4.7L V8 Engine: Removal & Installation Dodge Pickup R2500

REMOVAL

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

Scheme 335

Scheme 336

Scheme 337

Scheme 338

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 335) 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 «STRUCTURAL COVER»(ref-189680-S22088503632005091100000) ).
12. Remove starter (Refer to «STARTERS»(ref-164936) ).
13. Drain cooling system (Refer to «COOLING»(ref-189654) ).
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 336) Remove breathers
21. Discharge A/C system (Refer to «STANDARD PROCEDURE»(ref-189725-S18587694352005091100000) ).
22. Remove A/C compressor (Refer to «A/C COMPRESSOR»(ref-189725-S01920583182005091100000) ).
23. Remove shroud, fan assembly (Refer to «FAN DRIVE VISCOUS CLUTCH (GAS)»(ref-189656-S33852084192005091200000) ) and accessory drive belt (Refer to «DRIVE BELTS -- 3.7L / 4.7L»(ref-189655-S16761653102005091200000) ).
24. Disconnect transmission oil cooler lines at the radiator.
25. Disconnect radiator upper and lower hoses.
26. Remove radiator (Refer to «RADIATOR (GAS)»(ref-189656-S03252315662005091200000) ), A/C condenser (Refer to «A/C CONDENSER»(ref-189725-S37314472812005091100000) ) and transmission oil cooler.
27. Remove generator (Refer to «GENERATOR»(ref-165616-S05478500212004083000000) ).
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 (LAT) sensor (Scheme 337) 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 «FUEL DELIVERY - GAS»(ref-189687) ) then disconnect the fuel supply quick connect fitting at the fuel rail (Refer to «FUEL DELIVERY - GAS»(ref-189687) ).
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 338) following these steps. Holding the lifting fixture at a slight angle, slide the large bore in the front plate over the hex portion of the lifting stud. Position the two remaining fixture arms onto the two Special Tools 8400 Lifting Studs, in the cylinder heads. Pull forward and upward on the lifting fixture so that the lifting stud rest in the slotted area below the large bore. Secure the lifting fixture to the three studs using three 7/16 - 14 N/C locknuts. Make sure the lifting loop in the lifting fixture is in the last hole (closest to the throttle body) to minimize the angle of engine during removal.
36. Disconnect body ground strap at the right side cowl (Scheme 339)
37. Disconnect body ground strap at the left side cowl (Scheme 340) 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 339

Scheme 340

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 338)
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 «FUEL DELIVERY - GAS»(ref-189687) ).
10. Connect the vacuum lines at the throttle body and intake manifold.
11. Connect engine harness at the following points (Scheme 337): Intake Air Temperature (LAT) 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»(ref-165616-S05478500212004083000000) ).
15. Install A/C condenser (Refer to «A/C CONDENSER»(ref-189725-S37314472812005091100000) ), radiator (Refer to «RADIATOR (GAS)»(ref-189656-S03252315662005091200000) ) 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 «DRIVE BELTS -- 3.7L / 4.7L»(ref-189655-S16761653102005091200000) ), fan assembly and shroud (Refer to «FAN DRIVE VISCOUS CLUTCH (GAS)»(ref-189656-S33852084192005091200000) ).
19. Install A/C compressor (Refer to «A/C COMPRESSOR»(ref-189725-S01920583182005091100000) ).
20. Install both breathers. Connect tube to both crankcase breathers (Scheme 336)
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 335)
27. 4X4 vehicles Position and install the axle isolator bracket onto the axle, transmission and engine block. Tighten bolts to specification (Refer to «ENGINE - SPECIFICATIONS»(ref-189680-S39344137762005091100000) ).
28. Install starter (Refer to «STARTERS»(ref-164936) ). 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 «STRUCTURAL COVER»(ref-189680-S22088503632005091100000) ).
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 «STANDARD PROCEDURE»(ref-189725-S18587694352005091100000) ).
36. Refill the engine cooling system (Refer to «STANDARD PROCEDURE -- REFILLING COOLING SYSTEM»(ref-189654-S40748863372005091200000) ).
37. Install the battery tray and battery.
38. Connect the battery positive and negative cables.
39. Start the engine and check for leaks.

Scheme 341

Scheme 342

Scheme 343

Scheme 344

Scheme 345

Scheme 346

Scheme 347

Scheme 348

1. Remove cylinder head cover (Refer to «ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL»(ref-189680-S35103323502005091100000) ).
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 347) 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 348)
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 349

Scheme 350

Scheme 351

Scheme 352

Scheme 353

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 349)
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 350) 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 351) 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 352)
10. Using Special Tool 6958 spanner wrench with adapter pins 8346 (Scheme 353), torque the camshaft sprocket retaining bolt to 122 N.m (90 ft. lbs.).
11. Install the cylinder head cover.

Scheme 354

Scheme 355

1. Remove the cylinder head covers (Refer to «ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL»(ref-189680-S35103323502005091100000) ).
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 ten-sioner arm and guide (Scheme 354)
6. Remove the camshaft position sensor (Scheme 355) 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 356)
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 356

Scheme 357

Scheme 358

Scheme 359

Scheme 360

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 357)
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 358) 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 359) CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over-torque resulting in bolt failure
8. Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and hand tighten.
9. Remove timing chain wedge special tool 8350 (Scheme 354)
10. Using Special Tool 6958 spanner wrench with adapter pins 8346 (Scheme 360), torque the camshaft sprocket retaining bolt to 122 N.m (90 ft. lbs.).
11. Install the camshaft position sensor (Scheme 355)
12. Install the cylinder head cover (Refer to «ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189680-S26588130842005091100000) ).

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

Scheme 361

1. Remove rocker arms and lash adjusters (Refer to «ENGINE/CYLINDER HEAD/ROCKER ARM/ADJUSTER ASSY - REMOVAL»(ref-189680-S22471823712005091100000) ). (Scheme 361)
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.

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

1. Remove the cylinder head cover (Refer to «ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL»(ref-189680-S35103323502005091100000) ).
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 362)

INSTALLATION

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

Scheme 362

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 362)
6. Install the cylinder head cover (Refer to «ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION»(ref-189680-S26588130842005091100000) ).

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

1. Coat the edges of the engine core plug and the core plug bore with Mopar Gasket Maker, or equivalent. NOTE: It is not necessary to wait for the sealant to cure on the core plugs. The cooling system can be filled and the vehicle returned to service immediately.
2. Using proper plug driver, drive core plug into the core plug bore. The sharp edge of the core plug should be at least 0.50 mm (0.020 in.) inside the lead in chamfer.
3. Refill the cooling system (Refer to «COOLING»(ref-189654) ).

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

Scheme 363

1. Remove the engine. (Refer to «ENGINE - REMOVAL»(ref-189680-S11217571052005091100000) ).
2. Remove the engine oil pump.(Refer to «ENGINE/LUBRICATION/OIL PUMP - REMOVAL»(ref-189680-S36662472822005091100000) ). 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 «ENGINE/LUBRICATION/OIL PAN - REMOVAL»(ref-189680-S40016240112005091100000) ).
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 363) to loosen the bedplate then remove the bedplate. CAUTION: When removing the crankshaft, use care not to damage bearing surfaces on the crankshaft
8. Remove the crankshaft.
9. Remove the crankshaft target wheel.

Scheme 364

Scheme 365

Scheme 366

Scheme 367

Scheme 368

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 364) CAUTION: The bedplate to cylinder block matting surface must be coated with sealant prior to installation. Failure to do so will cause severe oil leaks NOTE: The installation time to install the bedplate after the sealant has been applied is critical. NOTE: Make sure that the bedplate and cylinder block sealing surfaces are clean and free of oil or other contaminants. Contaminants on the sealing surfaces may cause main bearing distortion and/or oil leaks.
5. Apply a 2.5mm (0.100 inch) (Scheme 365) bead of Mopar® Gen II Silicone Rubber Adhesive sealant to the cylinder block-to-bedplate mating surface as shown (Scheme 366)
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 367) 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 «ENGINE/ENGINE BLOCK/CRANKSHAFT - STANDARD PROCEDURE»(ref-189680-S32805167922005091100000) ).
9. Install the connecting rods and measure side clearance. (Refer to «ENGINE/ENGINE BLOCK/CONNECTING ROD BEARINGS - STANDARD PROCEDURE»(ref-189680-S25399531502005091100000) ).
10. Position the oil pan gasket/windage tray, using a new o-ring, install the oil pickup tube. Torque the bolt to 28N-n (20 ft. lbs.) torque the nuts to 28 N.m (20 ft. lbs.).
11. Install the oil pan. Torque the retaining bolts to 15 N.m (11 ft. lbs.) in the sequence shown (Scheme 368)
12. Install the engine (Refer to «ENGINE - INSTALLATION»(ref-189680-S23344914642005091100000) ).

Scheme 369

1. Using Special Tool 8348 and 8512, install crankshaft front seal (Scheme 369)
2. Install vibration damper (Refer to «ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION»(ref-189680-S23214863252005091100000) ).
3. Install radiator cooling fan and shroud (Refer to «FAN DRIVE VISCOUS CLUTCH (GAS)»(ref-189656-S33852084192005091200000) ).
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 «DRIVE BELTS -- 3.7L / 4.7L»(ref-189655-S16761653102005091200000) ).
7. Refill cooling system (Refer to «COOLING»(ref-189654) ).
8. Connect negative cable to battery.

Note. This procedure can be performed in vehicle.

Scheme 370

1. If being performed in vehicle, remove the transmission.
2. Remove the flexplate (Refer to «ENGINE/ENGINE BLOCK/FLEX PLATE - REMOVAL»(ref-189680-S08777356682005091100000) ). 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 370), remove the crankshaft rear oil seal.

Scheme 371

Scheme 372

1. Lubricate the crankshaft flange with engine oil.
2. Position the magnetic seal guide Special Tool 8349-2 (Scheme 371) 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 372), with a hammer, tap the seal into place. Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore.
4. Install the flexplate.
5. Install the transmission.

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

Scheme 373

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 373)
3. Install the transmission.

Scheme 374

Scheme 375

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 374) Once assembled coat the threaded rod's threads with Mopar® Nickel Anti-Seize or (Loctite No. 771).
3. Using Special Tool 8512-A, press damper onto crankshaft (Scheme 375)
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)»(ref-189656-S33852084192005091200000) ).
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 «DRIVE BELTS -- 3.7L / 4.7L»(ref-189655-S16761653102005091200000) ).
10. Refill cooling system (Refer to «COOLING»(ref-189654) ).
11. Connect negative cable to battery.

Scheme 376

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 376) to 54 N.m (40 ft. lbs.), then tighten bolts (2) (Scheme 376) 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.).

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 61 N.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 54 N.m (40 ft. lbs.).

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

Scheme 377

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 377) 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 378

1. Lightly lubricate oil filter gasket with engine oil.
2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Scheme 378) 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»(ref-189686-S01720353762005091100000) ). 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 379

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 379)
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»(ref-189686-S01720353762005091100000) ).
9. Fill engine oil.
10. Reconnect the negative battery cable.
11. Start engine and check for leaks.

Solid-State Engine Oil Pressure Sensor

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

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 «ENGINE/LUBRICATION/OIL PAN - REMOVAL»(ref-189680-S40016240112005091100000) ).
2. Remove the timing chain cover (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - REMOVAL»(ref-189680-S20200377832005091100000) ).
3. Remove the timing chains and tensioners (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL»(ref-189680-S06209447232005091100000) ).
4. Remove the four bolts, primary timing chain tensioner and the oil pump.

1. Install intake manifold gaskets.
2. Position intake manifold.
3. Install intake manifold retaining bolts and tighten in sequence shown in see scheme 149 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 DELIVERY - GAS»(ref-189687) ).
9. Install ignition coil towers (Refer to «IGNITION COIL»(ref-158737-S37509552622003101600000) ).
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 (LAT) 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 «COOLING»(ref-189654) ).
17. Install resonator assembly and air inlet hose.
18. Connect negative cable to battery.

1. Clean timing chain cover and block surface. Inspect cover gasket and replace as necessary.
2. Install cover and gasket. Tighten fasteners in sequence as shown in see scheme 163 to 54 N.m (40 ft. lbs.).
3. Install the A/C compressor (Refer to «A/C COMPRESSOR»(ref-189725-S01920583182005091100000) ).
4. Install the generator (Refer to «GENERATOR»(ref-165616-S05478500212004083000000) ).
5. Install crankshaft damper (Refer to «ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION»(ref-189680-S23214863252005091100000) ).
6. Install accessory drive belt tensioner assembly (Refer to «BELT TENSIONERS -- 3.7L / 4.7L»(ref-189655-S20389765472005091200000) ).
7. Install radiator lower hose.
8. Install both heater hoses.
9. Install radiator shroud and viscous fan drive assembly (Refer to «FAN DRIVE VISCOUS CLUTCH (GAS)»(ref-189656-S33852084192005091200000) ).
10. Fill cooling system (Refer to «COOLING»(ref-189654) ).
11. Connect the battery negative cable.

Scheme 380

Scheme 381

Scheme 382

Scheme 383

Scheme 384

1. Disconnect negative cable from battery.
2. Drain cooling system (Refer to «COOLING»(ref-189654) ).
3. Remove right and left cylinder head covers (Refer to «ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL»(ref-189680-S35103323502005091100000) ).
4. Remove radiator fan shroud.
5. Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover (Scheme 380) (#1 cylinder exhaust stroke) and the camshaft sprocket "V8" marks are at the 12 o'clock position (Scheme 381)
6. Remove power steering pump (Refer to «PUMP»(ref-189696-S25973685692005091100000) ).
7. Remove access plugs (2) from left and right cylinder heads for access to chain guide fasteners (Scheme 382)
8. Remove the oil fill housing to gain access to the right side tensioner arm fastener.
9. Remove crankshaft damper (Refer to «ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL»(ref-189680-S11523917402005091100000) ) and timing chain cover (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - REMOVAL»(ref-189680-S20200377832005091100000) ).
10. Collapse and pin primary chain tensioner (Scheme 383) 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 384) 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, see scheme 169 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, see scheme 170 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.

1. Remove the primary and secondary timing chains and sprockets (Refer to «ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL»(ref-189680-S06209447232005091100000) ). 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 «ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION»(ref-189680-S28843629942005091100000) ).