4.7L Engine - Service Information: Other Dodge Durango II

STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS

Damaged or worn threads can be repaired. Essentially, this repair consists of

1. Drilling out worn or damaged threads.
2. Tapping the hole with a special Heli-Coil Tap, or equivalent.
3. Installing an insert into the tapped hole to bring the hole back to its original thread size.

STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS

There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in-place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket.

There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Engine RTV GEN II, Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties and can not be used in place of the other.

MOPAR® ENGINE RTV GEN II

Mopar® Engine RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® ATF RTV

Mopar® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® GASKET MAKER

Mopar® Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.

MOPAR® GASKET SEALANT

Mopar® Gasket Sealant is a slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This material is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 4 oz./16 oz. can w/applicator.

CYLINDER BLOCK

CYLINDER BLOCK SPECIFICATIONS

PISTONS

PISTONS SPECIFICATIONS

PISTON PINS

PISTON PINS SPECIFICATIONS

PISTON RINGS

PISTON RINGS SPECIFICATIONS

CONNECTING RODS

CONNECTING RODS SPECIFICATIONS

CRANKSHAFT

CRANKSHAFT SPECIFICATIONS

CAMSHAFT

CAMSHAFT SPECIFICATIONS

VALVE TIMING

VALVE TIMING SPECIFICATIONS

VALVES

VALVES SPECIFICATIONS

VALVE SPRING

VALVE SPRING SPECIFICATIONS

CYLINDER HEAD

CYLINDER HEAD SPECIFICATIONS

OIL PUMP

OIL PUMP SPECIFICATIONS

OIL PRESSURE

OIL PRESSURE SPECIFICATIONS

CLEANING

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components. (Refer to STANDARD PROCEDURE ,)

Clean cylinder head cover gasket surface.

Clean head rail, if necessary.

STANDARD PROCEDURE - REFACING

Note. Valve seats that are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced.

Note. When refacing valves and valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained.

Scheme 274

1. Using a suitable dial indicator measure the center of the valve seat Total run out must not exceed 0.051 mm (0.002 in).
2. Apply a small amount of Prussian blue to the valve seat, insert the valve into the cylinder head, while applying light pressure on the valve rotate the valve. Remove the valve and examine the valve face. If the blue is transferred below the top edge of the valve face, lower the valve seat using a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, raise the valve seat using a 65 degree stone.
3. When the seat is properly positioned the width of the intake seat must be 1.75 - 2.36 mm (0.0689 -0.0928 in.) and the exhaust seat must be 1.71 -2.32 mm (0.0673 - 0.0911 in.).
4. Check the valve spring installed height after refacing the valve and seat. The installed height for both intake and exhaust valve springs must not exceed 40.74 mm (1.6039 in.).
5. The valve seat and valve face must maintain a face angle of 44.5 - 45 ° angle.

STANDARD PROCEDURE - CYLINDER BORE HONING

Before honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area.

Scheme 275

1. Used carefully, the Cylinder Bore Sizing Hone C-823, equipped with 220 grit stones, is the best tool for this job. In addition to deglazing, it will reduce taper and out-of-round, as well as removing light scuffing, scoring and scratches. Usually, a few strokes will clean up a bore and maintain the required limits. CAUTION: DO NOT use rigid type hones to remove cylinder wall glaze.
2. Deglazing of the cylinder walls may be done if the cylinder bore is straight and round. Use a cylinder surfacing hone, Honing Tool C-3501, equipped with 280 grit stones (C-3501-3810). about 20-60 strokes, depending on the bore condition, will be sufficient to provide a satisfactory surface. Using honing oil C-3501-3880, or a light honing oil, available from major oil distributors. CAUTION: DO NOT use engine or transmission oil, mineral spirits, or kerosene.
3. Honing should be done by moving the hone up and down fast enough to get a Crosshatch pattern. The hone marks should INTERSECT at 50° to 60° for proper seating of rings.
4. A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper cross-hatch angle. The number of up and down strokes per minute can be regulated to get the desired 50° to 60° angle. Faster up and down strokes increase the Crosshatch angle.
5. After honing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash parts with a solution of hot water and detergent. Dry parts thoroughly. Use a clean, white, lint-free cloth to check that the bore is clean. Oil the bores after cleaning to prevent rusting.

Thoroughly clean the oil pan and engine block gasket surfaces.

Use compressed air to clean out

1. The galley at the oil filter adaptor hole.
2. The front and rear oil galley holes.
3. The feed holes for the crankshaft main bearings.

Once the block has been completely cleaned, apply Loctite PST pipe sealant with Teflon 592 to the threads of the front and rear oil galley plugs. Tighten the plugs to 34 N.m (25 ft. lbs.) torque.

Scheme 276

1. It is mandatory to use a dial bore gauge to measure each cylinder bore diameter. To correctly select the proper size piston, a cylinder bore gauge, capable of reading in 0.003 mm (.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer.
2. Measure the inside diameter of the cylinder bore at three levels below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft and then take two additional reading.
3. Measure the cylinder bore diameter crosswise to the cylinder block near the top of the bore. Repeat the measurement near the middle of the bore, then repeat the measurement near the bottom of the bore.
4. Determine taper by subtracting the smaller diameter from the larger diameter.
5. Rotate measuring device 90° and repeat steps above.
6. Determine out-of-roundness by comparing the difference between each measurement.
7. If cylinder bore taper does not exceed 0.025 mm (0.001 inch) and out-of-roundness does not exceed 0.025 mm (0.001 inch), the cylinder bore can be honed. If the cylinder bore taper or out- of-round condition exceeds these maximum limits, the cylinder block must be replaced. A slight amount of taper always exists in the cylinder bore after the engine has been in use for a period of time.

STANDARD PROCEDURE - CONNECTING ROD BEARING FITTING

Inspect the connecting rod bearings for scoring and bent alignment tabs. Check the bearings for normal wear patterns, scoring, grooving, fatigue and pitting. Replace any bearing that shows abnormal wear.

Scheme 277

Inspect the connecting rod journals for signs of scoring, nicks and burrs.

Scheme 278

Misaligned or bent connecting rods can cause abnormal wear on pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft connecting rod journals. If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod, inspect it for correct rod alignment. Replace misaligned, bent or twisted connecting rods.

Scheme 279

Scheme 280

Scheme 281

1. Wipe the oil from the connecting rod journal.
2. Lubricate the upper bearing insert and install in connecting rod.
3. Use piston ring compressor and Guide Pins Special Tool 8507 to install the rod and piston assemblies. The oil slinger slots in the rods must face front of the engine. The "F"'s near the piston wrist pin bore should point to the front of the engine.
4. Install the lower bearing insert in the bearing cap. The lower insert must be dry. Place strip of Plastigage across full width of the lower insert at the center of bearing cap. Plastigage must not crumble in use. If brittle, obtain fresh stock.
5. Install bearing cap and connecting rod on the journal and tighten bolts to 27 N.m (20 ft. lbs.) plus a 90° turn. DO NOT rotate crankshaft. Plastigage will smear, resulting in inaccurate indication.
6. Remove the bearing cap and determine amount of bearing-to-journal clearance by measuring the width of compressed Plastigage. Refer to «SPECIFICATIONS - 4.7L ENGINE»(ref-212815-S38534378052005122700000) for the proper clearance. Plastigage should indicate the same clearance across the entire width of the insert. If the clearance varies, it may be caused by either a tapered journal, bent connecting rod or foreign material trapped between the insert and cap or rod.
7. If the correct clearance is indicated, replacement of the bearing inserts is not necessary. Remove the Plastigage from crankshaft journal and bearing insert. Proceed with installation.
8. If bearing-to-journal clearance exceeds the specification, determine which services bearing set to use the bearing sizes are as follows: BEARING MARK AND SIZE Bearing Mark SIZE USED WITH JOURNAL SIZE .025 US .025 mm (.001 in.) 50.983-50.967 mm (2.0073-2.0066 in.) Std. STANDARD 50.992-51.008 mm (2.0076-2.0082 in.) .250 US .250 mm (.010 in.) 50.758-50.742 mm (1.9984-1.9978 in.)
9. Repeat the Plastigage measurement to verify your bearing selection prior to final assembly. CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed.
10. Once you have selected the proper insert, install the insert and cap. Tighten the connecting rod bolts to 27 N.m (20 ft. lbs.) plus a 90° turn. Slide snug-fitting feeler gauge between the connecting rod and crankshaft journal flange. Refer to «SPECIFICATIONS - 4.7L ENGINE»(ref-212815-S38534378052005122700000) for the proper clearance. Replace the connecting rod if the side clearance is not within specification.

Scheme 282

1. Drain the cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
2. Using a blunt tool such as a drift or a screw driver and a hammer, strike the bottom edge of the cup plug
3. Using a suitable pair of pliers, grasp the core plug and remove.

MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)

Crankshaft removed from the cylinder block. Clean the oil off the main bearing journal.

Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal.

The maximum allowable taper is 0.008mm (0.0004 inch.) and maximum out of round is 0.005mm (0.002 inch). Compare the measured diameter with the journal diameter specification (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance.

CRANKSHAFT MAIN BEARING SELECTION

The main bearings are "select fit" to achieve proper oil clearances. For main bearing selection, the crankshaft position sensor target wheel has grade identification marks stamped into it. These marks are read from left to right, corresponding with journal number 1, 2, 3, 4 and 5. The crankshaft position sensor target wheel is mounted to the number 8 counter weight on the crankshaft.

Scheme 283

Note. Service main bearings are coded. These codes identify what size (grade) the bearing is.

MAIN BEARING SELECTION CHART - 4.7L

MAIN BEARING SELECTION CHART - 4.7L

1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry.
2. Use a wood or plastic scraper to clean the ring land grooves.

STANDARD PROCEDURE - PISTON RING FITTING

Before reinstalling used rings or installing new rings, the ring clearances must be checked.

Scheme 284

Scheme 285

Scheme 286

Scheme 287

Scheme 288

1. Wipe the cylinder bore clean.
2. Insert the ring in the cylinder bore. NOTE: The ring gap measurement must be made with the ring positioned at least 12mm (0.50 inch.) from bottom of cylinder bore.
3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder.
4. Using a feeler gauge check the ring end gap. Replace any rings not within specification. PISTON RING SIDE CLEARANCE NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs.
5. Measure the ring side clearance as shown make sure the feeler gauge fits snugly between the ring land and the ring. Replace any ring not within specification.
6. Rotate the ring around the piston, the ring must rotate in the groove with out binding. PISTON RING SPECIFICATION CHART PISTON RING SPECIFICATION CHART Ring Position Groove Clearance Maximum Clearance Upper Ring .051-.094 mm (0.0020-.0037 in.) 0.11 mm (0.004 in.) Intermediate Ring 0.04-0.08 mm (0.0016-0.0031 in.) 0.10 mm (0.004 in.) Oil Control Ring (Steel Rails) .019-.229 mm (.0007-.0090 in.) .25 mm (0.010 in.) Ring Position Ring Gap Wear Limit Upper Ring 0.20-0.36 mm (0.0079-0.0142 in.) 0.43 mm (0.0017 in.) Intermediate Ring 0.37-0.63 mm (0.0146-0.0249 in.) 0.74 mm (0.029 in.) Oil Control Ring (Steel Rail) 0.025-0.76 mm (0.0099- 0.03 in.) 1.55 mm (0.061 in.)
7. The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston. NOTE: Piston rings are installed in the following order: Oil ring expander. Upper oil ring side rail. Lower oil ring side rail. No. 2 Intermediate piston ring. No. 1 Upper piston ring.
8. Install the oil ring expander.
9. Install upper side rail by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail.
10. Install No. 2 intermediate piston ring using a piston ring installer.
11. Install No. 1 upper piston ring using a piston ring installer.
12. Position piston ring end gaps as shown in. It is important that expander ring gap is at least 45° from the side rail gaps, but not on the piston pin center or on the thrust direction.

Scheme 289

Scheme 290

1. Disconnect negative cable from battery.
2. Remove accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
3. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
4. Remove radiator upper hose.
5. Remove upper fan shroud.
6. Using Special Tools 6958 Spanner with Adapter Pins 8346, loosen fan and viscous assembly from water pump.
7. Remove fan and viscous assembly.
8. Disconnect electrical connector for fan mounted inside radiator shroud. NOTE: Transmission cooler line snaps into shroud lower right hand corner.
9. Remove crankshaft damper bolt.
10. Remove damper using Special Tools 8513 Insert and 1026 Three Jaw Puller.

2WD

1. Disconnect the negative cable from the battery. CAUTION: Remove the viscous fan before raising engine. Failure to do so may cause damage to the fan blade, fan clutch and fan shroud.
2. Remove the viscous fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
3. Raise the vehicle.
4. Remove the engine oil filter.
5. Remove the oil drain trough.
6. Support the engine with a suitable jack and a block of wood across the full width of the engine oil pan.
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 through bolts
12. Raise the engine far enough to be able to remove the left and right engine mounts.
13. Remove the (8) mount to engine attaching bolts
14. Remove the engine mounts.

Scheme 291

Scheme 292

1. Disconnect the negative cable from the battery.
2. Remove the viscous fan.
3. Raise the vehicle.
4. Remove the skid plate.
5. Remove the front crossmember.
6. Remove the engine oil filter.
7. Remove the oil drain trough.
8. Support the engine with a suitable jack and a block of wood across the full width of the engine oil pan.
9. Support the front axle with a suitable jack.
10. Remove the (4) bolts that attach the engine mounts to the front axle.
11. Remove the (3) bolts that attach the front axle to the left engine bracket
12. Lower the front axle.
13. Remove the (6) through bolts
14. Raise the engine far enough to be able to remove the left and right engine mounts.
15. Remove the engine mounts.

Note. For mount to engine block and left engine bracket to front axle bolts, apply Mopar® Lock and Seal Adhesive, Medium Strength Threadlocker.

1. Install the right and left side engine mounts to the engine block with (8) bolts. Torque bolts to 54 N.m (40 ft. lbs.).
2. Insert the (2) through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts.
3. Lower the engine until the through bolts rest onto the slots in the frame brackets.
4. Tighten the through bolt nuts to 94 N.m (70 ft. lbs.).
5. Install the oil drain trough.
6. Install the engine oil filter.
7. Lower the vehicle.
8. Install the viscous fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
9. Reconnect the negative battery cable.

4WD

Note. For mount to engine block and left engine bracket to front axle bolts, apply Mopar® Lock and Seal Adhesive, Medium Strength Threadlocker.

Scheme 293

1. Install the right and left side engine mounts to the front axle. Torque nuts to 94 N.m (70 ft. lbs.).
2. Raise the front axle into the frame and install the left and right side through bolts. Torque nuts to 94 N.m (70 ft, lbs.).
3. Insert the two upper through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts.
4. Lower the engine until the left and right side engine brackets rest on the through bolts, and the lower engine bracket through holes align with the engine mounts, and the left engine bracket holes align with the front axle slots.
5. Loose assemble the (3) bolts that attach the front axle to the left engine bracket.
6. Loose assemble the lower through bolts.
7. Torque the nuts for the (4) through bolts to 101 N.m (75 ft. lbs.).
8. Torque the (3) bolts that attach the front axle to the left engine bracket to 101 N.m (75 ft. lbs.).
9. Install the oil drain trough.
10. Install the engine oil filter.
11. Install the front crossmember.
12. Install the skid plate.
13. Lower the vehicle.
14. Install the viscous fan (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
15. Reconnect the negative battery cable.

Scheme 294

Scheme 295

Scheme 296

1. Raise vehicle on hoist.
2. Using a suitable jack, support transmission.
3. Remove the nut from the insulator mount through bolt (Manual transmission and 4x2 automatic transmission only).
4. Remove the four bolts and washers retaining the mount to the transmission (4x4 automatic transmission only).
5. Raise the transmission enough to remove the through bolt (Manual transmission and 4x2 automatic transmission only).
6. Raise the transmission and remove the bolts retaining the mount to the crossmember (4x4 automatic transmission only).
7. Remove the two nuts retaining the isolator to the crossmember (Manual transmission and 4x2 automatic transmission only).
8. Remove the bolts (two bolts manual transmission-)(three bolts 4x2 automatic transmission) retaining the insulator bracket to the transmission.

STANDARD PROCEDURE ENGINE OIL SERVICE

API SERVICE GRADE CERTIFIED

Use an engine oil that is API Service Grade Certified. MOPAR® provides engine oils that conform to this service grade.

SAE VISCOSITY

An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30 in the 4.7L engines. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation.

Scheme 297

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.

OIL LEVEL INDICATOR (DIPSTICK)

The engine oil level indicator is located at the right rear of the engine on the 4.7L engines.

Scheme 298

ENGINE OIL CHANGE

Change engine oil at mileage and time intervals described in Maintenance Schedules.

Run engine until achieving normal operating temperature.

1. Position the vehicle on a level surface and turn engine off.
2. Hoist and support vehicle on safety stands.
3. Remove oil fill cap.
4. Place a suitable drain pan under crankcase drain.
5. Remove drain plug from crankcase and allow oil to drain into pan, Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged.
6. Install drain plug in crankcase.
7. Lower vehicle and fill crankcase with specified type and amount of engine oil described in this section.
8. Install oil fill cap.
9. Start engine and inspect for leaks.
10. Stop engine and inspect oil level.

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING at beginning of this section.

4X2

1. Disconnect the negative battery cable.
2. Loosen both left and right side engine mount through bolts. Do not remove bolts.
3. Install engine support fixture special tool # 8534. Do not raise engine at this time.
4. Remove the structural dust cover, if equipped.
5. Remove fan and fan shroud.
6. Drain engine oil.
7. Remove the front crossmember.
8. Raise engine using special tool # 8534 to provide clearance to remove oil pan. NOTE: Do not pry on oil pan or oil pan gasket. Gasket is integral to engine windage tray and does not come out with oil pan. NOTE: If more clearance is needed to remove oil pan, the transmission mount can be removed, and the transmission raised to gain clearance.
9. Remove the oil pan mounting bolts and oil pan.
10. Unbolt oil pump pickup tube and remove tube.
11. Inspect the integral windage tray and gasket and replace as needed.

4X4

1. Follow all steps for 4X2 removal.
2. Unbolt and lower the steering rack, without disconnecting the lines. NOTE: The front axle must be lowered to remove the oil pan on 4X4 vehicles.
3. Remove the front driveshaft at the axle. Mark for reassembly.
4. Support the front axle.
5. Remove the right and left axle to mount, bolts.
6. Lower axle.
7. Remove the oil pan mounting bolts and oil pan.
8. Unbolt oil pump pickup tube and remove tube.
9. Inspect the integral windage tray and gasket and replace as needed.

Scheme 299

1. Clean the oil pan gasket mating surface of the bedplate and oil pan.
2. Position the oil pan gasket and pickup tube with new o-ring. Install the mounting bolt and nuts. Tighten bolt and nuts to 28 N.m (20 ft. lbs.).
3. Position the oil pan and install the mounting bolts. Tighten the mounting bolts to 15 N.m (11 ft. lbs.) in the sequence shown.
4. Install structural dust cover, if equipped.
5. Reinstall the front axle, if removed.
6. Install the steering rack, if removed.
7. Lower the engine into mounts using special tool # 8534.
8. Install both the left and right side engine mount through bolts. Tighten the nuts to 68 N.m (50 ft. lbs.).
9. Install the rear transmission mount, if removed.
10. Remove special tool # 8534.
11. Install the front crossmember.
12. Install the fan shroud and fan.
13. Fill engine oil.
14. Reconnect the negative battery cable.
15. Start engine and check for leaks.

1. Wash all parts in a suitable solvent.

Note. There is NO approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced.

Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry.

1. Clean the exhaust manifold using a suitable cleaning solvent, then allow to air dry.
2. Clean all gasket residue from the manifold mating surface.

RIGHT EXHAUST MANIFOLD

1. Install exhaust manifold and gasket from below engine compartment.
2. Install lower exhaust manifold fasteners. DO NOT tighten until all fasteners are in place.
3. Lower vehicle and install upper exhaust manifold fasteners. Tighten all manifold bolts starting at center and working outward to 25 N.m (18 ft. lbs.). CAUTION: Over tightening heat shield fasteners, may cause shield to distort and/or crack.
4. Install exhaust manifold heat shield. Tighten fasteners to 8 N.m (72 in. lbs.), then loosen 45 degrees.
5. Install starter and fasteners.
6. Connect exhaust pipe to manifold.
7. Connect heater hoses at engine.
8. Install fastener attaching A/C accumulator.
9. Install A/C compressor and fasteners.
10. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
11. Install air cleaner assembly, resonator assembly and air inlet hose.
12. Install battery and connect cables.
13. Fill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).

LEFT EXHAUST MANIFOLD

1. Install exhaust manifold and gasket from below engine compartment.
2. Install lower exhaust manifold fasteners. DO NOT tighten until all fasteners are in place.
3. Lower vehicle and install upper exhaust manifold fasteners. Tighten all manifold bolts starting at center and working outward to 25 N.m (18 ft. lbs.). CAUTION: Over tightening heat shield fasteners, may cause shield to distort and/or crack.
4. Install exhaust manifold heat shield. Tighten fasteners to 8 N.m (72 in. lbs.), then loosen 45 degrees.
5. Connect exhaust pipe to manifold.
6. Connect negative cable to battery.

Scheme 300

The timing drive system has been designed to provide quiet performance and reliability to support a non-free wheeling engine. Specifically the intake valves are non-free wheeling and can be easily damaged with forceful engine rotation if camshaft-to-crankshaft timing is incorrect. The timing drive system consists of a primary chain and two secondary timing chain drives.

STANDARD PROCEDURE - MEASURING TIMING CHAIN WEAR

Note. This procedure must be performed with the timing chain cover removed.

Scheme 301

1. Remove the timing chain cover. (Refer to «REMOVAL»(ref-212815-S12373249852005122700000) ).
2. To determine if the secondary timing chains are worn, rotate the engine clockwise until maximum tensioner piston extension is obtained. Measure the distance between the secondary timing chain tensioner housing and the step ledge on the piston. The measurement at point (A) must be less than 15mm (0.5906 inches).
3. If the measurement exceeds the specification the secondary timing chains are worn and require replacement. (Refer to «REMOVAL»(ref-212815-S26161026662005122700000) ). NOTE: If the secondary chains are to be replaced the primary chain must also be replaced.

STANDARD PROCEDURE - ENGINE TIMING - VERIFICATION

Note. Components referred to as left hand or right hand are as viewed from the drivers position inside the vehicle.

Note. The blue link plates on the chains and the dots on the camshaft drive sprockets may not line up during the timing verification procedure. The blue link plates are lined up with the sprocket dots only when re-timing the complete timing drive. Once the timing drive is rotated blue link-to-dot alignment is no longer valid.

Engine base timing can be verified by the following procedure

Scheme 302

Scheme 303

1. Remove the cylinder head covers (Refer to «REMOVAL»(ref-212815-S28311795922005122700000) ,).
2. Using a mirror, locate the TDC arrow on the front cover. Rotate the crankshaft until the mark on the crankshaft damper is aligned with the TDC arrow on the front cover. The engine is now at TDC.
3. Note the location of the V8 mark stamped into the camshaft drive gears. If the V8 mark on each camshaft drive gear is at the twelve o'clock position, the engine is at TDC (cylinder #1) on the exhaust stroke. If the V8 mark on each gear is at the six o'clock position, the engine is at TDC (cylinder #1) on the compression stroke.
4. If both of the camshaft drive gears are off in the same or opposite directions, the primary chain or both secondary chains are at fault. Refer to «BELT/CHAIN-TIMING AND SPROCKETS»(ref-212815-S36198109712005122700000) .
5. If only one of the camshaft drive gears is off and the other is correct, the problem is confined to one secondary chain. Refer to «SINGLE CAMSHAFT TIMING»(ref-212815-S23279982022005122700000) .
6. If both camshaft drive gear V8 marks are at the twelve o'clock or the six o'clock position the engine base timing is correct. Reinstall the cylinder head covers.

SINGLE CAMSHAFT TIMING

Note. to adjust the timing on one camshaft, preform the following procedure.

Scheme 304

Scheme 305

Scheme 306

Scheme 307

1. Using Chain Tensioner Wedge, special tool 8350, stabilize the secondary chain drive. For reference purposes, mark the chain-to-sprocket position.
2. Remove the camshaft drive gear retaining bolt.
3. Carefully remove the camshaft drive gear from the camshaft.
4. Re-index the camshaft drive gear in the chain until the V8 mark is at the same position as the V8 mark on the opposite camshaft drive gear. NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas.
5. Using a suitable pair of adjustable pliers, rotate the camshaft until the alignment dowel on the camshaft is aligned with the slot in the camshaft drive gear. CAUTION: Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt. Failure to do so may cause over-torqueing of bolt resulting in bolt failure.
6. Position the camshaft drive gear onto the camshaft, remove oil from bolt then install the retaining bolt. Using Special Tools, Spanner Wrench 6958 with Adapter Pins 8346 and a suitable torque wrench, Tighten retaining bolt to 122N.m (90 ft. Lbs.).
7. Remove special tool 8350.
8. Rotate the crankshaft two full revolutions, then reverify that the camshaft drive gear V8 marks are in fact aligned.
9. Install the cylinder head covers (Refer to «INSTALLATION»(ref-212815-S41354626732005122700000) ,).

Scheme 308

Scheme 309

1. Disconnect the battery negative cable.
2. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
3. Disconnect both heater hoses at timing cover.
4. Disconnect lower radiator hose at engine.
5. Remove crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(ref-212815-S27538834182005122700000) ).
6. Remove accessory drive belt tensioner assembly.
7. Remove the generator and A/C compressor. CAUTION: The 4.7L engine uses an RTV sealer instead of a gasket to seal the front cover to the engine block, from the factory. For service, Mopar® Engine RTV sealant must be substituted. NOTE: It is not necessary to remove the water pump for timing cover removal.
8. Remove the bolts holding the timing cover to engine block.
9. Remove cover.