SM 1

2009 Dodge Journey R/T
2009 ENGINE 2.4L Gas - Service Information - Journey
2009 ENGINE
2.4L Gas - Service Information - Journey
DESCRIPTION
DESCRIPTION
The 2.4 Liter (148 cu. in.) inline four cylinder engine is a double over head camshaft design with mechanical
lash tappets and four valves per cylinder design. This engine is NOT free-wheeling; meaning that the pistons
will contact the valves in the event of a timing chain failure.
The cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2.
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Fig. 1: Serial Number
Courtesy of CHRYSLER LLC
The engine serial number (1) is located on the rear of the cylinder block behind the oil pan. The serial number is
visible with the oil pan in place. The serial number contains engine build date information.
DIAGNOSIS AND TESTING

INTRODUCTION
Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine
maintenance.
These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine
idles rough and stalls).
Refer to MECHANICAL and PERFORMANCE diagnostic charts, for possible causes and corrections of
malfunctions.
For fuel system diagnosis, see FUEL SYSTEM .
Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that cannot be
isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided
within the following:
 Cylinder Compression Pressure Test: Refer to CYLINDER COMPRESSION PRESSURE TEST.

 Cylinder Combustion Pressure Leakage Test: Refer to CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST.
 Engine Cylinder Head Gasket Failure Diagnosis: Refer to CYLINDER HEAD GASKET.
 Intake Manifold Leakage Diagnosis: Refer to INTAKE MANIFOLD LEAKS.
 Mechanical Valve Tappet Noise Diagnosis: Refer to MECHANICAL VALVE TAPPET NOISE
DIAGNOSIS.
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 Engine Oil Leak Inspection: Refer to ENGINE OIL LEAK INSPECTION.
PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION

ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. Refer to Electrical -
Engine Systems/Battery System
- Diagnosis and Testing .
2. Corroded or loose battery 2. Clean and tighten battery
connections. connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. Check for
codes. (Refer to Appropriate
Diagnostic Information)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. Refer to Electrical -
Ignition Control/Ignition
Control - Specifications .
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES 1. Idle speed too low. 1. Test minimum air flow. (Refer
ROUGH to Appropriate Diagnostic
Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate
3. Intake manifold leakage. 3. Inspect intake manifold,
manifold gasket, and vacuum
hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
Information)
5. Remove OCV and inspect for
5. Contamination in Oil Control
contamination. Replace OCV if
Valve (OCV).
contaminated.
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped 1. Clean plugs and set gap.
plugs.
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filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
Information)
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
7. Burned, warped, or pitted 7. Replace valves.
valves.
8. Plugged or restricted exhaust 8. Perform exhaust restriction test.
system. Install new parts. Refer to
Exhaust System - Diagnosis and
Testing , as necessary.
Information)
ENGINE MISSES ON 1. Dirty or incorrectly gapped 1. Clean spark plugs and set gap.
ACCELERATION spark plugs.
2. Contamination in Fuel System. 2. Clean fuel system and replace
fuel filter.
3. Burned, warped, or pitted 3. Replace valves.
valves.
Information)
ENGINE MISSES AT HIGH 1. Dirty or incorrect spark plug 1. Clean spark plugs and set gap.
SPEED gap.
Information)
3. Dirty fuel injector(s). 3. Test and replace as necessary.
Information)
filter.
MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION

VALVETRAIN NOISE 1. High or low oil level in 1. Check and correct engine oil
crankcase. level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.
3. Thick oil 3. (a) Change engine oil and filter.
- (b) Run engine to operating
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temperature.
- (c) Change engine oil and filter
again.
4. Low oil pressure. 4. (a) Check and correct engine oil
level.
- (b) Check pressure regulating valve.
5. Worn cam lobe. 5. Install new camshaft.
6. Worn tappet bucket. 6. Install new select fit tappet
bucket.
7. Worn valve guides. 7. Replace cylinder head.
8. Excessive runout of valve seats 8. Grind valve seats and replace
on valve faces. valves.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect
oil pump relief valve and spring.
(b) Run engine to operating
-
temperature.
(c) Change engine oil and filter
-
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Connecting rod journal out-of- 6. Replace crankshaft or grind
round. surface.
7. Connecting rod out-of-round. 7. Replace connecting rod.
8. Misaligned connecting rods. 8. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect
oil pump relief valve and spring.

(b) Run engine to operating
-
temperature.
(c) Change engine oil and filter
-
again.
clearance. Repair as necessary.
6. Excessive end play. 6. Check thrust bearing for wear on
flanges.
7. Crankshaft journal out-of- 7. Replace crankshaft or grind
round or worn. journals.
8. Loose flywheel or torque 8. Tighten to correct torque.
converter.
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OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sending 2. Install new sending unit.
unit.
3. Low oil pressure. 3. Check sending unit and main
bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace balance shaft module.
7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean,
or replace.
clearance.
OIL LEAKS 1. Misaligned or deteriorated 1. Replace gasket(s).
gaskets.
2. Loose fastener, broken or 2. Tighten, repair or replace the
porous metal part. part.
3. Misaligned or deteriorated cup 3. Replace as necessary.
or threaded plug.
OIL CONSUMPTION OR 1. PCV system malfunction. 1. Check system and repair as
SPARK PLUGS FOULED necessary. Refer to Emissions
Control/Evaporative
Emissions/VALVE, Positive
Crankcase Ventilation (PCV) -
Diagnosis and Testing .
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Install new rings.
4. Rings fitted too tightly in 4. Remove rings and check grooves.
grooves. If groove is not proper width,
replace piston.
5. Worn valve guide(s). 5. Replace cylinder head.

6. Valve stem seal(s) worn or 6. Replace seal(s).
damaged.
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST
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/compression pressure loss.
WARNING: Do not remove the pressure cap with the system hot and under pressure
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because serious burns from coolant can occur.
1. Check the coolant level and fill as required. DO NOT install the pressure cap.
2. Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.
3. Clean spark plug recesses with compressed air.
4. Remove the spark plugs.
5. Remove the oil filler cap.
6. Remove the air cleaner.
7. 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, with 552 kPa (80 psi) recommended.
8. Perform the test procedures on each cylinder according to the tester manufacturer's instructions. While
testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening.
Check for bubbles in the coolant.
9. All gauge pressure indications should be equal, with no more than 25% leakage per cylinder.
10. FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be
maintained in the cylinder.
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.
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. Check engine oil level and add oil if necessary.

2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and
other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly.
3. Remove engine cover.

4. Disconnect coil electrical connectors and remove coils.
5. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal
firing indicators such as fouled, hot, oily, etc. Record cylinder number of spark plug for future reference.
6. Disconnect injector electrical connectors.
7. Install a suitable compression test gauge into the #1 spark plug hole in cylinder head.
8. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure.
9. Repeat the previous step for all remaining cylinders.
10. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder
to cylinder.
11. If one or more cylinders have abnormally low compression pressures, repeat the compression test.
12. 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. The recommended compression
pressures are to be used only as a guide to diagnosing engine problems. An engine should not be
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disassembled to determine the cause of low compression unless some malfunction is present.
ENGINE OIL LEAK INSPECTION
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,
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 as necessary.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat
inspection.
5. If the oil leak source is not positively identified at this time , proceed with the AIR LEAK
DETECTION TEST METHOD as follows:
 Disconnect the fresh air hose (make-up air) at the cylinder head cover and plug or cap the nipple on
the cover.
 Remove the PCV valve hose from the cylinder head cover. Cap or plug the PCV valve nipple on
the cover.
 Attach an air hose with pressure gauge and regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3
psi) of test pressure.
 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 provides the best bubbles
which will pinpoint the leak source. If the oil leak is detected and identified, repair per service
information procedures.
 If the leakage occurs at the crankshaft rear oil seal area, refer to INSPECTION FOR REAR
SEAL AREA LEAKS.
6. If no leaks are detected, turn off the air supply. Remove the air hose, all plugs, and caps. Install the PCV
valve and fresh air hose (make-up air). Proceed to next step.
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.
NOTE: If oil leakage is observed at the dipstick tube to block location; remove the
tube, clean and reseal using Mopar® Stud AND Bearing Mount (press fit
tube applications only), and for O-ring style tubes, remove tube and
replace the O-ring seal.
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CAUTION: Do not exceed 20.6 kPa (3 psi).
CAUTION: Use extreme caution when crankshaft polishing is necessary to

remove minor nicks and scratches. The crankshaft seal flange is
especially machined to complement the function of the rear oil seal.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more
involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.
If the leakage occurs at the crankshaft rear oil seal area:
1. Disconnect the battery.

2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a
black light to check for the oil leak. If a leak is present in this area, remove transmission for further
inspection.
a. Circular spray pattern generally indicates seal leakage or crankshaft damage.
b. Where leakage tends to run straight down, possible causes are a porous block, oil gallery cup plug,
bed plate to cylinder block mating surfaces and seal bore. See proper repair procedures for these
items.
4. If no leaks are detected, pressurize the crankcase as previously described in step 5 under ENGINE OIL
LEAK INSPECTION.
CAUTION: Do not exceed 20.6 kPa (3 psi).

5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected
between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal
surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be
polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft polishing is necessary to

remove minor nicks and scratches. The crankshaft seal flange is
especially machined to complement the function of the rear oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled.
7. After the oil leak root cause and appropriate corrective action have been identified, replace component(s)
as necessary.
STANDARD PROCEDURE
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REPAIR OF DAMAGED OR WORN THREADS
Damaged or worn threads (excluding spark plug and camshaft bearing cap attaching threads) can be repaired.
Essentially, this repair consists of drilling out worn or damaged threads, tapping the hole with a special Heli-
Coil Tap, (or equivalent) and installing an insert into the tapped hole. This brings the hole back to its original
thread size.
CAUTION: Be sure that the tapped holes maintain the original center line.
Heli-Coil tools and inserts are readily available from automotive parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following
steps should be used.
CAUTION: DO NOT use starter motor to rotate the engine, severe damage may occur.
1. Inspect air cleaner, induction system and intake manifold to insure system is dry and clear of foreign
material.
2. Remove negative battery cable.
3. Place a shop towel around the spark plugs when removing them from the engine. This will catch any fluid
that may possibly be in the cylinder under pressure.
4. With all spark plugs removed, rotate engine crankshaft using a breaker bar and socket.
5. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other).
6. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.)

7. Repair engine or components as necessary to prevent this problem from reoccurring.
CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotate
engine to lubricate the cylinder walls to prevent damage on restart.
8. Install new spark plugs.

9. Drain engine oil and remove oil filter.
10. Install a new oil filter.
11. Fill engine with specified amount of approved oil.
12. Connect negative battery cable.
13. Start engine and check for any leaks.
FORM-IN-PLACE GASKETS AND SEALERS
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NOTE: All of the sealants mentioned below are not used on every engine, they are
listed as general reference guide. See service information for specific sealer
usage.
There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when
applying form-in-place gaskets to assure obtaining the desired results.Do not use form-in-place gasket
material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can
result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A
continuous bead of the proper width is essential to obtain a leak-free gasket. All sealing surfaces that use form-
in-place gaskets and sealers must free of grease or oil. Surfaces should be cleaned with Mopar® brake parts
cleaner prior to sealer application. After the sealer is applied, the parts should be assembled in no more than 10
minutes.
There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Sealant
RTV Silicone Rubber Adhesive, MOPAR® Silicone Rubber RTV Mopar® ATF-RTV, and Mopar® Gasket
Maker gasket materials, each have different properties and can not be used in place of the other.
MOPAR® SEALANT RTV SILICONE RUBBER ADHESIVE is used to seal components exposed to
engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing
properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available
in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always
inspect the package for the expiration date before use.
MOPAR® SILICONE RUBBER RTV is used to seal components exposed to engine oil, gear lubricant, and
coolant. This material is a specially designed gray silicone rubber RTV that retains adhesion and sealing
properties when exposed to engine oil gear lubricant and coolant. Excellent adhesion , even on oily surfaces.
Withstands temperatures to 330°C (650°F). Moisture in the air causes the material to cure. This material is
available in three ounce tubes and has a shelf life of one year. After one year this material will not properly
cure. Always inspect the package for the expiration date before use.
MOPAR® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing
properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This
material is available in three ounce tubes and has a shelf life of one year. After one year this material will not
properly cure. Always inspect the package for the expiration date before use.
MOPAR® GASKET MAKER is an anaerobic type gasket material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces. Do not use on flexible metal flanges.
MOPAR® GASKET SEALANT is a slow drying, permanently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined
parts under all temperatures. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a
13 oz. aerosol can or 4oz./16 oz. can w/applicator.
SEALER APPLICATION
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Mopar® Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one
gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off.
Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during
assembly to prevent smearing material off the location.
Mopar® RTV or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120
in.) in diameter. For corner sealing and "T" joint locations and waffle pad area, a mm (1/8 or 1/4 in.) drop is
placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components
should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating
dowel is recommended during assembly to prevent smearing material off the location.
ENGINE GASKET SURFACE PREPARATION
Fig. 2: PROPER TOOL USAGE FOR SURFACE PREPARATION

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 (2,3).
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Fig. 3: PROPER TOOL USAGE FOR SURFACE PREPARATION
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).
Sealing surfaces must be free of grease or oil residue. Clean surfaces with Mopar® brake parts cleaner (or
equivalent).
CORE/GALLERY PLUGS
CYLINDER HEAD CORE PLUGS

Fig. 4: CORE HOLE PLUG REMOVAL
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Using a blunt tool (3) such as a drift and a hammer, strike the bottom edge of the cup plug (5). With the cup
plug rotated, grasp firmly with pliers or other suitable tool (2) and remove plug (5).
CAUTION: Do not drive cup plug into the casting as restricted cooling can result and
cause serious engine problems.
Thoroughly clean inside of cup plug hole in cylinder head. Be sure to remove old sealer. Lightly coat inside of
cup plug hole with Mopar® Stud and Bearing Mount (or equivalent). Make certain the new plug is cleaned of
all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5
mm (0.020 in.) inside the lead-in chamfer.
It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in
service immediately.
CYLINDER BLOCK MAIN OIL GALLERY PLUGS

Fig. 5: GALLERY PLUG
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CAUTION: Excessive use of brake parts cleaner to clean threads in block could cause
#5 main bearing failure.
1. Use Mopar® Brake Parts Cleaner (or equivalent) sparingly to clean plug and block.
2. Coat plug threads with Mopar® Thread Sealant (or equivalent).
3. Install plug (2). The plug (2) is correctly installed when it is protruding 1 mm to flush with the block boss
face (1).
MEASURING BEARING CLEARANCE USING PLASTIGAGE

Fig. 6: Plastigage Placed in Lower Shell-Typical

Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the
recommended procedure for the use of Plastigage:
1. Remove oil film from surface to be checked. Plastigage is soluble in oil.

2. Place a piece of Plastigage (1) across the entire width of the journal. (In addition, suspected areas can be
checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.
3. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the
package. Locate the band closest to the same width. This band shows the amount of clearance.
Differences in readings between the ends indicate the amount of taper present. Record all readings taken.
Compare clearance measurements to specs found in Engine - Specifications. Plastigage generally is
accompanied by two scales. One scale is in inches, the other is a metric scale.
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NOTE: Plastigage is available in a variety of clearance ranges. Use the most
appropriate range for the specifications you are checking.
4. Install the proper crankshaft bearings to achieve the specified bearing clearances.
REMOVAL
ENGINE COVER
Fig. 7: Engine Cover

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

ENGINE ASSEMBLY
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1. Remove engine cover (1).
Fig. 9: Coil Connector

2. Perform fuel pressure release procedure, then disconnect and remove fuel line (3). Refer to Fuel
System/Fuel Delivery - Standard Procedure .
3. Remove make-up air hose (2).
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Fig. 10: Air Cleaner Housing Assembly
4. Remove air cleaner housing assembly (1). See Engine/Air Intake System/BODY, Air Cleaner -
Removal.
Fig. 11: BATTERY CABLE

5. Disconnect negative battery cable (1).

6. Discharge air conditioning system, if equipped.
7. Drain cooling system.
Fig. 12: COOLANT RESERVOIR
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8. Remove coolant reservoir (1).

9. Remove power steering reservoir (2).
Fig. 13: Power Steering Line Support

10. Remove power steering line support at engine mount (1).

11. Remove power steering pump and set aside.
Fig. 14: Coolant Adapter
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12. Remove coolant hoses from coolant adapter (3).

13. Disconnect coolant temperature sensor connector (1) and capacitor connector (2).

14. Disconnect coils (1), injectors (4), cam sensors, oil temperature sensor, and oil control valve electrical
connectors and reposition harness.
15. Remove PCV hose (5) from valve cover.
16. Remove harness from intake (2).
17. Remove throttle body support bracket (1).
18. Remove vacuum lines from throttle body and intake manifold.
19. Disconnect electronic throttle control and manifold flow control valve electrical connectors.
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Fig. 16: INTAKE TORQUE SEQUENCE
20. Remove dipstick.

21. Remove intake bolts and remove intake.
22. Disconnect coolant temperature sensor at block, knock sensor, oil pressure sensor, generator, starter,
block heater (if equipped), A/C compressor (if equipped), and block ground.
23. Remove accessory drive belt.
Fig. 17: Oil Drain Plug

24. Raise vehicle.

25. Remove front splash shield.

26. Drain oil (2).
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Fig. 18: Exhaust Manifold Bolts, Heat Shield & Oxygen Sensor Connector
27. Remove exhaust pipe to exhaust manifold bolts (1).

28. Disconnect oxygen sensor connector (3).
29. Remove exhaust manifold heat shield (2).
30. Remove exhaust manifold.
Fig. 19: INSPECTION COVER

31. Remove inspection cover (1) and mark torque converter to flywheel.
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Fig. 20: MODULAR CLUTCH TO FLEX PLATE BOLTS
32. On vehicles equipped with an automatic transaxle, remove torque converter bolts (1).
33. On vehicles equipped with an manual transaxle, remove modular clutch bolts (1).
34. Remove lower bellhousing bolts (2).
Fig. 21: A/C COMPRESSOR

35. Remove A/C compressor (1) from engine and set aside.
36. Remove generator and lower idler pulley.
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Fig. 22: CRANKSHAFT POSITION SENSOR
37. Disconnect CKP sensor (2) electrical connector.
Fig. 23: Right Engine Mount Bracket Retaining Bolts

38. Remove right engine mount bracket retaining bolts (4).

39. Remove power steering hose hold down (3).
40. Remove retaining nuts (2) and position mount bracket (1) aside.
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Fig. 24: LIFT CHAIN
41. Remove intake oil control valve to prevent damage.

42. Install engine lift chain to rear lift bracket and bolt to cylinder head (1) in the front.
43. Hoist engine from vehicle.
44. Separate engine and transmission.
INSTALLATION
ENGINE COVER

1. Position engine cover (1) over mounting studs.

2. Seat the cover on the rear studs by pushing downwards.
3. Push downward on the front of the cover to seat the front studs.
ENGINE ASSEMBLY
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Fig. 26: LIFT CHAIN
1. Connect engine lift chain (1) to engine.

2. Slowly lower engine assembly in to position.
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3. Position right mount bracket (1) and install bolts (4).

4. Install retaining nuts (2) and tighten nuts (2) to 30 N.m (22 ft. lbs.).
5. Tighten bolts (4) to 50 N.m (37 ft. lbs.).

6. Install A/C compressor mounting bracket (2).

7. Install A/C compressor (1) and connect lines.
8. Install exhaust manifold and upper lower heat shields (Refer to Manifolds).
9. Install oxygen sensor and connect electrical connector.
Fig. 29: GROUND STRAP
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10. Install Ground strap (1) near right strut tower.

11. Raise vehicle.

12. Install crankshaft position sensor (CKP) (2).

13. Connect CKP electrical connector (2).
Fig. 31: Exhaust Pipe Bolts
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14. Install manifold to exhaust pipe bolts (1) and tighten bolts.
15. Install generator.
Fig. 32: MODULAR CLUTCH TO FLEX PLATE BOLTS

16. Install lower bell housing bolts (2) and tighten.

17. Align torque converter and flex plate mark. Install torque converter bolts (1) and tighten.
Fig. 33: INSPECTION COVER
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18. Install inspection cover (1).
Fig. 34: OIL FILTER

19. Install new oil filter (1).

20. Lower vehicle.
21. Install upper idler pulley.
22. Install power steering pump.
Fig. 35: POWER STEERING LINE SUPPORT
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23. Install power steering line support bracket (1).

24. Install power steering pump.
25. Install accessory drive belt.
26. Connect electrical connectors at block ground, starter, A/C compressor, knock sensor, oil pressure sensor,
generator, coolant temperature sensor at block, and block heater.

27. Install intake manifold and tighten bolts to 24 N.m (18 ft. lbs.) as shown in illustration.
Fig. 37: THROTTLE BODY SUPPORT
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28. Install throttle body support bracket (1).

29. Connect manifold flow control valve and electronic throttle control electrical connectors.
30. Insert wiring harness retainer into intake manifold (2).
31. Install engine oil dip stick.
Fig. 38: COIL CONNECTOR

32. Install PCV hose (5).

33. Install vacuum lines at throttle body and intake manifold.
34. Install intake air tube on throttle body.
35. Connect engine harness electrical connectors.
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Fig. 39: COOLANT ADAPTER
36. Install coolant hoses at coolant adapter (3).
Fig. 40: Coolant Reservoir

37. Install coolant reservoir (1) and connect hose.

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38. Connect fuel line to fuel rail (3).

39. Connect negative battery cable (1).

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Fig. 43: Air Cleaner Housing
40. Install air cleaner housing (1) and connect inlet air hose (Refer to Air Intake System).
41. Fill with coolant.
42. Fill with oil.
CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system. Failure to follow this caution
will result in serious A/C compressor damage.
43. Evacuate the refrigerant system (refer to appropriate HVAC article).

44. Charge the refrigerant system (refer to appropriate HVAC article).
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45. Start engine and check for leaks.

46. Install engine cover (1).
SPECIFICATIONS
2.4L ENGINE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Metric Standard
Type In-Line OHV, DOHC
Number of Cylinders 4
Firing Order 1-3-4-2
Compression Ratio 10.5:1
Displacement 2.4 Liters 146.5 cu. in.
Bore 88 mm 3.465 in.
Stroke 97 mm 3.819 in.
Compression Pressure 1172 - 1551 kPa 170 - 225 psi
Max. Variation Between Cylinders 25%
CYLINDER BLOCK
Metric Standard
Material Cast Aluminum
Cylinder Bore Diameter

A 88.000 - 88.010 mm 3.4645 - 3.4649 in.
B 88.010 - 88.020 mm 3.4649 - 3.4653 in.
C 88.020 - 88.030 mm 3.4653 - 3.4657 in.
Cylinder Bore Out-of-Round 0.020 mm 0.0008 in.
(Max.)
Cylinder Bore Diameter Taper 0.028 mm 0.001 in.
(Max.)
Main Bearing Bore Diameter
1 56.000 - 56.006 mm 2.2047 - 2.2049 in.
2 56.006 - 56.012 mm 2.2049 - 2.2051 in.
3 56.012 - 56.018 mm 2.2051 - 2.2054 in.
Main Bearing Bore Diameter
0.0082 mm 0.0003 in.
Taper (Max.)
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PISTONS
Metric Standard
Piston Diameter
A 87.995 - 88.015 mm 3.4644 - 3.4652 in.
B 88.005 - 88.025 mm 3.4648 - 3.4656 in.
C 88.015 - 88.035 mm 3.4652 - 3.4659 in.
Clearance to Bore (-0.015) - 0.015 mm (-0.0006) - 0.0006 in.
Weight 302 - 312 grams 10.65 - 11.00 oz.
Land Clearance (Diametrical) 0.60 - 0.73 mm 0.0236 - 0.0287 in.
Piston Length 51.5 mm 2.028 in.
Piston Ring Groove Depth No. 1 3.51 - 3.68 mm 0.1382 - 0.0256 in.
PISTON RINGS
Metric Standard
Ring Gap-Top Compression Ring 0.15 - 0.30 mm 0.0059 - 0.0118 in.
Wear Limit 0.8 mm 0.031 in.
Ring Gap-2nd Compression Ring 0.30 - 0.45 mm 0.0118 - 0.0177 in.
Ring Gap-Oil Control Steel Rails 0.20 - 0.70 mm 0.0079 - 0.0276 in.
Ring Side Clearance-Compression
0.03 - 0.07 mm 0.1182 - 0.0028 in.
Rings

Ring Side Clearance-Oil Ring
0.06 - 0.15 mm 0.0024 - 0.0059 in.
Pack
Ring Width-Top Compression
2.95 - 3.25 mm 0.1161 - 0.1280 in.
Ring
Ring Width-2nd Compression
3.45 - 3.75 mm 0.1358 - 0.1476 in.
Ring
Ring Width-Oil Ring Pack 2.30 - 2.60 mm 0.0906 - 0.1024 in.
Ring Thickness-Top Compression
1.17 - 1.19 mm 0.0461 - 0.0469 in.
Ring
Ring Thickness-2nd Compression
1.17 - 1.19 mm 0.0461 - 0.0469 in.
Ring
Ring Thickness-Oil Ring Pack 1.88 - 1.95 mm 0.0740 - 0.0768 in.
CONNECTING ROD
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Metric Standard
Bearing Clearance 0.032 - 0.060 mm 0.0012 - 0.0023 in.
Bore Diameter-Piston Pin 20.974 - 20.985 mm 0.8257 - 0.8261 in.
Bore Diameter-Crankshaft End 51 - 51.015 mm 2.0078 - 2.0084 in.
Side Clearance 0.1 - 0.25 mm 0.0039 - 0.00098 in.
Weight-Total (Less Bearing) 484 grams 17.07 oz.
CRANKSHAFT
SPECIFICATION
DESCRIPTION
Metric Standard
Connecting Rod Journal Diameter
Journal Grade
1 47.966 - 47.972 mm 1.8884 - 1.8886 in.
2 47.960 - 47.966 mm 1.8884 - 1.8881 in.
3 47.954 - 47.960 mm 1.8879 - 1.8881 in.
Rod Journal- Taper (Max) 0.005 mm 0.0001 in.
Main Bearing Journal Diameter
Journal Grade
0 51.985 - 51.988 mm 2.0466 - 2.0467 in.
1 51.982 - 51.985 mm 2.0465 - 2.0466 in.
2 51.979 - 51.982 mm 2.0464 - 2.0465 in.
3 51.976 - 51.979 mm 2.0462 - 2.0464 in.
4 51.973 - 51.976 mm 2.0461 - 2.0462 in.
Journal Out-of-Round (Max.) 0.005 mm 0.0001 in.
Journal Taper (Max.) 0.006 mm 0.0002 in.

End Play 0.05 - 0.25 mm 0.0019 - 0.0098 in.
Main Bearing Diametrical
0.028 - 0.048 mm 0.0011 - 0.0018 in.
Clearance
Main Bearing Diametrical
0.058 mm 0.0022 in.
Clearance (Max)
CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER

Metric Standard
Cam Bearing Bore
Front Intake 30.000 - 30.021 mm 1.1810 - 1.1819 in.
Front Exhaust 40.000 - 40.024 mm 1.5747 - 1.5756 in.
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Cam Bearing Bore No. 1-4 24.000 - 24.021 mm 0.9448 - 0.9457 in.
CAMSHAFT
Metric Standard
Cam Journal Diameter
Front Intake Cam 29.964 - 29.980 mm 1.1797 - 1.1803 in.
Front Exhaust Cam 35.984 - 36.000 mm 1.4166 - 1.4173 in.
Cam Journal Diameter No. 1-4 23.954 - 23.970 mm 0.943 - 0.944 in.
Bearing Clearance - Diametrical
Front Intake Journal 0.020 - 0.057 mm 0.0008 - 0.0022 in.
Front Exhaust Journal 0.019 - 0.051 mm 0.0007 - 0.0020 in.
All Others 0.020 - 0.067 mm 0.0008 - 0.0026 in.
End Play 0.11 - 0.25 mm 0.004 - 0.009 in.
Max Lift @ 0.2 mm (0.007 in.) lash
Intake 9.2 mm 0.362 in.
Max Lift @ 0.28 mm (0.011 in.) lash
Exhaust 8.42 mm 0.331 in.
Intake Valve Timing w/VVT in lock-pin position*
Closes (ABDC) 49.3°
Opens (ATDC) 10.3°
Duration 219°
Exhaust Valve Timing w/VVT in lock-pin position*
Closes (BTDC) 8.45°
Opens (BBDC) 45°
Duration 216.55°
Valve Overlap @ 0.5 mm (0.019 18.75°
in.) w/ VVT in lock-pin position

* All reading in crankshaft degrees at 0.5 mm (0.019 in.) valve lift.
CYLINDER HEAD
Metric Standard
Material Cast Aluminum - Heat treated
Gasket Thickness (Compressed) 0.54 mm 0.021 in.
Valve Tappet Bore I.D. 32.000 - 32.025 mm 1.2598 - 1.2608 in.
Valve Tappet O.D. 31.964 - 31.980 mm 1.2584 - 1.2590 in.
VALVE SEAT
Metric Standard
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Angle 44.75° - 45.10°
Seat Outer Diameter - Intake 34.45 - 34.61 mm 1.3562 - 1.3625 in.
Seat Outer Diameter - Exhaust 28.04 - 28.20 mm 1.1039 - 1.1102 in.
Runout (Max.) 0.05 mm 0.002 in.
Valve Seat Width
Intake 1.16 - 1.46 mm 0.0456 - 0.0574 in.
Service Limit 2.0 mm 0.079 in.
Exhaust 1.35 - 1.65 mm 0.0531 - 0.0649 in.
Service Limit 2.5 mm 0.098 in.
VALVE GUIDE
Metric Standard
Diameter I.D. 5.500 - 5.518 mm 0.2165 - 0.2172 in.
Guide Bore Diameter 10.983 - 11.001 mm 0.432 - 0.4331 in.
Guide Height (spring seat to guide
14.6 - 15.2 mm 0.5748 - 0.5984 in.
tip)
VALVES
Metric Standard
Face Angle - Intake and Exhaust 45.25° - 45.75°
Head Diameter - Intake 34.9 - 35.1 mm 1.374 - 1.3818 in.
Head Diameter - Exhaust 28.9 - 29.1 mm 1.1377 - 1.1456 in.
Valve Lash
Intake 0.17 - 0.23 mm 0.006 - 0.009 in.
Exhaust 0.27 - 0.33 mm 0.010 - 0.012 in.
Valve Length (Overall)

Intake 113.18 mm 4.455 in.
Exhaust 105.887 mm 4.168 in.
Valve Stem Diameter
Intake 5.465 - 5.480 mm 0.2151 - 0.2157 in.
Exhaust 5.458 - 5.470 mm 0.2148 - 0.2153 in.
VALVE MARGIN
Metric Standard
Intake 0.672 mm 0.0264 in.
Exhaust 0.744 mm 0.02929 in.
VALVE STEM TIP
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Metric Standard
Intake 48.04 mm 1.891 in.
Exhaust 47.99 mm 1.889 in.
VALVE STEM TO GUIDE CLEARANCE

Metric Standard
Intake 0.020 - 0.053 mm 0.0008 - 0.0021 in.
Max. Allowable 0.076 mm 0.003 in.
Exhaust 0.030 - 0.060 mm 0.0012 - 0.0024 in.
Max. Allowable 0.101 mm 0.004 in.
VALVE SPRINGS
Metric Standard
Free Length (Approx.) 47.0 mm 1.850 in.
Nominal Force (Valve Closed) 179.5 N ± 9 @ 35.0 mm 40.35 lbs. @ 1.38 in.
Nominal Force (Valve Open) 364.8 N ± 17 N @ 29.25 mm 82.01 lbs. ± 3.82 lbs. @ 1.152 in.
Installed Height 35.00 mm 1.378 in.
Number of Coils 8.5 ± 0.1
Wire Diameter 2.90 mm ± 0.03 0.114 in ± 0.001 in.
OIL PRESSURE
Metric Standard
At Curb Idle Speed* 25 kPa 4 psi min.
At 3000 RPM 170 - 550 kPa 25 - 80 psi

CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine at 3000 RPM.
TORQUE
DESCRIPTION N.m Ft. Lbs. In. Lbs.

Balance Shaft Module Refer to Procedure
Bell Housing-Bolts 48 35 -
Camshaft Bearing Cap-Bolts - - -
M6 Bolts 12 - 106
M8 Bolts 30 22 -
Coils 8 - 71
Connecting Rod Cap-Bolts 20 + 90° 15 + 90° -
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Coolant Temperature Sender 18 13 -
Crankshaft Main Bearing Cap-Bolts Refer to Procedure
Crankshaft Damper-Bolt 210 155 -
Cylinder Head-Bolts Refer to Procedure
Cylinder Head Cover-Bolts Refer to Procedure
Engine Support Bracket-Bolts 40 30 -
Exhaust Manifold-Bolts 34 25 -
Exhaust Manifold Heat Shield-Bolts - - -
M6x25mm Bolts 7 - 62
M6x70mm Bolts 9 - 80
Flex Plate to Crankshaft-Bolts 29 + 51° 22 + 51° -
Intake Manifold-Bolts 24 18 -
Ladder Frame 22 16 -
Oil Cooler Connector Bolt 49 36 -
Oil Filter 14 10 -
Oil Filter Nipple 49 36 -
Oil Jet Fastener 12 - 106
Oil Pan-Bolts - - -
M6 Bolts 9 - 80
M8 Bolts 24 18 -
Oil Pan Drain-Plug 40 30 -
Oil Pressure Switch 8 - 71
PCV Valve 5 - 44
Phaser to Camshaft-Bolt 59 44 -
Spark Plugs 27 20 239
Timing Chain Cover - - -
M6 Bolts 9 - 80
M8 Bolts 26 19 -
Timing Chain Tensioner Assembly-Bolts 12 - 106
Timing Chain Guides 12 - 106
SPECIAL TOOLS
SPECIAL TOOLS
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Fig. 45: GAUGE, PRESSURE - C-3292A
Fig. 46: DRIVER HANDLE, UNIVERSAL - C-4171

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Fig. 47: BLOC-CHEK-KIT - C-3685-A
Fig. 48: TESTER, COOLING SYSTEM - 7700-A

Fig. 49: INSTALLER, OIL SEAL - 9506

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Fig. 50: HOLDER, VIBRATION DAMPER - 9707
Fig. 51: WEDGE, LOCKING - 9701

Fig. 52: INSTALLER, OIL SEAL - 9509

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Fig. 53: INSTALLER, REAR MAIN SEAL - 9706
Fig. 54: PIN, TENSIONER - 9703

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PLATE, IDENTIFICATION
DESCRIPTION
DESCRIPTION

The engine serial number (1) is located between the oil pan and the bellhousing. The serial number contains
engine build date, build location, and displacement.
Example: 8CAP1339710217
GAS ENGINE
8 C A P1 339 7 1 0217
Model Engine
Engine Displacement
Year Plant
Engine Build P1 =
A = 1.8L Variation GEMA Julian Julian Build
(with oil North Day of Year Shift Sequence
2008 cooler, turbo, P2 = Year 2007 Number
B = 2.0L for MMNA) GEMA
South
C = 2.4L -
AIR INTAKE SYSTEM

AIR CLEANER
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Removal
REMOVAL
Fig. 56: AIR FILTER ELEMENT

1. Lift air cleaner housing cover (1).

2. Remove filter element (2).
3. If necessary, clean the inside of the air cleaner housing.
Installation
INSTALLATION
Fig. 57: AIR FILTER ELEMENT
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1. Install new filter element (2).

2. Lower cover (1) and snap in place.
BODY, AIR CLEANER
Removal
REMOVAL
Fig. 58: Air Cleaner Housing Retaining Bolt

1. Remove air cleaner housing retaining bolt (2).

2. Remove clean air hose from air cleaner housing.
3. Lift air cleaner housing (1) upwards and remove.
Installation
INSTALLATION
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1. Position air cleaner housing (1) in place.

2. Install retaining bolt (2).
3. Install clean air hose.
CYLINDER HEAD
DESCRIPTION
DESCRIPTION
The cross flow designed, aluminum cylinder head contains dual over-head camshafts with four valves per
cylinder. The valves are arranged in two inline banks. The intake valves face toward the front of the vehicle.
The exhaust valves face the dash panel. The cylinder head incorporates powdered metal valve guides and seats.
The cylinder head is sealed to the block using a multi-layer steel head gasket and retaining bolts.
Integral oil galleries provide lubrication passages to the variable camshaft timing phasers, camshafts, and valve
mechanisms.
NOTE: Replacement cylinder heads will come complete with valves, seals, springs,
retainers, keepers, lash buckets, and camshafts.
CYLINDER HEAD GASKET
A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent
water jacket or from an oil passage to the exterior of the engine.
Possible indications of the cylinder head gasket leaking between adjacent cylinders are:
 Loss of engine power

 Engine misfiring
 Poor fuel economy
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Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
 Engine overheating
 Loss of coolant
 Excessive steam (white smoke) emitting from exhaust
 Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in
Cylinder Compression Pressure Test. See CYLINDER COMPRESSION PRESSURE TEST. An engine
cylinder head gasket leaking between adjacent cylinders will result in approximately a 50-70% reduction in
compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH

COOLANT PRESSURE CAP REMOVED.
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 POINT.
NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester's
pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also be checked by using combustion leak tester C-3685-A or
equivalent. Perform test following the procedures supplied with the tool kit.
REMOVAL
REMOVAL
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1. Remove engine cover (1) by pulling upward.

2. Perform fuel system pressure release procedure. Refer to Fuel System/Fuel Delivery - Standard
Procedure .
3. Disconnect and isolate the negative battery cable.
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4. Drain cooling system. Refer to Cooling - Standard Procedure .

5. Remove clean air hose and air cleaner housing (2). See Engine/Air Intake System/BODY, Air Cleaner
- Removal.

6. Remove coolant recovery bottle (1). Refer to Cooling/Engine/BOTTLE, Coolant Recovery - Removal .
7. Remove and reposition power steering reservoir (2).
8. Remove accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Removal .
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Fig. 64: POWER STEERING PUMP - GAS

10. Remove the three power steering pump mounting bolts (1) through the openings in the pulley (3) and
reposition the pump.
Fig. 65: Cylinder Head Cover Torque Sequence
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11. Remove the cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Removal.
12. Remove ignition coils from the cylinder head cover.
Fig. 66: Top Dead Center

13. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure .
14. Remove the frame cover portion of the right splash shield. Refer to Body/Exterior/SHIELD, Splash -
Removal .
15. Set engine to TDC (1).
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16. Remove lower A/C compressor bolts if equipped.

17. Remove lower A/C compressor mount (2) if equipped.
Fig. 68: Accessory Drive Belt Idler Pulley

18. Remove accessory drive belt lower idler pulley (2).

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Fig. 69: Right Side Engine Mount Bracket Bolt
19. Remove crankshaft damper (2). See Engine/Engine Block/DAMPER, Vibration - Removal.
20. Remove three bolts and water pump pulley (4) from water pump.
21. Remove lower bolt from right side engine mount bracket (1).
Fig. 70: TIMING CHAIN COVER LOWER BOLTS

22. Remove timing chain cover lower bolts (1).

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Fig. 71: Catalytic Converter
23. Remove exhaust manifold. See Engine/Manifolds/MANIFOLD, Exhaust - Removal.

24. Lower vehicle.
25. Support engine with suitable jack.


27. Remove retaining nuts (2) and reposition mount bracket (1).
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28. Remove accessory drive upper idler pulley (1).

29. Remove right upper engine mount bracket (1).

30. Remove accessory drive belt tensioner.
31. Remove upper timing chain cover retaining bolts.
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Fig. 75: TIMING CHAIN COVER PRY POINTS
32. Remove timing chain cover using pry points (1,2,3).
Fig. 76: TIMING DRIVE

33. Remove tensioner (5) and timing chain (2). See Engine/Valve Timing/CHAIN and SPROCKETS,
Timing - Removal.
34. Remove timing chain guide (4) and timing chain pivot guide (6).
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Fig. 77: FUEL LINE AT RAIL
35. Disconnect the fuel line from the fuel rail. Refer to Fuel System/Fuel Delivery/FITTING, Quick
Connect - Standard Procedure .
Fig. 78: Electrical Connectors From Fuel Injectors

36. Unlock and disconnect the electrical connectors from the fuel injectors.
Fig. 79: RAIL REMOVAL/INSTALL
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37. Remove two fuel rail retaining bolts and remove fuel rail.

38. Disconnect electrical connectors from coolant temperature sensor (1), oil temperature sensor, variable
valve timing solenoids, camshaft position sensors, MAP sensor, manifold tuning valve, ignition
interference suppressor (2) and electronic throttle control.
Fig. 81: Throttle Body Support Bracket
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39. Remove wiring harness retainer from intake manifold (2) and reposition harness.
41. Disconnect vacuum lines at intake.
Fig. 82: Intake Manifold Retaining Bolts Torque Sequence

42. Remove intake manifold retaining bolts and remove intake manifold.
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43. Remove four bolts and reposition coolant adapter (3).

44. Remove ground strap (1) at right rear of cylinder head if equipped.
Fig. 85: Front Camshaft Cap Removal Sequence
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NOTE: Camshaft bearing caps should have been marked during engine
manufacturing. For example, number one exhaust camshaft bearing is
marked "E1>".
CAUTION: DO NOT use a number stamp or a punch to mark camshaft bearing

caps. Damage to bearing caps could occur.
45. Using a permanent ink or paint marker, identify location and position on each camshaft bearing cap.
46. Remove the front camshaft bearing cap.
47. Slowly remove the remaining intake and exhaust camshaft bearing cap bolts one turn at a time.
48. Remove the camshafts.
Fig. 86: FRONT HEAD BOLT WASHERS
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NOTE: All of the cylinder head bolts have captured washers EXCEPT the front two
(1).
49. Remove cylinder head bolts and two uncaptured washers.

50. Remove cylinder head from engine block.
51. Inspect and clean cylinder head and block sealing surfaces. See Engine/Cylinder Head - Inspection. See
Engine/Cylinder Head - Cleaning.
NOTE: Ensure cylinder head bolt holes in the block are clean, dry (free of residual
oil or coolant), and threads are not damaged.
CLEANING
CLEANING
To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of
aluminum engine components and multi-layer steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.
Remove all gasket material from cylinder head and block. See Engine - Standard Procedure. Be careful not to
gouge or scratch the aluminum head sealing surface.
Clean all engine oil passages.
INSPECTION
INSPECTION
NOTE: Replacement cylinder heads will come complete with valves, seals, springs,
retainers, keepers, tappets, and camshafts.
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Fig. 87: Checking Cylinder Head Flatness
1. Check cylinder head warpage with a straight edge (2) and feeler gauge (1).
2. Cylinder head must be flat within 0.1 mm (0.004 in.).
3. Verify that the valve tappets move freely in theirs bores and that they have been rotating.
4. Inspect camshaft bearing journals for scoring.
5. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
6. Inspect the following components and verify that they are within specification. See Engine -
Specifications:
 Camshafts
 Valve Tappets
 Springs
 Valve Seats
 Valve Guides
 Valves
7. Prior to installing cylinder head, the cylinder block should be checked for flatness. See Engine/Engine
Block - Inspection.
INSTALLATION
INSTALLATION
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Fig. 88: Checking Cylinder Head Bolts for Stretching (Necking)
CAUTION: The cylinder head bolts are tightened using a torque plus angle procedure.
The bolts must be examined BEFORE reuse. If the threads are necked
down the bolts must be replaced.
1. Check cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the
threads do not contact the scale (2) the bolt must be replaced.
Fig. 89: Variable Valve Timing Filter Screen

NOTE: Ensure cylinder head bolt holes in the block are clean, dry (free of residual
oil or coolant), and threads are not damaged.
CAUTION: Always replace the variable valve timing filter screen (3) when
servicing the head gasket or engine damage could result.
2. Replace the variable valve timing filter screen (3).
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Fig. 90: Two Dots Of Mopar® Engine Sealant RTV On Cylinder Block
NOTE: When using RTV, the sealing surfaces must be clean and free from grease
and oil.
NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to
final torque within 45 minutes.
3. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder block as shown in
illustration.
Fig. 91: Two Dots Of Mopar® Engine Sealant RTV On Cylinder Head Gasket
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4. Position the new cylinder head gasket on engine block with the part number facing up. Ensure gasket is
seated over the locating dowels in block.
5. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder head gasket as
shown in illustration.
NOTE: The head must be installed within 15 minutes before the RTV skins.
6. Position cylinder head onto engine block.
Fig. 92: CYLINDER HEAD BOLT IDENTIFICATION

CAUTION: This engine was built with 2 different style cylinder head bolts. Each
style bolt requires a different torque value. The bolts can be identified
by the short bolt head (1) and the long bolt head (2).
7. Measure the bolt head from the washer to the top of the bolt head. The short bolt head (1) measures 8 mm
(5/16") and the long bolt head (2) measures 13 mm (1/2").
8. Identify whether your engine has the short head design (1) or the long head design (2).
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Fig. 93: Washer
NOTE: The front two cylinder head bolts do not have captured washers. The
washers must be installed with the bevel edge (1) up towards the bolt
head.
Fig. 94: FRONT HEAD BOLT WASHERS

9. Install washers (1) for the front two cylinder head bolts with the beveled edge facing up.
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Fig. 95: CYLINDER HEAD TORQUE SEQUENCE
NOTE: Before installing the cylinder head bolts, lubricate the threads with clean
engine oil.
10. Install the cylinder head bolts and tighten in the sequence shown in illustration.
Fig. 96: CYLINDER HEAD BOLT IDENTIFICATION

11. If your bolt has the short head (1), use the following torque specifications:
 First: All to 30 N.m (25 ft. lbs.)
 Second: All to 61 N.m (45 ft. lbs.)
 Third: All to 61 N.m (45 ft. lbs.)
 Fourth: All an additional 90°
CAUTION: Do not use a torque wrench for the Fourth step.
12. If your bolt has the long head (2), use the following torque specifications:
 First: All to 30 N.m (25 ft. lbs.)
 Second: All to 73 N.m (54 ft. lbs.)
 Third: All to 73 N.m (54 ft. lbs.)
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 Fourth: All an additional 90°
CAUTION: Do not use a torque wrench for the Fourth step.
13. Clean excess RTV from the timing chain cover sealing surface.

14. Install coolant adapter (3) with new seals. Tighten bolts to 18.1 N.m (159 in. lbs.).
Fig. 98: Camshaft Cap Bearing Identification
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15. The front camshaft bearing cap (1) is numbered (2) either one, two, or three, this corresponds to the select
fit front exhaust camshaft bearing to use.
Fig. 99: Camshaft Bearing Identification

16. Install the corresponding select fit front exhaust camshaft bearing (1).
17. Oil all of the camshaft journals with clean engine oil.
Fig. 100: Camshaft Timing
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18. Position exhaust camshaft (1) and intake camshaft (2) on bearing journals in the cylinder head.
19. Align camshaft timing marks (3) so that they are facing each other and are in line with the cylinder head
cover sealing surface.
CAUTION: Install the front intake and exhaust camshaft bearing cap last. Ensure
that the dowels are seated and follow torque sequence or damage to
engine could result.
NOTE: If the front camshaft bearing cap is broken, the cylinder head MUST be
replaced.
Fig. 101: Camshaft Cap Torque Sequence

20. Install intake and exhaust camshaft bearing caps and slowly tighten bolts to 9.5 N.m (85 in. lbs.) in the
sequence shown in illustration.
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Fig. 102: Front Camshaft Cap Torque Sequence
NOTE: Verify that the exhaust bearing shells are correctly installed, and the
dowels are seated in the head, prior to torquing bolts.
21. Install the front intake and exhaust bearing cap and tighten bolts to 25 N.m (18 ft. lbs.) in the sequence

22. Install timing chain guide (4) and tighten bolts to 12 N.m (105 in. lbs.).
23. Install the moveable timing chain pivot guide (6) and tighten bolt to 12 N.m (105 in. lbs.).
24. Install timing chain (2) and tensioner (5). See Engine/Valve Timing/CHAIN and SPROCKETS,
Timing - Installation.
25. Install timing chain cover, engine mount, pulleys and accessory drive belt. See Engine/Valve
Timing/COVER(S), Engine Timing - Installation.
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26. Install cylinder head cover and ignition coils. See Engine/Cylinder Head/COVER(S), Cylinder Head -
Installation.
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Fig. 105: Catalytic Converter
27. Install exhaust manifold. See Engine/Manifolds/MANIFOLD, Exhaust - Installation.

28. Install ground strap (1) at right rear of cylinder head if equipped.
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29. Install intake manifold, vacuum lines and fuel rail. See Engine/Manifolds/MANIFOLD, Intake -
Installation.

30. Connect coil (1) and injector (4) electrical connectors.

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31. Connect electrical connectors to coolant temperature sensor (1), camshaft position sensors, oil
temperature sensor, variable valve timing solenoids, MAP sensor, manifold tuning valve, ignition
interference suppressor (2) and electronic throttle control.

32. Install power steering pump reservoir (2). Tighten mounting screw to 12 N.m (106 in. lbs.).
33. Install coolant recovery reservoir (1). Tighten mounting bolts to 10 N.m (89 in. lbs.).
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34. Install clean air hose (1) and air cleaner housing (2). See Engine/Air Intake System/BODY, Air
Cleaner - Installation.
35. Fill cooling system. Refer to Cooling - Standard Procedure .
36. Install new oil filter and fill engine with oil.

38. Operate engine until it reaches normal operating temperature. Check oil and cooling systems for leaks and
correct fluid levels.
ASSEMBLY, VARIABLE VALVE TIMING
Description
DESCRIPTION
The Gas engine is equipped with Variable Valve Timing (VVT). This system advances and/or retards intake
and/or exhaust camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy,
and reduce emissions. The camshaft sprockets are integrated with the VVT assemblies and are serviced as an
assembly. VVT assemblies are sometimes referred to as camshaft phasers.
Operation
OPERATION
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The Variable Valve Timing (VVT) assemblies are actuated with engine oil pressure. The oil flow to the VVT
assemblies are controlled by two Oil Control Valves (OCV). There is an OCV and Camshaft Position Sensor
(CMP) for each camshaft. The OCV's 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. 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 camshaft with respect to the timing chain. Thus, the VVT assemblies change
valve timing by changing the relationship between the camshaft and the timing chain. An integral oil pressure
activated pin is used to lock base camshaft timing for engine start up. Oil pressure releases the pin and allows
the PCM to control cam timing once the engine is running. 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
NOTE: Camshaft phaser and camshaft sprocket are supplied as an assembly, do not
attempt to disassemble.
Fig. 113: Camshafts Phaser Removal/Installation
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1. Remove camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Removal.

2. Remove camshaft phaser (2) retaining bolt while holding the camshaft in place with a wrench (1) on the
camshaft flats.
3. Remove phaser (2) assembly from camshaft.
Installation
INSTALLATION
Fig. 114: Camshafts Phaser Removal/Installation

CAUTION: Do not use an impact wrench to tighten camshaft sprocket bolts. Damage
to the camshaft-to-sprocket locating dowel pin and camshaft phaser may
occur.
1. Install phaser (2) assembly on camshaft.
NOTE: Make sure the dowel is seated in the dowel hole and not in a oil feed hole.
The dowel hole is larger than the 4 oil feed holes.
2. Install phaser retaining bolt. Hold camshaft in place with a wrench (1) and tighten bolt to 59 N.m (44 ft.
lbs.).
3. Install camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Installation.
BUCKET, TAPPET
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Diagnosis and Testing
MECHANICAL VALVE TAPPET NOISE DIAGNOSIS
A tappet-like noise may be produced from incorrect valve lash. See Engine/Cylinder Head/BUCKET, Tappet
- Standard Procedure.
Standard Procedure
MEASURING VALVE LASH

NOTE: The engine must be cold to measure valve lash.


2. Remove cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Removal.
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Fig. 116: LOBES VERTICAL
3. Rotate camshaft so lobes are vertical (1).

4. Check clearance using feeler gauges.
5. Repeat for all tappets and record readings.
6. If clearance was too small, refer to Clearance too Small.
7. If clearance was too large, refer to Clearance too Large.
Clearance too Small

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Fig. 117: TAPPET IDENTIFICATION

2. Specification - clearance = change.
3. Decrease tappet thickness by change figure.
5. Verify that valve lash is correct.
Clearance too Large



2. Clearance - specification = change.
3. Increase tappet thickness by change figure.
5. Verify that valve lash is correct.
Removal
REMOVAL
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NOTE: This procedure is for in-vehicle service with camshafts installed.
NOTE: Camshaft tappets must be replaced if cylinder head or camshafts are replaced.
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3. Remove camshaft tappets (1).

4. Repeat removal procedure for each camshaft tappet (1).
5. If reusing, mark each tappet for reassembly in original position.
Installation
INSTALLATION

NOTE: If reinstalling original tappets they must go back in their original location or
engine damage could result.
1. Apply a light coat of clean engine oil to camshafts tappets (1) prior to assembly.
2. Install camshaft tappets (1) into cylinder head.
3. Repeat installation procedure for each camshaft tappet.
NOTE: If installing new tappets, the valve lash procedure must be performed.
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5. Install cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Installation.
CAMSHAFT, ENGINE
Description
DESCRIPTIONS
Both camshafts have five bearing journal surfaces and two cam lobes per cylinder. The two front journals are
larger to allow for feeding oil to the variable valve timing (VVT) camshaft phasers. Flanges on the third smaller
journal control camshaft end play. At the rear of each camshaft is an integral cam sensor target.
CAMSHAFT BEARING CAPS

Fig. 123: Camshaft Bearing Caps
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The front cam bearing cap spans both camshafts, and includes dowels for precise alignment. The front exhaust
camshaft journal has a select fit bearing insert. This bearing is required to seal the oil passage to the camshaft
phaser, because a portion of the lower bearing saddle is machined away for head bolt access. The select fit is
required to minimize bearing clearance and oil leakage. An exhaust bearing grade (1, 2 or 3) is stamped into the
front bearing cap adjacent to the exhaust cam journal. The bearings are also marked with the corresponding
grade markings. If the bearing is replaced, the same grade must be used. Due to the unique purpose of this
bearing, it may appear to have uneven wear patterns (1). Maximum wear of 0.05 mm (.002 in.) is acceptable.
Unless the wear is excessive it is no cause for concern and the bearing should not be replaced. Cam bearing
inspection should not be the sole reason for removal of the exhaust camshaft. The upper cam bearing may be
replaced if the front bearing cap is removed. The lower cam bearing should be replaced if the camshaft is
removed due to a failure of a component within the cylinder head.
The front intake cam journal has a full lower bearing saddle, and therefore, no bearing insert is required.
All small bearing caps have a formed-in arrow to assist in assembly. All small bearing cap arrows must point
towards the center of the cylinder head. The small bearing caps are marked for position during the
manufacturing process, and must be reinstalled in their original position.
The #1 small cap includes a passage to direct oil from the cylinder head oil gallery to the #1 small bearing
journal, and into the camshaft as well. The hollow camshaft then distributes oil to the remainder of the small
journals. Oil flowing out of each cam journal lubricates the valve tappets.
The #3 small cap is machined at the front and rear face to control camshaft end-play. This cap has dowels for
precise alignment.
Operation
OPERATION
The camshaft is driven by the crankshaft via drive sprockets and a chain. The camshaft has precisely machined
lobes to provide accurate valve timing and duration.
Standard Procedure
MEASURING CAMSHAFT END PLAY
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Fig. 124: Camshaft End Play
1. Using a suitable tool, move camshaft as far rearward as it will go.

2. Zero dial indicator.
3. Move camshaft as far forward as it will go.
4. Record reading on dial indicator. For end play specification, see Engine - Specifications.
5. If end play is excessive, check cylinder head and camshaft for wear; replace as necessary.
Removal
REMOVAL
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Removal .
6. Rotate engine to TDC (1).
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Fig. 127: TIMING CHAIN TIMING MARKS
7. Make sure camshaft timing marks (3) are in line with the cylinder head cover sealing surface.
8. Mark the chain link corresponding to timing marks (1) with a paint marker.
Fig. 128: TENSIONER ACCESS PLUG

9. Remove timing tensioner plug (1) from front cover.

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Fig. 129: TENSIONER RESET
10. Insert small Allen wrench through timing tensioner plug hole and lift ratchet (2) upward to release the
tensioner and push Allen wrench inward. Leave the Allen wrench installed during the remainder of this
procedure.
Fig. 130: WEDGE TOOL

11. Insert Locking Wedge 9701 (1) between camshaft phasers.

Fig. 131: SEATING WEDGE TOOL
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12. Lightly tap Locking Wedge 9701 (2) into place until it will no longer sink down.
Fig. 132: Front Camshaft Cap Removal Sequence

NOTE: Camshaft bearing caps should have been marked during engine
manufacturing. For example, number one exhaust camshaft bearing is
marked "E1>".
CAUTION: DO NOT use a number stamp or a punch to mark camshaft bearing

caps. Damage to bearing caps could occur.
13. Using a permanent ink or paint marker, identify location and position on each camshaft bearing cap.
14. Remove the front camshaft bearing cap.
15. Slowly remove the remaining intake and exhaust camshaft bearing cap bolts one turn at a time.
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Fig. 133: Raise Intake Camshaft
16. Remove intake camshaft (1) by lifting the rear of the camshaft upward.
Fig. 134: ROLL CAMSHAFT

17. Rotate the camshaft while lifting out of the front bearing cradle.
Fig. 135: CHAIN REMOVAL
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18. Lift the timing chain (2) off the sprocket (1).
19. Remove exhaust camshaft.
20. Secure timing chain with wire so that it does fall into the timing chain cover.
Cleaning
CLEANING
Clean camshafts with a suitable solvent.
Inspection
INSPECTION
1. Inspect camshaft bearing journals for damage. If journals are damaged, check the cylinder head for
damage. Also check cylinder head oil holes for clogging.
2. Check the cam lobe and bearing surfaces for abnormal wear and damage. Replace camshaft if defective.
NOTE: If camshaft is replaced due to lobe wear or damage, always replace the
lash buckets.
Installation
INSTALLATION
Fig. 136: Camshaft Cap Bearing Identification
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1. The front camshaft bearing cap (1) is numbered (2) either one, two, or three, this corresponds to the select
fit front exhaust camshaft bearing to use.
Fig. 137: Camshaft Bearing Identification

2. Install the corresponding select fit front exhaust camshaft bearing (1).
3. Oil all of the camshaft journals with clean engine oil.
4. Install camshaft phasers on camshafts if removed. See Engine/Cylinder Head/ASSEMBLY, Variable
Valve Timing - Installation.
Fig. 138: Timing Chain Timing Marks
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5. Install timing chain onto exhaust cam sprocket making sure that the timing marks (1) on the sprocket and
the painted chain link are aligned.
6. Position exhaust camshaft and on bearing journals in the cylinder head.
7. Align exhaust cam timing mark (3) so it is in line with the cylinder head cover sealing surface (2).
Fig. 139: Raise Intake Camshaft

8. Install intake camshaft by raising the rear of the camshaft upward and roll the sprocket into the chain.
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9. Align the timing marks (1) on the intake cam sprocket with the painted chain link.
10. Position the intake camshaft into the bearing journals in the cylinder head.
11. Verify that the timing marks (1) are aligned on both camshafts and that the timing marks (3) are facing
each other and are in line with the cylinder head cover sealing surface (2).
CAUTION: Install the front intake and exhaust camshaft bearing cap last. Ensure
that the dowels are seated and follow torque sequence or damage to
engine could result.
NOTE: If the front camshaft bearing cap is broken, the cylinder head MUST be
replaced.
Fig. 141: Camshaft Cap Torque Sequence

12. Install intake and exhaust camshaft bearing caps and slowly tighten bolts to 9.5 N.m (85 in. lbs.) in the
sequence shown in illustration.
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Fig. 142: Front Camshaft Cap Torque Sequence
NOTE: Verify that the exhaust bearing shells are correctly installed, and the
dowels are seated in the head, prior to torquing bolts.
13. Install the front intake and exhaust bearing cap and tighten bolts to 25 N.m (18 ft. lbs.) in the sequence
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Fig. 143: TIMING CHAIN TIMING MARKS
14. Verify that all timing marks (1,3) are aligned.

15. Remove Allen wrench from timing chain tensioner.
Fig. 144: WEDGE TOOL

16. Remove Locking Wedge 9701 (1) by pulling straight upward on pull rope.
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Fig. 145: TENSIONER ACCESS PLUG
17. Apply MOPAR® thread sealant to timing tensioner plug (1) and Install.
18. Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned at the
TDC position.

19. Verify that the camshafts timing marks (3) are in the proper position and in line with the cylinder head
cover sealing surface. If the marks do not line up, the timing chain is not correctly installed.
20. Install right splash shield. Refer to Body/Exterior/SHIELD, Splash - Installation .
Fig. 147: GASKET LOCATION
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21. Remove RTV from gasket (1).

22. Inspect cylinder head cover gaskets (1,2) for damage. If no damage is present, gaskets can be reinstalled.

26. Fill with oil.
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27. Operate engine until it reaches normal operating temperature. Check oil and cooling systems for correct
fluid levels.
COVER(S), CYLINDER HEAD
Removal
REMOVAL


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3. Remove make up air hose (2).

4. Remove PCV hose (5).
5. Disconnect ignition coil electrical connectors (1).

6. Use compressed air to blow dirt and debris off the cylinder head cover prior to removal.
7. Remove cylinder head cover bolts.
8. Remove cylinder head cover from cylinder head.
Installation
INSTALLATION
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Fig. 153: GASKET LOCATION
1. Install new cylinder head cover gaskets (1,2).
Fig. 154: STUD LOCATION

2. Install studs in cover as shown in illustration.
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Fig. 155: Cylinder Head/Front Cover T-Joint
3. Clean all RTV from cylinder head. See Engine - Standard Procedure.
NOTE: When using RTV, the sealing surfaces must be clean and free from grease
and oil.
NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to
final torque within 45 minutes.
4. Apply a dot of Mopar® engine sealant RTV or equivalent to cylinder head/front cover T-joint (1).
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5. Install cylinder head cover assembly to cylinder head and install all bolts, ensuring the studs are located
as shown in illustration.
6. Tighten bolts in sequence shown in illustration using a 2 step torque method as follows:
a. Tighten all bolts to 5 N.m (44 in. lbs.).
b. Tighten all bolts to 10 N.m (90 in. lbs.).

7. Install ignition coils. Tighten fasteners to 8 N.m (70 in. lbs.).

8. If the PCV valve was removed, tighten PCV valve to 5 N.m (44 in. lbs.).
9. Connect coil electrical connectors (1).
10. Connect PCV hose (5) to PCV valve.

11. Connect make up air hose (2).
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13. Install engine cover (1) by pressing the rear of the cover down first.
SPRING(S), VALVE
Removal
CYLINDER HEAD ON
Fig. 159: VALVE REMOVAL
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3. Mark valve tappet location for assembly.
4. Remove valve tappets.
5. Rotate crankshaft until piston is at TDC on compression.
6. With air hose attached to adapter tool installed in spark plug hole, apply 90-120 psi air pressure.
CAUTION: Care must be taken not to damage the tappet bore or engine damage
may result.
7. Using metric valve keeper tool (1) such as Snap-on® GA317 (or equivalent), and remove valve spring
keepers and retainer.
8. Remove valve spring(s).
9. Remove valve stem seal(s) by a using valve stem seal tool.
CYLINDER HEAD OFF

Fig. 160: VALVE REMOVAL
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1. With cylinder head removed from cylinder block, place a ball of rags in the combustion chamber.
CAUTION: Care must be taken not to damage the tappet bore or engine damage
may result.
2. Mark valve tappet location for assembly.

3. Remove valve tappets.
4. Using metric valve keeper tool such as Snap-on® GA317 (or equivalent) remover (1) , remove valve
keepers with a downward push.
5. Remove retainer and springs.
6. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the
valve guides. Identify valves, locks and retainers to insure installation in original location.
7. Inspect the valves. See Engine/Cylinder Head/SPRING(S), Valve - Inspection.
Inspection
INSPECTION
1. Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should
be tested for correct load. Discard the springs that do not meet specifications. The following
specifications apply to both intake and exhaust valves springs:
 Valve closed nominal load - 179.5 N ± 9 N @ 35.0 mm (40.35 lbs. ± 2 lbs. @ 1.38 in.).
 Valve open nominal load - 364.8 N ± 17 N @ 29.25 mm (82 lbs. ± 3.8 lbs. @ 1.152 in.).
2. Inspect each valve spring for squareness with a steel square and surface plate, test springs from both ends.
If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring.
Installation
CYLINDER HEAD ON
CAUTION: Care must be taken not to damage the tappet bore or engine damage may
result.
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Fig. 161: Valve Spring Assembly
1. Install valve seal/valve spring seat (3) assembly. Push the assembly down with appropriate size socket to
seat it onto the valve guide.
2. Install valve spring (2) and retainer (4) with keepers (1).
Fig. 162: VALVE INSTALLATION

3. Place the valve keepers in the retainer. Using metric valve keeper tool such as Snap-on® GA317 (or
equivalent) installer (2) and remover (1) as a handle, install valve keepers with a downward push.
4. Remove air hose and install spark plugs.
5. Install valve tappets.
CYLINDER HEAD OFF
CAUTION: Care must be taken not to damage the tappet bore or engine damage may
result.
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Fig. 163: Valve Spring Assembly
1. Coat valve stems with clean engine oil and insert in cylinder head.
2. Install new valve stem seals (3) on all valves using an appropriate sized socket to seat the seal/spring seat.
The valve stem seals should be pushed firmly and squarely over valve guide.
3. Install valve springs (2).
4. Install keepers in retainer and place on valve spring.
Fig. 164: VALVE INSTALLATION
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5. Using metric valve keeper tool such as Snap-on® GA317 (or equivalent) installer (2) and remover (1) as
a handle, push downward to install keepers.
Fig. 165: Spring Installed Height and Valve Tip to Spring Seat Dimensions
6. Check the valve spring installed height B after refacing the valve and seat. Make sure measurements are
taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm
(1.525 in.), install a 0.762 mm (0.030 in.) spacer under the valve spring seat to bring spring height back
within specification.
7. Install valve tappets.
VALVES, INTAKE AND EXHAUST
Description
DESCRIPTION
The valves are made of heat resistant steel. They have nitrated stems to prevent scuffing. Viton rubber valve
stem seals are integral with the spring seats. The valves have a single bead lock keepers to retain the springs.
Operation
OPERATION
The four valves per cylinder (two intake and two exhaust) are opened by using direct acting tappets which are
actuated by the camshaft.
Cleaning
CLEANING
Clean all valves thoroughly and discard burned, warped and cracked valves.
CAUTION: Due to the small margin on the valves, grinding is not recommended.
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ENGINE BLOCK
DESCRIPTION
DESCRIPTION
The die cast aluminum cylinder block is a two-piece assembly, consisting of the cylinder block and ladder
frame. The block is an open deck design with cast in place cast iron cylinder liners. The cast iron cylinder liners
are recessed below the aluminum deck surface. The ladder frame bolts to the cylinder block and does not
incorporate the main bearing caps. This design offers a much stronger lower end and increased cylinder block
and transaxle rigidity. The rear oil seal retainer is integral with the block and ladder frame. The ladder frame
and block are serviced as an assembly.

The engine serial number (1) is located on the bottom of the ladder frame just behind the oil pan. The serial
number can be seen with the oil pan in place.
STANDARD PROCEDURE
CYLINDER BORE HONING
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Fig. 167: Cylinder Bore Cross-Hatch Pattern
1 - CROSS-HATCH PATTERN
2 - 40°-60°
1. Deglazing of the cylinder walls may be done using a quality commercially available flex hone, if the
cylinder bore is straight and round. 20-60 strokes depending on the bore condition, will be sufficient to
provide a satisfactory surface. Use a light honing oil. Do not use engine or transmission oil, mineral
spirits or kerosene. Inspect cylinder walls after each 20 strokes.
2. Honing should be done by moving the hone up and down fast enough to get a cross-hatch pattern. When
hone marks intersect at 30-50 degrees, the cross hatch angle is most satisfactory for proper seating of
rings .
3. A controlled hone motor speed between 200-300 RPM is necessary to obtain the proper cross-hatch
angle. The number of up and down strokes per minute can be regulated to get the desired 30-50 degree
angle. Faster up and down strokes increase the cross-hatch angle.
4. After honing, it is necessary that the block be cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from engine parts after honing. It is
recommended that a solution of soap and hot water be used with a

brush and the parts then thoroughly dried. The bore can be
considered clean when it can be wiped clean with a white cloth and
cloth remains clean. Oil the bores after cleaning to prevent rusting.
CLEANING
CLEANING
Clean cylinder block thoroughly using a suitable cleaning solvent.
INSPECTION
INSPECTION
ENGINE BLOCK
Fig. 168: Checking Cylinder Bore Size

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1. Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking.
2. Examine block and cylinder bores for cracks or fractures.
3. Check block deck surfaces for flatness. Deck surface must be within service limit of 0.050 mm (0.002
in.).
CYLINDER BORE
NOTE: The cylinder bores should be measured at normal room temperature, 21°C (70°
F).
The cylinder walls should be checked for out-of-round and taper with Tool C119 or equivalent . See Engine -
Specifications. If the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new
pistons and rings fitted.
Measure the cylinder bore at three levels in directions A and B . Top measurement should be 10 mm (3/8 in.)
down and bottom measurement should be 10 mm (3/8 in.) up from bottom of bore. See Engine -
Specifications.
BEARING(S), CONNECTING ROD
Standard Procedure
CONNECTING ROD - FITTING
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Fig. 169: BEARING SELECTION
There are three different sizes of rod bearings available. Connecting rod bearing identification (4) can be found
on the nose of the crankshaft (3). Use the CONNECTING ROD BEARING SELECTION table for proper
bearing selection.
CONNECTING ROD BEARING SELECTION

CONNECTING ROD CONNECTING ROD
CRANKSHAFT PIN
DIMENSION BEARING BEARING
DIAMETER GRADE
CLASSIFICATION DIMENSION
1 48 mm 1 (Black) 1.5 mm
2 48 mm 2 (No Color) 1.5 mm
3 48 mm 3 (Green) 1.5 mm
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Fig. 170: Connecting Rod Bearing Clearance - Typical
1. For measuring connecting rod bearing clearance procedure and use of Plastigage, see Engine - Standard
Procedure. For bearing clearance, refer to Engine - Specifications.
NOTE: The rod bolts should not be reused.
2. Before installing the NEW rod bolts the threads and under the bolt head should be oiled with clean engine
oil.
3. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly.
4. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following
values:
CAUTION: Do not use a torque wrench for the second step.
1. Tighten the bolts to 20 N.m (15 ft. lbs.).

2. Tighten the connecting rod bolts an additional 90°.
Fig. 171: Connecting Rod Side Clearance

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5. Using a feeler gauge, check connecting rod side clearance. Refer to Engine - Specifications.
BEARING(S), CRANKSHAFT, MAIN
Standard Procedure
MAIN BEARING SELECTION
NOTE: There are three different possibilities for the upper main bearings and five
different lower main bearings. The upper and lower bearing shells are not
interchangeable.
Fig. 172: BEARING SELECTION

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

JOURNAL LOWER MAIN
LOWER MAIN BEARING
DIAMETER DIMENSION BEARING
SIZE CLASSIFICATION
GRADE DIMENSION
52 mm, -0.012 to -
0 0 (Pink or Red) 2 mm, 0 to -0.003 mm
0.015 mm
52 mm, -0.015 to -
1 1 (Black) 2 mm, +0.003 to 0 mm
0.018 mm
52 mm, -0.018 to - 2 mm, +0.006 to +0.003
2 2 (No Color)
0.021 mm mm
52 mm, -0.021 to - 2 mm, +0.009 to +0.006
3 3 (Green)
0.024 mm mm
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52 mm, -0.024 to - 2 mm, +0.012 to +0.009
4 4 (Blue)
0.027 mm mm
Fig. 173: MAIN BEARING SELECTION CHART

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

CYLINDER BLOCK
UPPER CRANKSHAFT BEARING SELECTION
IDENTIFICATION
MAIN BEARING UPPER MAIN BEARING SIZE UPPER MAIN BEARING

DIMENSION
GRADE CLASSIFICATION DIMENSION
56.000<56.006
1 1 (Black) 2 mm, 0 to -0.006 mm
mm
56.006<56.012
2 2 (No Color) 2 mm, +0.006 to 0 mm
mm
56.012<56.018 2 mm, +0.012 to +0.006
3 3 (Green)
mm mm
CRANKSHAFT
Standard Procedure
MEASURING CRANKSHAFT END PLAY
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Fig. 174: Checking Crankshaft End Play - Dial Indicator
1 - Crankshaft
2 - DIAL INDICATOR
1. Mount a dial indicator (2) to front of engine with the locating probe on nose of crankshaft (1) .
2. Move crankshaft all the way to the rear of its travel.
3. Zero the dial indicator.
4. Move crankshaft all the way to the front and read the dial indicator. See Engine - Specifications for end
play specification.
Removal
REMOVAL
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Fig. 175: FLEX PLATE
NOTE: Crankshaft can not be removed when engine is in vehicle.
1. Remove engine assembly from vehicle. See Engine - Removal.

2. Separate transaxle from engine.
3. Remove flex plate/flywheel (1).
4. Remove crankshaft rear oil seal. See Engine/Engine Block/SEAL, Crankshaft Oil - Removal.
5. Mount engine on a suitable repair stand.
Fig. 176: OIL DRAIN PLUG

6. Drain engine oil (2).
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Fig. 177: OIL FILTER
7. Remove oil filter (1).
Fig. 178: RIGHT ENGINE MOUNT BRACKET

8. Remove crankshaft vibration damper (2). See Engine/Engine Block/DAMPER, Vibration - Removal.
9. Remove water pump pulley (3).
10. Remove engine mount support bracket (1).
Fig. 179: OIL PAN REMOVAL
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11. Remove the oil pan (2). See Engine/Lubrication/PAN, Oil - Removal.
12. Remove timing chain cover. See Engine/Valve Timing/COVER(S), Engine Timing - Removal.
13. Remove the timing chain. See Engine/Valve Timing/CHAIN and SPROCKETS, Timing - Removal.
14. Remove balance shaft module.
Fig. 180: CRANKSHAFT SPROCKET

15. Remove the crankshaft sprocket (1).

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16. Remove crankshaft position sensor retaining bolt (1) and remove sensor (2).
17. Remove ladder frame. See Engine/Engine Block/FRAME, Ladder - Removal.
Fig. 182: Identify Connecting Rod to Cylinder-Typical

NOTE: If piston/connecting rod replacement is necessary, remove cylinder head.

See Engine/Cylinder Head - Removal.
CAUTION: DO NOT use a number stamp or a punch to mark connecting rods.

Damage to connecting rod could occur.
18. Using a permanent ink or paint marker, identify cylinder number on each connecting rod and cap.
19. Remove all connecting rod bolts and caps. Care should be taken not to damage the fracture rod and cap
surfaces.
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Fig. 183: MAIN BEARING CAP TORQUE SEQUENCE
NOTE: Do not reuse connecting rod bolts.
20. Remove main bearing caps.
CAUTION: Use extreme care when handling crankshaft. Tone wheel damage can
occur if crankshaft is mishandled.
21. Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the
crankshaft.
Inspection
INSPECTION
Fig. 184: Crankshaft Journal Measurements - Typical

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The crankshaft main journals should be checked for excessive wear, taper and scoring. Limits of taper on any
crankshaft main journals should be held to 0.006 mm (0.00024 in.). Limits of taper on any crankshaft rod
journals should be held to 0.005 mm (0.0002 in.). DO NOT nick crank pin or bearing fillets. Limits of out of
round on any crankshaft journals should be held to 0.005 mm (0.0002 in). DO NOT nick crank pin or bearing
fillets.
Installation
INSTALLATION
Fig. 185: BEARING IDENTIFICATION

The crankshaft is supported in five main bearings. All upper bearing shells (2) in the crankcase have oil grooves
and holes. All lower bearing shells (1) are smooth. Crankshaft end play is controlled by a two piece thrust
bearing (3) on the number three main bearing journal.
1. Clean main bearing cap bolt holes with Mopar® brake parts cleaner or equivalent and blow out with
compressed air.
2. Install the main bearing upper (2) shells with the lubrication groove and oil hole in the engine block.
3. Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab
slots.
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Fig. 186: TARGET WHEEL
NOTE: If the crankshaft is sent out for machine work, it must be balanced as an
assembly with the target ring installed.
4. Clean crankshaft and target ring with MOPAR® Brake Parts cleaner and dry with compressed air to
ensure that the crankshaft mating surface and target ring mounting holes are free from oil and lock patch
debris.
NOTE: Always use NEW mounting screws whether installing original or new
target ring.
5. Install NEW mounting screws finger tight starting with the #1 location. Make sure engagement occurs
with the shoulder of the screws and mounting hole before starting all other screws.
6. Tighten all mounting screws to 13 N.m (110 in-lbs) in the sequence shown in illustration.
Fig. 187: INSTALLING THRUST BEARING
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NOTE: Lightly apply trans gel to thrust bearings to hold bearings in block.
NOTE: The thrust bearings must be installed the notches facing the crankshaft.
7. Install thrust bearings (2) in block (1).
CAUTION: Do not get oil on the ladder frame mating surface. It will affect the
ability of the RTV to seal the ladder frame to cylinder block.
NOTE: Ensure main bearing cap bolt holes in the block are clean, dry (free of
residual oil or coolant), and threads are not damaged.
8. Oil the bearings and journals. Install crankshaft in engine block.

Fig. 188: BEARING IDENTIFICATION
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9. Install lower main bearings (1) into main bearing cap. Make certain the bearing tabs are seated into the
bearing cap slots.
NOTE: Main bearing caps are stamped 1 - 5 front to rear. Arrows on the caps must
point towards the front of the engine.
10. Install main bearing caps to engine block.

11. Before installing the bolts the threads should be clean and dry.
12. Loosely install main bearing cap bolts.
13. To ensure correct thrust bearing alignment, perform the following steps:
CAUTION: There are different sets main bolts supplied with this engine. Each
bolt set has a different torque value and engine damage could result
if bolts are not torqued correctly. The bolts are not interchangeable.
Fig. 189: MAIN BOLT IDENTIFICATION

Step 1: Rotate crankshaft until number 4 piston is at TDC.

 Step 2: Move crankshaft rearward to limits of travel.
 Step 3: Then, move crankshaft forward to limits of travel.
 Step 4: Wedge an appropriate tool between the rear of the cylinder block and the rear crankshaft
counterweight. This will hold the crankshaft in its furthest forward position.
14. If your bolt heads look like this (1,2), go to step 15. If your bolt heads do not look like this (1,2), go to
step 16.
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Fig. 190: MAIN BEARING CAP TORQUE SEQUENCE
CAUTION: Before tightening bolts, you must identify the bolt head to obtain the
correct torque value. Failure to identify the bolts correctly, could
result in improperly tightened bolts which could result in engine
damage.
15. Tighten bolts using a three step method, in the sequence shown in illustration.
 Tighten bolts to 15 N.m (11 ft. lbs.)
 Rotate an additional 45°.
16. Tighten bolts using a three step method, in the sequence shown in illustration.
 Rotate an additional 45°.

17. Remove wedge tool used to hold crankshaft.

18. Check the crankshaft turning torque, it should not exceed 5.6 N.m (50 in. lbs.).
19. Check crankshaft end play. See Engine/Engine Block/CRANKSHAFT - Standard Procedure.
20. Install connecting rod bearings and caps. Do Not Reuse Connecting Rod Bolts. Tighten connecting rod
bolts to 20 N.m + 90° (15 ft. lbs.) + 90°. See Engine/Engine Block/ROD, Piston and Connecting -
Installation.
21. Install the ladder frame assembly. See Engine/Engine Block/FRAME, Ladder - Installation.
22. Install the balance shaft module. See Engine/Lubrication/PUMP, Engine Oil - Installation.
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23. Install crankshaft position sensor (2) and tighten bolt (1).
24. Install cylinder head if it was removed. See Engine/Cylinder Head - Installation.
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25. Install front crankshaft sprocket (1).

26. Install the timing chain. See Engine/Valve Timing/CHAIN and SPROCKETS, Timing - Installation.
27. Install the timing chain front cover. See Engine/Valve Timing/COVER(S), Engine Timing -
Installation.
28. Install the oil pan. See Engine/Lubrication/PAN, Oil - Installation.
29. Install rear crankshaft oil seal. See Engine/Engine Block/SEAL, Crankshaft Oil - Installation.
30. Install front crankshaft oil seal. See Engine/Engine Block/SEAL, Crankshaft Oil - Installation.

31. Install engine mount support bracket (1).

32. Install crankshaft vibration damper (2). See Engine/Engine Block/DAMPER, Vibration - Installation.
33. Install water pump pulley (3).
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Fig. 194: LIFT CHAIN
34. Remove engine from repair stand and install engine lift chain (1).
35. Install crankshaft rear oil seal. See Engine/Engine Block/SEAL, Crankshaft Oil - Installation.
36. Install drive plate/flex plate using new bolts. Tighten bolts to 95 N.m (70 ft. lbs.).
37. Attach transaxle to engine. Tighten bellhousing bolts to 101 N.m (75 ft. lbs.).
38. Install the engine assembly. See Engine - Installation.

39. Install new oil filter (1) and fill with oil.
40. Fill with coolant. Refer to Cooling - Standard Procedure .
42. Install engine cover.
DAMPER, VIBRATION
Removal
REMOVAL
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Fig. 196: DAMPER REMOVAL
1. Remove accessory drive belts. Refer to Cooling/Accessory Drive/BELT, Serpentine - Removal .

2. Install Damper holder 9707 (1).
3. Remove crankshaft damper bolt.
4. Pull damper off crankshaft.
Installation
INSTALLATION
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Fig. 197: DAMPER REMOVAL
1. Install crankshaft damper.

2. Apply clean engine oil crankshaft damper bolt threads and between bolt head and washer. Tighten bolt to
210 N.m (155 ft. lbs.).
3. Install accessory drive belts. Refer to Cooling/Accessory Drive/BELT, Serpentine - Installation .
FLEXPLATE
Removal
REMOVAL

1. Remove transmission. Refer to Transmission and Transfer Case/Manual - Removal or Transmission

and Transfer Case/Automatic - 41TE - Removal .
2. Remove flex plate bolts (3) and discard.
3. Remove washer (2).
4. Remove flex plate (1).
Installation
INSTALLATION
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1. Install flex plate (1).

2. Install washer (2).
3. Install new flex plate bolts (3) and tighten in a crisscross pattern to 29 N.m (22 ft. lbs.) plus 51° rotation.
4. Install transaxle. Refer to Transmission and Transfer Case/Manual - Installation or Transmission
and Transfer Case/Automatic - 41TE - Installation .
FRAME, LADDER
Removal
REMOVAL
Fig. 200: PRY POINT 1
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1. Remove oil pan. See Engine/Lubrication/PAN, Oil - Removal.

2. Remove balance shaft assembly. See Engine/Lubrication/PUMP, Engine Oil - Removal.
3. Remove ladder frame retaining bolts.
4. Remove ladder frame using pry point cast in the rear of the block (1).
Fig. 201: PRY POINT 2

5. To assist in removing the ladder frame another (1) pry point cast in the right side of the block.
Cleaning
CLEANING
Clean ladder frame with a plastic or wooden scraper and a suitable solvent. See Engine - Standard Procedure.
Installation
INSTALLATION
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Fig. 202: SEALING LADDER FRAME
NOTE: When using RTV, the sealing surfaces must be clean and free from grease and
oil.
NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to final
torque within 45 minutes.
1. Apply a 2 mm bead of Mopar® engine sealant RTV or equivalent as shown in illustration.

Fig. 203: LADDER FRAME TORQUE
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2. Install bolts and tighten as shown in illustration following a two step method.
 First: All to 10 N.m (89 in. lbs.).
 Second: All to 26 N.m (19 ft. lbs.).
3. Install balance shaft module. See Engine/Lubrication/PUMP, Engine Oil - Installation.

4. Install oil pan. See Engine/Lubrication/PAN, Oil - Installation.
RING(S), PISTON
Standard Procedure
PISTON RING - FITTING
Fig. 204: Check Gap on Piston Rings

1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring
gap measurement must be made with the ring positioning at least 13 mm (0.50 inch) from bottom of
cylinder bore and below the bottom of the oil ring travel where cylinder bore has minimal wear. Check
gap with feeler gauge. Refer to Engine - Specifications.
NOTE: Ring end gap measurements are sensitive to the ring being square in the
bore. Care must be used to avoid tilting the rings in cylinder bores when
taking measurements.
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Fig. 205: Checking Piston Ring To Groove Side Clearance
2. Check piston ring to groove side clearance. Refer to Engine - Specifications.
CAUTION: Exercise care when using tools on piston. Do not scratch or gouge
piston surface or ring grooves as this may cause engine damage.
Removal
REMOVAL
Fig. 206: Piston Rings-Removing and Installing

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1. Using a suitable ring expander, remove upper and intermediate piston rings.
2. Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston.
3. Clean ring grooves of any carbon deposits.
Installation
INSTALLATION
Fig. 207: Installing Side Rail

NOTE: The identification mark on face of upper and intermediate piston rings must
point toward top of piston.
CAUTION: Install piston rings in the following order:

A. Oil ring expander.

B. Upper oil ring side rail.
C. Lower oil ring side rail.
D. No. 2 Intermediate piston ring.
E. No. 1 Upper piston ring.
1. Install oil ring expander.

2. Install upper side rail first and then the lower side rail. Install the side rails by placing one end between
the piston ring groove and the oil ring expander. Hold end firmly and press down the portion to be
installed until side rail is in position. Do not use a piston ring expander.
NOTE: The compression rings are marked Y1 for the upper compression ring and
Y2 for the second compression ring. These markings must face upward.
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3. Install No. 2 piston ring and then No. 1 piston ring.
Fig. 208: Piston Ring End Gap Position

4. Position piston ring end gaps as shown in illustration.

5. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on
the thrust direction. Staggering ring gap is important for oil control.
ROD, PISTON AND CONNECTING
Description
DESCRIPTION
The pistons are made of a cast aluminum alloy. The pistons have pressed-in pins attached to forged connecting
rods. The piston pin is offset 0.8 mm (0.0314 in.) towards the thrust side of the piston. The connecting rods are
a cracked cap design and are not repairable. The piston with rings, connecting rod and piston pin are serviced as
an assembly.
Standard Procedure
PISTON and BORE MEASUREMENT
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Fig. 209: Measuring Pistons & Cylinder Bores
NOTE: Pistons and cylinder bores should be measured at normal room temperature,
21°C (70°F).
Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin
(1).
1. Measurement should be taken approximately 17 mm (0.669 in.) from the bottom of the skirt (2) as shown
in illustration.
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Fig. 210: Checking Cylinder Bore Size
NOTE: Correct piston to bore clearance must be established in order to assure

quiet and economical operation.
2. Cylinder bores should be measured halfway down the cylinder bore and transverse (measurement location
B) to the engine crankshaft center line shown in illustration. See Engine - Specifications.
PISTON SELECTION
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Fig. 211: Main Bearing Selection Chart
The pistons are select fit to each bore. There are three different grades of pistons available; A, B, and C. The
piston identification (2) is located in the middle of the block on the right side of the engine. The bore
identification starts at the top and reads downward. Bore #1 is at the top and bore #4 is at the bottom.
The piston, rings and rod are serviced as an assembly. After determining what size piston is needed, refer to
Engine/Engine Block/BEARING(S), Connecting Rod - Standard Procedure to determine correct rod
bearing size.
Removal
REMOVAL
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NOTE: Pistons, rings, and rods are serviced as an assembly.
CAUTION: To maintain engine balance, 1, 3, or 4 pistons can be replaced. If 2 pistons

are replaced, engine will be out of balance.
1. Remove engine. See Engine - Removal.

2. Separate engine from transaxle.
3. Mount engine on a suitable engine stand and remove engine lift chain (1).
4. Remove cylinder head. See Engine/Cylinder Head - Removal.

5. Drain engine oil (2).

6. Remove oil pan (1). See Engine/Lubrication/PAN, Oil - Removal.
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8. Remove balance shaft assembly.
9. Remove ladder frame.
NOTE: Remove any carbon build up and clean debris from cylinder prior to piston
removal to avoid scratching piston skirts.
10. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder
block. Be sure to keep tops of pistons covered during this operation .
Fig. 215: Identify Connecting Rod to Cylinder-Typical

11. Rotate crankshaft so that each connecting rod is centered in cylinder bore.
12. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap.
CAUTION: DO NOT use a number stamp or a punch to mark connecting rods, as

damage to connecting rod could occur.
CAUTION: Care must be taken not to damage the fractured rod and cap joint
surfaces, as engine damage may occur.
13. Remove connecting rod bolts and cap.
CAUTION: Do not reuse connecting rod bolts. These are one-time-use bolts and
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reuse could result in engine failure.
14. Carefully push each piston and rod assembly out of cylinder bore. Reinstall bearing cap on the mating
rod.
15. Repeat procedure for each piston and connecting rod assembly.
Installation
INSTALLATION
Fig. 216: Piston Ring End Gap Position

1. Install piston rings on piston. See Engine/Engine Block/RING(S), Piston - Installation.

2. Before installing pistons and connecting rod assemblies into the bore, be sure that top compression ring
gap (1) and the second compression ring gap (3) are staggered so that neither is in line with oil ring rail
gap.
3. Before installing the ring compressor, make sure the oil ring expander ends are butted (1) and the rail
gaps (2,4) located as shown in illustration above. As viewed from the top of the piston.
NOTE: Be sure the position of piston rings on the piston does not change during
the following step.
4. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston.
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Fig. 217: PISTON INSTALLATION
5. The directional arrow stamped on the piston should face toward the front of the engine.
6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate
connecting rod journal with clean engine oil.
Fig. 218: RING COMPRESSOR
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NOTE: Rod bearing sizes are indicated on the nose of the crankshaft. There are
three different size rod bearings. Perform rod bearing selection procedure.
7. Install connecting rod upper bearing half into connecting rod.

8. Install ring compressor (3).
9. Tap the piston (1) down in cylinder bore, using a hammer handle (2). At the same time, guide connecting
rod into position on connecting rod journal.
NOTE: The connecting rod cap bolts should NOT be reused.
10. Before installing the NEW bolts, the threads should be coated with clean engine oil.
11. Install connecting rod lower bearing half into connecting rod cap. Install connecting rod cap.
12. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly.
CAUTION: Do not use a torque wrench for the second step.
13. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten the bolts to 20 N.m (15 ft.
lbs.), then an additional 90°.
Fig. 219: Connecting Rod Side Clearance

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14. Using a feeler gauge, check connecting rod side clearance. See Engine - Specifications for connecting
rod side clearance.
15. Install the ladder frame. See Engine/Engine Block/FRAME, Ladder - Installation.
16. Install oil pump/balance shaft carrier assembly. See Engine/Lubrication/PUMP, Engine Oil -
Installation.
18. Install cylinder head. See Engine/Cylinder Head - Installation.

19. Install engine lift chain (1).

20. Connect transaxle assembly to engine.

21. Install engine. See Engine - Installation.
SEAL, CRANKSHAFT OIL, FRONT
Removal
REMOVAL
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Fig. 221: Damper Removal
1. Remove accessory drive belt.

2. Install damper holder 9707 (1) and remove damper retaining bolt.
3. Pull damper off crankshaft.
Fig. 222: FRONT CRANKSHAFT SEAL REMOVAL
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4. Remove front crankshaft oil seal (1) by prying out with a screw driver (2). Be careful not to damage the
cover seal surface.
Installation
INSTALLATION
Fig. 223: FRONT CRANKSHAFT SEAL INSTALLER

1. Place seal (1) onto Seal installer 9506 (2) with seal spring towards the inside of engine.
Fig. 224: INSTALLING FRONT SEAL
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2. Install new seal (1) by using Seal installer 9506 (2) and crankshaft damper bolt (3).
Fig. 225: FRONT SEAL INSTALLED

3. Press seal into front cover until Seal Installer 9506 (1) seats against timing chain cover (3).
4. Remove seal installer 9506 (1).
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Fig. 226: Damper Removal
5. Install crankshaft vibration damper.

6. Oil the bolt threads and between the bolt head and washer.
7. Install damper retaining bolt and damper holder 9707 (1). Tighten bolt to 210 N.m (155 ft. lbs.).
SEAL, CRANKSHAFT OIL, REAR
Removal
REMOVAL

1. Remove transmission and flexplate (1). See Engine/Engine Block/FLEXPLATE - Removal.
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Fig. 228: Rear Crankshaft Oil Seal - Removal
2. Insert a 3/16 flat bladed screwdriver (7) between the dust lip (8) and the metal case (4) of the crankshaft
seal (1). Angle the screwdriver through the dust lip against metal case of the seal. Pry out seal.
CAUTION: Do not permit the screwdriver blade to contact crankshaft seal

surface. Contact of the screwdriver blade against crankshaft edge
(chamfer) is permitted.
3. Check to make sure the seals garter spring is not on the crankshaft.
Installation
INSTALLATION
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Fig. 229: REAR MAIN INSTALLATION
CAUTION: If a burr or scratch is present on the crankshaft edge (chamfer), cleanup

with 800 emery cloth to prevent seal damage during installation of new
seal. If emery cloth is used, the crankshaft must be cleaned off Mopar®
brake parts cleaner.
NOTE: When installing seal, lubricate Seal Guide 9509 with clean engine oil.
1. Place Seal Guide 9509 (3) on crankshaft.

2. Position seal (2) over guide tool. Guide tool should remain on crankshaft during installation of seal.
Ensure that the lip of the seal is facing towards the crankcase during installation.
3. Drive the seal into the block using Seal Driver 9706 (1) and Driver Handle C-4171 (4) until Seal Driver
9706 bottoms out against the block.
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4. Install the flexplate (1) and transmission. See Engine/Engine Block/FLEXPLATE - Installation.
ENGINE MOUNTING
DESCRIPTION
DESCRIPTION
The engine mounting system consists of a four-point system utilizing two load-carrying mounts and two torque
controlling mounts. The load-carrying mounts are located on each frame rail. The right and left mounts are
hydro-elastic mounts. The two torque controlling mounts are attached to a fore/aft member and the front and
rear of the engine.
OPERATION
OPERATION
The four-point engine mounting system minimizes the transmission of structure-borne engine noise to the
passenger compartment. The load-carrying right and left mounts dampen and isolate vertical motion and
vibration. The front and rear mount absorb torque reaction forces and torsional vibrations.
INSULATOR, ENGINE MOUNT, LEFT
Removal
REMOVAL
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Fig. 231: Air Cleaner Assembly
1. Remove air cleaner assembly (1).

2. Disconnect negative cable from battery.
3. Remove PCM.
4. Remove PCM mounting bracket.
Fig. 232: LEFT MOUNT

5. Support transaxle with a suitable jack.

6. Remove mount to transaxle bolts (2).

7. Remove left mount to frame rail fasteners (4).
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Fig. 233: Frame Rail Fastener
8. Lower transaxle to gain access to mount to frame rail fastener (2).

9. Remove mount isolator (3).
Installation
INSTALLATION
Fig. 234: Frame Rail Fastener

1. Position mount isolator (3) in place, install bolts (1,2) and tighten to 55 N.m (40 ft. lbs.).
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Fig. 235: LEFT MOUNT
2. Raise transaxle into position, install bolts (2) and tighten to 98 N.m (72 ft. lbs.).
3. Remove jack.
Fig. 236: Air Cleaner Assembly

4. Install PCM mounting bracket.

5. Install PCM. Refer to Electrical - Electronic Control Modules/Electronic Control
Modules/MODULE, Engine Control - Installation .
7. Install air cleaner assembly (1). See Engine/Air Intake System/BODY, Air Cleaner - Installation.
INSULATOR, ENGINE MOUNT, RIGHT
Removal
REMOVAL
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1. Remove coolant reservoir (1) and set aside.

Fig. 238: Power Steering Line Support Bracket
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2. Remove power steering line support bracket (3) from engine mount.
3. Support transaxle with a block of wood and a suitable jack.
Fig. 239: Engine Mount Bracket Retaining Bolts

4. Remove engine mount bracket (2) retaining bolts.

5. Remove engine mount isolator bolts.
6. Remove engine mount isolator (1).
Installation
INSTALLATION
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Fig. 240: Engine Mount Bracket Retaining Bolts
1. Position right engine mount isolator (1).

2. Install engine mount isolator retaining bolts and tighten to 55 N.m (41 ft. lbs.).
Fig. 241: Power Steering Line Support Bracket

3. Position right mount bracket (1) and install bolts (4).

6. Remove jack.
7. Install power steering line support (3) at engine mount.
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8. Install coolant reservoir (1).
INSULATOR, ENGINE MOUNT, FRONT
Removal
REMOVAL
Fig. 243: LOWER SILENCER

1. Raise vehicle.
2. Remove lower silencer (1).
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Fig. 244: FRONT MOUNT
3. Remove mount through bolt (2).

4. Remove front mount retaining bolts (3).
5. Remove front mount (1).
Installation
INSTALLATION
Fig. 245: FRONT MOUNT

1. Position mount (1) and

2. Install retaining bolts (3) and torque to 47 N.m (35 ft. lbs.).
3. Install mount through bolt (2) and torque to 47 N.m (35 ft. lbs.).
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4. Install lower silencer (1).

5. Lower vehicle.
INSULATOR, ENGINE MOUNT, REAR
Removal
REMOVAL
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1. Raise vehicle.
2. Remove lower silencer (1).
Fig. 248: Rear Mount Retaining Bolts

3. Remove rear mount retaining bolts (3).

4. Remove rear mount through bolt (1).
Fig. 249: Rear Mount Retaining Bolts & Oxygen Sensor
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5. Remove oxygen sensor (1).

6. Remove rear mount retaining bolts (2).
Fig. 250: Removing/Installing Rear Mount Towards Rear Of Vehicle

7. Remove rear mount (1) towards the rear of the vehicle.
Installation
INSTALLATION
Fig. 251: Removing/Installing Rear Mount Towards Rear Of Vehicle
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1. Position rear mount (1) in place from the rear of the vehicle.
Fig. 252: Rear Mount Retaining Bolts & Oxygen Sensor

2. Install rear mount retaining bolts (2) and torque to 50 N.m (37 ft. lbs.).
3. Install oxygen sensor (1).
Fig. 253: Rear Mount Retaining Bolts
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4. Install rear mount retaining bolts (3) and torque to 50 N.m (37 ft. lbs.).
5. Install rear mount through bolt (1) and torque to 47 N.m (35 ft. lbs.).

6. install lower silencer (1).
LUBRICATION
DESCRIPTION
DESCRIPTION
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Fig. 255: OIL FLOW DIAGRAM
The lubrication system is a full-flow filtration, pressure feed type. The balance shaft module (BSM) is mounted
below the ladder frame and chain driven by the crankshaft. The BSM consists of a non-serviceable pump, oil
pressure relief valve, and a non-serviceable balance assembly.
Fig. 256: OIL HOLE
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NOTE: Not all blocks have the bolt on timing chain oil squirter. Engine blocks either
have a bolt-on oil squirter or a 1.0 mm hole (1) drilled into the oil gallery
passage. Engine blocks with the 1.0 mm hole no longer use an oil squirter even
though the threaded mounting hole may still be present.
OPERATION
OPERATION
Engine oil is drawn up through the pickup tube and is pressurized by the oil pump and routed through the full-
flow filter to the main oil gallery running the length of the cylinder block. A diagonal hole in each bulkhead
feeds oil to each main bearing. Drilled passages within the crankshaft route oil from main bearing journals to
connecting rod journals. Balance shaft lubrication is provided through an internal oil passage at the #3 bearing
location around the BSM mounting bolt. A vertical hole at the number one bulkhead routes pressurized oil
through a filter screen and head gasket up to the cylinder head. The oil then divides into three passages; one to
the intake cam phaser, one to the exhaust cam phaser and one to the camshafts. The passage to the camshafts
divides to feed both of the hollow camshafts at the second cam journal. The rest of cam journals are feed oil
through the hollow camshafts. The #1 cam journals are fed oil through the VVT oil passages. Oil passages to
the phasers are directed through the OCV (oil control valves) to the #1 journals. The oil then flows through the
camshafts then to the cam phasers. Oil returning to the pan from pressurized components supplies lubrication to
the valve stems, cam lobes, and tappets. Cylinder bores and wrist pins are splash lubricated from directed slots
on the connecting rod thrust collars.
CHECKING ENGINE OIL PRESSURE

Fig. 257: OIL TEMPERATURE SENSOR
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NOTE: Anytime the oil temperature sensor is removed, it should be replaced with a
new sensor.
1. Disconnect and remove oil temperature sensor (1).
Fig. 258: OIL PRESSURE ADAPTER 9879

CAUTION: Threads in cylinder head are British Standard Pipe (BSP). Do not
install a NPT threaded adapter, this could crack the cylinder head.
2. Install threaded adapter 9879 (1).

3. Install oil pressure gauge (2).
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Fig. 259: OIL PSI GAUGE
4. Start engine and record reading on oil pressure gauge (1).
CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test
5. If oil pressure is 0 at idle, shut off engine. Check for pressure relief valve stuck open, a clogged oil pick-
up screen.
6. Remove oil pan and inspect for debris. See Engine/Lubrication/PAN, Oil - Removal.
7. Remove oil pressure relief valve. See Engine/Lubrication/VALVE, Oil Pressure Relief - Removal.
8. Inspect oil pressure relief valve and replace if damaged. See Engine/Lubrication/VALVE, Oil Pressure
Relief - Inspection.
9. If pressure relief valve is OK, replace balance shaft module assembly. See Engine/Lubrication/PUMP,
Engine Oil - Removal.
Fig. 260: OIL PRESSURE ADAPTER 9879
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10. After test is complete, remove oil pressure gauge (2) and adapter 9879 (1).

11. Install a new oil pressure temperature sensor (1) and connect electrical connector.
CHECKING VVT OIL PRESSURE
This test can be used to help diagnose VVT faults.

Fig. 262: OIL SENDER
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1. Disconnect and remove oil pressure sensor (1).
Fig. 263: OIL PRESSURE GAUGE

CAUTION: Threads in block are 1/8"-28 British Standard Pipe (BSP). Do not
install a National Pipe Thread (NPT) threaded adapter, this could
crack the cylinder block.
2. Install an 1/8-28 BSP male to 1/8-27 female threaded adapter (2).

3. Install oil pressure gauge (1).
4. Start engine and record oil pressure.
CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test
5. If oil pressure is 0 at idle, shut off engine. check for pressure relief valve stuck open, a clogged oil pick-
up screen.
6. Remove oil pan and inspect for debris. See Engine/Lubrication/PAN, Oil - Removal.
7. Remove oil pressure relief valve and inspect. If damaged replace pressure relief valve. See
Engine/Lubrication/VALVE, Oil Pressure Relief - Removal.
8. If pressure relief valve is OK, replace balance shaft module assembly. See Engine/Lubrication/PUMP,
Engine Oil - Removal.
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Fig. 264: OIL PRESSURE GAUGE
9. After test is complete, remove test gauge (1) and fitting (2).
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10. Install oil pressure sensor and electrical connector.
CONTROL VALVE, OIL INTAKE
Description
DESCRIPTION
Fig. 266: SOLENOID ASSEMBLY

Variable valve timing solenoid assembly. The solenoid receives pulse width modulation signal and the current
is controlled within 0 ma to 1000 ma. The spool position is controllable at any position to control supply of oil
between the advance and retard ports.
Operation
OPERATION
There is both an Intake and an exhaust camshaft sensor on vehicles equipped with a Gas Engine. The variable
valve timing system used on Gas Engines requires the exact position of both the intake and exhaust camshaft.
The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the
camshafts. Intake and exhaust phaser oil control valves are required on Gas Engine vehicles using variable
valve timing. The oil valves direct oil to the Intake and exhaust phasers. Oil pressure in the phasers moves the
camshafts to an advanced or retarded position.
To resolve this inherent conflict between optimum high and low speed valve timing, the GPEC1 controlled
engine uses a variable valve timing system. The variable valve timing system advances and retards valve timing
by rotating the position of both the intake and exhaust camshafts. With this system, the intake valve opening can
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range from 80 to 120 crankshaft degrees after Top Dead Center. Likewise, the exhaust valve opening can range
from 85 to 120 crankshaft degrees before Top Dead Center. This degree of flexibility provides many benefits,
including: Improved Engine Performance, Increased Fuel Economy, Improved Idle Stability and Decreased
Engine Emissions. In non operating condition, the camshaft stays in lock pin position of cam phases. This is
120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft.
The variable valve timing system is electronically controlled and hydraulically operated. The GPEC1 receives
information from many sensors to determine the optimum valve timing. It then pulse-width modulates oil
control valves which direct oil to the cam phasers. The cam phasers use oil pressure to rotate the intake and
exhaust camshafts. The rotation of the camshafts is referred to as cam phasing. Before the GPEC1 can begin
commanding the camshaft phasing, several enabling conditions must be met:
 The engine oil temperature must be at least -6.6°C (20°F)

 The oil control valve coil temperature must be less than 140°C (284°F)
 Engine speed must be at least 600 to 1000 RPM to achieve minimum oil pressure.
 Battery voltage must be at least 10 volts
 And there must be no camshaft or crankshaft sensor faults, engine timing faults, or oil control valve faults
First we will examine variable valve timing enabling conditions, and then we will take a closer look at the
inputs and outputs of the system:
 Accelerator pedal position sensor

 Oil temperature sensor
 Map sensor
 Intake cam sensor
 Exhaust cam sensor
 Crankshaft sensor
 GPEC1
Exhaust phaser oil control valve
 Intake phaser oil control valve

 Inputs
 Engine control module
 Outputs
 Sensed battery voltage
A minimum oil temperature is required to enable variable valve timing operation. Oil temperature and viscosity
also have an impact on the operation of variable valve timing after start-up. Oil is used to control the movement
of the camshafts. An incorrect oil viscosity could adversely affect the operation of the system or even render the
system inoperative. It may even set a fault code.
The accelerator pedal position sensor indicates how far the driver wants to open the throttle plate. The GPEC1
calculates an initial camshaft set point based on whether the accelerator pedal is at part throttle or wide open
throttle.
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The MAP sensor provides information regarding engine load.
Sensed battery voltage provides information regarding current system voltage. Sensed battery voltage must be
at least 10 volts in order for the oil control valves to function properly.
This information allows the GPEC1 to adjust camshaft timing to achieve the best fuel economy, the best engine
performance or a combination of both. The hall-effect crankshaft sensor provides RPM information and
determines when the number one piston is approaching Top Dead Center. The sensor generates a signal as the
tone wheel, attached to the crankshaft, rotates. The tone wheel has 60 teeth minus two. When the gap, created
by the missing teeth passes by the sensor, a signal is produced that indicates the number one piston is at Top
Dead Center. The GPEC1 uses crankshaft sensor data along with camshaft data to determine the actual position
of the camshaft. There are two hall-effect camshaft sensors on engines equipped with variable valve timing. The
GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshaft.
The GPEC1 individually controls each valve. It sends a pulse width modulated signal to move a spool within
the outer casing of the valve. Depending upon spool movement, oil is directed through the passages to advance
or retard cam timing. The oil control valve also has a special cleaning strategy at key-on. The cleaning strategy
is known as "debris crush mode". At key-on the GPEC1 cycles the oil control valve on and off several (5) times
to crush any debris in the oil control valve and prevent the spool valve from sticking. In non operating
condition, the camshaft stays in lock pin position of cam phases. This is 120 degrees ATDC for intake camshaft
and 120 degrees BTDC for exhaust camshaft.
There are two oil control valves. One valve directs oil to the intake cam phaser, the other valve directs oil to the
exhaust cam phaser. The valves are designed and function in the same manner. The outer casing of each oil
valve has five oil passages. A passage for pressurized supply oil. A passage to the advance chamber of the cam
phaser. A passage to the retard chamber of the cam phaser. A passage for oil return from the advance chamber
of the cam phaser. A passage for oil return from the retard chamber of the cam phaser. Oil flows through the
passages and applies pressure to the cam phasers to change cam timing.
There are two cam phasers. One phaser controls the position of the intake camshaft. The other phaser controls
the position of the exhaust camshaft. The phasers consist of a sprocket, a rotor vane, and a housing or stator.
The exhaust cam phaser also consists of a front bushing and spring. We will discuss the purpose and function of
the bushing and spring later. The housing is bolted and permanently fixed to the camshaft sprocket, while the
rotor vane is bolted and permanently fixed to the camshaft. With this design, any movement of the rotor vane in
relation to the housing will also move the camshaft. The phaser and sprocket are serviced as an assembly.
Camshaft and crankshaft sensors provide feedback to the GPEC1 regarding the actual position of the camshafts.
The GPEC1 then compares the actual camshaft positioning with desired positioning. If the desired positioning is
not achieved within a specified time, during the second key cycle a trouble code is set.
There are six new diagnostic trouble codes available to help you determine if the control circuit from the
GPEC1 to the oil control valve is intact and operating properly. The codes identify whether the control circuit is
open, shorted to ground, or shorted to power. Three trouble codes are related to intake camshaft positioning, the
other three codes are specific to exhaust camshaft positioning.
The oil control valve contains both electrical and mechanical components. It is electrically controlled by the
GPEC1. The electrical current that energizes the coil results in mechanical motion of the spool valve. It is
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possible to verify both the electrical and mechanical operation of the valve. The oil control valve consists of a
coil that is energized to move a spool within an outer casing. The condition of the coil can be tested with a
Digital Volt Ohmmeter or DVOM. With the DVOM set to measure resistance, check the coil for an open, a
short to ground, or excessive resistance. The correct resistance value of the coil is between 6 and 8 ohms. The
mechanical operation of the oil control valve can be tested using actuator commands on the scan tool. Remove
the oil control valve, then navigate to the actuator menu and select the oil control valve. Use commands to
activate the valve and watch as the spool valve moves back and forth inside the casing.
Because the cam phasers are hydraulically operated by engine oil, the condition of the oil is very important. The
oil must be of the correct viscosity, not obstructed by debris, to maintain correct pressure. Maintaining the
correct oil viscosity is critical to the operation of the variable valve timing system. The wrong oil viscosity may
cause the variable valve timing to malfunction and trouble codes to set. The correct oil viscosity for this system
is 5W20. Oil must be clean, unobstructed and free to flow through the variable valve timing system. Oil could
become obstructed in oil passages located in the cylinder head, cylinder block, or even in the oil screen. In the
event oil flow is obstructed, further diagnosis or disassembly may be required to pin point the source of the
obstruction. The variable valve timing system relies on oil pressure to advance or retard the position of the
camshaft. Insufficient oil pressure will adversely affect the operation of variable valve timing. The minimum oil
pressure for this system is 15 psi at normal operating temperature.
Though not directly used to change camshaft positioning, the oil screen is an important component of the
variable valve timing system. It helps to remove debris going to the variable valve timing components. The oil
screen is located in the cylinder block, immediately below the cylinder head. Oil must pass through the oil
screen before entering the oil control valve. The cylinder head must be removed to service the oil screen. The
intention is not to service the oil screen during vehicle life.
How the cam phaser works. The cam phaser assembly has eight separate chambers; four advance chambers and
four retard chambers. When camshaft advance is requested, oil enters all four advance chambers and exerts
force on the rotor vane. Because the rotor vane is bolted to the camshaft, the entire camshaft profile moves
along with the rotor vane. At the same time, oil is forced out of the retard chambers. When camshaft retard is
requested oil enters the retard chambers to move the camshaft in the opposite direction. There is a lock pin on
one side of the rotor vane that fits inside a recessed area in the housing. The lock pin ensures that the default
position of the intake cam phaser is 120 crankshaft degrees full retard and the default position of the exhaust
cam phaser is 120 crankshaft degrees full advance. When the engine is turned off, rotational force and inertia
move the intake camshaft and rotor vane toward the retard position. The exhaust cam phaser includes a spring
and bushing to work against the rotational force of the engine, allowing the exhaust cam phaser to lock in the
fully advanced position. Under most conditions the cam phasers are returned to lock pin position when the
engine is turned off. In the unique condition of an engine stall, which abruptly shuts off the engine, the cam
phasers may not return to the lock pin position. In this case, the phasers will return to the lock pin position at the
next start-up. Lock pin position is the most ideal cam timing for idle stability. When engine RPM exceeds
approximately 600 to 1000 RPM, oil pressure unlocks the pins and variable valve timing resumes. Once
enabling conditions are met, the GPEC1 uses input from sensors to calculate optimum valve timing.
There are four preprogrammed modes from which the GPEC1 bases initial valve timing.
 Starting
 Idle or Part throttle
 Wide open throttle
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 Limp-in or Default
From each preprogrammed mode, the GPEC1 adjusts valve timing based on operating conditions.
GPEC1 has calculated optimum intake valve timing of 112 degrees after Top Dead Center and optimum exhaust
valve timing of 97 degrees before Top Dead Center. The GPEC1 pulse width modulates the oil control valves to
advance or retard the camshaft to their desired location. The spool valve inside the intake oil control valve is
energized and moves to allow pressurized oil into the advance chambers of the intake cam phaser. At the same
time, the spool valve inside the exhaust oil control valve is energized and moves to allow pressurized oil into
the retard chambers of the exhaust cam phaser. Oil enters the advance chambers of the intake phaser and the
retard chambers of the exhaust phaser. Oil pressure releases the lock pin from its locked position and pushes
against the rotor vane. Both the rotor vanes are moved, advancing the intake camshaft and retarding the exhaust
camshaft.
Removal
FRONT SOLENOID 1/1

Fig. 267: OIL PRESSURE SENSOR
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1. Disconnect negative battery cable.

3. Rotate hose clamp out of way.
4. Disconnect oil pressure sensor electrical connector.
5. Remove oil pressure sensor.
6. Disconnect variable valve timing solenoid electrical connector.
Fig. 268: SOLENOID MOUNTING BOLT

7. Remove variable valve timing solenoid mounting bolt.

Fig. 269: SOLENOID MOUNTING TAB 1/1
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8. Pull solenoid straight out of cylinder head.
REAR SOLENOID 1/2
Fig. 270: SOLENOID LOCATION 1/2

1. Disconnect negative battery cable.

4. Remove variable valve timing solenoid mounting bolt.
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5. Pull solenoid straight out of cylinder head.
Installation
FRONT SOLENOID 1/1

1. Solenoid for front location 1/1. Note mounting tab location is different between front and rear solenoids.
Fig. 273: SOLENOID MOUNTING BOLT
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2. Install solenoid into cylinder head.

3. Install mounting bolt and tighten to 12 N.m (9 ft. lbs.).
Fig. 274: OIL PRESSURE SENSOR

4. Install oil pressure sensor.

5. Connect electrical connector to oil pressure sensor.
6. Connect electrical connector to Variable valve timing solenoid.
REAR SOLENOID 1/2
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1. Rear variable valve timing solenoid. Note mounting tab location is different between front and rear
solenoids.
2. Install solenoid into cylinder head.
3. Install mounting bolt and tighten to 12 N.m (9 ft. lbs.).
4. Connect electrical connector to Variable valve timing solenoid.
Fig. 276: SOLENOID LOCATION 1/2


COOLER, OIL
Description
DESCRIPTION
An engine oil cooler is used on some engine packages. The cooler is a coolant-to-oil type and mounted between
the oil filter and oil filter adapter.
Removal
REMOVAL
NOTE: The oil cooler can not be cleaned out. In the event that the engine requires
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rebuilding or replacement, the oil cooler should be replaced.
Fig. 277: OIL COOLER

1. Raise vehicle on hoist.

2. Drain cooling system. Refer to Cooling - Standard Procedure .
3. Disconnect oil cooler coolant hoses.
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Fig. 278: OIL COOLER MOUNTING
5. Remove oil cooler connector bolt (2).

6. Remove oil cooler (1).
Installation
INSTALLATION
Fig. 279: OIL COOLER MOUNTING

1. Replace oil cooler seal (1).

2. Lubricate seal and position oil cooler to oil filter adapter, aligning notch to tab.
3. Install oil cooler connector bolt (2). Tighten connector bolt to 49 N.m (36 ft. lbs.).
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Fig. 280: OIL COOLER
4. Install oil filter (3).

5. Connect oil cooler coolant hose.
6. Lower vehicle.
FILTER, ENGINE OIL
Removal
REMOVAL
Fig. 281: Oil Filter
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CAUTION: When servicing the oil filter, avoid deforming the filter can by installing the
remove/install tool band strap against the can to base lock seam. The lock
seam joining the can to the base is reinforced by the base plate.
1. Using a suitable filter wrench, turn oil filter (1) counterclockwise to remove.
Installation
INSTALLATION

1. Clean and check filter mounting surface. The surface must be smooth, flat and free of debris or pieces of
gasket.
2. Lubricate new oil filter gasket.
3. Screw oil filter (1) on until the gasket contacts base. Tighten to 14 N.m (10 ft. lbs.).
OIL
Standard Procedure
ENGINE OIL LEVEL CHECK
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Fig. 283: OIL LEVEL INDICATOR
NOTE: The engine must be HOT when checking oil level.
The best time to check engine oil level is after the engine is at operating temperature. Allow the engine to be
shut off for at least 5 minutes before checking oil level.
Fig. 284: DIP STICK
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Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove
dipstick (1), and observe oil level. Add oil only when the level is at or below the SAFE mark. If the oil level is
in the safe (2) range, do not add oil.
CAUTION: Do not operate engine if the oil level is above the MAX mark on the
dipstick. Excessive oil volume can cause oil aeration which can lead to
engine failure due to loss of oil pressure or increase in oil temperature.
ENGINE OIL AND FILTER CHANGE
WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or
repeated skin contact with engine oil. Contaminants in used engine oil,
caused by internal combustion, can be hazardous to your health.
Thoroughly wash exposed skin with soap and water. Do not wash skin
with gasoline, diesel fuel, thinner, or solvents, health problems can result.
Do not pollute, dispose of used engine oil properly. Contact your dealer
or government agency for location of collection center in your area.
CAUTION: On export vehicles, refer to the owners manual for the correct grade of oil.
Change engine oil at mileage and time intervals described in the Maintenance Schedule. Refer to Vehicle
Quick Reference/Maintenance Schedules - Description .
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1. Run engine until achieving normal operating temperature.

2. Position the vehicle on a level surface and turn engine off.
3. Remove oil fill cap.
5. Place a suitable oil collecting container under oil pan drain plug (2).
6. Remove oil pan drain plug (2) or and allow oil to drain into collecting container. Inspect drain plug
threads for stretching or other damage. Replace drain plug and gasket if damaged.

7. Remove oil filter (1). See Engine/Lubrication/FILTER, Engine Oil - Removal.

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8. Install oil pan drain plug (2) and tighten drain plug to 40 N.m (30 ft. lbs.).

9. Install new oil filter (1), tighten to 14 Nm (10 ft. lbs.). See Engine/Lubrication/FILTER, Engine Oil -
Installation.
10. Lower vehicle and fill crankcase with specified type and amount of engine oil. Refer to Vehicle Quick
Reference/Capacities and Recommended Fluids - Specifications and Vehicle Quick
Reference/Capacities and Recommended Fluids - Description .
11. Install oil fill cap.
12. Start engine and inspect for leaks.
13. Stop engine and inspect oil level.
OIL FILTER SPECIFICATION
All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a
Mopar® or the equivalent.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer
to the WARNING listed above.
PAN, OIL
Removal
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REMOVAL


2. Remove oil drain plug (2) and drain the engine oil.
3. Remove accessory drive belt splash shield.
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4. Remove lower A/C compressor mounting bolt (if equipped).

5. Remove A/C mounting bracket (2).
Fig. 291: OIL PAN REMOVAL

NOTE: Do not use pry points in block to remove oil pan.
6. Remove oil pan retaining bolts.

7. Using a putty knife (1), loosen seal around oil pan (2).
8. Remove oil pan (2).
Installation
INSTALLATION
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Fig. 292: SEALER LOCATION
NOTE: Oil pan sealing surfaces must be free of grease or oil.
NOTE: Parts must be assembled within 10 minutes of applying RTV.
1. Apply Mopar® Engine RTV GEN II at the front cover to engine block parting lines (1).
Fig. 293: SEALING OIL PAN

2. Apply a 2 mm bead of Mopar® Engine RTV GEN II around the oil pan as shown in illustration.
3. Position oil pan and install bolts. Tighten bolts to 12 N.m (105 in. lbs.).
NOTE: The 2 long bolts must be tightened to 22 N.m (195 in. lbs.).
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4. Install oil drain plug (2).

5. Lower vehicle and fill engine crankcase with proper oil to correct level.
PLUG, OIL
Description
DESCRIPTION
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Fig. 295: Engine Block Tapered Plugs
The engine block has three tapered plugs sealing the high pressure oil gallery. These threaded plugs do not have
a torque specification but instead are installed to a specific depth. Do not attempt to further tighten these plugs,
damage to the engine block could result. Whenever these plugs are removed they must be replaced. Service
plugs have a lock patch and do not require the application of additional sealant.
Removal
REMOVAL
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NOTE: Rear plug shown in illustration, other plugs are similar.
1. Remove the plug (2) from the engine block.

2. Use Mopar® Brake Parts Cleaner (or equivalent) sparingly to clean the block.
Installation
INSTALLATION

NOTE: Rear plug shown in illustration, other plugs are similar.
1. Use Mopar® Brake Parts Cleaner (or equivalent) sparingly to clean the block.
2. Install the plug (2) flush with the block boss face (1). The plug (2) is correctly installed when it is flush or
protruding no more than 1 mm from the block boss face (1).
PUMP, ENGINE OIL
Description
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DESCRIPTION
Fig. 298: Balance Shaft Module Identification

The oil pump is integral to the balance shaft module (BSM) (2). The oil pump cannot be disassembled for
inspection. The pressure relief valve is serviceable and can be removed and inspected. The BSM can be
identified by the plastic end caps (1).
Removal
REMOVAL
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1. Rotate engine to TDC (1,2) on #1 compression stroke.
Fig. 300: Balance Shaft Module Tensioner


3. Mark the chain (6) and the sprocket (5) for reassembly.
Fig. 301: OIL PUMP TENSIONER RESET
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4. Push tensioner piston back into the tensioner body.

5. With piston held back insert tensioner pin 9703 (4) into the tensioner body to hold the piston in the
retracted position.
NOTE: Do not remove sprocket from BSM.
6. Remove BSM mounting bolts. Discard 180 mm bolts, 185 mm bolts can be reused.
7. Lower the back of the BSM and remove the chain (6) from the sprocket (5).
8. Remove BSM from the engine.
Inspection
INSPECTION
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Fig. 303: OIL PUMP CHAIN STRETCH
3. Measure the distance between the tensioner body and the guide shoe as shown in illustration.
4. If the distance is 10.1 mm (0.397 in.) or greater, replace the chain.
Installation
INSTALLATION
CAUTION: There are two different Balance Shaft Module (BSM) to engine block bolts
used. 180 mm bolts with a lock-patch on the threads or 185 mm bolts
without lock-patch. Do not reuse the 180 mm bolts. Always discard 180
mm bolts after removing. Failure to replace these bolts can result in
engine damage. The 185 mm bolts are reusable. Install the same length
bolts that were removed and use either four new 180 mm bolts or four 185
mm bolts.
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Fig. 304: Checking Cylinder Head Bolts for Stretching (Necking)
1. The 185 mm (7.283 in.) length bolts must be checked for stretching. Check the bolts with a straight edge
for necking (2). If the bolts are necked down, they must be replaced.
Fig. 305: Balance Shaft Module Timing

2. Clean BSM mounting holes with Mopar® brake parts cleaner.

3. If chain was removed, align marks on crankshaft sprocket (2) and chain (1).
4. Align marks on oil pump sprocket (5) and chain (4).
5. Install chain on sprocket.
6. Pivot BSM assembly upwards and position on ladder frame.
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Fig. 306: Balance Shaft Module Torque Sequence
7. Start BSM mounting bolts by hand.
NOTE: Use a three step procedure when tightening BSM mounting bolts. For new
180 mm bolts, go to step 8. For 185 mm bolts, go to step 9.
8. Tighten new 180 mm BSM mounting bolts as follows:

a. Tighten to 15 N.m (11 ft. lbs.) in the sequence shown in illustration.
b. Tighten to 33 N.m (24 ft. lbs.) in the sequence shown in illustration.
c. Rotate bolts an additional 90° in the sequence shown in illustration.
9. Tighten 185 mm BSM mounting bolts as follows:
a. Tighten to 15 N.m (11 ft. lbs.) in the sequence shown in illustration.
b. Tighten to 29 N.m (22 ft. lbs.) in the sequence shown in illustration.
c. Rotate bolts an additional 90° in the sequence shown in illustration.
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10. Remove tensioner pin 9703 (4).

12. Fill with oil.
SENSOR, OIL TEMPERATURE
Removal
REMOVAL

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

2. Remove sensor (1).
Installation
INSTALLATION
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1. If reusing the oil temperature sensor, coat the threads with Mopar® thread sealant.
2. Install oil temperature sensor (1). Tighten to 18 N.m (160 in. lbs.).
3. Connect electrical connector.
SWITCH, OIL PRESSURE
Description
DESCRIPTION
The oil pressure switch is located on the left front side of the engine block. The oil pressure switch is a pressure
sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two
terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal
housing that screws into the engine block).
Operation
OPERATION
The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit,
on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit,
on decreasing pressure, between 2 psig and 4 psig.
Removal
REMOVAL
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Fig. 310: A/C Compressor Removal/Installation

3. Remove the splash shield from the right side frame rail. Refer to Body/Exterior/SHIELD, Splash -
Removal .
4. Remove the accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Removal .
5. Remove the three bolts (2) and reposition the A/C compressor (1).
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6. Disconnect the oil pressure switch electrical connector.

7. Remove the oil pressure switch using oil pressure socket C-4597 (1) or equivalent.
Installation
INSTALLATION

NOTE: If the oil pressure switch is removed, it must be replaced with a new switch.
CAUTION: The oil pressure switch has tapered threads, over tightening could crack
the engine block.
1. Install the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Tighten switch to 8 N.m
(71 in. lbs.).
2. Connect the oil pressure switch electrical connector.
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Fig. 313: A/C Compressor Removal/Installation
3. Position the A/C compressor (1) and install three mounting bolts (2). Tighten bolts to 25 N.m (18 ft. lbs.).
4. Install the accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Installation .
5. Install the splash shield to the right side frame rail. Refer to Body/Exterior/SHIELD, Splash -
Installation .
6. Reconnect the negative battery cable.
VALVE, OIL PRESSURE RELIEF
Removal
REMOVAL
Fig. 314: OIL PRESSURE RELIEF VALVE
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1. Remove oil pan. See Engine/Lubrication/PAN, Oil - Removal

2. Remove pressure regulating valve cap (2).
3. Remove pressure regulating valve spring (3) and valve (4).
Inspection
INSPECTION

NOTE: Pressure regulating valve (4) can be service separately from the oil pump
assembly.
1. Inspect pressure relief valve (4) scoring, gouging, or debris. Replace as needed.
2. Inspect the pressure relief valve bore in the pump for scoring, gouging, or debris.
3. If pump bore is damaged, replace balance shaft module.
Installation
INSTALLATION
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1. Lightly coat pressure regulating valve with clean engine oil and install valve (4).
2. Install spring (3) and cap (2).
3. Tighten cap to 44 N.m (32 lbs. ft.).
MANIFOLDS
MANIFOLD, EXHAUST
Description
DESCRIPTION
Fig. 317: Partially Zero Emission Vehicle Manifold
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The 2.4L engine can be equipped with a Partially Zero Emission Vehicle (PZEV) package. The PZEV package
has a specific manifold and gasket that can not be interchanged with non-PZEV engines.
Operation
OPERATION
Fig. 318: Manifold

Air is pump into the manifold (1) through a check valve and is distributed to the cylinders through a passage (2)
machined in the manifold.
Removal
REMOVAL
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2. Disconnect negative cable from battery.
Fig. 320: EXHAUST MANIFOLD HEAT SHIELD

3. Remove bolts (2) attaching upper heat shield.

4. Remove upper heat shield (1).
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Fig. 321: Catalytic Converter At Exhaust Manifold
5. Disconnect exhaust pipe (1) from manifold.

6. Disconnect oxygen sensor electrical connector (3).
Fig. 322: EXHAUST MANIFOLD SUPPORT BRACKET

7. Remove manifold support bracket (2).

8. Remove lower exhaust manifold heat shield.
Fig. 323: Exhaust Manifold Retaining Fasteners Torque Sequence
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9. Remove exhaust manifold retaining fasteners.

10. Remove and discard manifold gasket.
Cleaning
CLEANING
1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head.
Inspection
INSPECTION
1. Inspect manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per
300 mm (0.006 in. per foot) of manifold length.
2. Inspect manifolds for cracks or distortion. Replace manifold as necessary.
Installation
INSTALLATION
Fig. 324: Exhaust Manifold Retaining Fasteners Torque Sequence
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1. Install a new exhaust manifold gasket DO NOT APPLY SEALER .

2. Position exhaust manifold in place.
3. Tighten the exhaust manifold bolts to 34 N.m (25 ft. lbs.).
Fig. 325: EXHAUST MANIFOLD HEAT SHIELD

4. Install exhaust manifold heat shields (1). Tighten bolts (2) to 12 N.m (105 in. lbs.).
Fig. 326: EXHAUST MANIFOLD SUPPORT BRACKET
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5. Install exhaust manifold support bracket (2).
Fig. 327: Catalytic Converter At Exhaust Manifold

6. Install new catalytic converter gasket.

7. Install exhaust pipe to manifold (1). Tighten fasteners to 28 N.m (250 in. lbs.).
8. Connect oxygen sensor electrical connector (3).
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Fig. 329: ENGINE COVER

MANIFOLD, INTAKE
Diagnosis and Testing
INTAKE MANIFOLD LEAKS

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.
1. Start the engine.

2. Spray a small stream of water (Spray Bottle) at the suspected leak area.
3. If engine RPM'S change, the area of the suspected leak has been found.
4. Repair as required.
Removal
REMOVAL
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WARNING: Release fuel system pressure before servicing system components.
Service vehicles in well ventilated areas and avoid ignition sources. Never
smoke while servicing the vehicle.


2. Perform fuel system pressure release procedure before attempting any repairs. Refer to Fuel System/Fuel
Delivery - Standard Procedure .
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3. Remove air cleaner housing (1).

4. Disconnect negative battery cable (1).

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5. Disconnect fuel line at rail (3).

6. Remove fuel injector electrical connectors (4).
7. Remove fuel rail retaining bolts and remove fuel rail.

8. Disconnect oil temperature sensor (1).

10. Disconnect intake camshaft position sensor electrical connector.
11. Position harness out of the way.
Fig. 335: THROTTLE BODY SUPPORT
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13. Disconnect electronic throttle control electrical connector.
14. Remove wiring harness retainer from the intake manifold (2).
15. Disconnect MAP sensor electrical connector.
16. Disconnect vacuum lines at intake.

17. Remove intake manifold retaining bolts.

18. Remove intake manifold.
Cleaning
CLEANING
1. Discard gasket(s).
2. Clean all sealing surfaces.
Inspection
INSPECTION
1. Inspect manifold for cracks, distortion, or mounting surface warpage. Replace manifold if necessary.
2. Inspect manifold gasket for surface damage or excessive swelling. Replace gaskets as necessary.
Installation
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INSTALLATION

1. Clean all gasket surfaces.

2. Replace intake manifold gasket.
3. Install intake manifold, tighten bolts to 25 N.m (220 in. lbs.).
4. Install the fuel rail assembly to intake manifold. Tighten bolts to 23 N.m (200 in. lbs.).
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5. Connect fuel injector electrical connectors (4).

6. Inspect quick connect fittings for damage, replace if necessary. Refer to Fuel System/Fuel
Delivery/FITTING, Quick Connect - Standard Procedure .
7. Connect fuel supply hose (3) to fuel rail assembly. Check connection by pulling on connector to make
sure it is locked into position.

8. Install air cleaner housing (1).

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10. Fill the cooling system. Refer to Cooling - Standard Procedure .


VALVE TIMING
DESCRIPTION
DESCRIPTION
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The timing drive system consists of the following:
 Timing Chain (2)

 Camshaft Sprockets (1,3)
 Crankshaft Sprocket
 Right Timing Chain Guide (Moveable) (6)
 Left Timing Chain Guide (Fixed) (4)
 Timing Chain Tensioner (5)
The camshaft sprockets are attached to the cam phasers which are attached to the front of the camshafts and are
used with the timing chain and crankshaft sprocket to turn the camshafts. The camshaft position sensors target is
part of the camshafts and is used with the camshaft position sensors to provide the PCM with valvetrain position
information.
The timing chain tensioner is installed in the right side of the engine block. Using engine oil pressure, the
tensioner applies constant pressure to the right side (movable) timing chain guide, which in turn applies
pressure to the timing chain. Also as the tensioner extends, it's ratchet locks in position to provide constant
timing chain tension.
STANDARD PROCEDURE
VALVE TIMING VERIFICATION

CAUTION: Painted or colored chain links are used during initial engine assembly and
can not be relied upon for valve timing verification. These markings are in
different locations for early production, late production and service parts.
Only use TDC marks, cylinder head cover sealing surface and camshaft
sprocket marks to verify valve timing or engine damage may result.
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3. Set engine to TDC (1,2).

4. The marks on the camshaft sprockets (3) should be in line with the cylinder head cover sealing surface.
6. Install the engine cover.
CHAIN AND SPROCKETS, TIMING
Removal
TIMING CHAIN
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1. Set engine to TDC.

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NOTE: If the timing chain plated links can no longer be seen, the timing chain
links corresponding to the timing marks must be marked prior to removal
if the chain is to be reused.
3. Mark chain link (1) corresponding to camshaft timing mark.
Fig. 347: Crankshaft Timing Marks

4. Mark chain link (3) corresponding to crankshaft timing mark (2).

Fig. 348: Timing Drive
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5. Remove timing chain tensioner (5). See Engine/Valve Timing/TENSIONER, Engine Timing -
Removal.
6. Remove timing chain (2).
CAMSHAFT SPROCKET(S)
NOTE: Camshaft phasers and camshaft sprockets are supplied as an assembly, do not
attempt to disassemble.
Refer to camshaft phaser removal. See Engine/Cylinder Head/CAMSHAFT, Engine - Removal.
CRANKSHAFT SPROCKET

1. Remove timing chain. See Engine/Valve Timing/CHAIN and SPROCKETS, Timing - Removal.
3. Remove oil pump drive chain tensioner.
4. Remove oil pump drive chain.
5. Remove crankshaft sprocket (1).
Inspection
INSPECTION
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Fig. 350: Measuring Distance From Tensioner Body & Edge Of Chain Guide
Inspect timing chain for stretching prior to removal.
1. Rotate engine while watching timing chain tensioner plunger. When the plunger reaches its maximum
travel stop rotating engine.
2. Measure the distance from the tensioner body and the edge of the chain guide as shown in illustration.
3. If the distance is greater than 20.5 mm (0.81 in.) inspect guide shoes for excessive wear.
4. If guides are okay, replace timing chain.
Installation
CRANKSHAFT SPROCKET
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1. Install crankshaft sprocket (1) onto crankshaft.

2. Install oil pump drive chain. Verify that Oil pump is correctly timed (1,2,5,6).
Fig. 353: OIL PUMP TENSIONER RESET
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3. Reset oil pump drive chain tensioner by pushing plunger inward and install tensioner pin 8514.

4. Install oil pump drive chain tensioner (3) and remove Tensioner Pin 8514 (4).
5. Install timing chain. See Engine/Valve Timing/CHAIN and SPROCKETS, Timing - Installation.
7. Fill engine with oil. See Engine/Lubrication/OIL - Standard Procedure.
CAMSHAFT SPROCKET(S)
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Fig. 355: Camshaft Phaser Installation
NOTE: The camshaft sprockets and the camshaft phasers are an assembly and cannot
be serviced separately.
CAUTION: Do not use an impact wrench to tighten camshaft sprocket bolts. Damage
to the camshaft-to-sprocket locating dowel pin and camshaft phaser may
occur.
1. Refer to Camshaft phaser (2) installation. See Engine/Cylinder Head/CAMSHAFT, Engine -

Installation.
TIMING CHAIN
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NOTE: The crankshaft timing mark (3) or (5) can be in one of two locations depending
on whether the engine is early production (5), late production (3) or assembled
with service parts (3). In all cases the keyway (2) will always be in the 9:00
position, in line with the ladder frame mounting surface (1) when the engine is
at TDC.
1. Verify that the engine is still set to TDC.

2. Align camshaft timing marks (3) so they are facing each other and in line with the cylinder head cover
sealing surface (2).
3. Install timing chain so plated (or marked) links on chain align with timing marks on camshaft sprockets
(1).
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4. Align timing mark on the crankshaft sprocket (3) or (5) with the plated (or marked) link (4) on the timing
chain. Position chain so slack will be on the tensioner side.

NOTE: Keep the slack in the timing chain on the tensioner side.
5. Install the timing chain tensioner (5). See Engine/Valve Timing/TENSIONER, Engine Timing -
Installation.
Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned at the
TDC position with the key way at the 9 o'clock position.
6. Verify that the camshafts timing marks (3) are in the proper position and in line with the cylinder head
cover sealing surface. If the marks do not line up, the timing chain is not correctly installed.
7. Install front timing chain cover. See Engine/Valve Timing/COVER(S), Engine Timing - Installation.
9. Operate engine until it reaches normal operating temperature. Check oil and cooling systems for correct
fluid levels.
COVER(S), ENGINE TIMING
Removal
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REMOVAL


2. Perform fuel pressure bleed procedure. Refer to Fuel System/Fuel Delivery - Standard Procedure .
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4. Remove coolant recovery bottle (1). Refer to Cooling/Engine/BOTTLE, Coolant Recovery - Removal .
5. Remove and reposition power steering reservoir (2).
6. Remove accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Removal .


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8. Remove the three power steering pump mounting bolts (1) through the openings in the pulley (3) and
reposition the pump.

9. Remove the cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Removal.
10. Remove ignition coils from the cylinder head cover.
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Removal .
13. Set engine to TDC (1).

14. Remove lower A/C compressor bolts if equipped.

15. Remove lower A/C compressor mount (2) if equipped.
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16. Remove accessory drive belt lower idler pulley (2).

17. Remove crankshaft damper (2). See Engine/Engine Block/DAMPER, Vibration - Removal.
18. Remove three bolts and water pump pulley (4) from water pump.
19. Remove lower bolt from right side engine mount bracket (1).
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20. Remove timing chain cover lower bolts (1).

21. Lower vehicle.
22. Support engine with suitable jack.


24. Remove retaining nuts (2) and reposition mount bracket (1).
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25. Remove accessory drive upper idler pulley (1).
Fig. 372: ENGINE FRONT

26. Remove right upper engine mount bracket (1).

27. Remove accessory drive belt tensioner.
28. Remove upper timing chain cover retaining bolts.
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Fig. 373: TIMING CHAIN COVER PRY POINTS
29. Remove timing chain cover using pry points (1,2,3).
Fig. 374: TIMING CHAIN COVER REMOVAL/INSTALLATION

30. Remove timing chain cover (1) out through the bottom of the vehicle.
Installation
INSTALLATION
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Fig. 375: FRONT COVER UPPER T-JOINT
NOTE: When using RTV, the sealing surfaces must be clean and free from grease and
oil.
NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to final
torque within 45 minutes.
1. Clean all sealing surfaces. See Engine - Standard Procedure.

2. Apply Mopar® engine sealant RTV (or equivalent) as shown in illustration at the cylinder head to block
parting line (1,2).
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Fig. 376: LOWER T-JOINTS
3. Apply Mopar® engine sealant RTV (or equivalent) as shown in illustration at the ladder frame to block
parting line (1,2).
Fig. 377: SEALING OIL PAN

4. Apply Mopar® engine sealant RTV (or equivalent) as shown in illustration in the corner of the oil pan
and block.
5. Apply 2 mm bead of Mopar® engine sealant RTV (or equivalent) to the oil pan as shown in illustration.
Fig. 378: TIMING CHAIN COVER SEALING
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6. Apply 2 mm bead of Mopar® engine sealant RTV (or equivalent) to the engine block (1,2) as shown in
illustration.
Fig. 379: TIMING CHAIN COVER REMOVAL/INSTALLATION

7. Install timing chain cover (1) upwards from under the vehicle.
8. Install timing chain cover upper retaining bolts and tighten M6 bolts to 9 N.m (80 in. lbs.) and M8 bolts
to 26 N.m (230 in. lbs.).
9. Install accessory drive belt tensioner. Tighten bolt to 24 N.m (212 in. lbs.).
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10. Install right engine mount bracket (1). Tighten bolts to 50 N.m (37 ft. lbs.).

11. Install accessory drive belt upper idler pulley (1). Tighten bolt to 48 N.m (35 ft. lbs.).
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12. Position engine mount adapter (1) and install bolts (4).
15. Remove jack from under engine.

17. Install oil pan to timing chain cover lower retaining bolts (1) and tighten M6 bolts to 9 N.m (80 in. lbs.).
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Fig. 384: ENGINE FRONT
18. Install water pump pulley (4) and tighten three bolts to 9 N.m (80 in. lbs.).
19. Install crankshaft damper (2). See Engine/Engine Block/DAMPER, Vibration - Installation.

20. Install accessory drive belt lower idler pulley (2). Tighten bolt to 48 N.m (35 ft. lbs.).
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21. Install lower A/C compressor mounting bracket (2). Tighten the bolts to 24 N.m (18 ft. lbs.).
22. Install A/C compressor (1). Tighten the bolts to 25 N.m (18 ft. lbs.).
23. Install right lower splash shield. Refer to Body/Exterior/SHIELD, Splash - Installation .
24. Lower vehicle.

25. Install cylinder head cover and ignition coils. See Engine/Cylinder Head/COVER(S), Cylinder Head -
Installation.
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26. Place the power steering pump in mounting position. Install the three bolts (1) through openings in the
pulley (3). Tighten the mounting bolts (1) to 26 N.m (19 ft. lbs.).

27. Install the power steering hose hold down (3).

28. Install accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Installation .
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29. Install power steering pump reservoir (2). Tighten mounting screw to 12 N.m (106 in. lbs.).
30. Install coolant recovery reservoir (1). Tighten mounting bolts to 10 N.m (89 in. lbs.).

31. Install clean air hose (1) and air cleaner housing (2). See Engine/Air Intake System/BODY, Air
Cleaner - Installation.
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33. Operate engine until it reaches normal operating temperature. Check oil system for leaks and correct fluid
level.
TENSIONER, ENGINE TIMING
Removal
REMOVAL

1. Remove the engine timing cover. See Engine/Valve Timing/COVER(S), Engine Timing - Removal.
NOTE: Tensioner will not come apart during removal.
2. Remove timing chain tensioner retaining bolts and remove tensioner (5).
Installation
INSTALLATION
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Fig. 394: TENSIONER RESET
1. Reset timing chain tensioner (4) by lifting up on ratchet (2) and pushing plunger (3) inward towards the
tensioner body (4). Insert Tensioner Pin 8514 into slot (1) to hold tensioner plunger in the retracted
position.
Fig. 395: TIMING CHAIN TENSIONER
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NOTE: Keep the slack in the timing chain on the tensioner side.
2. Install timing chain tensioner (1) and tighten bolts to 12 N.m (105 in. lbs.).
3. Remove timing Tensioner Pin 8514 (2).
4. Install the engine timing cover. See Engine/Valve Timing/COVER(S), Engine Timing - Installation.

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2009 Dodge Journey R/T

2009 ENGINE 2.4L Gas - Service Information - Journey

2.4L Gas - Service Information - Journey

DIAGNOSIS AND TESTING

For fuel system diagnosis, see FUEL SYSTEM .

 Cylinder Compression Pressure Test: Refer to CYLINDER COMPRESSION PRESSURE TEST.

CONDITION POSSIBLE CAUSE CORRECTION

CONDITION POSSIBLE CAUSES CORRECTION

oil pump relief valve and spring.

5. Worn valve guide(s). 5. Replace cylinder head.

CYLINDER COMBUSTION PRESSURE LEAKAGE TEST

Combustion pressure leakage testing will detect:

 Exhaust and intake valve leaks (improper seating).

CYLINDER COMPRESSION PRESSURE TEST

1. Check engine oil level and add oil if necessary.

3. Remove engine cover.

ENGINE OIL LEAK INSPECTION

CAUTION: Use extreme caution when crankshaft polishing is necessary to

INSPECTION FOR REAR SEAL AREA LEAKS

If the leakage occurs at the crankshaft rear oil seal area:

1. Disconnect the battery.

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

CAUTION: Use extreme caution when crankshaft polishing is necessary to

HYDROSTATIC LOCKED ENGINE

rods, pistons, valves, etc.)

8. Install new spark plugs.

FORM-IN-PLACE GASKETS AND SEALERS

ENGINE GASKET SURFACE PREPARATION

Fig. 2: PROPER TOOL USAGE FOR SURFACE PREPARATION

Courtesy of CHRYSLER LLC

Never use the following to clean gasket surfaces:

 Metal scraper (1).

Only use the following for cleaning gasket surfaces:

 Solvent or a commercially available gasket remover

CYLINDER HEAD CORE PLUGS

Fig. 4: CORE HOLE PLUG REMOVAL

CYLINDER BLOCK MAIN OIL GALLERY PLUGS

Fig. 5: GALLERY PLUG

MEASURING BEARING CLEARANCE USING PLASTIGAGE

Fig. 6: Plastigage Placed in Lower Shell-Typical

1. Remove oil film from surface to be checked. Plastigage is soluble in oil.

Fig. 7: Engine Cover

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

1. Remove engine cover (1).

Fig. 9: Coil Connector

Fig. 11: BATTERY CABLE

5. Disconnect negative battery cable (1).

Fig. 12: COOLANT RESERVOIR

8. Remove coolant reservoir (1).

Fig. 13: Power Steering Line Support

10. Remove power steering line support at engine mount (1).

Fig. 14: Coolant Adapter

12. Remove coolant hoses from coolant adapter (3).

Fig. 15: Coil Connector

20. Remove dipstick.