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OIL PUMP (Continued)
(2) If crankshaft has been rotated, it must be repo-
sitioned to 60° ATDC of No.1 cylinder prior to oil
pump installation (Fig. 94).
(3) Install oil pump carefully over crankshaft and
into position.
(4) Install oil pump attaching bolts. Tighten bolts
to 28 N·m (250 in. lbs.) (Fig. 95).
(5) Install oil pick-up tube with new O-ring. Lubri-
cate O-ring before installation. Tighten attaching
bolts to 28 N·m (250 in. lbs.) (Fig. 95).
(6) Install oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION)
(7) Install timing chain and sprockets. (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
AND SPROCKETS - INSTALLATION)
(8) Install timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(9) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
(10) Fill crankcase with engine oil to correct level.
INTAKE MANIFOLD
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 sus-
pected leak has been found.
(4) Repair as required.
STANDARD PROCEDURE - INTAKE MANIFOLD
VACUUM PORT REPAIR
The composite intake manifold vacuum ports can
be repaired. Although, if the manifold plenum cham-
ber is damaged or cracked, the manifold must be
replaced.
To repair a broken or damaged vacuum nipple
(port) on the composite intake manifold, perform the
following procedure:
PARTS REQUIRED
Brass Nipple – 3/8 O.D.
x 1/4 pipe thread (Speed
Control Port)
Brass Nibble – 1/2 O.D.
x 1/4 pipe thread (Brake
NOTE: While performing this procedure, avoid get-
ting the manifold material residue into the plenum
chamber.
(1) File or sand the remaining port back until a
BELT/CHAIN
flat surface is obtained (plane normal to nipple (port)
axis).
(2) Drill out the nipple (port) base using a 7/16"
drill bit (Fig. 104).
(3) Using a 1/4"–18 NPT pipe tap, cut internal
threads (Fig. 104). Use caution to start tap in a axis
same as original nipple.
(4) Apply Mopar
repair nipple(s).
(5) Install repair nipple(s). Do not over torque
repair nipple(s).
Fig. 104 MANIFOLD PORT (NIPPLE) REPAIR
1 - 1/4" — 18NPT PIPE TAP
2 - NIPPLE (PORT)
REMOVAL
REMOVAL - INTAKE MANIFOLD UPPER
(1) Disconnect negative battery cable.
(2) Remove throttle body air inlet hose and air
cleaner housing assembly.
ENGINE 2.7L DOHC
Pipe Tap – 1/4 - 18 NPT
Drill Bit – 7/16
File/Sand Paper
Booster Port)
Thread Sealant to threads of
9 - 213
TOOLS REQUIRED
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