4.7l Engine - Overhaul Dodge Pickup R1500

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE

The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.

Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.

1. Clean the spark plug recesses with compressed air.
2. Remove the spark plugs.
3. Disable the fuel system (Refer to «FUEL DELIVERY - GAS»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine) ).
4. Remove the ASD relay (Refer to «AUTOMATIC SHUT DOWN RELAY»(/dodge/pickup-r1500/1997-2012/remont/ignition-system/#ignition-control) ).
5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders.
7. (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ) for the correct engine compression pressures.

DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE

The combustion pressure leakage test provides an accurate means for determining engine condition.

Combustion pressure leakage testing will detect

1. Exhaust and intake valve leaks (improper seating).
2. Leaks between adjacent cylinders or into water jacket.
3. Any causes for combustion/compression pressure loss.

1. Check the coolant level and fill as required. DO NOT install the radiator cap.
2. Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.
3. Remove the spark plugs.
4. Remove the oil filler cap.
5. Remove the air cleaner hose.
6. Calibrate the tester according to the manufacturer's instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379 kPa (200 psi) maximum and 552 kPa (80 psi) recommended.
7. Perform the test procedures on each cylinder according to the tester manufacturer's instructions. Set piston of cylinder to be tested at TDC compression, While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the radiator coolant.

All gauge pressure indications should be equal, with no more than 25% leakage.

FOR EXAMPLE : At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the cylinder.

Refer to CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART .

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS-INTRODUCTION

Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance.

These malfunctions may be classified as either performance (e.g., engine idles rough and stalls) or mechanical (e.g., a strange noise).

(Refer to DIAGNOSIS AND TESTING ) and (Refer to DIAGNOSIS AND TESTING - MECHANICAL ) for possible causes and corrections of malfunctions. (Refer to FUEL DELIVERY - GAS ) and (Refer to FUEL INJECTION - GAS ) for the fuel system diagnosis.

Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the following diagnosis

1. Cylinder Compression Pressure Test (Refer to «DIAGNOSIS AND TESTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
2. Cylinder Combustion Pressure Leakage Test (Refer to «DIAGNOSIS AND TESTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
3. Engine Cylinder Head Gasket Failure Diagnosis (Refer to «CYLINDER HEAD»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
4. Intake Manifold Leakage Diagnosis (Refer to «MANIFOLD DIAGNOSIS AND TESTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul__diagnosis-and-testing-intake-manifold) ).

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 4oz./16 oz. can w/applicator.

FORM-IN-PLACE GASKET AND SEALER APPLICATION

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

REMOVAL

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

Scheme 170

Scheme 171

Scheme 172

1. Disconnect the battery negative and positive cables.
2. Remove the battery and the battery tray.
3. Raise vehicle on hoist.
4. Remove exhaust crossover pipe from exhaust manifolds.
5. 4X4 vehicles Disconnect axle vent tube from left side engine mount.
6. Remove the through bolt retaining nut and bolt from both the left and right side engine mounts.
7. 4X4 vehicles Remove locknut from left and right side engine mount brackets.
8. Disconnect two ground straps from the lower left hand side and one ground strap from the lower right hand side of the engine.
9. Disconnect crankshaft position sensor. (Scheme 170) NOTE: The following step applies to 4X4 vehicles equipped with automatic transmission only.
10. 4X4 vehicles Remove the axle isolator bracket from the engine, transmission and the axle.
11. Remove structural cover (Refer to «COVER-STRUCTURAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
12. Remove starter (Refer to «STARTERS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) ).
13. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas) ).
14. Remove torque converter bolts (Automatic Transmission Only).
15. Remove transmission to engine mounting bolts.
16. Disconnect the engine block heater power cable from the block heater, if equipped.
17. Lower vehicle.
18. Remove throttle body resonator assembly and air inlet hose.
19. Disconnect throttle and speed control cables.
20. Disconnect tube from both the left and right side crankcase breathers (Scheme 171) Remove breathers
21. Discharge A/C system (Refer to «REFRIGERANT SYSTEM RECOVERY»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing__refrigerant-system-recovery) ) and transmission oil cooler.
22. Remove a/c compressor (refer to «A/C COMPRESSOR»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing__ac-compressor) ) and transmission oil cooler.
23. Remove shroud fan assembly (Refer to «RADIATOR-3.7L/4.7L/5.7L»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ), and accessory drive belt belt transmission oil cooler. Refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) ).
24. Disconnect transmission oil cooler lines at the radiator.
25. Disconnect radiator upper and lower hoses
26. Remove radiator Refer to «RADIATOR-3.7L/4.7L/5.7L»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ), A/C Condensor (refer to «A/C CONDENSER»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing) ) and transmission oil cooler.
27. Remove generator (Refer to «GENERATOR»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) ).
28. Disconnect the two heater hoses from the timing chain cover and heater core.
29. Unclip and remove heater hoses and tubes from the intake manifold.
30. Disconnect engine harness at the following points: Intake air temperature (IAT) sensor (Scheme 172) 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
31. Disconnect the vacuum lines at the throttle body and intake manifold.
32. Release fuel rail pressure (Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine__standard-procedure-fuel-system-pressure) ) then disconnect the fuel supply quick connect fitting at the fuel rail (Refer to «QUICK CONNECT FITTING»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine) ).
33. Remove power steering pump and position out of the way.
34. Install Special Tools 8400 Lifting Studs, into the cylinder heads.
35. Install Engine Lifting Fixture Special Tool 8347 (Scheme 173) 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 foward 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.
36. Disconnect body ground strap at the right side cowl (Scheme 174)
37. Disconnect body ground strap at the left side cowl (Scheme 175) NOTE: It will be necessary to support the transmission in order to remove the engine.
38. Position a suitable jack under the transmission.
39. Remove engine from the vehicle.

Scheme 173

Scheme 174

Scheme 175

1. Position engine in the vehicle. Position both the left and right side engine mount brackets and install the through bolts and nuts. Tighten nuts to 4X2 vehicles 95 N.m (70 ft. lbs.). 4X4 vehicles 102 N.m (75 ft. lbs.).
2. 4X4 vehicles Install locknuts onto the engine mount brackets. Tighten locknuts to 41 N.m (30 ft. lbs.).
3. Remove jack from under the transmission.
4. Remove Engine Lifting Fixture Special Tool 8347 (Scheme 173)
5. Remove Special Tools 8400 Lifting Studs.
6. Position generator wiring behind the oil dipstick tube, then install the oil dipstick tube upper mounting bolt.
7. Connect both left and right side body ground straps.
8. Install power steering pump.
9. Connect fuel supply line quick connect fitting (Refer to «QUICK CONNECT FITTING»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine) ).
10. Connect the vacuum lines at the throttle body and intake manifold.
11. Connect engine harness at the following points (Scheme 172) 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
12. Position and install heater hoses and tubes onto (intake Manifold.
13. Install the heater hoses onto the heater core and the engine front cover.
14. Install generator (Refer to «GENERATOR»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) ).
15. Install A/C condenser (Refer to «A/C CONDENSER»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing) ), radiator (Refer to «RADIATOR-3.7L/4.7L/5.7L»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ) and transmission oil cooler.
16. Connect radiator upper and lower hoses.
17. Connect the transmission oil cooler lines to the radiator.
18. Install accessory drive belt (Refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) ), fan assembly and shroud (Refer to «RADIATOR-3.7L/4.7L/5.7L»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
19. Install A/C compressor (Refer to «A/C COMPRESSOR»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing__ac-compressor) ).
20. Install both breathers. Connect tube to both crankcase breathers (Scheme 171)
21. Connect throttle and speed control cables.
22. Install throttle body resonator assembly and air inlet hose. Tighten clamps 4 N.m (35 in. lbs.).
23. Raise vehicle.
24. Install transmission to engine mounting bolts. Tighten the bolts to 41 N.m (30 ft. lbs.).
25. Install torque converter bolts (Automatic Transmission Only).
26. Connect crankshaft position sensor (Scheme 170)
27. 4X4 vehicles Position and install the axle isolator bracket onto the axle, transmission and engine block. Tighten bolts to specification (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
28. Install starter (Refer to «STARTERS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) ). 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 (Refer to «COVER-STRUCTURAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
30. Install exhaust crossover pipe.
31. Install engine block heater power cable, If equipped.
32. 4X4 Vehicles Connect axle vent tube to left side engine mount.
33. Lower vehicle.
34. Check and fill engine oil.
35. Recharge the A/C system (Refer to «REFRIGERANT SYSTEM CHARGE»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing__refrigerant-system-charge) ).
36. Refill the engine cooling system (Refer to «REFILLING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).
37. Install the battery tray and battery.
38. Connect the battery positive and negative cables.
39. Start the engine and check for leaks.

GENERAL DESCRIPTION

GENERAL DESCRIPTION

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

TORQUE

TORQUE SPECIFICATIONS

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Filter Element Only

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

Scheme 205

1. Loosen clamp (Scheme 205) and disconnect air duct at air cleaner cover.
2. Pry over 4 spring clips (Scheme 205) from housing cover (spring clips retain cover to housing).
3. Release housing cover from locating tabs on housing (Scheme 205) and remove cover.
4. Remove air cleaner element (filter) from housing.
5. Clean inside of housing before replacing element.

Housing Assembly

1. Loosen clamp (Scheme 205) and disconnect air duct at air cleaner cover.
2. Lift entire housing assembly from 4 locating pins (Scheme 206)

Scheme 206

1. Install filter element into housing.
2. Position housing cover into housing locating tabs (Scheme 205)
3. Pry up 4 spring clips (Scheme 205) and lock cover to housing.
4. Install air duct to air cleaner cover and tighten hose clamp to 3 N.m (30 in. lbs.) torque.
5. If any other hose clamps were removed from air intake system, tighten them to 3.4 N.m (30 in. lbs.) torque.
6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 N.m (40 in. lbs.) torque.

DESCRIPTION - CYLINDER HEAD

The cylinder heads are made of an aluminum alloy. The cylinder head features two valves per cylinder with pressed in powdered metal valve guides. The cylinder heads also provide enclosures for the timing chain drain, necessitating unique left and right cylinder heads.

DESCRIPTION - VALVE GUIDES

The valve guides are made of powered metal and are pressed into the cylinder head. The guides are not replaceable or serviceable, and valve guide reaming is not recommended. If the guides are worn beyond acceptable limits, replace the cylinder heads.

Scheme 207

Scheme 208

Scheme 209

Scheme 210

1. Disconnect the negative cable from the battery.
2. Raise the vehicle on a hoist.
3. Disconnect the exhaust pipe at the left side exhaust manifold.
4. Drain the engine coolant. Refer to «DRAINING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas).
5. Lower the vehicle.
6. Remove the intake manifold (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
7. Remove the master cylinder and booster assembly. Refer to «POWER BRAKE BOOSTER»(/dodge/pickup-r1500/1997-2012/remont/mechanical-hydraulic/#disc-brakes).
8. Remove the cylinder head cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
9. Remove the fan shroud and fan blade assembly (Refer to «FAN DRIVE VISCOUS CLUTCH-GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
10. Remove accessory drive belt (Refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) ).
11. Remove the power steering pump and set aside.
12. Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark (Scheme 207)
13. Verify the V8 mark on the camshaft sprocket is at the 12 o'clock position (Scheme 209) Rotate the crankshaft one turn if necessary.
14. Remove the crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
15. Remove the timing chain cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
16. Lock the secondary timing chains to the idler sprocket using Special Tool 8515 (Scheme 208) NOTE: Mark the secondary timing chain prior to removal to aid in installation.
17. Mark the secondary timing chain, one link on each side of the V8 mark on the camshaft drive gear (Scheme 209)
18. Remove the left side secondary chain tensioner (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
19. Remove the cylinder head access plug (Scheme 210)
20. Remove the left side secondary chain guide (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
21. Remove the retaining bolt and the camshaft drive gear. CAUTION: Do not allow the engine to rotate. Severe damage to the valve train can occur. CAUTION: Do not overlook the four smaller bolts at the front of the cylinder head. Do not attempt to remove the cylinder head without removing these four bolts. NOTE: The cylinder head is attached to the cylinder block with fourteen bolts.
22. Remove the cylinder head retaining bolts.
23. Remove the cylinder head and gasket. Discard the gasket. CAUTION: Do not lay the cylinder head on its gasket sealing surface, due to the design of the cylinder head gasket any distortion to the cylinder head sealing surface may prevent the gasket from properly sealing resulting in leaks.

Scheme 211

Scheme 212

Scheme 213

Scheme 214

1. Disconnect battery negative cable.
2. Raise the vehicle on a hoist.
3. Disconnect the exhaust pipe at the right side exhaust manifold.
4. Drain the engine coolant (Refer to «DRAINING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas) ).
5. Lower the vehicle.
6. Remove the intake manifold (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
7. Remove the cylinder head cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
8. Remove the fan shroud (Refer to «FAN DRIVE VISCOUS CLUTCH-GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
9. Remove oil fill housing from cylinder head.
10. Remove accessory drive belt (Refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) ).
11. Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark (Scheme 211)
12. Verify the V8 mark on the camshaft sprocket is at the 12 o'clock position (Scheme 212) Rotate the crankshaft one turn if necessary.
13. Remove the crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
14. Remove the timing chain cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
15. Lock the secondary timing chains to the idler sprocket using Special Tool 8515 (Scheme 213) NOTE: Mark the secondary timing chain prior to removal to aid in installation.
16. Mark the secondary timing chain, one link on each side of the V8 mark on the camshaft drive gear (Scheme 212)
17. Remove the right side secondary chain ten-sioner (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
18. Remove the cylinder head access plug (Scheme 214)
19. Remove the right side secondary chain guide (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
20. Remove the retaining bolt and the camshaft drive gear. CAUTION: Do not allow the engine to rotate, severe damage to the valve train can occur. CAUTION: Do not overlook the four smaller bolts at the front of the cylinder head. Do not attempt to remove the cylinder head without removing these four bolts. CAUTION: Do not hold or pry on the camshaft target wheel for any reason. A damaged target wheel can result in a vehicle no start condition. NOTE: The cylinder head is attached to the cylinder block with fourteen bolts.
21. Remove the cylinder head retaining bolts.
22. Remove the cylinder head and gasket. Discard the gasket.

CLEANING

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

INSPECTION

1. Inspect the cylinder head for out-of-flatness, using a straightedge and a feeler gauge. If tolerances exceed 0.0508 mm (0.002 in.) replace the cylinder head.
2. Inspect the valves seats for damage. Service the valve seats as necessary.
3. Inspect the valve guides for wear, cracks or looseness. If either condition exist, replace the cylinder head.

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 215

Scheme 216

Scheme 217

Scheme 218

1. Clean the cylinder head and cylinder block mating surfaces (Scheme 216)
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 (Scheme 217) 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.). INDICATES SEALER APPLIED TO THREADS
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»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
10. Install the cylinder head access plug (Scheme 218)
11. Re-set and Install the left side secondary chain tensioner (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
12. Remove Special Tool 8515.
13. Install the timing chain cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
14. Install the crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
15. Install the power steering pump.
16. Install the fan blade assembly and fan shroud (Refer to «FAN DRIVE VISCOUS CLUTCH-GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
17. Install the cylinder head cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
18. Reinstall the master cylinder and booster assembly. Refer to «POWER BRAKE BOOSTER»(/dodge/pickup-r1500/1997-2012/remont/mechanical-hydraulic/#disc-brakes).
19. Install the intake manifold (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
20. Refill the cooling system (Refer to «REFILLING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).
21. Raise the vehicle.
22. Install the exhaust pipe onto the left exhaust manifold.
23. Lower the vehicle.
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 219)

Scheme 219

Scheme 220

Scheme 221

Scheme 222

1. Clean the cylinder head and cylinder block mating surfaces (Scheme 220)
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 (Scheme 221) 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.). DIAMOND IN FIGURE NEXT TO BOLT INDICATES SEALER APPLIED TO THREADS
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»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
10. Install the right side cylinder head access plug (Scheme 222)
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»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
14. Install the crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
15. Install accessory drive belt (Refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) ).
16. Install the fan shroud.
17. Install the cylinder head cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
18. Install the intake manifold (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
19. Install oil fill housing onto cylinder head.
20. Refill the cooling system (Refer to «REFILLING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).
21. Raise the vehicle.
22. Install the exhaust pipe onto the right exhaust manifold.
23. Lower the vehicle.
24. Reconnect battery negative cable.
25. Start the engine and check for leaks.

DESCRIPTION

The camshafts consist of powdered metal steel lobes which are sinter-bonded to a steel tube. A steel post or nose piece is friction-welded to the steel camshaft tube. Five bearing journals are machined into the camshaft, four on the steel tube and one on the steel nose piece. Camshaft end play is controlled by two thrust walls that border the nose piece journal. Engine oil enters the hollow camshafts at the third journal and lubricates every intake lobe rocker through a drilled passage in the intake lobe.

Scheme 223

Scheme 224

1. Remove cylinder head cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
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 (Scheme 223) 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 (Scheme 224)
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 225

Scheme 226

Scheme 227

Scheme 228

Scheme 229

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 (Scheme 225)
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) (Scheme 226) 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 (Scheme 227) 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 (Scheme 228)
10. Using Special Tool 6958 spanner wrench with adapter pins 8346 (Scheme 229), torque the camshaft sprocket retaining bolt to 122 N.m (90 ft. lbs.).
11. Install the cylinder head cover.

The camshafts consist of powdered metal steel lobes which are sinter-bonded to a steel tube. A steel post or nose piece is friction-welded to the steel camshaft tube. Five bearing journals are machined into the camshaft, four on the steel tube and one on the steel nose piece. Camshaft end play is controlled by two thrust walls that border the nose piece journal. Engine oil enters the hollow camshafts at the third journal and lubricates every intake lobe rocker through a drilled passage in the intake lobe.

Scheme 230

Scheme 231

Scheme 232

1. Remove the cylinder head covers (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
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 (Scheme 230)
6. Remove the camshaft position sensor (Scheme 231) 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 (Scheme 232)
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 233

Scheme 234

Scheme 235

Scheme 236

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 (Scheme 233)
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) (Scheme 234) 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 (Scheme 235) CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt overtorque 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 (Scheme 230)
10. Using Special Tool 6958 spanner wrench with adapter pins 8346 (Scheme 236), torque the camshaft sprocket retaining bolt to 122 N.m (90 ft. lbs.).
11. Install the camshaft position sensor (Scheme 231)
12. Install the cylinder head cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).

The cylinder head covers are made of injection molded thermo-set plastic, and are not interchangeable from side-to-side. It is imperative that nothing rest on the cylinder head covers. Prolonged contact with other items may wear a hole in the cylinder head cover.

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 GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas) ).
4. Remove accessory drive belt (Refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) ).
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.

Clean cylinder head cover gasket surface. Clean head rail, if necessary.

INSTALLATION - RIGHT 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 double ended studs are in the correct location shown in (Scheme 237)
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 «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) ).
11. Fill Cooling system (Refer to «REFILLING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).
12. Install air cleaner assembly, resonator assembly and air inlet hose.
13. Connect battery negative cable.

INSTALLATION - LEFT SIDE

Scheme 238

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 (Scheme 238)
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.

The valves are made of heat resistant steel and have chrome plated stems to prevent scuffing. Each valve is actuated by a roller rocker arm which pivots on a stationary lash adjuster. All valves use three bead lock keepers to retain the springs and promote valve rotation.

Note. The cylinder heads must be removed in order to perform this procedure.

Scheme 239

1. Remove rocker arms and lash adjusters (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ). (Scheme 239)
2. Remove the camshaft bearing caps and the camshaft. NOTE: All six valve springs and valves are removed in the same manner; this procedure only covers one valve and valve spring.
3. Using Special Tool C-3422-B or C-3422-C Valve Spring Compressor and Special tool 8519 Adapter, compress the valve spring. NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
4. Remove the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
5. Remove the valve spring compressor.
6. Remove the spring retainer, and the spring. NOTE: Check for sharp edges on the keeper grooves. Remove any burrs from the valve stem before removing the valve from the cylinder head.
7. Remove the valve from the cylinder head. NOTE: The valve stem seals are common between intake and exhaust.
8. Remove the valve stem seal. Mark the valve for proper installation.

TESTING VALVE SPRINGS

Note. Whenever the valves are removed from the cylinder head it is recommended that the valve springs be inspected and tested for reuse.

Inspect the valve springs for physical signs of wear or damage. Turn table of tool C-647 until surface is in line with the 40.12 mm (1.579 in.) mark on the threaded stud and the zero mark on the front. Place spring over the stud on the table and lift compressing lever to set tone device. Pull on torque wrench until a Ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to SPECIFICATIONS to obtain specified height and allowable tensions. Replace any springs that do not meet specifications (Scheme 240)

Scheme 240

Scheme 241

Scheme 242

1. coat the valve stem with clean engine oil and insert it into the cylinder head.
2. Install the valve stem seal, make sure the seal is fully seated and that the garter spring at the top of the seal is intact.
3. Install the spring and the spring retainer (Scheme 241)
4. Using the valve spring compressor, compress the spring and install the two valve spring retainer halves.
5. Release the valve spring compressor and make sure the two spring retainer halves and the spring retainer are fully seated.
6. lubricate the camshaft journal with clean engine oil then Position the camshaft (with the sprocket dowel on the left camshaft at 11 o'clock and the right camshaft at 12 o'clock), then position the camshaft bearing caps.
7. Install the camshaft bearing cap retaining bolts. Tighten the bolts 9 - 13 N.m (100 in. lbs.) in 1/2 turn increments in the sequence shown (Scheme 242)
8. Position the hydraulic lash adjusters and rocker arms.

The rocker arms are steel stampings with an integral roller bearing. The rocker arms incorporate a 2.8 mm (0.11 inch) oil hole in the lash adjuster socket for roller and camshaft lubrication.

DIAGNOSIS AND TESTING -HYDRAULIC LASH ADJUSTER

A tappet-like noise may be produced from several items. Check the following items.

1. Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy.
2. Insufficient running time after rebuilding cylinder head. Low speed running up to 1 hour may be required.
3. Turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature.
4. Low oil pressure.
5. The oil restrictor in cylinder head gasket or the oil passage to the cylinder head is plugged with debris.
6. Air ingested into oil due to broken or cracked oil pump pick up.
7. Worn valve guides.
8. Rocker arm ears contacting valve spring retainer.
9. Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system.
10. Oil leak or excessive cam bore wear in cylinder head.
11. Faulty lash adjuster. Check lash adjusters for sponginess while installed in cylinder head and cam on camshaft at base circle. Depress part of rocker arm over adjuster. Normal adjusters should feel very firm. Spongy adjusters can be bottomed out easily. Remove suspected lash adjusters, and replace. Before installation, make sure adjusters are at least partially full of oil. This can be verified by little or no plunger travel when lash adjuster is depressed.

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

1. Remove the cylinder head cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
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 (Scheme 243)

INSTALLATION

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

Scheme 243

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 (Scheme 243)
6. Install the cylinder head cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).

The valve springs are made from high strength chrome silicon steel. The springs are common for intake and exhaust applications. The valve spring seat is integral with the valve stem seal, which is a positive type seal to control lubrication.

Scheme 244

1. Remove the cylinder head cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
2. Using Special Tool 8516 Rocker Arm Remover, remove the rocker arms and the hydraulic lash adjusters (Scheme 244)
3. Remove the spark plug for the cylinder the valve spring and seal are to be removed from.
4. Apply shop air to the cylinder to hold the valves in place when the spring is removed NOTE: All eight valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.
5. Using Special Tool 8387 Valve Spring Compressor, compress the valve spring. NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
6. Remove the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
7. Remove the valve spring compressor.
8. Remove the spring retainer, and the spring.
9. Remove the valve stem seal.

Note. The valve stem seals are common between intake and exhaust.

Scheme 245

1. Coat the valve stem with clean engine oil and install the valve stem seal. Make sure the seal is fully seated and that the garter spring at the top of the seal is intact.
2. Install the spring and the spring retainer (Scheme 245)
3. Using Special Tool 8387 Valve Spring Compressor, compress the spring and install the two valve spring retainer halves.
4. Release the valve spring compressor and make sure the two spring retainer halves and the spring retainer are fully seated.
5. Position the hydraulic lash adjusters and rocker arms (Scheme 244)
6. Install the cylinder head cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).

The valve stem seals are made of rubber and incorporate an integral steel valve spring seat. The integral garter spring maintains consistent lubrication control to the valve stems.

The cylinder block is made of cast iron. The block is a closed deck design with the left bank forward. To provide high rigidity and improved NVH an enhanced compacted graphite bedplate is bolted to the block. The block design allows coolant flow between the cylinders bores, and an internal coolant bypass to a single poppet inlet thermostat is included in the cast aluminum front cover.

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 246

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 (Scheme 246)
4. A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper crosshatch 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 cross-hatch 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, lintfree 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 1/4 inch NPT plugs to 20 N.m (177 in. lbs.) torque. Tighten the 3/8 inch NPT plugs to 27 N.m (240 in. lbs.) torque.

Scheme 247

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 (Scheme 247)
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 (Scheme 248) Check the bearings for normal wear patterns, scoring, grooving, fatigue and pitting (Scheme 249) Replace any bearing that shows abnormal wear.

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

Scheme 248

Scheme 249

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 250

Scheme 251

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 (Scheme 250) 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 (Scheme 251) Refer to Engine Specifications 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, determin which services bearing set to use the bearing sizes are as follows: SIZE SPECIFICATION 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.
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 (Scheme 252) Refer to Engine Specifications for the proper clearance. Replace the connecting rod if the side clearance is not within specification.

Scheme 252

1. Drain the cooling system (Refer to «DRAINING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas) ).
2. Using a blunt tool such as a drift or a screw driver and a hammer, strike the bottom edge of the cup plug (Scheme 253)
3. Using a suitable pair of pliers, grasp the core plug and remove.

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

Scheme 253

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 - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).

The crankshaft is constructed of nodular cast iron. The crankshaft is a crosshaped four throw design with eight counterweights for balancing purposes. The crankshaft is supported by five select fit main bearings with the number three serving as the thrust washer location. The main journals of the crankshaft are cross drilled to improve rod bearing lubrication. The number eight counterweight has provisions for crankshaft position sensor target wheel mounting. The select fit main bearing markings are located on the rear side of the target wheel. The crankshaft oil seals are one piece design. The front oil seal is retained in the timing chain cover, and the rear seal is pressed in to a bore formed by the cylinder block and the bedplate assembly.

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

Scheme 254

1. Remove the engine. (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul__removal) ).
2. Remove the engine oil pump.(Refer to «PUMP-ENGINE OIL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ). 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»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
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 (Scheme 254) 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.

Note. Thoroughly inspect the connecting rod bearing bores and main bearing bores for scoring, blueing or severe scratches. Further disassembly may be required.

If connecting rod bearing bores show damage, the cylinder heads must be removed to service the piston and rod assemblies. If the bedplate or the cylinder block main bearing bores show damage the engine must be replaced.

1. If required, remove the main bearing halves from the cylinder block and bedplate.
2. Thoroughly clean the bedplate to cylinder block sealing surfaces and main bearing bores. Remove all oil and sealant residue.
3. Inspect the bedplate main bearing bores for cracks, scoring or severe blueing. If either condition exists the engine must be replaced.
4. Inspect the crankshaft thrust washers for scoring, scratches, wear or blueing. If either condition exist replace the thrust washer.
5. Inspect the oil pan gasket/windage tray for splits, tears or cracks in the gasket sealing surfaces. Replace gasket as necessary.

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

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 (Scheme 255) CAUTION: The bedplate to cylinder block mateing 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) (Scheme 256) bead of Mopar® Gen II Silicone Rubber Adhesive sealant to the cylinder block-to-bedplate mating surface as shown (Scheme 257)
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 (Scheme 258) 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 - CRANKSHAFT MAIN BEARING - FITTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
9. Install the connecting rods and measure side clearance. (Refer to «STANDARD PROCEDURE»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul__standard-procedure-connecting-rod-bearing) ).
10. Position the oil pan gasket/windage tray, using a new o-ring, install the oil pickup tube. Torque the bolt to 28 N.m (20 ft. lbs.) torque the nuts to 28N.m (20 ft. lbs.).
11. Install the oil pan. Torque the retaining bolts to 15 N.m (11 ft. lbs.) in the sequence shown (Scheme 259)
12. Install the engine (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul__installation) ).

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 SELECTION CHART - 4.7L ). 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 (Scheme 260) 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 260

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

Wipe the inserts clean and inspect for abnormal wear patterns and for metal or other foreign material imbedded in the lining. Normal main bearing insert wear patterns are illustrated (Scheme 261)

Scheme 261

Note. If any of the crankshaft journals are scored, the crankshaft must be repaired or replaced.

Inspect the back of the inserts for fractures, scrapings or irregular wear patterns.

Inspect the upper insert locking tabs for damage. Replace all damaged or worn bearing inserts.

Scheme 262

Scheme 263

1. Disconnect negative cable from battery.
2. Remove accessory drive belt (Refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) ).
3. Remove A/C compressor mouning fasteners and set aside.
4. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas) ).
5. Remove upper radiator hose.
6. Disconnect electrical connector for fan mounted inside radiator shroud.
7. Remove radiator shroud attaching fasteners. NOTE: Transmission cooler line snaps into shroud lower right hand corner.
8. Remove radiator cooling fan and shroud (Refer to «FAN DRIVE VISCOUS CLUTCH-GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
9. Remove crankshaft damper bolt.
10. Remove damper using Special Tools 8513 Insert and 1026 Three Jaw Puller (Scheme 262)
11. Using Special Tool 8511, remove crankshaft front seal (Scheme 263)

Scheme 264

1. Using Special Tool 8348 and 8512, install crankshaft front seal (Scheme 264)
2. Install vibration damper (Refer to «DAMPER-CRANKSHAFT»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
3. Install radiator cooling fan and shroud (Refer to «FAN DRIVE VISCOUS CLUTCH-GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
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 «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) ).
7. Refill cooling system (Refer to «REFILLING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).
8. Connect negative cable to battery.

DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS

Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.

If the leakage occurs at the crankshaft rear oil seal area

1. Disconnect the battery.
2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak: Circular spray pattern generally indicates seal leakage or crankshaft damage. Where leakage tends to run straight down, possible causes are a porous block, camshaft bore cup plugs, oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. See appropriate section for proper repair procedures of these items.
4. If no leaks are detected, pressurized the crank-case as outlined in the CAUTION: Do not exceed 20.6 kPa (3 psi).
5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks or scratches. The crankshaft seal flange is specially machined to complement the function of the rear oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. (Refer to «DIAGNOSIS AND TESTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ), under the , for components inspections on possible causes and corrections.
7. After the oil leak root cause and appropriate corrective action have been identified, (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).

Note. This procedure can be performed in vehicle.

Scheme 265

1. If being performed in vehicle, remove the transmission.
2. Remove the flexplate (Refer to «PLATE-TORQUE CONVERTER DRIVE»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ). 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 (Scheme 265), remove the crankshaft rear oil seal.

Scheme 266

Scheme 267

1. Lubricate the crankshaft flange with engine oil.
2. Position the magnetic seal guide Special Tool 8349-2 (Scheme 266) 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 (Scheme 267), 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. (Refer to «OVERHAUL - 45 RFE/545RFE»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#overhaul-45-rfe545rfe-automatic-transmission) ).
2. Remove the bolts and flexplate.

Scheme 268

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 (Scheme 268)
3. Install the transmission. (Refer to «OVERHAUL - 45 RFE/545RFE»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#overhaul-45-rfe545rfe-automatic-transmission) ).

The pistons are made of a high strength aluminum alloy. The anodized top ring groove and crown has been replaced with a coated top ring that is blue in color on the bottom surface. Piston skirts are coated with a solid lubricant (Molykote) to reduce friction and provide scuff resistance. The connecting rods are made of forged powdered metal, with a "fractured cap" design. A pressed fit piston pin is used to attach the piston and connecting rod.

Scheme 269

Scheme 270

1. 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 a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B (Scheme 270)
3. The coated pistons will be serviced with the piston pin and connecting rod pre-assembled.
4. The coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston will not provide accurate results (Scheme 269) Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY. To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (.0001 in.) increments is required.
5. Piston installation into the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.

Scheme 271

1. Disconnect negative cable from battery.
2. Remove the following components: Oil pan and gasket/windage tray (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ) Cylinder head covers (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ) and (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ). Timing chain cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ). Cylinder head(s) (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ) and (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool (Scheme 271) CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
5. Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur
6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
7. Carefully remove piston rings from piston(s), starting from the top ring down.

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.

Check the connecting rod journal for excessive wear, taper and scoring (Refer to STANDARD PROCEDURE ).

Check the connecting rod for signs of twist or bending.

Check the piston for taper and elliptical shape before it is fitted into the cylinder bore (Refer to STANDARD PROCEDURE ).

Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration.

Scheme 272

Scheme 273

1. Before installing piston and connecting rod assemblies into the bore, install the piston rings.
2. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation.
3. Position bearing onto connecting rod. Ensure that hole in bearing shell aligns with hole in connecting rod. Lubricate bearing surface with clean engine oil.
4. Install Special Tool 8507 Connecting Rod Guides into connecting rod bolt threads (Scheme 272)
5. The pistons are marked on the piston pin bore surface with an raised "F" indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks. The connecting rod oil slinger slot faces the front of the engine (Scheme 273)
6. Wipe cylinder bore clean and lubricate with engine oil.
7. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal.
8. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal. 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.
9. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 27 N.m (20 ft. lbs.) plus 90°.
10. Install the following components: Cylinder head(s). (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ). Timing chain and cover. (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ). Cylinder head covers (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ). Oil pan and gasket/windage tray. (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
11. Fill crankcase with proper engine oil to correct level.
12. Connect negative cable to battery.

STANDARD PROCEDURE - PISTON RING FITTING

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

Scheme 274

Scheme 275

Scheme 276

Scheme 277

Scheme 278

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 (Scheme 274) 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 (Scheme 275) 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 ID. 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 (Scheme 276) 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 (Scheme 277)
11. Install No. 1 upper piston ring using a piston ring installer (Scheme 277)
12. Position piston ring end gaps as shown in (Scheme 278) 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 279

1. Disconnect negative cable from battery.
2. Remove accessory drive belt (Refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) ).
3. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas) ).
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 (Scheme 279)
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 (Scheme 280)

Scheme 280

Scheme 281

Scheme 282

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 (Scheme 281) 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 (Scheme 282)
4. Install then tighten crankshaft damper bolt to 175 N.m (130 ft. lbs.).
5. Install fan blade assembly (Refer to «FAN DRIVE VISCOUS CLUTCH-GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
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 «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) ).
10. Refill cooling system (Refer to «REFILLING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).
11. Connect negative cable to battery.

The structural dust cover is made of die cast aluminum and joins the lower half of the transmission bell housing to the engine bedplate.

OPERATION

The structural cover provides additional power-train stiffness and reduces noise and vibration.

Scheme 283

1. Raise vehicle on hoist.
2. Remove the left hand exhaust pipe from exhaust manifold.
3. Loosen the right hand exhaust manifold-to-exhaust pipe retaining bolts.
4. Remove the eight bolts retaining structural cover (Scheme 283) in the sequence shown.
5. Pivot the exhaust pipe downward and remove the structural cover.

Scheme 284

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) (Scheme 284) to 54 N.m (40 ft. lbs.), then tighten bolts (2) (Scheme 284) 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.)

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 DRIVE VISCOUS CLUTCH-GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) )
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 285

Scheme 286

Scheme 287

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 (Scheme 285)
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 (Scheme 287) and right (Scheme 286) 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 DRIVE VISCOUS CLUTCH-GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
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 288

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 (Scheme 288)
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 DRIVE VISCOUS CLUTCH-GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
15. Reconnect the negative battery cable.

Scheme 289

1. Raise the vehicle on a hoist.
2. Using a suitable jack, support transmission.
3. Remove the nuts from the transmission mount (Scheme 289)
4. Remove the two bolts that attach the transmission mount to the engine bracket.
5. Raise the transmission enough to remove the mount from the crossmember.
6. Remove the mount.

Note. Threadlocking compound must be applied to the bolts before installation.

1. Install the two bolts that attach the transmission mount to the transmission bracket.
2. Torque the bolts to 61N.m (45 ft.lbs.) torque.
3. Lower the transmission so the transmission mount rests on the crossmember, and the studs of the transmission mount are aligned in the slots in the crossmember.
4. Install the nuts onto the transmission mount studs through the crossmember access slot.
5. Torque the nuts to 54N.m (40 ft. lbs.).

The lubrication system (Scheme 290) is a full flow filtration pressure feed type.

Scheme 290

Oil from the oil pan is pumped by a gerotor type oil pump directly mounted to the crankshaft nose. Oil pressure is controlled by a relief valve mounted inside the oil pump housing. For lubrication flow (Scheme 290)

The camshaft exhaust valve lobes and rocker arms are lubricated through a small hole in the rocker arm; oil flows through the lash adjuster then through the rocker arm and onto the camshaft lobe. Due to the orentation of the rocker arm, the camshaft intake lobes are not lubed in the same manner as the exhaust lobes. The intake lobes are lubed through internal passages in the camshaft. Oil flows through a bore in the number 3 camshaft bearing bore, and as the camshaft turns, a hole in the camshaft aligns with the hole in the camshaft bore allowing engine oil to enter the camshaft tube. The oil then exits through 1.6mm (0.063 in.) holes drilled into the intake lobes, lubricating the lobes and the rocker arms.

ENGINE LUBRICATION FLOW CHART-BLOCK: TABLE 1

ENGINE LUBRICATION FLOW CHART-BLOCK

ENGINE LUBRICATION FLOW CHART-CYLINDER HEADS: TABLE 2

ENGINE LUBRICATION FLOW CHART-CYLINDER HEADS

Scheme 291

1. Remove oil pressure sending unit (Scheme 291)and install gauge assembly C-3292.
2. Run engine until thermostat opens.
3. Oil Pressure: Curb Idle - 25 kPa (4 psi) minimum 3000 rpm - 170 - 758 kPa (25 - 110 psi)
4. If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck open.

DIAGNOSIS AND TESTING - ENGINE OIL LEAK

Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed

1. Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak.
2. Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light.
3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair per service manual instructions.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspection.If the oil leak source is not positively identified at this time, proceed with the air leak detection test method.

Air Leak Detection Test Method

1. Disconnect the breather cap to air cleaner hose at the breather cap end. Cap or plug breather cap nipple.
2. Remove the PCV valve from the cylinder head cover. Cap or plug the PCV valve grommet.
3. Attach an air hose with pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.
4. Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual procedures.
5. If the leakage occurs at the rear oil seal area, refer to «INSPECTION FOR REAR SEAL AREA LEAK»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul__inspection-for-rear-seal-area-leaks) .
6. If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve and breather cap hose.
7. Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.

INSPECTION FOR REAR SEAL AREA LEAKS

Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.

If the leakage occurs at the crankshaft rear oil seal area

1. Disconnect the battery.
2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak: Circular spray pattern generally indicates seal leakage or crankshaft damage. Where leakage tends to run straight down, possible causes are a porous block, distributor seal, camshaft bore cup plugs oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces.
4. If no leaks are detected, pressurize the crankcase as outlined in the, Inspection (Engine oil Leaks in general) CAUTION: Do not exceed 20.6 kPa (3 psi).
5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled.

STANDARD PROCEDURE - ENGINE OIL SERVICE

The engine oil level indicator (2) is located at the right rear of the engine on the 4.7L engines (Scheme 292)

Scheme 292

CRANKCASE OIL LEVEL INSPECTION

Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about five minutes before checking oil level. Checking engine oil level on a cold engine is not accurate.

To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick.

1. Position vehicle on level surface.
2. With engine OFF, allow approximately ten minutes for oil to settle to bottom of crankcase, remove engine oil dipstick.
3. Wipe dipstick clean.
4. Install dipstick and verify it is seated in the tube.
5. Remove dipstick, with handle held above the tip, take oil level reading.
6. Add oil only if level is below the ADD mark on dipstick.

ENGINE OIL CHANGE

Change engine oil at mileage and time intervals described in owner's manual.

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.

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

Scheme 293

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.

1. Position a drain pan under the oil filter.
2. Using a suitable oil filter wrench loosen filter.
3. Rotate the oil filter counterclockwise (Scheme 293)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 294

1. Lightly lubricate oil filter gasket with engine oil.
2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Scheme 294) 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. Disconnect the negative battery cable.
2. Install engine support fixture special tool # 8534. Do not raise engine at this time.
3. Loosen both left and right side engine mount through bolts. Do not remove bolts.
4. Remove the structural dust cover, if equipped.
5. Drain engine oil.
6. Remove the front crossmember (Refer to «FRONT CROSSMEMBER»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#frames-bumpers) ). CAUTION: Only raise the engine enough to provide clearance for oil pan removal. Check for proper clearance at fan shroud to fan and cowl to intake manifold.
7. 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.
8. Remove the oil pan mounting bolts and oil pan.
9. Unbolt oil pump pickup tube and remove tube.
10. Inspect the integral windage tray and gasket and replace as needed.

Scheme 295

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 (Scheme 295)
4. Lower the engine into mounts using special tool # 8534.
5. Install both the left and right side engine mount through bolts. Tighten the nuts to 68 N.m (50 ft. lbs.).
6. Remove special tool # 8534.
7. Install structural dust cover, if equipped.
8. Install the front crossmember (Refer to «FRONT CROSSMEMBER»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#frames-bumpers) ).
9. Fill engine oil.
10. Reconnect the negative battery cable.
11. Start engine and check for leaks.

The 3 wire, solid-state engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery.

The 3-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery.

The oil pressure sensor uses three circuits. They are

1. A 5 volt power supply from the Powertrain Control Module (PCM)
2. A sensor ground through the PCM's sensor return
3. A signal to the PCM relating to engine oil pressure

The oil pressure sensor has a 3 wire electrical function very much like the Manifold Absolute Pressure (MAP) sensor. Meaning different pressures relate to different output voltages.

A 5 volt supply is sent to the sensor from the PCM to power up the sensor. The sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on either a CCD or PCI bus circuit (depending on vehicle line) to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low-noise sensor return.

The oil pressure sensor uses two circuits. They are

1. A signal to the PCM relating to engine oil pressure
2. A sensor ground through the PCM's sensor return

The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low-noise sensor return.

Scheme 296

1. Disconnect the negative cable from the battery.
2. Raise vehicle on hoist.
3. Remove front splash shield.
4. Disconnect oil pressure sender wire (Scheme 296)
5. Remove the pressure sender (Scheme 296)

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»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
2. Remove the timing chain cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
3. Remove the timing chains and tensioners (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
4. Remove the four bolts, primary timing chain tensioner and the oil pump.

DISASSEMBLY

1. Remove oil pump cover screws and lift off cover plate.
2. Remove pump inner and outer rotors. NOTE: Once the oil pressure relief valve, cup plug, and pin are removed, the pump assembly must be replaced.
3. If it is necessary to remove the pressure relief valve, drive the roll pin from pump housing and remove cup plug, spring and valve.

1. Wash all parts in a suitable solvent.

Scheme 297

Scheme 298

Scheme 299

Scheme 300

Scheme 301

Scheme 302

1. Clean all parts thoroughly. Mating surface of the oil pump housing should be smooth. If the pump cover is scratched or grooved the oil pump assembly should be replaced.
2. Lay a straight edge across the pump cover surface (Scheme 297) If a 0.025 mm (0.001 in.) feeler gauge can be inserted between the cover and the straight edge the oil pump assembly should be replaced.
3. Measure the thickness of the outer rotor (Scheme 298) If the outer rotor thickness measures at 12.005 mm (0.472 in.) or less the oil pump assembly must be replaced.
4. Measure the diameter of the outer rotor. If the outer rotor diameter measures at 85.925 mm (3.382 in.) or less the oil pump assembly must be replaced.
5. Measure the thickness of the inner rotor (Scheme 299) If the inner rotor thickness measures at 12.005 mm (0.472 in.) or less then the oil pump assembly must be replaced.
6. Slide outer rotor into the body of the oil pump. Press the outer rotor to one side of the oil pump body and measure clearance between the outer rotor and the body (Scheme 300) If the measurement is 0.235mm (0.009 in.) or more the oil pump assembly must be replaced.
7. Install the inner rotor in the into the oil pump body. Measure the clearance between the inner and outer rotors (Scheme 301) If the clearance between the rotors is.150 mm (0.006 in.) or more the oil pump assembly must be replaced.
8. Place a straight edge across the body of the oil pump (between the bolt holes), if a feeler gauge of.095 mm (0.0038 in.) or greater can be inserted between the straightedge and the rotors, the pump must be replaced (Scheme 302) NOTE: The 4.7 Oil pump is released as an assembly. There are no DaimlerChrysler part numbers for Sub-Assembly components. In the event the oil pump is not functioning or out of specification It must be replaced as an assembly.

ASSEMBLY

1. Wash all parts in a suitable solvent and inspect carefully for damage or wear.
2. Install inner and outer rotors
3. Install oil pump cover plate and install cover bolts and tighten them to 12 N.m (105 in. lbs.).
4. Prime oil pump before installation by filling rotor cavity with engine oil
5. If oil pressure is low and pump is within specifications, inspect for worn engine bearings or other causes for oil pressure loss.

Scheme 303

1. Position the oil pump onto the crankshaft and install one oil pump retaining bolts.
2. Position the primary timing chain tensioner md install three retaining bolts.
3. Tighten the oil pump and primary timing chain ensioner retaining bolts to 28 N.m (250 in. lbs.) in he sequence shown (Scheme 303)
4. Install the secondary timing chain tensioners md timing chains (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
5. Install the timing chain cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
6. Install the pick-up tube and oil pan (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).

The intake manifold is made of a composite material and features long runners which maximizes low end torque. The intake manifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent leaks. Eight studs and two bolts are used to fasten the intake to the head.

DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKAGE

An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.

1. Start the engine.
2. Spray a small stream of water at the suspected leak area.
3. If a change in RPM is observed the area of the suspected leak has been found.
4. Repair as required.

Scheme 304

1. Disconnect negative cable from battery.
2. Remove resonator assembly and air inlet hose.
3. Disconnect throttle and speed control cables.
4. Disconnect electrical connectors for the following components: Manifold Absolute Pressure (MAP) Sensor Intake Air Temperature (IAT) Sensor Throttle Position (TPS) Sensor Coolant Temperature (CTS) Sensor Idle Air Control (IAC) Motor
5. Disconnect brake booster hose and positive crankcase ventilation (PCV) hose.
6. Disconnect generator electrical connections.
7. Disconnect air conditioning compressor electrical connections.
8. Disconnect left and right radio suppressor straps.
9. Disconnect and remove ignition coil towers (Refer to «IGNITION COIL»(/dodge/pickup-r1500/1997-2012/remont/ignition-system/#ignition-control) )
10. Remove top oil dipstick tube retaining bolt and ground strap.
11. Bleed fuel system (Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE REL»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine__standard-procedure-fuel-system-pressure) ).
12. Remove fuel rail (Refer to «FUEL RAIL»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine) ).
13. Remove throttle body assembly and mounting bracket.
14. Drain cooling system below coolant temperature level (Refer to «DRAINING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas) ).
15. Remove the heater hoses from the engine front cover and the heater core.
16. Unclip and remove heater hoses and tubes from intake manifold (Scheme 304)
17. Remove coolant temperature sensor (Refer to «ENGINE COOLANT TEMPERATURE SENSOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
18. Remove intake manifold retaining fasteners in reverse order of tightening sequence (Scheme 305)
19. Remove intake manifold.

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. Inspect the intake sealing surface for cracks, nicks and distortion.
2. Inspect the intake manifold vacuum hose fittings for looseness or blockage.
3. Inspect the manifold to throttle body mating surface for cracks, nicks and distortion.

Scheme 305

1. Install intake manifold gaskets.
2. Position intake manifold.
3. Install intake manifold retaining bolts and tighten in sequence shown in (Scheme 305) to 12 N.m (105 in. lbs.).
4. Install left and right radio suppressor straps.
5. Install throttle body assembly.
6. Install throttle cable bracket.
7. Connect throttle cable and speed control cable to throttle body.
8. Install fuel rail (Refer to «FUEL RAIL»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine) ).
9. Install ignition coil towers (Refer to «IGNITION COIL»(/dodge/pickup-r1500/1997-2012/remont/ignition-system/#ignition-control) ).
10. Position and install heater hoses and tubes onto intake manifold.
11. Install the heater hoses to the heater core and engine front cover.
12. Connect electrical connectors for the following components: Manifold Absolute Pressure (MAP) Sensor Intake Air Temperature (IAT) Sensor Throttle Position (TPS) Sensor Coolant Temperature (CTS) Sensor Idle Air Control (IAC) Motor Ignition coil towers Fuel injectors
13. Install top oil dipstick tube retaining bolt and ground strap.
14. Connect generator electrical connections.
15. Connect Brake booster hose and Positive crankcase ventilation (PCV) hose.
16. Fill cooling system (Refer to «REFILLING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).
17. Install resonator assembly and air inlet hose.
18. Connect negative cable to battery.

The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold.

RIGHT EXHAUST MANIFOLD

1. Disconnect negative cable for battery.
2. Remove air cleaner assembly, resonator assembly and air inlet hose.
3. Remove accessory drive belt (Refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) ).
4. Remove A/C compressor (Refer to «A/C COMPRESSOR»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing__ac-compressor) ).
5. Remove A/C accumulator support bracket fastener
6. Drain coolant below heater hose level (Refer to «DRAINING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas) ).
7. Remove heater hoses at engine.
8. Remove fasteners attaching exhaust manifold heat shield.
9. Remove heat shield.
10. Remove upper exhaust manifold attaching fasteners.
11. Raise vehicle on hoist.
12. Disconnect exhaust pipe from manifold.
13. Remove fasteners attaching starter. Move starter aside.
14. Remove lower exhaust manifold attaching fasteners.
15. Remove exhaust manifold and gasket (Scheme 306) Manifold is removed from below the engine compartment.

Scheme 306

Scheme 307

1. Disconnect negative cable for battery.
2. Hoist vehicle.
3. Disconnect exhaust pipe at manifold.
4. Lower vehicle.
5. Remove the front two exhaust heat shield retaining fasteners. Raise vehicle and remove the fasteners at rear of heat shield.
6. Remove heat shield (Scheme 307)
7. Lower vehicle and remove the upper exhaust manifold retaining bolts (Scheme 307)
8. Raise vehicle and remove the lower exhaust manifold retaining bolts (Scheme 307)
9. Remove exhaust manifold and gasket (Scheme 307) Manifold is removed from below the engine compartment.

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.

1. Inspect the exhaust manifold for cracks in the mating surface and at every mounting bolt hole.
2. Using a straight edge and a feeler gauge, check the mating surface for warp and twist.
3. Inspect the manifold to exhaust pipe mating surface for cracks, gouges, or other damage that would prevent sealing.

Scheme 308

1. Install exhaust manifold and gasket (Scheme 308) 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 «SPECIFICATIONS & DRIVE BELT ROUTING»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing) ).
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 - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).

Scheme 309

1. Install exhaust manifold and gasket from below engine compartment.
2. Install lower exhaust manifold fasteners (Scheme 309) DO NOT tighten until all fasteners are in place.
3. Lower vehicle and install upper exhaust manifold fasteners (Scheme 309) 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 (Scheme 309) 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.

DESCRIPTION-TIMING DRIVE SYSTEM

The timing drive system (Scheme 310) 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.

OPERATION - TIMING DRIVE SYSTEM

The primary timing chain is a single inverted tooth type. The primary chain drives the large fifty tooth idler sprocket directly from a 25 tooth crankshaft sprocket. Primary chain motion is controlled by a pivoting leaf spring tensioner arm and a fixed guide. The arm and the guide both use nylon plastic wear faces for low friction and long wear. The primary chain receives oil splash lubrication from the secondary chain drive and oil pump leakage. The idler sprocket assembly connects the primary and secondary chain drives. The idler sprocket assembly consists of two integral thirty tooth sprockets and a fifty tooth sprocket that is splined to the assembly. The spline joint is a non - serviceable press fit anti rattle type. The idler sprocket assembly spins on a stationary idler shaft. The idler shaft is press-fit into the cylinder block. A large washer on the idler shaft bolt and the rear flange of the idler shaft are used to control sprocket thrust movement. Pressurized oil is routed through the center of the idler shaft to provide lubrication for the two bushings used in the idler sprocket assembly.

There are two secondary drive chains, both are inverted tooth type, one to drive the camshaft in each SOHC cylinder head. There are no shaft speed changes in the secondary chain drive system. Each secondary chain drives a thirty tooth cam sprocket directly from the thirty tooth sprocket on the idler sprocket assembly. A fixed chain guide and a hydraulic oil damped tensioner are used to maintain tension in each secondary chain system. The hydraulic tensioners for the secondary chain systems are fed pressurized oil from oil reservoir pockets in the block. Each tensioner also has a mechanical ratchet system that limits chain slack if the tensioner piston bleeds down after engine shut down. The tensioner arms and guides also utilize nylon wear faces for low friction and long wear. The secondary timing chains receive lubrication from a small orifice in the tensioners. This orifice is protected from clogging by a fine mesh screen which is located on the back of the hydraulic tensioners.

Scheme 310

STANDARD PROCEDURE - MEASURING TIMING CHAIN WEAR

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

Scheme 311

1. Remove the timing chain cover. (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
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 (Scheme 311) 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»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).

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 312

Scheme 313

1. Remove the cylinder head covers (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
2. Using a mirror, locate the TDC arrow on the front cover (Scheme 312) 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 (Scheme 313) 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 «TIMING CHAIN AND SPROCKETS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul).
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»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul__single-camshaft-timing).
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 314

Scheme 315

Scheme 316

Scheme 317

1. Using Chain Tensioner Wedge, special tool 8350, stabilize the secondary chain drive (Scheme 314) For reference purposes, mark the chain-to-sprocket position (Scheme 314)
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 (Scheme 315) 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.) (Scheme 316) (Scheme 317)
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»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).

Scheme 318

Scheme 319

1. Disconnect the battery negative cable.
2. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas) ).
3. Disconnect both heater hoses at timing cover.
4. Disconnect lower radiator hose at engine.
5. Remove crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
6. Remove accessory drive belt tensioner assembly (Scheme 318)
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. (Scheme 319)
9. Remove cover (Scheme 319)

Scheme 320

Scheme 321

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 (Scheme 320)
4. Install cover. Tighten flange head fasteners in sequence as shown in (Scheme 321) to 58 N.m (43 ft. lbs.).
5. Install the A/C compressor and generator.
6. Install crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
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 - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).
11. Connect the battery negative cable.

Scheme 322

Scheme 323

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

1. Disconnect negative cable from battery.
2. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas) ).
3. Remove right and left cylinder head covers (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
4. Remove radiator fan shroud.
5. Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover (Scheme 322) (#1 cylinder exhaust stroke) and the camshaft sprocket "V8" marks are at the 12 o'clock position (Scheme 323)
6. Remove power steering pump (Refer to «PUMP»(/dodge/pickup-r1500/1997-2012/remont/manual-power-steering/#power-steering-system) ).
7. Remove access plugs (2) from left and right cylinder heads for access to chain guide fasteners (Scheme 324)
8. Remove the oil fill housing to gain access to the right side tensioner arm fastener.
9. Remove crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ) and timing chain cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
10. Collapse and pin primary chain tensioner (Scheme 325) 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 (Scheme 326) 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, (Scheme 327) 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, (Scheme 328) 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.

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 329)

Scheme 329

Scheme 330

Scheme 331

Scheme 332

Scheme 333

Scheme 334

Scheme 335

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 (Scheme 330)
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 (Scheme 331)
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 (Scheme 329)
9. Lubricate idler shaft and bushings with clean engine oil.
10. Install all chains, crankshaft sprocket, and idler sprocket as an assembly (Scheme 332) 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 prockets 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 (Scheme 329) 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 tensioner(s) 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 (Scheme 333) and right (Scheme 334) 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 (Scheme 329) primary chain crankshaft sprocket dot is at 6 o'clock (Scheme 329) secondary chain camshaft sprockets "V8" marks are at 12 o'clock (Scheme 329)
20. Lubricate all three chains with engine oil.
21. After installing all chains, it is recommended that the idler gear end play be checked (Scheme 335) 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»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ) and crankshaft damper (Refer to «DAMPER-CRANKSHAFT»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).
23. Install cylinder head covers (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ). 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.) (Scheme 324)
25. Install the oil fill housing.
26. Install access plug in left cylinder head (Scheme 324)
27. Install power steering pump (Refer to «PUMP»(/dodge/pickup-r1500/1997-2012/remont/manual-power-steering/#power-steering-system) ).
28. Install radiator fan shroud.
29. Fill cooling system (Refer to «REFILLING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).
30. Connect negative cable to battery.

1. Remove the primary and secondary timing chains and sprockets (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ). 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»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#47l-engine-overhaul) ).

See also:
• STARTERS
• IGNITION COIL
• IDLE AIR CONTROL MOTOR
• POWERTRAIN DIAGNOSTIC PROCEDURES (PART 1)
• FUEL DELIVERY - GAS
• DRAINING COOLING SYSTEM - ALL GAS ENGINES
• REFRIGERANT SYSTEM RECOVERY
• A/C COMPRESSOR
• RADIATOR-3.7L/4.7L/5.7L
• SPECIFICATIONS & DRIVE BELT ROUTING
• A/C CONDENSER
• GENERATOR
• STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE
• REFRIGERANT SYSTEM CHARGE
• REFILLING COOLING SYSTEM - ALL GAS ENGINES
• POWER BRAKE BOOSTER
• OVERHAUL - 45 RFE/545RFE
• FRONT CROSSMEMBER
• PUMP
• STANDARD PROCEDURE
• CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
• DIAGNOSIS AND TESTING - MECHANICAL
• MANIFOLD DIAGNOSIS AND TESTING
• REMOVAL
• STANDARD PROCEDURE
• INSTALLATION
• INSPECTION FOR REAR SEAL AREA LEAK
• SINGLE CAMSHAFT TIMING