise and support the vehicle.

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Fig. 16: Lower Splash Shield & Fasteners
Courtesy of CHRYSLER GROUP, LLC

14. Remove the belly pan retainers (1) and remove the belly pan.
15. Drain the cooling system. Refer to STANDARD PROCEDURE .
16. Drain the engine oil. Refer to Engine/Lubrication/OIL - Standard Procedure.

Fig. 17: Removing/Installing A/C Compressor

Courtesy of CHRYSLER GROUP, LLC

17. Remove the A/C compressor (3). Refer to COMPRESSOR, A/C, REMOVAL .
 Fig. 18: Engine Mount Heat Shield Retaining Nuts, Lower Mount Retaining Bolts & Heat

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Shields
Courtesy of CHRYSLER GROUP, LLC

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

18. Remove both left/right engine mount heat shield (4) retaining nuts (3) and remove the heat
shields.
19. Remove both left/right engine mount to frame retaining bolts (2).
20. Disconnect the transmission oil cooler lines from their retainers at the oil pan.

Fig. 19: Lower Radiator Hose & Radiator Fan Assembly

Courtesy of CHRYSLER GROUP, LLC
 1 - LOWER RADIATOR HOSE
2 - RADIATOR FAN ASSEMBLY

21. Remove the lower radiator hose (1).

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Fig. 20: Knock Sensor, Electrical Connector & Bolt
Courtesy of CHRYSLER GROUP, LLC

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.

22. Remove the heat shields from both knock sensors (shield snaps on/off sensor).
23. Disconnect the knock sensor electrical connectors (3).

CAUTION: When separating the catalytic converters from the manifolds,

disconnect the oxygen sensor connectors. Allowing the catalytic
converters hanging from the oxygen sensor wires damages the
harness and/or sensors.
 cardiagn.com
Fig. 21: Oxygen Sensor, Oxygen Sensor Connector, Ball Flange Nut & LH Catalytic
Converter
Courtesy of CHRYSLER GROUP, LLC

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

24. Disconnect all oxygen sensor electrical connectors (2).

25. Saturate all exhaust bolts and nuts (3) with Mopar® Rust Penetrant. Allow five minutes for
penetration.
26. Remove the both catalytic converter to manifold flange nuts (3) and separate the catalytic
converters (4) from the exhaust manifolds.
 cardiagn.com
Fig. 22: Removing/Installing Starter
Courtesy of CHRYSLER GROUP, LLC

27. Remove the starter motor (1) heat shield (4).

28. Disconnect the starter wires, remove the starter motor retaining bolts (2) and remove the starter
(1). Refer to STARTER, REMOVAL .

Fig. 23: Crankshaft Position Sensor Electrical Connector

Courtesy of CHRYSLER GROUP, LLC

NOTE: The Crankshaft Position (CKP) sensor is located at the right-rear side of
the engine block.
29. Remove the CKP sensor electrical connector (1).

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Fig. 24: Support Bracket, Bolt & Nut
Courtesy of CHRYSLER GROUP, LLC

30. Remove the generator support bracket to engine mount retaining nut (1).
31. Remove the generator support bracket retaining bolt (2) and remove the support bracket (3).
32. Lower the vehicle.

Fig. 25: Generator & Retaining Bolt

Courtesy of CHRYSLER GROUP, LLC

33. Unsnap the plastic insulator cap from the B+ output terminal.
34. Remove the B+ terminal mounting nut at the rear of the generator and remove the B+ terminal.
35. Depress the field wire connector tab at the rear of the generator and disconnect the field wire
connector.
36. Remove the two generator retaining bolts (1) and remove the generator (2).

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Fig. 26: Removing/Installing A/C Liquid Line
Courtesy of CHRYSLER GROUP, LLC

37. Remove the nut (1) from the front section of the A/C liquid line (2) to the rear section of the
liquid line (3), separate the lines, remove and discard the dual plane seal.
38. Install plugs or tape over the opened liquid line fittings.
39. Remove the front section of the A/C liquid line (2) from the engine compartment.

Fig. 27: Removing/Installing A/C Suction Lines

 Courtesy of CHRYSLER GROUP, LLC

40. Remove the nut (1) from the front section of the A/C suction line (2) to the rear section of the
suction line (3), separate the lines, remove and discard the dual plane seal.
41. Install plugs or tape over the opened suction line fittings.
42. Remove the front section of the A/C suction line (2) from the engine compartment.

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Fig. 28: Oil Pressure Sensor Electrical Connector
Courtesy of CHRYSLER GROUP, LLC

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

44. Remove the oil temperature sensor electrical connector.

Fig. 29: Power Steering Reservoir, Pump, Pulley & Bolts

Courtesy of CHRYSLER GROUP, LLC
 NOTE: It is not necessary to disconnect power steering pump hoses from power
steering pump for power steering pump removal.

45. Remove the three power steering pump (4) mounting bolts (2) through the access holes in the
pulley (3) and position the pump aside.

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Fig. 30: Upper Radiator Hose, Clamp, Oil Cooler Return Line Hose & Clamp
Courtesy of CHRYSLER GROUP, LLC

46. Remove the upper radiator hose clamp (1) and remove the upper radiator hose (2).
47. Remove the oil cooler hose clamp (3) and remove the oil cooler hose (4).

Fig. 31: Coolant Temperature (ECT) Sensor Electrical Connector, Heater Tube &
Retaining Bolt
Courtesy of CHRYSLER GROUP, LLC
48. Remove the heater tube retaining bolt (1).
49. Remove the coolant temperature sensor electrical connector (2).
50. Lift the heater tube (3) out of the water pump.

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Fig. 32: Camshaft Position Sensor Electrical Connector & Bolt
Courtesy of CHRYSLER GROUP, LLC

51. Disconnect the camshaft position sensor electrical connector (1).

Fig. 33: Heater Hose Supply

Courtesy of CHRYSLER GROUP, LLC

52. Remove the heater hoses (1, 2).

 Fig. 34: Coolant Recovery Container Pressure Cap, Tube & Screws

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Courtesy of CHRYSLER GROUP, LLC

NOTE: It is not necessary to remove the hoses from the coolant bottle for coolant
bottle removal.

53. Remove the coolant bottle retaining bolts (2) and position the coolant bottle (1) aside.

Fig. 35: Ignition Coil Connector, Ignition Coil & Mounting Bolts
Courtesy of CHRYSLER GROUP, LLC

54. Remove all ignition coil electrical connectors (1) and position the harness aside.
 Fig. 36: TIPM/PDC Mounting Bracket
Courtesy of CHRYSLER GROUP, LLC

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55. Remove the Power Distribution Center (PDC) and mounting bracket.
56. Unfasten the wire harness mounted on the right hand inner fender panel and position aside.

Fig. 37: Ignition Capacitor, Electrical Connector & Intake Manifold

Courtesy of CHRYSLER GROUP, LLC

NOTE: The ignition capacitor (2) is located near the left rear corner of the intake
manifold (3).

57. Remove the ignition capacitor (1) electrical connector (2).

58. Remove the ground wires from the rear of each cylinder head.
59. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
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Fig. 38: Remove/Install Torque Converter Access Cover
Courtesy of CHRYSLER GROUP, LLC

60. Remove the transmission inspection cover retaining bolt (2) and remove the inspection cover
(1).

Fig. 39: Torque Converter Bolts

Courtesy of CHRYSLER GROUP, LLC

61. 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 (1).
 Fig. 40: Remove/Install Transmission To Oil Pan Bolts
Courtesy of CHRYSLER GROUP, LLC

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62. Remove the oil pan to transmission bolts (1).

Fig. 41: Remove/Install Transmission To Engine Bolts

Courtesy of CHRYSLER GROUP, LLC

63. Remove the transmission bell housing to engine block bolts (2).

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.

64. Lower the vehicle.

 cardiagn.com
Fig. 42: Engine Lift Fixture & Adapter
Courtesy of CHRYSLER GROUP, LLC

65. Using a suitable jack, support the transmission.

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

66. Install the (special tool #8984B, Fixture, Engine Lifting) (2) and (special tool #8984-UPD,
Adapter, Engine Lift) (4).
67. Using a suitable engine hoist, separate the engine from the transmission and remove the
engine from the engine compartment.
68. Secure the engine onto a suitable engine stand.

INSTALLATION
INSTALLATION

CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler must
be replaced or damage to the new engine and/or components could result.
 cardiagn.com
Fig. 43: Engine Lift Fixture & Adapter
Courtesy of CHRYSLER GROUP, LLC

NOTE: Do not use air tools to install (special tool #8984B, Fixture, Engine Lifting) (2, 3).

1. Install the engine lift fixture (2) (special tool #8984B, Fixture, Engine Lifting) and adapter
(special tool #8984-UPD, Adapter, Engine Lift) (4).
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.
 Fig. 44: Engine Mount Heat Shield Retaining Nuts, Lower Mount Retaining Bolts & Heat

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Shields
Courtesy of CHRYSLER GROUP, LLC

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

6. Align the engine mounts, install both left/right engine mount to frame retaining bolts (2) and
tighten to 68 N.m (50 ft. lbs.).
7. Position both left and right engine mount heat shields (4), install the retaining nuts (3) and
tighten to 27 N.m (20 ft. lbs.).
8. Remove the engine hoist and the jack supporting the transmission.
9. Raise and support the vehicle.

Fig. 45: Remove/Install Transmission To Oil Pan Bolts

Courtesy of CHRYSLER GROUP, LLC

10. Automatic transmission equipped vehicles, install the oil pan to transmission bolts (1) and
 tighten to 54 N.m (40 ft. lbs.).

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Fig. 46: Remove/Install Transmission To Engine Bolts
Courtesy of CHRYSLER GROUP, LLC

11. Install the remaining transmission bell housing to engine block bolts (2) and tighten to 68 N.m
(50 ft. lbs.).

Fig. 47: Torque Converter Bolts

Courtesy of CHRYSLER GROUP, LLC

CAUTION: It is essential that the correct length bolts are used to attach the
converter to the flexplate. Bolts that are too long will damage the
 clutch surface inside the torque converter.

12. Rotate the crankshaft in clockwise direction and install all torque converter to flexplate bolts (1)
finger tight.
13. Verify that the torque converter is pulled flush to the flexplate and tighten bolts to 88 N.m (65 ft.
lbs.).

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Fig. 48: Remove/Install Torque Converter Access Cover
Courtesy of CHRYSLER GROUP, LLC

14. Install the inspection cover (1) and tighten the retaining bolt (2) to 11 N.m (8 ft. lbs.).

Fig. 49: Crankshaft Position Sensor Electrical Connector

Courtesy of CHRYSLER GROUP, LLC
 NOTE: The Crankshaft Position (CKP) sensor is located at the right rear side of
the engine block.

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

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Fig. 50: Removing/Installing Starter
Courtesy of CHRYSLER GROUP, LLC

16. Position the starter motor (1) into the transmission.

17. Install the three starter motor retaining bolts (2) and tighten to 54 N.m (40 ft. lbs.).
18. Connect the solenoid wire to the starter motor (snaps in place).
19. Position the battery cable to the solenoid stud, install the battery cable eyelet nut and tighten to
11 N.m (8 ft. lbs.).
20. Position the starter heat shield (4) and install the retaining nuts (3).
 cardiagn.com
Fig. 51: Oxygen Sensor, Oxygen Sensor Connector, Ball Flange Nut & LH Catalytic
Converter
Courtesy of CHRYSLER GROUP, LLC

21. Position the catalytic converters (4) onto the exhaust manifold flanges, install the flange nuts (3)
and tighten to 41 N.m (30 ft. lbs.).
22. Connect the oxygen sensor electrical connectors (2).

Fig. 52: Knock Sensor, Electrical Connector & Bolt

Courtesy of CHRYSLER GROUP, LLC

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

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

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Fig. 53: Lower Radiator Hose & Radiator Fan Assembly
Courtesy of CHRYSLER GROUP, LLC

1 - LOWER RADIATOR HOSE

2 - RADIATOR FAN ASSEMBLY

26. Install the lower radiator hose (1).

27. Lower the vehicle.
 cardiagn.com
Fig. 54: Engine Lift Fixture & Adapter
Courtesy of CHRYSLER GROUP, LLC

28. Remove the engine lift fixture (special tool #8984B, Fixture, Engine Lifting) (2) and adapter
(special tool #8984-UPD, Adapter, Engine Lift) (4).
29. Position the left and right side wiring harness.

Fig. 55: Oil Control Valve, Electrical Connector & Retaining Bolt
Courtesy of CHRYSLER GROUP, LLC

30. Lubricate the oil control valve (OCV) rubber O-ring seal with clean engine oil.
31. Install the OCV (3) and rotate into position.
32. Install the OCV retaining bolt (2) and tighten to 11 N.m (8 ft. lbs.).
33. Connect the OCV electrical connector (1).

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Fig. 56: Coolant Temperature (ECT) Sensor Electrical Connector, Heater Tube &
Retaining Bolt
Courtesy of CHRYSLER GROUP, LLC

34. Position the heater core tube (3) into the water pump.
35. Install the heater core tube retaining bolt (1) and tighten to 11 N.m (8 ft. lbs.).
36. Connect the electrical connector to the coolant temperature (ECT) sensor (2).

Fig. 57: Camshaft Position Sensor Electrical Connector & Bolt

Courtesy of CHRYSLER GROUP, LLC

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

 Fig. 58: Intake Manifold Removal/Tightening Sequence

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

NOTE: Install the intake manifold and throttle body as an assembly.

38. Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION.

Fig. 59: Heater Hose Supply

Courtesy of CHRYSLER GROUP, LLC

39. Connect the heater hoses (1, 2).

40. Connect the ground wires to the rear of each cylinder head.
 cardiagn.com
Fig. 60: Ignition Capacitor, Electrical Connector & Intake Manifold
Courtesy of CHRYSLER GROUP, LLC

NOTE: The ignition capacitor (2) is attached to the rear of the left cylinder head.

41. Connect the ignition capacitor (2) electrical connector (1).

Fig. 61: Power Steering Reservoir, Pump, Pulley & Bolts

Courtesy of CHRYSLER GROUP, LLC

42. Position the power steering pump (4).

43. Install the three power steering pump (4) mounting bolts (2) through the access holes in the
pulley and tighten the bolts to 28 N.m (21 ft. lbs.).
 Fig. 62: Oil Pressure Sensor Electrical Connector

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

44. Connect the oil pressure sensor electrical connector (1).

45. Connect the oil temperature sensor electrical connector.

Fig. 63: Generator & Mounting Bolts

Courtesy of CHRYSLER GROUP, LLC

46. Position the generator (2) and install two generator mounting bolts (1) finger tight.
47. Raise and support the vehicle.
 Fig. 64: Support Bracket, Bolt & Nut

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

48. Position the generator support bracket (3) to the engine mount, install the retaining nut (1) finger
tight.
49. Position the generator support bracket (3) to the generator, install the retaining bolt (2) and
tighten to 65 N.m (48 ft. lbs.).
50. Tighten the generator support bracket (3) to engine mount retaining nut (1) to 28 N.m (21 ft.
lbs.).

Fig. 65: Removing/Installing A/C Compressor

Courtesy of CHRYSLER GROUP, LLC

51. Install the A/C compressor (3). Refer to COMPRESSOR, A/C, REMOVAL .
 Fig. 66: Lower Splash Shield & Fasteners

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

52. Position the belly pan and install the belly pan retainers (1).
53. Lower the vehicle.

Fig. 67: Generator & Mounting Bolts

Courtesy of CHRYSLER GROUP, LLC

54. Tighten two generator mounting bolts (1) to 65 N.m (48 ft. lbs.).
55. Snap the field wire connector into the rear of the generator.
56. Position the generator B+ terminal eyelet to the generator output stud, install the retaining nut
and tighten to 13 N.m (10 ft. lbs.).
57. Snap the plastic insulator cap onto the B+ output terminal.
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Fig. 68: Removing/Installing A/C Suction Lines
Courtesy of CHRYSLER GROUP, LLC

58. Position the front section of the A/C suction line (2) into the engine compartment.
59. Remove the tape or plugs from the fittings that connect the front section of the A/C suction line
to the rear section of the A/C suction line (3).

NOTE: Use only the specified seal as it is made of a special material for the R-
134a system. Use only refrigerant oil of the type recommended for the A/C
compressor in the vehicle.

60. Lubricate the new dual plane seal with clean refrigerant oil and position the seal onto the
suction line fitting.
61. Connect the front section of the A/C suction line to the rear section of the A/C suction line.
62. Install the nut (1) that secures the front section of the A/C suction line to the rear section of the
A/C suction line and tighten the nut to 22 N.m (16 ft. lbs.).
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Fig. 69: Removing/Installing A/C Liquid Line
Courtesy of CHRYSLER GROUP, LLC

63. Position the front section of the A/C liquid line into the engine compartment.
64. Remove the tape or plugs from the fittings that connect the front section of the A/C liquid line to
the rear section of the A/C liquid line (3).

NOTE: Use only the specified seal as it is made of a special material for the R-
134a system. Use only refrigerant oil of the type recommended for the A/C
compressor in the vehicle.

65. Lubricate the new dual plane seal with clean refrigerant oil and position the seal onto the liquid
line fitting.
66. Connect the front section of the A/C liquid line to the rear section of the A/C liquid line.
67. Install the nut (1) that secures the front section of the A/C liquid line to the rear section of the
A/C liquid line and tighten the nut to 22 N.m (16 ft. lbs.).
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Fig. 70: Ignition Coil Connector, Ignition Coil & Mounting Bolts
Courtesy of CHRYSLER GROUP, LLC

68. Position the ignition coil electrical harness and connect all ignition coil electrical connectors (1).

Fig. 71: Coolant Recovery Container Pressure Cap, Tube & Screws
Courtesy of CHRYSLER GROUP, LLC

69. Position the coolant bottle (1) and install the coolant bottle retaining bolts (2).
 Fig. 72: TIPM/PDC Mounting Bracket
Courtesy of CHRYSLER GROUP, LLC

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70. Install the Totally Integrated Power Module (TIPM) mounting bracket.
71. Install the PDC bracket.
72. Position the wire harness and secure to the right hand inner fender panel.
73. Secure the PDC to the bracket.

Fig. 73: Accessory Drive Belt Routing, Tensioner & Pulleys

Courtesy of CHRYSLER GROUP, LLC

CAUTION: Do not let the tensioner arm snap back to the freearm position, sever
damage may occur to the tensioner.

74. Rotate the accessory drive belt tensioner (8) clockwise until it contacts the stop and install the
 accessory drive belt (2) onto the pulleys, then slowly release the tensioner.

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Fig. 74: Cooling Fan Module Components
Courtesy of CHRYSLER GROUP, LLC

75. Install the cooling fan. Refer to FAN, COOLING, INSTALLATION .

Fig. 75: Upper Radiator Hose, Clamp, Oil Cooler Return Line Hose & Clamp
Courtesy of CHRYSLER GROUP, LLC

76. Position the oil cooler hose (4) and Install oil cooler hose clamp (3).
77. Position the upper radiator hose (2) and Install the upper radiator hose clamp (1).
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Fig. 76: Cowl Panel, Push-Pins & Fasteners
Courtesy of CHRYSLER GROUP, LLC

78. Install the strut tower support (6) and tighten bolts to 38 N.m (28 ft. lbs.).
79. Install the cowl panel cover (1). Refer to COVER, COWL PANEL, INSTALLATION .
80. Fill the crankcase with the specified type and amount of engine oil. Refer to CAPACITIES AND
RECOMMENDED FLUIDS, SPECIFICATIONS .
81. Fill the cooling system with the specified type and amount of engine coolant. Refer to
STANDARD PROCEDURE .

Fig. 77: Engine Covers

Courtesy of CHRYSLER GROUP, LLC

82. Install the engine covers (1) onto the ball studs.
 Fig. 78: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

83. Connect the negative battery cable (3).

84. Perform the Refrigerant System Charge procedure. Refer to PLUMBING, STANDARD
PROCEDURE .
85. Start the engine and inspect for leaks.

SPECIAL TOOLS
SPECIAL TOOLS

1023 - Puller
(Originally Shipped In Kit Number(s) 8678.)
10368 - Set, Universal Protective Cap
10386 - Holder, Vibration Damper
10387 - Installer, Vibration Damper
6871 - Installer, A/C Hub
(Originally Shipped In Kit Number(s) 6896.)
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.)
8507 - Guides, Connecting Rod
(Originally Shipped In Kit Number(s) 8283, 8283CC, 8527, 8527CC, 8575, 8575CC.)
8512A - Installer, Damper
(Originally Shipped In Kit Number(s) 8283, 8527, 8575, 8575CC, 8660, 8661.)
8514 - Pins, Tensioner
(Originally Shipped In Kit Number(s) 8283, 8283CC, 8527, 8527CC, 8575, 8575CC, 9975.)
8534B - Fixture, Driveline Support
 (Originally Shipped In Kit Number(s) 8534, 8534B, 8849, 9565.)
8984-UPD - Adapter, Engine Lift
(Originally Shipped In Kit Number(s) 9516, 9516-CAN, 9517, 9517-CAN, 9518, 9519.)
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.)
9065B - Compressor, Valve Spring
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.)
9072 - Installer, Seal
(Originally Shipped In Kit Number(s) 8999, 8999CC, 9329, 9515, 9540, 9541, 9577, 9975,

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9976.)
C-119 - Cylinder Indicator
C-3292A - Gauge, Pressure
C-3422-D - Compressor, Valve Spring
C-3685-A - Bloc-Chek Kit

MDS SYSTEM
DESCRIPTION

DESCRIPTION

Fig. 79: MDS Lifter

Courtesy of CHRYSLER GROUP, LLC
The Multiple Displacement System (MDS) selectively deactivates cylinders 1, 4, 6 and 7 during
steady speed, low acceleration and shallow grade climbing conditions to increase fuel economy.

The MDS can provide a 5 to 20% fuel economy benefit when operating in four-cylinder mode.
Depending on driving habits and vehicle usage. For EPA rating purposes the fuel economy is 8 to
15% higher than if the engine was operating on eight-cylinders at all times.

The MDS deactivating lifter (1) can be distinguished from the non-MDS lifter (2) by the disconnecting
pin (3) on the side of the MDS lifter.

MDS is integrated into the basic engine architecture requiring these additional components:

Unique MDS camshaft

8 deactivating roller lifters
4 MDS control valve solenoids

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MDS control valve solenoid wiring harness
Oil temperature sensor

OPERATION

OPERATION

Fig. 80: MDS Lifter Cross Section

Courtesy of CHRYSLER GROUP, LLC

The Multiple Displacement System (MDS) provides cylinder deactivation during steady speed, low
acceleration and shallow grade climbing conditions to increase fuel economy. Both four and eight
cylinder configurations have even firing intervals to provide smooth operation. The MDS selectively
deactivates cylinders 1, 4, 6, and 7, to improve fuel economy. All deactivated cylinders have unique
hydraulic lifters that collapse when deactivated to prevent the valves from opening. Engine oil
pressure is used to activate and deactivate the valves. Oil is delivered through special oil passages
drilled into the cylinder block. The MDS solenoid valves control the flow. When activated, pressurized
oil pushes a latching pin on each MDS lifter which becomes a lost motion link. The base of the MDS
lifter follows the camshaft while the top remains stationary. The MDS lifter is held in place against the
pushrod by light spring pressure but unable to move because of the much higher force of the valve
spring.

NOTE: It is critical to use the recommended oil viscosity in engines that use MDS.

Deactivation occurs during the compression stroke of each cylinder, after air and fuel enter the
cylinder. Ignition occurs, but the combustion products remain trapped in the cylinder under high
pressure, because the valves no longer open. No fuel/air enters or leaves during subsequent piston
strokes, this high pressure gas is repeatedly compressed and expanded like an air spring.

AIR INTAKE SYSTEM

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AIR CLEANER

REMOVAL

REMOVAL

Fig. 81: Air Cleaner Housing Cover Retaining Screws

Courtesy of CHRYSLER GROUP, LLC

1. Remove the air cleaner housing cover retaining screws (1).

 Fig. 82: Air Cleaner Housing Cover & Air Cleaner Element

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Courtesy of CHRYSLER GROUP, LLC

2. Lift the air cleaner housing cover (1) while separating the locating tabs from the housing.
3. Remove air cleaner element (2) from the housing.
4. Clean the inside of air cleaner housing before replacing element.

INSTALLATION

INSTALLATION

Fig. 83: Air Cleaner Housing Cover & Air Cleaner Element
Courtesy of CHRYSLER GROUP, LLC

1. Install the air cleaner element (2) into the housing.

2. Align the air cleaner housing cover (1) locating tabs into the housing while lowering the cover
 into position.

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Fig. 84: Air Cleaner Housing Cover Retaining Screws
Courtesy of CHRYSLER GROUP, LLC

3. Install the air cleaner housing cover retaining screws (1) and tighten to 3 N.m (30 in. lbs.).

BODY, AIR CLEANER

REMOVAL

REMOVAL

Fig. 85: Air Duct Retaining Clamp, Intake Air Temperature Sensor Electrical Connector,
Makeup Air Hose, Bolt & Air Cleaner Housing
Courtesy of CHRYSLER GROUP, LLC
 1. Loosen the air duct retaining clamp (1) at the throttle body.
2. Disconnect the intake air temperature sensor electrical connector (2).
3. Remove the makeup air hose (3) at the air cleaner housing.
4. Remove the air cleaner housing retaining bolt (4).
5. While lifting up the air cleaner housing (5), slide the air duct off the throttle body and remove the
air cleaner housing from the vehicle.

INSTALLATION

INSTALLATION

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Fig. 86: Air Duct Retaining Clamp, Intake Air Temperature Sensor Electrical Connector,
Makeup Air Hose, Bolt & Air Cleaner Housing
Courtesy of CHRYSLER GROUP, LLC

1. While sliding the air duct onto the throttle body, lower the air cleaner housing (5) into position
and align the locating pin on the bottom of the housing.
2. Install the air cleaner housing retaining bolt (4) and tighten to 5 N.m (44 in. lbs.).
3. Install the makeup air hose (3) at the air cleaner housing.
4. Connect the intake air temperature sensor electrical connector (2).
5. Position the air duct retaining clamp (1) at the throttle body and tighten to 3 N.m (30 in. lbs.).

CYLINDER HEAD
OPERATION

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

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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 LEAKAGE test in this information. 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 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

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Fig. 87: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

1. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE
RELEASE .
2. Disconnect the negative battery cable (1).
 Fig. 88: Engine Covers

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Courtesy of CHRYSLER GROUP, LLC

3. Remove the engine covers (1).

4. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL.
5. Drain the cooling system. Refer to STANDARD PROCEDURE .

Fig. 89: Heater Hose Supply

Courtesy of CHRYSLER GROUP, LLC

6. Disconnect the heater hoses (1, 2).

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Fig. 90: Oxygen Sensor, Oxygen Sensor Connector, Ball Flange Nut & LH Catalytic
Converter
Courtesy of CHRYSLER GROUP, LLC

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

7. Remove the catalytic converters. Refer to CONVERTER, CATALYTIC, REMOVAL .

8. Lower the vehicle.

Fig. 91: Accessory Drive Belt Routing, Tensioner & Pulleys

Courtesy of CHRYSLER GROUP, LLC

CAUTION: Do not let the tensioner arm snap back to the freearm position, sever
 damage may occur to the tensioner.

9. Rotate the accessory drive belt tensioner (8) clockwise until it contacts it's stop. Remove the
accessory drive belt (2), then slowly rotate the tensioner into the freearm position. Refer to
BELT, SERPENTINE, REMOVAL .

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Fig. 92: Power Steering Reservoir, Pump, Pulley & Bolts
Courtesy of CHRYSLER GROUP, LLC

NOTE: It is not necessary to disconnect the power steering pump hoses from the
pump, for power steering pump removal.

10. Remove the three power steering pump (1) retaining bolts (2) through the access holes in the
pulley (3).
11. Remove the power steering pump (1) and secure out of the way.
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Fig. 93: Cylinder Head Cover Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

12. Using the sequence shown in illustration, remove the cylinder head cover retaining bolts and
remove cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL.
13. If removing the right cylinder head, remove the engine oil dip stick tube retaining nut at the
exhaust manifold and remove the oil dip stick tube.

Fig. 94: Rocker Shafts Retaining Bolt Removal & Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

CAUTION: Pushrods and rocker arm assemblies must be installed in their

 original locations or engine damage could result.

NOTE: Make sure to identify the original location of the rocker arms and push
rods for correct assembly.

14. Remove the rocker arms and pushrods. Refer to ROCKER ARM, VALVE, REMOVAL.

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Fig. 95: Cylinder Head Bolt Removal & Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

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

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

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

Fig. 96: Cylinder Head Gasket & Cylinder Head

 Courtesy of CHRYSLER GROUP, LLC

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

16. Discard the cylinder head gasket (1).

17. Inspect and clean the cylinder head (2) mating surface.

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Fig. 97: Exhaust Manifold Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

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

18. If necessary, using the sequence shown in illustration, remove the exhaust manifold bolts and
remove the manifold.

CLEANING

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

INSPECTION

1. Inspect the cylinder head for 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 any of these conditions exist, replace
the cylinder head.
4. Inspect push rods. Replace worn or bent push rods.

INSTALLATION

INSTALLATION

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Fig. 98: Exhaust Manifold Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

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 retaining bolts to 31 N.m (23 ft. lbs.).
 Fig. 99: Cylinder Head Gasket & Cylinder Head

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Courtesy of CHRYSLER GROUP, LLC

CAUTION: The cylinder head gaskets (1) are not interchangeable between left
and right sides. They are marked "UP" to indicate direction to face up
and "L" or "R" to indicate left side or right side of engine block.

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

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.
6. Install the cylinder head bolts finger tight.

CAUTION: The 6.4L engine uses a unique 4 layer steel head gasket that must be
compressed evenly and completely across the deck surface for
proper sealing. The tightening sequence must be followed to ensure
all layers are compressed before applying the additional 90 degree
turn.
 Fig. 100: Cylinder Head Bolt Removal & 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.).

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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 34 N.m (25 ft. lbs.).

Fig. 101: Rocker Shafts Retaining Bolt Removal & Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

CAUTION: Pushrods and rocker arm assemblies must be installed in their

original locations or engine damage could result.
 8. Install the pushrods and rocker arms. Refer to ROCKER ARM, VALVE, INSTALLATION.
9. If removed, install the oil dip stick tube and tighten the retaining nut at the exhaust manifold.

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Fig. 102: Cylinder Head Cover Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

10. Position the cylinder head covers, using the sequence shown in illustration, tighten the cylinder
head cover bolts to 8 N.m (70 lbs in.). Refer to COVER(S), CYLINDER HEAD,
INSTALLATION.

Fig. 103: Power Steering Reservoir, Pump, Pulley & Bolts

Courtesy of CHRYSLER GROUP, LLC
11. Install the power steering pump. Refer to PUMP, INSTALLATION .

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Fig. 104: Accessory Drive Belt Routing, Tensioner & Pulleys
Courtesy of CHRYSLER GROUP, LLC

CAUTION: Do not let the tensioner arm snap back to the freearm position, sever
damage may occur to the tensioner.

12. Rotate the accessory drive belt tensioner (8) clockwise until it contacts it's stop, install the
accessory drive belt (2), then slowly release the tensioner into position. Refer to BELT,
SERPENTINE, INSTALLATION .

Fig. 105: Oxygen Sensor, Oxygen Sensor Connector, Ball Flange Nut & LH Catalytic
 Converter
Courtesy of CHRYSLER GROUP, LLC

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

13. Raise and support the vehicle.

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

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Fig. 106: Heater Hose Supply
Courtesy of CHRYSLER GROUP, LLC

15. Lower the vehicle.

16. Connect the heater hoses (1, 2).
17. Install the intake manifold and throttle body as an assembly. Refer to MANIFOLD, INTAKE,
INSTALLATION.
18. Connect the fuel supply line.
 Fig. 107: Engine Covers

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Courtesy of CHRYSLER GROUP, LLC

19. Install the engine covers (1).

Fig. 108: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

20. Fill cooling system. Refer to STANDARD PROCEDURE .

21. Connect the negative battery cable (1).
22. Start engine check for leaks.

COVER(S), CYLINDER HEAD

REMOVAL
REMOVAL

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Fig. 109: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable (1).

Fig. 110: Engine Covers

Courtesy of CHRYSLER GROUP, LLC

2. Remove the engine covers (1).

 Fig. 111: Ignition Coil Electrical Connectors, Harness & Bolts

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Courtesy of CHRYSLER GROUP, LLC

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

3. Disconnect the ignition coil electrical connectors (1).

4. Position the electrical harness (2) aside.
5. Remove the ignition coil retaining bolts (3).

Fig. 112: Removing/Installing Ignition Coil

Courtesy of CHRYSLER GROUP, LLC

6. Remove the ignition coils (1).

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Fig. 113: Cylinder Head Cover Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

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

Fig. 114: Cylinder Head & Cover

Courtesy of CHRYSLER GROUP, LLC

8. Remove the cylinder head cover (1).

9. 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

INSTALLATION

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Fig. 115: Cylinder Head & Cover
Courtesy of CHRYSLER GROUP, LLC

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 and
replace gasket if necessary.
2. Install the cylinder head cover and hand start all fasteners.
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Fig. 116: Cylinder Head Cover Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

3. Using the sequence shown in illustration, tighten the cylinder head cover bolts to 8 N.m (70 lbs
in.).

Fig. 117: Removing/Installing Ignition Coil

Courtesy of CHRYSLER GROUP, LLC

4. Before installing the ignition coils, apply dielectric grease to the inside of the spark plug boots
(1).
5. Install the ignition coils.

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Fig. 118: Ignition Coil Electrical Connectors, Harness & Bolts
Courtesy of CHRYSLER GROUP, LLC

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

6. Tighten the ignition coil retaining bolts (3) to 7 N.m (62 in. lbs.).
7. Position the electrical harness (2).
8. Connect the ignition coil electrical connectors (1).

Fig. 119: Engine Covers

Courtesy of CHRYSLER GROUP, LLC

9. Install the engine covers (1).

 Fig. 120: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

10. Connect the negative battery cable.

ROCKER ARM, VALVE

REMOVAL

REMOVAL

Fig. 121: Cylinder Head Cover Removal/Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC
1. Remove the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL.

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Fig. 122: Pushrod Retaining Plate
Courtesy of CHRYSLER GROUP, LLC

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

Fig. 123: Rocker Shaft Removal/Tightening Sequence

 Courtesy of CHRYSLER GROUP, LLC

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 pushrods. Note the pushrod location for reassembly.

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Fig. 124: Rocker Arm Retainers
Courtesy of CHRYSLER GROUP, LLC

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

INSTALLATION
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Fig. 125: Pushrod Retaining Plate
Courtesy of CHRYSLER GROUP, LLC

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

1. Install the pushrods in the same order as removed.

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

Fig. 126: Rocker Arm Retainers

Courtesy of CHRYSLER GROUP, LLC

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. 127: Rocker Shaft Removal/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 to 22 N.m (16 ft. lbs.).
 cardiagn.com
Fig. 128: Pushrod Retaining Plate
Courtesy of CHRYSLER GROUP, LLC

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).
 cardiagn.com
Fig. 129: Cylinder Head Cover Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

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

SEAL(S), VALVE GUIDE

DESCRIPTION

DESCRIPTION

The valve guide seals are made of rubber and incorporate an integral steel valve spring seat. The
integral garter spring maintains consistent lubrication control to the valve stems. The intake valve
stem seal has a smaller valve spring seat compared to the exhaust valve stem seal. The intake and
exhaust valve stem seals are identified by different colors.

SPRING(S), VALVE

REMOVAL

REMOVAL
Fig. 130: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

1. Disconnect and isolate the negative battery cable (1).

Fig. 131: Air Duct Retaining Clamp, Intake Air Temperature Sensor Electrical Connector,
Makeup Air Hose, Bolt & Air Cleaner Housing
Courtesy of CHRYSLER GROUP, LLC

2. Remove the air cleaner housing (5) and clean air tube (1). Refer to BODY, AIR CLEANER,
INSTALLATION.
 cardiagn.com
Fig. 132: Cylinder Head Cover Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

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

Fig. 133: Pushrod Retaining Plate

Courtesy of CHRYSLER GROUP, LLC
 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 pushrod retainer
(special tool #9070, Retainer, Push Rod) (1) to retain the intake push rods
(2).

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

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Fig. 134: Rocker Shafts Retaining Bolt Removal & 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 an "I".

6. Using the sequence shown in illustration, remove the rocker arm shaft bolts and remove the
rocker arm shaft.
 cardiagn.com
Fig. 135: Rocker Arm Shaft Adapter & Air Hose
Courtesy of CHRYSLER GROUP, LLC

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

Fig. 136: Intake Valve Spring Removal/Installation

Courtesy of CHRYSLER GROUP, LLC

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 valve spring compressor (special tool #9065B, 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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Fig. 137: Valve Spring Compressor & Adapter
Courtesy of CHRYSLER GROUP, LLC

11. Install the valve spring compressor (special tool #9065B, Compressor, Valve Spring) (2) and the
rocker arm adapter (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

INSTALLATION
 cardiagn.com
Fig. 138: Valve Spring Compressor & Adapter
Courtesy of CHRYSLER GROUP, LLC

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

NOTE: The intake seal has a smaller spring seat diameter compared to the exhaust
seal.

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.
4. Using the valve spring compressor (special tool #9065B, Compressor, Valve Spring) (3) and the
rocker arm adapter (special tool #9065-3, Adapter, Valve Spring Compressor) (1), compress the
valve spring and install the valve spring retainer locks.
 cardiagn.com
Fig. 139: Air Charge, Valve Spring Compressor & Adapter
Courtesy of CHRYSLER GROUP, LLC

5. Remove the valve spring compressor (special tool #9065B, Compressor, Valve Spring) (3) and
the rocker arm adapter (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 ROCKER ARM, VALVE, INSTALLATION.

Fig. 140: Rocker Shafts Retaining Bolt Removal & Tightening Sequence
 Courtesy of CHRYSLER GROUP, LLC

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

8. Using the sequence shown in illustration, tighten the rocker arm shaft bolts to 22 N.m (16 ft.
lbs.).

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Fig. 141: Pushrod Retaining Plate
Courtesy of CHRYSLER GROUP, LLC

9. Remove the pushrod retainer (special tool #9070, Retainer, Push Rod) (1).
 cardiagn.com
Fig. 142: Cylinder Head Cover Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

10. Position the cylinder head cover onto the cylinder head.
11. Using the sequence shown in illustration, tighten the cylinder head cover bolts to 8 N.m (6 ft.
lbs.). Refer to COVER(S), CYLINDER HEAD, INSTALLATION.

Fig. 143: Air Duct Retaining Clamp, Intake Air Temperature Sensor Electrical Connector,
Makeup Air Hose, Bolt & Air Cleaner Housing
Courtesy of CHRYSLER GROUP, LLC

12. Install the air cleaner housing (5) and clean air tube (1). Refer to BODY, AIR CLEANER,
 INSTALLATION.

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Fig. 144: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

13. Connect the negative battery cable.

14. Road test the vehicle.

VALVES, INTAKE AND EXHAUST

DESCRIPTION

VALVES
 cardiagn.com
Fig. 145: Valve Assembly Configuration
Courtesy of CHRYSLER GROUP, LLC

Both the intake (4) and exhaust (5) 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 (1) and retainers (2) to retain the springs (6) 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 chart below 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

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(INT. AND EXT.) 44.5° - 45°
FACE ANGLE
INTAKE 45.5° - 46°
EXHAUST 45° - 45.5°
SPRING HEIGHT
INTAKE 52.1 mm 2.051 in.
EXHAUST 51.2 mm 2.016 in.

Fig. 146: Valve Assembly Configuration

Courtesy of CHRYSLER GROUP, LLC
 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° - 45.5° for the
exhaust.

REMOVAL

REMOVAL

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Fig. 147: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect and isolate the negative battery cable (1).

Fig. 148: Cylinder Head Bolt Removal & Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

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

 cardiagn.com
Fig. 149: Valve Assembly Configuration
Courtesy of CHRYSLER GROUP, LLC

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 (1), valve spring retainers (2), valve stem seals (3) and
valve springs (6).
5. Before removing the valves, remove any burrs from the valve spring retainer lock grooves in the
valve stems (4) to prevent damage to the valve guides. Identify the valves to ensure installation
in their original location.
6. Remove the valves (4, 5).

INSTALLATION

INSTALLATION
 cardiagn.com
Fig. 150: Valve Assembly Configuration
Courtesy of CHRYSLER GROUP, LLC

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 (4, 5) 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 (3) on all valve guides. Install the valve springs (6) and valve spring retainers
(2).
 cardiagn.com
Fig. 151: Valve Spring Compressor
Courtesy of CHRYSLER GROUP, LLC

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.

Fig. 152: Cylinder Head Bolt Removal & Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

8. Install the cylinder head (2). Refer to CYLINDER HEAD, INSTALLATION.

 Fig. 153: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

9. Connect the negative battery cable (1).

ENGINE BLOCK
CLEANING

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 to 20 N.m (15 ft. lbs.).
Tighten the 3/8 inch NPT plugs to 27 N.m (20 ft. lbs.) and the coolant drain plugs to 34 N.m (25 ft.
lbs.).

INSPECTION

INSPECTION

ENGINE BLOCK
Fig. 154: Checking Engine Block Deck Surface With Precision Straightedge & Feeler Gauge

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

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
 cardiagn.com
Fig. 155: Measuring Cylinder Bore Diameter
Courtesy of CHRYSLER GROUP, LLC

1. Use Cylinder Indicator (special tool #C-119, Cylinder Indicator) (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
Fig. 156: Main Bearing Inserts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

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, wear or blueing.
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 must
be replaced or damage to the new engine and/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 0.008 mm (0.0004 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.

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 - 6.4L

GRADE COLOR mm In FOR USE WITH
JOURNAL SIZE

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LOWER 64.988-64.995 mm
A ORANGE 0.008 mm U/S (0.0004 in.) U/S (2.5585- 2.5588 in.)
LOWER 64.996-65.004 mm
B BLACK NOMINAL NOMINAL (2.5588-2.5592 in.)
LOWER 65.005-65.012 mm
C GREEN 0.008 mm O/S (0.0004 in.) O/S (2.5592-2.5595 in.)

INSPECTION

INSPECTION

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

Fig. 157: Main Bearing Wear Patterns

Courtesy of CHRYSLER GROUP, LLC
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.

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

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5.7L / 6.4L - CAMSHAFT CORE HOLE PLUG

Fig. 158: Camshaft Core Hole Plug

Courtesy of CHRYSLER GROUP, LLC

1. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE
RELEASE .
2. Remove the engine from the vehicle. Refer to REMOVAL.
3. Remove the flexplate. Refer to FLEXPLATE, 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

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Fig. 159: Cylinder Head & Gasket
Courtesy of CHRYSLER GROUP, LLC

1. Remove both cylinder heads (2). Refer to CYLINDER HEAD, REMOVAL.

CAUTION: The 6.4L Multi Displacement System (MDS) engine uses both
standard roller lifters and deactivating roller lifters. The deactivating
roller lifters must be used in cylinders 1, 4, 6, 7. The deactivating
lifters can be identified by the two holes in the side of the lifter body,
for the latching pins.

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.

 Fig. 160: Hydraulic Lifters/Tappets & Retainer/Guide Holder

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

2. Remove the lifters (2) and retainer (1) as an assembly. Refer to LIFTER(S), HYDRAULIC,
ROLLER, REMOVAL.

Fig. 161: Generator & Retaining Bolt

Courtesy of CHRYSLER GROUP, LLC

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

 Fig. 162: A/C Condenser & Radiator

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

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

5. Remove the radiator (12). Refer to RADIATOR, ENGINE COOLING, REMOVAL .
6. Remove the A/C condenser (7). Refer to CONDENSER, A/C, REMOVAL .
7. Raise and support vehicle.

Fig. 163: Integral Windage Tray, Oil Pump Pickup Tube & Bolts
Courtesy of CHRYSLER GROUP, LLC

8. Remove the oil pan and oil pump pickup tube (2). Refer to PAN, OIL, REMOVAL.
 Fig. 164: Front Cover Slide Bushings

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Courtesy of CHRYSLER GROUP, LLC

NOTE: It is not necessary to remove the water pump for timing cover removal.

9. Remove the engine timing cover. Refer to COVER(S), ENGINE TIMING, REMOVAL.

Fig. 165: Remove/Install Oil Pump

Courtesy of CHRYSLER GROUP, LLC

10. Remove the oil pump. Refer to PUMP, ENGINE OIL, REMOVAL.
 Fig. 166: Timing Chain, Sprockets, Timing Chain Tensioner & Guide

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

11. Remove the timing chain (5) and camshaft phaser (1). Refer to CHAIN AND SPROCKETS,
TIMING, REMOVAL.

Fig. 167: Camshaft Thrust Plate

Courtesy of CHRYSLER GROUP, LLC

12. Remove the camshaft thrust plate (1).

CAUTION: Use care when removing the camshaft, do not damage the camshaft
bearings with the camshaft lobes.
 cardiagn.com
Fig. 168: Removing/Installing Camshaft
Courtesy of CHRYSLER GROUP, LLC

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

INSPECTION

INSPECTION

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

INSTALLATION

5.7L / 6.4L - CAMSHAFT CORE HOLE PLUG

Fig. 169: Camshaft Core Hole Plug

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

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. Install the flexplate. Refer to FLEXPLATE, INSTALLATION.
4. Install the engine. Refer to INSTALLATION.

CAMSHAFT

CAUTION: The 6.4L engine uses a unique camshaft for use with the Multi
Displacement System (MDS). When installing a new camshaft, the
replacement camshaft must be compatible with MDS.

CAUTION: Use care when installing the camshaft into the engine block, do not
damage the camshaft bearings with the camshaft lobes.
 cardiagn.com
Fig. 170: Removing/Installing Camshaft
Courtesy of CHRYSLER GROUP, LLC

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.

Fig. 171: Camshaft Thrust Plate

Courtesy of CHRYSLER GROUP, LLC

3. Install the camshaft thrust plate (1) and tighten retaining bolts to 12 N.m (106 in. lbs.).
 Fig. 172: Timing Chain, Sprockets, Timing Chain Tensioner & Guide

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Courtesy of CHRYSLER GROUP, LLC

4. Install the timing chain and camshaft phaser. Refer to CHAIN AND SPROCKETS, TIMING,
INSTALLATION.
5. Using a suitable dial indicator, measure the camshaft end play. Refer to Engine -
Specifications. If not within specification, install a new thrust plate.

Fig. 173: Remove/Install Oil Pump

Courtesy of CHRYSLER GROUP, LLC

6. Install the oil pump. Refer to PUMP, ENGINE OIL, INSTALLATION.

 Fig. 174: Front Cover Slide Bushings

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Courtesy of CHRYSLER GROUP, LLC

7. Install the engine timing cover. Refer to COVER(S), ENGINE TIMING, INSTALLATION.
8. Raise and support vehicle.

Fig. 175: Integral Windage Tray, Oil Pump Pickup Tube & Bolts
Courtesy of CHRYSLER GROUP, LLC

9. Install the oil pump pickup tube (2) and oil pan. Refer to PAN, OIL, INSTALLATION.
 Fig. 176: A/C Condenser & Radiator

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Courtesy of CHRYSLER GROUP, LLC

10. Install the A/C condenser (7). Refer to CONDENSER, A/C, INSTALLATION .
11. Install the radiator (12). Refer to RADIATOR, ENGINE COOLING, INSTALLATION .
12. Install the A/C compressor. Refer to COMPRESSOR, A/C, INSTALLATION .

Fig. 177: Generator & Retaining Bolt

Courtesy of CHRYSLER GROUP, LLC

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

CAUTION: The 6.4L Multi Displacement System (MDS) engine uses both
standard roller lifters and deactivating roller lifters. The deactivating
 roller lifters must be used in cylinders 1, 4, 6, 7. The deactivating
lifters can be identified by the two holes in the side of the lifter body,
for the latching pins.

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.

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Fig. 178: Hydraulic Lifters/Tappets & Retainer/Guide Holder
Courtesy of CHRYSLER GROUP, LLC

14. Install the lifters (2) and retainer (1) as an assembly into their original location. Refer to LIFTER
(S), HYDRAULIC, ROLLER, INSTALLATION.
 cardiagn.com
Fig. 179: Cylinder Head & Gasket
Courtesy of CHRYSLER GROUP, LLC

15. Install both cylinder heads (2). Refer to CYLINDER HEAD, INSTALLATION.
16. Install the pushrods in the same location as removed.
17. Install the rocker arms. Refer to ROCKER ARM, VALVE, INSTALLATION.

Fig. 180: Cylinder Head Cover Removal/Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC
18. Install the cylinder head covers. Refer to COVER(S), CYLINDER HEAD, INSTALLATION.

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Fig. 181: Accessory Drive Belt Routing, Tensioner & Pulleys
Courtesy of CHRYSLER GROUP, LLC

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

Fig. 182: Air Duct Retaining Clamp, Intake Air Temperature Sensor Electrical Connector,
Makeup Air Hose, Bolt & Air Cleaner Housing
Courtesy of CHRYSLER GROUP, LLC

20. Install the air cleaner housing (5) and clean air tube (1).
 Fig. 183: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

21. Install the negative battery cable.

22. Fill the cooling system with the specified type and amount of engine coolant. Refer to
STANDARD PROCEDURE .

Fig. 184: Engine Covers

Courtesy of CHRYSLER GROUP, LLC

23. Fill the crankcase with the specified type and amount of engine oil. Refer to
Engine/Lubrication/OIL - Standard Procedure.
24. Install engine covers (1).
25. Start the engine and check for leaks.

CRANKSHAFT
REMOVAL

REMOVAL

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

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Fig. 185: 6.4L HEMI V-8 Engine
Courtesy of CHRYSLER GROUP, LLC

1. Remove the engine. Refer to REMOVAL.

2. Secure the engine onto a suitable engine stand.
 Fig. 186: Vibration Damper & Bolt Grip Puller

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Courtesy of CHRYSLER GROUP, LLC

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

3. Remove the crankshaft damper retaining bolt.

4. Install the puller tool (2) making sure the bolts are fully threaded through the entire crankshaft
damper.
5. Remove the crankshaft damper (1).
 Fig. 187: Flex Plate Bolt Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

6. Remove the flexplate (1). Refer to FLEXPLATE, REMOVAL.

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Fig. 188: Integral Windage Tray, Oil Pump Pickup Tube & Bolts
Courtesy of CHRYSLER GROUP, LLC

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.

7. Remove the oil pan and the oil pump pickup tube (2). Refer to PAN, OIL, REMOVAL.
8. Remove and discard the oil pan gasket/windage tray (3).
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Fig. 189: Rear Seal Retainer Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

9. Remove the crankshaft rear oil seal retainer. Refer to RETAINER, CRANKSHAFT REAR OIL
SEAL, REMOVAL.

Fig. 190: Engine Timing Cover

Courtesy of CHRYSLER GROUP, LLC

10. Remove the engine timing cover. Refer to COVER(S), ENGINE TIMING, REMOVAL.
 Fig. 191: Oil Pump & Retaining Bolts

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Courtesy of CHRYSLER GROUP, LLC

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

Fig. 192: Timing Chain, Sprockets, Timing Chain Tensioner & Guide
Courtesy of CHRYSLER GROUP, LLC

12. Remove the timing chain (5), camshaft phaser (1) and crankshaft sprocket (3). Refer to CHAIN
AND SPROCKETS, TIMING, REMOVAL.

CAUTION: Do not use a number stamp or a punch to mark connecting rods or

caps, as damage to connecting rods could occur.
 Fig. 193: Mark On Connecting Rod & Bearing Cap
Courtesy of CHRYSLER GROUP, LLC

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

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13. Mark the connecting rod and bearing cap location using a permanent ink marker or scribe tool.
14. 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 and/or bearings could occur.

Fig. 194: Main Bearing Caps & Arrows

Courtesy of CHRYSLER GROUP, LLC
 NOTE: Main bearing caps are not interchangeable and should be marked before
removal to ensure correct reassembly.

15. Mark the main bearing caps (1) using a permanent ink marker or scribe tool.

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Fig. 195: Main Bearing Cap Removal
Courtesy of CHRYSLER GROUP, LLC

16. Remove the main bearing cap bolts.

17. Remove the main bearing cap crossbolts.
18. Remove main bearing caps (1) and bearings one at a time.
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Fig. 196: Thrust Washer Locations
Courtesy of CHRYSLER GROUP, LLC

19. Remove the thrust bearings.

Fig. 197: Crankshaft

Courtesy of CHRYSLER GROUP, LLC

20. Remove the crankshaft (1) out of the engine block.

INSTALLATION

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

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Fig. 198: Main Bearings
Courtesy of CHRYSLER GROUP, LLC

1. Select the proper main bearings (1). Refer to Engine/Engine Block/BEARING(S), Crankshaft
- Standard Procedure.
2. Lubricate the main bearing shells with clean engine oil.
3. Install the main bearings into the engine block.

Fig. 199: Main Bearing Shells In The Bearing Caps

Courtesy of CHRYSLER GROUP, LLC

4. Install the main bearing shells (2) into the bearing caps (1).
 Fig. 200: Crankshaft

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Courtesy of CHRYSLER GROUP, LLC

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

Fig. 201: Thrust Washer Installation

Courtesy of CHRYSLER GROUP, LLC

6. Lubricate and install the thrust bearings (1).

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Fig. 202: Main Bearing Caps & Arrows
Courtesy of CHRYSLER GROUP, LLC

7. Install all main bearing caps (1) in the location as noted during removal making sure the arrow
(2) faces forward.

Fig. 203: 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. 204: Crossbolt Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

NOTE: The main bearing cap crossbolts are torqued after the final torque of the
main cap bolts. Always use a new seal washers on crossbolts.

12. Install the crossbolts with new seal washers finger tight.
13. Using the sequence shown in illustration, tighten the crossbolts to 31 N.m (23 ft. lbs.).
14. Again, using the sequence shown in illustration, repeat the crossbolt tightening procedure.
15. Measure the crankshaft end play. Refer to Engine/Engine Block/BEARING(S), Crankshaft -
Standard Procedure.

CAUTION: The connecting rod bolts must not be reused. Always replace the
connecting rod bolts whenever they are loosened or removed.
 Fig. 205: Mark On Connecting Rod & Bearing Cap
Courtesy of CHRYSLER GROUP, LLC

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. Lubricate the new connecting rod bolts with clean engine oil and install the bolts finger tight.
19. Tighten the connecting rod bolts to 21 N.m (15 ft. lbs.) plus an additional 90° turn.

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Fig. 206: Connecting Rod Proper Installation
Courtesy of CHRYSLER GROUP, LLC

20. If required, measure the connecting rod side clearance (1, 2). Refer to Engine - Specifications.
 Fig. 207: Timing Chain, Sprockets, Timing Chain Tensioner & Guide

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Courtesy of CHRYSLER GROUP, LLC

21. Install the timing chain (5), camshaft phaser (1) and crankshaft sprocket (3). Refer to CHAIN
AND SPROCKETS, TIMING, INSTALLATION.

Fig. 208: Oil Pump Retaining Bolt Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

22. Position the oil pump on the crankshaft and install the oil pump retaining bolts finger tight.
23. Using the sequence shown in illustration, tighten the oil pump retaining bolts to 28 N.m (21 ft.
lbs.).
 Fig. 209: Engine Timing Cover

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Courtesy of CHRYSLER GROUP, LLC

24. Install the engine timing cover (1). Refer to COVER(S), ENGINE TIMING, INSTALLATION.

Fig. 210: Rear Seal Retainer Removal/Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

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.
25. Thoroughly clean all gasket residue from the engine block.
26. Position the gasket onto the new crankshaft rear oil seal retainer.
27. Position the crankshaft rear oil seal retainer onto the engine block.
28. Using the sequence shown in illustration, install the crankshaft rear oil seal retainer mounting
bolts and tighten to 15 N.m (11 ft. lbs.).

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Fig. 211: Integral Windage Tray, Oil Pump Pickup Tube & Bolts
Courtesy of CHRYSLER GROUP, LLC

29. Install the oil pump pickup tube (2) and oil pan. Refer to PAN, OIL, INSTALLATION.

Fig. 212: Pressing Cup & Damper Installer

Courtesy of CHRYSLER GROUP, LLC

CAUTION: To prevent severe damage to the crankshaft Damper Installer (special

 tool #8512A, Installer, Damper), thoroughly clean the damper bore
and the crankshaft nose before installing damper.

30. Position the damper on the crankshaft.

CAUTION: The Damper Installer (special tool #8512A, Installer, Damper) is

assembled in a specific sequence. Failure to assemble this tool in
this sequence may result in tool failure and severe damage to either
the tool or the crankshaft.

31. Assemble the Damper Installer (special tool #8512A, Installer, Damper) (2) as follows:
1. Install the nut onto the threaded shaft.
2. Install the roller bearing onto the threaded shaft making sure the hardened bearing
surface is facing the nut.
3. Install the pressing cup (2) from the A/C Hub Installer (special tool #6871, Installer, A/C

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Hub) onto the threaded shaft.
4. Coat the threaded shaft with MOPAR® Nickel Anti-Seize or equivalent.

Fig. 213: Pressing Damper Onto Crankshaft

Courtesy of CHRYSLER GROUP, LLC

32. Using the Damper Installer (special tool #8512A, Installer, Damper) (3) and the pressing cup (2)
from A/C Hub Installer (special tool #6871, Installer, A/C Hub), press the crankshaft damper (1)
onto the crankshaft.
33. Install the crankshaft damper bolt and tighten to 176 N.m (129 ft. lbs.).
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Fig. 214: Flex Plate Bolt Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

34. Install the flexplate (1). Refer to FLEXPLATE, INSTALLATION.

Fig. 215: 6.4L HEMI V-8 Engine

 Courtesy of CHRYSLER GROUP, LLC

35. Install the engine. Refer to INSTALLATION.

36. Start the engine and check for leaks.

DAMPER, VIBRATION

DESCRIPTION

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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Fig. 216: Crankshaft Damper & Harden Steel Bolt
Courtesy of CHRYSLER GROUP, LLC

The crankshaft damper on the engines is held to the crankshaft by means of a harden steel bolt. The
damper is pressed onto a specific machined surface of the crankshaft.
Fig. 217: HEMI® Engine Crankshaft Damper

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Courtesy of CHRYSLER GROUP, LLC

The HEMI® Engines incorporate various crankshaft vibration dampers depending on the engine
application. And can be removed depending on the application used.

Fig. 218: Removing Vibration Damper

Courtesy of CHRYSLER GROUP, LLC

Finding the proper puller for the application will ensure no damage will come to the damper. The
flange puller is used by installing 3 bolts into the pre-tapped holes in the damper.
Fig. 219: Removing Vibration Damper

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Courtesy of CHRYSLER GROUP, LLC

Some pulleys that do not have bolt holes can be removed with a three jaw style (special tool #1023,
Puller).

REMOVAL

REMOVAL

Fig. 220: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable (1).

2. Drain the cooling system. Refer to STANDARD PROCEDURE .
 Fig. 221: Upper Radiator Hose, Clamp, Oil Cooler Return Line Hose & Clamp

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Courtesy of CHRYSLER GROUP, LLC

3. Remove the upper radiator hose clamps (1) and remove the upper radiator hose (2).
4. Remove the oil cooler hose clamp (3) and remove oil cooler hose (4) and position aside.

Fig. 222: Accessory Drive Belt Routing, Tensioner & Pulleys

Courtesy of CHRYSLER GROUP, LLC

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

 Fig. 223: Cooling Fan Electrical Connector, Bolts & Radiator Cooling Fan Assembly

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Courtesy of CHRYSLER GROUP, LLC

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

Fig. 224: Vibration Damper & Bolt Grip Puller

Courtesy of CHRYSLER GROUP, LLC

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

7. Remove the vibration damper bolt.

8. Install the puller tool (2) making sure the bolts are fully threaded through the entire crankshaft
damper.
9. Remove the crankshaft damper (1).
INSTALLATION

INSTALLATION

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Fig. 225: Installing Vibration Damper Onto Crankshaft Using Special Tool
Courtesy of CHRYSLER GROUP, LLC

1. Using (special tool #10387, Installer, Vibration Damper), install the threaded rod (1) onto the
crankshaft (2).
2. Tighten the threaded rod (4) until it is seated to the face (3) of the crankshaft.

Fig. 226: Installing Vibration Damper

Courtesy of CHRYSLER GROUP, LLC

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

4. Install the press washer, bearing, washer, and the press nut onto the threaded rod.
5. Using Damper Installer (1) and a deep well socket, press the damper onto the crankshaft till
seated.

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Fig. 227: Installing Vibration Damper
Courtesy of CHRYSLER GROUP, LLC

6. Install the vibration damper bolt.

7. Position the (special tool #10386, Holder, Vibration Damper) (2), onto the vibration pulley (3).
8. Tighten the bolt to 250 N.m (184 ft. lbs.).

Fig. 228: Accessory Drive Belt Routing, Tensioner & Pulleys

Courtesy of CHRYSLER GROUP, LLC

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

 Fig. 229: Cooling Fan Electrical Connector, Bolts & Radiator Cooling Fan Assembly

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Courtesy of CHRYSLER GROUP, LLC

10. Install the cooling fan. Refer to FAN, COOLING, INSTALLATION .

Fig. 230: Upper Radiator Hose, Clamp, Oil Cooler Return Line Hose & Clamp
Courtesy of CHRYSLER GROUP, LLC

11. Install the oil cooler hose (4) and clamp (3).
12. Install the upper radiator hose (2) and clamp (1).
13. Refill the cooling system. Refer to STANDARD PROCEDURE .
 Fig. 231: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

14. Connect the negative battery cable (1).

FLEXPLATE

REMOVAL

REMOVAL

Fig. 232: Flex Plate Bolt Removal/Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC
 1. Remove the transmission. Refer to REMOVAL .
2. Using the sequence shown in illustration, remove the flexplate (1) retaining bolts.
3. Remove the flexplate.

INSTALLATION

INSTALLATION

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Fig. 233: Flex Plate Bolt Removal/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 95 N.m (70 ft.
lbs.).
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.

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,

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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

REMOVAL
Fig. 234: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

1. Disconnect and isolate the negative battery cable.

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

Fig. 235: Hydraulic Lifters/Tappets & Retainer/Guide Holder

Courtesy of CHRYSLER GROUP, LLC

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

INSTALLATION

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Fig. 236: Hydraulic Lifters/Tappets & Retainer/Guide Holder
Courtesy of CHRYSLER GROUP, LLC

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

Fig. 237: Rear MDS Lifter Assembly

Courtesy of CHRYSLER GROUP, LLC

CAUTION: The 6.4L Multi Displacement System (MDS) engine uses both
 standard roller lifters and deactivating roller lifters. The deactivating
roller lifters must be used in cylinders 1, 4, 6, 7. The deactivating
lifters can be identified by the two holes in the side of the lifter body,
for the latching pins.

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 12 N.m (9 ft. lbs.).

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4. Install the cylinder head. Refer to CYLINDER HEAD, INSTALLATION.

Fig. 238: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

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.

6. Start the engine and check for leaks.

7. Road test the vehicle.

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:

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Circular spray pattern generally indicates seal leakage or crankshaft damage.
Where leakage tends to run straight down, possible causes are a porous block, camshaft
bore cup plugs, oil gallery pipe plugs, oil filter runoff and main bearing cap to cylinder
block mating surfaces. See appropriate Engine information, for proper repair procedures
of these items.
4. If no leaks are detected, pressurize the crankcase "Engine Oil Leak" . Refer to ENGINE OIL
LEAK.

CAUTION: Do not exceed 20.6 kPa (3 psi).

5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or
scratches that can be polished out using an emery cloth.

CAUTION: Use extreme caution when crankshaft polishing is necessary to

remove minor nicks or scratches. The crankshaft seal flange is
specially machined to complement the function of the rear oil seal.

6. For bubbles that remain steady with shaft rotation, no further inspection can be done. Refer to
RETAINER, CRANKSHAFT REAR OIL SEAL, REMOVAL.

REMOVAL

REMOVAL
Fig. 239: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

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 (1).

2. Remove the transmission. Refer to REMOVAL .
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Fig. 240: Flex Plate Bolt Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

3. Remove the flexplate (1). Refer to FLEXPLATE, REMOVAL.

4. Remove the oil pan. Refer to PAN, OIL, REMOVAL.

Fig. 241: Rear Seal Retainer Removal/Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC
 5. Using the sequence shown in illustration, remove the rear oil seal retainer mounting bolts.
6. Remove and discard the rear oil seal retainer.

INSTALLATION

INSTALLATION

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Fig. 242: Rear Seal Retainer Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

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.
4. Using the sequence shown in illustration, install the crankshaft rear oil seal retainer mounting
bolts and tighten to 15 N.m (11 ft. lbs.).
5. Install the oil pan. Refer to PAN, OIL, INSTALLATION.
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Fig. 243: Flex Plate Bolt Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

6. Install the flexplate (1). Refer to FLEXPLATE, INSTALLATION.

7. Install the transmission. Refer to INSTALLATION .
8. Fill the crankcase with the specified type and amount of engine oil. Refer to
Engine/Lubrication/OIL - Standard Procedure.

Fig. 244: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

9. Connect the negative battery cable (1).

10. Start the engine and check for leaks.

RING(S), PISTON

STANDARD PROCEDURE

STANDARD PROCEDURE - PISTON RING FITTING

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Fig. 245: Using Feeler Gauge To Check Ring End Gap
Courtesy of CHRYSLER GROUP, LLC

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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Fig. 246: Measuring Piston Ring Side Clearance
Courtesy of CHRYSLER GROUP, LLC

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

Fig. 247: Installing Piston Ring Side Rail
Courtesy of CHRYSLER GROUP, LLC

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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.

Fig. 248: Installing Upper & Intermediate Rings

Courtesy of CHRYSLER GROUP, LLC

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.
 Fig. 249: Piston Ring End Gap Position
Courtesy of CHRYSLER GROUP, LLC

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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

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 aluminum alloy. Piston skirts are coated with a solid lubricant
(Molykote) 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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Fig. 250: Measuring Cylinder Bore Diameter
Courtesy of CHRYSLER GROUP, LLC

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.

Fig. 251: Moly Coated Piston

Courtesy of CHRYSLER GROUP, LLC

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 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

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REMOVAL

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

Fig. 252: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

1. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE
RELEASE .
2. Disconnect and isolate the negative battery cable (1).
 Fig. 253: Cylinder Head

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Courtesy of CHRYSLER GROUP, LLC

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

Fig. 254: Integral Windage Tray, Oil Pump Pickup Tube & Bolts
Courtesy of CHRYSLER GROUP, LLC

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.

4. Remove the oil pan. Refer to PAN, OIL, REMOVAL.

5. Remove and discard the oil pan gasket/windage tray (3).
6. 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.

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Fig. 255: Piston Oil Jet & Bolt
Courtesy of CHRYSLER GROUP, LLC

7. 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 surfaces as engine damage may occur.

CAUTION: Care must be taken not to nick crankshaft journals as engine damage
may occur.
 Fig. 256: Mark On Connecting Rod & Bearing Cap
Courtesy of CHRYSLER GROUP, LLC

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

8. 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.

9. Remove the connecting rod cap and carefully remove the piston from the cylinder bore, repeat
this procedure for each piston being removed.

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10. 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.
11. Carefully remove the piston rings from the piston(s), starting from the top ring down.

CLEANING

CLEANING

CAUTION: DO NOT use a wire wheel or other abrasive cleaning devise to clean the
pistons or connecting rods. The pistons have a Moly 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

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
Engine/Engine Block/ROD, Piston and Connecting - Standard Procedure.

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

INSTALLATION
INSTALLATION

CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler must
be replaced or damage to the new engine and/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 Engine/Engine Block/RING(S), Piston - Standard

Procedure.
2. Before installing piston and connecting rod assemblies into the bore, install the piston rings.
Refer to Engine/Engine Block/RING(S), Piston - Standard Procedure.

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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.

Fig. 257: Piston Direction Arrow

Courtesy of CHRYSLER GROUP, LLC

4. The pistons are marked on the piston pin bore surface with an raised "F" or arrow on top of
piston indicating installation position. This mark must be pointing toward the front of 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.
7. Insert the piston and rod assembly into the cylinder bore and carefully position the connecting
rod over the crankshaft journal.
8. Tap 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 ENGINE BLOCK.

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Fig. 258: Connecting Rod Cap & Bearing
Courtesy of CHRYSLER GROUP, LLC

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.
 Fig. 259: Connecting Rod Guides

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Courtesy of CHRYSLER GROUP, LLC

12. Install the (special tool #8507, Guides, Connecting Rod) (1) into the connecting rod bolt threads.

Fig. 260: Connecting Rod Proper Installation

Courtesy of CHRYSLER GROUP, LLC

13. 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.
14. Lubricate the new rod cap bolts with clean engine oil, install and tighten to 45 N.m (33 ft. lbs.)
plus an additional 60° turn.

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.

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Fig. 261: Piston Oil Jet & Bolt
Courtesy of CHRYSLER GROUP, LLC

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

16. Install the piston oil cooler jet retaining bolt(s) (2) and tighten to 13 N.m (10 ft. lbs.).

Fig. 262: Integral Windage Tray, Oil Pump Pickup Tube & Bolts
 Courtesy of CHRYSLER GROUP, LLC

17. Install the new oil pan gasket/windage tray (3), oil pump pickup tube (2) and oil pan. Refer to
PAN, OIL, INSTALLATION.
18. Install the engine oil dipstick tube and dipstick.
19. Lower the vehicle.

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Fig. 263: Cylinder Head
Courtesy of CHRYSLER GROUP, LLC

20. Install the cylinder head(s). Refer to CYLINDER HEAD, INSTALLATION.

Fig. 264: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

21. Connect the negative battery cable (3).

22. Start the engine and check for leaks.

SEAL, CRANKSHAFT OIL, FRONT

REMOVAL

REMOVAL

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Fig. 265: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable (1).

2. Drain the cooling system. Refer to STANDARD PROCEDURE .

Fig. 266: Upper Radiator Hose, Clamp, Oil Cooler Return Line Hose & Clamp
Courtesy of CHRYSLER GROUP, LLC
3. Remove the upper radiator hose clamp (1) and remove the upper radiator hose (2).
4. Remove the oil cooler hose clamp (3) and remove oil cooler hose (4).

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Fig. 267: Accessory Drive Belt Routing, Tensioner & Pulleys
Courtesy of CHRYSLER GROUP, LLC

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

Fig. 268: Vibration Damper & Bolt Grip Puller

Courtesy of CHRYSLER GROUP, LLC

NOTE: When installing the puller tool, ensure the bolts are fully threaded through
the entire crankshaft damper.
 6. Remove the crankshaft damper retaining bolt.
7. Install the puller tool (2) making sure the bolts are fully threaded through the entire crankshaft
damper.
8. Remove the crankshaft damper (1).

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Fig. 269: Front Crankshaft Seal Removal
Courtesy of CHRYSLER GROUP, LLC

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

INSTALLATION

INSTALLATION

CAUTION: The front crankshaft seal must be installed dry. Do not apply lubricant to
sealing lip or to outer edge.
Fig. 270: Installing Vibration Damper Onto Crankshaft Using Special Tool

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Courtesy of CHRYSLER GROUP, LLC

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

Fig. 271: Front Seal Installation

Courtesy of CHRYSLER GROUP, LLC

2. Using Seal Installer (special tool #9072, Installer, Seal) and (special tool #10387, Installer,
Vibration Damper) (2), install the crankshaft front oil seal.
 Fig. 272: Installing Vibration Damper

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Courtesy of CHRYSLER GROUP, LLC

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

4. Install the press washer, bearing, washer, and the press nut onto the threaded rod.
5. Using Damper Installer (1) and a deep well socket, press the damper onto the crankshaft till
seated.

Fig. 273: Installing Vibration Damper

Courtesy of CHRYSLER GROUP, LLC

6. Install the vibration damper bolt.

7. Position the (special tool #10386, Holder, Vibration Damper) (2), onto the vibration pulley (3).
8. Tighten the bolt to 250 N.m (184 ft. lbs.).
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Fig. 274: Accessory Drive Belt Routing, Tensioner & Pulleys
Courtesy of CHRYSLER GROUP, LLC

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

Fig. 275: Upper Radiator Hose, Clamp, Oil Cooler Return Line Hose & Clamp
Courtesy of CHRYSLER GROUP, LLC

10. Install the upper radiator hose (2) and clamp (1).
11. Install the oil cooler hose (4) and clamp (3).
 Fig. 276: Cooling Fan Motor Assembly

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Courtesy of CHRYSLER GROUP, LLC

12. Install the cooling fan. Refer to FAN, COOLING, INSTALLATION .

13. Refill the cooling system. Refer to STANDARD PROCEDURE .

Fig. 277: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

14. Connect the negative battery cable (1).

SEAL, CRANKSHAFT OIL, REAR

DESCRIPTION

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

Diagnosis and Testing: Refer to Engine/Engine Block/RETAINER, Crankshaft Rear Oil

Seal - Diagnosis and Testing.
Removal: Refer to RETAINER, CRANKSHAFT REAR OIL SEAL, REMOVAL.
Installation: Refer to RETAINER, CRANKSHAFT REAR OIL SEAL, INSTALLATION.

SOLENOID, MULTIPLE DISPLACEMENT

DESCRIPTION

DESCRIPTION

The Multi Displacement System (MDS) selectively deactivates cylinders 1, 4, 6, and 7 to improve fuel
economy. It has two modes of operation:

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8 cylinders for acceleration and heavy loads
4 cylinders for cruising and city traffic

The main components of the Multi Displacement System are:

Unique MDS camshaft

Deactivating roller lifters
4 control valve solenoids
Control valve solenoid wiring harness
Oil temperature sensor

OPERATION

OPERATION

Cylinder Deactivation

Trap an exhaust charge from a normal combustion event

Normal combustion event
Deactivate the exhaust valve
Deactivate the intake valve
Piston is an air spring
Cylinders deactivated in firing sequence

Cylinder Reactivation

Normal combustion event

 Activate the exhaust valve
Activate the intake valve
Empty the cylinder
Cylinders reactivated in firing sequence

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - 6.4L - MDS SOLENOID

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

Solenoid circuit
Fail to deactivate a cylinder(s)
Fail to reactivate a cylinder(s)

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Low oil pressure

CONDITION POSSIBLE CAUSES CORRECTION

MDS does not activate 1. Low oil pressure 1. Check for proper oil pressure
2. Bad oil temperature sensor
2. Replace the oil temperature
sensor
3. Malfunctioning MDS solenoid 3. Replace the MDS solenoid
4. Malfunctioning MDS lifter 4. Replace lifter(s)
MDS does not deactivate 1. Low oil pressure 1. Check or proper oil pressure
2. Bad oil temperature sensor 2. Replace the oil temp sensor
3. Malfunctioning MDS solenoid 3. Replace the MDS solenoid
4. Malfunctioning MDS lifter(s) 4. Replace lifter(s)

REMOVAL

REMOVAL
Fig. 278: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

1. Disconnect and isolate the negative battery cable (1).

Fig. 279: Intake Manifold Foam Insulator Pad, MDS Solenoids & Bolts
Courtesy of CHRYSLER GROUP, LLC

2. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL.

3. Remove foam insulator pad (1).
 Fig. 280: MDS Solenoids, Electrical Connectors & Retaining Bolts

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Courtesy of CHRYSLER GROUP, LLC

4. Remove the Multiple Displacement Solenoid (MDS) (2) electrical connector(s) (1).
5. Remove the MDS solenoid (2) retaining bolt(s) (3).

CAUTION: Do not try to pry the solenoid out. This could lead to breakage and
contamination of the lubrication system.

Fig. 281: Removing/Installing MDS Solenoid

Courtesy of CHRYSLER GROUP, LLC

6. Lightly tap on the MDS solenoid(s) with a rubber mallet. Rotate the MDS solenoid(s) from side
to side to break the seal.
7. Remove the MDS solenoid(s).
INSTALLATION

INSTALLATION

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Fig. 282: Removing/Installing MDS Solenoid
Courtesy of CHRYSLER GROUP, LLC

1. Verify the MDS solenoid bores are free of debris before installing the MDS solenoid into the
engine block.
2. Install the MDS solenoid(s) (3), ensure the seal is fully seated into the engine block.

Fig. 283: MDS Solenoids, Electrical Connectors & Retaining Bolts

Courtesy of CHRYSLER GROUP, LLC

3. Install the retaining bolt(s) (3) and tighten to 11 N.m (8 ft. lbs.).
4. Connect the MDS electrical connector to the solenoid(s) (1).
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Fig. 284: Intake Manifold Foam Insulator Pad, MDS Solenoids & Bolts
Courtesy of CHRYSLER GROUP, LLC

5. Install the foam insulator pad (1).

6. Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION.

Fig. 285: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

7. Connect the negative battery cable (1).

ENGINE MOUNTING
INSULATOR, ENGINE MOUNT, REAR
REMOVAL

REMOVAL

AUTOMATIC TRANSMISSION

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Fig. 286: Rear Cross Member & Bolts
Courtesy of CHRYSLER GROUP, LLC

1. Raise and support the vehicle.

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 (4).
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Fig. 287: Rear Transmission Mount Isolator
Courtesy of CHRYSLER GROUP, LLC

5. Remove the rear transmission mount isolator (3) retaining bolts (1) and remove the isolator.

Fig. 288: Rear Transmission Mount Bracket

Courtesy of CHRYSLER GROUP, LLC

6. If required, remove the rear transmission mount bracket (2) retaining bolts (1) and remove the
bracket.

MANUAL TRANSMISSION
Fig. 289: Rear Cross Member & Retaining Bolts

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Courtesy of CHRYSLER GROUP, LLC

1. Raise and support the vehicle.

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

Fig. 290: Rear Transmission Mount Isolator & Retaining Bolts

Courtesy of CHRYSLER GROUP, LLC

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

INSTALLATION

INSTALLATION
AUTOMATIC TRANSMISSION

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Fig. 291: Rear Transmission Mount Bracket
Courtesy of CHRYSLER GROUP, LLC

1. If removed, position the rear transmission mount bracket (2), install the retaining bolts (1) and
tighten to 68 N.m (50 ft. lbs.).

Fig. 292: Rear Transmission Mount Isolator

Courtesy of CHRYSLER GROUP, LLC

2. Position the rear transmission mount isolator (3) to the rear transmission mount bracket (2),
install the retaining bolts (1) and tighten to 33 N.m (24 ft. lbs.).
 Fig. 293: Rear Cross Member & Bolts

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Courtesy of CHRYSLER GROUP, LLC

3. Position the transmission crossmember (4), 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 68 N.m (50 ft. lbs.).
6. Lower the transmission and remove the jack.
7. Tighten the rear transmission mount isolator retaining bolts (2) to 47 N.m (35 ft. lbs.).

MANUAL TRANSMISSION

Fig. 294: Rear Transmission Mount Isolator & Retaining Bolts

Courtesy of CHRYSLER GROUP, LLC

1. Position the rear transmission mount isolator (2), install the retaining bolts (1) and tighten to 68
 N.m (50 ft. lbs.).

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Fig. 295: Rear Cross Member & Retaining Bolts
Courtesy of CHRYSLER GROUP, LLC

2. Position the rear cross member, install the retaining bolts (2) finger tight.
3. Install the rear transmission mount isolator nuts (1) finger tight.
4. Tighten the transmission crossmember retaining bolts (2) to 68 N.m (50 ft. lbs.).
5. Lower the transmission and remove the jack.
6. Tighten the rear transmission mount isolator retaining nuts (1) to 47 N.m (35 ft. lbs.).

INSULATOR, ENGINE MOUNT, FRONT

REMOVAL

REMOVAL
Fig. 296: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable (1).

2. Remove the engine oil dipstick tube retaining nut at the right exhaust manifold.
3. Raise and support the vehicle.

Fig. 297: Lower Splash Shield & Fasteners

Courtesy of CHRYSLER GROUP, LLC

4. Remove the belly pan retainers (1) and remove the belly pan.
 Fig. 298: Engine Mount Heat Shield Retaining Nuts, Lower Mount Retaining Bolts & Heat

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Shields
Courtesy of CHRYSLER GROUP, LLC

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

5. Remove both left/right engine mount heat shield (4) retaining nuts (3) and remove the heat
shields.
6. Remove both left/right engine mount lower retaining bolts (2).
7. Lower the vehicle.

Fig. 299: Intake Manifold

Courtesy of CHRYSLER GROUP, LLC

8. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL.

 Fig. 300: Oil Control Valve, Electrical Connector & Retaining Bolt

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Courtesy of CHRYSLER GROUP, LLC

9. Remove the Oil Control Valve (OCV). Refer to CONTROL VALVE, OIL INTAKE, REMOVAL.

Fig. 301: Engine Lift Fixture & Adapter

Courtesy of CHRYSLER GROUP, LLC

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) (2) and the Engine Support Fixture
(special tool #8534B, Fixture, Driveline Support) (3).
11. Raise the engine to provide clearance to remove the engine mounts.
12. Raise and support the vehicle.
 Fig. 302: Support Bracket, Bolt & Nut

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Courtesy of CHRYSLER GROUP, LLC

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).

Fig. 303: Engine Mounting Bracket & Retaining Bolts

Courtesy of CHRYSLER GROUP, LLC

NOTE: Left side shown in illustration, right side similar. Mounting brackets shown
in illustration without the engine mounts.

15. Remove engine mount to engine block mounting bracket retaining bolts (1) and remove the
mounting brackets (2).
 Fig. 304: Intermediate Steering Coupler & Rack And Pinion

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Courtesy of CHRYSLER GROUP, LLC

16. For removing the left side engine mount. Disconnect the intermediate steering coupler (1) from
the rack and pinion (2).

Fig. 305: Starter & Right Side Engine Mount

Courtesy of CHRYSLER GROUP, LLC

17. For removing the right side engine mount. Remove the starter (1).
 Fig. 306: Engine Mount

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Courtesy of CHRYSLER GROUP, LLC

18. Remove the engine mount (1) assembly through the rear side of the engine.

Fig. 307: Engine Mounting Bracket, Engine Mount & Fasteners

Courtesy of CHRYSLER GROUP, LLC

19. Separate the engine mount (4) from the engine mounting bracket (1).

INSTALLATION

INSTALLATION
Fig. 308: Engine Mounting Bracket, Engine Mount & Fasteners

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Courtesy of CHRYSLER GROUP, LLC

1. Install the engine mount to the engine bracket. Tighten the nut (2) and studs (3) to 60 N.m (44 ft.
lbs.)

Fig. 309: Engine Mount

Courtesy of CHRYSLER GROUP, LLC

2. Position the engine mount assembly into the vehicle through the rear side of the engine.
 Fig. 310: Left Side Mounting Bracket

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Left side shown in illustration, right side similar. Mounting brackets shown
in illustration without the engine mounts.

3. Position the engine mount to engine block. Install the retaining bolts and tighten to 61 N.m (45
ft. lbs.).

Fig. 311: Support Bracket, Bolt & Nut

Courtesy of CHRYSLER GROUP, LLC

4. Position the generator support bracket (3) to the engine mount, install the retaining nut (1) and
tighten finger tight.
5. Position the generator support bracket (3) to the generator, install the retaining bolt (2) and
tighten to 65 N.m (48 ft. lbs.).
6. Tighten the generator support bracket (3) to engine mount retaining nut (1) to 28 N.m (21 ft.
lbs.).
7. Lower the vehicle.

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Fig. 312: Engine Lift Fixture & Adapter
Courtesy of CHRYSLER GROUP, LLC

8. Lower the Engine Support Fixture (special tool #8534B, Fixture, Driveline Support) (3) until the
engine mounts are seated in the engine cradle.
9. 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 #8534B, Fixture, Driveline Support) (3).

Fig. 313: Oil Control Valve, Electrical Connector & Retaining Bolt
Courtesy of CHRYSLER GROUP, LLC
10. Install the Oil Control Valve (OCV). Refer to CONTROL VALVE, OIL INTAKE, INSTALLATION.

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Fig. 314: Intake Manifold
Courtesy of CHRYSLER GROUP, LLC

11. Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION.

12. Raise and support the vehicle.

Fig. 315: Engine Mount Heat Shield Retaining Nuts, Lower Mount Retaining Bolts & Heat
Shields
Courtesy of CHRYSLER GROUP, LLC

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

13. Install both left/right engine mount lower retaining bolts (2) and tighten to 61 N.m (45 ft. lbs.).
14. Position both left/right engine mount heat shields (4), install the retaining nuts (3) and tighten to
27 N.m (20 ft. lbs.).

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Fig. 316: Intermediate Steering Coupler & Rack And Pinion
Courtesy of CHRYSLER GROUP, LLC

15. If disconnected. Install the intermediate steering coupler to the rack and pinion. Tighten the bolt
to 45 N.m (33 ft. lbs.).

Fig. 317: Starter & Right Side Engine Mount

Courtesy of CHRYSLER GROUP, LLC

16. If removed. Install the starter. Tighten the bolts to 27 N.m (20 ft. lbs.).
 Fig. 318: Lower Splash Shield & Fasteners

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Courtesy of CHRYSLER GROUP, LLC

17. Position the belly pan and install the belly pan retainers (1).
18. Lower the vehicle.

Fig. 319: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

19. Position the engine oil dipstick tube, install the retaining nut at the right exhaust manifold.
20. Connect the negative battery cable (1).

LUBRICATION
DESCRIPTION
DESCRIPTION

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Fig. 320: 6.4L Lubrication System
Courtesy of CHRYSLER GROUP, LLC

The lubrication system is a full flow filtration pressure feed type system.

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 - 25 kPa (4 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.

If the oil leak source is not positively identified at this time, proceed with the AIR LEAK
DETECTION TEST METHOD below.

AIR LEAK DETECTION TEST METHOD

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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 the battery.

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

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TEST METHOD.

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

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.

CONTROL VALVE, OIL INTAKE

DESCRIPTION

DESCRIPTION
Fig. 321: Oil Control Valve, Electrical Connector & Retaining Bolt

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

The 6.4L engine is equipped with Variable Valve Timing (VVT). This system uses an Oil Control
Valve (OCV) 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 OCV (3) is located under the intake manifold.

OPERATION

OPERATION

Fig. 322: Camshaft Phaser & Bolt

Courtesy of CHRYSLER GROUP, LLC

The Variable Valve Timing (VVT) assembly is actuated with engine oil pressure. The oil flow to the
VVT assemblies are controlled by an Oil Control Valve (OCV). The OCV consist of a Pulse Width
Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through
the spool valve into the VVT assemblies. The VVT assembly consists of a rotor, stator, and sprocket
(Phaser) (2). The stator is connected to the timing chain through the sprocket. The rotor is connected
to the camshaft. Oil flow in to the VVT assembly rotates the rotor with respect to the stator, thus
rotating the exhaust camshaft with respect to the timing chain and intake camshaft. An infinitely
variable valve timing position can be achieved within the limits of the hardware. The CMP monitors
the position of the camshaft with respect to the crankshaft and provides feedback to the PCM.

REMOVAL

REMOVAL

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Fig. 323: Oil Control Valve, Electrical Connector & Retaining Bolt
Courtesy of CHRYSLER GROUP, LLC

NOTE: The Oil Control Valve (OCV) (3) is located under the intake manifold.

1. Remove intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL.

2. Disconnect OCV electrical connector (1).
3. Remove OCV retaining bolt (2).
 Fig. 324: Removing/Installing OCV

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Courtesy of CHRYSLER GROUP, LLC

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

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

INSTALLATION

INSTALLATION

Fig. 325: Removing/Installing OCV

Courtesy of CHRYSLER GROUP, LLC

1. Lubricate the oil control valve (OCV) rubber O-ring seal with clean engine oil.
2. Install the OCV and rotate into position.
 Fig. 326: Oil Control Valve, Electrical Connector & Retaining Bolt

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Courtesy of CHRYSLER GROUP, LLC

3. Install the OCV (3) retaining bolt (2) and tighten to 11 N.m (8 ft. lbs.).
4. Connect OCV electrical connector (1).
5. Install intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL.

COOLER, OIL

DESCRIPTION

DESCRIPTION

Fig. 327: Oil Filter, Oil Cooler & Hoses

Courtesy of CHRYSLER GROUP, LLC
The engine oil cooler (2) is engineered for maximum cooling efficiency with no restriction in oil flow.
The oil cooler is a stack plate design coolant-to-oil heat exchanger.

The oil cooler (2) is mounted between the oil filter (1) and the engine block. The oil cooler uses the
radiator coolant system; coolant is circulated through two coolant hoses to maintain a consistent
engine oil temperature.

REMOVAL

REMOVAL

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

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Fig. 328: Lower Splash Shield & Fasteners
Courtesy of CHRYSLER GROUP, LLC

1. Raise and support the vehicle.

2. Remove the belly pan retainers (1) and remove the belly pan.
3. Drain the cooling system. Refer to STANDARD PROCEDURE .
 Fig. 329: Oil Filter, Oil Cooler & Hoses

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Courtesy of CHRYSLER GROUP, LLC

4. Remove the oil filter (1) from the oil cooler (2).

Fig. 330: Clamps, Allen Wrench Socket & Oil Cooler Retaining Bolt
Courtesy of CHRYSLER GROUP, LLC

5. Remove the clamps (1) from the cooling hoses at the oil cooler and remove hoses.
6. Using a 12 mm Allen Wrench socket (2), remove the oil cooler retaining bolt (3).
 Fig. 331: O-Ring Seal & Oil Cooler

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Courtesy of CHRYSLER GROUP, LLC

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

7. Remove and discard the oil cooler (2) rubber O-ring seal (1).

INSTALLATION

INSTALLATION

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

Fig. 332: O-Ring Seal & Oil Cooler

Courtesy of CHRYSLER GROUP, LLC

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

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

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Fig. 333: Clamps, Allen Wrench Socket & Oil Cooler Retaining Bolt
Courtesy of CHRYSLER GROUP, LLC

3. Using a 12 mm Allen Wrench socket (2), install the oil cooler retaining bolt (3) and tighten to 28
N.m (21 ft. lbs.).
4. Position the cooling hoses and install the clamps (1).

Fig. 334: Oil Filter, Oil Cooler & Hoses

Courtesy of CHRYSLER GROUP, LLC
 5. Lightly lubricate the oil filter gasket with clean engine oil.

NOTE: Do not over tighten the oil filter.

6. Thread the oil filter (1) onto the oil cooler (2) oil filter boss.
7. 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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Fig. 335: Lower Splash Shield & Fasteners
Courtesy of CHRYSLER GROUP, LLC

8. Position the belly pan to the under side of the vehicle and install the retainers (1).
9. Lower the vehicle.
10. Fill the cooling system. Refer to STANDARD PROCEDURE .
11. Start the engine and check for leaks.
12. Turn the engine off and check the oil level.

FILTER, ENGINE OIL

REMOVAL

REMOVAL
Fig. 336: Lower Splash Shield & Fasteners

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Courtesy of CHRYSLER GROUP, LLC

All engines are equipped with a high quality full-flow, disposable type oil filter.

1. Raise and support the vehicle.

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

Fig. 337: Oil Filter, Oil Cooler & Hoses

Courtesy of CHRYSLER GROUP, LLC

3. Position a drain pan under the oil filter.

4. Using a suitable oil filter wrench, rotate the oil filter (1) counterclockwise to remove it from the oil
cooler (2).
5. When the oil filter separates from the oil cooler, 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.

INSTALLATION

INSTALLATION

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Fig. 338: Oil Filter, Oil Cooler & Hoses
Courtesy of CHRYSLER GROUP, LLC

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

NOTE: Do not over tighten the oil filter.

2. Thread the oil filter (1) onto the oil cooler (2) oil filter boss.
3. When the oil filter gasket makes contact with the oil cooler sealing surface, hand tighten the oil
filter one half turn, or 180°.
 Fig. 339: Lower Splash Shield & Fasteners

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

4. Position the belly pan to the under side of the vehicle and install the retainers (1).
5. Lower the vehicle.
6. Fill the crankcase with the specified type and amount of engine oil as described in this
information.
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

DESCRIPTION
 cardiagn.com
Fig. 340: Engine Oil Jet & Bolt
Courtesy of CHRYSLER GROUP, LLC

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

REMOVAL
Fig. 341: Oil Pan Bolt Removal/Installation Sequence
Courtesy of CHRYSLER GROUP, LLC

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

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Fig. 342: Piston Oil Jet & Bolt
Courtesy of CHRYSLER GROUP, LLC

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

INSTALLATION
 cardiagn.com
Fig. 343: Piston Oil Jet & Bolt
Courtesy of CHRYSLER GROUP, LLC

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

2. Install the piston oil cooler jet retaining bolt and tighten to 13 N.m (10 ft. lbs.) (2).

Fig. 344: Oil Pan Bolt Removal/Installation Sequence

Courtesy of CHRYSLER GROUP, LLC

3. Install the engine oil pump pickup tube and oil pan. Refer to PAN, OIL, INSTALLATION.
OIL

STANDARD PROCEDURE

STANDARD PROCEDURE - ENGINE OIL SERVICE

CRANKCASE OIL LEVEL INSPECTION

On the 6.4L engine, 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.

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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 .

Run the engine until it reaches normal operating temperature.

1. Remove the oil fill cap.

2. Raise and support the vehicle.
3. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
4. Place a suitable drain pan under the oil pan drain.
5. Remove the drain plug from the oil pan and allow the oil to drain.
6. Inspect the drain plug threads for stretching or other damage and replace if necessary.
7. Install the drain plug and tighten to 27 N.m (20 ft. lbs.).
8. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
 9. Lower the vehicle and fill the crankcase with the specified type and amount of engine oil
described in this information.
10. Install the oil fill cap.
11. Start the engine and check for leaks.
12. Stop the engine and check the oil level.

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

PAN, OIL

REMOVAL

REMOVAL

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Fig. 345: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

1. Disconnect the negative battery cable (1).

2. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL.
3. Remove the engine oil dipstick and tube from the oil pan.
4. Raise and support the vehicle.
 Fig. 346: Lower Splash Shield & Fasteners

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Courtesy of CHRYSLER GROUP, LLC

5. Remove the belly pan retainers (1) and remove the belly pan.
6. Drain the engine oil and remove the oil filter.

Fig. 347: Gear Mounting Bolts & Steering Gear

Courtesy of CHRYSLER GROUP, LLC

NOTE: Do not remove P/S hoses, tie rod ends or disconnect the steering column
coupler.

7. Remove the steering gear mounting bolts (1) and lower the steering gear (2) to provide
clearance to remove the oil pan.
 Fig. 348: Engine Mount Heat Shield Retaining Nuts, Lower Mount Retaining Bolts & Heat

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Shields
Courtesy of CHRYSLER GROUP, LLC

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

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

Fig. 349: Engine Lift Fixture & Adapter

Courtesy of CHRYSLER GROUP, LLC

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

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

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Fig. 350: Oil Pan Bolt Removal/Installation Sequence
Courtesy of CHRYSLER GROUP, LLC

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.

13. Raise and support the vehicle.

14. Remove the M10 retaining bolts (horizontal 11, 12, 15, 18 and vertical 20, 21, 22, 23) from the
rear of the oil pan to the transmission.
15. Remove the M6 retaining bolts and remove the oil pan.
 Fig. 351: Integral Windage Tray, Oil Pump Pickup Tube & Bolts

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Courtesy of CHRYSLER GROUP, LLC

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.

16. Remove the oil pump pickup tube retaining bolt and nut (1).
17. Remove the oil pump pickup tube (2).
18. Remove and discard the oil pan gasket/windage tray (3).

INSTALLATION

INSTALLATION
 cardiagn.com
Fig. 352: T-Joint RTV Sealant Application Locations
Courtesy of CHRYSLER GROUP, LLC

1 - Front Cover T-Joints

2 - Rear Oil Retainer T-Joints

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).
 Fig. 353: Integral Windage Tray, Oil Pump Pickup Tube & Bolts

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Courtesy of CHRYSLER GROUP, LLC

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 (3).

4. Using a new O-ring, position the oil pump pickup tube (2) into the oil pump.
5. Install the oil pump pickup tube retaining bolt and nut (1) and tighten to 28 N.m (21 ft. lbs.).

Fig. 354: Oil Pan Bolt Removal/Installation 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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Fig. 355: Engine Lift Fixture & Adapter
Courtesy of CHRYSLER GROUP, LLC

11. Using the Engine Lift Fixture (special tool #8984B, Fixture, Engine Lifting) (1), Engine Lift
Adapter (special tool #8984-UPD, Adapter, Engine Lift) (2) and the Engine Support Fixture
(special tool #8534B, Fixture, Driveline Support) (3) lower the engine into position and remove.
12. Install the engine oil dipstick tube and dipstick.
13. Raise and support the vehicle.
 Fig. 356: Engine Mount Heat Shield Retaining Nuts, Lower Mount Retaining Bolts & Heat

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Shields
Courtesy of CHRYSLER GROUP, LLC

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

14. Install both engine mount lower retaining bolts (2) and tighten to 61 N.m (45 ft. lbs.).
15. Position both engine mount heat shields (4) and install retaining nuts (3).

Fig. 357: Gear Mounting Bolts & Steering Gear

Courtesy of CHRYSLER GROUP, LLC

16. Position the steering gear (2), install mounting bolts (1) and tighten to 95 N.m (70 ft. lbs.).
 Fig. 358: Oil Filter, Oil Cooler & Hoses

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Courtesy of CHRYSLER GROUP, LLC

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

NOTE: Do not over tighten the oil filter.

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

Fig. 359: Lower Splash Shield & Fasteners

Courtesy of CHRYSLER GROUP, LLC

20. Position the belly pan to the under side of vehicle and install belly pan retainers (1).
21. Lower the vehicle.
22. Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION.
23. Fill the engine with oil. Refer to Engine/Lubrication/OIL - Standard Procedure.

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Fig. 360: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

24. Connect the negative battery cable (1).

25. Start the engine and check for leaks.

PUMP, ENGINE OIL

REMOVAL

REMOVAL
Fig. 361: Engine Timing Cover
Courtesy of CHRYSLER GROUP, LLC

NOTE: It is not necessary to remove water pump for timing cover removal.

1. Remove the engine timing cover. Refer to COVER(S), ENGINE TIMING, REMOVAL.

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Fig. 362: Integral Windage Tray, Oil Pump Pickup Tube & Bolts
Courtesy of CHRYSLER GROUP, LLC

NOTE: When the oil pan is removed, a new oil pan gasket and the integral
windage tray (3) assembly must be installed, the old gasket cannot be
reused.

2. Remove the oil pan and oil pump pickup tube (2). Refer to PAN, OIL, REMOVAL.
 Fig. 363: Oil Pump & Retaining Bolts
Courtesy of CHRYSLER GROUP, LLC

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

CLEANING

CLEANING

1. Wash all parts in a suitable solvent.

2. Using compressed air, carefully dry parts.

INSPECTION

INSPECTION

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Fig. 364: Measuring Outer Rotor Clearance in Housing
Courtesy of CHRYSLER GROUP, LLC

1 - FEELER GAUGE
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 0.235 mm (0.009 in.) or greater the oil pump assembly must be replaced.

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Fig. 365: Measuring Clearance Between Inner & Outer Rotors
Courtesy of CHRYSLER GROUP, LLC

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 0.150 mm (0.006 in.) or greater the oil
pump assembly must be replaced.
 Fig. 366: Measuring Clearance Over Rotors
Courtesy of CHRYSLER GROUP, LLC

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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 0.095 mm (0.0038 in.) or greater the oil pump must be replaced.
6. Install the pump cover and tighten retainers to 15 N.m (11 ft. lbs.)

NOTE: The 6.4L oil pump is serviced as an assembly. There are no Chrysler part
numbers for sub-assembly components. In the event the oil pump is not
functioning or out of specification it must be replaced as an assembly.

INSTALLATION

INSTALLATION
Fig. 367: Oil Pump & Retaining Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

1. Position the oil pump (1) onto the crankshaft, install the retaining bolts (2) and tighten to 28 N.m
(21 ft. lbs.).

Fig. 368: Engine Timing Cover

Courtesy of CHRYSLER GROUP, LLC

2. Install the timing chain cover. Refer to COVER(S), ENGINE TIMING, INSTALLATION.
 Fig. 369: Integral Windage Tray, Oil Pump Pickup Tube & Bolts

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Courtesy of CHRYSLER GROUP, LLC

3. Install the oil pump pickup tube (2) and oil pan. Refer to PAN, OIL, INSTALLATION.

SENSOR, OIL PRESSURE

DESCRIPTION

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

REMOVAL

1. Disconnect and isolate the negative battery cable.

2. Remove the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL .
3. Remove the upper generator mounting bolt.
4. Raise and support the vehicle.
 Fig. 370: Lower Splash Shield & Fasteners

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Courtesy of CHRYSLER GROUP, LLC

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

Fig. 371: Lower Generator Retaining Bolts

Courtesy of CHRYSLER GROUP, LLC

6. Remove the lower generator retaining bolts (1).

7. Lower the vehicle.
8. Position the generator aside to gain access to the oil pressure sensor.
 Fig. 372: Oil Pressure Sensor Electrical Connector

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Courtesy of CHRYSLER GROUP, LLC

9. Disconnect the oil pressure sensor electrical connector (1).

Fig. 373: Oil Pressure Sensor

Courtesy of CHRYSLER GROUP, LLC

10. Remove the oil pressure sensor (1).

INSTALLATION

INSTALLATION
Fig. 374: Oil Pressure Sensor

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

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

1. Install the oil pressure sensor (1).

Fig. 375: Oil Pressure Sensor Electrical Connector

Courtesy of CHRYSLER GROUP, LLC

2. Connect the oil pressure sensor electrical connector (1).

3. Position the generator and install the upper mounting bolt finger tight.
4. Raise and support the vehicle.
 Fig. 376: Lower Generator Retaining Bolts

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Courtesy of CHRYSLER GROUP, LLC

5. Install the lower mounting bolts (1) and tighten to 55 N.m (41 ft. lbs).

Fig. 377: Lower Splash Shield & Fasteners

Courtesy of CHRYSLER GROUP, LLC

6. Position the lower splash shield and install the retainers (1).
7. Lower the vehicle
8. Tighten the upper generator mounting bolt to 55 N.m (41 ft. lbs).

CAUTION: When installing a serpentine accessory drive belt, the belt MUST be
routed correctly. The water pump may be rotating in the wrong
direction if the belt is installed incorrectly, causing the engine to
 overheat.

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

10. Connect the negative battery cable.

SENSOR, OIL TEMPERATURE

DESCRIPTION

DESCRIPTION

The oil temperature sensor uses the following two circuits:

Signal circuit to the PCM

Ground circuit from the PCM

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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

REMOVAL

1. Disconnect and isolate the negative battery cable.

2. Remove the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL .
3. Remove the generator upper mounting bolt.
4. Raise and support the vehicle.

Fig. 378: Lower Splash Shield & Fasteners

 Courtesy of CHRYSLER GROUP, LLC

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

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Fig. 379: Lower Generator Retaining Bolts
Courtesy of CHRYSLER GROUP, LLC

6. Remove the generator lower mounting bolts (1).

7. Lower the vehicle.
8. Position the generator aside to gain access to the oil temperature sensor.

Fig. 380: Oil Temperature Sensor Electrical Connector

Courtesy of CHRYSLER GROUP, LLC

9. Disconnect the oil temperature sensor electrical connector (1).

 Fig. 381: Oil Temperature Sensor

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Courtesy of CHRYSLER GROUP, LLC

10. Remove the oil temperature sensor (1).

INSTALLATION

INSTALLATION

Fig. 382: Oil Temperature Sensor

Courtesy of CHRYSLER GROUP, LLC

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

1. Install the oil temperature sensor (1).

 Fig. 383: Oil Temperature Sensor Electrical Connector

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Courtesy of CHRYSLER GROUP, LLC

2. Connect the oil temperature sensor electrical connector (1).

3. Position the generator and install the upper mounting bolt finger tight.
4. Raise and support the vehicle.

Fig. 384: Lower Generator Retaining Bolts

Courtesy of CHRYSLER GROUP, LLC

5. Install the generator lower mounting bolts (1) and tighten to 55 N.m (41 ft. lbs.).
 Fig. 385: Lower Splash Shield & Fasteners

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Courtesy of CHRYSLER GROUP, LLC

6. Position the belly pan to the under side of the vehicle and install the retainers (1).
7. Lower the vehicle.
8. Tighten the generator upper mounting bolt to 55 N.m (41 ft. lbs.).

CAUTION: When installing a serpentine accessory drive belt, the belt MUST be
routed correctly. The water pump may be rotating in the wrong
direction if the belt is installed incorrectly, causing the engine to
overheat.

9. Install the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL .

10. Connect the negative battery cable.

MANIFOLDS
MANIFOLD, EXHAUST

DESCRIPTION

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

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.

REMOVAL

REMOVAL

EXHAUST MANIFOLDS

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Fig. 386: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

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

1. Disconnect the negative battery cable (1).

Fig. 387: Cylinder Head

 Courtesy of CHRYSLER GROUP, LLC

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

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Fig. 388: Exhaust Manifold & Bolts
Courtesy of CHRYSLER GROUP, LLC

3. Remove the exhaust manifold (2) top row of bolts (1).

Fig. 389: Exhaust Manifold Heat Shield & Bolts

Courtesy of CHRYSLER GROUP, LLC

4. Remove the exhaust manifold heat shield.

5. Remove the exhaust manifold bottom row of bolts (1).

CLEANING
CLEANING

Clean the mating surfaces on cylinder head and manifold. Wash with solvent and blow dry with
compressed air.

INSPECTION

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

INSTALLATION

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EXHAUST MANIFOLDS

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

Fig. 390: Exhaust Manifold Heat Shield & Bolts

Courtesy of CHRYSLER GROUP, LLC

1. Clean the sealing surfaces of the exhaust manifold and cylinder head.
2. Using a new exhaust manifold gasket, position the exhaust manifold (2).
3. Install the exhaust manifold bottom row of bolts (1) finger tight.
 Fig. 391: Exhaust Manifold & Bolts

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Courtesy of CHRYSLER GROUP, LLC

4. Install the exhaust manifold (2) top row of bolts (1) and tighten to 31 N.m (23 ft. lbs.).
5. Position the coolant bottle (1) and install the retaining bolts (2).
6. Raise and support the vehicle.

Fig. 392: Exhaust Manifold Heat Shield & Bolts

Courtesy of CHRYSLER GROUP, LLC

7. Tighten the exhaust manifold bottom row of bolts to 31 N.m (23 ft. lbs.).
8. Install the exhaust manifold heat shield.
 Fig. 393: Cylinder Head

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Courtesy of CHRYSLER GROUP, LLC

9. Install the cylinder head. Refer to CYLINDER HEAD, INSTALLATION.

Fig. 394: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

10. Connect the negative battery cable (1).

11. Start the engine and check for leaks.

MANIFOLD, INTAKE

DESCRIPTION

DESCRIPTION
Fig. 395: Intake Manifold

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Courtesy of CHRYSLER GROUP, LLC

The intake manifold is made of a composite material and features a dual shaft Short Runner Valve
(SRV) system to maximize both low end torque and peak power. The SRV is bolted to the rear of the
intake manifold and can be service separately from the manifold. The manifold uses a single plane
sealing system with individual port seals and a separate PCV port seal to prevent leaks.

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKAGE

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

WARNING: Use extreme caution when the engine is operating. Do not stand in a
direct line with the fan. Do not put your hands near the pulleys, belts or
the fan. Do not wear loose clothing. Failure to follow this warning may
result in serious or fatal injury.

1. Start the engine.

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

REMOVAL

REMOVAL
Fig. 396: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

1. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE
RELEASE .
2. Disconnect the negative battery cable (1).

Fig. 397: Engine Covers

Courtesy of CHRYSLER GROUP, LLC

3. Remove the engine covers (1).

4. Disconnect the fuel supply line. Refer to FITTING, QUICK CONNECT .
 Fig. 398: Air Duct Retaining Clamp, Intake Air Temperature Sensor Electrical Connector,

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Makeup Air Hose, Bolt & Air Cleaner Housing
Courtesy of CHRYSLER GROUP, LLC

5. Remove the air cleaner housing (5). Refer to BODY, AIR CLEANER, REMOVAL.
6. Disconnect the brake booster hose and the EVAP purge hose.

Fig. 399: Intake Manifold Removal/Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

7. Disconnect the electrical connectors from the following components:

Manifold Absolute Pressure (MAP) Sensor
Short Runner Valve (SRV)
Fuel Injectors
Electronic Throttle Control (ETC)
 NOTE: Remove the intake manifold and throttle body as an assembly.

8. Using the sequence shown in illustration, remove the intake manifold retaining bolts.
9. Remove the intake manifold and throttle body as an assembly from the vehicle.

CLEANING

CLEANING

NOTE: There is NO approved repair procedure for the intake manifold. If severe
damage is found during inspection, the intake manifold must be replaced.

Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning
solvent, then air dry.

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INSPECTION

INSPECTION

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

INSTALLATION

INSTALLATION

Fig. 400: Intake Manifold & PCV Seals

Courtesy of CHRYSLER GROUP, LLC

NOTE: The intake manifold seals (1, 3) may be used again, provided no cuts, tears, or
deformation have occurred.
1. Inspect the intake manifold seals and replace if necessary.

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

2. If required, apply Mopar® Lock & Seal Adhesive to the intake manifold bolts.
3. Position the intake manifold (2).

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Fig. 401: Intake Manifold Removal/Tightening Sequence
Courtesy of CHRYSLER GROUP, LLC

4. Using the sequence shown in illustration, install the intake manifold retaining bolts and tighten to
12 N.m (9 ft. lbs.).
5. Connect the fuel supply line. Refer to FITTING, QUICK CONNECT .
6. Connect the brake booster hose and the EVAP purge hose.
7. Connect the electrical connectors to the following components:
Manifold Absolute Pressure (MAP) Sensor
Short Runner Valve (SRV)
Fuel Injectors
Electronic Throttle Control (ETC)
 Fig. 402: Air Duct Retaining Clamp, Intake Air Temperature Sensor Electrical Connector,

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Makeup Air Hose, Bolt & Air Cleaner Housing
Courtesy of CHRYSLER GROUP, LLC

8. While sliding the air duct onto the throttle body, lower the air cleaner housing (5) into position
and align the locating pin on the bottom of the housing.
9. Install the air cleaner housing retaining bolt (4) and tighten to 5 N.m (44 in. lbs.).
10. Install the makeup air hose (3) at the air cleaner housing.
11. Connect the intake air temperature sensor electrical connector (2).
12. Position the air duct retaining clamp (1) at the throttle body and tighten to 3 N.m (30 in. lbs.).

Fig. 403: Engine Covers

Courtesy of CHRYSLER GROUP, LLC

13. Install the engine covers (1) on to the ball studs.

 Fig. 404: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

14. Connect the negative battery cable (1).

VALVE TIMING
CHAIN AND SPROCKETS, TIMING

REMOVAL

REMOVAL

Fig. 405: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC
1. Disconnect the negative battery cable.
2. Raise and support the vehicle.
3. Drain the cooling system.

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Fig. 406: Integral Windage Tray, Oil Pump Pickup Tube & Bolts
Courtesy of CHRYSLER GROUP, LLC

4. Remove the oil pan and oil pump pick up tube (2). Refer to PAN, OIL, REMOVAL.

Fig. 407: Front Cover Slide Bushings

Courtesy of CHRYSLER GROUP, LLC

5. Remove the engine timing cover. Refer to COVER(S), ENGINE TIMING, REMOVAL.
6. Verify the slide bushings (1) remain located in the engine timing cover during removal.
 Fig. 408: Oil Pump & Retaining Bolts

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Courtesy of CHRYSLER GROUP, LLC

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

Fig. 409: Aligning Timing Marks With Timing Chain Sprockets

Courtesy of CHRYSLER GROUP, LLC

8. 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).
 Fig. 410: Retracting Tensioner Shoe Using Pliers
Courtesy of CHRYSLER GROUP, LLC

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

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Fig. 411: Timing Chain Tensioner, Pin & Bolts
Courtesy of CHRYSLER GROUP, LLC

10. 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.
 Fig. 412: Camshaft Phaser Retaining Bolt
Courtesy of CHRYSLER GROUP, LLC

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

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Fig. 413: Timing Chain Tensioner, Pin & Bolts
Courtesy of CHRYSLER GROUP, LLC

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

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

Fig. 414: Timing Chain Guide & Bolts

Courtesy of CHRYSLER GROUP, LLC

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

INSTALLATION

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Fig. 415: Crankshaft Sprocket
Courtesy of CHRYSLER GROUP, LLC

1. Install the crankshaft sprocket (1) and position halfway onto the crankshaft.

Fig. 416: Aligning Timing Chain & Camshaft Phaser Marks

Courtesy of CHRYSLER GROUP, LLC

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.
 Fig. 417: Aligning Timing Chain & Crankshaft Sprocket Marks

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Courtesy of CHRYSLER GROUP, LLC

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.

Fig. 418: Camshaft Phaser Retaining Bolt

Courtesy of CHRYSLER GROUP, LLC

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.
 Fig. 419: Timing Chain Guide & Bolts

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Courtesy of CHRYSLER GROUP, LLC

6. If removed, install the timing chain guide (1) and tighten the bolts (2) to 11 N.m (8 ft. lbs.).

Fig. 420: Timing Chain Tensioner, Pin & Bolts

Courtesy of CHRYSLER GROUP, LLC

7. If removed, install the timing chain tensioner (2) and tighten the bolts (3) to 11 N.m (8 ft. lbs.).
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.
 cardiagn.com
Fig. 421: Aligning Timing Marks With Timing Chain Sprockets
Courtesy of CHRYSLER GROUP, LLC

9. Rotate the crankshaft two revolutions and verify the alignment of the timing marks (1, 2). If the
timing marks do not line up, remove the camshaft sprocket and realign.

Fig. 422: Camshaft Phaser Retaining Bolt

Courtesy of CHRYSLER GROUP, LLC

10. Tighten the camshaft phaser bolt (1) to 85 N.m (63 ft. lbs.).
 Fig. 423: Remove/Install Oil Pump

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Courtesy of CHRYSLER GROUP, LLC

11. Position the oil pump onto the crankshaft and install the oil pump retaining bolts finger tight.

Fig. 424: Oil Pump Retaining Bolt Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

12. Using the sequence shown in illustration, tighten the oil pump retaining bolts to 28 N.m (21 ft.
lbs.).
 Fig. 425: Front Cover Slide Bushings

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Courtesy of CHRYSLER GROUP, LLC

13. Verify the slide bushings (1) remain located in the engine timing cover.

Fig. 426: Engine Timing Cover

Courtesy of CHRYSLER GROUP, LLC

14. Using a new gasket, install the engine timing cover and tighten the retaining bolts to 28 N.m (21
ft. lbs.).

NOTE: The large lifting stud is torqued to 55 N.m (40 ft. lbs.).

15. Tighten the large lifting stud to 55 N.m (40 ft. lbs.).
 Fig. 427: Integral Windage Tray, Oil Pump Pickup Tube & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

16. Raise and support the vehicle.

17. Install the oil pump pickup tube (2) and the oil pan. Refer to PAN, OIL, INSTALLATION.

Fig. 428: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

18. Install the negative battery cable.

19. Fill the cooling system with the specified type and amount of engine coolant. Refer to
STANDARD PROCEDURE .
 Fig. 429: Engine Covers

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Courtesy of CHRYSLER GROUP, LLC

20. Fill the crankcase with the specified type and amount of engine oil. Refer to
Engine/Lubrication/OIL - Standard Procedure.
21. Install the engine covers (1).
22. Start the engine and check for leaks.

COVER(S), ENGINE TIMING

REMOVAL

REMOVAL

Fig. 430: Engine Covers

Courtesy of CHRYSLER GROUP, LLC
1. Remove the engine covers (1).
2. Perform the fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .

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Fig. 431: Negative Battery Cable
Courtesy of CHRYSLER GROUP, LLC

3. Disconnect the negative battery cable (1).

Fig. 432: Integral Windage Tray, Oil Pump Pickup Tube & Bolts
Courtesy of CHRYSLER GROUP, LLC

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.

4. Remove the oil pan. Refer to PAN, OIL, REMOVAL.

 5. Remove the oil pump pickup tube retaining bolt and nut (1).
6. Remove the oil pump pickup tube (2).
7. Remove and discard the oil pan gasket/windage tray (3).
8. Lower the vehicle.

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Fig. 433: Upper Radiator Hose, Clamp, Oil Cooler Return Line Hose & Clamp
Courtesy of CHRYSLER GROUP, LLC

9. Remove the upper radiator hose clamp (1) and remove the upper radiator hose (2).
10. Remove the oil cooler hose clamp (3) and remove oil cooler hose (4).

Fig. 434: Coolant Temperature (ECT) Sensor Electrical Connector, Heater Tube &
Retaining Bolt
Courtesy of CHRYSLER GROUP, LLC
11. Remove the coolant temperature sensor electrical connector (2).
12. Remove the heater tube retaining bolt (1).
13. Lift the heater tube (3) out of the water pump.

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Fig. 435: Camshaft Position Sensor Electrical Connector & Bolt
Courtesy of CHRYSLER GROUP, LLC

14. Disconnect the camshaft position sensor electrical connector (1).

Fig. 436: Cooling Fan Electrical Connector, Bolts & Radiator Cooling Fan Assembly
Courtesy of CHRYSLER GROUP, LLC

15. Remove the cooling fan. Refer to FAN, COOLING, REMOVAL .

 cardiagn.com
Fig. 437: Accessory Drive Belt Routing, Tensioner & Pulleys
Courtesy of CHRYSLER GROUP, LLC

16. Remove the accessory drive belt (2). Refer to BELT, SERPENTINE, REMOVAL .
17. Remove the lower radiator hose clamp and remove the lower radiator hose.
18. Remove the idler pulley (6).
19. Remove the belt tensioner (8).

Fig. 438: Power Steering Reservoir, Pump, Pulley & Bolts

Courtesy of CHRYSLER GROUP, LLC

NOTE: It is not necessary to remove the power steering pump hoses for power
steering pump removal.
20. Remove the three power steering pump mounting bolts (2) through the access holes in the
pulley (3).
21. Remove the power steering pump (1) from the engine and position aside.

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Fig. 439: Removing/Installing A/C Compressor
Courtesy of CHRYSLER GROUP, LLC

22. Remove A/C compressor from the front timing chain cover and position aside. Refer to
COMPRESSOR, A/C, REMOVAL .

Fig. 440: Generator & Retaining Bolt

Courtesy of CHRYSLER GROUP, LLC

23. Remove the generator from the front timing chain cover and position aside. Refer to
GENERATOR, REMOVAL .
 Fig. 441: Vibration Damper & Bolt Grip Puller

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Courtesy of CHRYSLER GROUP, LLC

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

24. Remove the vibration damper. Refer to DAMPER, VIBRATION, REMOVAL.

25. Install the puller tool (2) making sure the bolts are fully threaded through the entire crankshaft
damper and remove the crankshaft damper (1).

Fig. 442: Engine Timing Cover

Courtesy of CHRYSLER GROUP, LLC

NOTE: It is not necessary to remove water pump for timing cover removal.
26. Remove the engine timing cover retaining bolts and remove the engine timing cover.

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Fig. 443: Front Cover Slide Bushings
Courtesy of CHRYSLER GROUP, LLC

27. Verify that the engine timing cover slide bushings (1) remain located in the engine timing cover.

INSTALLATION

INSTALLATION

Fig. 444: Front Cover Slide Bushings

Courtesy of CHRYSLER GROUP, LLC

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

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

2. Verify that the engine timing cover slide bushings (1) remain located in the engine timing cover.

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Fig. 445: Engine Timing Cover
Courtesy of CHRYSLER GROUP, LLC

3. Using a new gasket, install the engine timing cover and tighten the retaining bolts to 28 N.m (21
ft. lbs.).

NOTE: The large lifting stud is torqued to 55 N.m (40 ft. lbs.).

4. Tighten the large lifting stud to 55 N.m (40 ft. lbs.).

Fig. 446: Integral Windage Tray, Oil Pump Pickup Tube & Bolts
Courtesy of CHRYSLER GROUP, LLC
5. Raise and support the vehicle.
6. Install the oil pump pickup tube (2) and the oil pan. Refer to PAN, OIL, INSTALLATION.
7. Install the lower radiator hose and clamp.

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Fig. 447: Installing Vibration Damper Onto Crankshaft Using Special Tool
Courtesy of CHRYSLER GROUP, LLC

8. Assemble the (special tool #10387, Installer, Vibration Damper) as follows:

1. Install the threaded shaft (1) onto the crankshaft (3) till its seated.
2. Position the crankshaft damper onto the crankshaft.
3. Install the thrust washer.
4. Install the roller bearing onto the threaded shaft making sure the hardened bearing
surface is facing away from the crankshaft.
5. Install the washer.
6. Install the nut onto the threaded shaft.
 Fig. 448: Installing Vibration Damper

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Courtesy of CHRYSLER GROUP, LLC

9. Using the crankshaft Damper Installer (1) press the vibration damper (2) onto the crankshaft.
Refer to DAMPER, VIBRATION, INSTALLATION.
10. Install the crankshaft damper bolt and tighten to 176 N.m (129 ft. lbs.).

Fig. 449: Generator & Retaining Bolt

Courtesy of CHRYSLER GROUP, LLC

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

 Fig. 450: Removing/Installing A/C Compressor

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Courtesy of CHRYSLER GROUP, LLC

12. Install the A/C compressor. Refer to COMPRESSOR, A/C, INSTALLATION .

Fig. 451: Power Steering Reservoir, Pump, Pulley & Bolts

Courtesy of CHRYSLER GROUP, LLC

13. Position the power steering pump, align the pump (1) with the mounting holes on the engine.
14. Install the three power steering pump mounting bolts (2) through access holes in the pulley (3)
and tighten to 28 N.m (21 ft. lbs.).
 cardiagn.com
Fig. 452: Accessory Drive Belt Routing, Tensioner & Pulleys
Courtesy of CHRYSLER GROUP, LLC

15. Install the accessory drive belt tensioner assembly (8) and idler pulley (6).
16. Install the accessory drive belt (2). Refer to BELT, SERPENTINE, INSTALLATION .
17. Install the oil dipstick tube and retaining nut.

Fig. 453: Cooling Fan Electrical Connector, Bolts & Radiator Cooling Fan Assembly
Courtesy of CHRYSLER GROUP, LLC

18. Install the cooling fan. Refer to FAN, COOLING, INSTALLATION .

 Fig. 454: Camshaft Position Sensor Electrical Connector & Bolt

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Courtesy of CHRYSLER GROUP, LLC

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

Fig. 455: Coolant Temperature (ECT) Sensor Electrical Connector, Heater Tube &
Retaining Bolt
Courtesy of CHRYSLER GROUP, LLC

20. Install the heater tube (3) into of the water pump.
21. Install the heater tube retaining bolt (1) and tighten to 12 N.m (9 ft. lbs.).
22. Connect the coolant temperature sensor electrical connector (2).
 Fig. 456: Upper Radiator Hose, Clamp, Oil Cooler Return Line Hose & Clamp

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Courtesy of CHRYSLER GROUP, LLC

23. Install the oil cooler hose (4) and clamp (3).
24. Install the upper radiator hose (2) and clamp (1).

Fig. 457: Intake Manifold Removal/Tightening Sequence

Courtesy of CHRYSLER GROUP, LLC

25. Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION.

26. Fill the cooling system with the specified type and amount of engine coolant. Refer to
STANDARD PROCEDURE .
27. Fill the crankcase with the specified type and amount of engine oil. Refer to
Engine/Lubrication/OIL - Standard Procedure.
 Fig. 458: Negative Battery Cable

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Courtesy of CHRYSLER GROUP, LLC

28. Connect the negative battery cable (1).

Fig. 459: Engine Covers

Courtesy of CHRYSLER GROUP, LLC

29. Install the engine covers (1).

30. Perform the Refrigerant System Charge procedure. Refer to PLUMBING, STANDARD
PROCEDURE .
31. Start the engine and check for leaks.

TENSIONER, ENGINE TIMING

DESCRIPTION
DESCRIPTION

Fig. 460: Timing Chain Tensioner Arm

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Courtesy of CHRYSLER GROUP, LLC

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

OPERATION

Fig. 461: Timing Chain Tensioner Arm

Courtesy of CHRYSLER GROUP, LLC

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.