Additional Step For Vehicles In Notification # 499 Only.

11. For vehicles in notification # 499 only: Replace the crankshaft timing sprocket as follows:
(A) Remove the crankshaft sprocket using Special Tool Holder C-4685, Screw C-4685-B2 and Insert C-4685-C2, (Figure 6).
Note:
Do not use an impact wrench on the special tool.

(B) Install the supplied sprocket using Plate L-4524, Installation Thrust Washer L-4524-C4 and Screw C-4685-C1, (Figure 6). Refasten with the original bolt and tighten to 85 ft.lbs. (115 N-m) torque.





12. Lower the vehicle.

13. (All vehicles): Remove the air cleaner fresh air duct.

14. Remove the ignition cable cover (Figure 7).





15. Remove the rocker cover and loosen each rocker arm assembly fastener 3 turns (Figure 8).





16. Align and pin both intake and exhaust cam sprockets with 3/16" drills, # 13 or # 14 drills or pin punches (Figure 9) to holes in the cylinder heads.


17. Remove the spark plugs.





18. Install a dial indicator in the number 1 spark plug hole (Figure 10).


19. Rotate the crankshaft until the number 1 piston is at top dead center (TDC). Mark the engine block opposite the TDC mark on the crankshaft timing sprocket, for TDC reference (Figure 10).





20. Locate the piece of foam rubber (Stuffer or Stone Guard) that is pushed into the right engine mount bracket (Figure 11). Push out the existing foam rubber piece and install the supplied, new piece. (The new piece should be positioned so that the bottom of the rubber is approximately 1-1/4" from the lower edge of the mount bracket).

21. Support the engine with Engine Support Tool C-4852. Separate the right front engine mount bracket.

22. Raise the vehicle.

23. Remove the driveshaft support bracket.


24. Remove the transmission inspection cover.

25. Remove the shield at the K-frame, above the power steering tubes.

26. Remove the oil pan.

27. Remove the oil pump pickup tube.

28. Remove the oil pump.





29. Remove the oil pump intermediate shaft pulley (Figure 12).

30. Remove the intermediate shaft retainer.

31. Remove the intermediate shaft.

32. Transfer the key from the removed intermediate shaft to the supplied shaft and install the supplied intermediate shaft.

33. Apply form-in-place gasket material to the intermediate shaft retainer contact surface, reinstall the retainer and tighten the bolts to 105 in.lbs. (12 N-m) torque.

34. Reinstall the intermediate shaft pulley and tighten the bolt to 53 ft.lbs. (72 N-m) torque.

35. Apply sealer (Loctite 515 or equivalent) to the supplied oil pump body-to-block interface (machined surface). Install the oil pump. Tighten the 2 bolts to 200 in. lbs. (23 N-m) torque.

CAUTION:
The oil pump must be held securely in place during the pump screw installation and tightening process.

36. Install the oil pump pickup tube and tighten 2 bolts to 250 in.lbs. (28 N-m) torque.


37. Reinstall the oil pan using the supplied gaskets. (Hold the gaskets in place with RTV for ease of assembly). Tighten M6 bolts to 220 in.lbs. (25 N-m) and M8 bolts to 260 in.lbs. (29 N-m) torque.

38. Remove and discard the engine oil filter. Install a new Mopar filter.





39. Locate the turbocharger oil return tube at the base of the turbocharger (Figure 13).


40. Disconnect the tube from the turbocharger.

41. Loosen the return hose clamp at the drainback nipple on the engine block and remove the tube and hose assembly.

42. Remove the return hose from the tube and attach the supplied hose.

43. Slide the supplied protective sleeve over the supplied hose and install the tube and hose assembly.

44. Reinstall the following parts:
- Shield at K-frame
- Transmission inspection cover
- Driveshaft support bracket.