Page 1865 of 5267
COVER - STRUCTURAL
DESCRIPTION
The structural dust cover is made of die cast aluminum and joins the lower half of the transmission bell housing to
the engine.
OPERATION
The structural cover provides additional powertrain stiffness and reduces noise and vibration.
REMOVAL
1. Raise vehicle on hoist.
CAUTION: On manual transmission vehicles, the
7/16 inch engine block to clutch housing bolts
must be loosened before removal of the structural
dust cover (1). Clutch housing distortion will occur
if this procedure is not followed.
2. Remove the bolts retaining structural cover (1,2).
3. Remove the structural cover.
Page 1866 of 5267

INSTALLATION
AUTOMATIC TRANSMISSION
CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will
cause severe damage to the cover.
1. Position the structural cover in the vehicle.
2. Install all four bolts retaining the cover-to-engine. DO NOT tighten the bolts at this time.
3. Install the four cover-to-transmission bolts. Do NOT tighten at this time.
CAUTION: The structural cover must be held tightly against both the engineand the transmission bell hous-
ing during tightening sequence. Failure to do so may cause damage to the cover.
4. Torque the (4) structural dust cover bolts that go
intothetransmissionto6-11Nꞏm(50-100in.lbs.).
5. Torque the (4) structural dust cover bolts that go
into the engine block to 6-11 Nꞏm (50-100 in.lbs.).
6. Starting with the two rearcover-to-engine bolts,
tighten bolts (1) to 54 Nꞏm (40 ft. lbs.), then tighten
bolts(2)and(3)to54Nꞏm(40ft.lbs.)inthe
sequence shown.
7. Install the exhaust pipe on left hand exhaust manifold.
8. Tighten exhaust manifold-to-exhaust pipe retaining bolts to 20–26 Nꞏm(15–20 ft. lbs.).
MANUAL TRANSMISSION
CAUTION: The 7/16 inch engine block to clutch housing bolts must be loosened before removal/installation
of the structural dust cover. Clutch housing distortion will occur if thisprocedure is not followed.
1. Position the structural cover in the vehicle.
CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will
cause severe damage to the cover, and engine noise.
Page 1867 of 5267

2. Install all bolts retaining the cover-to-engine. DO
NOT tighten the bolts at this time.
3. Install the cover-to-transmission bolts. Do NOT
tighten at this time.
CAUTION: The structural cover must be held
tightly against the corner formed by the engine
and the transmission clutch housing during tight-
ening sequence. Failure to do so may cause dam-
age to the cover and engine noise.
4. Torque the (2) structural dust cover bolts that go
into the clutch housing to 6-11 Nꞏm (50-100 in.lbs.).
5. Torque the (4) structural dust cover bolts that go
into the engine block to 6-11 Nꞏm (50-100 in.lbs.).
6. Torque the structural cover bolt that is closest to
the rear face of block on the passenger side of
blockto54Nꞏm(40ft.lbs.).
7. Torque the structural cover bolt that is closest to
the front face of block on the drivers side to 54
Nꞏm (40 ft. lbs.).
8. Torque the remaining (2) structural cover bolts that
go into theblockin an “X” pattern to 54 Nꞏm (40 ft.
lbs.).
9. Torque the structural cover bolts that go into theclutch housingto 54 Nꞏm (40 ft. lbs.).
10. Torque the 7/16 inch engine block to clutch housing bolts to 68 Nꞏm (50 ft.lbs.).
Page 1868 of 5267

SOLENOID-MDS
DESCRIPTION
The Multi Displacement System selectively deactivates cylinders 1,4,6,and 7, to improve fuel economy. It has two
modes of operation :
8 cylinders for acceleraton and heavy loads.
4 cylinders for cruising and city traffic.
The main components of the Multi Displacement System are :
Unique MDS camshaft.
Deactivating roller tappets.
4 control valves/solenoids.
control valve/solenoid wiring harness.
oil temp sensor.
OPERATION
Cylinder Deactivation
Trap an exhaust charge from a normal combustion event
Normal combustion event
Don’t open the exhaust valve
Don’t open the intake valve
Piston is an air spring
Cylinders deactivated in firing sequence
Cylinder Reactivation
Open the exhaust valve
Empty the cylinder
Open the intake valve
Normal combustion event
Cylinders reactivated in firing sequence
DIAGNOSIS AND TESTING
The Multi Displacement System has the following detectible issues:
Solenoid circuit
Fail to deactivate a cylinder(s)
Fail to reactivate a cylinder(s)
Low oil pressure
CONDITION POSSIBLE CAUSES CORRECTION
MDS does not activate 1. Low oil pressure 1. Check for proper oil pressure
2. Bad oil temp sensor 2. Replace oil temp sensor
3. Malfunctioning MDS Solenoid 3. Replace Solenoid
4. Malfunctioning MDS Tappet 4. Replace Tappet
MDS Does Not Deactivate 1. Low oil pressure 1. Check for proper oil pressure
2. Bad oil temp sensor 2. Replace oil temp sensor
3. Malfunctioning MDS Solenoid 3. Replace Solenoid
4. Malfunctioning MDS Tappet 4. Replace Tappet
Page 1869 of 5267
REMOVAL
1. Disconnect the negative battery cable.
2. Remove the intake manifold. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
3. Remove wiring harness connectors from the MDS solenoids.
4. Remove hold down bolt from MDS solenoid.
5. Remove MDS solenoid.
INSTALLATION
1. Verify that MDS bores are free of debris, before solenoid installation.
2. Install MDS solenoid fully into block.
3. Install hold down bolt and torque to 11 Nꞏm (97 in. lbs.).
4. Reconnect the MDS wiring harness to the solenoids.
5. Install the intake manifold. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION).
Page 1870 of 5267
MOUNT - FRONT
REMOVAL
2WD
1. Disconnect negative battery cable.
2. Raise vehicle.
3. Remove engine mount through bolts.
4. Raise engine using engine support fixture special
tool # 8534.
5. Remove engine mount to insulator bolts (1).
6. Remove insulator (2) from engine.
Page 1871 of 5267
4WD
1. Disconnect the negative cable from the battery.
2. Raise the vehicle.
3. Removetheskidplate.
4. Remove the front crossmember (Refer to 13 - FRAME & BUMPERS/FRAME/FRONTCROSSMEMBER -
REMOVAL).
5. Remove the engine oil filter.
6. Support the engine using engine support fixture, special tool # 8534.
7. Support the front axle with a suitable jack.
8. Remove the (4) bolts that attach the engine mounts to the front axle.
9. Remove the (3) bolts that attach the front axle to the left engine bracket.
10. Lower the front axle.
11. Remove the (6) through bolts
12. Raise the engine far enough to be able to remove the left (4) and right (8)engine mounts.
13. Remove the engine mounts (4,8).
Page 1872 of 5267
INSTALLATION
2WD
1. Install insulator (2) on the engine.
NOTE: For mount to engine block and left engine
bracket to front axle bolts, apply Mopar
Lock and
Seal Adhesive, Medium Strength Threadlocker.
2. Install upper and lower mount mounting bolts.
Tighten bolts to 61 Nꞏm (45 ft. lbs.).
3. Lower the engine using engine support fixture spe-
cial tool # 8534.
4. Install mount through bolts.
5. Tighten through bolts on both sides to 61 Nꞏm (45
ft. lbs.).
6. Lower vehicle.
7. Connect negative battery cable.
4WD
NOTE: For mount to engine block and left engine bracket to front axle bolts,apply MoparLock and Seal
Adhesive, Medium Strength Threadlocker.
1. Install the right (8) and left (4) side engine mounts to the front axle. Torque nuts to 94 Nꞏm (70 ft. lbs.).
2. Raise the front axle into the frame and install the left and right side through bolts. Torque nuts to 94 Nꞏm (70 ft.
lbs.).