4.7L Engine - Service Information: Removal & Installation Dodge Durango II

REMOVAL

Note. This procedure applies to both the 4X2 and 4X4 vehicles, steps that apply to the 4X4 vehicle only, are identified.

Scheme 211

Scheme 212

Scheme 213

1. Release fuel rail pressure, then disconnect the fuel supply quick connect fitting at the fuel rail. Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(ref-564649-S02344868012013070500000) and «FITTING, QUICK CONNECT»(ref-564649-S03316152772013070500000) .
2. Disconnect the battery negative and positive cables.
3. Remove the wiper module (Refer to «MODULE-WINDSHIELD WIPER»(ref-212806-S16497299482005122700000) ).
4. Raise vehicle on hoist.
5. Remove exhaust crossover pipe from exhaust manifolds.
6. 4X4 vehicles Disconnect axle vent tube from left, side engine mount.
7. Remove the through bolt retaining nut and bolt from both the left and right side engine mounts.
8. 4X4 vehicles Remove locknut from left and right side engine mount brackets.
9. Disconnect two ground straps from the lower left hand side and one ground strap from the lower right hand side of the engine.
10. Disconnect crankshaft position sensor. NOTE: The following step applies to 4X4 vehicles equipped with automatic transmission only.
11. 4X4 vehicles Remove the axle isolator bracket from the engine, transmission and the axle.
12. Remove structural cover (Refer to «REMOVAL»(ref-212815-S38526847082005122700000) ).
13. Remove starter (Refer to «STARTER MOTOR»(ref-164418-S32337521402004082300000) ).
14. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
15. Remove torque converter bolts (Automatic Transmission Only).
16. Remove transmission to engine mounting bolts.
17. Disconnect the engine block heater power cable from the block heater, if equipped.
18. Lower vehicle.
19. Remove throttle body resonator assembly and air inlet hose.
20. Disconnect throttle and speed control cables.
21. Disconnect tube from both the left and right side crankcase breathers. Remove breathers
22. Discharge A/C system (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-212855-S22954270352005122700000) ).
23. Remove A/C compressor (Refer to «COMPRESSOR-A/C»(ref-212855-S21919888982005122700000) ).
24. Remove the A/C condenser (Refer to «CONDENSER-A/C»(ref-212855-S07394227692005122700000) ).
25. Remove shroud, fan assembly (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ) and accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
26. Disconnect transmission oil cooler lines at the radiator.
27. Disconnect radiator upper and lower hoses.
28. Remove radiator (Refer to «RADIATOR»(ref-212747-S10591844532006072400000) ), A/C condenser (Refer to «CONDENSER-A/C»(ref-212855-S07394227692005122700000) ) and transmission oil cooler.
29. Remove generator (Refer to «GENERATOR»(ref-166557-S21300542562004092300000) ).
30. Disconnect the two heater hoses from the timing chain cover and heater core.
31. Unclip and remove heater hoses and tubes from the intake manifold.
32. Disconnect engine harness at the following points: Intake air temperature (IAT) sensor Fuel Injectors Throttle Position (TPS) Switch Idle Air Control (IAC) Motor Engine Oil Pressure Switch Engine Coolant Temperature (ECT) Sensor Manifold absolute pressure (MAP) Sensor Camshaft Position (CMP) Sensor Coil Over Plugs
33. Disconnect the vacuum lines at the throttle body and intake manifold.
34. Remove power steering pump and position out of the way.
35. Install Special Tools 8400 Lifting Studs, into the cylinder heads.
36. Install Engine Lifting Fixture Special Tool 8347 following these steps. Holding the lifting fixture at a slight angle, slide the large bore in the front plate over the hex portion of the lifting stud. Position the two remaining fixture arms onto the two Special Tools 8400 Lifting Studs, in the cylinder heads. Pull forward and upward on the lifting fixture so that the lifting stud rest in the slotted area below the large bore. Secure the lifting fixture to the three studs using three 7/16-14 N/C locknuts. Make sure the lifting loop in the lifting fixture is in the last hole (closest to the throttle body) to minimize the angle of engine during removal. NOTE: It will be necessary to support the transmission in order to remove the engine.
37. Position a suitable jack under the transmission.
38. Remove engine from the vehicle.

INSTALLATION

1. Position engine in the vehicle. Position both the left and right side engine mount brackets and install the through bolts and nuts and tighten.
2. Remove jack from under the transmission.
3. Remove Engine Lifting Fixture Special Tool 8347.
4. Remove Special Tools 8400 Lifting Studs.
5. Install power steering pump.
6. Connect fuel supply line quick connect fitting. Refer to «FITTING, QUICK CONNECT»(ref-564649-S03316152772013070500000) .
7. Connect the vacuum lines at the throttle body and intake manifold.
8. Connect engine harness at the following points: Intake Air Temperature (IAT) Sensor Idle Air Control (IAC) Motor Fuel Injectors Throttle Position (TPS) Switch Engine Oil Pressure Switch Engine Coolant Temperature (ECT) Sensor Manifold Absolute Pressure (MAP) Sensor Camshaft Position (CMP) Sensor Coil Over Plugs
9. Install the heater hoses onto the heater core and the engine front cover.
10. Install generator (Refer to «GENERATOR»(ref-166557-S21300542562004092300000) ).
11. Install A/C condenser (Refer to «CONDENSER-A/C»(ref-212855-S07394227692005122700000) ).
12. Install the radiator (Refer to «RADIATOR»(ref-212747-S10591844532006072400000) ).
13. Connect the transmission oil cooler lines.
14. Connect radiator upper and lower hoses.
15. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ), fan assembly and shroud (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
16. Install A/C compressor (Refer to «COMPRESSOR-A/C»(ref-212855-S21919888982005122700000) ).
17. Install both breathers. Connect tube to both crankcase breathers.
18. Connect throttle and speed control cables.
19. Install throttle body resonator assembly and air inlet hose. Tighten clamps 4 N.m (35 in. lbs.).
20. Raise vehicle.
21. Install transmission to engine mounting bolts. Tighten the bolts to 41 N.m (30 ft. lbs.)
22. Install torque converter bolts (Automatic Transmission Only).
23. Connect crankshaft position sensor.
24. 4X4 vehicles Position and install the axle isolator bracket onto the axle, transmission and engine block. Tighten bolts to specification (Refer to «SPECIFICATIONS»(ref-212815-S08543634492005122700000) ,).
25. Install starter (Refer to «STARTER MOTOR»(ref-164418-S32337521402004082300000) ). CAUTION: The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover.
26. Install structural cover (Refer to «INSTALLATION»(ref-212815-S37283934022005122700000) ).
27. Install exhaust crossover pipe.
28. Install engine block heater power cable, If equipped.
29. Lower vehicle.
30. Check and fill engine oil.
31. Recharge the A/C system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-212855-S42838088152005122700000) ).
32. Refill the engine cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
33. Install the wiper module (Refer to «MODULE-WINDSHIELD WIPER»(ref-212806-S16497299482005122700000) ).
34. Connect the battery negative cable.
35. Start the engine and check for leaks.

Housing removal is not necessary for element (filter) replacement.

Scheme 214

1. Pry up spring clips from housing cover (spring clips retain cover to housing).
2. Release housing cover from locating tabs on housing and remove cover.
3. Remove air cleaner element (filter) from housing.
4. Clean inside of housing before replacing element.

1. Install element into housing.
2. Position housing cover into housing locating tabs.
3. Pry up spring clips and lock cover to housing.

INSTALLATION - LEFT CYLINDER HEAD

Note. The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced.

Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced.

Scheme 215

Scheme 216

Scheme 217

1. Clean the cylinder head and cylinder block mating surfaces.
2. Position the new cylinder head gasket on the locating dowels. CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm.
3. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels. NOTE: The four smaller cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.
4. Lubricate the cylinder head bolt threads with clean engine oil and install the ten M11 bolts.
5. Coat the four M8 cylinder head bolts with Mopar® Lock and Seal Adhesive then install the bolts. NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.
6. Tighten the bolts in sequence using the following steps and torque values: Step 1: Tighten bolts 1-10, 20 N.m (15 ft. lbs.). Step 2: Tighten bolts 1-10, 47 N.m (35 ft. lbs.). Tighten bolts 11-14, 25 N.m (18 ft. lbs.). Step 3: Tighten bolts 1-10, 90 degrees. Tighten bolts 11-14, 30 N.m (22 ft. lbs.).
7. Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V8 mark on the gear and position the gear onto the camshaft.
8. Install the camshaft drive gear retaining bolt.
9. Install the left side secondary chain guide (Refer to «INSTALLATION»(ref-212815-S35687228632005122700000) ).
10. Install the cylinder head access plug.
11. Re-set and Install the left side secondary chain tensioner (Refer to «INSTALLATION»(ref-212815-S35687228632005122700000) ).
12. Remove Special Tool 8515.
13. Install the timing chain cover (Refer to «INSTALLATION»(ref-212815-S42844273362005122700000) ).
14. Install the crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(ref-212815-S27538834182005122700000) ).
15. Install the power steering pump.
16. Install the fan blade assembly and fan shroud (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
17. Install the cylinder head cover (Refer to «INSTALLATION»(ref-212815-S41354626732005122700000) ,).
18. Install the intake manifold (Refer to «INSTALLATION»(ref-212815-S14367373072005122700000) ).
19. Refill the cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
20. Raise the vehicle.
21. Install the exhaust pipe onto the left exhaust manifold.
22. Lower the vehicle.
23. Install the wiper module (Refer to «MODULE-WINDSHIELD WIPER»(ref-212806-S16497299482005122700000) ).
24. Connect the negative cable to the battery.
25. Start the engine and check for leaks.

INSTALLATION - RIGHT CYLINDER HEAD

Note. The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced.

Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced.

Scheme 218

Scheme 219

Scheme 220

Scheme 221

1. Clean the cylinder head and cylinder block mating surfaces.
2. Position the new cylinder head gasket on the locating dowels. CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm.
3. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels. NOTE: The four smaller cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.
4. Lubricate the cylinder head bolt threads with clean engine oil and install the ten M10 bolts.
5. Coat the four M8 cylinder head bolts with Mopar® Lock and Seal Adhesive then install the bolts. NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.
6. Tighten the bolts in sequence using the following steps and torque values: Step 1: Tighten bolts 1-10, 20 N.m (15 ft. lbs.). Step 2: Tighten bolts 1-10, 47 N.m (35 ft. lbs.). Tighten bolts 11-14, 25 N.m (18 ft. lbs.). Step 3: Tighten bolts 1-10, 90 degrees. Tighten bolts 11-14, 30 N.m (22 ft. lbs.).
7. Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V8 mark on the gear and position the gear onto the camshaft.
8. Install the camshaft drive gear retaining bolt.
9. Install the right side secondary chain guide (Refer to «INSTALLATION»(ref-212815-S42844273362005122700000) ).
10. Install the right side cylinder head access plug.
11. Re-set and install the right side secondary chain tensioner.
12. Remove Special Tool 8515.
13. Install the timing chain cover (Refer to «INSTALLATION»(ref-212815-S42844273362005122700000) ).
14. Install the crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(ref-212815-S27538834182005122700000) ).
15. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
16. Install the fan shroud.
17. Install the cylinder head cover (Refer to «INSTALLATION»(ref-212815-S41354626732005122700000) ,).
18. Install the intake manifold (Refer to «INSTALLATION»(ref-212815-S14367373072005122700000) ).
19. Install oil fill housing onto cylinder head.
20. Refill the cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
21. Raise the vehicle.
22. Install the exhaust pipe onto the right exhaust manifold.
23. Lower the vehicle.
24. Install the wiper module (Refer to «MODULE-WINDSHIELD WIPER»(ref-212806-S16497299482005122700000) ).
25. Reconnect battery negative cable.
26. Start the engine and check for leaks.

Scheme 222

Scheme 223

1. Remove cylinder head cover (Refer to «REMOVAL»(ref-212815-S28311795922005122700000) ,).
2. Set engine to TDC cylinder #1, camshaft sprocket V8 marks at the 12 o'clock position.
3. Mark one link on the secondary timing chain on both sides of the V8 mark on the camshaft sprocket to aid in installation. CAUTION: Do not hold or pry on the camshaft target wheel (Located on the right side camshaft sprocket) for any reason, Severe damage will occur to the target wheel resulting in a vehicle no start condition.
4. Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave the bolt snug against the sprocket. NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners. CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur.
5. Position Special Tool 8350 timing chain wedge between the timing chain strands, tap the tool to securely wedge the timing chain against the tensioner arm and guide. 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.
6. Hold the camshaft with adjustable pliers while removing the camshaft sprocket bolt and sprocket.
7. Using the pliers, gently allow the camshaft to rotate 15° clockwise until the camshaft is in the neutral position (no valve load).
8. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps. CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS. NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
9. Remove the camshaft bearing caps and the camshaft.

Scheme 224

Scheme 225

Scheme 226

Scheme 227

Scheme 228

1. Lubricate camshaft journals with clean engine oil. NOTE: Position the left side camshaft so that the camshaft sprocket dowel is near the 1 o'clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
2. Position the camshaft into the cylinder head.
3. Install the camshaft bearing caps, hand tighten the retaining bolts.
4. Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward.
5. Torque the camshaft bearing cap retaining bolts to 11 N.m (100 in. lbs.).
6. Position the camshaft drive gear into the timing chain aligning the V8 mark between the two marked chain links (Two links marked during removal). 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.
7. Using the adjustable pliers, rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft. CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over-torque resulting in bolt failure.
8. Remove excess oil from bolt, then install the camshaft sprocket retaining bolt and hand tighten.
9. Remove Special Tool 8350 timing chain wedge.
10. Using Special Tool 6958 spanner wrench with adapter pins 8346, torque the camshaft sprocket retaining bolt to 122 N.m (90 ft. lbs.).
11. Install the cylinder head cover.

Scheme 229

Scheme 230

Scheme 231

1. Remove the cylinder head covers (Refer to «REMOVAL»(ref-212815-S28311795922005122700000) ,).
2. Set engine to TDC cylinder #1, camshaft sprocket V8 marks at the 12 o'clock position.
3. Mark one link on the secondary timing chain on both sides of the V8 mark on the camshaft sprocket to aid in installation. CAUTION: Do not hold or pry on the camshaft target wheel for any reason, Severe damage will occur to the target wheel. A damaged target wheel could cause a vehicle no start condition.
4. Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave bolt snug against sprocket. NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners. CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur.
5. Position Special Tool 8350 timing chain wedge between the timing chain strands. Tap the tool to securely wedge the timing chain against the tensioner arm and guide.
6. Remove the camshaft position sensor. 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.
7. Hold the camshaft with adjustable pliers while removing the camshaft sprocket bolt and sprocket.
8. Using the pliers, gently allow the camshaft to rotate 45° counter-clockwise until the camshaft is in the neutral position (no valve load).
9. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps. CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS. NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
10. Remove the camshaft bearing caps and the camshaft.

Scheme 232

Scheme 233

Scheme 234

Scheme 235

1. Lubricate camshaft journals with clean engine oil. NOTE: Position the right side camshaft so that the camshaft sprocket dowel is near the 10 o'clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
2. Position the camshaft into the cylinder head.
3. Install the camshaft bearing caps, hand tighten the retaining bolts.
4. Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward.
5. Torque the camshaft bearing cap retaining bolts to 11 N.m (100 in. lbs.).
6. Position the camshaft drive gear into the timing chain aligning the V8 mark between the two marked chain links (Two links marked during removal). 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.
7. Using the adjustable pliers, rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft. CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over-torque resulting in bolt failure.
8. Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and hand tighten.
9. Remove timing chain wedge special tool 8350.
10. Using Special Tool 6958 spanner wrench with adapter pins 8346, torque the camshaft sprocket retaining bolt to 122 N.m (90 ft. lbs.).
11. Install the camshaft position sensor.
12. Install the cylinder head cover (Refer to «INSTALLATION»(ref-212815-S41354626732005122700000) ,).

REMOVAL - RIGHT SIDE

1. Disconnect battery negative cable.
2. Remove air cleaner assembly, resonator assembly and air inlet hose.
3. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
4. Remove accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
5. Remove air conditioning compressor retaining bolts and move compressor to the left.
6. Remove heater hoses.
7. Disconnect injector and ignition coil connectors.
8. Disconnect and remove positive crankcase ventilation (PCV) hose.
9. Remove oil fill tube.
10. Un-clip injector and ignition coil harness and move away from cylinder head cover.
11. Remove right rear breather tube and filter assembly.
12. Remove cylinder head cover retaining bolts.
13. Remove cylinder head cover.

Note. The gasket may be used again, provided no cuts, tears, or deformation has occurred.

REMOVAL - LEFT SIDE

1. Disconnect negative cable from battery.
2. Remove the resonator assemble and air inlet hose.
3. Disconnect injector connectors and un-clip the injector harness.
4. Route injector harness in front of cylinder head cover.
5. Disconnect the left side breather tube and remove the breather tube.
6. Remove the cylinder head cover mounting bolts.
7. Remove cylinder head cover and gasket.

Note. The gasket may be used again, provided no cuts, tears, or deformation has occurred.

INSTALLATION - RIGHT SIDE

Scheme 236

1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary.
2. Install cylinder head cover and hand start all fasteners. Verify that all double ended studs are in the correct location shown in.
3. Tighten cylinder head cover bolts and double ended studs to 12 N.m (105 in. lbs).
4. Install right rear breather tube and filter assembly.
5. Connect injector, ignition coil electrical connectors and harness retaining clips.
6. Install the oil fill tube.
7. Install PCV hose.
8. Install heater hoses.
9. Install air conditioning compressor retaining bolts.
10. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
11. Fill Cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
12. Install air cleaner assembly, resonator assembly and air inlet hose.
13. Connect battery negative cable.

INSTALLATION - LEFT SIDE

Scheme 237

1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary.
2. Install cylinder head cover and hand start all fasteners. Verify that all studs are in the correct location shown in.
3. Tighten cylinder head cover bolts and double ended studs to 12 N.m (105 in. lbs.).
4. Install left side breather and connect breather tube.
5. Connect injector electrical connectors and injector harness retaining clips.
6. Install the resonator and air inlet hose.
7. Connect negative cable to battery.

Note. Disconnect the battery negative cable to prevent accidental starter engagement.

Scheme 238

1. Remove the cylinder head cover (Refer to «REMOVAL»(ref-212815-S28311795922005122700000) ,).
2. For rocker arm removal on cylinders 3 and 5 Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke.
3. For rocker arm removal on cylinders 2 and 8 Rotate the crankshaft until cylinder #1 is at TDC compression stroke.
4. For rocker arm removal on cylinders 4 and 6 Rotate the crankshaft until cylinder #3 is at TDC compression stroke.
5. For rocker arm removal on cylinders 1 and 7 Rotate the crankshaft until cylinder #2 is at TDC compression stroke.
6. Using special tool 8516 Rocker Arm Remover, press downward on the valve spring, remove rocker arm.

Note. Coat the rocker arms with clean engine oil prior to installation.

1. For rocker arm installation on cylinders 3 and 5 Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke.
2. For rocker arm installation on cylinders 2 and 8 Rotate the crankshaft until cylinder #1 is at TDC compression stroke.
3. For rocker arm installation on cylinders 4 and 6 Rotate the crankshaft until cylinder #3 is at TDC compression stroke.
4. For rocker arm installation on cylinders 1 and 7 Rotate the crankshaft until cylinder #2 is at TDC compression stroke.
5. Using special tool 8516 press downward on the valve spring, install rocker arm.
6. Install the cylinder head cover (Refer to «INSTALLATION»(ref-212815-S41354626732005122700000) ,).

Note. Thoroughly clean core plug bore, remove all of the old sealer.

1. Coat the edges of the engine core plug and the core plug bore with Mopar Gasket Maker, or equivalent. NOTE: It is not necessary to wait for the sealant to cure on the core plugs. The cooling system can be filled and the vehicle returned to service immediately.
2. Using proper plug driver, drive core plug into the core plug bore. The sharp edge of the core plug should be at least 0.50 mm (0.020 in.) inside the lead in chamfer.
3. Refill the cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).

Note. To remove the crankshaft from the engine, the engine must be removed from the vehicle.

Scheme 239

1. Remove the engine. (Refer to «REMOVAL»(ref-212815-S10493363142005122700000) ,).
2. Remove the engine oil pump. (Refer to «REMOVAL»(ref-212815-S05654299772005122700000) ). CAUTION: DO NOT pry on the oil pan gasket when removing the oil pan, The oil pan gasket is mounted to the cylinder block in three locations and will remain attached to block when removing oil pan. Gasket can not be removed with oil pan.
3. Remove oil pan. (Refer to «REMOVAL»(ref-212815-S09016296762005122700000) ).
4. Remove the oil pump pickup tube and oil pan gasket /windage tray.
5. Remove the bedplate mounting bolts. Note the location of the three stud bolts for installation.
6. Remove the connecting rods from the crankshaft. CAUTION: The bedplate to cylinder block mating surface is a critical sealing surface. Do not pry on or damage this surface in anyway. NOTE: The bedplate contains the lower main bearing halves. Use care when handling bedplate as not to drop or damage bearing halves. Installing main bearing halves in the wrong position will cause sever damage to the crankshaft. NOTE: The bedplate has pry points cast into it. Use these points only. The pry points are on both the left and right sides, only the left side is shown.
7. Carefully pry on the pry points to loosen the bedplate then remove the bedplate. CAUTION: When removing the crankshaft, use care not to damage bearing surfaces on the crankshaft.
8. Remove the crankshaft.
9. Remove the crankshaft target wheel.

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

1. Lubricate upper main bearing halves with clean engine oil. CAUTION: When installing crankshaft, use care not to damage bearing surfaces on the crankshaft. NOTE: Apply sealant to the target wheel retaining screws prior to installation.
2. Install the crankshaft target wheel. Torque the mounting screws to 15 N.m (12 ft. lbs.).
3. Position crankshaft in cylinder block.
4. Install the thrust washers. CAUTION: The bedplate to cylinder block matting surface must be coated with sealant prior to installation. Failure to do so will cause severe oil leaks. NOTE: The installation time to install the bedplate after the sealant has been applied is critical. NOTE: Make sure that the bedplate and cylinder block sealing surfaces are clean and free of oil or other contaminants. Contaminants on the sealing surfaces may cause main bearing distortion and/or oil leaks.
5. Apply a 2.5mm (0.100 inch) bead of Mopar® Gen II Silicone Rubber Adhesive sealant to the cylinder block-to-bedplate mating surface as shown.
6. Coat the crankshaft main bearing journals with clean engine oil and position the bedplate onto the cylinder block. NOTE: Lubricate the bedplate retaining bolts with clean engine oil prior to installation.
7. Install the bedplate retaining bolts, making sure to place the stud bolts in the correct location, Torque the bolts in the sequence shown. Tighten bolts A - L to 54 N.m (40 ft. lbs.) Tighten bolts 1-10 to 2.8 N.m (25 in. lbs.) Turn bolts 1-10 an additional 90°. Tighten bolts A1- A6 to 27 N.m (20 ft. lbs.)
8. Measure crankshaft end play. (Refer to «STANDARD PROCEDURE»(ref-212815-S01295070442005122700000) ).
9. Install the connecting rods and measure side clearance. (Refer to «STANDARD PROCEDURE»(ref-212815-S38445755332005122700000) ).
10. Position the oil pan gasket/windage tray, using a new o-ring, install the oil pickup tube. Torque the bolt to 28N-n (20 ft. lbs.) torque the nuts to 28 N.m (20 ft. lbs.).
11. Install the oil pan. Torque the retaining bolts to 15 N.m (11 ft. lbs.) in the sequence shown.
12. Install the engine (Refer to «INSTALLATION»(ref-212815-S36667205622005122700000) ,).

Scheme 245

1. Using Special Tool 8348 and 8512, install crankshaft front seal.
2. Install vibration damper (Refer to «DAMPER-CRANKSHAFT»(ref-212815-S27538834182005122700000) ).
3. Install radiator cooling fan and shroud (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
4. Install upper radiator hose.
5. Install A/C compressor and tighten fasteners to 54 N.m (40 ft. lbs.).
6. Install accessory drive belt refer (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
7. Refill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
8. Connect negative cable to battery.

Note. This procedure can be performed in vehicle.

Scheme 246

1. If being performed in vehicle, remove the transmission.
2. Remove the flexplate (Refer to «PLATE-TORQUE CONVERTER DRIVE»(ref-212815-S14078301112005122700000) ). NOTE: The crankshaft oil seal CAN NOT be reused after removal. NOTE: The crankshaft rear oil seal remover Special Tool 8506 must be installed deeply into the seal. Continue to tighten the removal tool into the seal until the tool can not be turned farther. Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine.
3. Using Special Tool 8506, remove the crankshaft rear oil seal.

Scheme 247

Scheme 248

1. Lubricate the crankshaft flange with engine oil.
2. Position the magnetic seal guide Special Tool 8349-2 onto the crankshaft rear face. Then position the crankshaft rear oil seal onto the guide.
3. Using Special Tools 8349 Crankshaft Rear Oil Seal Installer and C-4171 Driver Handle, with a hammer, tap the seal into place. Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore.
4. Install the flexplate.
5. Install the transmission.

1. Remove the transmission.
2. Remove the bolts and flexplate.

Scheme 249

1. Position the flexplate onto the crankshaft and install the bolts hand tight.
2. Tighten the flexplate retaining bolts to 60 N.m (45 ft. lbs.) in the sequence shown.
3. Install the transmission.

Scheme 250

Scheme 251

1. Align crankshaft damper slot with key in crankshaft. Slide damper onto crankshaft slightly. CAUTION: Special Tool 8512-A, is assembled in a specific sequence. Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft.
2. Assemble Special Tool 8512-A as follows, The nut is threaded onto the shaft first. Then the roller bearing is placed onto the threaded rod (The hardened bearing surface of the bearing MUST face the nut). Then the hardened washer slides onto the threaded rod. Once assembled coat the threaded rod's threads with Mopar® Nickel Anti-Seize or equivalent.
3. Using Special Tool 8512-A, press damper onto crankshaft.
4. Install then tighten crankshaft damper bolt to 175 N.m (130 ft. lbs.).
5. Install fan blade assembly (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
6. Install radiator upper shroud and tighten fasteners to 11 N.m (95 in. lbs.).
7. Connect electrical connector for shroud fan.
8. Install radiator upper hose.
9. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212748-S08533630352005122700000) ).
10. Refill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
11. Connect negative cable to battery.

Scheme 252

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 engine and the transmission bell housing during tightening sequence. Failure to do so may cause damage to the cover.
4. Starting with the two rear cover-to-engine bolts, tighten bolts (1) to 54 N.m (40 ft. lbs.), then tighten bolts (2) and (3) to 54 N.m ( 40 ft. lbs.) in the sequence shown.
5. Install the exhaust pipe on left hand exhaust manifold.
6. Tighten exhaust manifold-to-exhaust pipe retaining bolts to 20-26 N.m (15-20 ft. lbs.).

1. Follow the removal procedure in the reverse order.
2. Tighten the through bolt retaining nut to 101 N.m (75 ft. lbs.).
3. Tighten the isolator bracket to transmission retaining bolts (Manual transmission and 4x2 automatic transmission only) to 68 N.m (50 ft. lbs.).
4. Tighten the mount bracket to transmission retaining bolts (4x4 automatic transmission only) to 68 N.m (50 ft. lbs.).
5. Tighten the isolator mount to crossmember retaining nuts (Manual transmission and 4x2 automatic transmission only) to 41 N.m (30 ft. lbs.).
6. Tighten the mount bracket to crossmember retaining bolts (4x4 automatic transmission only) to 28 N.m (250 in. lbs.).

Scheme 253

The lubrication system is a full flow filtration pressure feed type.

All engines are equipped with a high quality full-flow, disposable type oil filter. DaimlerChrysler Corporation recommends a Mopar® or equivalent oil filter be used.

Scheme 254

1. Position a drain pan under the oil filter.
2. Using a suitable oil filter wrench loosen filter.
3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss.
4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter.
5. With a wiping cloth, clean the gasket sealing surface of oil and grime.

Scheme 255

1. Lightly lubricate oil filter gasket with engine oil.
2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one full turn, do not over tighten.
3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks.

1. Install oil pressure sender.
2. Connect oil pressure sender wire.
3. Install front splash shield.
4. Lower vehicle.
5. Connect the negative battery cable.

1. Remove the oil pan and pick-up tube (Refer to «REMOVAL»(ref-212815-S09016296762005122700000) ).
2. Remove the timing chain cover (Refer to «REMOVAL»(ref-212815-S12373249852005122700000) ).
3. Remove the timing chains and tensioners (Refer to «REMOVAL»(ref-212815-S26161026662005122700000) ).
4. Remove the four bolts, primary timing chain tensioner and the oil pump.

Scheme 256

Scheme 257

1. Clean timing chain cover and block surface using rubbing alcohol. CAUTION: The 4.7L can use a special RTV sealer instead of a carrier gasket to seal the timing cover to the engine block, from the factory. For service repairs, Mopar® Engine RTV must be used as a substitute, if RTV is present.
2. Inspect the water passage o-rings for any damage, and replace as necessary.
3. Apply Mopar® Engine RTV sealer to the front cover following the path below, using a 3 to 4mm thick bead.
4. Install cover. Tighten flange head fasteners in sequence as shown in to 58 N.m (43 ft. lbs.).
5. Install the A/C compressor and generator.
6. Install crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(ref-212815-S27538834182005122700000) ).
7. Install accessory drive belt tensioner assembly. Tighten fastener to 54 N.m (40 ft. lbs.).
8. Install lower radiator hose.
9. Install both heater hoses.
10. Fill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
11. Connect the battery negative cable.

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

Scheme 264

1. Disconnect negative cable from battery.
2. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
3. Remove right and left cylinder head covers (Refer to «REMOVAL»(ref-212815-S28311795922005122700000) ,).
4. Remove radiator fan shroud.
5. Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover (#1 cylinder exhaust stroke) and the camshaft sprocket "V8" marks are at the 12 o'clock position.
6. Remove power steering pump (Refer to «PUMP»(ref-212826-S04969560452005122700000) ).
7. Remove access plugs (2) from left and right cylinder heads for access to chain guide fasteners.
8. Remove the oil fill housing to gain access to the right side tensioner arm fastener.
9. Remove crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(ref-212815-S27538834182005122700000) ) and timing chain cover (Refer to «REMOVAL»(ref-212815-S12373249852005122700000) ).
10. Collapse and pin primary chain tensioner. CAUTION: Plate behind left secondary chain tensioner could fall into oil pan. Therefore, cover pan opening.
11. Remove secondary chain tensioners.
12. Remove camshaft position sensor from right cylinder head. CAUTION: Care should be taken not to damage camshaft target wheel. Do not hold target wheel while loosening or tightening camshaft sprocket. Do not place the target wheel near a magnetic source of any kind. A damaged or magnetized target wheel could cause a vehicle no start condition. CAUTION: Do not forcefully rotate the camshafts or crankshaft independently of each other. Damaging intake valve to piston contact will occur. Ensure negative battery cable is disconnected to guard against accidental starter engagement.
13. Remove left and right camshaft sprocket bolts.
14. While holding the left camshaft steel tube with adjustable pliers, remove the left camshaft sprocket. Slowly rotate the camshaft approximately 15 degrees clockwise to a neutral position.
15. While holding the right camshaft steel tube with adjustable pliers, remove the right camshaft sprocket. Slowly rotate the camshaft approximately 45 degrees counterclockwise to a neutral position.
16. Remove idler sprocket assembly bolt.
17. Slide the idler sprocket assembly and crank sprocket forward simultaneously to remove the primary and secondary chains.
18. Remove both pivoting tensioner arms and chain guides.
19. Remove chain tensioner.

Scheme 265

Inspect the following components

1. Sprockets for excessive tooth wear. Some tooth markings are normal and not a cause for sprocket replacement.
2. Idler sprocket assembly bushing and shaft for excessive wear.
3. Idler sprocket assembly spline joint. The joint should be tight with no backlash or axial movement.
4. Chain guides and tensioner arms. Replace these parts if grooving in plastic face is more than 1 mm (0.039 in.) deep. If plastic face is severely grooved or melted, the tensioner lube jet may be clogged. The tensioner should be replaced.
5. Secondary chain tensioner piston and ratcheting device. Inspect for evidence of heavy contact between tensioner piston and tensioner arm. If this condition exist the tensioner and tensioner arm should be replaced.
6. Primary chain tensioner plastic faces. Replace as required.

Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

1. Using a vise, lightly compress the secondary chain tensioner piston until the piston step is flush with the tensioner body. Using a pin or suitable tool, release ratchet pawl by pulling pawl back against spring force through access hole on side of tensioner. While continuing to hold pawl back, Push ratchet device to approximately 2 mm from the tensioner body. Install Special Tool 8514 lock pin into hole on front of tensioner. Slowly open vise to transfer piston spring force to lock pin.
2. Position primary chain tensioner over oil pump and insert bolts into lower two holes on tensioner bracket. Tighten bolts to 28 N.m (250 in. lbs.). CAUTION: Overtightening the tensioner arm Torx® bolt can cause severe damage to the cylinder head. Tighten Torx® bolt to specified torque only.
3. Install right side chain tensioner arm. Apply Mopar® Lock N, Seal to Torx® bolt, tighten bolt to 17 N.m (150 in. lbs.). NOTE: The silver bolts retain the guides to the cylinder heads and the black bolts retain the guides to the engine block.
4. Install the left side chain guide. Tighten the bolts to 28 N.m (250 in. lbs.). CAUTION: Overtightening the tensioner arm Torx® bolt can cause severe damage to the cylinder head. Tighten Torx® bolt to specified torque only.
5. Install left side chain tensioner arm. Apply Mopar® Lock N, Seal to Torx® bolt, tighten bolt to 17 N.m (150 in. lbs.).
6. Install the right side chain guide. Tighten the bolts to 28 N.m (250 in. lbs.).
7. Install both secondary chains onto the idler sprocket. Align two plated links on the secondary chains to be visible through the two lower openings on the idler sprocket (4 o'clock and 8 o'clock). Once the secondary timing chains are installed, position special tool 8515 to hold chains in place for installation.
8. Align primary chain double plated links with the timing mark at 12 o'clock on the idler sprocket. Align the primary chain single plated link with the timing mark at 6 o'clock on the crankshaft sprocket.
9. Lubricate idler shaft and bushings with clean engine oil.
10. Install all chains, crankshaft sprocket, and idler sprocket as an assembly. After guiding both secondary chains through the block and cylinder head openings, affix chains with a elastic strap or the equivalent, This will maintain tension on chains to aid in installation. NOTE: It will be necessary to slightly rotate camshafts for sprocket installation.
11. Align left camshaft sprocket "L" dot to plated link on chain.
12. Align right camshaft sprocket "R" dot to plated link on chain. CAUTION: Remove excess oil from the camshaft sprocket bolt. Failure to do so can result in over-torque of bolt resulting in bolt failure.
13. Remove Special Tool 8515, then attach both sprockets to camshafts. Remove excess oil from bolts, then Install sprocket bolts, but do not tighten at this time.
14. Verify that all plated links are aligned with the marks on all sprockets and the "V8" marks on camshaft sprockets are at the 12 o'clock position. CAUTION: Ensure the plate between the left secondary chain tensioner and block is correctly installed.
15. Install both secondary chain tensioners. Tighten bolts to 28 N.m (250 in. lbs.). NOTE: Left and right secondary chain tensioners are not common.
16. Before installing idler sprocket bolt, lubricate washer with oil, and tighten idler sprocket assembly retaining bolt to 34 N.m (25 ft. lbs.).
17. Remove all locking pins (3) from tensioners. CAUTION: After pulling locking pins out of each tensioner, DO NOT manually extend the tensioners) ratchet. Doing so will over tension the chains, resulting in noise and/or high timing chain loads.
18. Using Special Tool 6958, Spanner with Adaptor Pins 8346, tighten left and right, camshaft sprocket bolts to 122 N.m (90 ft. lbs.).
19. Rotate engine two full revolutions. Verify timing marks are at the follow locations: primary chain idler sprocket dot is at 12 o'clock primary chain crankshaft sprocket dot is at 6 o'clock secondary chain camshaft sprockets "V8" marks are at 12 o'clock
20. Lubricate all three chains with engine oil.
21. After installing all chains, it is recommended that the idler gear end play be checked. The end play must be within 0.10-0.25 mm (0.004-0.010 in.). If not within specification, the idler gear must be replaced.
22. Install timing chain cover (Refer to «INSTALLATION»(ref-212815-S42844273362005122700000) ) and crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(ref-212815-S27538834182005122700000) ).
23. Install cylinder head covers (Refer to «INSTALLATION»(ref-212815-S41354626732005122700000) ). NOTE: Before installing threaded plug in right cylinder head, the plug must be coated with sealant to prevent leaks.
24. Coat the large threaded access plug with Mopar® Thread Sealant with Teflon, then install into the right cylinder head and tighten to 81 N.m (60 ft. lbs.).
25. Install the oil fill housing.
26. Install access plug in left cylinder head.
27. Install power steering pump (Refer to «PUMP»(ref-212826-S04969560452005122700000) ).
28. Install radiator fan shroud.
29. Fill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
30. Connect negative cable to battery.

1. Remove the primary and secondary timing chains and sprockets (Refer to «REMOVAL»(ref-212815-S26161026662005122700000) ) . NOTE: To remove the idler shaft, it is necessary to tap threads into the shaft, to install the removal tool.
2. Using a 12 mm X 1.75 tap, cut threads in the idler shaft center bore.
3. Cover the radiator core with a suitable cover. CAUTION: Use care when removing the idler shaft, Do not strike the radiator cooling fins with the slide hammer.
4. Using Special Tool 8517 Slide Hammer, remove the idler shaft.

1. Thoroughly clean the idler shaft bore.
2. Position the idler shaft in the bore. NOTE: The two lubrication holes in the idler shaft do not require any special alignment. NOTE: Before using the retaining bolt to install the idler shaft, coat the threads and the pilot on the idler shaft, with clean engine oil.
3. Using the primary idler sprocket retaining bolt and washer, carefully draw the idler shaft into the bore until fully seated.
4. Coat the idler shaft with clean engine oil.
5. Install the timing chains and sprockets (Refer to «INSTALLATION»(ref-212815-S35687228632005122700000) ).