Cylinder Head Cover(s) - Installation

INSTALLATION





1. If required, install a new oil filler neck O-ring (1).





2. If required, install the oil filler neck (1) to the cylinder head cover. Secure the oil filler neck (1) with the oil filler neck lock (2) and bolt (3) tightened to 9 Nm (80 in. lbs.).






CAUTION: When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.

3. Install the cylinder head cover gasket (1).
4. The spark plug tube seals (2) can be reused if not damaged.





5. Clean the variable valve actuator assembly, camshaft caps, camshaft housing and cylinder head cover mating surfaces with isopropyl alcohol in preparation for sealant application.

CAUTION: Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar(R) Engine RTV GEN II may result in engine fluid leakage.

CAUTION: Following the application of Mopar(R) Engine RTV GEN II to the gasket surfaces, the components must be assembled within 10 minutes and the attaching fasteners must be tightened to specification within the next 10 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.

6. Apply a 2 to 3 mm wide bead of Mopar(R) Engine RTV GEN II sealant (1) to the cylinder head cover T-joints as shown.





7. Install the cylinder head cover and fuel rail blocker (1) with twelve bolts. Tighten the twelve bolts in two steps following the sequence shown:
- Step 1: All to 5 Nm (44 in. lbs.).
- Step 2: All to 9 Nm (80 in. lbs.).





8. Install the upper timing belt cover (1) with two bolts (2 and 3) tightened to 9 Nm (80 in. lbs.).





9. Install four new intake manifold seals (1).





10. Loosely install an intake manifold flange bolt (3) and the support bolt (2) to hold the intake manifold in position.





11. Raise and support the vehicle Maintenance.
12. Install the remaining six of the seven intake manifold flange bolts (1). Tighten all seven intake manifold flange bolts in the sequence shown to 15 Nm (11 ft. lbs.).





13. Position the wire harness and close the two wire harness retainers (1).





14. Lower the vehicle.
15. Tighten the intake manifold support bolt (2) to 9 Nm (80 in. lbs.).





16. Install the A/C compressor (1) A/C Compressor - Installation.





17. Install the accessory drive belt (4) Serpentine Accessory Drive Belt - Installation.





18. Install the frame splash shield (3) with three screws (1).
19. Install two screws (2) to the front wheelhouse splash shield.
20. Install the right vertical brace (5) with two bolts (4) tightened to 45 Nm (33 ft. lbs.).





21. Install the belly pan Belly Pan - Installation.





22. Install the wiring harness duct (1) to the cylinder head cover with two bolts (3) tightened to 9 Nm (80 in. lbs.).
23. Install the ground lug (2) to the cylinder head cover and tighten the bolt (2) to 9 Nm (80 in. lbs.).






NOTE: Number 1 cylinder ignition coil shown, all others similar.

24. Install the ignition coils (1) Ignition Coil - Installation.





25. Install the oil separator housing bracket (1) with two bolts (2) and one nut (3). Tighten the three fasteners to 13 Nm (115 in. lbs.).





26. Connect the vacuum line to the vacuum pump (1).





27. Connect and lock the electrical connector (3) to the Electronic Throttle Control (ETC) (4) and engage the ETC harness to the clip (2) on the throttle body.





28. Connect and lock the fuel injector wire harness electrical connector (2).
29. Connect and lock the evaporative emissions purge solenoid electrical connector (1).





30. Connect and lock the IAT/MAP sensor electrical connector (3).





31. Connect the fuel vapor purge hose (3) to the intake manifold.
32. Connect the fuel line (2) to the fuel rail and close the hose retainer (1)Service and Repair.





33. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 Nm (115 in. lbs.).
34. Connect the vent hose (3) to the oil filler neck.
35. Connect the PCV hose (1) to the intake manifold.





36. Install the air cleaner body (6) Air Cleaner Body - Installation.





37. Evacuate and charge the refrigerant system Refrigerant System Charge.
38. Install the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).
39. Install the engine cover (1).
40. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level Service and Repair