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to the cylinder block in three locations and will remain attached to block when removing oil pan. Gasket can not be removed with oil pan.
(3) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
Fig.56BedplatePryPointLocation
1 - CYLINDER BLOCK 2 - BEDPLATE 3 - PRY POINT
CAUTION: When removing the crankshaft, use care not to damage bearing surfaces on the crankshaft.
(8) Remove the crankshaft. (9) Remove the crankshaft target wheel.
DR CRANKSHAFT (Continued) INSPECTION
NOTE: Thoroughly inspect the connecting rod bear- ing bores and main bearing bores for scoring, blue- ing or severe scratches. Further disassembly may be required.
ENGINE - 4.7L
9 - 131
If connecting rod bearing bores show damage, the cylinder heads must be removed to service the piston and rod assemblies. If the bedplate or the cylinder block main bearing bores show damage the engine must be replaced.
(1) If required, remove the main bearing halves
from the cylinder block and bedplate.
(2) Thoroughly clean the bedplate to cylinder block sealing surfaces and main bearing bores. Remove all oil and sealant residue.
(3) Inspect the bedplate main bearing bores for cracks, scoring or severe blueing. If either condition exists the engine must be replaced.
(4) Inspect the crankshaft thrust washers for scor- ing, scratches, wear or blueing. If either condition exist replace the thrust washer.
(5) Inspect the oil pan gasket/windage tray for splits, tears or cracks in the gasket sealing surfaces. Replace gasket as necessary.
INSTALLATION
CAUTION: Main bearings are select fit. (Refer to 9 - ENGINE/ENGINE MAIN BEARINGS - STANDARD PROCEDURE) for proper bearing selections.
BLOCK/CRANKSHAFT
(1) Lubricate upper main bearing halves with
clean engine oil.
CAUTION: When installing crankshaft, use care not to damage bearing surfaces on the crankshaft.
NOTE: Apply sealant to the target wheel retaining screws prior to installation.
(2) Install the crankshaft target wheel. Torque the
mounting screws to 15 N·m (12 ft. lbs.).
(3) Position crankshaft in cylinder block. (4) Install the thrust washers (Fig. 57).
Fig.57CrankshaftThrustWasherInstallation
1 - CRANKSHAFT THRUST WASHER
NOTE: Make sure that the bedplate and cylinder block sealing surfaces are clean and free of oil or other contaminants. Contaminants on the sealing surfaces may cause main bearing distortion and/or oil leaks.
(5) Apply a 2.5mm (0.100 inch) (Fig. 58) bead of Mopart Gen II Silicone Rubber Adhesive sealant to the cylinder block-to-bedplate mating surface as shown (Fig. 59).
CAUTION: The bedplate to cylinder block mateing surface must be coated with sealant prior to instal- lation. Failure to do so will cause severe oil leaks.
NOTE: The installation time to install the bedplate after the sealant has been applied is critical.
Fig.58CuttingAplicatortoAchieve2.5mm(0.100in.)
Bead
1 - CUT HERE
ENGINE - 4.7L
9 - 132
CRANKSHAFT (Continued)DR
(8) Measure crankshaft end play.
(Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT - STAN- DARD PROCEDURE).
(9) Install the connecting rods and measure side clearance. (Refer to 9 - ENGINE/ENGINE BLOCK/ CONNECTING ROD BEARINGS - STANDARD PROCEDURE).
(10) Position the oil pan gasket/windage tray, using a new o-ring, install the oil pickup tube. Torque the bolt to 28N·n (20 ft. lbs.) torque the nuts to 28N·m (20 ft. lbs.).
(11) Install the oil pan. Torque the retaining bolts to
15 N·m (11 ft. lbs.) in the sequence shown (Fig. 61).
Fig.61OilPanTighteningSequence
(12) Install the engine (Refer to 9 - ENGINE -
INSTALLATION).
Fig.59CylinderBlock-to-Bedplate
SealentBeadLocation
1 - CYLINDER BLOCK 2 - SEALANT BEAD LOCATION
(6) Coat
the crankshaft main bearing journals with clean engine oil and position the bedplate onto the cylinder block.
NOTE: Lubricate the bedplate retaining bolts with clean engine oil prior to installation.
(7) Install the bedplate retaining bolts, making sure to place the stud bolts in the correct location, Torque the bolts in the sequence shown (Fig. 60). † Tighten bolts A – L to 54 N·m (40 ft. lbs.) † Tighten bolts 1–10 to 2.8 N·m (25 in. lbs.) † Turn bolts 1–10 an additional 90°. † Tighten bolts A1– A6 to 27 N·m (20 ft. lbs.)
1 - BEDPLATE
Fig.60BedplateTighteningSequence 2 - CYLINDER BLOCK
DR
ENGINE - 4.7L
9 - 133
CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE—CRANKSHAFT MAIN BEARING - FITTING
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)
Crankshaft removed from the cylinder block. Clean the oil off the main bearing journal. Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal.
The maximum allowable taper is 0.008mm (0.0004
inch.) and maximum out of round is 0.005mm (0.002
inch). Compare the measured diameter with the jour- nal diameter specification (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance.CRANKSHAFT MAIN BEARING SELECTION
The main bearings are “select fit” to achieve proper oil clearances. For main bearing selection, the crank- shaft position sensor target wheel has grade identifi- cation marks stamped into it (Fig. 62). These marks are read from left to right, corresponding with jour- nal number 1, 2, 3, 4 and 5. The crankshaft position sensor target wheel is mounted to the number 8
counter weight on the crankshaft.NOTE: Service main bearings are coded. These codes identify what size (grade) the bearing is.
MAIN BEARING SELECTION CHART—4.7L
GRADE
MARKING
SIZE mm
(in.)
FOR USE WITH
JOURNAL SIZE
0.008 mm
63.488–63.496 mm
U/S
(0.0004 in.)
(2.4996–2.4999 in.)
U/S
NOMINAL
63.496–63.504 mm (2.4999–2.5002 in.)
0.008 mm
63.504–63.512 mm
O/S
(0.0004 in.)
(2.5002–2.5005 in.)
O/S
INSPECTION
Wipe the inserts clean and inspect for abnormal wear patterns and for metal or other foreign material imbedded in the lining. Normal main bearing insert wear patterns are illustrated (Fig. 63).
Fig.62MainBearingMarkingsonTargetWheel
1 - REARMOST CRANKSHAFT COUNTER WEIGHT 2 - TARGET WHEEL 3 - MAIN BEARING SELECT FIT MARKINGS
Fig.63MainBearingWearPatterns
1 - UPPER INSERT 2 - NO WEAR IN THIS AREA 3 - LOW AREA IN BEARING LINING 4 - LOWER INSERT
NOTE: If any of the crankshaft journals are scored, the crankshaft must be repaired or replaced.
Inspect the back of the inserts for fractures, scrap-
ings or irregular wear patterns.
Inspect the upper insert locking tabs for damage. Replace all damaged or worn bearing inserts.
9 - 134
ENGINE - 4.7L
DR
CRANKSHAFT OIL SEAL - FRONT REMOVAL
(11) Using Special Tool 8511, remove crankshaft
front seal (Fig. 65).
(1) Disconnect negative cable from battery. (2) Remove accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(3) Remove A/C compressor mouning fasteners and
set aside.
(4) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(5) Remove upper radiator hose. (6) Disconnect electrical connector for fan mounted
inside radiator shroud.
(7) Remove radiator shroud attaching fasteners.
NOTE: Transmission cooler line snaps into shroud lower right hand corner.
(8) Remove radiator cooling fan and shroud (Refer - COOLING/ENGINE/RADIATOR FAN -
to REMOVAL).
(9) Remove crankshaft damper bolt. (10) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 64).
Fig.65CrankshaftFrontSealRemoval
1 - SPECIAL TOOL 8511
INSTALLATION
CAUTION: To prevent severe damage to the Crank- shaft, Damper or Special Tool 8512, thoroughly clean the damper bore and the crankshaft nose before installing Damper.
(1) Using Special Tool 8348 and 8512,
install
crankshaft front seal (Fig. 66).
(2) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTAL- LATION).
(3) Install radiator cooling fan and shroud (Refer - COOLING/ENGINE/RADIATOR FAN -
to INSTALLATION).
(4) Install upper radiator hose. (5) Install A/C compressor and tighten fasteners to
54 N·m (40 ft. lbs.).
(6) Install accessory drive belt refer (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(7) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(8) Connect negative cable to battery.
Fig.64CrankshaftDamperRemoval
1 - SPECIAL TOOL 8513 INSERT 2 - SPECIAL TOOL 1026
DR CRANKSHAFT OIL SEAL - FRONT (Continued)
ENGINE - 4.7L
9 - 135
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks or scratches. The crankshaft seal flange is specially machined to complement the function of the rear oil seal.
(6) For bubbles that remain steady with shaft rotation, no further inspection can be done until dis- assembled. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING), under the Oil Leak row, for components inspections on possible causes and corrections.
(7) After the oil leak root cause and appropriate corrective action have been identified, (Refer to 9 - ENGINE/ENGINE OIL SEAL - REAR - REMOVAL).
BLOCK/CRANKSHAFT
REMOVAL
NOTE: This procedure can be performed in vehicle.
(1) If being preformed in vehicle, remove the
transmission.
(2) Remove the flexplate (Refer to 9 - ENGINE/
ENGINE BLOCK/FLEX PLATE - REMOVAL).
NOTE: The crankshaft oil seal CAN NOT be reused after removal.
NOTE: The crankshaft rear oil seal remover Special Tool 8506 must be installed deeply into the seal. Continue to tighten the removal tool into the seal until the tool can not be turned farther. Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine.
Fig.66CrankshaftFrontSealInstallation
1 - TIMING CHAIN COVER 2 - SPECIAL TOOL 8348
3 - SPECIAL TOOL 8512CRANKSHAFT OIL SEAL - REAR DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery. (2) Raise the vehicle. (3) Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down, possible causes are a porous block, camshaft bore cup plugs, oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating sur- faces. See Engine, for proper repair procedures of these items. (4) If no leaks are detected, pressurized the crank- case as outlined in the section, Inspection (Engine oil Leaks in general)
ENGINE - 4.7L
9 - 136
CRANKSHAFT OIL SEAL - REAR (Continued)(3) Using Special Tool 8506 (Fig. 67), remove the
crankshaft rear oil seal.
DR
(3) Using Special Tools 8349 Crankshaft Rear Oil Seal Installer and C-4171 Driver Handle (Fig. 69), with a hammer, tap the seal into place. Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore.
Fig.67CrankshaftRearOilSealRemoval
1 - REAR CRANKSHAFT SEAL 2 - SPECIAL TOOL 8506
INSTALLATION
(1) Lubricate the crankshaft flange with engine oil. (2) Position the magnetic seal guide Special Tool 8349–2 (Fig. 68) onto the crankshaft rear face. Then position the crankshaft rear oil seal onto the guide.
Fig.69CrankshaftRearOilSealInstallation
1 - REAR CRANKSHAFT SEAL 2 - SPECIAL TOOL 8349–1 INSTALLER 3 - SPECIAL TOOL C-4171 HANDLE
(4) Install the flexplate. (5) Install the transmission.
Fig.68CrankshaftRearOilSealGuideSpecialTool
8349–2andOil
1 - REAR CRANKSHAFT SEAL 2 - SPECIAL TOOL 8349–2 GUIDE
DR
ENGINE - 4.7L
9 - 137
FLEX PLATE REMOVAL
(1) Remove the transmission. (2) Remove the bolts and flexplate.
INSTALLATION
(1) Position the flexplate onto the crankshaft and
install the bolts hand tight.
(2) Tighten the flexplate retaining bolts to 60 N·m
(45 ft. lbs.) in the sequence shown (Fig. 70).
(3) Install the transmission.
STANDARD PROCEDURE—PISTON FITTING
(1) To correctly select the proper size piston, a cyl- inder bore gauge, capable of reading in 0.003 mm ( .0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer.
(2) Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B (Fig. 72).
(3) The coated pistons will be serviced with the
piston pin and connecting rod pre-assembled.
(4) The coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston will not pro- vide accurate results (Fig. 71). Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY. To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (.0001 in.) increments is required.
(5) Piston installation into
cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.
the
Fig.70FlexplateTighteningSequence
1 - FLEXPLATE
PISTON & CONNECTING ROD DESCRIPTION
CAUTION: Do not use a metal stamp to mark con- necting rods as damage may result, instead use ink or a scratch awl.
The pistons are made of a high strength aluminum alloy. The anodized top ring groove and crown has been replaced with a coated top ring that is blue in color on the bottom surface. Piston skirts are coated with a solid lubricant (Molykote) to reduce friction and provide scuff resistance. The connecting rods are made of forged powdered metal, with a “fractured cap” design. A pressed fit piston pin is used to attach the piston and connecting rod.
Fig.71DONOTMEASUREMOLYCOATEDPISTON 1 - MOLY COATED 2 - MOLY COATED
REMOVAL
(1) Disconnect negative cable from battery. (2) Remove the following components: † Oil pan and gasket/windage tray (Refer to 9 - † Cylinder head covers (Refer to 9 - ENGINE/ CYLINDER HEAD/CYLINDER HEAD COVER(S) -
ENGINE/LUBRICATION/OIL PAN - REMOVAL).
ENGINE - 4.7L
9 - 138
PISTON & CONNECTING ROD (Continued)DR
Fig.73IdentifyConnectingRodtoCylinder
Position—Typical
CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
(5) Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed.
CAUTION: Care must be taken not to nick crank- shaft journals, as engine damage may occur
(6) Immediately after piston and connecting rod removal, install bearing cap on the mating connect- ing rod to prevent damage to the fractured cap and rod surfaces.
(7) Carefully remove piston rings from piston(s),
starting from the top ring down.
CLEANING
CAUTION: DO NOT use a wire wheel or other abra- sive cleaning devise to clean the pistons or con- necting rods. The pistons have a Moly coating, this coating must not be damaged.
(1) Using a suitable cleaning solvent clean the pis-
tons in warm water and towel dry.
(2) Use a wood or plastic scraper to clean the ring
land grooves.
CAUTION: DO NOT remove the piston pin from the piston and connecting rod assembly.
INSPECTION
Check the connecting rod journal
for excessive wear, taper and scoring (Refer to 9 - ENGINE/EN- GINE BLOCK/CONNECTING ROD BEARINGS - STANDARD PROCEDURE).
Check the connecting rod for signs of twist or bend-
ing.
Fig.72BOREGAUGE-TYPICAL
1 - FRONT 2 - BORE GAUGE 3 - CYLINDER BORE 4 - 38 MM (1.5 in)
REMOVAL) and (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL). † Timing chain cover (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). † Cylinder head(s) (Refer to 9 - ENGINE/CYLIN- DER HEAD - REMOVAL) and (Refer to 9 - ENGINE/ CYLINDER HEAD - REMOVAL).
(3) If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pis- tons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore.
CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur
NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
(4) Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool (Fig. 73).
DR PISTON & CONNECTING ROD (Continued)
Check the piston for taper and elliptical shape before it is fitted into the cylinder bore (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECT- ING ROD - STANDARD PROCEDURE).
Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration.
INSTALLATION
ENGINE - 4.7L
9 - 139
(5) The pistons are marked on the piston pin bore surface with an raised “F” indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks. The connect- ing rod oil slinger slot faces the front of the engine (Fig. 75).
(1) Before installing piston and connecting rod
assemblies into the bore, install the piston rings.
(2) Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure posi- tion of rings do not change during this opera- tion.
(3) Position bearing onto connecting rod. Ensure that hole in bearing shell aligns with hole in connect- ing rod. Lubricate bearing surface with clean engine oil.
(4) Install Special Tool 8507 Connecting Rod
Guides into connecting rod bolt threads (Fig. 74).
Fig.75PISTONANDCONNECTINGROD
ORIENTATION
1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SLINGER SLOT
(6) Wipe cylinder bore clean and lubricate with
engine oil.
(7) Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and pis- ton into cylinder bore and carefully position connect- ing rod guides over crankshaft journal.
(8) Tap piston down in cylinder bore using a ham- mer handle. While at the same time, guide connect- ing rod into position on rod journal.
Fig.74PISTONANDCONNECTINGROD
INSTALLATION
1 - “F” TOWARD FRONT OF ENGINE 2 - OIL SLINGER SLOT 3 - RING COMPRESSOR 4 - SPECIAL TOOL 8507
CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed.
(9) Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 27 N·m (20 ft. lbs.) plus 90°.
DER HEAD - INSTALLATION).
(10) Install the following components: † Cylinder head(s). (Refer to 9 - ENGINE/CYLIN- † Timing chain and cover. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
DR
PISTON RING SIDE CLEARANCE
NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs.
(5) Measure the ring side clearance as shown (Fig. 77)make sure the feeler gauge fits snugly between the ring land and the ring. Replace any ring not within specification.
Fig.77MeasuringPistonRingSideClearance
1 - FEELER GAUGE
(6) Rotate the ring around the piston, the ring
must rotate in the groove with out binding.
ENGINE - 4.7L
9 - 140
PISTON & CONNECTING ROD (Continued) † Cylinder head covers (Refer to 9 - ENGINE/ CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION). † Oil pan and gasket/windage tray. (Refer to 9 - INSTALLA- ENGINE/LUBRICATION/OIL PAN - TION).(11) Fill crankcase with proper engine oil to cor-
rect level.
(12) Connect negative cable to battery.
PISTON RINGS STANDARD PROCEDURE - PISTON RING FITTING
Before reinstalling used rings or installing new
rings, the ring clearances must be checked.
(1) Wipe the cylinder bore clean. (2) Insert the ring in the cylinder bore.
NOTE: The ring gap measurement must be made with the ring positioned at least 12mm (0.50 inch.) from bottom of cylinder bore.
(3) Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder.
(4) Using a feeler gauge check the ring end gap (Fig. 76). Replace any rings not within specification.
Fig.76RingEndGapMeasurement-Typical
1 - FEELER GAUGE
DR PISTON RINGS (Continued)
ENGINE - 4.7L
9 - 141
PISTON RING SPECIFICATION CHART
least 45° from the side rail gaps, but not on the pis- ton pin center or on the thrust direction.
Ring Position
Groove
Upper Ring
Clearance .051-.094mm (0.0020- .0037
in.)
Maximum Clearance
0.11mm (0.004 in.)
Intermediate
0.04-0.08mm
0.10mm
Ring
(0.0016-0.0031
(0.004 in.)
Oil Control Ring
(Steel Rails)
in.)
.019-.229mm (.0007-.0090
in.)
Ring Position
Ring Gap
Upper Ring
0.20-0.36mm (0.0079-0.0142
in.)
.25mm
(0.010 in.)
Wear Limit
0.43mm
(0.0017 in.)
Intermediate
0.37-0.63mm
0.74mm
Ring
(0.0146-0.0249
(0.029 in.)
in.)
Oil Control Ring
(Steel Rail)
0.025-0.76mm (0.0099- 0.03
1.55mm (0.061 in.)
in.)
(7) The No. 1 and No. 2 piston rings have a differ- ent cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston.
NOTE: Piston rings are installed in the following
order:† Oil ring expander. † Upper oil ring side rail. † Lower oil ring side rail. † No. 2 Intermediate piston ring. † No. 1 Upper piston ring. (8) Install the oil ring expander. (9) Install upper side rail (Fig. 78) by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail.
(10) Install No. 2 intermediate piston ring using a
piston ring installer (Fig. 79).
(11) Install No. 1 upper piston ring using a piston
ring installer (Fig. 79).
(12) Position piston ring end gaps as shown in (Fig. 80). It is important that expander ring gap is at
Fig.78SideRail—Installation
1 - SIDE RAIL END
Fig.79UpperandIntermediateRings—Installation VIBRATION DAMPER REMOVAL
(1) Disconnect negative cable from battery. (2) Remove accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove radiator upper hose. (5) Remove upper fan shroud. (6) Using Special Tools 6958 Spanner with Adapter loosen fan and viscous assembly from
Pins 8346, water pump (Fig. 81).
(7) Remove fan and viscous assembly. (8) Disconnect electrical connector for fan mounted
inside radiator shroud.
ENGINE - 4.7L
9 - 142
VIBRATION DAMPER (Continued)DR
Fig.80PistonRingEndGapPosition
1 - SIDE RAIL UPPER 2 - NO. 1 RING GAP 3 - PISTON PIN 4 - SIDE RAIL LOWER 5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig.81FANASSEMBLY-REMOVAL/ASSEMBLY 1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER PINS 8346
2 - FANNOTE: Transmission cooler line snaps into shroud lower right hand corner.
(9) Remove crankshaft damper bolt. (10) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 82).
Fig.82CRANKSHAFTDAMPER-REMOVAL
1 - SPECIAL TOOL 8513 INSERT 2 - SPECIAL TOOL 1026
INSTALLATION
CAUTION: To prevent severe damage to the Crank- shaft, Damper or Special Tool 8512–A, thoroughly clean the damper bore and the crankshaft nose before installing Damper.
(1) Align crankshaft damper slot with key in
crankshaft. Slide damper onto crankshaft slightly.
CAUTION: Special Tool 8512–A, is assembled in a specific sequence. Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft.
(2) Assemble Special Tool 8512–A as follows, The nut is threaded onto the shaft first. Then the roller bearing is placed onto the threaded rod (The hard- ened bearing surface of the bearing MUST face the nut). Then the hardened washer slides onto the threaded rod (Fig. 83). Once assembled coat the threaded rod’s threads with Mopart Nickel Anti- Seize or (Loctite No. 771).
(3) Using Special Tool 8512–A, press damper onto
crankshaft (Fig. 84).
175 N·m (130 ft. lbs.).
(4) Install then tighten crankshaft damper bolt to
(5) Install fan blade assembly (Refer to 7 - COOL- ING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).
DR VIBRATION DAMPER (Continued)
ENGINE - 4.7L
9 - 143
(10) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(11) Connect negative cable to battery.
STRUCTURAL COVER DESCRIPTION
The structural dust cover is made of die cast alu- minum and joins the lower half of the transmission bell housing to the engine bedplate.
OPERATION
The structural cover provides additional power-
train stiffness and reduces noise and vibration.
REMOVAL
(1) Raise vehicle on hoist. (2) Remove the left hand exhaust pipe from
exhaust manifold.
(3) Loosen the right hand exhaust manifold-to-ex-
haust pipe retaining bolts.
(4) Remove the eight bolts retaining structural
cover (Fig. 85) in the sequence shown.
(5) Pivot the exhaust pipe downward and remove
the structural cover.
Fig.85StructuralCover
1 - BOLT 2 - BOLT 3 - BOLT
INSTALLATION
CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will cause severe damage to the cover.
(1) Position the structural cover in the vehicle. (2) Install all four bolts retaining the cover-to-en-
gine. DO NOT tighten the bolts at this time.
Fig.83PROPERASSEMBLYMETHODFOR
SPECIALTOOL8512–A
1 - BEARING 2 - NUT 3 - THREADED ROD 4 - BEARING HARDENED SURFACE (FACING NUT) 5 - HARDENED WASHER
Fig.84CrankshaftDamperInstallation
1 - SPECIAL TOOL 8512
(6) Install radiator upper shroud and tighten fas-
teners to 11 N·m (95 in. lbs.).
(7) Connect electrical connector for shroud fan. (8) Install radiator upper hose. (9) Install accessory drive belt (Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- LATION).
ENGINE - 4.7L
9 - 144
STRUCTURAL COVER (Continued)(3) Install the four cover-to-transmission bolts. Do
NOT tighten at this time.
CAUTION: The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence. Failure to do so may cause damage to the cover.
(4) Starting with the two rear cover-to-engine bolts, tighten bolts (1) (Fig. 86) to 54 N·m (40 ft. lbs.), then tighten bolts (2) (Fig. 86) and (3) to 54 N·m ( 40
ft. lbs.) in the sequence shown.Fig.86StructuralCover
1 - BOLT 2 - BOLT 3 - BOLT
(5) Install the exhaust pipe on left hand exhaust
manifold.
(6) Tighten
exhaust manifold-to-exhaust retaining bolts to 20–26 N·m (15–20 ft. lbs.).
pipe
FRONT MOUNT REMOVAL
2WD
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the viscous fan before raising engine. Failure to do so may cause damage to the fan blade, fan clutch and fan shroud.
(2) Remove the viscous fan (Refer to 7 - COOL- ING/ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
(3) Raise the vehicle. (4) Remove the engine oil filter. (5) Remove the oil drain trough.
DR
(6) Support the engine with a suitable jack and a block of wood across the full width of the engine oil pan.
(7) Support the front axle with a suitable jack. (8) Remove the (4) bolts that attach the engine
mounts to the front axle.
(9) Remove the (3) bolts that attach the front axle
to the left engine bracket.
(10) Lower the front axle. (11) Remove the through bolts (12) Raise the engine far enough to be able to
remove the left and right engine mounts.
(13) Remove the (8) mount to engine attaching
(14) Remove the engine mounts.
bolts
4WD
(1) Disconnect the negative cable from the battery. (2) Remove the viscous fan. (3) Raise the vehicle. (4) Remove the skid plate. (5) Remove the front crossmember. (6) Remove the engine oil filter. (7) Remove the oil drain trough. (8) Support the engine with a suitable jack and a block of wood across the full width of the engine oil pan.
(9) Support the front axle with a suitable jack. (10) Remove the (4) bolts that attach the engine
mounts to the front axle (Fig. 87).
(11) Remove the (3) bolts that attach the front axle
to the left engine bracket.
(12) Lower the front axle. (13) Remove the (6) through bolts (14) Raise the engine far enough to be able to remove the left (Fig. 89) and right (Fig. 88) engine mounts.
(15) Remove the engine mounts.
INSTALLATION
2WD
NOTE: For mount to engine block and left engine bracket to front axle bolts, apply MoparT Lock and Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to the engine block with (8) bolts. Torque bolts to 54
N·m (40 ft. lbs.).(2) Insert the (2) through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts.
(3) Lower the engine until the through bolts rest
onto the slots in the frame brackets.
(4) Tighten the through bolt nuts to 94 N·m (70 ft.
lbs.).
DR FRONT MOUNT (Continued)
ENGINE - 4.7L
9 - 145
Fig.87ENGINEINSULATORMOUNTS4X4
1 - RH INSULATOR TO AXLE BOLT 2 - NUT 3 - PINION SUPPORT MOUNT 4 - LH INSULATOR MOUNT
5 - LH INSULATOR TO AXLE BOLT 6 - FRONT AXLE 7 - NUT 8 - RH INSULATOR MOUNT
(5) Install the oil drain trough. (6) Install the engine oil filter. (7) Lower the vehicle. (8) Install the viscous fan (Refer to 7 - COOLING/ ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
(9) Reconnect the negative battery cable.
4WD
NOTE: For mount to engine block and left engine bracket to front axle bolts, apply MoparT Lock and Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to
the front axle. Torque nuts to 94 N·m (70 ft. lbs.).
(2) Raise the front axle into the frame and install the left and right side through bolts. Torque nuts to 94 N·m (70 ft. lbs.).
(3) Insert the two upper through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts.
Fig.88ENGINEMOUNTSUPPORTBRACKETRH 1 - BOLT 2 - ENGINE MOUNT SUPPORT BRACKET
ENGINE - 4.7L
9 - 146
FRONT MOUNT (Continued)DR
(4) Lower the engine until the left and right side engine brackets rest on the through bolts, and the lower engine bracket through holes align with the engine mounts, and the left engine bracket holes align with the front axle slots (Fig. 90).
(5) Loose assemble the (3) bolts that attach the
front axle to the left engine bracket.
(6) Loose assemble the lower through bolts. (7) Torque the nuts for the (4) through bolts to 101
N·m (75 ft. lbs.).
(8) Torque the (3) bolts that attach the front axle
to the left engine bracket to 101 N·m (75 ft. lbs.).
(9) Install the oil drain trough. (10) Install the engine oil filter. (11) Install the front crossmember. (12) Install the skid plate. (13) Lower the vehicle. (14) Install the viscous fan (Refer to 7 - COOL- ING/ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
(15) Reconnect the negative battery cable.
Fig.89ENGINEMOUNTSUPPORTBRACKET
1 - BOLT 2 - ENGINE MOUNT SUPPORT BRACKET 3 - BOLT
Fig.90ENGINEINSULATORMOUNTS4X4
1 - RH INSULATOR TO AXLE BOLT 2 - NUT 3 - PINION SUPPORT MOUNT 4 - LH INSULATOR MOUNT
5 - LH INSULATOR TO AXLE BOLT 6 - FRONT AXLE 7 - NUT 8 - RH INSULATOR MOUNT
ENGINE - 4.7L
9 - 147
INSTALLATION
NOTE: Threadlocking compound must be applied to the bolts before installation.
(1) Install the two bolts that attach the transmis-
sion mount to the transmission bracket.
(2) Torque the bolts to 61N·m (45 ft.lbs.) torque. (3) Lower the transmission so the transmission mount rests on the crossmember, and the studs of the transmission mount are aligned in the slots in the crossmember.
(4) Install the nuts onto the transmission mount
studs through the crossmember access slot. (5) Torque the nuts to 54N·m (40 ft. lbs.).
DR
REAR MOUNT REMOVAL
(1) Raise the vehicle on a hoist. (2) Using a suitable jack, support transmission. (3) Remove the nuts from the transmission mount
(Fig. 91).
Fig.91TRANSMISSIONMOUNT
1 - MOUNT 2 - CROSSMEMBER 3 - NUT 4 - BOLT
(4) Remove the two bolts that attach the transmis-
sion mount to the engine bracket.
(5) Raise the transmission enough to remove the
mount from the crossmember.
(6) Remove the mount.
9 - 148
ENGINE - 4.7L
LUBRICATION DESCRIPTION
The lubrication system (Fig. 92) is a full flow fil-
tration pressure feed type.
DR
OPERATION
Oil from the oil pan is pumped by a gerotor type oil pump directly mounted to the crankshaft nose. Oil pressure is controlled by a relief valve mounted inside the oil pump housing. For lubrication flow refer to (Fig. 92).
1 - LEFT CYLINDER HEAD OIL GALLERY 2 - OIL PRESSURE SENSOR LOCATION 3 - TO LEFT CYLINDER HEAD 4 - OIL FEED TO IDLER SHAFT 5 - OIL PUMP OUTLET TO BLOCK 6 - OIL PUMP
Fig.92EngineOilLubricationSystem
7 - TO CRANKSHAFT MAIN JOURNALS 8 - RIGHT CYLINDER HEAD OIL GALLERY 9 - TO RIGHT CYLINDER HEAD 10 - CYLINDER BLOCK MAIN GALLERY 11 - OIL FEED TO BOTH SECONDARY TENSIONERS
DR LUBRICATION (Continued)
ENGINE - 4.7L
9 - 149
The camshaft exhaust valve lobes and rocker arms are lubricated through a small hole in the rocker arm; oil flows through the lash adjuster then through the rocker arm and onto the camshaft lobe. Due to the orentation of the rocker arm, the camshaft intake lobes are not lubed in the same manner as the exhaust lobes. The intake lobes are lubed through internal passages in the camshaft. Oil flows through
a bore in the number 3 camshaft bearing bore, and as the camshaft turns, a hole in the camshaft aligns with the hole in the camshaft bore allowing engine oil to enter the camshaft tube. The oil then exits through 1.6mm (0.063 in.) holes drilled into the intake lobes, lubricating the lobes and the rocker arms.
ENGINE LUBRICATION FLOW CHART—BLOCK: TABLE 1
FROM
Oil Pickup Tube
Oil Pump Oil Filter
Block Main Oil Gallery
Crankshaft Main Journals
Crankshaft Number One Main Journal
Left Cylinder Head Right Cylinder Head
TO
Oil Pump Oil Filter
Block Main Oil Gallery
1. Crankshaft Main Journal 2. Left Cylinder Head* 3. Right Cylinder Head*
Crankshaft Rod Journals
1.Front Timing Chain Idler Shaft 2.Both Secondary Chain Tensioners
See Table 2
See Table 2* The cylinder head gaskets have an oil restricter to control oil flow to the cylinder heads.
ENGINE LUBRICATION FLOW CHART—CYLINDER HEADS: TABLE 2
FROM
TO
Cylinder Head Oil Port (in bolt hole)
Diagonal Cross Drilling to Main Oil Gallery
Main Oil Gallery (drilled through head from rear to
front)
Base of Camshaft Towers Lash Adjuster Towers ** The number three camshaft bearing journal feeds oil into the hollow camshaft tubes. Oil is routed to the intake
1. Base of Camshaft Towers 2. Lash Adjuster Towers Vertical Drilling Through Tower to Camshaft Bearings** Diagonal Drillings to Hydraulic Lash Adjuster Pockets
lobes, which have oil passages drilled into them to lubricate the rocker arms.
ENGINE - 4.7L
9 - 150
LUBRICATION (Continued) DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE
(1) Remove oil pressure sending unit (Fig. 93)and
install gauge assembly C-3292.
DR
(3) Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var- ious speeds for approximately 24 km (15 miles), and repeat inspection. If the oil leak source is not pos- itively identified at this time, proceed with the air leak detection test method.
Air Leak Detection Test Method
(1) Disconnect the breather cap to air cleaner hose at the breather cap end. Cap or plug breather cap nipple.
(2) Remove the PCV valve from the cylinder head
cover. Cap or plug the PCV valve grommet.
(3) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.
(4) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus- pected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual procedures.(5) If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak.
(6) If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve and breather cap hose.
(7) Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery. (2) Raise the vehicle. (3) Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down, possible causes are a porous block, distributor seal,
Fig.93OILPRESSURESENDINGUNIT-TYPICAL 1 - BELT 2 - OIL PRESSURE SENSOR 3 - OIL FILTER 4 - ELEC. CONNECTOR
(2) Run engine until thermostat opens. (3) Oil Pressure: † Curb Idle–25 kPa (4 psi) minimum † 3000 rpm–170 - 758 kPa (25 - 110 psi) (4) If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck open.
Begin with a thorough visual
DIAGNOSIS AND TESTING—ENGINE OIL LEAK inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed:
(1) Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light.
DR LUBRICATION (Continued)
camshaft bore cup plugs oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. (4) If no leaks are detected, pressurize the crank- case as outlined in the, Inspection (Engine oil Leaks in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal.
(6) For bubbles that remain steady with shaft rotation, no further inspection can be done until dis- assembled.
OIL STANDARD PROCEDURE - ENGINE OIL SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi- fied. MOPARt provides engine oils that conform to this service grade.
ENGINE - 4.7L
9 - 151
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis- cosity of engine oil. Use only engine oils with multi- ple viscosities such as 5W-30 or 10W-30 in the 4.7L engines. These are specified with a dual SAE viscos- ity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and vari- ation (Fig. 94).
Fig.94TEMPERATURE/ENGINEOILVISCOSITY-
4.7LENGINE
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CON- SERVING is located on the label of an engine oil con- tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans (Fig. 95).
Fig.95EngineoilContainerStandardNotations
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the right
rear of the engine on the 4.7L engines. (Fig. 96).
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result.
ENGINE - 4.7L
9 - 152
OIL (Continued)DR
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged.
(6) Install drain plug in crankcase. (7) Lower vehicle and fill crankcase with specified type and amount of engine oil described in this sec- tion.
(8) Install oil fill cap. (9) Start engine and inspect for leaks. (10) Stop engine and inspect oil level.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING at beginning of this section.
OIL FILTER REMOVAL
All engines are equipped with a high quality full- flow, disposable type oil filter. DaimlerChrysler Cor- poration recommends a Mopart or equivalent oil filter be used.
(1) Position a drain pan under the oil filter. (2) Using a suitable oil filter wrench loosen filter. (3) Rotate the oil filter counterclockwise (Fig. 97)to
remove it from the cylinder block oil filter boss.
Fig.97OilFilter-4.7LEngine
1 - ENGINE OIL FILTER
Fig.96ENGINEOILDIPSTICK4.7LENGINE
1 - TRANSMISSION DIPSTICK 2 - ENGINE OIL DIPSTICK 3 - ENGINE OIL FILL CAP
Inspect engine oil level approximately every 800
kilometers (500 miles). Unless the engine has exhib- ited loss of oil pressure, run the engine for about five minutes before checking oil level. Checking engine oil level on a cold engine is not accurate.To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick.
(1) Position vehicle on level surface. (2) With engine OFF, allow approximately ten min- utes for oil to settle to bottom of crankcase, remove engine oil dipstick.
(3) Wipe dipstick clean. (4) Install dipstick and verify it is seated in the
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the ADD mark on
tube.
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in Maintenance Schedules.
Run engine until achieving normal operating tem-
(1) Position the vehicle on a level surface and turn
perature.
engine off.
(2) Hoist and support vehicle on safety stands. (3) Remove oil fill cap.
DR OIL FILTER (Continued)
(4) When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle.
NOTE: Make sure filter gasket was removed with fil- ter.
(5) With a wiping cloth, clean the gasket sealing
surface of oil and grime.
INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil.
(2) Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Fig. 98) hand tighten filter one full turn, do not over tighten.
(3) Add oil, verify crankcase oil
level and start
engine. Inspect for oil leaks.
ENGINE - 4.7L
9 - 153
(8) Raise engine using special tool # 8534 to pro-
vide clearance to remove oil pan.
NOTE: Do not pry on oil pan or oil pan gasket. Gas- ket is integral to engine windage tray and does not come out with oil pan.
(9) Remove the oil pan mounting bolts and oil pan. (10) Unbolt oil pump pickup tube and remove
(11) Inspect the integral windage tray and gasket
tube.
and replace as needed.
INSTALLATION
bedplate and oil pan.
(1) Clean the oil pan gasket mating surface of the
(2) Position the oil pan gasket and pickup tube with new o-ring. Install the mounting bolt and nuts. Tighten bolt and nuts to 28 N·m (20 ft. lbs.).
(3) Position the oil pan and install the mounting bolts. Tighten the mounting bolts to 15 N·m (11 ft. lbs.) in the sequence shown (Fig. 99).
Fig.98OilFilterSealingSurface-Typical
1 - SEALING SURFACE 2 - RUBBER GASKET 3 - OIL FILTER
OIL PAN REMOVAL
(1) Disconnect the negative battery cable. (2) Install engine support fixture special tool #
8534. Do not raise engine at this time.
(3) Loosen both left and right side engine mount
through bolts. Do not remove bolts.
(4) (5) Remove the structural dust cover, if equipped. (6) Drain engine oil. (7) Remove the front crossmember(Refer to 13 - FRAME & BUMPERS/FRAME/FRONT CROSS- MEMBER - REMOVAL).
CAUTION: Only raise the engine enough to provide clearance for oil pan removal. Check for proper clearance at fan shroud to fan and cowl to intake manifold.
Fig.99OilPanMountingBoltsandOilPan
(4) Lower the engine into mounts using special
tool # 8534.
(5) Install both the left and right side engine mount through bolts. Tighten the nuts to 68 N·m (50
ft. lbs.).(6) Remove special tool # 8534. (7) Install structural dust cover, if equipped. (8) Install the front crossmember(Refer to 13 - FRAME & BUMPERS/FRAME/FRONT CROSS- MEMBER - INSTALLATION).
(9) Fill engine oil. (10) Reconnect the negative battery cable. (11) Start engine and check for leaks.
9 - 154
ENGINE - 4.7L
DR
OIL PRESSURE SENSOR/ SWITCH
DESCRIPTION
DESCRIPTION
The 3–wire, solid-state engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery.
DESCRIPTION
The 3–wire, electrical/mechanical engine oil pres- sure sensor (sending unit) is located in an engine oil pressure gallery.
OPERATION
OPERATION
The oil pressure sensor uses three circuits. They are:† A 5–volt power supply from the Powertrain Con- trol Module (PCM) † A sensor ground through the PCM’s sensor return† A signal to the PCM relating to engine oil pres- sure The oil pressure sensor has a 3–wire electrical function very much like the Manifold Absolute Pres- sure (MAP) sensor. Meaning different pressures relate to different output voltages.
A 5–volt supply is sent to the sensor from the PCM to power up the sensor. The sensor returns a voltage signal back to the PCM relating to engine oil pres- sure. This signal is then transferred (bussed) to the instrument panel on either a CCD or PCI bus circuit (depending on vehicle line) to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low-noise sensor return.
OPERATION
The oil pressure sensor uses two circuits. They are: † A signal to the PCM relating to engine oil pres- sure† A sensor ground through the PCM’s sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pres- sure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low- noise sensor return.
REMOVAL
(1) Disconnect the negative cable from the battery. (2) Raise vehicle on hoist. (3) Remove front splash shield. (4) Disconnect oil pressure sender wire (Fig. 100). (5) Remove the pressure sender (Fig. 100).
Fig.100OILPRESSURESENDINGUNIT
1 - BELT 2 - OIL PRESSURE SENSOR 3 - OIL FILTER 4 - ELEC. CONNECTOR
INSTALLATION
(1) Install oil pressure sender. (2) Connect oil pressure sender wire. (3) Install front splash shield. (4) Lower vehicle. (5) Connect the negative battery cable.
OIL PUMP REMOVAL
(1) Remove the oil pan and pick-up tube (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). (2) Remove the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(3) Remove the timing chains and tensioners (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).
(4) Remove the four bolts, primary timing chain
tensioner and the oil pump.
DR OIL PUMP (Continued) DISASSEMBLY
(1) Remove oil pump cover screws and lift off cover
plate.
(2) Remove pump inner and outer rotors.
NOTE: Once the oil pressure relief valve, cup plug, and pin are removed, the pump assembly must be replaced.
(3) If it is necessary to remove the pressure relief valve, drive the roll pin from pump housing and remove cup plug, spring and valve.
CLEANING
(1) Wash all parts in a suitable solvent.
INSPECTION
CAUTION: Oil pump pressure relief valve and spring should not be removed from the oil pump. If these are disassembled and or removed from the pump the entire oil pump assem- bly must be replaced.
components
(1) Clean all parts thoroughly. Mating surface of the oil pump housing should be smooth. If the pump cover is scratched or grooved the oil pump assembly should be replaced.
(2) Lay a straight edge across the pump cover sur- face (Fig. 101). If a 0.025 mm (0.001 in.) feeler gauge can be inserted between the cover and the straight edge the oil pump assembly should be replaced.
(3) Measure the thickness of the outer rotor (Fig. 102). If the outer rotor thickness measures at 12.005
mm (0.472 in.) or less the oil pump assembly must be replaced.(4) Measure the diameter of the outer rotor. If the outer rotor diameter measures at 85.925 mm (3.382
in.) or less the oil pump assembly must be replaced. (5) Measure the thickness of the inner rotor (Fig. 103). If the inner rotor thickness measures at 12.005
mm (0.472 in.) or less then the oil pump assembly must be replaced.(6) Slide outer rotor into the body of the oil pump. Press the outer rotor to one side of the oil pump body and measure clearance between the outer rotor and the body (Fig. 104). If the measurement is 0.235mm (0.009 in.) or more the oil pump assembly must be replaced.
(7) Install the inner rotor in the into the oil pump body. Measure the clearance between the inner and outer rotors (Fig. 105). If the clearance between the
ENGINE - 4.7L
9 - 155
rotors is .150 mm (0.006 in.) or more the oil pump assembly must be replaced.
(8) Place a straight edge across the body of the oil pump (between the bolt holes), if a feeler gauge of .095 mm (0.0038 in.) or greater can be inserted between the straightedge and the rotors, the pump must be replaced (Fig. 106).
NOTE: The 3.7 Oil pump is released as an assem- bly. There are no DaimlerChrysler part numbers for Sub-Assembly components. the oil pump is not functioning or out of specification it must be replaced as an assembly.
In the event
Fig.101CheckingOilPumpCoverFlatness
1 - STRAIGHT EDGE 2 - FEELER GAUGE 3 - OIL PUMP COVER
Fig.102MeasuringOuterRotorThickness
ENGINE - 4.7L
9 - 156
OIL PUMP (Continued)DR
Fig.103MeasuringInnerRotorThickness
Fig.105MeasuringClearanceBetweenRotors
1 - OUTER ROTOR 2 - FEELER GAUGE 3 - INNER ROTOR
Fig.104MeasuringOuterRotorClearance
1 - FEELER GAUGE 2 - OUTER ROTOR
ASSEMBLY
(1) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
(2) Install inner and outer rotors (3) Install oil pump cover plate and install cover
bolts and tighten them to 12 N·m (105 in. lbs.).
(4) Prime oil pump before installation by filling
rotor cavity with engine oil.
(5) If oil pressure is low and pump is within spec- ifications, inspect for worn engine bearings or other causes for oil pressure loss.
Fig.106MeasuringClearanceOverRotors
1 - STRAIGHT EDGE 2 - FEELER GAUGE
DR OIL PUMP (Continued) INSTALLATION
(1) Position the oil pump onto the crankshaft and
install one oil pump retaining bolts.
(2) Position the primary timing chain tensioner
and install three retaining bolts.
(3) Tighten the oil pump and primary timing chain tensioner retaining bolts to 28 N·m (250 in. lbs.) in the sequence shown (Fig. 107).
ENGINE - 4.7L
9 - 157
DIAGNOSIS AND TESTING—INTAKE MANIFOLD LEAKAGE
An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine. (2) Spray a small stream of water at the suspected
(3) If a change in RPM is observed the area of the
suspected leak has been found.
(4) Repair as required.
leak area.
REMOVAL
ing components:
(1) Disconnect negative cable from battery. (2) Remove resonator assembly and air inlet hose. (3) Disconnect throttle and speed control cables. (4) Disconnect electrical connectors for the follow- † Manifold Absolute Pressure (MAP) Sensor † Intake Air Temperature (IAT) Sensor † Throttle Position (TPS) Sensor † Coolant Temperature (CTS) Sensor † Idle Air Control (IAC) Motor (5) Disconnect brake booster hose and positive
crankcase ventilation (PCV) hose.
(6) Disconnect generator electrical connections. (7) Disconnect air conditioning compressor electri-
left and right radio suppressor
cal connections. (8) Disconnect
straps.
(9) Disconnect and remove ignition coil
towers (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ IGNITION COIL - REMOVAL).
(10) Remove top oil dipstick tube retaining bolt
and ground strap.
(11) Bleed fuel system (Refer to 14 - FUEL SYS- TEM/FUEL DELIVERY - STANDARD PROCE- DURE).
(12) Remove fuel rail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
(13) Remove throttle body assembly and mounting
bracket.
ture level PROCEDURE).
(14) Drain cooling system below coolant tempera- (Refer to 7 - COOLING - STANDARD
(15) Remove the heater hoses from the engine
front cover and the heater core.
Fig.107OilPumpAndPrimaryTimingChain
TensionerTighteningSequence
(4) Install the secondary timing chain tensioners and timing chains (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).
(5) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(6) Install the pick-up tube and oil pan (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - INSTALLA- TION).INTAKE MANIFOLD DESCRIPTION
The intake manifold is made of a composite mate- rial and features long runners which maximizes low end torque. The intake manifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent leaks. Eight studs and two bolts are used to fasten the intake to the head.
ENGINE - 4.7L
9 - 158
INTAKE MANIFOLD (Continued)(16) Unclip and remove heater hoses and tubes
from intake manifold (Fig. 108).
CLEANING
DR
NOTE: There is NO approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced.
Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry.
INSPECTION
(1) Inspect the intake sealing surface for cracks,
nicks and distortion.
(2) Inspect the intake manifold vacuum hose fit-
tings for looseness or blockage.
(3) Inspect the manifold to throttle body mating
surface for cracks, nicks and distortion.
INSTALLATION
Fig.108HeaterHosesandTubesRemoval/
Installation
1 - HEATER HOSES AND TUBES 2 - ROUTING/RETAINING CLIPS
