Login- Download PDF Manual
-
1 - BOLT 2 - ENGINE MOUNT SUPPORT BRACKET 3 - BOLT
Fig.90ENGINEINSULATORMOUNTS4X4
1 - RH INSULATOR TO AXLE BOLT 2 - NUT 3 - PINION SUPPORT MOUNT 4 - LH INSULATOR MOUNT
5 - LH INSULATOR TO AXLE BOLT 6 - FRONT AXLE 7 - NUT 8 - RH INSULATOR MOUNT
ENGINE - 4.7L
9 - 147
INSTALLATION
NOTE: Threadlocking compound must be applied to the bolts before installation.
(1) Install the two bolts that attach the transmis-
sion mount to the transmission bracket.
(2) Torque the bolts to 61N·m (45 ft.lbs.) torque. (3) Lower the transmission so the transmission mount rests on the crossmember, and the studs of the transmission mount are aligned in the slots in the crossmember.
(4) Install the nuts onto the transmission mount
studs through the crossmember access slot. (5) Torque the nuts to 54N·m (40 ft. lbs.).
DR
REAR MOUNT REMOVAL
(1) Raise the vehicle on a hoist. (2) Using a suitable jack, support transmission. (3) Remove the nuts from the transmission mount
(Fig. 91).
Fig.91TRANSMISSIONMOUNT
1 - MOUNT 2 - CROSSMEMBER 3 - NUT 4 - BOLT
(4) Remove the two bolts that attach the transmis-
sion mount to the engine bracket.
(5) Raise the transmission enough to remove the
mount from the crossmember.
(6) Remove the mount.
9 - 148
ENGINE - 4.7L
LUBRICATION DESCRIPTION
The lubrication system (Fig. 92) is a full flow fil-
tration pressure feed type.
DR
OPERATION
Oil from the oil pan is pumped by a gerotor type oil pump directly mounted to the crankshaft nose. Oil pressure is controlled by a relief valve mounted inside the oil pump housing. For lubrication flow refer to (Fig. 92).
1 - LEFT CYLINDER HEAD OIL GALLERY 2 - OIL PRESSURE SENSOR LOCATION 3 - TO LEFT CYLINDER HEAD 4 - OIL FEED TO IDLER SHAFT 5 - OIL PUMP OUTLET TO BLOCK 6 - OIL PUMP
Fig.92EngineOilLubricationSystem
7 - TO CRANKSHAFT MAIN JOURNALS 8 - RIGHT CYLINDER HEAD OIL GALLERY 9 - TO RIGHT CYLINDER HEAD 10 - CYLINDER BLOCK MAIN GALLERY 11 - OIL FEED TO BOTH SECONDARY TENSIONERS
DR LUBRICATION (Continued)
ENGINE - 4.7L
9 - 149
The camshaft exhaust valve lobes and rocker arms are lubricated through a small hole in the rocker arm; oil flows through the lash adjuster then through the rocker arm and onto the camshaft lobe. Due to the orentation of the rocker arm, the camshaft intake lobes are not lubed in the same manner as the exhaust lobes. The intake lobes are lubed through internal passages in the camshaft. Oil flows through
a bore in the number 3 camshaft bearing bore, and as the camshaft turns, a hole in the camshaft aligns with the hole in the camshaft bore allowing engine oil to enter the camshaft tube. The oil then exits through 1.6mm (0.063 in.) holes drilled into the intake lobes, lubricating the lobes and the rocker arms.
ENGINE LUBRICATION FLOW CHART—BLOCK: TABLE 1
FROM
Oil Pickup Tube
Oil Pump Oil Filter
Block Main Oil Gallery
Crankshaft Main Journals
Crankshaft Number One Main Journal
Left Cylinder Head Right Cylinder Head
TO
Oil Pump Oil Filter
Block Main Oil Gallery
1. Crankshaft Main Journal 2. Left Cylinder Head* 3. Right Cylinder Head*
Crankshaft Rod Journals
1.Front Timing Chain Idler Shaft 2.Both Secondary Chain Tensioners
See Table 2
See Table 2* The cylinder head gaskets have an oil restricter to control oil flow to the cylinder heads.
ENGINE LUBRICATION FLOW CHART—CYLINDER HEADS: TABLE 2
FROM
TO
Cylinder Head Oil Port (in bolt hole)
Diagonal Cross Drilling to Main Oil Gallery
Main Oil Gallery (drilled through head from rear to
front)
Base of Camshaft Towers Lash Adjuster Towers ** The number three camshaft bearing journal feeds oil into the hollow camshaft tubes. Oil is routed to the intake
1. Base of Camshaft Towers 2. Lash Adjuster Towers Vertical Drilling Through Tower to Camshaft Bearings** Diagonal Drillings to Hydraulic Lash Adjuster Pockets
lobes, which have oil passages drilled into them to lubricate the rocker arms.
ENGINE - 4.7L
9 - 150
LUBRICATION (Continued) DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE
(1) Remove oil pressure sending unit (Fig. 93)and
install gauge assembly C-3292.
DR
(3) Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var- ious speeds for approximately 24 km (15 miles), and repeat inspection. If the oil leak source is not pos- itively identified at this time, proceed with the air leak detection test method.
Air Leak Detection Test Method
(1) Disconnect the breather cap to air cleaner hose at the breather cap end. Cap or plug breather cap nipple.
(2) Remove the PCV valve from the cylinder head
cover. Cap or plug the PCV valve grommet.
(3) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.
(4) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus- pected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual procedures.(5) If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak.
(6) If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve and breather cap hose.
(7) Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery. (2) Raise the vehicle. (3) Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down, possible causes are a porous block, distributor seal,
Fig.93OILPRESSURESENDINGUNIT-TYPICAL 1 - BELT 2 - OIL PRESSURE SENSOR 3 - OIL FILTER 4 - ELEC. CONNECTOR
(2) Run engine until thermostat opens. (3) Oil Pressure: † Curb Idle–25 kPa (4 psi) minimum † 3000 rpm–170 - 758 kPa (25 - 110 psi) (4) If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck open.
Begin with a thorough visual
DIAGNOSIS AND TESTING—ENGINE OIL LEAK inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed:
(1) Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light.
DR LUBRICATION (Continued)
camshaft bore cup plugs oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. (4) If no leaks are detected, pressurize the crank- case as outlined in the, Inspection (Engine oil Leaks in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal.
(6) For bubbles that remain steady with shaft rotation, no further inspection can be done until dis- assembled.
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.
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.
ENGINE - 4.7L
9 - 151
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. 94).
Fig.94TEMPERATURE/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. 95).
Fig.95EngineoilContainerStandardNotations
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the right
rear of the engine on the 4.7L engines. (Fig. 96).
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result.
ENGINE - 4.7L
9 - 152
OIL (Continued)DR
(4) Place a suitable drain pan under crankcase
drain.
(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.
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. (2) Using a suitable oil filter wrench loosen filter. (3) Rotate the oil filter counterclockwise (Fig. 97)to
remove it from the cylinder block oil filter boss.
Fig.97OilFilter-4.7LEngine
1 - ENGINE OIL FILTER
Fig.96ENGINEOILDIPSTICK4.7LENGINE
1 - TRANSMISSION DIPSTICK 2 - ENGINE OIL DIPSTICK 3 - ENGINE OIL FILL CAP
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 OIL CHANGE
Change engine oil at mileage and time intervals
described in Maintenance Schedules.
Run engine until achieving normal operating tem-
(1) Position the vehicle on a level surface and turn
perature.
engine off.
(2) Hoist and support vehicle on safety stands. (3) Remove oil fill cap.
DR OIL FILTER (Continued)
(4) When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle.
NOTE: Make sure filter gasket was removed with 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. 98) hand tighten filter one full turn, do not over tighten.
(3) Add oil, verify crankcase oil
level and start
engine. Inspect for oil leaks.
ENGINE - 4.7L
9 - 153
(8) Raise engine using special tool # 8534 to pro-
vide clearance to remove oil pan.
NOTE: Do not pry on oil pan or oil pan gasket. Gas- ket is integral to engine windage tray and does not come out with oil pan.
(9) Remove the oil pan mounting bolts and oil pan. (10) Unbolt oil pump pickup tube and remove
(11) Inspect the integral windage tray and gasket
tube.
and replace as needed.
INSTALLATION
bedplate and oil pan.
(1) Clean the oil pan gasket mating surface of the
(2) Position the oil pan gasket and pickup tube with new o-ring. Install the mounting bolt and nuts. Tighten bolt and nuts to 28 N·m (20 ft. lbs.).
(3) Position the oil pan and install the mounting bolts. Tighten the mounting bolts to 15 N·m (11 ft. lbs.) in the sequence shown (Fig. 99).
Fig.98OilFilterSealingSurface-Typical
1 - SEALING SURFACE 2 - RUBBER GASKET 3 - OIL FILTER
OIL PAN REMOVAL
(1) Disconnect the negative battery cable. (2) Install engine support fixture special tool #
8534. Do not raise engine at this time.
(3) Loosen both left and right side engine mount
through bolts. Do not remove bolts.
(4) (5) Remove the structural dust cover, if equipped. (6) Drain engine oil. (7) Remove the front crossmember(Refer to 13 - FRAME & BUMPERS/FRAME/FRONT CROSS- MEMBER - REMOVAL).
CAUTION: Only raise the engine enough to provide clearance for oil pan removal. Check for proper clearance at fan shroud to fan and cowl to intake manifold.
Fig.99OilPanMountingBoltsandOilPan
(4) Lower the engine into mounts using special
tool # 8534.
(5) Install both the left and right side engine mount through bolts. Tighten the nuts to 68 N·m (50
ft. lbs.).(6) Remove special tool # 8534. (7) Install structural dust cover, if equipped. (8) Install the front crossmember(Refer to 13 - FRAME & BUMPERS/FRAME/FRONT CROSS- MEMBER - INSTALLATION).
(9) Fill engine oil. (10) Reconnect the negative battery cable. (11) Start engine and check for leaks.
9 - 154
ENGINE - 4.7L
DR
OIL PRESSURE SENSOR/ SWITCH
DESCRIPTION
DESCRIPTION
The 3–wire, solid-state engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery.
DESCRIPTION
The 3–wire, electrical/mechanical engine oil pres- sure sensor (sending unit) is located in an engine oil pressure gallery.
OPERATION
OPERATION
The oil pressure sensor uses three circuits. They are:† A 5–volt power supply from the Powertrain Con- trol Module (PCM) † A sensor ground through the PCM’s sensor return† A signal to the PCM relating to engine oil pres- sure The oil pressure sensor has a 3–wire electrical function very much like the Manifold Absolute Pres- sure (MAP) sensor. Meaning different pressures relate to different output voltages.
A 5–volt supply is sent to the sensor from the PCM to power up the sensor. The sensor returns a voltage signal back to the PCM relating to engine oil pres- sure. This signal is then transferred (bussed) to the instrument panel on either a CCD or PCI bus circuit (depending on vehicle line) to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low-noise sensor return.
OPERATION
The oil pressure sensor uses two circuits. They are: † A signal to the PCM relating to engine oil pres- sure† A sensor ground through the PCM’s sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pres- sure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low- noise sensor return.
REMOVAL
(1) Disconnect the negative cable from the battery. (2) Raise vehicle on hoist. (3) Remove front splash shield. (4) Disconnect oil pressure sender wire (Fig. 100). (5) Remove the pressure sender (Fig. 100).
Fig.100OILPRESSURESENDINGUNIT
1 - BELT 2 - OIL PRESSURE SENSOR 3 - OIL FILTER 4 - ELEC. CONNECTOR
INSTALLATION
(1) Install oil pressure sender. (2) Connect oil pressure sender wire. (3) Install front splash shield. (4) Lower vehicle. (5) Connect the negative battery cable.
OIL PUMP REMOVAL
(1) Remove the oil pan and pick-up tube (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). (2) Remove the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(3) Remove the timing chains and tensioners (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).
(4) Remove the four bolts, primary timing chain
tensioner and the oil pump.
DR OIL PUMP (Continued) DISASSEMBLY
(1) Remove oil pump cover screws and lift off cover
plate.
(2) Remove pump inner and outer rotors.
NOTE: Once the oil pressure relief valve, cup plug, and pin are removed, the pump assembly must be replaced.
(3) If it is necessary to remove the pressure relief valve, drive the roll pin from pump housing and remove cup plug, spring and valve.
CLEANING
(1) Wash all parts in a suitable solvent.
INSPECTION
CAUTION: Oil pump pressure relief valve and spring should not be removed from the oil pump. If these are disassembled and or removed from the pump the entire oil pump assem- bly must be replaced.
components
(1) Clean all parts thoroughly. Mating surface of the oil pump housing should be smooth. If the pump cover is scratched or grooved the oil pump assembly should be replaced.
(2) Lay a straight edge across the pump cover sur- face (Fig. 101). If a 0.025 mm (0.001 in.) feeler gauge can be inserted between the cover and the straight edge the oil pump assembly should be replaced.
(3) Measure the thickness of the outer rotor (Fig. 102). If the outer rotor thickness measures at 12.005
mm (0.472 in.) or less the oil pump assembly must be replaced.(4) Measure the diameter of the outer rotor. If the outer rotor diameter measures at 85.925 mm (3.382
in.) or less the oil pump assembly must be replaced. (5) Measure the thickness of the inner rotor (Fig. 103). If the inner rotor thickness measures at 12.005
mm (0.472 in.) or less then the oil pump assembly must be replaced.(6) Slide outer rotor into the body of the oil pump. Press the outer rotor to one side of the oil pump body and measure clearance between the outer rotor and the body (Fig. 104). 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. 105). If the clearance between the
ENGINE - 4.7L
9 - 155
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. 106).
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
Fig.101CheckingOilPumpCoverFlatness
1 - STRAIGHT EDGE 2 - FEELER GAUGE 3 - OIL PUMP COVER
Fig.102MeasuringOuterRotorThickness
ENGINE - 4.7L
9 - 156
OIL PUMP (Continued)DR
Fig.103MeasuringInnerRotorThickness
Fig.105MeasuringClearanceBetweenRotors
1 - OUTER ROTOR 2 - FEELER GAUGE 3 - INNER ROTOR
Fig.104MeasuringOuterRotorClearance
1 - FEELER GAUGE 2 - OUTER ROTOR
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.
Fig.106MeasuringClearanceOverRotors
1 - STRAIGHT EDGE 2 - FEELER GAUGE
DR OIL PUMP (Continued) INSTALLATION
(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. 107).
ENGINE - 4.7L
9 - 157
DIAGNOSIS AND TESTING—INTAKE MANIFOLD LEAKAGE
An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.
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. (2) Spray a small stream of water at the suspected
(3) If a change in RPM is observed the area of the
suspected leak has been found.
(4) Repair as required.
leak area.
REMOVAL
ing components:
(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- † Manifold Absolute Pressure (MAP) Sensor † Intake Air Temperature (IAT) Sensor † Throttle Position (TPS) Sensor † Coolant Temperature (CTS) Sensor † Idle Air Control (IAC) Motor (5) Disconnect brake booster hose and positive
crankcase ventilation (PCV) hose.
(6) Disconnect generator electrical connections. (7) Disconnect air conditioning compressor electri-
left and right radio suppressor
cal connections. (8) Disconnect
straps.
(9) Disconnect and remove ignition coil
towers (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ IGNITION COIL - REMOVAL).
(10) Remove top oil dipstick tube retaining bolt
and ground strap.
(11) Bleed fuel system (Refer to 14 - FUEL SYS- TEM/FUEL DELIVERY - STANDARD PROCE- DURE).
(12) Remove fuel rail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
(13) Remove throttle body assembly and mounting
bracket.
ture level PROCEDURE).
(14) Drain cooling system below coolant tempera- (Refer to 7 - COOLING - STANDARD
(15) Remove the heater hoses from the engine
front cover and the heater core.
Fig.107OilPumpAndPrimaryTimingChain
TensionerTighteningSequence
(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).
(6) Install the pick-up tube and oil pan (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - INSTALLA- TION).INTAKE MANIFOLD DESCRIPTION
The intake manifold is made of a composite mate- rial and features long runners which maximizes low end torque. The intake manifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent leaks. Eight studs and two bolts are used to fasten the intake to the head.
ENGINE - 4.7L
9 - 158
INTAKE MANIFOLD (Continued)(16) Unclip and remove heater hoses and tubes
from intake manifold (Fig. 108).
CLEANING
DR
NOTE: There is NO approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced.
Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry.
INSPECTION
(1) Inspect the intake sealing surface for cracks,
nicks and distortion.
(2) Inspect the intake manifold vacuum hose fit-
tings for looseness or blockage.
(3) Inspect the manifold to throttle body mating
surface for cracks, nicks and distortion.
INSTALLATION
Fig.108HeaterHosesandTubesRemoval/
Installation
1 - HEATER HOSES AND TUBES 2 - ROUTING/RETAINING CLIPS
(17) Remove coolant temperature sensor (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT TEM- PERATURE SENSO - REMOVAL).
(18) Remove intake manifold retaining fasteners in
reverse order of tightening sequence (Fig. 109).
(19) Remove intake manifold.
Fig.109IntakeManifoldTighteningSequence
(1) Install intake manifold gaskets. (2) Position intake manifold. (3) Install
intake manifold retaining bolts and tighten in sequence shown in (Fig. 109) to 12 N·m (105 in. lbs.).
(4) Install left and right radio suppressor straps. (5) Install throttle body assembly. (6) Install throttle cable bracket. (7) Connect throttle cable and speed control cable
to throttle body.
(8) Install fuel rail (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL RAIL - INSTALLATION).
(9) Install ignition coil towers (Refer to 8 - ELEC- TRICAL/IGNITION CONTROL/IGNITION COIL - INSTALLATION).
(10) Position and install heater hoses and tubes
onto intake manifold.
engine front cover.
(11) Install the heater hoses to the heater core and
components:
(12) Connect electrical connectors for the following † Manifold Absolute Pressure (MAP) Sensor † Intake Air Temperature (IAT) Sensor † Throttle Position (TPS) Sensor † Coolant Temperature (CTS) Sensor † Idle Air Control (IAC) Motor † Ignition coil towers † Fuel injectors (13) Install top oil dipstick tube retaining bolt and
ground strap.
(14) Connect generator electrical connections. (15) Connect Brake booster hose and Positive
crankcase ventilation (PCV) hose.
(16) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(17) Install resonator assembly and air inlet hose. (18) Connect negative cable to battery.
DR
ENGINE - 4.7L
9 - 159
EXHAUST MANIFOLD DESCRIPTION
The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer lam- inated heat shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold.
REMOVAL
RIGHT EXHAUST MANIFOLD
(1) Disconnect negative cable for battery. (2) Remove air cleaner assembly, resonator assem-
bly and air inlet hose.
(3) Remove accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(4) Remove A/C compressor (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/A/C COM- PRESSOR - REMOVAL).
(5) Remove A/C accumulator support bracket fas-
tener.
(6) Drain coolant below heater hose level (Refer to
7 - COOLING - STANDARD PROCEDURE).
(7) Remove heater hoses at engine. (8) Remove fasteners attaching exhaust manifold
heat shield.
teners.
starter aside.
teners.
(9) Remove heat shield. (10) Remove upper exhaust manifold attaching fas-
(11) Raise vehicle on hoist. (12) Disconnect exhaust pipe from manifold. (13) Remove fasteners attaching starter. Move
(14) Remove lower exhaust manifold attaching fas-
(15) Remove exhaust manifold and gasket (Fig. 110). Manifold is removed from below the engine compartment.
ENGINE - 4.7L
9 - 160
EXHAUST MANIFOLD (Continued)DR
Fig.110ExhaustManifold—Right
ITEM
DESCRIPTION
Stud (Qty 2) Bolt (Qty 4) Stud (Qty 2)
TORQUE
25 N·m (18 ft. lbs.)
ITEM
DESCRIPTION
Nut (Qty 2) Nut (Qty 2)
TORQUE
8 N·m (72 in. lbs.), then loosen 45
degreesDR EXHAUST MANIFOLD (Continued) LEFT EXHAUST MANIFOLD
(1) Disconnect negative cable for battery. (2) Hoist vehicle. (3) Disconnect exhaust pipe at manifold. (4) Lower vehicle. (5) Remove the front
two exhaust heat shield retaining fasteners. Raise vehicle and remove the fasteners at rear of heat shield.
(6) Remove heat shield (Fig. 111). (7) Lower vehicle and remove the upper exhaust
manifold retaining bolts (Fig. 111).
(8) Raise vehicle and remove the lower exhaust
manifold retaining bolts (Fig. 111).
(9) Remove exhaust manifold and gasket
(Fig. 111). Manifold is removed from below the engine compartment.
ENGINE - 4.7L
9 - 161
CLEANING
(1) Clean the exhaust manifold using a suitable
cleaning solvent, then allow to air dry.
(2) Clean all gasket residue from the manifold
mating surface.
INSPECTION
(1) Inspect the exhaust manifold for cracks in the
mating surface and at every mounting bolt hole.
(2) Using a straight edge and a feeler gauge, check
the mating surface for warp and twist.
(3) Inspect the manifold to exhaust pipe mating surface for cracks, gouges, or other damage that would prevent sealing.
Fig.111ExhaustManifold—Left
ITEM
DESCRIPTION
Stud (Qty 2) Bolt (Qty 4) Stud (Qty 2)
TORQUE
25 N·m (18 ft. lbs.)
ITEM
DESCRIPTION
Nut (Qty 2) Nut (Qty 2)
TORQUE
8 N·m (72 in. lbs.), then loosen 45
degreesENGINE - 4.7L
9 - 162
EXHAUST MANIFOLD (Continued) INSTALLATIONRIGHT EXHAUST MANIFOLD
(1) Install exhaust manifold and gasket (Fig. 112)
from below engine compartment.
(2) Install lower exhaust manifold fasteners. DO
NOT tighten until all fasteners are in place.
(3) Lower vehicle and install upper exhaust mani- fold fasteners. Tighten all manifold bolts starting at center and working outward to 25 N·m (18 ft. lbs.).
CAUTION: Over tightening heat shield fasteners, may cause shield to distort and/or crack.
DR
(4) Install exhaust manifold heat shield. Tighten lbs.), then loosen 45
fasteners to 8 N·m (72 in. degrees.
(5) Install starter and fasteners. (6) Connect exhaust pipe to manifold. (7) Connect heater hoses at engine. (8) Install fastener attaching A/C accumulator. (9) Install A/C compressor and fasteners. (10) Install accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(11) Install air cleaner assembly, resonator assem-
bly and air inlet hose.
(12) Install battery and connect cables. (13) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
Fig.112ExhaustManifold—Right
ITEM
DESCRIPTION
Stud (Qty 2) Bolt (Qty 4) Stud (Qty 2)
TORQUE
25 N·m (18 ft. lbs.)
ITEM
DESCRIPTION
Nut (Qty 2) Nut (Qty 2)
TORQUE
8 N·m (72 in. lbs.), then loosen 45
degreesDR EXHAUST MANIFOLD (Continued) LEFT EXHAUST MANIFOLD
(1) Install exhaust manifold and gasket from below
engine compartment.
(2) Install lower exhaust manifold fasteners (Fig. 113). DO NOT tighten until all fasteners are in place. (3) Lower vehicle and install upper exhaust mani- fold fasteners (Fig. 113). Tighten all manifold bolts starting at center and working outward to 25 N·m (18 ft. lbs.).
ENGINE - 4.7L
9 - 163
CAUTION: Over tightening heat shield fasteners, may cause shield to distort and/or crack.
(4) Install exhaust manifold heat shield (Fig. 113). Tighten fasteners to 8 N·m (72 in. lbs.), then loosen 45 degrees.
(5) Connect exhaust pipe to manifold. (6) Connect negative cable to battery.
Fig.113ExhaustManifold—Left
ITEM
DESCRIPTION
Stud (Qty 2) Bolt (Qty 4) Stud (Qty 2)
TORQUE
25 N·m (18 ft. lbs.)
ITEM
DESCRIPTION
Nut (Qty 2) Nut (Qty 2)
TORQUE
8 N·m (72 in. lbs.), then loosen 45
degrees9 - 164
ENGINE - 4.7L
DR
VALVE TIMING DESCRIPTION—TIMING DRIVE SYSTEM
The timing drive system (Fig. 114) has been designed to provide quiet performance and reliability to support a non-free wheeling engine. Specifically the intake valves are non-free wheeling and can be easily damaged with forceful engine rotation if cam- shaft-to-crankshaft timing is incorrect. The timing drive system consists of a primary chain and two sec- ondary timing chain drives.
OPERATION - TIMING DRIVE SYSTEM
The primary timing chain is a single inverted tooth type. The primary chain drives the large fifty tooth idler sprocket directly from a 25 tooth crankshaft 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 primary
chain receives oil splash lubrication from the second- ary chain drive and oil pump leakage. The idler sprocket assembly connects the primary and second- ary chain drives. The idler sprocket assembly con- sists of two integral thirty tooth sprockets and a fifty tooth sprocket that is splined to the assembly. The spline joint is a non – serviceable press fit anti rattle type. The idler sprocket assembly spins on a station- ary idler shaft. The idler shaft is 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 con- trol sprocket thrust movement. Pressurized oil is routed through the center of the idler shaft to pro- vide lubrication for the two bushings used in the idler sprocket assembly.
There are two secondary drive chains, both are inverted tooth 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 thirty tooth cam sprocket
Fig.114TimingDriveSystem
1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN 2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT SIDE NOT COMMON) 3 - SECONDARY TENSIONER ARM 4 - LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN 5 - CHAIN GUIDE 6 - TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN
7 - PRIMARY CHAIN 8 - IDLER SPROCKET 9 - CRANKSHAFT SPROCKET 10 - PRIMARY CHAIN TENSIONER 11 - TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN 12 - SECONDARY TENSIONER ARM
DR VALVE TIMING (Continued)
directly from the thirty tooth sprocket on the idler sprocket assembly. A fixed chain guide and a hydrau- lic oil damped tensioner are used to maintain tension in each secondary chain system. The hydraulic ten- sioners for the secondary chain systems are fed pres- surized oil from oil reservoir pockets in the block. 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 fric- tion and long wear. The secondary timing chains receive lubrication from a small orifice in the ten- sioners. This orifice is protected from clogging by a fine mesh screen which is located on the back of the hydraulic tensioners.
STANDARD PROCEDURE
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 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(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 (Fig. 115). The measurement at point (A) must be less than 15mm (0.5906 inches).
(3) If the measurement exceeds the specification the secondary timing chains are worn and require replacement. (Refer to 9 - ENGINE/VALVE TIMING/ TIMING BELT/CHAIN AND SPROCKETS REMOVAL).
NOTE: If the secondary chains are to be replaced the primary chain must also be replaced.
ENGINE - 4.7L
9 - 165
Fig.115MeasuringSecondaryTimingChainsFor
Wear 1 - SECONDARY TENSIONER ARM 2 - SECONDARY CHAIN TENSIONER PISTON
STANDARD PROCEDURE - ENGINE TIMING - VERIFICATION
CAUTION: The 4.7L is a non free-wheeling design engine. Therefore, correct engine timing is critical.
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 - 4.7L
9 - 166
VALVE TIMING (Continued)DR
Engine base timing can be verified by the following
procedure:
(1) Remove the cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(2) Using a mirror, locate the TDC arrow on the front cover (Fig. 116). 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.
(3) Note the location of the V8 mark stamped into the camshaft drive gears (Fig. 117). If the V8 mark on each camshaft drive gear is at the twelve o’clock position, the engine is at TDC (cylinder #1) on the exhaust stroke. If the V8 mark on each gear is at the six o’clock position, the engine is at TDC (cylinder #1) on the compression stroke.
(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 V8 marks are at the twelve o’clock or the six o’ clock position the engine base timing is correct. Reinstall the cylinder head covers.
Fig.116EngineTopDeadCenter(TDC)Indicator
Mark
1 - TIMING CHAIN COVER 2 - CRANKSHAFT TIMING MARKS
1 - LEFT CYLINDER HEAD
Fig.117CamshaftSprocketV8Marks
2 - RIGHT CYLINDER HEAD
DR VALVE TIMING (Continued) SINGLE CAMSHAFT TIMING
NOTE: to adjust the timing on one camshaft, pre- form the following procedure.
ENGINE - 4.7L
9 - 167
(1) Using Chain Tensioner Wedge, special
tool 8350, stabilize the secondary chain drive (Fig. 118). For reference purposes, mark the chain-to-sprocket position (Fig. 118).
(2) Remove the camshaft drive gear retaining bolt. (3) Carefully remove the camshaft drive gear from
the camshaft.
(4) Re-index the camshaft drive gear in the chain until the V8 mark is at the same position as the V8
mark on the opposite camshaft drive gear.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.
(5) Using a suitable pair of adjustable pliers, rotate the camshaft until the alignment dowel on the camshaft is aligned with the slot in the camshaft drive gear (Fig. 119).
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.
Fig.119CamshaftDowel
1 - ADJUSTABLE PLIERS 2 - CAMSHAFT DOWEL
(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,
Fig.118SecuringTimingChainTensionersUsingTimingChainWedge
1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD
3 - SPECIAL TOOL 8350 WEDGE 4 - SPECIAL TOOL 8350 WEDGE
ENGINE - 4.7L
9 - 168
VALVE TIMING (Continued)Tighten retaining bolt to 122N·m (90 ft. Lbs.) (Fig. 120) (Fig. 121).
DR
Fig.121CamshaftSprocketInstallation—Right
CylinderHead
1 - TORQUE WRENCH 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET 4 - RIGHT CAMSHAFT SPROCKETFig.120CamshaftSprocketLeftCylinderHead
1 - TORQUE WRENCH 2 - CAMSHAFT SPROCKET 3 - LEFT CYLINDER HEAD 4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
(7) Remove special tool 8350. (8) Rotate the crankshaft two full revolutions, then reverify that the camshaft drive gear V8 marks are in fact aligned.
(9) Install the cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
TIMING BELT / CHAIN COVER(S) REMOVAL
(1) Disconnect the battery negative cable. (2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove fan and fan drive assembly (Refer to 7
VISCOUSCOOLING/ENGINE/FAN
DRIVE
CLUTCH - REMOVAL).
(4) Disconnect both heater hoses at timing cover.
(5) Disconnect lower radiator hose at engine. (6) Remove crankshaft damper
to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(Refer
(7) Remove accessory drive belt tensioner assembly
(Fig. 122).
Fig.122AccessoryDriveBeltTensioner
1 - TENSIONER ASSEMBLY 2 - FASTENER TENSIONER TO FRONT COVER
DR TIMING BELT / CHAIN COVER(S) (Continued)
ENGINE - 4.7L
9 - 169
(8) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(9) Remove A/C compressor (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/A/C COM- PRESSOR - REMOVAL).
(10) Remove cover and gasket (Fig. 123).
Fig.123TimingChainCoverFasteners
INSTALLATION
(1) Clean timing chain cover and block surface.
Inspect cover gasket and replace as necessary.
(2) Install cover and gasket. Tighten fasteners in sequence as shown in (Fig. 123) to 54 N·m (40 ft. lbs.).
(3) Install the A/C compressor (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/A/C COM- PRESSOR - INSTALLATION).
(4) Install the generator (Refer to 8 - ELECTRI- CAL/CHARGING/GENERATOR - INSTALLATION). to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
crankshaft damper
(5) Install
(Refer
(6) Install accessory drive belt tensioner assembly (Refer to 7 - COOLING/ACCESSORY DRIVE/BELT TENSIONERS - INSTALLATION).
(7) Install radiator lower hose. (8) Install both heater hoses. (9) Install radiator shroud and viscous fan drive assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).
(10) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(11) 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 (Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN- DER HEAD COVER(S) - REMOVAL).
(4) Remove radiator fan shroud. (5) Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover (Fig. 124) (#1 cylinder exhaust stroke) and the cam- shaft sprocket “V8” marks are at the 12 o’clock posi- tion (Fig. 125).
Fig.124EngineTopDeadCenter(TDC)Indicator
Mark
1 - TIMING CHAIN COVER 2 - CRANKSHAFT TIMING MARKS
(6) Remove power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(7) Remove access plugs (2) from left and right cyl- inder heads for access to chain guide fasteners (Fig. 126).
(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
ENGINE - 4.7L
9 - 170
TIMING BELT/CHAIN AND SPROCKETS (Continued)DR
1 - LEFT CYLINDER HEAD
Fig.125CamshaftSprocketV8Marks
2 - RIGHT CYLINDER HEAD
Fig.126CylinderHeadAccessPlugLocation
1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
(10) Collapse and pin primary chain tensioner
(Fig. 127).
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 from right
cylinder head (Fig. 128).
Fig.127CollapsingAndPinningPrimaryChain
Tensioner
1 - PRIMARY CHAIN TENSIONER 2 - ADJUSTABLE PLIERS 3 - SPECIAL TOOL 8514
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.
DR TIMING BELT/CHAIN AND SPROCKETS (Continued)
ENGINE - 4.7L
9 - 171
Fig.128CamshaftPositionSensor—Removal
1 - CRANKSHAFT POSITION SENSOR 2 - CYLINDER HEAD COVER 3 - CAMSHAFT POSITION SENSOR 4 - RIGHT SIDE CYLINDER BLOCK
Fig.129CamshaftRotation—LeftSide
1 - CAMSHAFT SPROCKET AND CHAIN 2 - ADJUSTABLE PLIERS 3 - CAMSHAFT
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 (Fig. 129) remove the left with adjustable pliers, camshaft camshaft approximately 15 degrees clockwise to a neutral posi- tion.
sprocket. Slowly rotate
the
(15) While holding the right camshaft steel tube with adjustable pliers, (Fig. 130) remove the right camshaft camshaft approximately 45 degrees counterclockwise to a neu- tral position.
sprocket. Slowly rotate
the
(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 chain tensioner.
INSPECTION
Inspect the following components:
Fig.130CamshaftRotation—RightSide
1 - ADJUSTABLE PLIERS 2 - CAMSHAFT DOWEL
† Sprockets for excessive tooth wear. Some tooth markings are normal and not a cause for sprocket replacement.
ENGINE - 4.7L
9 - 172
TIMING BELT/CHAIN AND SPROCKETS (Continued)DR
Fig.131TimingChainSystem
1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN 2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT SIDE NOT COMMON) 3 - SECONDARY TENSIONER ARM 4 - LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN 5 - CHAIN GUIDE 6 - TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN
7 - PRIMARY CHAIN 8 - IDLER SPROCKET 9 - CRANKSHAFT SPROCKET 10 - PRIMARY CHAIN TENSIONER 11 - TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN 12 - SECONDARY TENSIONER ARM
excessive wear.
† 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 and tensioner arm should be replaced. † Primary chain tensioner plastic faces. Replace as
required (Fig. 131).
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. Slowly open vise to transfer piston spring force to lock pin (Fig. 132).
(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.).
CAUTION: Overtightening the tensioner arm torxT bolt can cause severe damage to the cylinder head. Tighten torxT bolt to specified torque only.
(3) Install right side chain tensioner arm. Apply Mopart Lock N, Seal to torxt bolt, tighten bolt to 17
N·m (150 in. lbs.).DR TIMING BELT/CHAIN AND SPROCKETS (Continued)
ENGINE - 4.7L
9 - 173
Fig.132ResettingSecondaryChainTensioners
1 - VISE 2 - INSERT LOCK PIN 3 - RATCHET PAWL 4 - RATCHET 5 - PISTON
NOTE: The silver bolts retain the guides to the cyl- inder heads and the black bolts retain the guides to the engine block.
(4) Install the left side chain guide. Tighten the
bolts to 28 N·m (250 in. lbs.).
CAUTION: Overtightening the tensioner arm torxT bolt can cause severe damage to the cylinder head. Tighten torxT bolt to specified torque only.
(5) Install
left side chain tensioner arm. Apply Mopart Lock N, Seal to torxt bolt, tighten bolt to 17
N·m (150 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 8515 to hold chains in place for installa- tion (Fig. 133).
(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 (Fig. 131).
Fig.133InstallingSecondaryTimingChainson
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
(9) Lubricate idler shaft and bushings with clean
engine oil.
(10) Install all chains, crankshaft sprocket, and idler sprocket as an assembly (Fig. 134). After guid- ing both secondary chains through the block and cyl- inder head openings, affix chains with a elastic strap or the equivalent, This will maintain tension on chains to aid in installation.
NOTE: It will be necessary to slightly rotate 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 8515, then attach both sprockets to camshafts. Remove excess oil from bolts, then Install sprocket bolts, but do not tighten at this time.
(14) Verify that all plated links are aligned with the marks on all sprockets and the “V8” marks on camshaft sprockets are at the 12 o’clock position (Fig. 131).
ENGINE - 4.7L
9 - 174
TIMING BELT/CHAIN AND SPROCKETS (Continued)DR
Fig.134InstallingIdlerGear,Primaryand
SecondaryTimingChains
1 - SPECIAL TOOL 8429
2 - PRIMARY CHAIN IDLER SPROCKET 3 - CRANKSHAFT SPROCKETCAUTION: 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) Before installing idler sprocket bolt, lubricate washer with oil, and tighten idler sprocket assembly retaining bolt to 34 N·m (25 ft. lbs.).
(17) Remove all locking pins (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.
ing marks are at the follow locations:
(18) Using Special Tool 6958, Spanner with Adap- tor Pins 8346, tighten left (Fig. 135) and right (Fig. 136). camshaft sprocket bolts to 122 N·m (90 ft. lbs.). (19) 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
† secondary chain camshaft sprockets “V8” markso’clock (Fig. 131)
(Fig. 131)
are at 12 o’clock (Fig. 131)
(20) Lubricate all three chains with engine oil.
Fig.135TighteningLeftSideCamshaftSprocket
Bolt
1 - TORQUE WRENCH 2 - CAMSHAFT SPROCKET 3 - LEFT CYLINDER HEAD 4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
(21) After installing all chains, it is recommended that the idler gear end play be checked (Fig. 137). The end play must be within 0.10–0.25 mm (0.004– 0.010 in.). If not within specification, the idler gear must be replaced.
(22) Install
timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VI- BRATION DAMPER - INSTALLATION).
INSTALLATION)
and
(23) Install cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
NOTE: Before installing threaded plug in right cylin- der head, the plug must be coated with sealant to prevent leaks.
(24) 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.) (Fig. 126).
DR TIMING BELT/CHAIN AND SPROCKETS (Continued)
ENGINE - 4.7L
9 - 175
(29) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(30) Connect negative cable to battery.
IDLER SHAFT REMOVAL
(1) Remove the primary and secondary timing chains and sprockets (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) .
NOTE: To remove the idler shaft, it is necessary to tap threads into the shaft, to install the removal tool.
Fig.136TighteningRightSideCamshaftSprocket
Bolt
1 - TORQUE WRENCH 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET 4 - RIGHT CAMSHAFT SPROCKETFig.137MeasuringIdlerGearEndPlay
1 - IDLER SPROCKET ASSEMBLY 2 - DIAL INDICATOR
(2) Using a 12 mm X 1.75 tap, cut threads in the
idler shaft center bore.
(3) Cover the radiator core with a suitable cover.
CAUTION: Use care when removing the idler shaft, Do not strike the radiator cooling fins with the slide hammer.
(4) Using Special Tool 8517 Slide Hammer, remove
the idler shaft.
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 9 - ENGINE/VALVE TIMING/TIMING BELT/ CHAIN AND SPROCKETS - INSTALLATION).
(25) Install the oil fill housing. (26) Install access plug in left cylinder head (Fig.
126).
(27) Install power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(28) Install radiator fan shroud.
9 - 176
ENGINE - 5.7L
ENGINE - 5.7L
TABLE OF CONTENTS
page
DR
page
ENGINE - 5.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 178
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - ENGINE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 198
ROCKER ARM / ADJUSTER ASSY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 198DIAGNOSIS - INTRODUCTION . . . . . . . . . . 178
VALVE STEM SEALS
DIAGNOSIS AND TESTING - ENGINE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 198
DIAGNOSIS - PERFORMANCE . . . . . . . . . . 179
VALVE SPRINGS
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . 181
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE . . . . . . . . . . . . 182
DIAGNOSIS AND TESTING - CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 199ENGINE BLOCK
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 200COMBUSTION PRESSURE LEAKAGE . . . . . 182
CAMSHAFT & BEARINGS (IN BLOCK)
DIAGNOSIS AND TESTING—ENGINE
DIAGNOSIS - LUBRICATION . . . . . . . . . . . . 183
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . 184
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS . . . . . . . . 186
STANDARD PROCEDURE—HYDROSTATIC
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 187
SPECIFICATIONS5.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 188
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 191SPECIAL TOOLS
REMOVAL
REMOVAL - CAMSHAFT CORE HOLE PLUG REMOVAL - CAMSHAFT
. 200
