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-
28
2834
13
58Ft.
Lbs. — 25
— — —— — —
— — —
25
— 43
In.
Lbs. 130
— 250
105
250130
105
250150
250
250—
115
—DR ENGINE - 4.7L (Continued) TORQUE
DESCRIPTION
N·m
Ft.
In.
Lbs.
Lbs.
Camshaft
Non - Oiled Sprocket Bolt Bearing Cap Bolts
Timing Chain Cover—Bolts Connecting Rod Cap—Bolts
122
11
58
2790
— 43
20— 100
— —Bed Plate—Bolts Crankshaft Damper—Bolt Cylinder Head—Bolts
M11 Bolts M8 Bolts
Cylinder Head Cover—Bolts Exhaust Manifold—Bolts Exhaust Manifold Heat Shield—Nuts
Flexplate—Bolts Engine Mount Bracket to Block—Bolts Rear Mount to Transmission—Bolts Generator Mounting—Bolts
M10 Bolts M8 Bolts
Intake Manifold—Bolts
PLUS 90° TURN Refer to Procedure 175
—130
81
26
12
2560
19
— 18
—— — 105
— 72Then loosen 45° — 60
61
—45
4546
34
—
40
— —— 54
250
28
12
105
Refer to Procedurefor
Tightening Sequence
ENGINE - 4.7L
9 - 102
ENGINE - 4.7L (Continued) SPECIAL TOOLS4.7L ENGINE
DR
SpannerWrench6958
FrontCrankshaftSealRemover8511
FrontCrankshaftSealInstaller8348
AdapterPins8346
EngineLiftingStuds8400
HandleC-4171
EngineLiftFixture8347
RearCrankshaftSealInstaller8349
DR ENGINE - 4.7L (Continued)
ENGINE - 4.7L
9 - 103
RearCrankshaftSealRemover8506
CrankshaftDamperRemovalInsert8513
ConnectingRodGuides8507
ChainTensionerWedge8350
CrankshaftDamperInstaller8512
ChainTensionerPins8514
Puller1026
SecondaryChainHolder8515
ENGINE - 4.7L
9 - 104
ENGINE - 4.7L (Continued)DR
Remover,RockerArm8516
ValveSpringTesterC-647
ValveSpringCompressor8387
IdlerShaftRemover8517
DialIndicatorC-3339
ValveSpringCompressorC-3422-B
BoreSizeIndicatorC-119
ValveSpringCompressorAdapters8519
OilPressureGaugeC-3292
DR ENGINE - 4.7L (Continued)
ENGINE - 4.7L
9 - 105
AIR CLEANER ELEMENT REMOVAL
Filter Element Only
Housing removal is not necessary for element (fil-
ter) replacement.
at air cleaner cover.
(1) Loosen clamp (Fig. 7) and disconnect air duct
(2) Pry over 4 spring clips (Fig. 7) from housing
cover (spring clips retain cover to housing).
(3) Release housing cover from locating tabs on
housing (Fig. 7) and remove cover.
(4) Remove air cleaner element (filter) from hous-
(5) Clean inside of housing before replacing ele-
ing.
ment.
PistonRingCompressorC-385
PressureTesterKit7700
Bloc–Chek–KitC-3685–A
ENGINESUPPORTFIXTURE8534
Fig.7AIRCLEANERHOUSINGCOVER
1 - CLAMP 2 - AIR DUCT 3 - AIR CLEANER COVER 4 - LOCATING TABS 5 - CLIPS (4)
Housing Assembly
(1) Loosen clamp (Fig. 7) and disconnect air duct
at air cleaner cover.
pins (Fig. 8).
(2) Lift entire housing assembly from 4 locating
INSTALLATION
(1) Install filter element into housing. (2) Position housing cover into housing locating
tabs (Fig. 7).
ENGINE - 4.7L
9 - 106
AIR CLEANER ELEMENT (Continued)DR
REMOVAL
REMOVAL - LEFT CYLINDER HEAD
(1) Disconnect the negative cable from the battery. (2) Raise the vehicle on a hoist. (3) Disconnect the exhaust pipe at the left side
(4) Drain the engine coolant. Refer to COOLING
exhaust manifold.
SYSTEM.
(5) Lower the vehicle. (6) Remove the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE REMOVAL).
(7) Remove the master cylinder and booster assem-
bly. Refer to section 5 brakes.
(8) Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(9) Remove the fan shroud and fan blade assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VIS- COUS CLUTCH - REMOVAL).
(10) Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(11) Remove the power steering pump and set
(12) Rotate the crankshaft until the damper tim- ing mark is aligned with TDC indicator mark (Fig. 9).
Fig.8AIRCLEANERHOUSING
1 - AIR CLEANER HOUSING ASSEMBLY 2 - LOCATING PINS (4)
(3) Pry up 4 spring clips (Fig. 7) and lock cover to
aside.
housing.
(4) Install air duct to air cleaner cover and tighten
hose clamp to 3 N·m (30 in. lbs.) torque.
(5) If any other hose clamps were removed from air intake system, tighten them to 3.4 N·m (30 in. lbs.) torque.
(6) If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 N·m (40 in. lbs.) torque.
CYLINDER HEAD
DESCRIPTION
DESCRIPTION - CYLINDER HEAD
The cylinder heads are made of an aluminum alloy. The cylinder head features two valves per cylinder with pressed in powdered metal valve guides. The cylinder heads also provide enclosures for the timing chain drain, necessitating unique left and right cylin- der heads.
DESCRIPTION - VALVE GUIDES
The valve guides are made of powered metal and are pressed into the cylinder head. The guides are not replaceable or serviceable, and valve guide ream- ing is not recommended. If the guides are worn beyond acceptable limits, replace the cylinder heads.
Fig.9EngineTopDeadCenter(TDC)IndicatorMark 1 - TIMING CHAIN COVER 2 - CRANKSHAFT TIMING MARKS
DR CYLINDER HEAD (Continued)
ENGINE - 4.7L
9 - 107
(13) Verify the V8 mark on the camshaft sprocket is at the 12 o’clock position (Fig. 11). Rotate the crankshaft one turn if necessary.
(14) Remove the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(15) Remove the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(16) Lock the secondary timing chains to the idler
sprocket using Special Tool 8515 (Fig. 10).
NOTE: Mark the secondary timing chain prior to removal to aid in installation.
(17) Mark the secondary timing chain, one link on each side of the V8 mark on the camshaft drive gear (Fig. 11).
(18) Remove the left side secondary chain ten- sioner (Refer to 9 - ENGINE/VALVE TIMING/TIM- ING BELT/CHAIN AND SPROCKETS - REMOVAL). (19) Remove the cylinder head access plug (Fig.
12).
(20) Remove the left side secondary chain guide (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).
(21) Remove the retaining bolt and the camshaft
drive gear.
CAUTION: Do not allow the engine to rotate. Severe damage to the valve train can occur.
Fig.10UsingSpecialTool8515toHoldChainsto
IdlerSprocket.
1 - LOCK ARM 2 - RIGHT CAMSHAFT CHAIN 3 - SECONDARY CHAINS RETAINING PINS (4) 4 - IDLER SPROCKET 5 - LEFT CAMSHAFT CHAIN 6 - SPECIAL TOOL 8515
CAUTION: Do not overlook the four smaller bolts at the front of the cylinder head. Do not attempt to remove the cylinder head without removing these four bolts.
1 - LEFT CYLINDER HEAD
Fig.11CamshaftSprocketV8Marks
2 - RIGHT CYLINDER HEAD
ENGINE - 4.7L
9 - 108
CYLINDER HEAD (Continued)DR
Fig.12CylinderHeadAccessPlugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
NOTE: The cylinder head is attached to the cylinder block with fourteen bolts.
(22) Remove the cylinder head retaining bolts. (23) Remove the cylinder head and gasket. Discard
the gasket.
CAUTION: Do not lay the cylinder head on its gas- ket sealing surface, due to the design of the cylin- der head gasket any distortion to the cylinder head sealing surface may prevent the gasket from prop- erly sealing resulting in leaks.
REMOVAL - RIGHT CYLINDER HEAD (1) Disconnect battery negitive cable. (2) Raise the vehicle on a hoist. (3) Disconnect the exhaust pipe at the right side
exhaust manifold.
(4) Drain the engine coolant (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(5) Lower the vehicle. (6) Remove the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE REMOVAL).
(7) Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(8) Remove the fan shroud (Refer to 7 - COOLING/ ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
(9) Remove oil fill housing from cylinder head. (10) Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(11) Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark (Fig. 13).
Fig.13EngineTopDeadCenter(TDC)Indicator
Mark
1 - TIMING CHAIN COVER 2 - CRANKSHAFT TIMING MARKS
(12) Verify the V8 mark on the camshaft sprocket is at the 12 o’clock position (Fig. 14). Rotate the crankshaft one turn if necessary.
(13) Remove the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(14) Remove the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(15) Lock the secondary timing chains to the idler
sprocket using Special Tool 8515 (Fig. 15).
NOTE: Mark the secondary timing chain prior to removal to aid in installation.
(16) Mark the secondary timing chain, one link on each side of the V8 mark on the camshaft drive gear (Fig. 14).
(17) Remove the right side secondary chain ten- sioner (Refer to 9 - ENGINE/VALVE TIMING/TIM- ING BELT/CHAIN AND SPROCKETS - REMOVAL). (18) Remove the cylinder head access plug (Fig.
16).
(19) Remove the right side secondary chain guide (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).
(20) Remove the retaining bolt and the camshaft
drive gear.
DR CYLINDER HEAD (Continued)
ENGINE - 4.7L
9 - 109
1 - LEFT CYLINDER HEAD
Fig.14CamshaftSprocketV8Marks
2 - RIGHT CYLINDER HEAD
Fig.15UsingSpecialTool8515toHoldChainsto
IdlerSprocket.
1 - LOCK ARM 2 - RIGHT CAMSHAFT CHAIN 3 - SECONDARY CHAINS RETAINING PINS (4) 4 - IDLER SPROCKET 5 - LEFT CAMSHAFT CHAIN 6 - SPECIAL TOOL 8515
CAUTION: Do not allow the engine to rotate. severe damage to the valve train can occur.
Fig.16CylinderHeadAccessPlugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
CAUTION: Do not overlook the four smaller bolts at the front of the cylinder head. Do not attempt to remove the cylinder head without removing these four bolts.
CAUTION: Do not hold or pry on the camshaft tar- get wheel for any reason. A damaged target wheel can result in a vehicle no start condition.
ENGINE - 4.7L
9 - 110
CYLINDER HEAD (Continued)NOTE: The cylinder head is attached to the cylinder block with fourteen bolts.
(21) Remove the cylinder head retaining bolts. (22) Remove the cylinder head and gasket. Discard
the gasket.
CAUTION: Do not lay the cylinder head on its gas- ket sealing surface, do to the design of the cylinder head gasket any distortion to the cylinder head sealing surface may prevent the gasket from prop- erly sealing resulting in leaks.
CLEANING
To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
INSPECTION
DR
Fig.17CheckingCylinderHeadBoltsforStretching
(Necking)
1 - STRETCHED BOLT 2 - THREADS ARE NOT STRAIGHT ON LINE 3 - THREADS ARE STRAIGHT ON LINE 4 - UNSTRETCHED BOLT
(1) Inspect the cylinder head for out-of-flatness, using a straightedge and a feeler gauge. If tolerances exceed 0.0508 mm (0.002 in.) replace the cylinder head.
(2) Inspect the valve seats for damage. Service the
valve seats as necessary.
(3) Inspect the valve guides for wear, cracks or looseness. If either condition exist, replace the cylin- der head.
INSTALLATION
INSTALLATION - LEFT CYLINDER HEAD
NOTE: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced.
Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced (Fig. 17).
CAUTION: When cleaning cylinder head and cylin- der block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use only a wooden or plastic scraper.
Fig.18ProperToolUsagefor
1 - PLASTIC/WOOD SCRAPER
(3) Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.
NOTE: The four smaller cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.
(1) Clean the cylinder head and cylinder block
mating surfaces (Fig. 18).
(2) Position the new cylinder head gasket on the
locating dowels.
CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm.
(4) Lubricate the cylinder head bolt threads with
clean engine oil and install the ten M11 bolts.
(5) Coat the four M8 cylinder head bolts with Mopart Lock and Seal Adhesive then install the bolts.
DR CYLINDER HEAD (Continued)
NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.
(6) Tighten the bolts in sequence (Fig. 19) using the following steps and torque values: † Step 1: Tighten bolts 1–10, 20 N·m (15 ft. lbs.). † Step 2: Tighten bolts 1–10, 47 N·m (35 ft. lbs.). Tighten bolts 11–14, 25 N·m (18 ft. lbs.). † Step 3: Tighten bolts 1–10, 90 degrees. Tighten bolts 11–14, 30 N·m (22 ft. lbs.).
Fig.19CylinderHeadTighteningSequence
(7) Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V8 mark on the gear and position the gear onto the camshaft.
(8) Install the camshaft drive gear retaining bolt. (9) Install the left side secondary chain guide (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLA- TION).
(10) Install the cylinder head access plug (Fig. 20). (11) Re-set and Install the left side secondary chain tensioner (Refer to 9 - ENGINE/VALVE TIM- ING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).
(12) Remove Special Tool 8515. (13) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(14) Install the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
(15) Install the power steering pump. (16) Install the fan blade assembly and fan shroud (Refer to 7 - COOLING/ENGINE/FAN DRIVE VIS- COUS CLUTCH - INSTALLATION).
(17) Install the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(18) Reinstall
the master cylinder and booster
assembly. Refer to section 5 brakes.
ENGINE - 4.7L
9 - 111
(19) Install
the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE INSTALLATION).
(20) Refill the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(21) Raise the vehicle. (22) Install the exhaust pipe onto the left exhaust
manifold.
(23) Lower the vehicle. (24) Connect the negative cable to the battery. (25) Start the engine and check for leaks.
Fig.20CylinderHeadAccessPlugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
INSTALLATION - RIGHT CYLINDER HEAD
NOTE: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced.
Necking can be checked by holding a straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced (Fig. 21).
CAUTION: When cleaning cylinder head and cylin- der block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use only a wooden or plastic scraper.
(1) Clean the cylinder head and cylinder block
mating surfaces (Fig. 22).
(2) Position the new cylinder head gasket on the
locating dowels.
CAUTION: When installing cylinder head, use care not damage the tensioner arm or the guide arm.
ENGINE - 4.7L
9 - 112
CYLINDER HEAD (Continued)DR
NOTE: The cylinder head bolts are tightened using an angle torque procedure, however, the bolts are not a torque-to-yield design.
Fig.21CheckingCylinderHeadBoltsforStretching
(Necking)
1 - STRETCHED BOLT 2 - THREADS ARE NOT STRAIGHT ON LINE 3 - THREADS ARE STRAIGHT ON LINE 4 - UNSTRETCHED BOLT
Fig.22ProperToolUsagefor
1 - PLASTIC/WOOD SCRAPER
(3) Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.
NOTE: The four smaller cylinder head mounting bolts require sealant to be added to them before installing. Failure to do so may cause leaks.
(4) Lubricate the cylinder head bolt threads with
clean engine oil and install the ten M10 bolts.
(5) Coat the four M8 cylinder head bolts with Mopart Lock and Seal Adhesive then install the bolts.
the following steps and torque values:
(6) Tighten the bolts in sequence (Fig. 23) using † Step 1: Tighten bolts 1–10, 20 N·m (15 ft. lbs.). † Step 2: Tighten bolts 1–10, 47 N·m (35 ft. lbs.). † Step 3: Tighten bolts 1–10, 90 degrees. Tighten
Tighten bolts 11–14, 25 N·m (18 ft. lbs.).
bolts 11–14, 30 N·m (22 ft. lbs.).
Fig.23CylinderHeadTighteningSequence
(7) Position the secondary chain onto the camshaft drive gear, making sure one marked chain link is on either side of the V8 mark on the gear and position the gear onto the camshaft.
(8) Install the camshaft drive gear retaining bolt. (9) Install the right side secondary chain guide (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(10) Install the right side cylinder head access
plug (Fig. 24).
Fig.24CylinderHeadAccessPlugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG
ENGINE - 4.7L
9 - 113
CAUTION: When removing the cam sprocket, timing chains or camshaft, Failure to use Special Tool 8350 will result in hydraulic tensioner ratchet over extension, requiring timing chain cover removal to reset the tensioner ratchet.
(1) Remove cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(2) Set engine to TDC cylinder #1,
camshaft
sprocket V8 marks at the 12 o’clock position.
(3) Mark one link on the secondary timing chain on both sides of the V8 mark on the camshaft sprocket to aid in installation.
CAUTION: Do not hold or pry on the camshaft tar- get wheel (Located on the right side camshaft sprocket) for any reason, Severe damage will occur to the target wheel resulting in a vehicle no start condition.
(4) Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave the bolt snug against the sprocket.
NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tension- ers to extend, requiring timing chain cover removal in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur.
(5) Position Special Tool 8350 timing chain wedge between the timing chain strands, tap the tool to securely wedge the timing chain against the ten- sioner arm and guide (Fig. 25).
NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas.
DR CYLINDER HEAD (Continued)
(11) Re-set and install the right side secondary
chain tensioner.
(12) Remove Special Tool 8515. (13) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(14) Install the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
(15) Install accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(16) Install the fan shroud. (17) Install the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(18) Install
the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE INSTALLATION).
(19) Install oil fill housing onto cylinder head. (20) Refill the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(21) Raise the vehicle. (22) Install
exhaust manifold.
the exhaust pipe onto the right
(23) Lower the vehicle. (24) Reconnect battery negitive cable. (25) Start the engine and check for leaks.
CAMSHAFT(S) - LEFT DESCRIPTION
The camshafts consist of powdered metal steel lobes which are sinter-bonded to a steel tube. A steel post or nose piece is friction-welded to the steel cam- shaft tube. Five bearing journals are machined into the camshaft, four on the steel tube and one on the steel nose piece. Camshaft end play is controlled by two thrust walls that border the nose piece journal. Engine oil enters the hollow camshafts at the third journal and lubricates every intake lobe rocker through a drilled passage in the intake lobe.
REMOVAL
CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT force- fully rotate the camshafts or crankshaft indepen- dently of each other. Severe valve and/or piston damage can occur.
ENGINE - 4.7L
9 - 114
CAMSHAFT(S) - LEFT (Continued)DR
Fig.25SecuringTimingChainTensionersUsingTimingChainWedge
1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD
3 - SPECIAL TOOL 8350 WEDGE 4 - SPECIAL TOOL 8350 WEDGE
(6) Hold the camshaft with adjustable pliers while removing the camshaft sprocket bolt and sprocket (Fig. 26).
Fig.26CamshaftSprocketandChain
1 - CAMSHAFT SPROCKET AND CHAIN 2 - ADJUSTABLE PLIERS 3 - CAMSHAFT
(7) Using the pliers, gently allow the camshaft to rotate 15° clockwise until the camshaft is in the neu- tral position (no valve load).
(8) Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM- SHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
(9) Remove the camshaft bearing caps and the
camshaft.
INSTALLATION
(1) Lubricate camshaft journals with clean engine
oil.
NOTE: Position the left side camshaft so that the camshaft sprocket dowel is near the 1 o’clock posi- tion, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
(2) Position the camshaft into the cylinder head.
DR CAMSHAFT(S) - LEFT (Continued)
ENGINE - 4.7L
9 - 115
(3) Install the camshaft bearing caps, hand tighten
(5) Torque the camshaft bearing cap retaining
the retaining bolts.
(4) Working in 1⁄2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward (Fig. 27).
bolts to 11 N·m (100 in. lbs.).
(6) Position the camshaft drive gear into the tim- ing chain aligning the V8 mark between the two marked chain links (Two links marked during removal) (Fig. 28).
NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas.
Fig.27CamshaftBearingCapsTightening
Sequence
1 - LEFT CYLINDER HEAD
Fig.28TimingChaintoSprocketAlignment
2 - RIGHT CYLINDER HEAD
ENGINE - 4.7L
9 - 116
CAMSHAFT(S) - LEFT (Continued)(7) Using the adjustable pliers, rotate the cam- shaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft (Fig. 29).
CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over- torque resulting in bolt failure.
DR
(8) Remove excess oil from bolt, then install the
camshaft sprocket retaining bolt and hand tighten.
(9) Remove Special Tool 8350 timing chain wedge
(Fig. 30).
Fig.29CamshaftSprocketInstallation
1 - ADJUSTABLE PLIERS 2 - CAMSHAFT DOWEL
1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD
3 - SPECIAL TOOL 8350 WEDGE 4 - SPECIAL TOOL 8350 WEDGE
Fig.30SPECIALTOOL8350
DR CAMSHAFT(S) - LEFT (Continued)
(10) Using Special Tool 6958 spanner wrench with adapter pins 8346 (Fig. 31), torque the camshaft sprocket retaining bolt to 122 N·m (90 ft. lbs.).
(11) Install the cylinder head cover.
ENGINE - 4.7L
9 - 117
REMOVAL
CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT force- fully rotate the camshafts or crankshaft indepen- dently of each other. Severe valve and/or piston damage can occur.
CAUTION: When removing the cam sprocket, timing chains or camshaft, Failure to use special tool 8350
will result in hydraulic tensioner ratchet over exten- sion, Requiring timing chain cover removal to re-set the tensioner ratchet.(1) Remove the cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(2) Set engine to TDC cylinder #1,
camshaft
sprocket V8 marks at the 12 o’clock position.
(3) Mark one link on the secondary timing chain on both sides of the V8 mark on the camshaft sprocket to aid in installation.
CAUTION: Do not hold or pry on the camshaft tar- get wheel for any reason, Severe damage will occur to the target wheel. A damaged target wheel could cause a vehicle no start condition.
(4) Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave bolt snug against sprocket.
NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tension- ers to extend, requiring timing chain cover removal in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur.
Fig.31TighteningLeftSideCamSprocket
RetainingBolt
1 - TORQUE WRENCH 2 - CAMSHAFT SPROCKET 3 - LEFT CYLINDER HEAD 4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
CAMSHAFT(S) - RIGHT DESCRIPTION
The camshafts consist of powdered metal steel lobes which are sinter-bonded to a steel tube. A steel post or nose piece is friction-welded to the steel cam- shaft tube. Five bearing journals are machined into the camshaft, four on the steel tube and one on the steel nose piece. Camshaft end play is controlled by two thrust walls that border the nose piece journal. Engine oil enters the hollow camshafts at the third journal and lubricates every intake lobe rocker through a drilled passage in the intake lobe.
ENGINE - 4.7L
9 - 118
CAMSHAFT(S) - RIGHT (Continued)(5) Position Special Tool 8350 timing chain wedge between the timing chain strands. Tap the tool to securely wedge the timing chain against the ten- sioner arm and guide (Fig. 32).
(6) Remove the camshaft position sensor (Fig. 33).
NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas.
DR
(7) Hold the camshaft with adjustable pliers while removing the camshaft sprocket bolt and sprocket (Fig. 34).
(8) Using the pliers, gently allow the camshaft to rotate 45° counter-clockwise until the camshaft is in the neutral position (no valve load).
(9) Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM- SHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft.
(10) Remove the camshaft bearing caps and the
camshaft.
Fig.33CamshaftPositionSensor
1 - CRANKSHAFT POSITION SENSOR 2 - CYLINDER HEAD COVER 3 - CAMSHAFT POSITION SENSOR 4 - RIGHT SIDE CYLINDER BLOCK
INSTALLATION
(1) Lubricate camshaft journals with clean engine
oil.
Fig.32SecuringTimingChainTensionersUsingTimingChainWedge
1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD
3 - SPECIAL TOOL 8350 WEDGE 4 - SPECIAL TOOL 8350 WEDGE
DR CAMSHAFT(S) - RIGHT (Continued)
ENGINE - 4.7L
9 - 119
Fig.35CamshaftBearingCapsTightening
Sequence
CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt over- torque resulting in bolt failure.
(8) Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and hand tighten.
(9) Remove timing chain wedge special tool 8350
(Fig. 32).
(10) Using Special Tool 6958 spanner wrench with adapter pins 8346 (Fig. 38), torque the camshaft sprocket retaining bolt to 122 N·m (90 ft. lbs.).
(11) Install the camshaft position sensor (Fig. 33). (12) Install the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
Fig.34CamshaftSprocketandChain
1 - ADJUSTABLE PLIERS 2 - SPROCKET BOLT 3 - CAMSHAFT SPROCKET AND CHAIN 4 - CAMSHAFT
NOTE: Position the right side camshaft so that the camshaft sprocket dowel is near the 10 o’clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps.
(2) Position the camshaft into the cylinder head. (3) Install the camshaft bearing caps, hand tighten
the retaining bolts.
(4) Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward (Fig. 35).
(5) Torque the camshaft bearing cap retaining
bolts to 11 N·m (100 in. lbs.).
(6) Position the camshaft drive gear into the tim- ing chain aligning the V8 mark between the two marked chain links (Two links marked during removal) (Fig. 36).
NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas.
(7) Using the adjustable pliers, rotate the cam- shaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft (Fig. 37).
ENGINE - 4.7L
9 - 120
CAMSHAFT(S) - RIGHT (Continued)DR
1 - LEFT CYLINDER HEAD
Fig.36TimingChaintoSprocketAlignment
2 - RIGHT CYLINDER HEAD
Fig.37CamshaftSprocketInstallation
1 - ADJUSTABLE PLIERS 2 - CAMSHAFT DOWEL
Fig.38TighteningRightSideCamSprocket
RetainingBolt
1 - TORQUE WRENCH 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET 4 - RIGHT CAMSHAFT SPROCKETDR
ENGINE - 4.7L
9 - 121
CYLINDER HEAD COVER(S) DESCRIPTION
The cylinder head covers are made of die cast mag- nesium, and are not interchangeable from side-to- side. is imperative that nothing rest on the cylinder head covers. Prolonged contact with other items may wear a hole in the cylinder head cover.
It
CLEANING
Clean cylinder head cover gasket surface. Clean head rail, if necessary.
INSTALLATION
INSTALLATION - RIGHT SIDE
REMOVAL
REMOVAL - RIGHT SIDE
(1) Disconnect battery negative cable. (2) Remove air cleaner assembly, resonator assem-
bly and air inlet hose.
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(5) Remove air conditioning compressor retaining
bolts and move compressor to the left.
(6) Remove heater hoses. (7) Disconnect injector and ignition coil connectors. (8) Disconnect and remove positive crankcase ven-
tilation (PCV) hose.
(9) Remove oil fill tube. (10) Un-clip injector and ignition coil harness and
move away from cylinder head cover.
(11) Remove right rear breather tube and filter
assembly.
(12) Remove cylinder head cover retaining bolts. (13) Remove cylinder head cover.
NOTE: The gasket may be used again, provided no cuts, tears, or deformation has occurred.
REMOVAL - LEFT SIDE
(1) Disconnect negative cable from battery. (2) Remove the resonator assemble and air inlet
hose.
cover.
bolts.
(3) Disconnect injector connectors and un-clip the
injector harness.
(4) Route injector harness in front of cylinder head
assembly.
(5) Disconnect
the left side breather tube and
remove the breather tube.
(6) Remove the cylinder head cover mounting
(7) Remove cylinder head cover and gasket.
bolts.
NOTE: The gasket may be used again, provided no cuts, tears, or deformation has occurred.
CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur.
CAUTION: DO NOT allow other components includ- ing the wire harness to rest on or against the engine cylinder head cover. Prolonged contact with other objects may wear a hole in the cylinder head cover.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2) Install cylinder head cover and hand start all fasteners. Verify that all double ended studs are in the correct location shown in (Fig. 39).
Fig.39CylinderHeadCover—Right
ITEM
DESCRIPTION Cover Fasteners
TORQUE
12 N·m (105 in. lbs.)
(3) Tighten cylinder head cover bolts and double
ended studs to 12 N·m (105 in. lbs).
(4) Install right rear breather tube and filter
(5) Connect injector, ignition coil electrical connec-
tors and harness retaining clips.
(6) Install the oil fill tube. (7) Install PCV hose. (8) Install heater hoses. (9) Install air conditioning compressor retaining
(10) Install accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
ENGINE - 4.7L
9 - 122
CYLINDER HEAD COVER(S) (Continued)DR
(11) Fill Cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(12) Install air cleaner assembly, resonator assem-
bly and air inlet hose.
(13) Connect battery negative cable.
INSTALLATION—LEFT SIDE
CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur.
CAUTION: DO NOT allow other components includ- ing the wire harness to rest on or against the cylin- der head cover. Prolonged contact with other objects may wear a hole in the engine cylinder head cover.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2) Install cylinder head cover and hand start all fasteners. Verify that all studs are in the correct loca- tion shown in (Fig. 40).
Fig.40CylinderHeadCover—Left
ITEM
DESCRIPTION Cover Fasteners
TORQUE
12 N·m (105 in. lbs.)
(3) Tighten cylinder head cover bolts and double
ended studs to 12 N·m (105 in. lbs.).
(4) Install left side breather and connect breather
tube.
(5) Connect injector electrical connectors and injec-
tor harness retaining clips.
(6) Install the resonator and air inlet hose. (7) Connect negative cable to battery.
INTAKE/EXHAUST VALVES & SEATS DESCRIPTION
The valves are made of heat resistant steel and have chrome plated stems to prevent scuffing. Each valve is actuated by a roller rocker arm which pivots on a stationary lash adjuster. All valves use three bead lock keepers to retain the springs and promote valve rotation.
REMOVAL
NOTE: The cylinder heads must be removed in order to perform this procedure.
(1) Remove rocker arms and lash adjusters(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - REMOVAL). (Fig. 41).
Fig.41RockerArmRemoval
1 - CAMSHAFT 2 - SPECIAL TOOL 8516
(2) Remove the camshaft bearing caps and the
camshaft.
NOTE: All six valve springs and valves are removed in the same manner; this procedure only covers one valve and valve spring.
(3) Using Special Tool C-3422–B or C-3422–C tool 8519
Valve Spring Compressor and Special Adapter, compress the valve spring.
DR INTAKE/EXHAUST VALVES & SEATS (Continued)
ENGINE - 4.7L
9 - 123
NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
(4) Remove the two spring retainer lock halves.
NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
(5) Remove the valve spring compressor. (6) Remove the spring retainer, and the spring.
NOTE: Check for sharp edges on the keeper grooves. Remove any burrs from the valve stem before removing the valve from the cylinder head.
(7) Remove the valve from the cylinder head.
Fig.42TestingValveSprings
NOTE: The valve stem seals are common between intake and exhaust.
1 - SPECIAL TOOL C-647
(8) Remove the valve stem seal. Mark the valve for
proper installation.
TESTING VALVE SPRINGS
NOTE: Whenever the valves are removed from the cylinder head it the valve springs be inspected and tested for reuse.
is recommended that
Inspect the valve springs for physical signs of wear or damage. Turn table of tool C-647 until surface is in line with the 40.12 mm (1.579 in.) mark on the threaded stud and the zero mark on the front. Place spring over the stud on the table and lift compress- ing lever to set tone device. Pull on torque wrench until Ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to Specifications Section to obtain specified height and allowable tensions. Replace any springs that do not meet specifications (Fig. 42).
INSTALLATION
(1) coat the valve stem with clean engine oil and
insert it into the cylinder head.
(2) Install the valve stem seal. make sure the seal is fully seated and that the garter spring at the top of the seal is intact.
(3) Install the spring and the spring retainer (Fig.
43).
(4) Using the valve spring compressor, compress the spring and install the two valve spring retainer halves.
(5) Release the valve spring compressor and make sure the two spring retainer halves and the spring retainer are fully seated.
Fig.43ValveAssemblyConfiguration
1 - VALVE LOCKS (3–BEAD) 2 - RETAINER 3 - VALVE STEM OIL SEAL 4 - INTAKE VALVE 5 - EXHAUST VALVE 6 - VALVE SPRING
(6) lubricate the camshaft
then Position the camshaft
journal with clean engine oil (with the sprocket dowel on the left camshaft at 11 o’clock and the right camshaft at 12 o’clock), then position the camshaft bearing caps.
ENGINE - 4.7L
9 - 124
INTAKE/EXHAUST VALVES & SEATS (Continued)DR
(7) Install
the camshaft bearing cap retaining bolts. Tighten the bolts 9–13 N·m (100 in. lbs.) in 1⁄2
turn increments in the sequence shown (Fig. 44).Fig.44CamshaftBearingCapsTightening
Sequence
(8) Position the hydraulic
rocker arms.
lash adjusters and
ROCKER ARM / ADJUSTER ASSEMBLY DESCRIPTION
The rocker arms are steel stampings with an inte- gral roller bearing. The rocker arms incorporate a 2.8
mm (0.11 inch) oil hole in the lash adjuster socket for roller and camshaft lubrication.DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy.
(2) Insufficient running time after rebuilding cylin- der head. Low speed running up to 1 hour may be required.
(3) Turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature.
(4) Low oil pressure.
(5) The oil restrictor in cylinder head gasket or the oil passage to the cylinder head is plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides. (8) Rocker arm ears
retainer.
contacting valve
spring
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Oil leak or excessive cam bore wear in cylin-
der head.
(11) Faulty lash adjuster. a. Check lash adjusters
sponginess while installed in cylinder head and cam on camshaft at base circle. Depress part of rocker arm over adjuster. Normal adjusters should feel very firm. Spongy adjusters can be bottomed out easily.
for
b. Remove suspected lash adjusters, and replace. c. Before installation, make sure adjusters are at least partially full of oil. This can be verified by little or no plunger travel when lash adjuster is depressed.
REMOVAL
NOTE: Disconnect the battery negative cable to pre- vent accidental starter engagement.
(1) Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(2) For rocker arm removal on cylinders 3 and 5
Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke.(3) For rocker arm removal on cylinders 2 and 8
Rotate the crankshaft until cylinder #1 is at TDC compression stroke.(4) For rocker arm removal on cylinders 4 and 6
Rotate the crankshaft until cylinder #3 is at TDC compression stroke.(5) For rocker arm removal on cylinders 1 and 7
Rotate the crankshaft until cylinder #2 is at TDC compression stroke.(6) Using special tool 8516 Rocker Arm Remover, press downward on the valve spring, remove rocker arm (Fig. 45).
INSTALLATION
CAUTION: Make sure the rocker arms are installed with the concave pocket over the lash adjusters. Failure to do so may cause severe damage to the rocker arms and/or lash adjusters.
NOTE: Coat the rocker arms with clean engine oil prior to installation.
DR ROCKER ARM / ADJUSTER ASSEMBLY (Continued)
ENGINE - 4.7L
9 - 125
REMOVAL
(1) Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(2) Using Special Tool 8516 Rocker Arm Remover, remove the rocker arms and the hydraulic lash adjusters (Fig. 46).
Fig.45RockerArm—Removal
1 - CAMSHAFT 2 - SPECIAL TOOL 8516
(1) For rocker arm installation on cylinders 3 and 5 Rotate the crankshaft until cylinder #1 is at TDC exhaust stroke.
(2) For rocker arm installation on cylinders 2 and 8 Rotate the crankshaft until cylinder #1 is at TDC compression stroke.
(3) For rocker arm installation on cylinders 4 and 6 Rotate the crankshaft until cylinder #3 is at TDC compression stroke.
(4) For rocker arm installation on cylinders 1 and 7 Rotate the crankshaft until cylinder #2 is at TDC compression stroke.
(5) Using special tool 8516 press downward on the
valve spring, install rocker arm (Fig. 45).
(6) Install the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
VALVE SPRINGS DESCRIPTION
The valve springs are made from high strength chrome silicon steel. The springs are common for intake and exhaust applications. The valve spring seat is integral with the valve stem seal, which is a positive type seal to control lubrication.
Fig.46RockerArm—Removal
1 - CAMSHAFT 2 - SPECIAL TOOL 8516
(3) Remove the spark plug for the cylinder the
valve spring and seal are to be removed from.
(4) Apply shop air to the cylinder to hold the
valves in place when the spring is removed
(5) Remove the camshaft (Refer to 9 - ENGINE/
CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: All eight valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring.
(6) Using Special Tool 8387 Valve Spring Compres-
sor, compress the valve spring.
NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed.
(7) Remove the two spring retainer lock halves.
NOTE: the valve spring is under tension use care when releasing the valve spring compressor.
(8) Remove the valve spring compressor.
ENGINE - 4.7L
9 - 126
VALVE SPRINGS (Continued)(9) Remove the spring retainer, and the spring. (10) Remove the valve stem seal.
NOTE: The valve stem seals are common between intake and exhaust.
INSTALLATION
(1) coat the valve stem with clean engine oil and install the valve stem seal. Make sure the seal is fully seated and that the garter spring at the top of the seal is intact.
(2) Install the spring and the spring retainer (Fig.
47).
(3) Using Special Tool 8387 Valve Spring Compres- sor, compress the spring and install the two valve spring retainer halves.
(4) Release the valve spring compressor and make sure the two spring retainer halves and the spring retainer are fully seated.
Fig.47ValveAssemblyConfiguration
1 - VALVE LOCKS (3–BEAD) 2 - RETAINER 3 - VALVE STEM OIL SEAL 4 - INTAKE VALVE 5 - EXHAUST VALVE 6 - VALVE SPRING
(5) Install the camshaft (Refer to 9 - ENGINE/ INSTALLA-
CYLINDER HEAD/CAMSHAFT(S) TION).
(6) Position the hydraulic
lash adjusters and
rocker arms (Fig. 46).
(7) Install the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
DR
VALVE STEM SEALS DESCRIPTION
The valve stem seals are made of rubber and incor- porate an integral steel valve spring seat. The inte- gral garter spring maintains consistent lubrication control to the valve stems.
ENGINE BLOCK DESCRIPTION
The cylinder block is made of cast iron. The block is a closed deck design with the left bank forward. To provide high rigidity and improved NVH an enhanced compacted graphite bedplate is bolted to the block. The block design allows coolant flow between the cylinders bores, and an internal coolant bypass to a single poppet inlet thermostat is included in the cast aluminum front cover.
STANDARD PROCEDURE—CYLINDER BORE HONING
Before honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area.
(1) Used carefully, the Cylinder Bore Sizing Hone C-823, equipped with 220 grit stones, is the best tool for this job. In addition to deglazing, it will reduce taper and out-of-round, as well as removing light scuffing, scoring and scratches. Usually, a few strokes will clean up a bore and maintain the required lim- its.
CAUTION: DO NOT use rigid type hones to remove cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if the cylinder bore is straight and round. Use a cylin- der surfacing hone, Honing Tool C-3501, equipped with 280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be suf- ficient to provide a satisfactory surface. Using honing oil C-3501-3880, or a light honing oil, available from major oil distributors.CAUTION: DO NOT use engine or transmission oil, mineral spirits, or kerosene.
DR ENGINE BLOCK (Continued)
(3) Honing should be done by moving the hone up and down fast enough to get a crosshatch pattern. The hone marks should INTERSECT at 50° to 60° for proper seating of rings (Fig. 48).
ENGINE - 4.7L
9 - 127
INSPECTION
(1) It is mandatory to use a dial bore gauge to measure each cylinder bore diameter. To correctly select the proper size piston, a cylinder bore gauge, capable of reading in 0.003 mm (.0001 in.) INCRE- MENTS is required. If a bore gauge is not available, do not use an inside micrometer (Fig. 49).
Fig.48CYLINDERBORECROSSHATCHPATTERN 1 - CROSSHATCH PATTERN 2 - INTERSECT ANGLE
(4) A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper cross- hatch angle. The number of up and down strokes per minute can be regulated to get the desired 50° to 60° angle. Faster up and down strokes increase the cross- hatch angle.
(5) After honing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash parts with a solution of hot water and deter- gent. Dry parts thoroughly. Use a clean, white, lint- free cloth to check that the bore is clean. Oil the bores after cleaning to prevent rusting.
CLEANING
Thoroughly clean the oil pan and engine block gas-
ket surfaces.
Use compressed air to clean out: † The galley at the oil filter adaptor hole. † The front and rear oil galley holes. † The feed holes for the crankshaft main bearings. Once the block has been completely cleaned, apply Loctite PST pipe sealant with Teflon 592 to the threads of the front and rear oil galley plugs. Tighten the 1/4 inch NPT plugs to 20 N·m (177 in. lbs.) torque. Tighten the 3/8 inch NPT plugs to 27 N·m (240 in. lbs.) torque.
Fig.49BOREGAUGE-TYPICAL
1 - FRONT 2 - BORE GAUGE 3 - CYLINDER BORE 4 - 38 MM (1.5 in)
(2) Measure the inside diameter of the cylinder bore at three levels below top of bore. Start perpen- dicular (across or at 90 degrees) to the axis of the crankshaft and then take two additional reading.
(3) Measure the cylinder bore diameter crosswise to the cylinder block near the top of the bore. Repeat the measurement near the middle of the bore, then repeat the measurement near the bottom of the bore. (4) Determine taper by subtracting the smaller
diameter from the larger diameter.
(5) Rotate measuring device 90° and repeat steps
above.
(6) Determine out-of-roundness by comparing the
difference between each measurement.
(7) If cylinder bore taper does not exceed 0.025
mm (0.001 inch) and out-of-roundness does not exceed 0.025 mm (0.001 inch), the cylinder bore can be honed. If the cylinder bore taper or out- of-round condition exceeds these maximum limits, the cylinder block must be replaced. A slight amount of taper always exists in the cylinder bore after the engine has been in use for a period of time.9 - 128
ENGINE - 4.7L
DR
CONNECTING ROD BEARINGS STANDARD PROCEDURE - CONNECTING ROD BEARING FITTING
Inspect the connecting rod bearings for scoring and bent alignment tabs (Fig. 50). Check the bearings for normal wear patterns, scoring, grooving, fatigue and pitting (Fig. 51). Replace any bearing that shows abnormal wear.
Inspect the connecting rod journals for signs of
scoring, nicks and burrs.
Fig.50LockingTabInspection
1 - ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS NOT FULLY SEATED OR BEING BENT
Fig.51ScoringCausedbyInsufficientLubrication
orDamagedCrankshaftJournal
Misaligned or bent connecting rods can cause abnormal wear on pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft con- necting rod journals. If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod, inspect it for correct rod alignment. Replace misaligned, bent or twisted con- necting rods.
(1) Wipe the oil from the connecting rod journal. (2) Lubricate the upper bearing insert and install
in connecting rod.
(3) Use piston ring compressor and Guide Pins Special Tool 8507 (Fig. 52) to install the rod and pis- ton assemblies. The oil slinger slots in the rods must face front of the engine. The “F”’s near the piston wrist pin bore should point to the front of the engine.
Fig.52PistonandConnectingRod-Installation
1 - “F” TOWARD FRONT OF ENGINE 2 - OIL SLINGER SLOT 3 - RING COMPRESSOR 4 - SPECIAL TOOL 8507
(4) Install the lower bearing insert in the bearing cap. The lower insert must be dry. Place strip of Plas- tigage across full width of the lower insert at the cen- ter of bearing cap. Plastigage must not crumble in use. If brittle, obtain fresh stock.
(5) Install bearing cap and connecting rod on the journal and tighten bolts to 27 N·m (20 ft. lbs.) plus a 90° turn. DO NOT rotate crankshaft. Plastigage will smear, resulting in inaccurate indication.
(6) Remove the bearing cap and determine amount of bearing-to-journal clearance by measuring the width of compressed Plastigage (Fig. 53). Refer to Engine Specifications for the proper clearance. Plas- tigage should indicate the same clearance across the entire width of the insert. If the clearance varies, it may be caused by either a
DR CONNECTING ROD BEARINGS (Continued)
tapered journal, bent connecting rod or foreign material trapped between the insert and cap or rod.
ENGINE - 4.7L
9 - 129
Fig.53MeasuringBearingClearancewith
Plastigage
1 - PLASTIGAGE SCALE 2 - COMPRESSED PLASTIGAGE
(7) If the correct clearance is indicated, replace- ment of the bearing inserts is not necessary. Remove the Plastigage from crankshaft journal and bearing insert. Proceed with installation.
(8) If bearing-to-journal
the specification, determin which services bearing set to use the bearing sizes are as follows:
clearance exceeds
Bearing
Mark
.025 US
SIZE
USED WITH
JOURNAL SIZE
.025 mm (.001 in.)
50.983-50.967 mm (2.0073-2.0066 in.)
Std.
STANDARD
50.992-51.008 mm (2.0076-2.0082 in.)
.250 US
.250 mm (.010 in.)
50.758-50.742 mm (1.9984-1.9978 in.)
(9) Repeat the Plastigage measurement to verify
your bearing selection prior to final assembly.
(10) Once you have selected the proper insert, install the insert and cap. Tighten the connecting rod bolts to 27 N·m (20 ft. lbs.) plus a 90° turn.
Slide snug-fitting feeler gauge between the con- necting rod and crankshaft journal flange (Fig. 54). Refer to Engine Specifications for the proper clear- ance. Replace the connecting rod if the side clearance is not within specification.
Fig.54CheckingConnectingRodSideClearance-
Typical
CORE PLUGS REMOVAL
(1) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(2) Using a blunt tool such as a drift or a screw driver and a hammer, strike the bottom edge of the cup plug (Fig. 55)
Fig.55EngineCorePlugRemoval
1 - CYLINDER BLOCK 2 - REMOVE PLUG WITH PLIERS 3 - STRIKE HERE WITH HAMMER 4 - DRIFT PUNCH 5 - CUP PLUG
(3) Using a suitable pair of pliers, grasp the core
plug and remove.
DR
(4) Remove the oil pump pickup tube and oil pan
gasket /windage tray.
(5) Remove the bedplate mounting bolts. Note the
location of the three stud bolts for installation.
(6) Remove the connecting rods from the crankshaft.
CAUTION: The bedplate to cylinder block mating surface is a critical sealing surface. Do not pry on or damage this surface in anyway.
NOTE: The bedplate contains the lower main bear- ing halves. Use care when handling bedplate as not to drop or damage bearing halves. Installing main bearing halves in the wrong position will cause sever damage to the crankshaft.
NOTE: The bedplate has pry points cast into it. Use these points only. The pry points are on both the left and right sides, only the left side is shown.
(7) Carefully pry on the pry points (Fig. 56) to
loosen the bedplate then remove the bedplate.
ENGINE - 4.7L
9 - 130
CORE PLUGS (Continued) INSTALLATIONNOTE: Thoroughly clean core plug bore, remove all of the old sealer.
(1) Coat the edges of the engine core plug and the core plug bore with Mopar Gasket Maker, or equivalent.
NOTE: It is not necessary to wait for the sealant to cure on the core plugs. The cooling system can be filled and the vehicle returned to service immediately.
(2) Using proper plug driver, drive core plug into the core plug bore. The sharp edge of the core plug should be at least 0.50 mm (0.020 in.) inside the lead in chamfer.
(3) Refill the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
CRANKSHAFT DESCRIPTION
The crankshaft is constructed of nodular cast iron. The crankshaft is a crosshaped four throw design with eight counterweights for balancing purposes. The crank- shaft is supported by five select fit main bearings with the number three serving as the thrust washer location. The main journals of the crankshaft are cross drilled to improve rod bearing lubrication. The number eight counterweight has provisions for crankshaft position sensor target wheel mounting. The select fit main bear- ing markings are located on the rear side of the target wheel. The crankshaft oil seals are one piece design. The front oil seal is retained in the timing chain cover, and the rear seal is pressed in to a bore formed by the cylinder block and the bedplate assembly.
REMOVAL
NOTE: To remove the crankshaft from the engine, the engine must be removed from the vehicle.
(1) Remove the engine. (Refer to 9 - ENGINE -
REMOVAL).
(2) Remove the engine oil pump.(Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - REMOVAL).
CAUTION: DO NOT pry on the oil pan gasket when removing the oil pan, The oil pan gasket is mounted
