Service Procedure

Engine Camshaft Cap Inspection and Bolt Tightening:

1. Discharge the fuel system pressure as follows:

a. Remove the lower rear seat cushion.

b. Remove the fuel pump module cover.

c. Disconnect the electrical connector to the fuel pump module.

d. Start and run engine until it stalls.

e. Attempt restarting engine until it will no longer run.

f. Turn ignition key to OFF position.

2. Remove air inlet duct over the battery.

3. Disconnect the battery.

NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure.

4. Remove the engine cover and the plastic retainers on the valve cover studs.

5. Disconnect the electrical connectors on the ignition coils.

6. Disconnect the PCV and make-up air hoses from cylinder head cover.

7. Unfasten the electrical harness and its retainer clips from the cylinder head cover studs.

8. Disconnect the fuel line at the engine fuel rail.

9. Use compressed air to blow dirt and debris off the cylinder head cover.

10. Remove the cylinder head cover, ignition coils, bolts and studs as a complete assembly.

CAUTION:
Do not remove the coils from the cylinder head cover at this time to minimize dirt from entering the engine during disassembly.

11. On the bench, remove the four ignition coils from the cylinder head cover.





12. Inspect the rear of the # 1 camshaft bearing cap at the exhaust camshaft (Figure 1):

If the split line of the bearings and the split line of the bearing cap-to-cylinder head are parallel to each other, continue with Step 13.

If the split line of the bearings and the split line of the bearing cap-to-cylinder head are NOT parallel to each other, (the bearing has rotated) contact the STAR Center for further assistance.





13. Tighten each of the front camshaft bearing cap bolts to 20 ft.lbs. (27 N.m) in the following order (Figure 2):

a. Exhaust side outside bolt (1).

b. Intake side outside bolt (2).

c. Exhaust side middle bolt (3).

d. Intake side middle bolt (4).

14. Clean all RTV from the cylinder head surface and wipe the surface with a clean cloth.





15. With a clean cloth, wipe the cylinder head cover gasket and inspect for damage (cuts, tears or voids). If damaged, replace with PN 04884765AA center gasket and/or PN 04884762AA perimeter gasket.





16. Apply a 1/8" (3mm) bead of Mopar Engine Sealant RTV to cylinder head/front cover T-joint (Figure 3).





17. Position the cylinder head cover on the engine and install cylinder head cover studs as shown. (Figure 4).

18. Position the cylinder head cover on the cylinder head and install all bolts.





19. Tighten the cylinder head cover fasteners in two steps following the sequence as shown in Figure 5:

a. Tighten all fasteners to 44 in. lbs. (5 N.m).

b. Tighten all bolts to 90 in. lbs. (10 N.m).

20. Install the four ignition coils. Tighten fasteners to 70 in. lbs. (8 N.m).

21. Connect the fuel line to the engine fuel rail.

22. Install the harness and its retainer clips onto the cylinder head cover studs.

23. Remove the plastic retainers (if any) from the engine cover and install the four retainers onto the appropriate studs of the cylinder head cover.

24. Connect the PCV and make-up air hoses to the cylinder head cover.

25. Install the engine cover. Check all four mounting grommets for proper engagement to the plastic retainers.

26. Connect the fuel pump harness connector to the fuel pump.

27. Install the fuel pump access cover and tighten the screw.

28. Install the rear seat lower cushion.

29. Connect the battery.

30. Install the air inlet duct over the battery.

NOTE:
Due to the fuel line pressure discharge procedure, a Diagnostic Trouble Code (DTC) may be set in some modules (PCM, TCV, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Connect the StarSCAN tool to the vehicle. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.