4.7L Engine - Service Information: Diagnosis RAM Pickup 2500

DIAGNOSTIC PROCEDURES

The following diagnostic procedures are used to determine the source of excessive internal oil Consumption, these procedures and tests apply to vehicles with 50,000 miles or less.

Note. Engine oil consumption may be greater than normal during engine break-in. Repairs should be delayed until vehicle has been driven at least 7,500 miles.

Severe service (high ambient temperature, short trips, heavy loading, trailer towing, taxi, off-road, or law enforcement use) may result in greater oil consumption than normal.

Sustained high speed driving and high engine RPM operation may result in increased oil consumption.

Failure to comply with the recommended oil type and viscosity rating, as outlined in the owners™ manual, may impact oil economy as well as fuel economy.

Oil consumption may increase with vehicle age and mileage due to normal engine wear.

Note. Because a few drops of external oil leakage per mile can quickly account for the loss of one quart of oil in a few hundred miles, ensure no external engine oil leaks are present.

1. Oil leakage is not the same as oil consumption and all external leakage must be eliminated before any action can be taken to verify and/or correct oil consumption complaints.
2. Verify that the engine has the correct oil level dipstick and dipstick tube installed.
3. Verify that the engine is not being run in an overfilled condition. Check the oil level 15 minutes after a hot shutdown with the vehicle parked on a level surface. In no case should the level be above MAX or the FULL mark on the dipstick.

OIL CONSUMPTION TEST

1. Check the oil level at least 15 minutes after a hot shutdown.
2. If the oil level is low, top off with the proper viscosity and API service level engine oil. Add one bottle of MOPAR® 4-In-1 Leak Detection Dye into the engine oil.
3. Tamper proof the oil pan drain plug, oil filter, dipstick and oil fill cap.
4. Record the vehicle mileage.
5. Instruct the customer to drive the vehicle as usual.
6. Ask the customer to return to the servicing dealer after accumulating 500 miles, Check the oil level at least 15 minutes after a hot shutdown. If the oil level is half way between the "FULL" and "ADD" mark continue with the next step.
7. Using a black light, recheck for any external engine oil leaks, repair as necessary, if no external engine oil leaks are present, continue with oil consumption diagnosis.

OIL CONSUMPTION DIAGNOSIS

1. Check the Positive Crankcase Ventilation (PCV) system. Make sure the system is not restricted and the PCV valve has the correct part number and correct vacuum source (18-20 in. Hg at idle below 3000 ft. above sea level is considered normal).
2. Perform a cylinder compression test and cylinder leak down test using the standard leak down gauge following manufacturers suggested best practices. NOTE: Verify the spark plugs are not oil saturated. If the spark plugs are oil saturated and compression is good it can be assumed the valve seals or valve guides are at fault.
3. If one or more cylinders have more than 15% leak down further engine tear down and inspection will be required.

DIAGNOSIS AND TESTING - CYLINDER HEAD GASKET

A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket.

Possible indications of the cylinder head gasket leaking between adjacent cylinders are

1. Loss of engine power
2. Engine misfiring
3. Poor fuel economy

Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are

1. Engine overheating
2. Loss of coolant
3. Excessive steam (white smoke) emitting from exhaust
4. Coolant foaming

CYLINDER-TO-CYLINDER LEAKAGE TEST

To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in Cylinder Compression Pressure Test. Refer to CYLINDER COMPRESSION PRESSURE LEAKAGE . An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50 - 70% reduction in compression pressure.

CYLINDER-TO-WATER JACKET LEAKAGE TEST

VISUAL TEST METHOD

With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens.

If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.

CHEMICAL TEST METHOD

Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit (special tool #C-3685-A, Bloc-Chek Kit) or equivalent. Perform test following the procedures supplied with the tool kit.

Scheme 184

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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 «ENGINE COOLING SYSTEM»(ref-457792) article.
5. Lower the vehicle.
6. Remove the intake manifold. Refer to «MANIFOLD, Intake , Removal , 4.7L»(ref-457796-S33174645932012030200000) .
7. Remove the master cylinder and booster assembly. Refer to «BOOSTER, Power Brake , Removal»(ref-457773-S34320349482012030200000) and «BOOSTER, Power Brake, Hydro-Boost , Removal»(ref-457773-S22799565192012030200000) .
8. Remove the cylinder head cover (1). Refer to «COVER(S), Cylinder Head , Removal , 4.7L»(ref-457796-S21006565632012030200000) . 1 - TIMING CHAIN COVER 2 - CRANKSHAFT TIMING MARKS
9. Remove the fan shroud and fan blade assembly.
10. Remove accessory drive belt.
11. Remove the power steering pump and set aside.
12. Rotate the crankshaft until the damper timing marks are aligned (2). 1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD
13. Verify the V8 mark on the camshaft sprocket is at the 12 o'clock position. Rotate the crankshaft one turn if necessary.
14. Remove the crankshaft damper. Refer to «DAMPER, Vibration , Removal , 4.7L»(ref-457796-S11283249352012030200000) .
15. Remove the timing chain cover. Refer to «COVER(S), Engine Timing , Removal , 4.7L»(ref-457796-S27348107972012030200000) .
16. Lock the secondary timing chains to the idler sprocket using secondary camshaft chain holder (special tool #8429, Holder, Secondary Camshaft Chain) (6). 1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD 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.
18. Remove the left side secondary chain tensioner. Refer to «CHAIN and SPROCKETS, Timing , Removal , 4.7L»(ref-457796-S16479639572012030200000) . 1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG CAUTION: Do not allow the engine to rotate. Severe damage to the valve train can occur.
19. Remove the cylinder head access plug (2).
20. Remove the left side secondary chain guide. Refer to «CHAIN and SPROCKETS, Timing , Removal , 4.7L»(ref-457796-S16479639572012030200000) .
21. Remove the retaining bolt and the camshaft drive gear. 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 using the sequence provided. 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.
23. Remove the cylinder head and gasket. Discard the gasket.

Scheme 191

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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.
5. Lower the vehicle.
6. Remove the intake manifold. Refer to «MANIFOLD, Intake , Removal , 4.7L»(ref-457796-S33174645932012030200000) .
7. Remove the cylinder head cover (1). Refer to «COVER(S), Cylinder Head , Removal , 4.7L»(ref-457796-S21006565632012030200000) . 1 - TIMING CHAIN COVER 2 - CRANKSHAFT TIMING MARKS
8. Remove the fan shroud. Refer to «ENGINE COOLING SYSTEM»(ref-457792) article.
9. Remove oil fill housing from cylinder head.
10. Remove accessory drive belt.
11. Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark (2). 1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD
12. Verify the V8 mark on the camshaft sprocket is at the 12 o'clock position (2). Rotate the crankshaft one turn if necessary.
13. Remove the crankshaft damper. Refer to «DAMPER, Vibration , Removal , 4.7L»(ref-457796-S11283249352012030200000) .
14. Remove the timing chain cover. Refer to «CHAIN and SPROCKETS, Timing , Removal , 4.7L»(ref-457796-S16479639572012030200000) . 1 - LOCK ARM 2 - RIGHT CAMSHAFT CHAIN 3 - SECONDARY CHAINS RETAINING PINS (4) 4 - IDLER SPROCKET 5 - LEFT CAMSHAFT CHAIN 6 - SECONDARY CAMSHAFT CHAIN HOLDER 8429
15. Lock the secondary timing chains to the idler sprocket using Secondary Camshaft Chain Holder (special tool #8429, Holder, Secondary Camshaft Chain) (6). 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 .
17. Remove the right side secondary chain tensioner. Refer to «CHAIN and SPROCKETS, Timing , Removal , 4.7L»(ref-457796-S16479639572012030200000) . 1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
18. Remove the cylinder head access plug (1).
19. Remove the right side secondary chain guide. Refer to «CHAIN and SPROCKETS, Timing , Removal , 4.7L»(ref-457796-S16479639572012030200000) .
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 using the sequence provided. 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.
22. Remove the cylinder head and gasket. Discard the gasket.

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.

1. 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.
2. Remove suspected lash adjusters, and replace.
3. 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.

Scheme 194

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

1. Remove the cylinder head cover. Refer to «COVER(S), Cylinder Head , Removal , 4.7L»(ref-457796-S21006565632012030200000) .
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 (special tool #8516A, Remover/Installer) Rocker Arm Remover (2), press downward on the valve spring, remove rocker arm.

Scheme 195

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

1. For rocker arm installation on cylinders 3 and 5 Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke.
2. For rocker arm installation on cylinders 2 and 8 Rotate the crankshaft until cylinder #1 is at TDC compression stroke.
3. For rocker arm installation on cylinders 4 and 6 Rotate the crankshaft until cylinder #3 is at TDC compression stroke.
4. For rocker arm installation on cylinders 1 and 7 Rotate the crankshaft until cylinder #2 is at TDC compression stroke.
5. Using valve spring compressor (special tool #10102, Remover/Installer, Valve Spring) press downward on the valve spring, install rocker arm.
6. Install the cylinder head cover. Refer to «COVER(S), Cylinder Head , Installation , 4.7L»(ref-457796-S35079994162012030200000) .

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.

Scheme 196

Inspect the valve springs for physical signs of wear or damage. Using a suitable valve spring tester (1), test the following

1. Specified Spring Height
2. Specified Spring Force (Valve Open)
3. Specified Spring Force (Valve Closed)

Replace any springs that do not meet specifications. Refer to Specifications .

INSPECTION

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.

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1. Lubricate upper main bearing halves with clean engine oil. CAUTION: When installing the crankshaft, use care not to damage bearing surfaces on the crankshaft.
2. Position crankshaft in cylinder block.
3. Install the thrust washers (1). CAUTION: The bedplate to cylinder block mating surface must be coated with sealant prior to installation. Failure to do so will cause severe oil leaks. NOTE: The parts must assembled and tightened within 10 after applying sealer. 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.
4. Apply a 2.5 mm (0.100 inch) bead of Mopar® Silicone Rubber RTV (2) to the cylinder block-to-bedplate mating surface (1) as shown in illustration.
5. 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. NOTE: Install the studs in locations three, five, and six.
6. Install the bedplate retaining bolts.
7. Tighten bolts to 3 N.m (26 in. lbs.) in the sequence shown in illustration.
8. Tighten bolts to 54 N.m (40 ft. lbs.) in the sequence shown in illustration.
9. Rotate bolts 90° in the sequence shown in illustration.
10. Tighten bolts to 23 N.m (20 ft. lbs.) in the sequence shown in illustration.
11. Measure crankshaft end play. Refer to «Specifications»(ref-457796-S29075114712012030200000) .
12. Install the connecting rods and measure side clearance. Refer to «Standard Procedure»(ref-457796-S30588149212012030200000) . NOTE: Install the stud in location 10.
13. Position the oil pan gasket/windage tray.
14. Install the oil pickup tube with a new O-ring and tighten the fasteners to 28 N.m (20 ft. lbs.).
15. Position oil pan in place and install bolts.
16. Tighten the oil pan bolts to 15 N.m (11 ft. lbs.) in the sequence shown in illustration.
17. Install the engine. Refer to «Installation , 4.7L»(ref-457796-S36657198752012030200000) .

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1. Disconnect and isolate the negative battery cable (1). CAUTION: Do not let the tensioner arm snap back to the freearm position, severe damage may occur to the tensioner.
2. Rotate the belt tensioner (6) until it contacts its stop and remove the belt (3), then slowly rotate the tensioner (6) into the freearm position.
3. Raise and support the vehicle. WARNING: Do not remove the radiator pressure cap, cylinder block drain plugs or loosen the radiator draincock with the system hot and under pressure. Serious burns from coolant can occur.
4. Drain the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
5. Lower the vehicle.
6. Remove the upper radiator hose. NOTE: The thermal viscous fan drive/fan blade assembly is attached (threaded) to the water pump hub shaft. NOTE: The transmission cooler line snaps onto the lower right hand corner of the fan shroud. CAUTION: After removing fan blade/viscous fan drive assembly, do not place viscous fan drive in horizontal position. If stored horizontally, silicone fluid in the viscous fan drive could drain into the bearing assembly and contaminate the bearing lubricant.
7. Remove the fan shroud and fan blade/viscous fan drive assembly as a complete unit from the vehicle Refer to «FAN, Cooling, Electric , Removal»(ref-457792-S13033663812012030200000) and «FAN, Cooling, Viscous , Removal»(ref-457792-S41329399382012030200000) .
8. Remove the vibration damper (1) retaining bolt (2).
9. Using the crankshaft insert (special tool #8513A, Insert, Crankshaft) (1) and the three jaw puller (special tool #8454, 3-Jaw Puller) (2) remove the crankshaft damper.

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Scheme 209

1. Position the damper onto the crankshaft.
2. Assemble the damper installer (special tool #8512A, Installer, Damper) (2) and the A/C hub installer cup (special tool #6871, Installer, A/C Hub) (1).
3. Using the damper installer (special tool #8512A, Installer, Damper) (2) and the A/C hub installer cup (special tool #6871, Installer, A/C Hub) (1), press the damper onto the crankshaft.
4. Coat the vibration damper bolt threads with Mopar® Nickel Anti-Seize or equivalent, install and tighten the bolt to 175 N.m (130 ft. lbs.).
5. Install the cooling fan assembly. Refer to «FAN, Cooling, Electric , Installation»(ref-457792-S30022413072012030200000) and «FAN, Cooling, Viscous , Installation»(ref-457792-S33156171422012030200000) .
6. Install the radiator upper shroud and tighten fasteners to 11 N.m (95 in. lbs.).
7. Install the radiator upper hose.
8. Install the accessory drive belt. Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .
9. Refill the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
10. Connect the negative battery cable.

Scheme 210

1. Remove the transmission. Refer to «Removal»(ref-457827-S33920064992012030200000) .
2. Remove the bolts and flexplate (1).

Check the connecting rod journal for excessive wear, taper and scoring. Refer to STANDARD PROCEDURE - CONNECTING ROD BEARING FITTING .

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.

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, oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. See appropriate Engine component service information for proper repair procedures of these items.
4. If no leaks are detected, pressurize the crankcase as outlined in «AIR LEAK DETECTION TEST METHOD»(ref-457796-S22536783442012030200000) . 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 OIL LEAK»(ref-457796-S09253058002012030200000) for components inspections on possible causes and corrections. .
7. After the oil leak root cause and appropriate corrective action have been identified, refer to «SEAL, Crankshaft Oil, Rear , Removal , 4.7L»(ref-457796-S20274289102012030200000) .

Scheme 211

Note. This procedure can be performed in vehicle.

1. If being performed in vehicle, remove the transmission.
2. Remove the flexplate. Refer to «FLEXPLATE , Removal , 4.7L»(ref-457796-S31572544732012030200000) . NOTE: The crankshaft oil seal CANNOT be reused after removal. NOTE: The crankshaft rear oil seal remover (special tool #8506, Remover, Seal) 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 Seal Remover (special tool #8506, Remover, Seal) (2), remove the crankshaft rear oil seal (1).

Scheme 212

Scheme 213

1. Lubricate the crankshaft flange with engine oil.
2. Position the magnetic seal guide (special tool #8349-2, Guide Crank Seal) onto the crankshaft rear face. Then position the crankshaft rear oil seal (1) onto the guide (2). 1 - REAR CRANKSHAFT SEAL 2 - SPECIAL TOOL 8349-1 INSTALLER 3 - SPECIAL TOOL C-4171 HANDLE
3. Using Crankshaft Rear Oil Seal Installer (special tool #8349, Installer, Crankshaft Rear Oil Seal) (2) and Driver Handle (special tool #C-4171, Driver Handle, Universal) (3), with a hammer, tap the seal (1) 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.

Scheme 214

1. Raise the vehicle on a hoist.
2. Using a suitable jack, support transmission.
3. Remove the nuts from the transmission mount (1).
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 (2). see scheme 147
6. Remove the mount (1).

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 information procedures.
5. If the leakage occurs at the rear oil seal area, refer to the «INSPECTION FOR REAR SEAL AREA LEAKS»(ref-457796-S38917207302012030200000) .
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, 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 «AIR LEAK DETECTION TEST METHOD»(ref-457796-S22536783442012030200000) . 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.

Scheme 215

All engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler 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 to remove it from the cylinder block oil filter boss. see scheme 154
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 216

1. Lightly lubricate oil filter gasket (2) with engine oil. see scheme 155
2. Thread filter (3) onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one full turn, do not over tighten.
3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks.

Scheme 217

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

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.

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.

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 218

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.
10. Remove top oil dipstick tube retaining bolt and ground strap.
11. Bleed fuel system. Refer to «STANDARD PROCEDURE»(ref-457834-S04226998202012030200000) .
12. Remove fuel rail. Refer to «RAIL, Fuel , Removal»(ref-457834-S22430072392012030200000) .
13. Remove throttle body assembly and mounting bracket.
14. Drain cooling system below coolant temperature level. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
15. Remove the heater hoses (1) from the engine front cover and the heater core.
16. Unclip (2) and remove heater hoses and tubes from intake manifold.
17. Remove coolant temperature sensor.
18. Remove intake manifold retaining fasteners in reverse order of tightening sequence.
19. Remove intake manifold.

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.

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 219

Scheme 220

Scheme 221

Scheme 222

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 (special tool #8514, Pins, Tensioner) lock pin (3) into hole on front of tensioner (2). Slowly open vise to transfer piston spring force to lock pin.
2. Position primary chain tensioner over oil pump and insert bolts into lower two holes on tensioner bracket. Tighten bolts to 28 N.m (250 in. lbs.).
3. Install right side chain tensioner arm. Apply Mopar® Lock N, Seal to Torx® bolt, tighten bolt to 28 N.m (250 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 28 N.m (250 in. lbs.).
6. Install the right side chain guide. Tighten the bolts to 28 N.m (250 in. lbs.). 1 - LOCK ARM 2 - RIGHT CAMSHAFT CHAIN 3 - SECONDARY CHAINS RETAINING PINS (4) 4 - IDLER SPROCKET 5 - LEFT CAMSHAFT CHAIN 6 - SPECIAL TOOL 8429 1 - SPECIAL TOOL 8429 2 - PRIMARY CHAIN IDLER SPROCKET 3 - CRANKSHAFT SPROCKET
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 (special tool #8429, Holder, Secondary Camshaft Chain) (6) to hold chains in place for installation .
8. Align primary chain double plated links with the timing mark at 12 o'clock (1) on the idler sprocket. Align the primary chain single plated link with the timing mark at 6 o'clock on the crankshaft sprocket (3) .
9. Lubricate idler shaft and bushings with clean engine oil.
10. Install all chains, crankshaft sprocket, and idler sprocket as an assembly. After guiding both secondary chains through the block and cylinder head openings, affix chains with a elastic strap or the equivalent, This will maintain tension on chains to aid in installation. NOTE: It will be necessary to slightly rotate camshafts for sprocket installation.
11. Align left camshaft sprocket "L" dot to plated link on chain.
12. Align right camshaft sprocket "R" dot to plated link on chain. CAUTION: Remove excess oil from the camshaft sprocket bolt. Failure to do so can result in over-torque of bolt resulting in bolt failure.
13. Remove Special Tool (special tool #8429, Holder, Secondary Camshaft Chain), then attach both sprockets to camshafts. Remove excess oil from bolts, then Install sprocket bolts, but do not tighten at this time.
14. Verify that all plated links are aligned with the marks on all sprockets and the "V8" marks on camshaft sprockets are at the 12 o'clock position . CAUTION: Ensure the plate between the left secondary chain tensioner and block is correctly installed.
15. Install both secondary chain tensioners. Tighten bolts to 28 N.m (250 in. lbs.). NOTE: Left and right secondary chain tensioners are not common.
16. Before installing idler sprocket bolt, lubricate washer with oil, and tighten idler sprocket assembly retaining bolt to 34 N.m (25 ft. lbs.).
17. Remove all locking pins 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. 1 - TORQUE WRENCH 2 - CAMSHAFT SPROCKET 3 - LEFT CYLINDER HEAD 4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346 1 - TORQUE WRENCH 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346 3 - LEFT CAMSHAFT SPROCKET 4 - RIGHT CAMSHAFT SPROCKET
18. Using Special Tool (special tool #6958, Wrench, Spanner), Spanner with Adaptor Pins (special tool #8346, Pins, Adapter), tighten left (3) and right (4), camshaft sprocket bolts to 122 N.m (90 ft. lbs.).
19. Rotate engine two full revolutions. Verify timing marks are at the follow locations: primary chain idler sprocket dot is at 12 o'clock primary chain crankshaft sprocket dot is at 6 o'clock secondary chain camshaft sprockets "V8" marks are at 12 o'clock
20. Lubricate all three chains with engine oil. 1 - IDLER SPROCKET ASSEMBLY 2 - DIAL INDICATOR
21. After installing all chains, it is recommended that the idler gear (1) end play be checked. The end play must be within 0.10-0.25 mm (0.004-0.010 in.). If not within specification, the idler gear must be replaced.
22. Install timing chain cover and crankshaft damper. Refer to «COVER(S), Engine Timing , Installation , 4.7L»(ref-457796-S32975697962012030200000) and «DAMPER, Vibration , Installation , 4.7L»(ref-457796-S39094303242012030200000) .
23. Install cylinder head covers. Refer to «COVER(S), Cylinder Head , Installation , 4.7L»(ref-457796-S35079994162012030200000) . NOTE: Before installing threaded plug in right cylinder head, the plug must be coated with sealant to prevent leaks.
24. Coat the large threaded access plug with Mopar® Thread Sealant with Teflon , then install into the right cylinder head and tighten to 81 N.m (60 ft. lbs.) .
25. Install the oil fill housing.
26. Install access plug in left cylinder head .
27. Install power steering pump. Refer to «Pump , Installation»(ref-457772-S27109949282012030200000) .
28. Install radiator fan shroud.
29. Fill cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
30. Connect negative cable to battery.

Scheme 223

1. Disconnect the battery negative cable.
2. Drain cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
3. Disconnect both heater hoses at timing cover.
4. Disconnect lower radiator hose at engine.
5. Remove crankshaft damper. Refer to «DAMPER, Vibration , Removal , 4.7L»(ref-457796-S11283249352012030200000) .
6. Remove accessory drive belt tensioner assembly (1).
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® Grey Engine RTV sealant must be substituted. NOTE: It is not necessary to remove the water pump for timing cover removal.
8. Remove the bolts holding the timing cover to engine block.
9. Remove cover .

Scheme 224

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® Grey Engine RTV must be used as a substitute, if RTV is present. If the front cover being used has no provisions for the water passage o-rings, then Mopar® Grey Engine RTV must be applied around the water passages.
2. Inspect the water passage o-rings, if equipped for any damage, and replace as necessary.
3. Apply Mopar® Grey Engine RTV sealer to the front cover following the path above, using a 3 to 4 mm thick bead.
4. Install cover. Tighten flange head fasteners in sequence as shown in illustration to 58 N.m (43 ft. lbs.).
5. Install the A/C compressor and generator.
6. Install crankshaft damper. Refer to «DAMPER, Vibration , Installation , 4.7L»(ref-457796-S39094303242012030200000) .
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 «Standard Procedure»(ref-457792-S30781673372012030200000) .
11. Connect the battery negative cable.