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(4) Remove fan and fan drive assembly (Refer to 7
VISCOUSCOOLING/ENGINE/FAN
DRIVE
CLUTCH - REMOVAL).
(5) Disconnect both heater hoses at timing cover. (6) Disconnect lower radiator hose at engine. (7) Remove accessory drive belt tensioner assembly
(Fig. 103).
(8) Remove crankshaft damper
to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(Refer
(9) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(10) Remove A/C compressor (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/A/C COM- PRESSOR - REMOVAL).
CAUTION: The 3.7L engine uses an anerobic sealer instead of a gasket to seal the front cover to the engine block, from the factory. For service, MoparT Engine RTV sealant must be substituted.
Fig.103ACCESSORYDRIVEBELTTENSIONER
1 - TENSIONER ASSEMBLY 2 - FASTENER TENSIONER TO FRONT COVER
NOTE: pump for timing cover removal.
It
is not necessary to remove the water
(11) Remove the bolts holding the timing cover to
engine block (Fig. 104).
Fig.104TIMINGCHAINCOVERFASTENERS
(12) Remove the timing cover.
ENGINE - 3.7L
9 - 81
DR TIMING BELT / CHAIN COVER(S) (Continued) INSTALLATION
CAUTION: Do not use oil based liquids to clean tim- ing cover or block surfaces. Use only rubbing alco- hol, along with plastic or wooden scrapers. Use no wire brushes or abrasive wheels or metal scrapers, or damage to surfaces could result.
(1) Clean timing chain cover and block surface
using rubbing alcohol.
CAUTION: The 3.7L uses a special anerobic sealer instead of a gasket to seal the timing cover to the engine block, from the factory. For service repairs, MoparT Engine RTV must be used as a substitute.
(2) Inspect the water passage o-rings for any dam-
age, and replace as necessary.
(3) Apply Mopart Engine RTV sealer to front cover following the path below using a 3 to 4mm thick bead (Fig. 105).
Fig.105TIMINGCOVERSEALANT
1 - TIMING CHAIN COVER 2 - WATER PASSAGE ORING 3 - MOPART ENGINE RTV SEALER
(4) Install cover. Tighten fasteners in sequence as
(5) Install
shown in to 58 N·m (43 ft. lbs.) (Fig. 106). (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
crankshaft damper
(6) Install the A/C compressor (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/A/C COM- PRESSOR - INSTALLATION).
Fig.106TIMINGCHAINCOVERFASTENERS
(7) Install the generator (Refer to 8 - ELECTRI- CAL/CHARGING/GENERATOR - INSTALLATION). (8) Install accessory drive belt tensioner assembly (Refer to 7 - COOLING/ACCESSORY DRIVE/BELT TENSIONERS - INSTALLATION).
(9) Install radiator upper and lower hoses. (10) Install both heater hoses. (11) Install electric fan shroud and viscous fan drive assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).
(12) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(13) Connect the battery negative cable.
TIMING BELT/CHAIN AND SPROCKETS REMOVAL
(1) Disconnect negative cable from battery. (2) Drain cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove right and left cylinder head covers(Re- fer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(4) Remove radiator fan shroud(Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(5) Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover (Fig. 108) and the camshaft sprocket “V6” marks are at the 12 o’clock position (#1 TDC exhaust stroke) (Fig. 107).
(6) Remove power steering pump(Refer to 19 -
STEERING/PUMP - REMOVAL).
(7) Remove access plug from left and right cylinder heads for access to chain guide fasteners (Fig. 109).
ENGINE - 3.7L
9 - 82
TIMING BELT/CHAIN AND SPROCKETS (Continued)DR
Fig.107CAMSHAFTSPROCKETV6MARKS,(#1TDCEXHAUSTSTROKE)
1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD
Fig.109CylinderHeadAccessPlugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
Fig.108EngineTopDeadCenter
1 - TIMING CHAIN COVER 2 - CRANKSHAFT TIMING MARKS
DR TIMING BELT/CHAIN AND SPROCKETS (Continued)
ENGINE - 3.7L
9 - 83
(8) Remove the oil fill housing to gain access to the
right side tensioner arm fastener.
(9) Remove crankshaft damper
to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL) and timing chain cover(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(Refer
(10) Collapse and pin primary chain tensioner.
CAUTION: Plate behind left secondary chain ten- sioner could fall into oil pan. Therefore, cover pan opening.
(11) Remove secondary chain tensioners. (12) Remove camshaft position sensor (Fig. 110).
Fig.110CamshaftPositionSensor
1 - CYLINDER HEAD 2 - CAMSAHFT POSITION SENSOR 3 - SCREW
to damage CAUTION: Care should be taken not camshaft target wheel. Do not hold target wheel while loosening or tightening camshaft sprocket. Do not place the target wheel near a magnetic source of any kind. A damaged or magnetized tar- get wheel could cause a vehicle no start condition.
CAUTION: Do not forcefully rotate the camshafts or crankshaft independently of each other. Damaging intake valve to piston contact will occur. Ensure negative battery cable is disconnected to guard against accidental starter engagement.
(13) Remove left and right camshaft sprocket bolts. (14) While holding the left camshaft steel tube with Special Tool 8428 Camshaft Wrench, remove the left camshaft sprocket. Slowly rotate the camshaft approximately 5 degrees clockwise to a neutral posi- tion.
(15) While holding the right camshaft steel tube with Special Tool 8428 Camshaft Wrench, remove the right camshaft sprocket.
(16) Remove idler sprocket assembly bolt. (17) Slide the idler sprocket assembly and crank sprocket forward simultaneously to remove the pri- mary and secondary chains.
(18) Remove both pivoting tensioner arms and
chain guides.
(19) Remove primary chain tensioner.
INSPECTION
excessive wear.
Inspect the following components: † Sprockets for excessive tooth wear. Some tooth markings are normal and not a cause for sprocket replacement. † Idler sprocket assembly bushing and shaft for † Idler sprocket assembly spline joint. The joint should be tight with no backlash or axial movement. † Chain guides and tensioner arms. Replace these parts if grooving in plastic face is more than 1 mm (0.039 in.) deep. If plastic face is severely grooved or melted, the tensioner lube jet may be clogged. The tensioner should be replaced. † Secondary chain tensioner piston and ratcheting device. Inspect for evidence of heavy contact between tensioner piston and tensioner arm. If this condition exist the tensioner tensioner arm and chain should be replaced. † Primary chain tensioner plastic faces. Replace as
required.
ENGINE - 3.7L
9 - 84
TIMING BELT/CHAIN AND SPROCKETS (Continued) INSTALLATION(1) Using a vise, lightly compress the secondary chain tensioner piston until the piston step is flush with the tensioner body. Using a pin or suitable tool, release ratchet pawl by pulling pawl back against spring force through access hole on side of tensioner. While continuing to hold pawl back, Push ratchet device to approximately 2 mm from the tensioner body. Install Special Tool 8514 lock pin into hole on front of tensioner (Fig. 111). Slowly open vise to transfer piston spring force to lock pin.
DR
(4) Install the left side chain guide. Tighten the
bolts to 28 N·m (250 in. lbs.).
(5) Install left side chain tensioner arm, and Torxt
bolt. Tighten Torxt bolt to 28 N·m (250 in. lbs.).
(6) Install the right side chain guide. Tighten the
bolts to 28 N·m (250 in. lbs.).
(7) Install both secondary chains onto the idler sprocket. Align two plated links on the secondary chains to be visible through the two lower openings on the idler sprocket (4 o’clock and 8 o’clock). Once the secondary timing chains are installed, position special tool 8429 to hold chains in place for installa- tion.
(8) Align primary chain double plated links with the timing mark at 12 o’clock on the idler sprocket. Align the primary chain single plated link with the timing mark at 6 o’clock on the crankshaft sprocket. (9) Lubricate idler shaft and bushings with clean
engine oil.
NOTE: The idler sprocket must be timed to the counterbalance shaft drive gear before the idler sprocket is fully seated.
Fig.111RESETTINGSECONDARYCHAIN
TENSIONERS
1 - VISE 2 - INSERT LOCK PIN 3 - RATCHET PAWL 4 - RATCHET 5 - PISTON
(2) Position primary chain tensioner over oil pump and insert bolts into lower two holes on tensioner bracket. Tighten bolts to 28 N·m (250 in. lbs.).
(3) Install right side chain tensioner arm. Install Torxt bolt. Tighten Torxt bolt to 28 N·m (250 in. lbs.).
CAUTION: The silver bolts retain the guides to the cylinder heads and the black bolts retain the guides to the engine block.
Fig.112INSTALLINGIDLERGEAR,PRIMARYAND
SECONDARYTIMINGCHAINS
1 - SPECIAL TOOL 8429
2 - PRIMARY CHAIN IDLER SPROCKET 3 - CRANKSHAFT SPROCKETDR TIMING BELT/CHAIN AND SPROCKETS (Continued)
ENGINE - 3.7L
9 - 85
(14) Verify that all plated links are aligned with the marks on all sprockets and the “V6” marks on camshaft sprockets are at the 12 o’clock position.
CAUTION: Ensure the plate between the left sec- ondary chain tensioner and block is correctly installed.
(15) Install
both secondary
chain tensioners.
Tighten bolts to 28 N·m (250 in. lbs.).
NOTE: Left and right secondary chain tensioners are not common.
(16) Remove all locking pins (3) from tensioners.
CAUTION: After pulling locking pins out of each tensioner, DO NOT manually extend the tensioner(s) ratchet. Doing so will over tension the chains, resulting in noise and/or high timing chain loads.
(17) Using Special Tool 6958, Spanner with Adap- tor Pins 8346, tighten left (Fig. 114) and right (Fig. 115). camshaft sprocket bolts to 122 N·m (90 ft. lbs.).
(10) Install all chains, crankshaft sprocket, and idler sprocket as an assembly (Fig. 112). After guid- ing both secondary chains through the block and cyl- inder head openings, affix chains with a elastic strap or equivalent. This will maintain tension on chains to aid in installation. Align the timing mark on the idler sprocket gear to the timing mark on the coun- terbalance shaft drive gear, then seat idler sprocket fully (Fig. 113). Before installing idler sprocket bolt, lubricate washer with oil, and tighten idler sprocket assembly retaining bolt to 34 N·m (25 ft. lbs.).
Fig.113COUNTERBALANCESHAFTALIGNMENT
MARKS 1 - COUNTERBALANCE SHAFT GEAR 2 - TIMING MARK 3 - IDLER SPROCKET GEAR
NOTE: It will be necessary to slightly rotate cam- shafts for sprocket installation.
(11) Align left camshaft sprocket “L” dot to plated
link on chain.
plated link on chain.
(12) Align right camshaft sprocket
“R” dot
to
CAUTION: Remove excess oil from the camshaft sprocket bolt. Failure to do so can result in over- torque of bolt resulting in bolt failure.
(13) Remove Special Tool 8429, then attach both sprockets to camshafts. Remove excess oil from bolts, then Install sprocket bolts, but do not tighten at this time.
Fig.114TIGHTENINGLEFTSIDECAMSHAFT
SPROCKETBOLT
1 - TORQUE WRENCH 2 - CAMSHAFT SPROCKET 3 - LEFT CYLINDER HEAD 4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
ENGINE - 3.7L
9 - 86
TIMING BELT/CHAIN AND SPROCKETS (Continued)DR
Fig.115TIGHTENINGRIGHTSIDECAMSHAFT
SPROCKETBOLT
1 - TORQUE WRENCH 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET 4 - RIGHT CAMSHAFT SPROCKETing marks are at the follow locations:
(18) Rotate engine two full revolutions. Verify tim- † primary chain idler sprocket dot is at 12 o’clock † primary chain crankshaft sprocket dot is at 6
o’clock† secondary chain camshaft sprockets “V6” marks are at 12 o’clock † counterbalancer shaft drive gear dot is alignedto the idler sprocket gear dot
(19) Lubricate all three chains with engine oil. (20) After installing all chains, it is recommended that the idler gear end play be checked. The end play must be within 0.10–0.25 mm (0.004–0.010 in.). If not within specification, the idler gear must be replaced (Fig. 116).
(21) Install
timing chain cover and crankshaft
damper. Refer to procedures.
(22) Install
to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
cylinder head covers(Refer
Fig.116MEASURINGIDLERGEARENDPLAY
1 - IDLER SPROCKET ASSEMBLY 2 - DIAL INDICATOR
NOTE: Before installing threaded plug in right cylin- der head, the plug must be coated with sealant to prevent leaks.
(23) Coat
the large threaded access plug with Mopart Thread Sealant with Teflon, then install into the right cylinder head and tighten to 81 N·m (60 ft. lbs.).
(24) Install the oil fill housing. (25) Install access plug in left cylinder head. (26) Install power steering pump(Refer to 19 -
STEERING/PUMP - INSTALLATION).
(27) Fill cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(28) Connect negative cable to battery.
DR
ENGINE - 4.7L
9 - 87
ENGINE - 4.7L
TABLE OF CONTENTS
page
page
ENGINE - 4.7L
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . 89
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . 91
DIAGNOSIS AND TESTING - CYLINDER
REMOVAL
REMOVAL - RIGHT SIDE . . . . . . . . . . . . . . . 121
REMOVAL - LEFT SIDE . . . . . . . . . . . . . . . . 121
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
INSTALLATIONINSTALLATION - RIGHT SIDE INSTALLATION—LEFT SIDE
. . . . . . . . . . . 121
. . . . . . . . . . . . 122COMPRESSION PRESSURE . . . . . . . . . . . . . 92
INTAKE/EXHAUST VALVES & SEATS
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE . . . . . . 92
DIAGNOSIS AND TESTING - ENGINE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 122
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123DIAGNOSIS - INTRODUCTION . . . . . . . . . . . 93
ROCKER ARM / ADJUSTER ASSEMBLY
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS . . . . . . . . . 93
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS . . . . . . . . . 93
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 96
SPECIFICATIONS4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 98
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 101SPECIAL TOOLS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 124
DIAGNOSIS AND TESTING - HYDRAULICLASH ADJUSTER . . . . . . . . . . . . . . . . . . . . . 124
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 125
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126VALVE STEM SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 126
4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 102
ENGINE BLOCK
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 105CYLINDER HEAD DESCRIPTION
DESCRIPTION - CYLINDER HEAD . . . . . . . 106
DESCRIPTION - VALVE GUIDES . . . . . . . . . 106REMOVAL
REMOVAL - LEFT CYLINDER HEAD . . . . . . 106
REMOVAL - RIGHT CYLINDER HEAD . . . . . 108
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATIONINSTALLATION - LEFT CYLINDER HEAD . . . 110
INSTALLATION - RIGHT CYLINDER HEAD . . 111CAMSHAFT(S) - LEFT
. . . . . . . . . . . . . . . . . . . . . . . . 113
DESCRIPTION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 114CAMSHAFT(S) - RIGHT
. . . . . . . . . . . . . . . . . . . . . . . . 117
DESCRIPTION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 118CYLINDER HEAD COVER(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 121
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 126
STANDARD PROCEDURE—CYLINDER BOREHONING
. . . . . . . . . . . . . . . . . . . . . . . . . . . 126
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 127CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING . . . . . . . . . . . . . . . 128
CORE PLUGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 130CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 130
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 131
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 131CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE—CRANKSHAFT
MAIN BEARING - FITTING . . . . . . . . . . . . . . 133
. . . . . . . . . . . . . . . . . . . . . . . . . 133INSPECTION
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 1349 - 88
ENGINE - 4.7L
DR
CRANKSHAFT OIL SEAL - REAR
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 135
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 136FLEX PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 137PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 137
STANDARD PROCEDURE—PISTON FITTING . 137
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 139PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 142STRUCTURAL COVER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 143
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 143
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 143FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 144REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 147LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 148
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 148
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . 150
DIAGNOSIS AND TESTING—ENGINE OIL
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 153OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 153OIL PRESSURE SENSOR/SWITCH
DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 154
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 154OPERATION
OPERATION OPERATION
. . . . . . . . . . . . . . . . . . . . . . . . 154
. . . . . . . . . . . . . . . . . . . . . . . . 154
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 154OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 155
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 155
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 157INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 157
DIAGNOSIS AND TESTING—INTAKEMANIFOLD LEAKAGE
. . . . . . . . . . . . . . . . . 157
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 158
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 158EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 159
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 161
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 162VALVE TIMING
DESCRIPTION—TIMING DRIVE SYSTEM . . . . 164
OPERATION - TIMING DRIVE SYSTEM . . . . . 164
STANDARD PROCEDURESTANDARD PROCEDURE—MEASURING
TIMING CHAIN WEAR . . . . . . . . . . . . . . . . . 165
STANDARD PROCEDURE - ENGINE TIMING
- VERIFICATION . . . . . . . . . . . . . . . . . . . . . 165
TIMING BELT / CHAIN COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 169TIMING BELT/CHAIN AND SPROCKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 171
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 172IDLER SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 175DR
ENGINE - 4.7L
ENGINE - 4.7L
9 - 89
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION
POSSIBLE CAUSE
CORRECTION
ENGINE WILL NOT START
1. Weak battery
1. Charge or replace as necessary.
2. Corroded or loose battery connections.
3. Faulty starter.
4. Faulty coil or control unit.
5. Incorrect spark plug gap.
6. Dirt or water in fuel system.
7. Faulty fuel pump, relay or wiring.
ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low.
2. Idle mixture too lean or too rich.
3. Vacuum leak.
4. Faulty coil.
5. Incorrect engine timing.
1. ENGINE LOSS OF POWER
1. Dirty or incorrectly gapped spark plugs.
2. Dirt or water in fuel system.
3. Faulty fuel pump.
4. Blown cylinder head gasket.
2. Clean and tighten battery connections. Apply a coat of light mineral grease to the terminals. 3. (Refer to 8 - ELECTRICAL/ STARTING - DIAGNOSIS AND TESTING). 4. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL). 5. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 6. Clean system and replace fuel filter. 7. Repair or replace as necessary.
1. (Refer to 14 - FUEL SYSTEM/ FUEL INJECTION/IDLE AIR CONTROL MOTOR - REMOVAL).
2. Refer to Powertrain Diagnosis Information. 3. Inspect intake manifold and vacuum hoses, repair or replace as necessary. 4. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL). 5. (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE).
1. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 2. Clean system and replace fuel filter. 3. (Refer to 14 - FUEL SYSTEM/ FUEL DELIVERY/FUEL PUMP - DIAGNOSIS AND TESTING). 4. Replace cylinder head gasket.
ENGINE - 4.7L
9 - 90
ENGINE - 4.7L (Continued)DR
CONDITION
POSSIBLE CAUSE
CORRECTION
5. Low compression.
6. Burned, warped or pitted valves. 7. Plugged or restricted exhaust system. 8. Faulty coil.
1. ENGINE MISSES ON ACCELERATION
1. Spark plugs dirty or incorrectly gapped.
2. Dirt in fuel system. 3. Burned, warped or pitted valves. 4. Faulty coil.
1. ENGINE MISSES AT HIGH SPEED
1. Spark plugs dirty or incorrectly gapped.
2. Faulty coil.
3. Dirt or water in fuel system.
5. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING). 6. Replace as necessary. 7. Inspect and replace as necessary. 8. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL).
1. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 2. Clean fuel system. 3. Replcae as necessary. 4. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL).
1. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING). 2. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL). 3. Clean system and replace fuel filter.
DR ENGINE - 4.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
ENGINE - 4.7L
9 - 91
CONDITION
POSSIBLE CAUSES
CORRECTIONS
NOISY VALVES
1. High or low oil level in crankcase.
2. Thin or diluted oil. 3. Low oil pressure.
4. Dirt in lash adjusters. 5. Worn rocker arms. 6. Worn lash adjusters 7. Worn valve guides.
8. Excessive runout of valve seats on valve faces.
CONNECTING ROD NOISE
1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil. 4. Excessive bearing clearance. 5. Connecting rod journal out-of-round. 6. Misaligned connecting rods.
MAIN BEARING NOISE
1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil. 4. Excessive bearing clearance. 5. Excessive end play. 6. Crankshaft journal out-of round. 7. Loose flywheel or torque converter.
1. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS)
2. Change oil and filter. 3. Check oil pump, if Ok, check rod and main bearings for excessive wear. 4. Replace as necessary. 5. Replace as necessary. 6. Replace as necessary. 7. (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE) 8. (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE)
1. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS)
2. Check oil pump, if Ok, check rod and main bearings for excessive wear. 3. Change oil and filter. 4. Replace as necessary. 5. Service or replace crankshaft.
6. Replace bent connecting rods.
1. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS) 2. Check oil pump, if Ok, check rod and main bearings for excessive wear. 3. Change oil and filter. 4. Replace as necessary. 5. Check thrust washers for wear. 6. Service or replace crankshaft. 7. Tighten to correct torque
ENGINE - 4.7L
9 - 92
ENGINE - 4.7L (Continued) DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSUREThe results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc- tions.
Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs. (3) Secure the throttle in the wide-open position. (4) Disable the fuel system (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DESCRIPTION).
(5) Remove the ASD relay (Refer to 8 - ELECTRI- CAL/IGNITION CONTROL/AUTO SHUT DOWN RELAY - REMOVAL).
(6) Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
(7) Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylin- ders.
(8) (Refer to 9 - ENGINE - SPECIFICATIONS) for
the correct engine compression pressures.
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition. Combustion pressure leakage testing will detect:
DR
† Exhaust and intake valve leaks (improper seat- ing).† Leaks between adjacent cylinders or into water jacket.† Any causes for combustion/compression pressure loss. (1) Check the coolant level and fill as required. DO
NOT install the radiator cap.
(2) Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.
(3) Remove the spark plugs. (4) Remove the oil filler cap. (5) Remove the air cleaner hose. (6) Calibrate the tester according to the manufac- turer’s instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom- mended.(7) Perform the test procedures on each cylinder according to the tester manufacturer’s instructions. Set piston of cylinder to be tested at TDC compres- sion,While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE: At 552 kPa (80 psi) input pres- sure, a minimum of 414 kPa (60 psi) should be main- tained in the cylinder.
Refer to CYLINDER COMBUSTION PRESSURE
LEAKAGE DIAGNOSIS CHART.
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION
AIR ESCAPES THROUGH THROTTLE BODY
POSSIBLE CAUSE
Intake valve bent, burnt, or not seated properly
AIR ESCAPES THROUGH TAILPIPE
Exhaust valve bent, burnt, or not seated properly
AIR ESCAPES THROUGH RADIATOR MORE THAN 50% LEAKAGE FROM ADJACENT CYLINDERS
MORE THAN 25% LEAKAGE AND AIR ESCAPES THROUGH OIL FILLER CAP OPENING ONLY
Head gasket leaking or cracked cylinder head or block Head gasket leaking or crack in cylinder head or block between adjacent cylinders Stuck or broken piston rings; cracked piston; worn rings and/or cylinder wall
CORRECTION
Inspect valve and valve seat. Reface or replace, as necessary. Inspect valve springs. Replace as necessary. Inspect valve and valve seat. Reface or replace, as necessary. Inspect valve springs. Replace as necessary. Remove cylinder head and inspect. Replace defective part Remove cylinder head and inspect. Replace gasket, head, or block as necessary Inspect for broken rings or piston. Measure ring gap and cylinder diameter, taper and out-of-round. Replace defective part as necessary
DR ENGINE - 4.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION Engine diagnosis is helpful
in determining the causes of malfunctions not detected and remedied by routine maintenance.
These malfunctions may be classified as either per- formance (e.g., engine idles rough and stalls) or mechanical (e.g., a strange noise).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST- ING)—PERFORMANCE and (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)—MECHANICAL for possible causes and corrections of malfunctions. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING) and (Refer to 14 - FUEL SYSTEM/FUEL INJECTION - DIAGNOSIS AND TESTING) for the fuel system diagnosis.
ENGINE - DIAGNOSIS AND TESTING).
Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts. Information concerning additional tests and diagno- sis is provided within the following diagnosis: † Cylinder Compression Pressure Test (Refer to 9 - † Cylinder Combustion Pressure Leakage Test (Refer to 9 - ENGINE - DIAGNOSIS AND TEST- ING).† Engine Cylinder Head Gasket Failure Diagnosis (Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNO- SIS AND TESTING). † Intake Manifold Leakage Diagnosis (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE DIAGNOSIS AND TESTING).
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain the original center line.
tially, this repair consists of:
Damaged or worn threads can be repaired. Essen- † Drilling out worn or damaged threads. † Tapping the hole with a special Heli-Coil Tap, or † Installing an insert into the tapped hole to bring
equivalent.
the hole back to its original thread size.
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in-
ENGINE - 4.7L
9 - 93
place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket materials that are used in the engine area. Mopart Engine RTV GEN II, Mopart ATF-RTV, and Mopart Gasket Maker gasket materials, each have different properties and can not be used in place of the other.
MOPARt ENGINE RTV GEN II Mopart Engine RTV GEN II is used to seal com- ponents exposed to engine oil. This material is a spe- cially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
MOPARt ATF RTV Mopart ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and seal- ing properties to seal components exposed to auto- matic coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
transmission fluid,
engine
MOPARt GASKET MAKER Mopart Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.
MOPARt GASKET SEALANT Mopart Gasket Sealant is a slow drying, perma- nently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This mate- rial is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will pre- vent corrosion. Mopart Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER APPLICATION
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gas- kets.
Mopart Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant
ENGINE - 4.7L
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
