DODGE RAM 1500 1998 2.G Workshop Manual

Crankshaft Damper Installer 8512
Puller 1026
Crankshaft Damper Removal Insert 8513
Chain Tensioner Wedge 8379
Chain Tensioner Pins 8514
VALVE SPRING COMPRESSOR 8426
ENGINE LIFTING FIXTURE 8427
CAMSHAFT HOLDER 8428
9 - 18 ENGINE - 3.7LDR
ENGINE - 3.7L (Continued)

HOLDER SECONDARY CAMSHAFT CHAIN 8429
Remover, Rocker Arm 8516
Idler Shaft Remover 8517
Valve Spring Compressor Adapters 8519
INSTALLER - REMOVER - COUNTER BALANCE
SHAFT 8641
Valve Spring Tester C-647
Dial Indicator C-3339
Valve Spring Compressor C-3422-B
DRENGINE - 3.7L 9 - 19
ENGINE - 3.7L (Continued)

Bore Size Indicator C-119
Oil Pressure Gauge C-3292
Piston Ring Compressor C-385
Pressure Tester Kit 7700
Bloc±Chek±Kit C-3685±A
ENGINE SUPPORT FIXTURE 8534
9 - 20 ENGINE - 3.7LDR
ENGINE - 3.7L (Continued)

AIR CLEANER ELEMENT
REMOVAL
Filter Element Only
Housing removal is not necessary for element (fil-
ter) replacement.
(1) Loosen clamp (Fig. 3) and disconnect air duct
at air cleaner cover.
(2) Pry over 4 spring clips (Fig. 3) from housing
cover (spring clips retain cover to housing).
(3) Release housing cover from locating tabs on
housing (Fig. 3) and remove cover.
(4) Remove air cleaner element (filter) from hous-
ing.
(5) Clean inside of housing before replacing ele-
ment.
Housing Assembly
(1) Loosen clamp (Fig. 3) and disconnect air duct
at air cleaner cover.
(2) Lift entire housing assembly from 4 locating
pins (Fig. 4).
INSTALLATION
(1) Install filter element into housing.
(2) Position housing cover into housing locating
tabs (Fig. 3).(3) Pry up 4 spring clips (Fig. 3) and lock cover to
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 - LEFT
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
Fig. 3 AIR CLEANER HOUSING COVER
1 - CLAMP
2 - AIR DUCT
3 - AIR CLEANER COVER
4 - LOCATING TABS
5 - CLIPS (4)
Fig. 4 AIR CLEANER HOUSING
1 - AIR CLEANER HOUSING ASSEMBLY
2 - LOCATING PINS (4)
DRENGINE - 3.7L 9 - 21

²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50 - 70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Disconnect the exhaust pipe at the left 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 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(7) Remove the master cylinder and booster assem-
bly(Refer to 5 - BRAKES/HYDRAULIC/MECHANI-
CAL/POWER BRAKE BOOSTER - REMOVAL).
(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 assem-
bly(Refer to 7 - COOLING/ENGINE/RADIATOR FAN
- REMOVAL).
(10) Remove accessory drive belt(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(11) Remove the power steering pump and set
aside.
(12) Rotate the crankshaft until the damper tim-
ing mark is aligned with TDC indicator mark (Fig.
5).
(13) Verify the V6 mark on the camshaft sprocket
is at the 12 o'clock position (Fig. 6). Rotate the crank-
shaft 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).
Fig. 5 Engine Top Dead Center
1 - TIMING CHAIN COVER
2 - CRANKSHAFT TIMING MARKS
9 - 22 ENGINE - 3.7LDR
CYLINDER HEAD - LEFT (Continued)

(16) Lock the secondary timing chains to the idler
sprocket using Special Tool 8429 Timing Chain Hold-
ing Fixture (Fig. 7).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 V6 mark on the camshaft drive gear.
(18) Remove the left side secondary chain ten-
sioner. Refer to Timing Chain and Sprockets.
(19) Remove the cylinder head access plug (Fig. 8).
Fig. 6 CAMSHAFT SPROCKET V6 MARKS (#1 TDC, Exhaust stroke)
1 - LEFT CYLINDER HEAD2 - RIGHT CYLINDER HEAD
Fig. 7 Using Special Tool 8429
1 - SPECIAL TOOL 8429
2 - CAMSHAFT CHAIN
3 - CRANKSHAFT TIMING GEAR
Fig. 8 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
DRENGINE - 3.7L 9 - 23
CYLINDER HEAD - LEFT (Continued)

(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 twelve 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.
INSTALLATION
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. 9).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. 10).
(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.
(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 eight M11 bolts.
(5) Coat the four M8 cylinder head bolts with
MopartLock and Seal Adhesivethen install the
bolts.
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 using the follow-
ing steps and torque values:
Fig. 9 Checking Cylinder Head Bolts for Stretching
(Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 10 Proper Tool Usage For Surface Preparation
1 - PLASTIC/WOOD SCRAPER
9 - 24 ENGINE - 3.7LDR
CYLINDER HEAD - LEFT (Continued)

²Step 1: Tighten bolts 1-8, 27 N´m (20 ft. lbs.).
²Step 2: Verify that bolts 1-8, all reached 27 N´m
(20 ft. lbs.), by repeating step 1 without loosening the
bolts. Tighten bolts 9 thru 12 to 14 N´m (10 ft. lbs.).
²Step 3: Tighten bolts 1-8, 90 degrees (Fig. 11).
²Step 4: Tighten bolts 1-8, 90 degrees, again.
Tighten bolts 9-12, 26 N´m (19 ft. lbs.)
(7) Position the secondary chain onto the camshaft
drive gear, making sure one marked chain link is on
either side of the V6 mark on the gear then using
Special Tool 8428 Camshaft Wrench, position the
gear onto the camshaft.
CAUTION: Remove excess oil from camshaft
sprocket retaining bolt before reinstalling bolt. Fail-
ure to do so may cause over-torqueing of bolt
resulting in bolt failure.
(8) Install the camshaft drive gear retaining bolt.
(9) Install the left side secondary chain guide(Re-
fer to 9 - ENGINE/VALVE TIMING/TIMING BELT/
CHAIN AND SPROCKETS - INSTALLATION).
(10) Install the cylinder head access plug.
(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 8429.
(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). Tighten damper bolt 175 N´m (130
Ft. Lbs.).
(15) Install the power steering pump.
(16) Install the fan blade assembly and fan shrou-
d(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(17) Install the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(18) Install the master cylinder and booster assem-
bly(Refer to 5 - BRAKES/HYDRAULIC/MECHANI-
CAL/POWER BRAKE BOOSTER - INSTALLATION).
(19) Install the intake manifold(Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
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.
CAMSHAFT(S)
DESCRIPTION
The camshafts consist of powdered metal steel
lobes which are sinter-bonded to a steel tube. Four
bearing journals are machined into the camshaft.
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 lubri-
cates every intake lobe rocker through a drilled pas-
sage 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
8379 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).
Fig. 11 Cylinder head Tightening Sequence
* - INDICATES SEALANT ON THREADS
DRENGINE - 3.7L 9 - 25
CYLINDER HEAD - LEFT (Continued)

(2) Set engine to TDC cylinder #1, camshaft
sprocket V6 marks at the 12 o'clock position.
(3) Mark one link on the secondary timing chain
on both sides of the V6 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 8379 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. 12).(6) Hold the camshaft with Special Tool 8428 Cam-
shaft Wrench, while removing the camshaft sprocket
bolt and sprocket (Fig. 13).
(7) Using Special Tool 8428 Camshaft Wrench,
gently allow the camshaft to rotate 5É clockwise until
the camshaft is in the neutral 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.
Fig. 12 SECURING TIMING CHAIN TENSIONERS
USING TIMING CHAIN WEDGE - Typical
1 - SPECIAL TOOL 8379
2 - CAMSHAFT SPROCKET
3 - CAMSHAFT SPROCKET BOLT
4 - CYLINDER HEAD
Fig. 13 Special Tool 8428
1 - Camshaft hole
2 - Special Tool 8428
9 - 26 ENGINE - 3.7LDR
CAMSHAFT(S) (Continued)

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.
NOTE: Caps should be installed so that the
stamped numbers on the caps are in numerical
order, ( 1 thru 4 ) from the front to the rear of the
engine. All caps should be installed so that the
stamped arrows on the caps point toward the front
of the engine.
(4) Working in 1/2 turn increments, tighten the
bearing cap retaining bolts starting with the middle
cap working outward (Fig. 14).
(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 V6 mark between the two
marked chain links (Two links marked during
removal).
(7) Using Special Tool 8428 Camshaft Wrench,
rotate the camshaft until the camshaft sprocketdowel is aligned with the slot in the camshaft
sprocket. Install the sprocket onto the camshaft.
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 bolt, then install the
camshaft sprocket retaining bolt and hand tighten.
(9) Remove Special Tool 8379 timing chain wedge.
(10) Using Special Tool 6958 spanner wrench with
adapter pins 8346, torque the camshaft sprocket
retaining bolt to 122 N´m (90 ft. lbs.).
(11) Install the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
CYLINDER HEAD COVER(S)
DESCRIPTION
The cylinder head covers are made of single layer
stamped steel, and are not interchangable from side-
to-side (Fig. 15).
Fig. 14 CAMSHAFT BEARING CAPS TIGHTENING
Fig. 15 CYLINDER HEAD COVERS
1 - LEFT SIDE CYLINDER HEAD COVER
2 - RIGHT SIDE CYLINDER HEAD COVER
DRENGINE - 3.7L 9 - 27
CAMSHAFT(S) (Continued)