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4.7L Engine - Service Information: Application Dodge Dakota III facelift

Mechanical 25 illustrations ~1212 words

FORM-IN-PLACE GASKET AND SEALER APPLICATION

Assembling parts using a form-in-place gasket requires care but it's easier than using pre-cut gaskets.

Mopar® Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing material off the location.

Mopar® Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location.

Mopar® Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets.

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  1. Release fuel rail pressure. Refer to «Fuel System/Fuel Delivery - Standard Procedure»(ref-352671-S16879298692010010600000) then disconnect the fuel supply quick connect fitting at the fuel rail. Refer to «Fuel System/Fuel Delivery/FITTING, Quick Connect - Standard Procedure»(ref-352671-S30005942992010010600000) .
  2. Disconnect the battery negative and positive cables.
  3. Disconnect two ground straps from the lower left hand side and one ground strap from the lower right hand side of the engine.
  4. Remove the through bolt retaining nut and bolt (3) from both the left and right side engine mounts.
  5. Disconnect crankshaft position sensor (1).
  6. Remove exhaust crossover pipe from exhaust manifolds.
  7. Remove the pinion bracket.
  8. Remove structural cover. See «Engine/Engine Block/COVER, Structural Dust - Removal»(ref-352672-S10737706532010010600000) .
  9. Remove starter (4). Refer to «Electrical - Engine Systems/Starting/STARTER - Removal»(ref-352652-S28034287452010010600000) .
  10. Drain cooling system. Refer to «Cooling - Standard Procedure»(ref-352638-S04738368652010010600000) .
  11. Remove torque converter bolts (3) (Automatic Transmission Only).
  12. Remove transmission to engine mounting bolts (3).
  13. Disconnect the engine block heater power cable from the block heater, if equipped.
  14. Lower vehicle.
  15. Remove throttle body resonator assembly and air inlet hose.
  16. Disconnect throttle and speed control cables.
  17. Disconnect tube from both the left and right side crankcase breathers (1). Remove breathers.
  18. Evacuate A/C system. Refer to «Heating and Air Conditioning/Plumbing - Standard Procedure»(ref-352632-S34386494402010010600000) .
  19. Remove A/C compressor (2). Refer to «Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Removal»(ref-352632-S28401469642010010600000) .
  20. Remove shroud, fan assembly accessory drive belt. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-352638-S36887958812010010600000) .
  21. Disconnect transmission oil cooler lines at the radiator.
  22. Disconnect radiator upper and lower hoses.
  23. Remove radiator, A/C condenser and transmission oil cooler. Refer to «Cooling/Engine/RADIATOR, Engine Cooling - Removal»(ref-352638-S08636206802010010600000) and «Heating and Air Conditioning/Plumbing/CONDENSER, A/C - Removal»(ref-352632-S24313892522010010600000) .
  24. Remove generator (3). Refer to «Electrical - Engine Systems/Charging/GENERATOR - Removal»(ref-352651-S30639789762010010600000) .
  25. Disconnect the two heater hoses from the timing chain cover and heater core.
  26. Unclip (2) and remove heater hoses (1) and tubes from the intake manifold.
  27. Disconnect engine harness at the following points: Intake air temperature (IAT) sensor (4) Fuel Injectors Throttle Position (TPS) Switch (2) Idle Air Control (IAC) Motor (3) Engine Oil Pressure Switch Engine Coolant Temperature (ECT) Sensor Manifold absolute pressure (MAP) Sensor Camshaft Position (CMP) Sensor Coil connectors
  28. Disconnect the vacuum lines at the throttle body and intake manifold.
  29. Remove power steering pump and position out of the way.
  30. Remove the intake manifold. See «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-352672-S41613498902010010600000) .
  31. Install Engine Lift Plate 10101 in place of the intake manifold.
  32. Disconnect body ground strap (3) at the right side cowl.
  33. Disconnect body ground strap (2) at the left side cowl. NOTE: It will be necessary to support the transmission in order to remove the engine.
  34. Position a suitable jack under the transmission.
  35. Remove engine from the vehicle.

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  1. Position engine in the vehicle.
  2. Remove jack from under the transmission.
  3. Remove Engine Lifting Plate 10101 (1).
  4. Position both the left and right side engine mount brackets and install the through bolts (3) and nuts. Tighten to 95 N.m (70 ft. lbs.)
  5. Install transmission to engine mounting bolts (3). Tighten the bolts to 41 N.m (30 ft. lbs.).
  6. Install torque converter bolts (3).
  7. Connect the right (1) side body ground strap.
  8. Connect the left (1) side body ground strap.
  9. Install the intake manifold. See «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-352672-S14449817722010010600000) .
  10. Position generator wiring behind the oil dipstick tube, then install the oil dipstick tube upper mounting bolt.
  11. Install power steering pump.
  12. Connect fuel supply line quick connect fitting. Refer to «Fuel System/Fuel Delivery/FITTING, Quick Connect - Standard Procedure»(ref-352671-S30005942992010010600000) .
  13. Connect the vacuum lines at the throttle body and intake manifold.
  14. Connect engine harness at the following points: Intake Air Temperature (IAT) Sensor (4) Idle Air Control (IAC) Motor (3) Fuel Injectors Throttle Position (TPS) Switch (2) Engine Oil Pressure Switch Engine Coolant Temperature (ECT) Sensor Manifold Absolute Pressure (MAP) Sensor Camshaft Position (CMP) Sensor Coil Over Plugs
  15. Position and install heater hoses (1) and tubes onto intake manifold.
  16. Install the heater hoses onto the heater core and the engine front cover, and install clips (2).
  17. Install generator (3). Refer to «Electrical - Engine Systems/Charging/GENERATOR - Installation»(ref-352651-S33016403372010010600000) .
  18. Install A/C condenser, radiator and transmission oil cooler. Refer to «Heating and Air Conditioning/Plumbing/CONDENSER, A/C - Installation»(ref-352632-S10718663932010010600000) . Refer to «Cooling/Engine/RADIATOR, Engine Cooling - Installation»(ref-352638-S42532203632010010600000) .
  19. Connect radiator upper and lower hoses.
  20. Connect the transmission oil cooler lines to the radiator.
  21. Install accessory drive belt, fan assembly and shroud. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-352638-S14708432792010010600000) . Refer to «Cooling/Engine/FAN, Cooling - Installation»(ref-352638-S08641480862010010600000) .
  22. Install A/C compressor (2). Refer to «Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Installation»(ref-352632-S00125584372010010600000) .
  23. Install both breathers (1). Connect tube to both crankcase breathers.
  24. Connect throttle and speed control cables.
  25. Install throttle body resonator assembly and air inlet hose. Tighten clamps 4 N.m (35 in. lbs.).
  26. Raise vehicle.
  27. Connect crankshaft position sensor (1).
  28. Install starter (4). Refer to «Electrical - Engine Systems/Starting/STARTER - Installation»(ref-352652-S29735316122010010600000) . CAUTION: The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover.
  29. Install structural cover. See «Engine/Engine Block/COVER, Structural Dust - Installation»(ref-352672-S25201715662010010600000) .
  30. Install the pinion bracket.
  31. Install exhaust crossover pipe.
  32. Install engine block heater power cable, If equipped.
  33. Check and fill engine oil.
  34. Recharge the A/C system. Refer to «Heating and Air Conditioning/Plumbing - Standard Procedure»(ref-352632-S34386494402010010600000) .
  35. Refill the engine cooling system. Refer to «Cooling - Standard Procedure»(ref-352638-S04738368652010010600000) .
  36. Connect the battery positive and negative cables.
  37. Start the engine and check for leaks.
DESCRIPTIONSPECIFICATION
MetricStandard
Displacement4.7 Liters/4701 cc287 Cubic Inches
Bore93.0 mm3.66 in.
Stroke86.5 mm3.40 in.
Engine Type90° SOHC V-8 16-Valve
Compression Ratio9.6:1
Max. Variation Between Cylinders25%
Horsepower302 BHP @ 5650 RPM
Torque329 LB-FT @ 3950 RPM
Lead Cylinder#1 Left Bank
Firing Order1-8-4-3-6-5-7-2

GENERAL DESCRIPTION

DESCRIPTIONSPECIFICATION
MetricStandard
Bore Diameter93.010 ±.0075 mm3.6619 ± 0.0003 in.
Out of Round (MAX)0.076 mm0.003 in.
Taper (MAX)0.051 mm0.002 in.

CYLINDER BLOCK

DESCRIPTIONSPECIFICATION
MetricStandard
Diameter92.975 mm3.6605 in.
Weight366 grams12.9 oz
No. 1 Ring Groove Diameter83.37 - 83.13 mm3.282 - 3.273 in
No. 2 Ring Groove Diameter82.833 - 83.033 mm3.261 - 3.310 in.
No. 3 Ring Groove Diameter83.88 - 84.08 mm3.302 - 3.310 in.

PISTONS

DESCRIPTIONSPECIFICATION
MetricStandard
Clearance In Piston0.010 - 0.019 mm0.0004 - 0.0008 in.
Diameter24.013 - 24.016 mm0.9454 - 0.9455 in.

PISTON PINS

DESCRIPTIONSPECIFICATION
MetricStandard
Top Compression Ring Gap0.20 - 0.36 mm0.0079 - 0.0142 in.
Second Compression Ring Gap0.37 - 0.63 mm0.0146 - 0.0249 in.
Oil Control (Steel Rails) Ring Gap0.25 - 0.76 mm0.0099 - 0.30 in.
Top Compression Ring Side Clearance051 -.094 mm0.0020 - 0.0037 in.
Second Compression Ring Side Clearance0.040 - 0.080 mm0.0016 - 0.0031 in.
Oil Ring (Steel Ring) Ring Side Clearance019 -.229 mm0007 -.0091 in.
Top Compression Ring Width1.472 - 1.490 mm0.057 - 0.058 in.
Second Compression Ring Width1.472 - 1.490 mm0.057 - 0.058 in.
Oil Ring (Steel Rails) Ring Width0.445 - 0.470 mm0.017 - 0.018 in.

PISTON RINGS

DESCRIPTIONSPECIFICATION
MetricStandard
Bearing Clearance0.015 - 0.055 mm0.0006 - 0.0022 in.
Side Clearance0.10 - 0.35 mm0.004 - 0.0138 in.
Piston Pin Bore Diameter025 -.048 mm0.001 - 0.0019 in.
(Interference Fit)
Bearing Bore Out of Round (MAX)0.004 mm0.0002 in.
Total Weight (Less Bearing)555 grams19.5771 ounces

CONNECTING RODS

DESCRIPTIONSPECIFICATION
MetricStandard
Main Bearing Journal Diameter63.488 - 63.512 mm2.4996 - 2.5005 in.
Bearing Clearance0.004 - 0.034 mm0.0002 - 0.0013 in.
Out of Round (MAX)0.005 mm0.0004 in.
Taper (MAX)0.008 mm0.0004 in.
End Play0.052 - 0.282 mm0.0021 - 0.0112 in.
End Play (MAX)0.282 mm0.0112 in.
Connecting Rod Journal Diameter50.992 - 51.008 mm2.0076 - 2.0082 in.
Bearing Clearance0.010 - 0.0480.0004 - 0.0019 in.
Out of Round (MAX)0.005 mm0.0002 in.
Taper (MAX)0.008 mm0.0004 in.

CRANKSHAFT

DESCRIPTIONSPECIFICATION
MetricStandard
Bore Diameter26.02 - 26.04 mm1.0245 - 1.0252 in.
Bearing Journal Diameter25.973 - 25.995 mm1.0227 - 1.0235 in.
Bearing Clearance0.025 - 0.065 mm0.001 - 0.0026 in.
Bearing Clearance (MAX)0.065 mm0.0026 in.
End Play075 -.200 mm0.003 - 0.0079 in.
End Play (MAX)200 mm0.0079 in.

CAMSHAFT

DESCRIPTIONLOCATIONSPECIFICATION
Intake Valve OpenBTDC4.4°
Intake Valve ClosedATDC239.1°
Exhaust Valve OpenBTDC240.5°
Exhaust Valve ClosedATDC13.2°
Intake Valve Duration243.5°
Exhaust Valve Duration253.70°
Valve Overlap17.6°

VALVE TIMING

DESCRIPTIONSPECIFICATION
MetricStandard
Intake Head Diameter48.52 - 48.78 mm1.9103 - 1.9205 in.
Exhaust Head Diameter36.87 - 37.13 mm1.4516 - 1.4618 in.
Intake Length (Overall)113.45 - 114.21 mm4.4666 - 4.4965
Exhaust Length (Overall)114.92 - 115.68 mm4.5244 - 4.5543 in.
Intake Stem Diameter6.931 - 6.957 mm0.2729 - 0.2739 in.
Exhaust Stem Diameter6.902 - 6.928 mm0.2717 - 0.2728 in.
Intake Stem-to-Guide Clearance0.018 - 0.069 mm0.0008 - 0.0028 in.
Exhaust Stem-to-Guide0.047 - 0.098 mm0.0019 - 0.0039 in.
Intake Maximum Stem-to-Guide Clearance (Rocking Method)0.069 mm0.0028 in.
Exhaust Maximum Stem-to-Guide Clearance (Rocking Method)0.098 mm0.0039 in.
Intake Valve Lift (Zero Lash)11.25 mm0.443 in.
Exhaust Valve Lift (Zero Lash)10.90 mm0.4292 in.
Face Angle45° - 45.5°

VALVES

DESCRIPTIONSPECIFICATION
MetricStandard
Intake Free Length (Approx.)49.0 mm1.9291 in.
Exhaust Free Length (Approx.)49.0 mm1.9291 in.
Intake and Exhaust Spring Force (Valve Closed)313.0 - 354.0 N @ 40.12 mm70.365 - 79.582 lbs. @ 1.5795 in.
Intake and Exhaust Spring Force (Valve Open)776.0 - 870.0 N @ 28.88 mm174.451 - 195.583 lbs. @ 1.137 in.
Intake and Exhaust Spring Wire Diameter4.6 x 3.67 mm0.1811 - 0.1445 in.
Intake and Exhaust Spring Nominal Installed Height (Spring Seat to Bottom of Retainer)40.12 mm1.579 in.
Intake and Exhaust Spring Number of Coils7.3

VALVE SPRING

DESCRIPTIONSPECIFICATION
MetricStandard
Gasket Thickness (Compressed)0.7 mm0.0276 in.
Valve Seat Runout (MAX)0.051 mm0.002 in.
Intake Valve Seat Width1.75 - 2.36 mm0.0698 - 0.0928 in.
Exhaust Valve Seat Width1.71 - 2.32 mm(0.0673 - 0.0911 in.)
Guide Bore Diameter (Std.)6.975 - 7.00 mm(0.2747 - 0.2756 in.)
Cylinder Head Warpage (Flatness)0.0508 mm(0.002 in.)
Valve Seat Angle44.5° - 45.0°

CYLINDER HEAD

DESCRIPTIONSPECIFICATION
MetricStandard
Clearance Over Rotors/End Face (MAX)0.095 mm0.0038 in.
Cover Out - of - Flat (MAX)0.025 mm0.001 in.
Inner and Outer Rotor Thickness12.02 mm0.4731 in.
Outer Rotor to pocket (Diametral) clearance (MAX)0.235 mm0.0093 in.
Outer Rotor Diameter (MIN)85.925 mm0.400 in.
Tip Clearance Between Rotors (MAX)0.150 mm0.006 in.

OIL PUMP

DESCRIPTIONSPECIFICATION
MetricStandard
At Curb Idle Speed (MIN)*48 kPa(7 psi)
@ 3000 RPM240 - 725 kPa(35 - 105 psi)
* CAUTION: If pressure is zero at curb idle, DO NOT run engine at 3000 RPM.

OIL PRESSURE

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