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and measure clearance between the outer rotor and the body (Fig. 80). If the measurement is 0.235mm (0.009 in.) or more the oil pump assembly must be replaced.
(7) Install the inner rotor in the into the oil pump body. Measure the clearance between the inner and outer rotors (Fig. 81). If the clearance between the rotors is .150 mm (0.006 in.) or more the oil pump assembly must be replaced.
(8) Place a straight edge across the body of the oil pump (between the bolt holes), if a feeler gauge of .095 mm (0.0038 in.) or greater can be inserted between the straightedge and the rotors, the pump must be replaced (Fig. 82).
ENGINE - 3.7L
9 - 68
OIL PUMP (Continued)NOTE: The 3.7 Oil pump is released as an assem- bly. There are no DaimlerChrysler part numbers for Sub-Assembly components. the oil pump is not functioning or out of specification it must be replaced as an assembly.
In the event
DR
Fig.79MeasuringInnerRotorThickness
Fig.77CheckingOilPumpCoverFlatness
1 - STRAIGHT EDGE 2 - FEELER GAUGE 3 - OIL PUMP COVER
Fig.80MeasuringOuterRotorClearance
1 - FEELER GAUGE 2 - OUTER ROTOR
INSTALLATION
Fig.78MeasuringOuterRotorThickness
ASSEMBLY
(1) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
(2) Install inner and outer rotors (3) Install oil pump cover plate and install cover
bolts and tighten them to 12 N·m (105 in. lbs.).
(4) Prime oil pump before installation by filling
rotor cavity with engine oil.
(5) If oil pressure is low and pump is within spec- ifications, inspect for worn engine bearings or other causes for oil pressure loss.
(1) Position the oil pump onto the crankshaft and
install one oil pump retaining bolts.
(2) Position the primary timing chain tensioner
and install three retaining bolts.
(3) Tighten the oil pump and primary timing chain tensioner retaining bolts to 28 N·m (250 in. lbs.) in the sequence shown (Fig. 83).
(4) Install the secondary timing chain tensioners and timing chains (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).
(5) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
DR OIL PUMP (Continued)
ENGINE - 3.7L
9 - 69
Fig.81MeasuringClearanceBetweenRotors
1 - OUTER ROTOR 2 - FEELER GAUGE 3 - INNER ROTOR
Fig.83OilPumpAndPrimaryTimingChain
TensionerTighteningSequence
(2) Using a suitable oil filter wrench loosen filter. (3) Rotate the oil filter counterclockwise (Fig. 84)
to remove it from the cylinder block oil filter boss.
Fig.82MeasuringClearanceOverRotors
1 - STRAIGHT EDGE 2 - FEELER GAUGE
(6) Install the pick-up tube and oil pan (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - INSTALLA- TION).OIL FILTER REMOVAL
All engines are equipped with a high quality full- flow, disposable type oil filter. DaimlerChrysler Cor- poration recommends a Mopart or equivalent oil filter be used.
(1) Position a drain pan under the oil filter.
Fig.84OILFILTER
1 - ENGINE OIL FILTER
(4) When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle.
ENGINE - 3.7L
9 - 70
OIL FILTER (Continued)NOTE: Make sure filter gasket was removed with fil- ter.
(5) With a wiping cloth, clean the gasket sealing
surface of oil and grime.
INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil.
(2) Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Fig. 85) hand tighten filter one full turn, do not over tighten.
(3) Add oil, verify crankcase oil
level and start
engine. Inspect for oil leaks.
DR
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi- fied. MOPARt provides engine oils that conform to this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis- cosity of engine oil. Use only engine oils with multi- ple viscosities such as 5W-30 or 10W-30 in the 4.7L engines. These are specified with a dual SAE viscos- ity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and vari- ation (Fig. 86).
Fig.85OilFilterSealingSurface-Typical
1 - SEALING SURFACE 2 - RUBBER GASKET 3 - OIL FILTER
OIL STANDARD PROCEDURE - ENGINE OIL SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result.
Fig.86TEMPERATURE/ENGINEOILVISCOSITY-
4.7LENGINE
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CON- SERVING is located on the label of an engine oil con- tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans (Fig. 87).
Fig.87EngineoilContainerStandardNotations
DR OIL (Continued) OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the right
rear of the engine on the 4.7L engines. (Fig. 88).
Fig.88ENGINEOILDIPSTICK4.7LENGINE
1 - TRANSMISSION DIPSTICK 2 - ENGINE OIL DIPSTICK 3 - ENGINE OIL FILL CAP
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result.
Inspect engine oil level approximately every 800
kilometers (500 miles). Unless the engine has exhib- ited 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 min- utes 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
(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
tube.
dipstick.
ENGINE - 3.7L
9 - 71
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in Maintenance Schedules.
Run engine until achieving normal operating tem-
perature.
engine off.
drain.
(1) Position the vehicle on a level surface and turn
(2) Hoist and support vehicle on safety stands. (3) Remove oil fill cap. (4) Place a suitable drain pan under crankcase
(5) Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged.
(6) Install drain plug in crankcase. (7) Lower vehicle and fill crankcase with specified type and amount of engine oil described in this sec- tion.
(8) Install oil fill cap. (9) Start engine and inspect for leaks. (10) Stop engine and inspect oil level.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING at beginning of this section.
INTAKE MANIFOLD DESCRIPTION
The intake manifold (Fig. 89) is made of a compos- ite material and features 300 mm (11.811 in.) long runners which maximizes low end torque. The intake manifold uses single plane sealing which consist of six individual press in place port gaskets to prevent leaks. The throttle body attaches directly to the intake manifold. Eight studs and two bolts are used to fasten the intake to the head.
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS
An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
ENGINE - 3.7L
9 - 72
INTAKE MANIFOLD (Continued)DR
(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 FUEL SYSTEM. (12) Remove fuel rail. (13) Remove throttle body assembly and mounting
bracket.
(14) Drain cooling system below coolant tempera-
ture level. Refer to COOLING SYSTEM.
(15) Remove the heater hoses from the engine
front cover and the heater core.
(16) Unclip and remove heater hoses and tubes
from intake manifold.
FUEL SYSTEM.
(17) Remove coolant temperature sensor. Refer to
(18) Remove intake manifold retaining fasteners in
reverse order of tightening sequence.
(19) Remove intake manifold.
INSTALLATION
(1) Install intake manifold gaskets. (2) Install intake manifold. (3) Install
intake manifold retaining bolts and tighten in sequence shown in to 12 N·m (105 in. lbs.) (Fig. 90).
Fig.89IntakeManifold
1 - THROTTLE BODY 2 - INTAKE MANIFOLD 3 - INTAKE PORT GASKETS
(2) Spray a small stream of water (spray bottle) at
the suspected leak area.
(3) If engine RPM’S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
(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 follow- ing components: Refer to FUEL SYSTEM for compo- nent locations.
† 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 vapor purge hose, brake booster hose, speed control servo hose, positive crankcase ventilation (PCV) hose.
(6) Disconnect generator electrical connections. (7) Disconnect air conditioning compressor electri-
cal connections.
Fig.90IntakeManifoldTighteningSequence
(4) Install left and right radio suppressor straps. (5) Install throttle body assembly. (6) Connect throttle cable and speed control cable
to throttle body.
(7) Install fuel rail. (8) Install ignition coil towers.
DR INTAKE MANIFOLD (Continued)
(9) Position and install heater hoses and tubes
onto intake manifold.
engine front cover.
(10) Install the heater hoses to the heater core and
(11) 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 (12) Install top oil dipstick tube retaining bolt and
ground strap.
(13) Connect generator electrical connections. (14) Connect Vapor purge hose, Brake booster hose, Speed control servo hose, Positive crankcase ventilation (PCV) hose.
(15) Fill cooling system. (16) Install resonator assembly and air inlet hose. (17) Connect negative cable to battery.
EXHAUST MANIFOLD DESCRIPTION
The exhaust manifolds (Fig. 91) are log style with a patented flow enhancing design to maximize perfor- mance. The exhaust manifolds are made of high sili- con molybdenum cast iron. A perforated core graphite
Fig.91EXHAUSTMANIFOLDS
1 - LEFT SIDE EXHAUST MANIFOLD 2 - RIGHT SIDE EXHAUST MANIFOLD
ENGINE - 3.7L
9 - 73
exhaust manifold gasket is used to improve sealing to the cylinder head. The exhaust manifolds are cov- ered by a three layer laminated heat shield for ther- mal protection and noise reduction. The heat shields (Fig. 92) are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold.
Fig.92ExhaustManifoldHeatShields
1 - RIGHT SIDE EXHAUST MANIFOLD HEAT SHIELD 2 - RIGHT SIDE EXHAUST MANIFOLD FLANGE 3 - LEFT SIDE EXHAUST MANIFOLD HEAT SHIELD 4 - LEFT SIDE EXHAUST MANIFOLD FLANGE
REMOVAL
RIGHT EXHAUST MANIFOLD
(1) Disconnect the negative cable from the battery. (2) Raise and support the vehicle. (3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold.
(4) Lower the vehicle. (5) Remove the exhaust heat shield (Fig. 93). (6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold and gasket from the cylinder
head.
ENGINE - 3.7L
9 - 74
EXHAUST MANIFOLD (Continued)DR
Fig.93ExhaustManifoldRight
Fig.94ExhaustManifoldleft
1 - HEAT SHIELD 2 - NUTS 3 - MANIFOLD FLANGE
LEFT EXHAUST MANIFOLD
(1) Disconnect the negative cable from the battery. (2) Raise and support the vehicle. (3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold.
(4) Lower the vehicle. (5) Remove the exhaust heat shields (Fig. 94). (6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold and gasket from the cylinder
head.
INSTALLATION
RIGHT EXHAUST MANIFOLD
CAUTION: If the studs came out with the nuts when removing the engine exhaust manifold, install new studs. Apply sealer on the coarse thread ends. Water leaks may develop at the studs if this precau- tion is not taken.
(1) Position the engine exhaust manifold and gas- ket on the two studs located on the cylinder head. Install conical washers and nuts on these studs.
(2) Install remaining conical washers. Starting at the center arm and working outward, tighten the bolts and nuts to 25 N·m (18 ft. lbs.) torque.
(3) Install the exhaust heat shields. (4) Raise and support the vehicle.
1 - HEAT SHIELD 2 - NUTS 3 - MANIFOLD FLANGE
CAUTION: Over tightening heat shield fasteners, may cause shield to distort and/or crack.
(5) Assemble exhaust pipe to manifold and secure with bolts, nuts and retainers. Tighten the bolts and nuts to 34 N·m (25 ft. lbs.) torque.
LEFT EXHAUST MANIFOLD
CAUTION: If the studs came out with the nuts when removing the engine exhaust manifold, install new studs. Apply sealer on the coarse thread ends. Water leaks may develop at the studs if this precau- tion is not taken.
(1) Position the engine exhaust manifold and gas- ket on the two studs located on the cylinder head. Install conical washers and nuts on these studs.
(2) Install remaining conical washers. Starting at the center arm and working outward, tighten the bolts and nuts to 25 N·m (18 ft. lbs.) torque.
(3) Install the exhaust heat shields. (4) Raise and support the vehicle.
CAUTION: Over tightening heat shield fasteners, may cause shield to distort and/or crack.
(5) Assemble exhaust pipe to manifold and secure with bolts, nuts and retainers. Tighten the bolts and nuts to 34 N·m (25 ft. lbs.) torque.
DR
VALVE TIMING DESCRIPTION
The timing drive system has been designed to pro- vide quiet performance and reliability to support a non-free wheeling engine. Specifically the intake valves are non-free wheeling and can be easily dam- aged with forceful engine rotation if camshaft-to- crankshaft timing is incorrect. The timing drive system consists of a primary chain, two secondary timing chain drives (Fig. 95) and a counterbalance shaft drive.
OPERATION
The primary timing chain is a single inverted tooth chain type. The primary chain drives the large 50
ENGINE - 3.7L
9 - 75
tooth idler sprocket directly from a 25 tooth crank- shaft sprocket. Primary chain motion is controlled by a pivoting leaf spring tensioner arm and a fixed guide. The arm and the guide both use nylon plastic wear faces for low friction and long wear. The pri- mary chain receives oil splash lubrication from the secondary chain drive and designed oil pump leak- age. The idler sprocket assembly connects the pri- mary chain drive, secondary chain drives, and the counterbalance shaft. The idler sprocket assembly consists of two integral 26 tooth sprockets a 50 tooth sprocket and a helical gear that is press-fit to the assembly. The spline joint for the 50 tooth sprocket is a non – serviceable press fit anti rattle type. A spiral ring is installed on the outboard side of the 50 tooth sprocket to prevent spline disengagement. The idler sprocket assembly spins on a stationary idler shaft.
Fig.95TimingDriveSystem
1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN 2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT SIDE NOT INTERCHANGEABLE) 3 - SECONDARY TENSIONER ARM 4 - LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN 5 - CHAIN GUIDE (LEFT AND RIGHT SIDE ARE NOT INTERCHANGEABLE)
6 - PRIMARY CHAIN 7 - IDLER SPROCKET 8 - CRANKSHAFT SPROCKET 9 - PRIMARY CHAIN TENSIONER
ENGINE - 3.7L
9 - 76
VALVE TIMING (Continued)The idler shaft is a light press-fit into the cylinder block. A large washer on the idler shaft bolt and the rear flange of the idler shaft are used to control sprocket thrust movement. Pressurized oil is routed through the center of the idler shaft to provide lubri- cation for the two bushings used in the idler sprocket assembly.
There are two secondary drive chains, both are roller type, one to drive the camshaft in each SOHC cylinder head. There are no shaft speed changes in the secondary chain drive system. Each secondary chain drives a 26 tooth cam sprocket directly from the 26 tooth sprocket on the idler sprocket assembly. A fixed chain guide and a hydraulic oil damped ten- sioner are used to maintain tension in each second- ary chain system. The hydraulic tensioners for the secondary chain systems are fed pressurized oil from oil reservoir pockets in the block. Each tensioner incorporates a controlled leak path through a device known as a vent disc located in the nose of the piston to manage chain loads. Each tensioner also has a mechanical ratchet system that limits chain slack if the tensioner piston bleeds down after engine shut down. The tensioner arms and guides also utilize nylon wear faces for low friction and long wear. The secondary timing chains receive lubrication from a small orifice in the tensioners. This orifice is pro- tected from clogging by a fine mesh screen which is located on the back of the hydraulic tensioners.
STANDARD PROCEDURE
MEASURING TIMING CHAIN WEAR
NOTE: This procedure must be performed with the timing chain cover removed.
(1) Remove the timing chain cover. Refer to Timing
Chain Cover in this section for procedure.
(2) To determine if the secondary timing chains are worn, rotate the engine clockwise until maximum tensioner piston extension is obtained. Measure the distance between the secondary timing chain ten- sioner housing and the step ledge on the piston. The measurement at point (A) must be less than 15mm (.5906 inches).
(3) If the measurement exceeds the specification the secondary timing chains are worn and require replacement. Refer to Timing Chain and Sprockets in this section for procedure.
SERVICE PROCEDURE - TIMING VERIFICATION
CAUTION: The 3.7L is a non free-wheeling design engine. Therefore, correct engine timing is critical.
DR
NOTE: Components referred to as left hand or right hand are as viewed from the drivers position inside the vehicle.
NOTE: The blue link plates on the chains and the dots on the camshaft drive sprockets may not line up during the timing verification procedure. The blue link plates are lined up with the sprocket dots only when re-timing the complete timing drive. Once the timing drive is rotated blue link-to-dot alignment is no longer valid.
Engine base timing can be verified by the following
procedure:
(1) Remove the cylinder head covers. Refer to the
procedure in this section.
(2) Using a mirror, locate the TDC arrow on the front cover (Fig. 96). Rotate the crankshaft until the mark on the crankshaft damper is aligned with the TDC arrow on the front cover. The engine is now at TDC.
Fig.96EngineTopDeadCenter(TDC)Indicator
Mark
1 - TIMING CHAIN COVER 2 - CRANKSHAFT TIMING MARKS
(3) Note the location of the V6 mark stamped into the camshaft drive gears. If the V6 mark on each camshaft drive gear is at the twelve o’clock position, the engine is at TDC on the exhaust stroke. If the V6
mark on each gear is at the six o’clock position, the engine is at TDC on the compression stroke. (Fig. 100)DR VALVE TIMING (Continued)
(4) If both of the camshaft drive gears are off in the same or opposite directions, the primary chain or both secondary chains are at fault. Refer to Timing Chain and Sprockets procedure in this section.
(5) If only one of the camshaft drive gears is off and the other is correct, the problem is confined to one secondary chain. Refer to Single camshaft tim- ing, in this procedure.
(6) If both camshaft drive gear V6 marks are at the twelve o’clock or the six o’clock position the engine base timing is correct. Reinstall the cylinder head covers.
ENGINE - 3.7L
9 - 77
TIMING - SINGLE CAMSHAFT
NOTE: to adjust the timing on one camshaft, pre- form the following procedure.
(1) Using Chain Tensioner Wedge (Fig. 99), Special Tool 8379, stabilize the secondary chain drive. For reference purposes, mark the chain-to-sprocket posi- tion. (Fig. 98)
(2) Remove the camshaft drive gear retaining bolt.
COUNTER BALANCE SHAFT TIMING
(1) Ensure that the engine is at TDC with both camshaft sprocket V6 marks in the 12 o’clock posi- tion. (Fig. 100)
(2) Look down the left cylinder head chain cavity. The timing dot on the counter balance shaft drive gear should be in the 6 o’clock position (Fig. 97).
Fig.98SECURINGTIMINGCHAINTENSIONER
USINGTIMINGCHAINWEDGE
1 - CYLINDER HEAD 2 -SPECIAL TOOL 8379
3 - TIMING CHAINFig.97COUNTERBALANCESHAFTALIGNMENT
MARKS 1 - COUNTERBALANCE SHAFT GEAR 2 - TIMING MARK 3 - IDLER SPROCKET GEAR
ENGINE - 3.7L
9 - 78
VALVE TIMING (Continued)DR
(5) Using Special Tool 8428 Camshaft Wrench, rotate the camshaft until the alignment dowel on the camshaft is aligned with the slot in the camshaft drive gear.
CAUTION: Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt. Fail- ure to do so may cause over-torqueing of bolt resulting in bolt failure.
(6) Position the camshaft drive gear onto the cam- shaft, remove oil from bolt then install the retaining bolt. Using Special Tools, Spanner Wrench 6958 with Adapter Pins 8346 and a suitable torque wrench, Tighten retaining bolt to 122 N·m (90 ft. Lbs.).
(7) Remove Special Tool 8379. (8) Rotate the crankshaft two full revolutions, then verify that the camshaft drive gear V6 marks are in fact aligned.
(9) Install the cylinder head covers. Refer to Cylin-
der Head Cover in this section.
Fig.99CAMSHAFTDRIVEGEARREMOVAL/
INSTALLATION
1 - SPECIAL TOOL 8279 TIMING CHAIN WEDGE 2 - CAMSHAFT DRIVE GEAR 3 - RETAINING BOLT 4 - CYLINDER HEAD
(3) Carefully remove the camshaft drive gear from
the camshaft.
(4) Re-index the camshaft drive gear in the chain until the V6 mark is at the same position as the V6
mark on the opposite camshaft drive gear.1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD
Fig.100CAMSHAFTSPROCKETV6MARKS(#1TDC,Exhauststroke)
DR
ENGINE - 3.7L
9 - 79
BALANCE SHAFT REMOVAL
(1) Remove the primary and secondary timing
chains. Refer to TIMING CHAIN and SPROCKET.
NOTE: The balance shaft and gear are serviced as an assembly. Do not attempt to remove the gear from the balance shaft.Remove the retaining bolt from the counterbalance shaft thrust plate (Fig. 101).
Fig.102CounterbalanceShaftRemoval/Installation
Tool
1 - COUNTERBALANCE SHAFT REMOVAL AND INSTALLATION TOOL 2 - COUNTERBALANCE SHAFT THRUST PLATE
Fig.101CounterbalanceShaftRetainingPlate
1 - IDLER SHAFT 2 - COUNTERBALANCE SHAFT THRUST PLATE 3 - COUNTERBALANCE SHAFT DRIVE GEAR 4 - RETAINING BOLT
(2) Using Special Tool 8641 Counterbalance shaft remover/installer tool, remove the counterbalance shaft from the engine (Fig. 102).
INSTALLATION
NOTE: The balance shaft and gear are serviced as an assembly. Do not attempt to remove the gear from the balance shaft.
(1) Coat
counterbalance shaft bearing journals
with clean engine oil.
NOTE: The balance shaft is heavy, and care should be used when installing shaft, so bearings are not damaged.
(2) Using Special Tool 8641 Counterbalance shaft remover/installer tool, carefully install counterbal- ance shaft into engine.
(3) Install Counterbalance
thrust plate retaining bolt finger tight.Do not tighten bolt at this time.
shaft
(4) Position the right side of the thrust plate with
the right chain guide bolt, install bolt finger tight.
(5) Torque the thrust plate retaining bolt to 28
N·m (250 in. lbs.).
be installed.
(6) Remove the chain guide bolt so that guide can
IDLER SHAFT REMOVAL
(1) Remove the primary and secondary timing chains and sprockets. Refer to procedure in this sec- tion.
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.
DR
ENGINE - 3.7L
9 - 80
IDLER SHAFT (Continued)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.
INSTALLATION
(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 procedure in this section.
TIMING BELT / CHAIN COVER(S) REMOVAL
(1) Disconnect the battery negative cable. (2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove electric cooling fan and fan shroud
assembly.
(4) Remove fan and fan drive assembly (Refer to 7
VISCOUSCOOLING/ENGINE/FAN
DRIVE
CLUTCH - REMOVAL).
(5) Disconnect both heater hoses at timing cover. (6) Disconnect lower radiator hose at engine. (7) Remove accessory drive belt tensioner assembly
(Fig. 103).
(8) Remove crankshaft damper
to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(Refer
(9) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(10) Remove A/C compressor (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/A/C COM- PRESSOR - REMOVAL).
CAUTION: The 3.7L engine uses an anerobic sealer instead of a gasket to seal the front cover to the engine block, from the factory. For service, MoparT Engine RTV sealant must be substituted.
Fig.103ACCESSORYDRIVEBELTTENSIONER
1 - TENSIONER ASSEMBLY 2 - FASTENER TENSIONER TO FRONT COVER
NOTE: pump for timing cover removal.
It
is not necessary to remove the water
(11) Remove the bolts holding the timing cover to
engine block (Fig. 104).
Fig.104TIMINGCHAINCOVERFASTENERS
(12) Remove the timing cover.
ENGINE - 3.7L
9 - 81
DR TIMING BELT / CHAIN COVER(S) (Continued) INSTALLATION
CAUTION: Do not use oil based liquids to clean tim- ing cover or block surfaces. Use only rubbing alco- hol, along with plastic or wooden scrapers. Use no wire brushes or abrasive wheels or metal scrapers, or damage to surfaces could result.
(1) Clean timing chain cover and block surface
using rubbing alcohol.
CAUTION: The 3.7L uses a special anerobic sealer instead of a gasket to seal the timing cover to the engine block, from the factory. For service repairs, MoparT Engine RTV must be used as a substitute.
(2) Inspect the water passage o-rings for any dam-
age, and replace as necessary.
(3) Apply Mopart Engine RTV sealer to front cover following the path below using a 3 to 4mm thick bead (Fig. 105).
Fig.105TIMINGCOVERSEALANT
1 - TIMING CHAIN COVER 2 - WATER PASSAGE ORING 3 - MOPART ENGINE RTV SEALER
(4) Install cover. Tighten fasteners in sequence as
(5) Install
shown in to 58 N·m (43 ft. lbs.) (Fig. 106). (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
crankshaft damper
(6) Install the A/C compressor (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/A/C COM- PRESSOR - INSTALLATION).
Fig.106TIMINGCHAINCOVERFASTENERS
(7) Install the generator (Refer to 8 - ELECTRI- CAL/CHARGING/GENERATOR - INSTALLATION). (8) Install accessory drive belt tensioner assembly (Refer to 7 - COOLING/ACCESSORY DRIVE/BELT TENSIONERS - INSTALLATION).
(9) Install radiator upper and lower hoses. (10) Install both heater hoses. (11) Install electric fan shroud and viscous fan drive assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).
(12) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(13) Connect the battery negative cable.
TIMING BELT/CHAIN AND SPROCKETS REMOVAL
(1) Disconnect negative cable from battery. (2) Drain cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove right and left cylinder head covers(Re- fer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(4) Remove radiator fan shroud(Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(5) Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover (Fig. 108) and the camshaft sprocket “V6” marks are at the 12 o’clock position (#1 TDC exhaust stroke) (Fig. 107).
(6) Remove power steering pump(Refer to 19 -
STEERING/PUMP - REMOVAL).
(7) Remove access plug from left and right cylinder heads for access to chain guide fasteners (Fig. 109).
ENGINE - 3.7L
9 - 82
TIMING BELT/CHAIN AND SPROCKETS (Continued)DR
Fig.107CAMSHAFTSPROCKETV6MARKS,(#1TDCEXHAUSTSTROKE)
1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD
Fig.109CylinderHeadAccessPlugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
Fig.108EngineTopDeadCenter
1 - TIMING CHAIN COVER 2 - CRANKSHAFT TIMING MARKS
DR TIMING BELT/CHAIN AND SPROCKETS (Continued)
ENGINE - 3.7L
9 - 83
(8) Remove the oil fill housing to gain access to the
right side tensioner arm fastener.
(9) Remove crankshaft damper
to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL) and timing chain cover(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(Refer
(10) Collapse and pin primary chain tensioner.
CAUTION: Plate behind left secondary chain ten- sioner could fall into oil pan. Therefore, cover pan opening.
(11) Remove secondary chain tensioners. (12) Remove camshaft position sensor (Fig. 110).
Fig.110CamshaftPositionSensor
1 - CYLINDER HEAD 2 - CAMSAHFT POSITION SENSOR 3 - SCREW
to damage CAUTION: Care should be taken not 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 tar- get 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 Special Tool 8428 Camshaft Wrench, remove the left camshaft sprocket. Slowly rotate the camshaft approximately 5 degrees clockwise to a neutral posi- tion.
(15) While holding the right camshaft steel tube with Special Tool 8428 Camshaft Wrench, remove the right camshaft sprocket.
(16) Remove idler sprocket assembly bolt. (17) Slide the idler sprocket assembly and crank sprocket forward simultaneously to remove the pri- mary and secondary chains.
(18) Remove both pivoting tensioner arms and
chain guides.
(19) Remove primary chain tensioner.
INSPECTION
excessive wear.
Inspect the following components: † Sprockets for excessive tooth wear. Some tooth markings are normal and not a cause for sprocket replacement. † Idler sprocket assembly bushing and shaft for † Idler sprocket assembly spline joint. The joint should be tight with no backlash or axial movement. † 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. † 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 tensioner arm and chain should be replaced. † Primary chain tensioner plastic faces. Replace as
required.
ENGINE - 3.7L
9 - 84
TIMING BELT/CHAIN AND SPROCKETS (Continued) INSTALLATION(1) Using a vise, lightly compress the secondary chain tensioner piston until the piston step is flush with the tensioner body. Using a pin or suitable tool, release ratchet pawl by pulling pawl back against spring force through access hole on side of tensioner. While continuing to hold pawl back, Push ratchet device to approximately 2 mm from the tensioner body. Install Special Tool 8514 lock pin into hole on front of tensioner (Fig. 111). Slowly open vise to transfer piston spring force to lock pin.
DR
(4) Install the left side chain guide. Tighten the
bolts to 28 N·m (250 in. lbs.).
(5) Install left side chain tensioner arm, and Torxt
bolt. Tighten Torxt 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.).
(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 8429 to hold chains in place for installa- tion.
(8) Align primary chain double plated links with the timing mark at 12 o’clock on the idler sprocket. Align the primary chain single plated link with the timing mark at 6 o’clock on the crankshaft sprocket. (9) Lubricate idler shaft and bushings with clean
engine oil.
NOTE: The idler sprocket must be timed to the counterbalance shaft drive gear before the idler sprocket is fully seated.
Fig.111RESETTINGSECONDARYCHAIN
TENSIONERS
1 - VISE 2 - INSERT LOCK PIN 3 - RATCHET PAWL 4 - RATCHET 5 - PISTON
(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. Install Torxt bolt. Tighten Torxt bolt to 28 N·m (250 in. lbs.).
CAUTION: The silver bolts retain the guides to the cylinder heads and the black bolts retain the guides to the engine block.
Fig.112INSTALLINGIDLERGEAR,PRIMARYAND
SECONDARYTIMINGCHAINS
1 - SPECIAL TOOL 8429
2 - PRIMARY CHAIN IDLER SPROCKET 3 - CRANKSHAFT SPROCKETDR TIMING BELT/CHAIN AND SPROCKETS (Continued)
ENGINE - 3.7L
9 - 85
(14) Verify that all plated links are aligned with the marks on all sprockets and the “V6” marks on camshaft sprockets are at the 12 o’clock position.
CAUTION: Ensure the plate between the left sec- ondary 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) Remove all locking pins (3) from tensioners.
CAUTION: After pulling locking pins out of each tensioner, DO NOT manually extend the tensioner(s) ratchet. Doing so will over tension the chains, resulting in noise and/or high timing chain loads.
(17) Using Special Tool 6958, Spanner with Adap- tor Pins 8346, tighten left (Fig. 114) and right (Fig. 115). camshaft sprocket bolts to 122 N·m (90 ft. lbs.).
(10) Install all chains, crankshaft sprocket, and idler sprocket as an assembly (Fig. 112). After guid- ing both secondary chains through the block and cyl- inder head openings, affix chains with a elastic strap or equivalent. This will maintain tension on chains to aid in installation. Align the timing mark on the idler sprocket gear to the timing mark on the coun- terbalance shaft drive gear, then seat idler sprocket fully (Fig. 113). Before installing idler sprocket bolt, lubricate washer with oil, and tighten idler sprocket assembly retaining bolt to 34 N·m (25 ft. lbs.).
Fig.113COUNTERBALANCESHAFTALIGNMENT
MARKS 1 - COUNTERBALANCE SHAFT GEAR 2 - TIMING MARK 3 - IDLER SPROCKET GEAR
NOTE: It will be necessary to slightly rotate cam- shafts for sprocket installation.
(11) Align left camshaft sprocket “L” dot to plated
link on chain.
plated link on chain.
(12) Align right camshaft sprocket
“R” dot
to
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 8429, then attach both sprockets to camshafts. Remove excess oil from bolts, then Install sprocket bolts, but do not tighten at this time.
Fig.114TIGHTENINGLEFTSIDECAMSHAFT
SPROCKETBOLT
1 - TORQUE WRENCH 2 - CAMSHAFT SPROCKET 3 - LEFT CYLINDER HEAD 4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
ENGINE - 3.7L
9 - 86
TIMING BELT/CHAIN AND SPROCKETS (Continued)DR
Fig.115TIGHTENINGRIGHTSIDECAMSHAFT
SPROCKETBOLT
1 - TORQUE WRENCH 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET 4 - RIGHT CAMSHAFT SPROCKETing marks are at the follow locations:
(18) Rotate engine two full revolutions. Verify tim- † primary chain idler sprocket dot is at 12 o’clock † primary chain crankshaft sprocket dot is at 6
o’clock† secondary chain camshaft sprockets “V6” marks are at 12 o’clock † counterbalancer shaft drive gear dot is alignedto the idler sprocket gear dot
(19) Lubricate all three chains with engine oil. (20) After installing all chains, it is recommended that the idler gear 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 (Fig. 116).
(21) Install
timing chain cover and crankshaft
damper. Refer to procedures.
(22) Install
to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
cylinder head covers(Refer
Fig.116MEASURINGIDLERGEARENDPLAY
1 - IDLER SPROCKET ASSEMBLY 2 - DIAL INDICATOR
NOTE: Before installing threaded plug in right cylin- der head, the plug must be coated with sealant to prevent leaks.
(23) Coat
the large threaded access plug with Mopart Thread Sealant with Teflon, then install into the right cylinder head and tighten to 81 N·m (60 ft. lbs.).
(24) Install the oil fill housing. (25) Install access plug in left cylinder head. (26) Install power steering pump(Refer to 19 -
STEERING/PUMP - INSTALLATION).
(27) Fill cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(28) Connect negative cable to battery.
DR
ENGINE - 4.7L
9 - 87
ENGINE - 4.7L
TABLE OF CONTENTS
page
page
ENGINE - 4.7L
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . 89
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . 91
DIAGNOSIS AND TESTING - CYLINDER
REMOVAL
REMOVAL - RIGHT SIDE . . . . . . . . . . . . . . . 121
REMOVAL - LEFT SIDE . . . . . . . . . . . . . . . . 121
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
INSTALLATIONINSTALLATION - RIGHT SIDE INSTALLATION—LEFT SIDE
. . . . . . . . . . . 121
. . . . . . . . . . . . 122COMPRESSION PRESSURE . . . . . . . . . . . . . 92
INTAKE/EXHAUST VALVES & SEATS
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE . . . . . . 92
DIAGNOSIS AND TESTING - ENGINE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 122
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123DIAGNOSIS - INTRODUCTION . . . . . . . . . . . 93
ROCKER ARM / ADJUSTER ASSEMBLY
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS . . . . . . . . . 93
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS . . . . . . . . . 93
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 96
SPECIFICATIONS4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 98
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 101SPECIAL TOOLS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 124
DIAGNOSIS AND TESTING - HYDRAULICLASH ADJUSTER . . . . . . . . . . . . . . . . . . . . . 124
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 125
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126VALVE STEM SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 126
4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 102
ENGINE BLOCK
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 105CYLINDER HEAD DESCRIPTION
DESCRIPTION - CYLINDER HEAD . . . . . . . 106
DESCRIPTION - VALVE GUIDES . . . . . . . . . 106REMOVAL
REMOVAL - LEFT CYLINDER HEAD . . . . . . 106
REMOVAL - RIGHT CYLINDER HEAD . . . . . 108
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATIONINSTALLATION - LEFT CYLINDER HEAD . . . 110
INSTALLATION - RIGHT CYLINDER HEAD . . 111CAMSHAFT(S) - LEFT
. . . . . . . . . . . . . . . . . . . . . . . . 113
DESCRIPTION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 114CAMSHAFT(S) - RIGHT
. . . . . . . . . . . . . . . . . . . . . . . . 117
DESCRIPTION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 118CYLINDER HEAD COVER(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 121
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 126
STANDARD PROCEDURE—CYLINDER BOREHONING
. . . . . . . . . . . . . . . . . . . . . . . . . . . 126
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 127CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING . . . . . . . . . . . . . . . 128
CORE PLUGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 130CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 130
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 131
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 131CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE—CRANKSHAFT
MAIN BEARING - FITTING . . . . . . . . . . . . . . 133
. . . . . . . . . . . . . . . . . . . . . . . . . 133INSPECTION
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 1349 - 88
ENGINE - 4.7L
DR
CRANKSHAFT OIL SEAL - REAR
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 135
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 136FLEX PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 137PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 137
STANDARD PROCEDURE—PISTON FITTING . 137
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 139PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 142STRUCTURAL COVER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 143
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 143
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 143FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 144REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 147LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 148
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 148
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . 150
DIAGNOSIS AND TESTING—ENGINE OIL
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 153OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 153OIL PRESSURE SENSOR/SWITCH
DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 154
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 154OPERATION
OPERATION OPERATION
. . . . . . . . . . . . . . . . . . . . . . . . 154
. . . . . . . . . . . . . . . . . . . . . . . . 154
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 154OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 155
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 155
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 157INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 157
DIAGNOSIS AND TESTING—INTAKEMANIFOLD LEAKAGE
. . . . . . . . . . . . . . . . . 157
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 158
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 158EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 159
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 161
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 162VALVE TIMING
DESCRIPTION—TIMING DRIVE SYSTEM . . . . 164
OPERATION - TIMING DRIVE SYSTEM . . . . . 164
STANDARD PROCEDURESTANDARD PROCEDURE—MEASURING
TIMING CHAIN WEAR . . . . . . . . . . . . . . . . . 165
STANDARD PROCEDURE - ENGINE TIMING
- VERIFICATION . . . . . . . . . . . . . . . . . . . . . 165
TIMING BELT / CHAIN COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 169TIMING BELT/CHAIN AND SPROCKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 171
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 172IDLER SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 175DR
ENGINE - 4.7L
ENGINE - 4.7L
9 - 89
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION
POSSIBLE CAUSE
CORRECTION
ENGINE WILL NOT START
1. Weak battery
1. Charge or replace as necessary.
2. Corroded or loose battery connections.
3. Faulty starter.
4. Faulty coil or control unit.
5. Incorrect spark plug gap.
6. Dirt or water in fuel system.
7. Faulty fuel pump, relay or wiring.
ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low.
2. Idle mixture too lean or too rich.
3. Vacuum leak.
4. Faulty coil.
5. Incorrect engine timing.
1. ENGINE LOSS OF POWER
1. Dirty or incorrectly gapped spark plugs.
2. Dirt or water in fuel system.
3. Faulty fuel pump.
4. Blown cylinder head gasket.
2. Clean and tighten battery connections. Apply a coat of light mineral grease to the terminals. 3. (Refer to 8 - ELECTRICAL/ STARTING - DIAGNOSIS AND TESTING). 4. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL). 5. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 6. Clean system and replace fuel filter. 7. Repair or replace as necessary.
1. (Refer to 14 - FUEL SYSTEM/ FUEL INJECTION/IDLE AIR CONTROL MOTOR - REMOVAL).
2. Refer to Powertrain Diagnosis Information. 3. Inspect intake manifold and vacuum hoses, repair or replace as necessary. 4. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL). 5. (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE).
1. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 2. Clean system and replace fuel filter. 3. (Refer to 14 - FUEL SYSTEM/ FUEL DELIVERY/FUEL PUMP - DIAGNOSIS AND TESTING). 4. Replace cylinder head gasket.
ENGINE - 4.7L
9 - 90
ENGINE - 4.7L (Continued)DR
CONDITION
POSSIBLE CAUSE
CORRECTION
5. Low compression.
6. Burned, warped or pitted valves. 7. Plugged or restricted exhaust system. 8. Faulty coil.
1. ENGINE MISSES ON ACCELERATION
1. Spark plugs dirty or incorrectly gapped.
2. Dirt in fuel system. 3. Burned, warped or pitted valves. 4. Faulty coil.
1. ENGINE MISSES AT HIGH SPEED
1. Spark plugs dirty or incorrectly gapped.
2. Faulty coil.
3. Dirt or water in fuel system.
5. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING). 6. Replace as necessary. 7. Inspect and replace as necessary. 8. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL).
1. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 2. Clean fuel system. 3. Replcae as necessary. 4. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL).
1. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 2. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL). 3. Clean system and replace fuel filter.
DR ENGINE - 4.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
ENGINE - 4.7L
9 - 91
CONDITION
POSSIBLE CAUSES
CORRECTIONS
NOISY VALVES
1. High or low oil level in crankcase.
2. Thin or diluted oil. 3. Low oil pressure.
4. Dirt in lash adjusters. 5. Worn rocker arms. 6. Worn lash adjusters 7. Worn valve guides.
8. Excessive runout of valve seats on valve faces.
CONNECTING ROD NOISE
1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil. 4. Excessive bearing clearance. 5. Connecting rod journal out-of-round. 6. Misaligned connecting rods.
MAIN BEARING NOISE
1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil. 4. Excessive bearing clearance. 5. Excessive end play. 6. Crankshaft journal out-of round. 7. Loose flywheel or torque converter.
1. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS)
2. Change oil and filter. 3. Check oil pump, if Ok, check rod and main bearings for excessive wear. 4. Replace as necessary. 5. Replace as necessary. 6. Replace as necessary. 7. (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE) 8. (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE)
1. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS)
2. Check oil pump, if Ok, check rod and main bearings for excessive wear. 3. Change oil and filter. 4. Replace as necessary. 5. Service or replace crankshaft.
6. Replace bent connecting rods.
1. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS) 2. Check oil pump, if Ok, check rod and main bearings for excessive wear. 3. Change oil and filter. 4. Replace as necessary. 5. Check thrust washers for wear. 6. Service or replace crankshaft. 7. Tighten to correct torque
ENGINE - 4.7L
9 - 92
ENGINE - 4.7L (Continued) DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSUREThe results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc- tions.
Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs. (3) Secure the throttle in the wide-open position. (4) Disable the fuel system (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DESCRIPTION).
(5) Remove the ASD relay (Refer to 8 - ELECTRI- CAL/IGNITION CONTROL/AUTO SHUT DOWN RELAY - REMOVAL).
(6) Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
(7) Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylin- ders.
(8) (Refer to 9 - ENGINE - SPECIFICATIONS) for
the correct engine compression pressures.
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition. Combustion pressure leakage testing will detect:
DR
† Exhaust and intake valve leaks (improper seat- ing).† Leaks between adjacent cylinders or into water jacket.† Any causes for combustion/compression pressure loss. (1) Check the coolant level and fill as required. DO
NOT install the radiator cap.
(2) Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.
(3) Remove the spark plugs. (4) Remove the oil filler cap. (5) Remove the air cleaner hose. (6) Calibrate the tester according to the manufac- turer’s instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom- mended.(7) Perform the test procedures on each cylinder according to the tester manufacturer’s instructions. Set piston of cylinder to be tested at TDC compres- sion,While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE: At 552 kPa (80 psi) input pres- sure, a minimum of 414 kPa (60 psi) should be main- tained in the cylinder.
Refer to CYLINDER COMBUSTION PRESSURE
LEAKAGE DIAGNOSIS CHART.
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION
AIR ESCAPES THROUGH THROTTLE BODY
POSSIBLE CAUSE
Intake valve bent, burnt, or not seated properly
AIR ESCAPES THROUGH TAILPIPE
Exhaust valve bent, burnt, or not seated properly
AIR ESCAPES THROUGH RADIATOR MORE THAN 50% LEAKAGE FROM ADJACENT CYLINDERS
MORE THAN 25% LEAKAGE AND AIR ESCAPES THROUGH OIL FILLER CAP OPENING ONLY
Head gasket leaking or cracked cylinder head or block Head gasket leaking or crack in cylinder head or block between adjacent cylinders Stuck or broken piston rings; cracked piston; worn rings and/or cylinder wall
CORRECTION
Inspect valve and valve seat. Reface or replace, as necessary. Inspect valve springs. Replace as necessary. Inspect valve and valve seat. Reface or replace, as necessary. Inspect valve springs. Replace as necessary. Remove cylinder head and inspect. Replace defective part Remove cylinder head and inspect. Replace gasket, head, or block as necessary Inspect for broken rings or piston. Measure ring gap and cylinder diameter, taper and out-of-round. Replace defective part as necessary
DR ENGINE - 4.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION Engine diagnosis is helpful
in determining the causes of malfunctions not detected and remedied by routine maintenance.
These malfunctions may be classified as either per- formance (e.g., engine idles rough and stalls) or mechanical (e.g., a strange noise).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST- ING)—PERFORMANCE and (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)—MECHANICAL for possible causes and corrections of malfunctions. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING) and (Refer to 14 - FUEL SYSTEM/FUEL INJECTION - DIAGNOSIS AND TESTING) for the fuel system diagnosis.
ENGINE - DIAGNOSIS AND TESTING).
Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts. Information concerning additional tests and diagno- sis is provided within the following diagnosis: † Cylinder Compression Pressure Test (Refer to 9 - † Cylinder Combustion Pressure Leakage Test (Refer to 9 - ENGINE - DIAGNOSIS AND TEST- ING).† Engine Cylinder Head Gasket Failure Diagnosis (Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNO- SIS AND TESTING). † Intake Manifold Leakage Diagnosis (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE DIAGNOSIS AND TESTING).
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain the original center line.
tially, this repair consists of:
Damaged or worn threads can be repaired. Essen- † Drilling out worn or damaged threads. † Tapping the hole with a special Heli-Coil Tap, or † Installing an insert into the tapped hole to bring
equivalent.
the hole back to its original thread size.
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in-
ENGINE - 4.7L
9 - 93
place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket materials that are used in the engine area. Mopart Engine RTV GEN II, Mopart ATF-RTV, and Mopart Gasket Maker gasket materials, each have different properties and can not be used in place of the other.
MOPARt ENGINE RTV GEN II Mopart Engine RTV GEN II is used to seal com- ponents exposed to engine oil. This material is a spe- cially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
MOPARt ATF RTV Mopart ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and seal- ing properties to seal components exposed to auto- matic coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
transmission fluid,
engine
MOPARt GASKET MAKER Mopart Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.
MOPARt GASKET SEALANT Mopart Gasket Sealant is a slow drying, perma- nently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This mate- rial is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will pre- vent corrosion. Mopart Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER APPLICATION
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gas- kets.
Mopart Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant
ENGINE - 4.7L
