vin DODGE RAM 1500 1998 2.G Workshop Manual

EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds (Fig. 90) are log style with
a patented flow enhancing design to maximize perfor-
mance. The exhaust manifolds are made of high sili-
con molybdenum cast iron. A perforated core graphite
exhaust manifold gasket is used to improve sealing
to the cylinder head. The exhaust manifolds are cov-
ered by a three layer laminated heat shield for ther-
mal protection and noise reduction. The heat shields
(Fig. 91) are fastened with a torque prevailing nut
that is backed off slightly to allow for the thermal
expansion of the exhaust manifold.
REMOVAL
RIGHT EXHAUST MANIFOLD
(1) Disconnect the negative cable from the battery.
(2) Raise and support the vehicle.
(3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold.
(4) Lower the vehicle.
(5) Remove the exhaust heat shield (Fig. 92).
(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold and gasket from the cylinder
head.
LEFT EXHAUST MANIFOLD
(1) Disconnect the negative cable from the battery.
(2) Raise and support the vehicle.
(3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold.
(4) Lower the vehicle.
(5) Remove the exhaust heat shields (Fig. 93).
(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold and gasket from the cylinder
head.
INSTALLATION
RIGHT EXHAUST MANIFOLD
CAUTION: If the studs came out with the nuts when
removing the engine exhaust manifold, install new
studs. Apply sealer on the coarse thread ends.
Water leaks may develop at the studs if this precau-
tion is not taken.
Fig. 90 EXHAUST MANIFOLDS
1 - LEFT SIDE EXHAUST MANIFOLD
2 - RIGHT SIDE EXHAUST MANIFOLD
Fig. 91 Exhaust Manifold Heat Shields
1 - RIGHT SIDE EXHAUST MANIFOLD HEAT SHIELD
2 - RIGHT SIDE EXHAUST MANIFOLD FLANGE
3 - LEFT SIDE EXHAUST MANIFOLD HEAT SHIELD
4 - LEFT SIDE EXHAUST MANIFOLD FLANGE
9 - 74 ENGINE - 3.7LDR

(1) Position the engine exhaust manifold and gas-
ket on the two studs located on the cylinder head.
Install conical washers and nuts on these studs .
(2) Install remaining conical washers. Starting at
the center arm and working outward, tighten the
bolts and nuts to 25 N´m (18 ft. lbs.) torque.
(3) Install the exhaust heat shields.
(4) Raise and support the vehicle.
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(5) Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and
nuts to 34 N´m (25 ft. lbs.) torque.
LEFT EXHAUST MANIFOLD
CAUTION: If the studs came out with the nuts when
removing the engine exhaust manifold, install newstuds. Apply sealer on the coarse thread ends.
Water leaks may develop at the studs if this precau-
tion is not taken.
(1) Position the engine exhaust manifold and gas-
ket on the two studs located on the cylinder head.
Install conical washers and nuts on these studs .
(2) Install remaining conical washers. Starting at
the center arm and working outward, tighten the
bolts and nuts to 25 N´m (18 ft. lbs.) torque.
(3) Install the exhaust heat shields.
(4) Raise and support the vehicle.
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(5) Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and
nuts to 34 N´m (25 ft. lbs.) torque.
Fig. 92 Exhaust Manifold Right
1 - HEAT SHIELD
2 - NUTS
3 - MANIFOLD FLANGE
Fig. 93 Exhaust Manifold left
1 - HEAT SHIELD
2 - NUTS
3 - MANIFOLD FLANGE
DRENGINE - 3.7L 9 - 75
EXHAUST MANIFOLD (Continued)

IDLER SHAFT
REMOVAL
(1) Remove the primary and secondary timing
chains and sprockets. Refer to procedure in this sec-
tion.
NOTE: To remove the idler shaft, it is necessary to
tap threads into the shaft, to install the removal
tool.
(2) Using a 12 mm X 1.75 tap, cut threads in the
idler shaft center bore.
(3) Cover the radiator core with a suitable cover.
CAUTION: Use care when removing the idler shaft,
Do not strike the radiator cooling fins with the slide
hammer.
(4) Using Special Tool 8517 Slide Hammer, remove
the idler shaft.
INSTALLATION
(1) Thoroughly clean the idler shaft bore.
(2) Position the idler shaft in the bore.
NOTE: The two lubrication holes in the idler shaft
do not require any special alignment.
NOTE: Before using the retaining bolt to install the
idler shaft, coat the threads and the pilot on the
idler shaft, with clean engine oil.
(3) Using the primary idler sprocket retaining bolt
and washer, carefully draw the idler shaft into the
bore until fully seated.
(4) Coat the idler shaft with clean engine oil.
(5) Install the timing chains and sprockets. Refer
to procedure in this section.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove electric cooling fan and fan shroud
assembly.
(4) Remove fan and fan drive assembly (Refer to 7
- COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL).
(5) Disconnect both heater hoses at timing cover.
(6) Disconnect lower radiator hose at engine.(7) Remove accessory drive belt tensioner assembly
(Fig. 103).
(8) Remove crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(9) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(10) Remove A/C compressor (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - REMOVAL).
CAUTION: The 3.7L engine uses an anerobic sealer
instead of a gasket to seal the front cover to the
engine block, from the factory. For service, MoparT
Engine RTV sealant must be substituted.
NOTE: It is not necessary to remove the water
pump for timing cover removal.
(11) Remove the bolts holding the timing cover to
engine block (Fig. 104).
(12) Remove the timing cover.
INSTALLATION
CAUTION: Do not use oil based liquids to clean tim-
ing cover or block surfaces. Use only rubbing alco-
hol, along with plastic or wooden scrapers. Use no
wire brushes or abrasive wheels or metal scrapers,
or damage to surfaces could result.
Fig. 103 ACCESSORY DRIVE BELT TENSIONER
1 - TENSIONER ASSEMBLY
2 - FASTENER TENSIONER TO FRONT COVER
DRENGINE - 3.7L 9 - 81

(7) Remove access plug from left and right cylinder
heads for access to chain guide fasteners (Fig. 109).
(8) Remove the oil fill housing to gain access to the
right side tensioner arm fastener.
(9) Remove crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL) and timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(10) Collapse and pin primary chain tensioner.
CAUTION: Plate behind left secondary chain ten-
sioner could fall into oil pan. Therefore, cover pan
opening.
(11) Remove secondary chain tensioners.
(12) Remove camshaft position sensor (Fig. 110).
CAUTION: Care should be taken not to damage
camshaft target wheel. Do not hold target wheel
while loosening or tightening camshaft sprocket.
Do not place the target wheel near a magnetic
source of any kind. A damaged or magnetized tar-
get wheel could cause a vehicle no start condition.
CAUTION: Do not forcefully rotate the camshafts or
crankshaft independently of each other. Damaging
intake valve to piston contact will occur. Ensure
negative battery cable is disconnected to guard
against accidental starter engagement.
(13) Remove left and right camshaft sprocket bolts.
(14) While holding the left camshaft steel tube
with Special Tool 8428 Camshaft Wrench, remove the
left camshaft sprocket. Slowly rotate the camshaft
approximately 5 degrees clockwise to a neutral posi-
tion.(15) While holding the right camshaft steel tube
with Special Tool 8428 Camshaft Wrench, remove the
right camshaft sprocket.
(16) Remove idler sprocket assembly bolt.
(17) Slide the idler sprocket assembly and crank
sprocket forward simultaneously to remove the pri-
mary and secondary chains.
(18) Remove both pivoting tensioner arms and
chain guides.
(19) Remove primary chain tensioner.
INSPECTION
Inspect the following components:
²Sprockets for excessive tooth wear. Some tooth
markings are normal and not a cause for sprocket
replacement.
²Idler sprocket assembly bushing and shaft for
excessive wear.
²Idler sprocket assembly spline joint. The joint
should be tight with no backlash or axial movement.
²Chain guides and tensioner arms. Replace these
parts if grooving in plastic face is more than 1 mm
(0.039 in.) deep. If plastic face is severely grooved or
melted, the tensioner lube jet may be clogged. The
tensioner should be replaced.
²Secondary chain tensioner piston and ratcheting
device. Inspect for evidence of heavy contact between
tensioner piston and tensioner arm. If this condition
exist the tensioner tensioner arm and chain should
be replaced.
Fig. 109 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
Fig. 110 Camshaft Position Sensor
1 - CYLINDER HEAD
2 - CAMSAHFT POSITION SENSOR
3 - SCREW
9 - 84 ENGINE - 3.7LDR
TIMING BELT/CHAIN AND SPROCKETS (Continued)

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.
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.
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.
Fig. 11 Camshaft Sprocket V8 Marks
1 - LEFT CYLINDER HEAD2 - RIGHT CYLINDER HEAD
Fig. 12 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
DRENGINE - 4.7L 9 - 109
CYLINDER HEAD (Continued)

(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.
CAUTION: Do not allow the engine to rotate. severe
damage to the valve train can occur.
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.
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
(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.
Fig. 15 Using Special Tool 8515 to Hold Chains to
Idler Sprocket.
1 - LOCK ARM
2 - RIGHT CAMSHAFT CHAIN
3 - SECONDARY CHAINS RETAINING PINS (4)
4 - IDLER SPROCKET
5 - LEFT CAMSHAFT CHAIN
6 - SPECIAL TOOL 8515
Fig. 16 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
DRENGINE - 4.7L 9 - 111
CYLINDER HEAD (Continued)

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.
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 butDO NOTremove 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.
Fig. 25 Securing Timing Chain Tensioners Using Timing Chain Wedge
1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD3 - SPECIAL TOOL 8350 WEDGE
4 - SPECIAL TOOL 8350 WEDGE
DRENGINE - 4.7L 9 - 115
CAMSHAFT(S) - LEFT (Continued)

(6) Hold the camshaft with adjustable pliers while
removing the camshaft sprocket bolt and sprocket
(Fig. 26).
(7) Using the pliers, gently allow the camshaft to
rotate 15É 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.
(3) Install the camshaft bearing caps, hand tighten
the retaining bolts.
(4) Working in
1¤2turn increments, tighten the
bearing cap retaining bolts starting with the middle
cap working outward (Fig. 27).
Fig. 26 Camshaft Sprocket and Chain
1 - CAMSHAFT SPROCKET AND CHAIN
2 - ADJUSTABLE PLIERS
3 - CAMSHAFT
Fig. 27 Camshaft Bearing Caps Tightening
Sequence
9 - 116 ENGINE - 4.7LDR
CAMSHAFT(S) - LEFT (Continued)

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 camshaft 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.
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 butDO NOTremove 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.
(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).
Fig. 32 Securing Timing Chain Tensioners Using Timing Chain Wedge
1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD3 - SPECIAL TOOL 8350 WEDGE
4 - SPECIAL TOOL 8350 WEDGE
DRENGINE - 4.7L 9 - 119

(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.
(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 45É 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.
INSTALLATION
(1) Lubricate camshaft journals with clean engine
oil.
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.
Fig. 33 Camshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
2 - CYLINDER HEAD COVER
3 - CAMSHAFT POSITION SENSOR
4 - RIGHT SIDE CYLINDER BLOCK
Fig. 34 Camshaft Sprocket and Chain
1 - ADJUSTABLE PLIERS
2 - SPROCKET BOLT
3 - CAMSHAFT SPROCKET AND CHAIN
4 - CAMSHAFT
9 - 120 ENGINE - 4.7LDR
CAMSHAFT(S) - RIGHT (Continued)