3.5L Engine Cover Installation Instruction Sheet

Transcription

1 3.5L Engine Cover Installation Instruction Sheet Please Read Carefully Our engine cover is designed to fit under a stock hood. If you have an aftermarket hood than it is you re responsibility to do a test fitment to confirm it will fit. Our engine cover will work with a properly installed 3G firewall cover. In some instances we have seen improperly installed firewall covers cause interference. If that is the case, then you will either need to properly install the firewall or trim/sand the engine cover for your custom fitment. If you have an aftermarket firewall cover than it is you re responsibility to do a test fitment to confirm it will fit. The engine cover is not designed to fit over aftermarket oil fill plugs on 2005/06 models. Use the stock one as it can not be seen anyhow. Every model and year will have some little differences therefore we strongly recommend that prior to prep and paint you install your engine cover and do a test fitment first. Make sure it fits correctly and there no interferences. Be sure that you have proper clearance on the top, back, sides and bottom and nothing is rubbing. If you have a 3G Firewall installed you may have to trim or sand the backside of the engine cover for a good clean fit. On some of the older models the hood liner tends to sag on the hinged side so be sure that it is properly attached and secured to eliminate any rubbing on the engine cover.

2 On the 05 s it should be noted that the cover will need to come off during oil change intervals to allow oil to be added to the engine. You can buy funnel with a nice corrugated hose so the oil change guys never have to remove the engine cover. On model years 2005/06 the Map Sensor might have a high profile type and therefore will have to be changed to the new lower profile (figure A ) one to allow for proper clearance for the inside top right of the cover. We recommend changing the Sensor with Mopar part # AC. It is an easy change. Just unplug the wire harness and twist the sensor a quarter turn and pull out.

3 Installing the Cover To install the engine cover first remove the (2) nuts on the intake support brackets on the passenger side (figure B ).

4 If you have a BigBully CAI then remove the timing chain bolt (figure C ).

5 Raise the front side of the cover and slide it in to position on an angle to fit under the rubber hood seal. Once the back is in tilt downward and slide the (2) passenger side brackets over the intake support mounting studs and then position the drivers side bracket as shown in (figure C ). Note: If cover is to close or even touching the strut tower purge solenoid then see Strut Tower Purge Solenoid instructions below. Secure the passenger side by reinstalling the (2) nuts and then reinstall the BigBully bolt, washers and nut. Note: If you are experiencing difficulty in re-installing either of the (2) nuts then see Intake Manifold Support Brackets (Passenger Side) below. The following was included in the shipping container (1) 3GCUSTOMZ 3.5L Engine Cover (1) 3/8-16 x 1-1/2 Stainless Steel bolt (2) 3/8 Stainless Steel washers (1) 3/8 self locking Stainless Steel nut (1) Instruction/installation sheet

6 Strut Tower Purge Solenoid Although in some cases this is not a problem but while doing your test fitment the cover may come to close or even touch the purge solenoid located on the passenger side strut tower as shown in figure D. If this is the case in your situation them we recommend completing following procedure. Slide the purge solenoid up and off the bracket. Remove the mounting bracket. The bracket has a slight twist in it as shown in figure E.

7 Straighten the bracket out using a bench vise or a couple of channel lock pliers or just hammering it flat as shown in figure F.

8 Once the bracket is flat put a 90 degree bend in it as shown in figure G.

9 Now this bracket will get re-mounted on the ground stud on top of the strut tower as shown in figure H.

10 Remove the nut and then the (3) ground wires then put the bracket on first then the (3) ground wires them turn the purge solenoid towards the back of the car and secure them all in place with the nut as shown in figure I.

11 Intake Manifold Support Brackets (Passenger Side) Although in some cases this is not a problem but while doing your test fitment the (2) Intake Manifold support brackets may spring outward when you remove the nuts as shown in figure B making it difficult to put them back on when the cover is in place. If this is the case in your situation then we recommend completing the following procedure. Loosen the lower bolt that secures the brackets as shown in figure J to the engine block first then install the cover securing the top nuts then go back and tighten the lower bracket bolts. By loosing the lower bolts should give enough play to move the upper part of the brackets inwards to install the cover and nuts.

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