4.7L V8 Engine: Other Dodge Pickup R2500

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. Secure the throttle in the wide-open position.
4. Disable the fuel system (Refer to «FUEL DELIVERY - GAS»(ref-189687) ).
5. Remove the ASD relay (Refer to «AUTO SHUTDOWN RELAY»(ref-157773-S11097280862003082600000) ).
6. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
7. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders.
8. (Refer to «ENGINE - SPECIFICATIONS»(ref-189680-S39344137762005091100000) ) for the correct engine compression pressures.

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 table.

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS

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.

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.

Filter Element Only

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

Scheme 386

1. Loosen clamp (Scheme 386) and disconnect air duct at air cleaner cover.
2. Pry over 4 spring clips (Scheme 386) from housing cover (spring clips retain cover to housing).
3. Release housing cover from locating tabs on housing (Scheme 386) and remove cover.
4. Remove air cleaner element (filter) from housing.
5. Clean inside of housing before replacing element.

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.

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 387

Scheme 388

Scheme 389

Scheme 390

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 «COOLING»(ref-189654).
5. Lower the vehicle.
6. Remove the intake manifold (Refer to «ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL»(ref-189680-S31953754812005091100000) ).
7. Remove the master cylinder and booster assembly. Refer to section 5 brakes.
8. Remove the cylinder head cover (Refer to «ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL»(ref-189680-S35103323502005091100000) ).
9. Remove the fan shroud and fan blade assembly (Refer to «FAN DRIVE VISCOUS CLUTCH (GAS)»(ref-189656-S33852084192005091200000) ).
10. Remove accessory drive belt (Refer to «DRIVE BELTS -- 3.7L / 4.7L»(ref-189655-S16761653102005091200000) ).
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 387)
13. Verify the V8 mark on the camshaft sprocket is at the 12 o'clock position (Scheme 389) Rotate the crankshaft one turn if necessary.
14. Remove the crankshaft damper (Refer to «ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL»(ref-189680-S11523917402005091100000) ).
15. Remove the timing chain cover (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - REMOVAL»(ref-189680-S20200377832005091100000) ).
16. Lock the secondary timing chains to the idler sprocket using Special Tool 8515 (Scheme 388) 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 389)
18. Remove the left side secondary chain ten-sioner (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL»(ref-189680-S06209447232005091100000) ).
19. Remove the cylinder head access plug (Scheme 390)
20. Remove the left side secondary chain guide (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL»(ref-189680-S06209447232005091100000) ).
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 391

Scheme 392

Scheme 393

Scheme 394

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 «COOLING»(ref-189654) ).
5. Lower the vehicle.
6. Remove the intake manifold (Refer to «ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL»(ref-189680-S31953754812005091100000) ).
7. Remove the cylinder head cover (Refer to «ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL»(ref-189680-S35103323502005091100000) ).
8. Remove the fan shroud (Refer to «FAN DRIVE VISCOUS CLUTCH (GAS)»(ref-189656-S33852084192005091200000) ).
9. Remove oil fill housing from cylinder head.
10. Remove accessory drive belt (Refer to «DRIVE BELTS -- 3.7L / 4.7L»(ref-189655-S16761653102005091200000) ).
11. Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark (Scheme 391)
12. Verify the V8 mark on the camshaft sprocket is at the 12 o'clock position (Scheme 392) Rotate the crankshaft one turn if necessary.
13. Remove the crankshaft damper (Refer to «ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL»(ref-189680-S11523917402005091100000) ).
14. Remove the timing chain cover (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - REMOVAL»(ref-189680-S20200377832005091100000) ).
15. Lock the secondary timing chains to the idler sprocket using Special Tool 8515 (Scheme 393) 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 392)
17. Remove the right side secondary chain ten-sioner (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL»(ref-189680-S06209447232005091100000) ).
18. Remove the cylinder head access plug (Scheme 394)
19. Remove the right side secondary chain guide (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL»(ref-189680-S06209447232005091100000) ).
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. CAUTION: Do not lay the cylinder head on its gasket sealing surface, do 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

CLEANING

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

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 395)

Scheme 395

Scheme 396

Scheme 397

Scheme 398

1. Clean the cylinder head and cylinder block mating surfaces (Scheme 396)
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 Mil 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 397) using the following steps and torque values: Step 1: Tighten bolts 1-10, 20 N.m (15 ft. lbs.). Step 2: Tighten bolts 1-10, 47 N.m (35 ft. lbs.). Tighten bolts 11-14, 25 N.m (18 ft. lbs.). Step 3: Tighten bolts 1-10, 90 degrees. Tighten bolts 11-14, 30 N.m (22 ft. lbs.).
7. Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V8 mark on the gear and position the gear onto the camshaft.
8. Install the camshaft drive gear retaining bolt.
9. Install the left side secondary chain guide (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION»(ref-189680-S28843629942005091100000) ).
10. Install the cylinder head access plug (Scheme 398)
11. Re-set and Install the left side secondary chain tensioner (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION»(ref-189680-S28843629942005091100000) ).
12. Remove Special Tool 8515.
13. Install the timing chain cover (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - INSTALLATION»(ref-189680-S22988718722005091100000) ).
14. Install the crankshaft damper (Refer to «ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION»(ref-189680-S23214863252005091100000) ).
15. Install the power steering pump.
16. Install the fan blade assembly and fan shroud (Refer to «FAN DRIVE VISCOUS CLUTCH (GAS)»(ref-189656-S33852084192005091200000) ).
17. Install the cylinder head cover (Refer to «ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189680-S26588130842005091100000) ).
18. Reinstall the master cylinder and booster assembly. Refer to section 5 brakes.
19. Install the intake manifold (Refer to «ENGINE/MANIFOLDS/INTAKE MANIFOLD INSTALLATION»(ref-189680-S06348953142005091100000) ).
20. Refill the cooling system (Refer to «COOLING»(ref-189654) ).
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.

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 399)

Scheme 399

Scheme 400

Scheme 401

Scheme 402

1. Clean the cylinder head and cylinder block mating surfaces (Scheme 400)
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 401) using the following steps and torque values: Step 1: Tighten bolts 1-10, 20 N.m (15 ft. lbs.). Step 2: Tighten bolts 1-10, 47 N.m (35 ft. lbs.). Tighten bolts 11-14, 25 N.m (18 ft. lbs.). Step 3: Tighten bolts 1-10, 90 degrees. Tighten bolts 11-14, 30 N.m (22 ft. lbs.).
7. Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V8 mark on the gear and position the gear onto the camshaft.
8. Install the camshaft drive gear retaining bolt.
9. Install the right side secondary chain guide (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - INSTALLATION»(ref-189680-S22988718722005091100000) ).
10. Install the right side cylinder head access plug (Scheme 402)
11. Re-set and install the right side secondary chain tensioner.
12. Remove Special Tool 8515.
13. Install the timing chain cover (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - INSTALLATION»(ref-189680-S22988718722005091100000) ).
14. Install the crankshaft damper (Refer to «ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION»(ref-189680-S23214863252005091100000) ).
15. Install accessory drive belt (Refer to «DRIVE BELTS -- 3.7L / 4.7L»(ref-189655-S16761653102005091200000) ).
16. Install the fan shroud.
17. Install the cylinder head cover (Refer to «ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189680-S26588130842005091100000) ).
18. Install the intake manifold (Refer to «ENGINE/MANIFOLDS/INTAKE MANIFOLD INSTALLATION»(ref-189680-S06348953142005091100000) ).
19. Install oil fill housing onto cylinder head.
20. Refill the cooling system (Refer to «COOLING»(ref-189654) ).
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.

RIGHT SIDE

1. Disconnect battery negative cable.
2. Remove air cleaner assembly, resonator assembly and air inlet hose.
3. Drain cooling system (Refer to «COOLING»(ref-189654) ).
4. Remove accessory drive belt (Refer to «DRIVE BELTS -- 3.7L / 4.7L»(ref-189655-S16761653102005091200000) ).
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.

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.

Scheme 403

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 403)
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 «DRIVE BELTS -- 3.7L / 4.7L»(ref-189655-S16761653102005091200000) ).
11. Fill Cooling system (Refer to «COOLING»(ref-189654) ).
12. Install air cleaner assembly, resonator assembly and air inlet hose.
13. Connect battery negative cable.

Scheme 404

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 404)
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.

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 405

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 405)
4. A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper cross-hatch angle. The number of up and down strokes per minute can be regulated to get the desired 50° to 60° angle. Faster up and down strokes increase the 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, lint-free cloth to check that the bore is clean. Oil the bores after cleaning to prevent rusting.

Thoroughly clean the oil pan and engine block gasket surfaces. Use compressed air to clean out

1. The galley at the oil filter adaptor hole.
2. The front and rear oil galley holes.
3. The feed holes for the crankshaft main bearings. Once the block has been completely cleaned, apply Loctite PST pipe sealant with Teflon 592 to the threads of the front and rear oil galley plugs. Tighten the 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 406

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 406)
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.

CONNECTING ROD BEARING FITTING

Inspect the connecting rod bearings for scoring and bent alignment tabs (Scheme 407) Check the bearings for normal wear patterns, scoring, grooving, fatigue and pitting (Scheme 408) Replace any bearing that shows abnormal wear.

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

Scheme 407

Scheme 408

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 409

Scheme 410

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 409) 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 Plas-tigage 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 410) 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, determine which services bearing set to use the bearing sizes are as follows: CONNECTING ROD BEARING SIZE SPECIFICATIONS 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 411) Refer to Engine Specifications for the proper clearance. Replace the connecting rod if the side clearance is not within specification.

Scheme 411

Scheme 412

1. Drain the cooling system (Refer to «COOLING»(ref-189654) ).
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 412)
3. Using a suitable pair of pliers, grasp the core plug and remove.

MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)

Crankshaft removed from the cylinder block.

Clean the oil off the main bearing journal.

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

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

CRANKSHAFT MAIN BEARING SELECTION

The main bearings are "select fit" to achieve proper oil clearances. For main bearing selection, the crankshaft position sensor target wheel has grade identification marks stamped into it (Scheme 413) 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 413

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

MAIN BEARING SELECTION CHART-4.7L

MAIN BEARING SELECTION (4.7L)

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 Engine, for proper repair procedures of these items.
4. If no leaks are detected, pressurized the crank-case as outlined in ( «ENGINE OIL LEAK»(ref-189680-S33326894082005091100000) ). 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 «ENGINE - DIAGNOSIS AND TESTING»(ref-189680-S14352863522005091100000) ), under the Oil Leak row, for components inspections on possible causes and corrections.
7. After the oil leak root cause and appropriate corrective action have been identified, (Refer to «ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - REMOVAL»(ref-189680-S19251030762005091100000) ).

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. CAUTION: DO NOT remove the piston pin from the piston and connecting rod assembly

STANDARD PROCEDURE

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

Scheme 414

Scheme 415

Scheme 416

Scheme 417

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 414) 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 415) 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 Ring Position Groove Clearance Maximum Clearance Upper Ring.051-.094mm (0.0020-.0037 in.) 0.11mm (0.004 in.) Intermediate Ring 0.04-0.08mm (0.0016-0.0031 in.) 0.10mm (0.004 in.) Oil Control Ring (Steel Rails).019-.229mm (.0007-.0090 in.).25mm (0.010 in.) Ring Position Ring Gap Wear Limit Upper Ring 0.20-0.36mm (0.0079-0.0142 in.) 0.43mm (0.0017 in.) Intermediate Ring 0.37-0.63mm (0.0146-0.0249 in.) 0.74mm (0.029 in.) Oil Control Ring (Steel Rail) 0.025-0.76mm (0.0099-0.03 in.) 1.55mm (0.061 in.)
7. The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston. NOTE: Piston rings are installed in the following order: Oil ring expander. Upper oil ring side rail. Lower oil ring side rail. No. 2 Intermediate piston ring. No. 1 Upper piston ring.
8. Install the oil ring expander.
9. Install upper side rail (Scheme 416) 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 417)
11. Install No. 1 upper piston ring using a piston ring installer (Scheme 417)
12. Position piston ring end gaps as shown in (Scheme 418) 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 418

Scheme 419

Scheme 420

1. Disconnect negative cable from battery.
2. Remove accessory drive belt (Refer to «DRIVE BELTS -- 3.7L / 4.7L»(ref-189655-S16761653102005091200000) ).
3. Drain cooling system (Refer to «COOLING»(ref-189654) ).
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 419)
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 420)

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)»(ref-189656-S33852084192005091200000) ).
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.

4WD

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 421)
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 423) and right (Scheme 422) 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.

Scheme 421

Scheme 422

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)»(ref-189656-S33852084192005091200000) ).
9. Reconnect the negative battery cable.

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

Scheme 423

Scheme 424

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 424)
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)»(ref-189656-S33852084192005091200000) ).
15. Reconnect the negative battery cable.

Scheme 425

1. Raise the vehicle on a hoist.
2. Using a suitable jack, support transmission.
3. Remove the nuts from the transmission mount (Scheme 425)
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.

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.

API SERVICE GRADE CERTIFIED

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

SAE VISCOSITY

An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30 in the 4.7L engines. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Scheme 426)

Scheme 426

ENERGY CONSERVING OIL

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

OIL LEVEL INDICATOR (DIPSTICK)

The engine oil level indicator is located at the right rear of the engine on the 4.7L engines. see scheme 136

ENGINE OIL CHANGE

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

Run engine until achieving normal operating temperature.

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

USED ENGINE OIL DISPOSAL

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

Electrical/Mechanical Engine Oil Pressure Sensor

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

Solid-State Engine Oil Pressure Sensor

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 427

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 427)
5. Remove the pressure sender (Scheme 427)

1. Wash all parts in a suitable solvent.

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

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

LEFT EXHAUST MANIFOLD

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 428)
7. Lower vehicle and remove the upper exhaust manifold retaining bolts (Scheme 428)
8. Raise vehicle and remove the lower exhaust manifold retaining bolts (Scheme 428)
9. Remove exhaust manifold and gasket (Scheme 428) 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.

Scheme 428

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 429

1. Install exhaust manifold and gasket (Scheme 429) 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 «DRIVE BELTS -- 3.7L / 4.7L»(ref-189655-S16761653102005091200000) ).
11. Install air cleaner assembly, resonator assembly and air inlet hose.
12. Install battery and connect cables.
13. Fill cooling system (Refer to «COOLING»(ref-189654) ).

Scheme 430

1. Install exhaust manifold and gasket from below engine compartment.
2. Install lower exhaust manifold fasteners (Scheme 430) DO NOT tighten until all fasteners are in place.
3. Lower vehicle and install upper exhaust manifold fasteners (Scheme 430) 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 430) 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.

MEASURING TIMING CHAIN WEAR

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

Scheme 431

1. Remove the timing chain cover. (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - REMOVAL»(ref-189680-S20200377832005091100000) ).
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 431) 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 «ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL»(ref-189680-S06209447232005091100000) ). NOTE: If the secondary chains are to be replaced the primary chain must also be replaced.

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 432

Scheme 433

1. Remove the cylinder head covers (Refer to «ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL»(ref-189680-S35103323502005091100000) ).
2. Using a mirror, locate the TDC arrow on the front cover (Scheme 432) 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 433) 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 BELT/CHAIN AND SPROCKETS»(ref-189680-S33678239162005091100000).
5. If only one of the camshaft drive gears is off and the other is correct, the problem is confined to one secondary chain. Refer to «SINGLE CAMSHAFT TIMING»(ref-189680-S01578802222005091100000).
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, perform the following procedure.

Scheme 434

Scheme 435

Scheme 436

1. Using Chain Tensioner Wedge, special tool 8350, stabilize the secondary chain drive (Scheme 434) For reference purposes, mark the chain-to-sprocket position (Scheme 434)
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 435) 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 122 N.m (90 ft. Lbs.) (Scheme 436) (Scheme 437)
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 «ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189680-S26588130842005091100000) ).

Scheme 437

Scheme 438

Scheme 439

1. Disconnect the battery negative cable.
2. Drain cooling system (Refer to «COOLING»(ref-189654) ).
3. Remove fan and fan drive assembly (Refer to «FAN DRIVE VISCOUS CLUTCH (GAS)»(ref-189656-S33852084192005091200000) ).
4. Disconnect both heater hoses at timing cover.
5. Disconnect lower radiator hose at engine.
6. Remove crankshaft damper (Refer to «ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL»(ref-189680-S11523917402005091100000) ).
7. Remove accessory drive belt tensioner assembly ( (Scheme 438) «BELT TENSIONERS -- 3.7L / 4.7L»(ref-189655-S20389765472005091200000) ).
8. Remove the generator (Refer to «GENERATOR»(ref-165616-S05478500212004083000000) ).
9. Remove A/C compressor (Refer to «A/C COMPRESSOR»(ref-189725-S01920583182005091100000) ).
10. Remove cover and gasket (Scheme 439)