4.7L Engine - Service Information: Removal & Installation RAM Pickup 2500

INSTALLATION

1. Install filter element into housing.
2. Position housing cover (3) into housing locating tabs.
3. Pry up 4 spring clips (5) and lock cover to housing.
4. Install air duct (2) to air cleaner cover (3) and tighten hose clamp (1) to 3 N.m (30 in. lbs.).

Scheme 225

Scheme 226

1. Loosen clamp (1) and disconnect air duct (2) at air cleaner cover (3).
2. Lift entire housing (1) assembly from 4 locating pins (2).

Scheme 227

Scheme 228

1. Position housing assembly (1) into 4 locating pins (2).
2. Connect air duct (2) at air cleaner cover (3) and tighten clamp (1).

INSTALLATION - LEFT CAMSHAFT

1. Lubricate the 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. Install the camshaft into the cylinder head while aligning the camshaft sprocket dowel near the 1 o'clock position. NOTE: The camshaft caps are marked for location. The arrow must point to the front of the engine.
3. Install the camshaft bearing caps in the same position as noted during removal.
4. Install the camshaft bearing cap retaining bolts hand tight.
5. Using the sequence shown in illustration, working in 1/2 turn increments, tighten the bearing cap retaining bolts to 11 N.m (8 ft. lbs.).
6. Check the camshaft end play. Refer to «CAMSHAFT, Engine , Standard Procedure , 4.7L»(ref-457796-S05841556012012030200000) .
7. Position the camshaft drive gear into the timing chain while aligning the two dots on the camshaft sprocket with the chain link (2) marked during removal.
8. Using Camshaft Holder (special tool #8428A, Holder, Camshaft) (1), rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket.
9. Position the sprocket onto the camshaft. CAUTION: Remove excess oil from the camshaft sprocket retaining bolt, failure to do so can cause bolt over-torque resulting in bolt failure.
10. Remove excess oil from the camshaft sprocket retaining bolt.
11. Install the camshaft sprocket retaining bolt hand tight.
12. Remove the timing chain (2) Locking Wedge (special tool #9867, Wedge, Locking) (1).
13. Using Spanner Wrench (special tool #6958, Wrench, Spanner) (4) with Adapter Pins (special tool #8346, Pins, Adapter), secure the camshaft sprocket (2) and tighten the retaining bolt (1) to 122 N.m (90 ft. lbs.).
14. Install the cylinder head cover (1). Refer to «COVER(S), Cylinder Head , Installation , 4.7L»(ref-457796-S35079994162012030200000) .

REMOVAL

The valve stem seal is integral with the valve spring seat. For removal, refer to SPRING(S), Valve , Removal , 4.7L .

The valve stem seal is integral with the valve spring seat. For installation, refer to SPRING(S), Valve , Installation , 4.7L .

1. Remove the cylinder head cover. Refer to «COVER(S), Cylinder Head , Removal , 4.7L»(ref-457796-S21006565632012030200000) .
2. Using Valve Spring Compressor (special tool #10102, Remover/Installer, Valve Spring) (2), remove the rocker arms and the hydraulic lash adjusters.
3. Remove the spark plug for the cylinder the valve spring and seal are to be removed from.
4. Apply shop air to the cylinder to hold the valves in place when the spring is removed NOTE: All eight valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.
5. Using Valve Spring Compressor (special tool #10102, Remover/Installer, Valve Spring), compress the valve spring. NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
6. Remove the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
7. Remove the valve spring compressor.
8. Remove the spring retainer, and the spring.
9. Remove the valve stem seal.

Scheme 229

1. Coat the valve stem with clean engine oil and install the valve stem seal. Make sure the seal is fully seated and that the garter spring at the top of the seal is intact.
2. Install the spring (6) and the spring retainer (2).
3. Using Valve Spring Compressor (special tool #10102, Remover/Installer, Valve Spring), compress the spring and install the two valve spring retainer halves.
4. Release the valve spring compressor and make sure the two spring retainer halves and the spring retainer are fully seated.
5. Position the hydraulic lash adjusters and rocker arms.
6. Install the cylinder head cover. Refer to «COVER(S), Cylinder Head , Installation , 4.7L»(ref-457796-S35079994162012030200000) .
7. Install spark plugs and plug wires.

Note. The cylinder head(s) must be removed in order to perform this procedure.

1. Remove and isolate the negative battery cable.
2. Remove the cylinder head covers. Refer to «COVER(S), Cylinder Head , Removal , 4.7L»(ref-457796-S21006565632012030200000) .
3. Remove the rocker arms and lash adjusters. Refer to «ROCKER ARM, Valve , Removal , 4.7L»(ref-457796-S26579772992012030200000) .
4. Remove the camshaft bearing caps and the camshaft. Refer to «CAMSHAFT, Engine , Removal , 4.7L»(ref-457796-S15185621032012030200000) .
5. Remove the cylinder head(s). Refer to «Cylinder Head , Removal , 4.7L»(ref-457796-S08821695472012030200000) . NOTE: All valve springs and valves are removed in the same manner; this procedure only covers one valve and valve spring.
6. Using Valve Spring Compressor (special tool #C-3422-D, Compressor, Valve Spring) and Adapter (special tool #8519, Adapters, Valve Spring), 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.
7. Remove the two spring retainer lock halves. NOTE: The valve spring is under tension, use care when releasing the valve spring compressor.
8. Remove the valve spring compressor.
9. 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.
10. Remove the valve from the cylinder head. NOTE: The valve stem seals are common between intake and exhaust.
11. Remove the valve stem seal. Mark the valve for proper installation.

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

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

1. Position the structural cover in the vehicle.
2. Install all four bolts (1, 2, 3)retaining the cover-to-engine. see scheme 112 DO NOT tighten the bolts at this time.
3. Install the four cover-to-transmission bolts (1, 2, 3). Do NOT tighten at this time. CAUTION: The structural dust cover must be held tightly against both the engine and the transmission bell housing during the tightening sequence. Failure to do so may cause severe damage to the cover.
4. Starting with the two rear cover-to-engine bolts, tighten bolts (1) to 54 N.m (40 ft. lbs.), then tighten bolts (2) and (3) to 54 N.m (40 ft. lbs.) in the sequence shown in illustration.
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. To remove the crankshaft from the engine, the engine must be removed from the vehicle.

Scheme 230

Scheme 231

1. Remove the engine. Refer to «Removal , 4.7L»(ref-457796-S26769621242012030200000) .
2. Remove the engine oil pump. Refer to «PUMP, Engine Oil , Removal , 4.7L»(ref-457796-S36420706632012030200000) . 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 «PAN, Oil , Removal , 4.7L»(ref-457796-S06968229502012030200000) .
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 any way. 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 in illustration.
7. Carefully pry on the pry points (3) to loosen the bedplate (2) then remove the bedplate. CAUTION: When removing the crankshaft, use care not to damage bearing surfaces on the crankshaft.
8. Remove the crankshaft.

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 in illustration.
3. Install the transmission. Refer to «Installation»(ref-457827-S35623041182012030200000) .

Scheme 232

1. Drain the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
2. Using a blunt tool such as a drift or a screw driver and a hammer, strike the bottom edge of the cup plug (5).
3. Using a suitable pair of pliers, grasp the core plug (5) and remove.

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 «Standard Procedure»(ref-457792-S30781673372012030200000) .

Scheme 233

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

Scheme 234

Scheme 235

Scheme 236

Scheme 237

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 12 mm (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 (1) check the ring end gap. Replace any rings not within specification. 1 - FEELER GAUGE 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 in illustration. Make sure the feeler gauge (1) fits snugly between the ring land and the ring. Replace any ring not within specification.
6. Rotate the ring around the piston, the ring must rotate in the groove with out binding. PISTON RING SPECIFICATION CHART (1 OF 2) Ring Position Groove Clearance Maximum Clearance Upper Ring 0.051 - 0.094 mm 0.11 mm - (0.0020 - 0.0037 in.) (0.004 in.) Intermediate Ring 0.04 - 0.08 mm 0.10 mm - (0.0016 - 0.0031 in.) (0.004 in.) Oil Control Ring 0.019 - 0.229 mm 0.25 mm (Steel Rails) (0.0007-.0090 in.) (0.010 in.) PISTON RING SPECIFICATION CHART (1 OF 2) Ring Position Ring Gap Wear Limit Upper Ring 0.20 - 0.36 mm 0.43 mm - (0.0079 - 0.0142 in.) (0.0017 in.) Intermediate Ring 0.37 - 0.63 mm 0.74 mm - (0.0146 - 0.0249 in.) (0.029 in.) Oil Control Ring 0.025 - 0.76 mm 1.55 mm (Steel Rail) (0.0099 - 0.03 in.) (0.061 in.) 1 - SIDE RAIL END
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 (1) 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.
11. Install No. 1 upper piston ring using a piston ring installer. 1 - SIDE RAIL UPPER 2 - NO. 1 RING GAP 3 - PISTON PIN 4 - SIDE RAIL LOWER 5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
12. Position piston ring end gaps as shown in illustration. It is important that expander ring gap (5) is at least 45° from the side rail gaps, but not on the piston pin center or on the thrust direction.

Scheme 238

1. Before installing piston and connecting rod assemblies into the bore, install the piston rings.
2. Immerse the piston head and rings in clean engine oil. Position a ring compressor (3) over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation.
3. Position bearing onto connecting rod. Ensure that hole in bearing shell aligns with hole in connecting rod. Lubricate bearing surface with clean engine oil.
4. Install Special Tool (special tool #8507, Guides, Connecting Rod) Connecting Rod Guides (4) into connecting rod bolt threads. 1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SLINGER SLOT
5. The pistons are marked on the piston pin bore surface with an raised "F" indicating installation position (1). This mark must be pointing toward the front of engine on both cylinder banks. The connecting rod oil slinger slot faces the front of the engine .
6. Wipe cylinder bore clean and lubricate with engine oil.
7. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal.
8. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal. CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed.
9. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 27 N.m (20 ft. lbs.) plus 90°.
10. Install the following components: Cylinder head(s). Refer to «Cylinder Head , Installation , 4.7L»(ref-457796-S37984006592012030200000) . Timing chain and cover. Refer to «COVER(S), Engine Timing , Installation , 4.7L»(ref-457796-S32975697962012030200000) . Cylinder head covers. Refer to «COVER(S), Cylinder Head , Installation , 4.7L»(ref-457796-S35079994162012030200000) . Oil pan and gasket/windage tray. Refer to «PAN, Oil , Installation , 4.7L»(ref-457796-S30829834102012030200000) .
11. Fill crankcase with proper engine oil to correct level.
12. Connect negative cable to battery.

Scheme 239

Scheme 240

1. Disconnect negative cable from battery.
2. Remove accessory drive belt. Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
3. Remove A/C compressor mounting fasteners and set compressor aside.
4. Drain cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
5. Remove upper radiator hose.
6. Disconnect electrical connector for fan mounted inside radiator shroud.
7. Remove radiator shroud attaching fasteners. NOTE: Transmission cooler line snaps into shroud lower right hand corner.
8. Remove radiator cooling fan and shroud. Refer to «FAN, Cooling, Electric , Removal»(ref-457792-S13033663812012030200000) and «FAN, Cooling, Viscous , Removal»(ref-457792-S41329399382012030200000) .
9. Remove crankshaft damper bolt.
10. Remove damper using Crankshaft Insert (special tool #8513A, Insert, Crankshaft) (1) and (special tool #1023, Puller) Three Jaw Puller (2).
11. Using Crankshaft Front Seal Remover (special tool #8511, Remover, Seal) (1), remove crankshaft front seal.

Scheme 241

1. Using Seal Installer (special tool #8348, Installer, Seal) and Damper Installer (special tool #8512A, Installer, Damper) (2, 3), install crankshaft front seal.
2. Install vibration damper. Refer to «DAMPER, Vibration , Installation , 4.7L»(ref-457796-S39094303242012030200000) .
3. Install radiator cooling fan and shroud. Refer to «FAN, Cooling, Electric , Installation»(ref-457792-S30022413072012030200000) and «FAN, Cooling, Viscous , Installation»(ref-457792-S33156171422012030200000) .
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 «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .
7. Refill cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
8. Connect negative cable to battery.

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.).

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 in illustration.
4. Lower the engine into mounts using special tool (special tool #8534B, Fixture, Driveline Support).
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 (special tool #8534B, Fixture, Driveline Support).
7. Connect cooler lines to radiator, transmission and clips. NOTE: When connecting the transmission oil cooler lines, it is necessary to replace the line clip that is located on the oil pan stud. The retention force of the clip is severely degraded upon removal.
8. Install structural dust cover, if equipped.
9. Install the front crossmember. Refer to «CROSSMEMBER, Lower Control Arm , Installation»(ref-457829-S30643828682012030200000) or «CROSSMEMBER, Transmission , Installation»(ref-457829-S11579147072012030200000) .
10. Fill engine oil.
11. Reconnect the negative battery cable.
12. Start engine and check for leaks.

1. Remove the oil pan and pick-up tube. Refer to «PAN, Oil , Removal , 4.7L»(ref-457796-S06968229502012030200000) .
2. Remove the timing chain cover. Refer to «COVER(S), Engine Timing , Removal , 4.7L»(ref-457796-S27348107972012030200000) .
3. Remove the timing chains and tensioner. Refer to «CHAIN and SPROCKETS, Timing , Removal , 4.7L»(ref-457796-S16479639572012030200000) .
4. Remove the four bolts, primary timing chain tensioner and the oil pump.

1. Disconnect the negative cable from the battery.
2. Raise vehicle on hoist.
3. Remove front splash shield.
4. Disconnect oil pressure sender wire (4).
5. Remove the pressure sender (2). see scheme 167

Scheme 242

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

1. Install intake manifold gaskets.
2. Position intake manifold.
3. Install intake manifold retaining bolts and tighten in sequence shown in illustration 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 «RAIL, Fuel , Installation»(ref-457834-S02263841702012030200000) .
9. Install ignition coil towers.
10. Position and install heater hoses and tubes onto intake manifold.
11. Install the heater hoses to the heater core and engine front cover.
12. Connect electrical connectors for the following components: Manifold Absolute Pressure (MAP) Sensor Intake Air Temperature (IAT) Sensor Throttle Position (TPS) Sensor Coolant Temperature (CTS) Sensor Idle Air Control (IAC) Motor Ignition coil towers Fuel injectors
13. Install top oil dipstick tube retaining bolt and ground strap.
14. Connect generator electrical connections.
15. Connect Brake booster hose and Positive crankcase ventilation (PCV) hose.
16. Fill cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
17. Install resonator assembly and air inlet hose.
18. Connect negative cable to battery.

Scheme 243

The timing drive system has been designed to provide quiet performance and reliability to support a non-free wheeling engine. Specifically the intake valves are non-free wheeling and can be easily damaged with forceful engine rotation if camshaft-to-crankshaft timing is incorrect. The timing drive system consists of a primary chain and two secondary timing chain drives.

1. Remove the primary and secondary timing chains and sprockets. Refer to «CHAIN and SPROCKETS, Timing , Removal , 4.7L»(ref-457796-S16479639572012030200000) . 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 (special tool #8517, Remover) 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 «CHAIN and SPROCKETS, Timing , Installation , 4.7L»(ref-457796-S29246556642012030200000) .