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9 - 94
ENGINE - 4.7L (Continued)DR
(12) Remove starter (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - REMOVAL).
(13) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
to one gasket surface. Be certain the material sur- rounds each mounting hole. Excess material can eas- ily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smear- ing material off the location.
Mopart Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location.
Mopart Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets.
REMOVAL
Fig.1CrankshaftPositionSensor
NOTE: This procedure applies to both the 4X2 and 4X4 vehicles, steps that apply to the 4X4 vehicle only, are identified.
1 - CRANKSHAFT POSITION SENSOR 2 - CYLINDER HEAD COVER 3 - CAMSHAFT POSITION SENSOR 4 - RIGHT SIDE CYLINDER BLOCK
(1) Disconnect the battery negative and positive
(2) Remove the battery and the battery tray. (3) Raise vehicle on hoist. (4) Remove exhaust crossover pipe from exhaust
bolts.
cables.
manifolds.
(5) 4X4 vehicles Disconnect axle vent tube from
left side engine mount.
(6) Remove the through bolt retaining nut and bolt
from both the left and right side engine mounts.
(7) 4X4 vehicles Remove locknut from left and
right side engine mount brackets.
(8) Disconnect two ground straps from the lower left hand side and one ground strap from the lower right hand side of the engine.
(9) Disconnect crankshaft position sensor. (Fig. 1)
NOTE: The following step applies to 4X4 vehicles equipped with automatic transmission only.
(10) 4X4 vehicles Remove
isolator bracket from the engine, transmission and the axle. to 9 - ENGINE/ENGINE BLOCK/STRUCTURAL COVER - REMOVAL).
(11) Remove
structural
the axle
(Refer
cover
(14) Remove torque converter bolts (Automatic
Transmission Only).
(15) Remove transmission to engine mounting
(16) Disconnect
the engine block heater power
cable from the block heater, if equipped.
(17) Lower vehicle. (18) Remove throttle body resonator assembly and
air inlet hose.
(19) Disconnect throttle and speed control cables. (20) Disconnect tube from both the left and right side crankcase breathers (Fig. 2). Remove breathers (21) Discharge A/C system (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/REFRIG- ERANT - STANDARD PROCEDURE).
(22) Remove A/C compressor (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/A/C COM- PRESSOR - REMOVAL).
(23) Remove shroud, fan assembly (Refer to 7 - VISCOUS COOLING/ENGINE/FAN CLUTCH - REMOVAL) and accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
DRIVE
(24) Disconnect transmission oil cooler lines at the
radiator.
DR ENGINE - 4.7L (Continued)
ENGINE - 4.7L
9 - 95
Fig.2CrankcaseBreatherConnectionPoints
1 - CRANKCASE BREATHERS
(25) Disconnect radiator upper and lower hoses. (26) Remove radiator (Refer to 7 - COOLING/EN- GINE/RADIATOR - REMOVAL), A/C condenser (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/A/C CONDENSER - REMOVAL) and transmission oil cooler.
(27) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
(28) Disconnect the two heater hoses from the tim-
ing chain cover and heater core.
(29) Unclip and remove heater hoses and tubes
from the intake manifold.
points :
(30) Disconnect engine harness at the following † Intake air temperature (IAT) sensor (Fig. 3) † Fuel Injectors † Throttle Position (TPS) Switch † Idle Air Control (IAC) Motor † Engine Oil Pressure Switch † Engine Coolant Temperature (ECT) Sensor † Manifold absolute pressure (MAP) Sensor † Camshaft Position (CMP) Sensor † Coil Over Plugs (31) Disconnect the vacuum lines at the throttle
body and intake manifold.
(32) Release fuel rail pressure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCE- DURE) then disconnect the fuel supply quick connect fitting at the fuel rail (Refer to 14 - FUEL SYSTEM/ FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE).
(33) Remove power steering pump and position out
of the way.
the cylinder heads.
(34) Install Special Tools 8400 Lifting Studs, into
8347 (Fig. 4) following these steps.
(35) Install Engine Lifting Fixture Special Tool † Holding the lifting fixture at a slight angle, slide the large bore in the front plate over the hex portion of the lifting stud.
sion.
Fig.3ThrottleBodyConnectionPoints
1 - THROTTLE BODY 2 - TPS 3 - IAC MOTOR 4 - IAT SENSOR 5 - MOUNTING SCREWS
† Position the two remaining fixture arms onto the two Special Tools 8400 Lifting Studs, in the cyl- inder heads. † Pull foward and upward on the lifting fixture so that the lifting stud rest in the slotted area below the large bore. † Secure the lifting fixture to the three studs † Make sure the lifting loop in the lifting fixture is in the last hole (closest to the throttle body) to min- imize the angle of engine during removal.
using three 7/16 – 14 N/C locknuts.
(36) Disconnect body ground strap at the right side
(37) Disconnect body ground strap at the left side
cowl (Fig. 5).
cowl (Fig. 6).
NOTE: It will be necessary to support the transmis- sion in order to remove the engine.
(38) Position a suitable jack under the transmis-
(39) Remove engine from the vehicle.
ENGINE - 4.7L
9 - 96
ENGINE - 4.7L (Continued)DR
Fig.5BodyGroundStrap—RightSideRemoval/
Installation
1 - NUT 2 - A/C ACCUMULATOR 3 - GROUND STRAP
Fig.4EngineLiftingFixtureAttachmentLocations 1 - ATTACHING LOCATION 2 - ADJUSTABLE HOOK 3 - SPECIAL TOOL 8347 ENGINE LIFT FIXTURE 4 - ATTACHING LOCATIONS
INSTALLATION
(1) Position engine in the vehicle. Position both the left and right side engine mount brackets and install the through bolts and nuts. Tighten nuts to 4X2 vehicles 95 N·m (70 ft. lbs.). 4X4 vehicles 102 N·m (75 ft. lbs.).
(2) 4X4 vehicles Install locknuts onto the engine mount brackets. Tighten locknuts to 41 N·m (30 ft. lbs.).
(3) Remove jack from under the transmission. (4) Remove Engine Lifting Fixture Special Tool
8347 (Fig. 4).
(5) Remove Special Tools 8400 Lifting Studs. (6) Position generator wiring behind the oil dip- stick tube, then install the oil dipstick tube upper mounting bolt.
(7) Connect both left and right side body ground
straps.
(8) Install power steering pump.
Fig.6BodyGroundStrap—LeftSideRemoval/
Installation
1 - NUT 2 - GROUND STRAP 3 - BRAKE BOOSTER
DR ENGINE - 4.7L (Continued)
ENGINE - 4.7L
9 - 97
(9) Connect fuel supply line quick connect fitting (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/ QUICK CONNECT FITTING - STANDARD PROCE- DURE).
(10) Connect the vacuum lines at the throttle body
and intake manifold.
the following
(11) Connect engine harness at points (Fig. 3): † Intake Air Temperature (IAT) Sensor † Idle Air Control (IAC) Motor † Fuel Injectors † Throttle Position (TPS) Switch † Engine Oil Pressure Switch † Engine Coolant Temperature (ECT) Sensor † Manifold Absolute Pressure (MAP) Sensor † Camshaft Position (CMP) Sensor † Coil Over Plugs (12) Position and install heater hoses and tubes
onto intake manifold.
(13) Install the heater hoses onto the heater core
and the engine front cover.
(14) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(15) Install A/C condenser (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C CON- DENSER - INSTALLATION), radiator (Refer to 7 - COOLING/ENGINE/RADIATOR - INSTALLATION) and transmission oil cooler.
(16) Connect radiator upper and lower hoses. (17) Connect the transmission oil cooler lines to
the radiator.
(18) Install accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION), fan assembly and shroud (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).
(19) Install A/C compressor (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/A/C COM- PRESSOR - INSTALLATION).
(20) Install both breathers. Connect tube to both
crankcase breathers (Fig. 2).
(21) Connect throttle and speed control cables. (22) Install throttle body resonator assembly and
air inlet hose. Tighten clamps 4 N·m (35 in. lbs.).
(23) Raise vehicle. (24) Install transmission to engine mounting bolts.
Tighten the bolts to 41 N·m (30 ft. lbs.). converter bolts
(25) Install
torque
(Automatic
Transmission Only).
(26) Connect crankshaft position sensor (Fig. 1). (27) 4X4 vehicles Position and install the axle isolator bracket onto the axle, transmission and engine block. Tighten bolts to specification (Refer to 9
- ENGINE - SPECIFICATIONS).(28) Install starter (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - INSTALLATION).
CAUTION: The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover.
(29) Install structural cover (Refer to 9 - ENGINE/ ENGINE BLOCK/STRUCTURAL COVER - INSTAL- LATION).
(30) Install exhaust crossover pipe. (31) Install engine block heater power cable, If
equipped.
side engine mount.
(32) 4X4 vehicles Connect axle vent tube to left
(33) Lower vehicle. (34) Check and fill engine oil. (35) Recharge the A/C system (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/REFRIG- ERANT - STANDARD PROCEDURE).
(36) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(37) Install the battery tray and battery. (38) Connect
the battery positive and negative
cables.
(39) Start the engine and check for leaks.
ENGINE - 4.7L
9 - 98
ENGINE - 4.7L (Continued) SPECIFICATIONS4.7L ENGINE
DESCRIPTION
SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type Displacement
Bore Stroke
90° SOHC V-8 16-Valve
4.7 Liters / 4701cc (287 Cubic Inches) 93.0 mm (3.66 in.) 86.5 mm (3.40 in.)
Compression Ratio
9.0:1
Horsepower
Torque
Lead Cylinder Firing Order
235 BHP @ 4800 RPM 295 LB-FT @ 3200 RPM
#1 Left Bank 1-8-4-3-6-5-7-2
CYLINDER BLOCK
Cylinder Block Bore Diameter
Out of Round (MAX)
Taper (MAX)
Cast Iron
93.010 ± .0075 mm (3.6619 ± 0.0003 in.) 0.076 mm (0.003 in.) 0.051 mm (0.002 in.)
PISTONS
Material Diameter Weight
Aluminum Alloy
92.975 mm (3.6605 in.) 367.5 grams (12.96 oz)
Ring Groove Diameter
No. 1
No. 2
No. 3
83.73 - 83.97 mm (3.296 - 3.269 in.) 82.833 - 83.033 mm (3.261 - 3.310 in.) 83.88 - 84.08 mm (3.302 - 3.310 in.)
PISTON PINS
Type
Pressed Fit
Clearance In Piston
0.010 - 0.019 mm
Diameter
(0.0004 - 0.0008 in.) 24.013 - 24.016 mm (0.9454 - 0.9455 in.)
PISTON RINGS
Ring Gap
DR
DESCRIPTION
Second Compression Ring
SPECIFICATION
(0.0146 - 0.0249 in.)
0.37 - 0.63 mm
(0.0146 - 0.0249 in.)
Oil Control (Steel Rails)
0.25 - 0.76 mm
(0.0099 - 0.30 in.)
Side Clearance
Top Compression Ring
.051 - .094 mm
Second Compression Ring
(0.0020 - 0.0037 in.)
0.040 - 0.080 mm
(0.0016 - 0.0031 in.)
Oil Ring (Steel Ring)
.019 - .229 mm
Ring Width
Top Compression Ring
Second Compression Ring
Oil Ring (Steel Rails)
(.0007 - .0091 in.)
1.472 - 1.490 mm (0.057 - 0.058 in.) 1.472 - 1.490 mm
(0.057 - 0.058 in.) 0.445 - 0.470 mm (0.017 - 0.018 in.)
CONNECTING RODS
Bearing Clearance
0.015 - 0.055 mm
Side Clearance
(0.0006 - 0.0022 in.)
0.10 - 0.35 mm
(0.004 - 0.0138 in.)
Piston Pin Bore Diameter
.025 - .048 mm
(Interference Fit)
Bearing Bore Out of
(0.001 - 0.0019 in.)
0.004 mm
Round (MAX)
(0.0002 in.)
Total Weight (Less
555 grams (19.5771
Bearing)
ounces)
CRANKSHAFT
Main BearingJournal
Diameter
63.488 - 63.512 mm (2.4996 - 2.5005 in.)
Bearing Clearance
0.018 - 0.052 mm
(0.0008 - 0.0021 in.) 0.005 mm (0.0002 in.)
Top Compression Ring
0.37 - 0.63 mm
Out of Round (MAX)
DR ENGINE - 4.7L (Continued)
DESCRIPTION Taper (MAX)
End Play
End Play (MAX)
Connecting Rod Journal
Diameter
Bearing Clearance
Out of Round (MAX)
Taper (MAX)
SPECIFICATION
0.008 mm (0.0004 in.)
0.052 - 0.282 mm (0.0021 - 0.0112 in.) 0.282 mm (0.0112 in)
50.992 - 51.008 mm (2.0076 - 2.0082 in.)
0.015 - 0.055 mm (0.0006 -0.0022 in.) 0.005 mm (0.0002 in.) 0.008 mm (0.0004 in.)
CAMSHAFT
Bore Diameter
Bearing Journal Diameter
Bearing Clearance
26.02 - 26.04 mm
(1.0245 - 1.0252 in.) 25.975 - 25.995 mm (1.0227 - 1.0235 in.)
0.025 - 0.065 mm (0.001 - 0.0026 in.)
Bearing Clearance (MAX)
0.065 mm (0.0026 in.)
End Play
End Play (MAX)
.075 - .200 mm
(0.003 - 0.0079 in.) .200 mm (0.0079 in.)
VALVE TIMING
Intake
Exhaust
Opens (BTDC) Closes (ATDC) Duration
Opens (BTDC) Closes (ATDC) Duration Valve Overlap
4.4° 239.1° 243.5°
240.5° 13.2° 253.70° 17.6°
VALVES
Face Angle
45° - 45.5°
Head Diameter
Intake
48.52 - 48.78 mm
Exhaust
(1.9103 - 1.9205 in.)
36.87 - 37.13 mm 1.4516 - 1.4618 in.)
ENGINE - 4.7L
9 - 99
DESCRIPTION
SPECIFICATION
Length (Overall)
Stem Diameter
Intake
113.45 - 114.21 mm
Exhaust
(4.4666 - 4.4965)
114.92 - 115.68 mm (4.5244 - 4.5543 in.)
Intake
6.931 - 6.957 mm
(0.2729 - 0.2739 in.)
Exhaust
6.902 - 6.928 mm
(0.2717 - 0.2728 in.)
Stem - to - Guide Clearance
Intake
.018 - .069 mm
(0.0008 - 0.0028 in.)
Exhaust
.047 - .098 mm
(0.0019 - 0.0039 in.)
Max. Allowable Stem - to - Guide Clearance (Rocking
Method)
Intake Exhaust
0.069 mm (0.0028 in.) 0.098 mm (0.0039 in.)
Valve Lift (Zero Lash)
Intake Exhaust VALVE SPRING
11.25 mm (0.443 in.) 10.90 mm (0.4292 in.)
Free Length (Approx)
Intake and Exhaust
49.0 mm (1.9291 in.)
Spring Force (Valve Closed)
Intake and Exhaust
Spring Force (Valve Open)
Intake and Exhaust
313.0 - 354.0 N @ 40.12
mm (70.3652 - 79.58237 lbs. @ 1.5795 in.)776.0 - 870.0 N @ 28.88
mm 174.4517 - 195.5838 lbs. @ 1.1370 in.)ENGINE - 4.7L
9 - 100
ENGINE - 4.7L (Continued)DR
DESCRIPTION
SPECIFICATION
DESCRIPTION
SPECIFICATION
Number of Coils
Intake and Exhaust
7.3
Wire Diameter
Intake and Exhaust
4.6 - 3.67 mm
(0.1811 - 0.1445 in.)
Installed Height (Spring Seat to Bottom of Retainer)
Nominal
Intake Exhaust CYLINDER HEAD
40.12 mm (1.5795 in.) 40.12 mm (1.5795 in.)
Gasket Thickness
(Compressed)
Valve Seat Angle
Valve Seat Runout (MAX) Valve Seat Width
.7 mm (0.0276 in.)
44.5° - 45.0°
0.051 mm (0.002 in.)
Intake
1.75 - 2.36 mm
(0.0698 - 0.0928 in.)
Exhaust
1.71 - 2.32 mm
(0.0673 - 0.0911 in.)
Guide Bore Diameter
6.975 - 7.00 mm
(Std.)
(0.2747 - 0.2756 in.)
Cylinder Head Warpage
(Flatness)
0.0508 mm (0.002 in.)
OIL PUMP
Clearance Over Rotors /
.095 mm - (0.0038 in.)
End Face (MAX)
Cover Out - of -Flat
.025 mm (0.001 in.)
(MAX)
Inner and Outer Rotor
Thickness
Outer Rotor to Pocket Diametral Clearance
(MAX)
12.02 mm (0.4731 in.) .235 mm (.0093 in.)
Outer Rotor Diameter
85.925 mm (0.400 in.)
(MIN)
Tip Clearance Between
Rotors (MAX)
.150 mm (0.006 in.)
OIL PRESSURE
At Curb Idle Speed
25 kPa (4 psi)
(MIN)*
@ 3000 rpm
170 - 758 kPa (25 - 110
psi)
* CAUTION: If pressure is zero at curb idle, DO NOT run
engine at 3000 rpm.
ENGINE - 4.7L
9 - 101
DESCRIPTION
N·m
Oil Pan—Bolts Oil Pan—Drain Plug Oil Pump—Bolts Oil Pump Cover—Bolts Oil Pickup Tube—Bolt and Nut Oil Dipstick Tube to Engine Block—Bolt Oil Fill Tube—Bolts Timing Chain Guide—Bolts Timing Chain Tensioner Arm—Special Pin Bolt Hydraulic Tensioner—Bolts Timing Chain Primary Tensioner—Bolts Timing Drive Idler Sprocket— Bolt Thermostat Housing—Bolts Water Pump—Bolts
15
34
28
12
2815
12
2817
28
2834
13
58Ft.
Lbs. — 25
— — —— — —
— — —
25
— 43
In.
Lbs. 130
— 250
105
250130
105
250150
250
250—
115
—DR ENGINE - 4.7L (Continued) TORQUE
DESCRIPTION
N·m
Ft.
In.
Lbs.
Lbs.
Camshaft
Non - Oiled Sprocket Bolt Bearing Cap Bolts
Timing Chain Cover—Bolts Connecting Rod Cap—Bolts
122
11
58
2790
— 43
20— 100
— —Bed Plate—Bolts Crankshaft Damper—Bolt Cylinder Head—Bolts
M11 Bolts M8 Bolts
Cylinder Head Cover—Bolts Exhaust Manifold—Bolts Exhaust Manifold Heat Shield—Nuts
Flexplate—Bolts Engine Mount Bracket to Block—Bolts Rear Mount to Transmission—Bolts Generator Mounting—Bolts
M10 Bolts M8 Bolts
Intake Manifold—Bolts
PLUS 90° TURN Refer to Procedure 175
—130
81
26
12
2560
19
— 18
—— — 105
— 72Then loosen 45° — 60
61
—45
4546
34
—
40
— —— 54
250
28
12
105
Refer to Procedurefor
Tightening Sequence
ENGINE - 4.7L
9 - 102
ENGINE - 4.7L (Continued) SPECIAL TOOLS4.7L ENGINE
DR
SpannerWrench6958
FrontCrankshaftSealRemover8511
FrontCrankshaftSealInstaller8348
AdapterPins8346
EngineLiftingStuds8400
HandleC-4171
EngineLiftFixture8347
RearCrankshaftSealInstaller8349
DR ENGINE - 4.7L (Continued)
ENGINE - 4.7L
9 - 103
RearCrankshaftSealRemover8506
CrankshaftDamperRemovalInsert8513
ConnectingRodGuides8507
ChainTensionerWedge8350
CrankshaftDamperInstaller8512
ChainTensionerPins8514
Puller1026
SecondaryChainHolder8515
ENGINE - 4.7L
9 - 104
ENGINE - 4.7L (Continued)DR
Remover,RockerArm8516
ValveSpringTesterC-647
ValveSpringCompressor8387
IdlerShaftRemover8517
DialIndicatorC-3339
ValveSpringCompressorC-3422-B
BoreSizeIndicatorC-119
ValveSpringCompressorAdapters8519
OilPressureGaugeC-3292
DR ENGINE - 4.7L (Continued)
ENGINE - 4.7L
9 - 105
AIR CLEANER ELEMENT REMOVAL
Filter Element Only
Housing removal is not necessary for element (fil-
ter) replacement.
at air cleaner cover.
(1) Loosen clamp (Fig. 7) and disconnect air duct
(2) Pry over 4 spring clips (Fig. 7) from housing
cover (spring clips retain cover to housing).
(3) Release housing cover from locating tabs on
housing (Fig. 7) and remove cover.
(4) Remove air cleaner element (filter) from hous-
(5) Clean inside of housing before replacing ele-
ing.
ment.
PistonRingCompressorC-385
PressureTesterKit7700
Bloc–Chek–KitC-3685–A
ENGINESUPPORTFIXTURE8534
Fig.7AIRCLEANERHOUSINGCOVER
1 - CLAMP 2 - AIR DUCT 3 - AIR CLEANER COVER 4 - LOCATING TABS 5 - CLIPS (4)
Housing Assembly
(1) Loosen clamp (Fig. 7) and disconnect air duct
at air cleaner cover.
pins (Fig. 8).
(2) Lift entire housing assembly from 4 locating
INSTALLATION
(1) Install filter element into housing. (2) Position housing cover into housing locating
tabs (Fig. 7).
ENGINE - 4.7L
9 - 106
AIR CLEANER ELEMENT (Continued)DR
REMOVAL
REMOVAL - LEFT CYLINDER HEAD
(1) Disconnect the negative cable from the battery. (2) Raise the vehicle on a hoist. (3) Disconnect the exhaust pipe at the left side
(4) Drain the engine coolant. Refer to COOLING
exhaust manifold.
SYSTEM.
(5) Lower the vehicle. (6) Remove the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE REMOVAL).
(7) Remove the master cylinder and booster assem-
bly. Refer to section 5 brakes.
(8) Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(9) Remove the fan shroud and fan blade assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VIS- COUS CLUTCH - REMOVAL).
(10) Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(11) Remove the power steering pump and set
(12) Rotate the crankshaft until the damper tim- ing mark is aligned with TDC indicator mark (Fig. 9).
Fig.8AIRCLEANERHOUSING
1 - AIR CLEANER HOUSING ASSEMBLY 2 - LOCATING PINS (4)
(3) Pry up 4 spring clips (Fig. 7) and lock cover to
aside.
housing.
(4) Install air duct to air cleaner cover and tighten
hose clamp to 3 N·m (30 in. lbs.) torque.
(5) If any other hose clamps were removed from air intake system, tighten them to 3.4 N·m (30 in. lbs.) torque.
(6) If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 N·m (40 in. lbs.) torque.
CYLINDER HEAD
DESCRIPTION
DESCRIPTION - CYLINDER HEAD
The cylinder heads are made of an aluminum alloy. The cylinder head features two valves per cylinder with pressed in powdered metal valve guides. The cylinder heads also provide enclosures for the timing chain drain, necessitating unique left and right cylin- der heads.
DESCRIPTION - VALVE GUIDES
The valve guides are made of powered metal and are pressed into the cylinder head. The guides are not replaceable or serviceable, and valve guide ream- ing is not recommended. If the guides are worn beyond acceptable limits, replace the cylinder heads.
Fig.9EngineTopDeadCenter(TDC)IndicatorMark 1 - TIMING CHAIN COVER 2 - CRANKSHAFT TIMING MARKS
DR CYLINDER HEAD (Continued)
ENGINE - 4.7L
9 - 107
(13) Verify the V8 mark on the camshaft sprocket is at the 12 o’clock position (Fig. 11). Rotate the crankshaft one turn if necessary.
(14) Remove the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(15) Remove the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(16) Lock the secondary timing chains to the idler
sprocket using Special Tool 8515 (Fig. 10).
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 (Fig. 11).
(18) Remove the left side secondary chain ten- sioner (Refer to 9 - ENGINE/VALVE TIMING/TIM- ING BELT/CHAIN AND SPROCKETS - REMOVAL). (19) Remove the cylinder head access plug (Fig.
12).
(20) Remove the left side secondary chain guide (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).
(21) Remove the retaining bolt and the camshaft
drive gear.
CAUTION: Do not allow the engine to rotate. Severe damage to the valve train can occur.
Fig.10UsingSpecialTool8515toHoldChainsto
IdlerSprocket.
1 - LOCK ARM 2 - RIGHT CAMSHAFT CHAIN 3 - SECONDARY CHAINS RETAINING PINS (4) 4 - IDLER SPROCKET 5 - LEFT CAMSHAFT CHAIN 6 - SPECIAL TOOL 8515
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.
1 - LEFT CYLINDER HEAD
Fig.11CamshaftSprocketV8Marks
2 - RIGHT CYLINDER HEAD
ENGINE - 4.7L
9 - 108
CYLINDER HEAD (Continued)DR
Fig.12CylinderHeadAccessPlugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
NOTE: The cylinder head is attached to the cylinder block with fourteen bolts.
(22) Remove the cylinder head retaining bolts. (23) Remove the cylinder head and gasket. Discard
the gasket.
CAUTION: Do not lay the cylinder head on its gas- ket sealing surface, due to the design of the cylin- der head gasket any distortion to the cylinder head sealing surface may prevent the gasket from prop- erly sealing resulting in leaks.
REMOVAL - RIGHT CYLINDER HEAD (1) Disconnect battery negitive cable. (2) Raise the vehicle on a hoist. (3) Disconnect the exhaust pipe at the right side
exhaust manifold.
(4) Drain the engine coolant (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(5) Lower the vehicle. (6) Remove the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE REMOVAL).
(7) Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(8) Remove the fan shroud (Refer to 7 - COOLING/ ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
(9) Remove oil fill housing from cylinder head. (10) Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(11) Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark (Fig. 13).
Fig.13EngineTopDeadCenter(TDC)Indicator
Mark
1 - TIMING CHAIN COVER 2 - CRANKSHAFT TIMING MARKS
(12) Verify the V8 mark on the camshaft sprocket is at the 12 o’clock position (Fig. 14). Rotate the crankshaft one turn if necessary.
(13) Remove the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(14) Remove the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(15) Lock the secondary timing chains to the idler
sprocket using Special Tool 8515 (Fig. 15).
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 (Fig. 14).
(17) Remove the right side secondary chain ten- sioner (Refer to 9 - ENGINE/VALVE TIMING/TIM- ING BELT/CHAIN AND SPROCKETS - REMOVAL). (18) Remove the cylinder head access plug (Fig.
16).
(19) Remove the right side secondary chain guide (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).
(20) Remove the retaining bolt and the camshaft
drive gear.
DR CYLINDER HEAD (Continued)
ENGINE - 4.7L
9 - 109
1 - LEFT CYLINDER HEAD
Fig.14CamshaftSprocketV8Marks
2 - RIGHT CYLINDER HEAD
Fig.15UsingSpecialTool8515toHoldChainsto
IdlerSprocket.
1 - LOCK ARM 2 - RIGHT CAMSHAFT CHAIN 3 - SECONDARY CHAINS RETAINING PINS (4) 4 - IDLER SPROCKET 5 - LEFT CAMSHAFT CHAIN 6 - SPECIAL TOOL 8515
CAUTION: Do not allow the engine to rotate. severe damage to the valve train can occur.
Fig.16CylinderHeadAccessPlugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
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 tar- get wheel for any reason. A damaged target wheel can result in a vehicle no start condition.
ENGINE - 4.7L
9 - 110
CYLINDER HEAD (Continued)NOTE: The cylinder head is attached to the cylinder block with fourteen bolts.
(21) Remove the cylinder head retaining bolts. (22) Remove the cylinder head and gasket. Discard
the gasket.
CAUTION: Do not lay the cylinder head on its gas- ket sealing surface, do to the design of the cylinder head gasket any distortion to the cylinder head sealing surface may prevent the gasket from prop- erly sealing resulting in leaks.
CLEANING
To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
INSPECTION
DR
Fig.17CheckingCylinderHeadBoltsforStretching
(Necking)
1 - STRETCHED BOLT 2 - THREADS ARE NOT STRAIGHT ON LINE 3 - THREADS ARE STRAIGHT ON LINE 4 - UNSTRETCHED BOLT
(1) Inspect the cylinder head for out-of-flatness, using a straightedge and a feeler gauge. If tolerances exceed 0.0508 mm (0.002 in.) replace the cylinder head.
(2) Inspect the valve seats for damage. Service the
valve seats as necessary.
(3) Inspect the valve guides for wear, cracks or looseness. If either condition exist, replace the cylin- der head.
INSTALLATION
INSTALLATION - LEFT CYLINDER HEAD
NOTE: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced.
Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced (Fig. 17).
CAUTION: When cleaning cylinder head and cylin- der block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use only a wooden or plastic scraper.
Fig.18ProperToolUsagefor
1 - PLASTIC/WOOD SCRAPER
(3) Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.
NOTE: The four smaller cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.
(1) Clean the cylinder head and cylinder block
mating surfaces (Fig. 18).
(2) Position the new cylinder head gasket on the
locating dowels.
CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm.
(4) Lubricate the cylinder head bolt threads with
clean engine oil and install the ten M11 bolts.
(5) Coat the four M8 cylinder head bolts with Mopart Lock and Seal Adhesive then install the bolts.
DR CYLINDER HEAD (Continued)
NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.
(6) Tighten the bolts in sequence (Fig. 19) using the following steps and torque values: † Step 1: Tighten bolts 1–10, 20 N·m (15 ft. lbs.). † Step 2: Tighten bolts 1–10, 47 N·m (35 ft. lbs.). Tighten bolts 11–14, 25 N·m (18 ft. lbs.). † Step 3: Tighten bolts 1–10, 90 degrees. Tighten bolts 11–14, 30 N·m (22 ft. lbs.).
Fig.19CylinderHeadTighteningSequence
(7) Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V8 mark on the gear and position the gear onto the camshaft.
(8) Install the camshaft drive gear retaining bolt. (9) Install the left side secondary chain guide (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLA- TION).
(10) Install the cylinder head access plug (Fig. 20). (11) Re-set and Install the left side secondary chain tensioner (Refer to 9 - ENGINE/VALVE TIM- ING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).
(12) Remove Special Tool 8515. (13) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(14) Install the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
(15) Install the power steering pump. (16) Install the fan blade assembly and fan shroud (Refer to 7 - COOLING/ENGINE/FAN DRIVE VIS- COUS CLUTCH - INSTALLATION).
(17) Install the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(18) Reinstall
the master cylinder and booster
assembly. Refer to section 5 brakes.
ENGINE - 4.7L
9 - 111
(19) Install
the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE INSTALLATION).
(20) Refill the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(21) Raise the vehicle. (22) Install the exhaust pipe onto the left exhaust
manifold.
(23) Lower the vehicle. (24) Connect the negative cable to the battery. (25) Start the engine and check for leaks.
Fig.20CylinderHeadAccessPlugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
INSTALLATION - RIGHT CYLINDER HEAD
NOTE: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced.
Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced (Fig. 21).
CAUTION: When cleaning cylinder head and cylin- der block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use only a wooden or plastic scraper.
(1) Clean the cylinder head and cylinder block
mating surfaces (Fig. 22).
(2) Position the new cylinder head gasket on the
locating dowels.
CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm.
ENGINE - 4.7L
9 - 112
CYLINDER HEAD (Continued)DR
NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.
Fig.21CheckingCylinderHeadBoltsforStretching
(Necking)
1 - STRETCHED BOLT 2 - THREADS ARE NOT STRAIGHT ON LINE 3 - THREADS ARE STRAIGHT ON LINE 4 - UNSTRETCHED BOLT
Fig.22ProperToolUsagefor
1 - PLASTIC/WOOD SCRAPER
(3) Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.
NOTE: The four smaller cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.
(4) Lubricate the cylinder head bolt threads with
clean engine oil and install the ten M10 bolts.
(5) Coat the four M8 cylinder head bolts with Mopart Lock and Seal Adhesive then install the bolts.
the following steps and torque values:
(6) Tighten the bolts in sequence (Fig. 23) using † Step 1: Tighten bolts 1–10, 20 N·m (15 ft. lbs.). † Step 2: Tighten bolts 1–10, 47 N·m (35 ft. lbs.). † Step 3: Tighten bolts 1–10, 90 degrees. Tighten
Tighten bolts 11–14, 25 N·m (18 ft. lbs.).
bolts 11–14, 30 N·m (22 ft. lbs.).
Fig.23CylinderHeadTighteningSequence
(7) Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V8 mark on the gear and position the gear onto the camshaft.
(8) Install the camshaft drive gear retaining bolt. (9) Install the right side secondary chain guide (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(10) Install the right side cylinder head access
plug (Fig. 24).
Fig.24CylinderHeadAccessPlugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
ENGINE - 4.7L
9 - 113
CAUTION: When removing the cam sprocket, timing chains or camshaft, Failure to use Special Tool 8350 will result in hydraulic tensioner ratchet over extension, requiring timing chain cover removal to reset the tensioner ratchet.
(1) Remove cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(2) Set engine to TDC cylinder #1,
camshaft
sprocket V8 marks at the 12 o’clock position.
(3) Mark one link on the secondary timing chain on both sides of the V8 mark on the camshaft sprocket to aid in installation.
CAUTION: Do not hold or pry on the camshaft tar- get wheel (Located on the right side camshaft sprocket) for any reason, Severe damage will occur to the target wheel resulting in a vehicle no start condition.
(4) Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave the bolt snug against the sprocket.
NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tension- ers to extend, requiring timing chain cover removal in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur.
(5) Position Special Tool 8350 timing chain wedge between the timing chain strands, tap the tool to securely wedge the timing chain against the ten- sioner arm and guide (Fig. 25).
NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas.
DR CYLINDER HEAD (Continued)
(11) Re-set and install the right side secondary
chain tensioner.
(12) Remove Special Tool 8515. (13) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(14) Install the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
(15) Install accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(16) Install the fan shroud. (17) Install the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(18) Install
the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE INSTALLATION).
(19) Install oil fill housing onto cylinder head. (20) Refill the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(21) Raise the vehicle. (22) Install
exhaust manifold.
the exhaust pipe onto the right
(23) Lower the vehicle. (24) Reconnect battery negitive cable. (25) Start the engine and check for leaks.
CAMSHAFT(S) - LEFT DESCRIPTION
The camshafts consist of powdered metal steel lobes which are sinter-bonded to a steel tube. A steel post or nose piece is friction-welded to the steel cam- shaft tube. Five bearing journals are machined into the camshaft, four on the steel tube and one on the steel nose piece. Camshaft end play is controlled by two thrust walls that border the nose piece journal. Engine oil enters the hollow camshafts at the third journal and lubricates every intake lobe rocker through a drilled passage in the intake lobe.
REMOVAL
CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT force- fully rotate the camshafts or crankshaft indepen- dently of each other. Severe valve and/or piston damage can occur.
ENGINE - 4.7L
9 - 114
CAMSHAFT(S) - LEFT (Continued)DR
Fig.25SecuringTimingChainTensionersUsingTimingChainWedge
1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD
3 - SPECIAL TOOL 8350 WEDGE 4 - SPECIAL TOOL 8350 WEDGE
(6) Hold the camshaft with adjustable pliers while removing the camshaft sprocket bolt and sprocket (Fig. 26).
Fig.26CamshaftSprocketandChain
1 - CAMSHAFT SPROCKET AND CHAIN 2 - ADJUSTABLE PLIERS 3 - CAMSHAFT
(7) Using the pliers, gently allow the camshaft to rotate 15° clockwise until the camshaft is in the neu- tral position (no valve load).
(8) Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM- SHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
(9) Remove the camshaft bearing caps and the
camshaft.
INSTALLATION
(1) Lubricate camshaft journals with clean engine
oil.
NOTE: Position the left side camshaft so that the camshaft sprocket dowel is near the 1 o’clock posi- tion, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
(2) Position the camshaft into the cylinder head.
DR CAMSHAFT(S) - LEFT (Continued)
ENGINE - 4.7L
9 - 115
(3) Install the camshaft bearing caps, hand tighten
(5) Torque the camshaft bearing cap retaining
the retaining bolts.
(4) Working in 1⁄2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward (Fig. 27).
bolts to 11 N·m (100 in. lbs.).
(6) Position the camshaft drive gear into the tim- ing chain aligning the V8 mark between the two marked chain links (Two links marked during removal) (Fig. 28).
NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas.
Fig.27CamshaftBearingCapsTightening
Sequence
1 - LEFT CYLINDER HEAD
Fig.28TimingChaintoSprocketAlignment
2 - RIGHT CYLINDER HEAD
ENGINE - 4.7L
9 - 116
CAMSHAFT(S) - LEFT (Continued)(7) Using the adjustable pliers, rotate the cam- shaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft (Fig. 29).
CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over- torque resulting in bolt failure.
DR
(8) Remove excess oil from bolt, then install the
camshaft sprocket retaining bolt and hand tighten.
(9) Remove Special Tool 8350 timing chain wedge
(Fig. 30).
Fig.29CamshaftSprocketInstallation
1 - ADJUSTABLE PLIERS 2 - CAMSHAFT DOWEL
1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD
3 - SPECIAL TOOL 8350 WEDGE 4 - SPECIAL TOOL 8350 WEDGE
Fig.30SPECIALTOOL8350
DR CAMSHAFT(S) - LEFT (Continued)
(10) Using Special Tool 6958 spanner wrench with adapter pins 8346 (Fig. 31), torque the camshaft sprocket retaining bolt to 122 N·m (90 ft. lbs.).
(11) Install the cylinder head cover.
ENGINE - 4.7L
9 - 117
REMOVAL
CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT force- fully rotate the camshafts or crankshaft indepen- dently of each other. Severe valve and/or piston damage can occur.
CAUTION: When removing the cam sprocket, timing chains or camshaft, Failure to use special tool 8350
will result in hydraulic tensioner ratchet over exten- sion, Requiring timing chain cover removal to re-set the tensioner ratchet.(1) Remove the cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(2) Set engine to TDC cylinder #1,
camshaft
sprocket V8 marks at the 12 o’clock position.
(3) Mark one link on the secondary timing chain on both sides of the V8 mark on the camshaft sprocket to aid in installation.
CAUTION: Do not hold or pry on the camshaft tar- get wheel for any reason, Severe damage will occur to the target wheel. A damaged target wheel could cause a vehicle no start condition.
(4) Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave bolt snug against sprocket.
NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tension- ers to extend, requiring timing chain cover removal in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur.
Fig.31TighteningLeftSideCamSprocket
RetainingBolt
1 - TORQUE WRENCH 2 - CAMSHAFT SPROCKET 3 - LEFT CYLINDER HEAD 4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
CAMSHAFT(S) - RIGHT DESCRIPTION
The camshafts consist of powdered metal steel lobes which are sinter-bonded to a steel tube. A steel post or nose piece is friction-welded to the steel cam- shaft tube. Five bearing journals are machined into the camshaft, four on the steel tube and one on the steel nose piece. Camshaft end play is controlled by two thrust walls that border the nose piece journal. Engine oil enters the hollow camshafts at the third journal and lubricates every intake lobe rocker through a drilled passage in the intake lobe.
ENGINE - 4.7L
9 - 118
CAMSHAFT(S) - RIGHT (Continued)(5) Position Special Tool 8350 timing chain wedge between the timing chain strands. Tap the tool to securely wedge the timing chain against the ten- sioner arm and guide (Fig. 32).
(6) Remove the camshaft position sensor (Fig. 33).
NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas.
DR
(7) Hold the camshaft with adjustable pliers while removing the camshaft sprocket bolt and sprocket (Fig. 34).
(8) Using the pliers, gently allow the camshaft to rotate 45° counter-clockwise until the camshaft is in the neutral position (no valve load).
(9) Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM- SHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
(10) Remove the camshaft bearing caps and the
camshaft.
Fig.33CamshaftPositionSensor
1 - CRANKSHAFT POSITION SENSOR 2 - CYLINDER HEAD COVER 3 - CAMSHAFT POSITION SENSOR 4 - RIGHT SIDE CYLINDER BLOCK
INSTALLATION
(1) Lubricate camshaft journals with clean engine
oil.
Fig.32SecuringTimingChainTensionersUsingTimingChainWedge
1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD
3 - SPECIAL TOOL 8350 WEDGE 4 - SPECIAL TOOL 8350 WEDGE
DR CAMSHAFT(S) - RIGHT (Continued)
ENGINE - 4.7L
9 - 119
Fig.35CamshaftBearingCapsTightening
Sequence
CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over- torque resulting in bolt failure.
(8) Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and hand tighten.
(9) Remove timing chain wedge special tool 8350
(Fig. 32).
(10) Using Special Tool 6958 spanner wrench with adapter pins 8346 (Fig. 38), torque the camshaft sprocket retaining bolt to 122 N·m (90 ft. lbs.).
(11) Install the camshaft position sensor (Fig. 33). (12) Install the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
Fig.34CamshaftSprocketandChain
1 - ADJUSTABLE PLIERS 2 - SPROCKET BOLT 3 - CAMSHAFT SPROCKET AND CHAIN 4 - CAMSHAFT
NOTE: Position the right side camshaft so that the camshaft sprocket dowel is near the 10 o’clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
(2) Position the camshaft into the cylinder head. (3) Install the camshaft bearing caps, hand tighten
the retaining bolts.
(4) Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward (Fig. 35).
(5) Torque the camshaft bearing cap retaining
bolts to 11 N·m (100 in. lbs.).
(6) Position the camshaft drive gear into the tim- ing chain aligning the V8 mark between the two marked chain links (Two links marked during removal) (Fig. 36).
NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas.
(7) Using the adjustable pliers, rotate the cam- shaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft (Fig. 37).
ENGINE - 4.7L
9 - 120
CAMSHAFT(S) - RIGHT (Continued)DR
1 - LEFT CYLINDER HEAD
Fig.36TimingChaintoSprocketAlignment
2 - RIGHT CYLINDER HEAD
Fig.37CamshaftSprocketInstallation
1 - ADJUSTABLE PLIERS 2 - CAMSHAFT DOWEL
Fig.38TighteningRightSideCamSprocket
RetainingBolt
1 - TORQUE WRENCH 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET 4 - RIGHT CAMSHAFT SPROCKETDR
