Index Dodge Dodge Ram Truck 1500-2500-3500 - service repair manual 2005 year

Content .. 1307 1308 1309 1310 ..

Dodge Ram Truck 1500-2500-3500. Manual - part 1309

NOTE: It will be necessary to slightly rotate camshafts for sprocket installation.

11. Align left camshaft sprocket “L” dot to plated link on chain.

12. Align right camshaft sprocket “R” dot to plated link on chain.

CAUTION: Remove excess oil from the camshaft sprocket bolt. Failure to do so can result in over-torque of
bolt resulting in bolt failure.

13. Remove Special Tool 8429, then attach both sprockets to camshafts. Remove excess oil from bolts, then Install

sprocket bolts, but do not tighten at this time.

14. Verify that all plated links are aligned with the marks on all sprockets and the “V6” marks on camshaft sprockets

are at the 12 o’clock position.

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ENGINE - 3.7L - SERVICE INFORMATION

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CAUTION: Ensure the plate between the left sec-
ondary chain tensioner and block is correctly
installed.

15. Install both secondary chain tensioners. Tighten

bolts to 28 N·m (250 in. lbs.).

NOTE: Left and right secondary chain tensioners
are not common.

16. Remove all 3 locking pins from tensioners.

CAUTION: After pulling locking pins out of each
tensioner, DO NOT manually extend the tension-
er(s) ratchet. Doing so will over tension the
chains, resulting in noise and/or high timing chain
loads.

17. Using Special Tool 6958, Spanner with Adaptor

Pins 8346, (4) tighten left and right. camshaft
sprocket bolts to 122 N·m (90 ft. lbs.).

18. Rotate engine two full revolutions. Verify timing marks are at the follow locations:

•

primary chain idler sprocket dot is at 12 o’clock

•

primary chain crankshaft sprocket dot is at 6 o’clock

•

secondary chain camshaft sprockets “V6” marks are at 12 o’clock

•

counterbalancer shaft drive gear dot is aligned to the idler sprocket gear dot

19. Lubricate all three chains with engine oil.

20. After installing all chains, it is recommended that

the idler gear end play be checked. The end play
must be within 0.10 -0.25 mm (0.004 - 0.010 in.).
If not within specification, the idler gear must be
replaced.

21. Install timing chain cover and crankshaft damper.

Refer to procedures.

22. Install cylinder head covers (Refer to 9 - ENGINE/

CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).

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ENGINE - 3.7L - SERVICE INFORMATION

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NOTE: Before installing threaded plug in right cyl-
inder head, the plug must be coated with sealant
to prevent leaks.

23. Coat the large threaded access plug with Mopar

T

Thread Sealant with Teflon, then install into the
right cylinder head (1) and tighten to 81 N·m (60
ft. lbs.).

24. Install the oil fill housing.

25. Install access plug in left cylinder head (2).

26. Install power steering pump (Refer to 19 -

STEERING/PUMP - INSTALLATION).

27. Fill cooling system (Refer to 7 - COOLING -

STANDARD PROCEDURE).

28. Connect negative cable to battery.

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ENGINE - 3.7L - SERVICE INFORMATION

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ENGINE - 4.7L - SERVICE INFORMATION

TABLE OF CONTENTS

page

page

ENGINE - 4.7L - SERVICE INFORMATION

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - ENGINE

DIAGNOSIS - PERFORMANCE . . . . . . . . . 2163

DIAGNOSIS AND TESTING - ENGINE

DIAGNOSIS - MECHANICAL . . . . . . . . . . . 2165

DIAGNOSIS AND TESTING - CYLINDER

COMPRESSION PRESSURE . . . . . . . . . . . 2166

DIAGNOSIS AND TESTING - CYLINDER

COMBUSTION PRESSURE LEAKAGE . . . . 2166

DIAGNOSIS AND TESTING - ENGINE

DIAGNOSIS - INTRODUCTION . . . . . . . . . . 2167

STANDARD PROCEDURE

STANDARD PROCEDURE - REPAIR

DAMAGED OR WORN THREADS . . . . . . . 2167

STANDARD PROCEDURE - FORM-IN-

PLACE GASKETS AND SEALERS . . . . . . . 2167

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2168

. . . . . . . . . . . . . . . . . . . . . . . 2174

SPECIFICATIONS - 4.7L ENGINE

. . . . . . . . 2179

. . . . . . . . . . . . . . . . . . . . . . . . . . 2184

. . . . . . . . . . . . . . . . . . . . . . . 2186

ELEMENT - AIR CLEANER

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2190

. . . . . . . . . . . . . . . . . . . . . . . 2191

CYLINDER HEAD

DESCRIPTION - CYLINDER HEAD

. . . . . . 2191

DESCRIPTION - VALVE GUIDES

. . . . . . . . 2191

DIAGNOSIS AND TESTING

CYLINDER HEAD GASKET

. . . . . . . . . . . . 2191

REMOVAL - LEFT CYLINDER HEAD

REMOVAL - RIGHT CYLINDER HEAD

. . . . . . . . . . . . . . . . . . . . . . . . . . 2198

. . . . . . . . . . . . . . . . . . . . . . . . . 2198

INSTALLATION - LEFT CYLINDER HEAD

INSTALLATION - RIGHT CYLINDER HEAD

CAMSHAFT - LEFT

. . . . . . . . . . . . . . . . . . . . . . . 2203

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2204

. . . . . . . . . . . . . . . . . . . . . . . 2206

CAMSHAFT - RIGHT

. . . . . . . . . . . . . . . . . . . . . . . 2209

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2209

. . . . . . . . . . . . . . . . . . . . . . . 2212

COVER - CYLINDER HEAD

. . . . . . . . . . . . . . . . . . . . . . . 2215

REMOVAL - RIGHT SIDE

. . . . . . . . . . . . . . 2215

REMOVAL - LEFT SIDE

. . . . . . . . . . . . . . . 2216

. . . . . . . . . . . . . . . . . . . . . . . . . . 2216

INSTALLATION - RIGHT SIDE

. . . . . . . . . . 2216

INSTALLATION - LEFT SIDE

. . . . . . . . . . . 2217

VALVES & SEATS - INTAKE/EXHAUST

. . . . . . . . . . . . . . . . . . . . . . . 2217

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2217

. . . . . . . . . . . . . . . . . . . . . . . 2218

ROCKER ARM - VALVE

. . . . . . . . . . . . . . . . . . . . . . . 2219

DIAGNOSIS AND TESTING - HYDRAULIC

. . . . . . . . . . . . . . . . . . . . 2219

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2220

. . . . . . . . . . . . . . . . . . . . . . . 2220

SPRINGS-VALVE

. . . . . . . . . . . . . . . . . . . . . . . 2220

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2221

. . . . . . . . . . . . . . . . . . . . . . . 2221

SEALS-VALVE GUIDE

. . . . . . . . . . . . . . . . . . . . . . . 2222

ENGINE BLOCK

. . . . . . . . . . . . . . . . . . . . . . . 2222

STANDARD PROCEDURE - CYLINDER BORE

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2222

. . . . . . . . . . . . . . . . . . . . . . . . . . 2222

. . . . . . . . . . . . . . . . . . . . . . . . . 2223

BEARINGS - CONNECTING ROD

STANDARD PROCEDURE - CONNECTING

ROD BEARING FITTING

. . . . . . . . . . . . . . 2223

PLUGS - CORE

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2226

. . . . . . . . . . . . . . . . . . . . . . . 2226

CRANKSHAFT

. . . . . . . . . . . . . . . . . . . . . . . 2227

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2227

. . . . . . . . . . . . . . . . . . . . . . . . . 2227

. . . . . . . . . . . . . . . . . . . . . . . 2228

BEARINGS - CRANKSHAFT MAIN

STANDARD PROCEDURE - CRANKSHAFT

MAIN BEARING - FITTING

. . . . . . . . . . . . . 2230

. . . . . . . . . . . . . . . . . . . . . . . . . 2231

SEAL - CRANKSHAFT OIL - FRONT

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2232

. . . . . . . . . . . . . . . . . . . . . . . 2233

SEAL - CRANKSHAFT OIL - REAR

DIAGNOSIS AND TESTING - REAR SEAL

. . . . . . . . . . . . . . . . . . . . . . . 2233

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2234

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ENGINE - 4.7L - SERVICE INFORMATION

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