oil leak DODGE RAM 1500 1998 2.G Owner's Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1998, Model line: RAM 1500, Model: DODGE RAM 1500 1998 2.GPages: 2627
Page 439 of 2627
MICRO 420 BATTERY TESTER
The Micro 420 automotive battery tester is
designed to help the dealership technician diagnose
the cause of a defective battery. Follow the instruc-
tion manual supplied with the tester to properly
diagnose a battery. If the instruction manual is not
available, refer to the standard procedure in this sec-
tion, which includes the directions for using the
Micro 420 battery tester.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
A battery that will not accept a charge is faulty,
and must be replaced. Further testing is not
required. A fully-charged battery must be load tested
to determine its cranking capacity. A battery that is
fully-charged, but does not pass the load test, is
faulty and must be replaced. Always test battery
using the Micro 420 battery tester before attempting
to replace a battery under the manufactures war-
ranty provisions.
NOTE: Completely discharged batteries may take
several hours to accept a charge. Refer to Standard
Procedures for the proper battery charging proce-
dures.
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY
CHARGING
Battery charging can be performed fast or slow, in
terms of time.Slowbattery charging is the best
means of restoring a battery to full potential. Fast
battery charging should only be performed when
absolutely necessary due to time restraints. A battery
is fully-charged when:²All of the battery cells are gassing freely during
battery charging.
²A green color is visible in the sight glass of the
battery built-in test indicator.
²Three hydrometer tests, taken at one-hour inter-
vals, indicate no increase in the temperature-cor-
rected specific gravity of the battery electrolyte.
²Open-circuit voltage of the battery is 12.65 volts
or above.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1É C [30É F] OR
LOWER) BATTERY. THE BATTERY MAY ARC INTER-
NALLY AND EXPLODE. PERSONAL INJURY AND/OR
VEHICLE DAMAGE MAY RESULT.
CAUTION: Always disconnect and isolate the bat-
tery negative cable before charging a battery. Do
not exceed sixteen volts while charging a battery.
Damage to the vehicle electrical system compo-
nents may result.
CAUTION: Battery electrolyte will bubble inside the
battery case during normal battery charging. Elec-
trolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
CAUTION: The battery should not be hot to the
touch. If the battery feels hot to the touch, turn off
the charger and let the battery cool before continu-
ing the charging operation. Damage to the battery
may result.
NOTE: Models equipped with the diesel engine are
equipped with two 12-volt batteries, connected in
parallel (positive-to-positive and negative-to-nega-
tive). In order to ensure proper charging of each
battery, these batteries MUST be disconnected from
each other, as well as from the vehicle electrical
system while being charged.
Some battery chargers are equipped with polarity-
sensing circuitry. This circuitry protects the battery
charger and the battery from being damaged if they
are improperly connected. If the battery state-of-
charge is too low for the polarity-sensing circuitry to
detect, the battery charger will not operate. This
makes it appear that the battery will not accept
charging current. See the instructions provided by
the manufacturer of the battery charger for details
on how to bypass the polarity-sensing circuitry.
8F - 8 BATTERY SYSTEMDR
BATTERY (Continued)
Page 452 of 2627
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Generator (short)
Horizontal Mounting Bolt -
3.7L / 4.7L Engines74 55 -
Generator B+ Output
Cable Terminal Nut12 - 108
BATTERY TEMPERATURE
SENSOR
DESCRIPTION
The Battery Temperature Sensor (BTS) is attached
to the battery tray located under the battery.
OPERATION
The BTS is used to determine the battery temper-
ature and control battery charging rate. This temper-
ature data, along with data from monitored line
voltage, is used by the PCM (ECM Diesel) to vary the
battery charging rate. System voltage will be higher
at colder temperatures and is gradually reduced at
warmer temperatures.
The PCM sends 5 volts to the sensor and is
grounded through the sensor return line. As temper-
ature increases, resistance in the sensor decreases
and the detection voltage at the PCM increases.
The BTS is also used for OBD II diagnostics. Cer-
tain faults and OBD II monitors are either enabled
or disabled, depending upon BTS input (for example,
disable purge and enable Leak Detection Pump
(LDP) and O2 sensor heater tests). Most OBD II
monitors are disabled below 20ÉF.
REMOVAL
The battery temperature sensor is located under
the vehicle battery and is attached (snapped into) a
mounting hole on battery tray (Fig. 1).
(1) Remove battery. Refer to 8, Battery for proce-
dures.
(2) Pry sensor straight up from battery tray
mounting hole to gain access to electrical connector
(Fig. 1).
(3) Disconnect sensor from engine wire harness
electrical connector.
INSTALLATION
The battery temperature sensor is located under
the vehicle battery and is attached (snapped into) a
mounting hole on battery tray.
(1) Pull electrical connector up through mounting
hole in top of battery tray.
(2) Connect sensor.
(3) Snap sensor into battery tray.(4) Install battery. Refer to 8, Battery for proce-
dures.
GENERATOR
DESCRIPTION
The generator is belt-driven by the engine using a
serpentine type drive belt. It is serviced only as a
complete assembly. If the generator fails for any rea-
son, the entire assembly must be replaced.
OPERATION
As the energized rotor begins to rotate within the
generator, the spinning magnetic field induces a cur-
rent into the windings of the stator coil. Once the
generator begins producing sufficient current, it also
provides the current needed to energize the rotor.
Fig. 1 BATTERY TEMPERATURE SENSOR
LOCATION
1 - BATTERY TEMP. SENSOR
2 - BATTERY
3 - SENSOR ELEC. CONNECT.
4 - BATTERY TRAY
DRCHARGING 8F - 21
CHARGING (Continued)
Page 504 of 2627
SPARK PLUG
DESCRIPTION
Resistor type spark plugs are used on all engines.
Sixteen spark plugs (2 per cylinder) are used with
5.7L V-8 engines.
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS
To prevent possible pre-ignition and/or mechanical
engine damage, the correct type/heat range/number
spark plug must be used.
Always use the recommended torque when tighten-
ing spark plugs. Incorrect torque can distort the
spark plug and change plug gap. It can also pull the
plug threads and do possible damage to both the
spark plug and the cylinder head.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. A sin-
gle plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
the Lubrication and Maintenance section.
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective, carbon or oil
fouled.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
Spark plug resistance values range from 6,000 to
20,000 ohms (when checked with at least a 1000 volt
spark plug tester).Do not use an ohmmeter to
check the resistance values of the spark plugs.
Inaccurate readings will result.
NORMAL OPERATING
The few deposits present on the spark plug will
probably be light tan or slightly gray in color. This is
evident with most grades of commercial gasoline
(Fig. 23). There will not be evidence of electrode
burning. Gap growth will not average more than
approximately 0.025 mm (.001 in) per 3200 km (2000
miles) of operation. Spark plugs that have normal
wear can usually be cleaned, have the electrodes
filed, have the gap set and then be installed.Some fuel refiners in several areas of the United
States have introduced a manganese additive (MMT)
for unleaded fuel. During combustion, fuel with MMT
causes the entire tip of the spark plug to be coated
with a rust colored deposit. This rust color can be
misdiagnosed as being caused by coolant in the com-
bustion chamber. Spark plug performance may be
affected by MMT deposits.
COLD FOULING/CARBON FOULING
Cold fouling is sometimes referred to as carbon
fouling. The deposits that cause cold fouling are basi-
cally carbon (Fig. 23). A dry, black deposit on one or
two plugs in a set may be caused by sticking valves
or defective spark plug cables. Cold (carbon) fouling
of the entire set of spark plugs may be caused by a
clogged air cleaner element or repeated short operat-
ing times (short trips).
WET FOULING OR GAS FOULING
A spark plug coated with excessive wet fuel or oil
is wet fouled. In older engines, worn piston rings,
leaking valve guide seals or excessive cylinder wear
can cause wet fouling. In new or recently overhauled
engines, wet fouling may occur before break-in (nor-
mal oil control) is achieved. This condition can usu-
ally be resolved by cleaning and reinstalling the
fouled plugs.
OIL OR ASH ENCRUSTED
If one or more spark plugs are oil or oil ash
encrusted (Fig. 24), evaluate engine condition for the
cause of oil entry into that particular combustion
chamber.
Fig. 23 NORMAL OPERATION AND COLD (CARBON)
FOULING
1 - NORMAL
2 - DRY BLACK DEPOSITS
3 - COLD (CARBON) FOULING
DRIGNITION CONTROL 8I - 17
Page 832 of 2627
8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch Relay............ 8W-30-9, 58
A/C Pressure Transducer......... 8W-30-23, 28, 29, 45
Accelerator Pedal Position Sensor . . . 8W-30-29, 47, 64, 65
Adjustable Pedal Motor................. 8W-30-61
Adjustable Pedal Relay.................. 8W-30-61
Adjustable Pedal Switch................. 8W-30-61
Ambient Temperature Sensor............. 8W-30-30
Auto Shut Down Relay................... 8W-30-4
Battery............................ 8W-30-52
Battery Temperature Sensor............ 8W-30-12, 56
Brake Lamp Switch............. 8W-30-8, 36, 57, 63
Camshaft Position Sensor........ 8W-30-10, 29, 45, 46
Capacitor........................... 8W-30-13
Clockspring..................... 8W-30-8, 36, 59
Coil On Plug No. 1.................. 8W-30-14, 39
Coil On Plug No. 2.................. 8W-30-15, 37
Coil On Plug No. 3.................. 8W-30-14, 39
Coil On Plug No. 4.................. 8W-30-15, 37
Coil On Plug No. 5.................. 8W-30-16, 39
Coil On Plug No. 6.................. 8W-30-13, 37
Coil On Plug No. 7.................. 8W-30-16, 39
Coil On Plug No. 8.................. 8W-30-13, 37
Condenser Fan Relay.................... 8W-30-9
Controller Antilock Brake............ 8W-30-6, 11, 57
Crankshaft Position Sensor............ 8W-30-10, 46
Data Link Connector............... 8W-30-9, 22, 55
Data Link Connector-Engine.............. 8W-30-51
EGR Solenoid................... 8W-30-28, 29, 32
Electronic Throttle Control Module.......... 8W-30-35
Engine Control Module....... 8W-30-42, 43, 44, 45, 46,
47, 48, 49, 50, 51, 52, 53, 54,
55, 56, 57, 58, 59, 60, 62, 63, 64, 65
Engine Coolant Temperature Sensor.... 8W-30-23, 41, 47
Engine Oil Pressure Switch.......... 8W-30-2, 53, 56
EVAP/Purge Solenoid................... 8W-30-12
Front Control Module................... 8W-30-61
Fuel Control Actuator................... 8W-30-50
Fuel Heater......................... 8W-30-60
Fuel Heater Relay..................... 8W-30-60
Fuel Injector No. 1.................. 8W-30-14, 40
Fuel Injector No. 2.................. 8W-30-15, 38
Fuel Injector No. 3.................. 8W-30-14, 40
Fuel Injector No. 4.................. 8W-30-15, 38
Fuel Injector No. 5.................. 8W-30-14, 40
Fuel Injector No. 6.................. 8W-30-15, 38
Fuel Injector No. 7.................. 8W-30-16, 40
Fuel Injector No. 8.................. 8W-30-13, 38
Fuel Injector Pack No. 1................. 8W-30-42
Fuel Injector Pack No. 2............ 8W-30-42, 43, 44
Fuel Injector Pack No. 3................. 8W-30-44
Fuel Pump Module................... 8W-30-3, 58
Fuel Pump Motor...................... 8W-30-48
Fuel Pump Relay....................... 8W-30-3
Fuse 2.............................. 8W-30-4
Fuse 5........................... 8W-30-25, 62
Fuse 12............................ 8W-30-60
Fuse 17............................. 8W-30-3
Fuse 19............................ 8W-30-52
Fuse 23............................. 8W-30-2Component Page
Fuse 36.......................... 8W-30-54, 61
Fuse 40............................ 8W-30-61
Fuse 49............................. 8W-30-4
Fuse 50..................... 8W-30-2, 55, 58, 62
Fusible Link......................... 8W-30-52
G104........................ 8W-30-3, 8, 25, 60
G105............................ 8W-30-56, 58
G107........... 8W-30-2, 7, 15, 18, 19, 20, 21, 30, 32
G114 .............................. 8W-30-53
G120............................ 8W-30-51, 60
G201............................... 8W-30-6
G202.............................. 8W-30-61
Generator......................... 8W-30-7, 51
Idle Air Control Motor................... 8W-30-9
Ignition Switch..................... 8W-30-6, 22
Inlet Air Temperature Sensor............. 8W-30-49
Input Speed Sensor.................... 8W-30-24
Instrument Cluster.................... 8W-30-30
Intake Air Heater Relay No. 1............. 8W-30-56
Intake Air Heater Relay No. 2............. 8W-30-56
Intake Air Temperature Sensor.......... 8W-30-23, 41
Intake Air Temperature/Manifold Absolute
Pressure Sensor..................... 8W-30-50
Integrated Power Module.... 8W-30-2, 3, 4, 9, 25, 52, 54,
55, 58, 60, 61, 62, 64
Knock Sensor........................ 8W-30-31
Knock Sensor-Left..................... 8W-30-33
Knock Sensor-Right.................... 8W-30-33
Lift Pump Motor...................... 8W-30-51
Line Pressure Sensor................... 8W-30-17
Manifold Absolute Pressure Sensor..... 8W-30-23, 29, 41
Natural Vacuum Leak Detection Assembly..... 8W-30-7
Output Speed Sensor................. 8W-30-24, 62
Oxygen Sensor 1/1 Upstream........... 8W-30-20, 21
Oxygen Sensor 1/2 Downstream......... 8W-30-18, 19
Oxygen Sensor 2/1 Upstream........... 8W-30-20, 21
Oxygen Sensor 2/2 Downstream......... 8W-30-18, 19
Oxygen Sensor Downstream Relay........... 8W-30-4
Power Steering Pressure Switch............ 8W-30-7
Powertrain Control Module....... 8W-30-2, 3, 4, 5, 6, 7,
8, 9, 10, 11, 12, 13, 14, 15, 16,
17, 18, 19, 20, 21, 22, 23, 24,
25, 26, 27, 28, 29, 30, 31, 32,
33, 35, 36, 37, 38, 39, 40, 41
PTCNo.1 ....................... 8W-30-3, 9, 58
Pto Switch........................... 8W-30-6
Speed Control Servo.................. 8W-30-8, 63
Speed Control Switch-Left............. 8W-30-36, 59
Speed Control Switch-Right............ 8W-30-36, 59
Starter Motor Relay.................. 8W-30-2, 64
Throttle Position Sensor................. 8W-30-17
Tow/Haul Overdrive Switch............. 8W-30-6, 64
Transmission Control Relay............ 8W-30-25, 62
Transmission Range Sensor............... 8W-30-64
Transmission Solenoid Assembly......... 8W-30-54, 62
Transmission Solenoid/TRS Assembly . 8W-30-5, 25, 26, 27
Vacuum Pump........................ 8W-30-58
Vistronic Fan Drive.................... 8W-30-54
Water In Fuel Sensor................ 8W-30-47, 48
DR8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1
Page 1225 of 2627
REMOVAL.............................38
INSTALLATION.........................38
ENGINE BLOCK
DESCRIPTION.........................38
STANDARD PROCEDURE - CYLINDER BORE
HONING............................38
CLEANING............................39
INSPECTION..........................39
CRANKSHAFT
DESCRIPTION.........................40
REMOVAL.............................40
INSPECTION..........................41
INSTALLATION.........................42
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE
MAIN BEARING FITTING................44
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................46
INSTALLATION.........................46
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................47
INSTALLATION.........................47
FLEX PLATE
REMOVAL.............................48
INSTALLATION.........................48
PISTON & CONNECTING ROD
DESCRIPTION.........................48
STANDARD PROCEDURE
CONNECTING ROD BEARING FITTING....49
STANDARD PROCEDURE - PISTON FITTING..51
REMOVAL.............................51
CLEANING............................52
INSPECTION..........................52
INSTALLATION.........................52
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING.............................53
VIBRATION DAMPER
REMOVAL.............................55
INSTALLATION.........................56
STRUCTURAL COVER
DESCRIPTION.........................57
OPERATION...........................57
REMOVAL.............................57
INSTALLATION.........................57
FRONT MOUNT
REMOVAL.............................58
INSTALLATION.........................59
REAR MOUNT
REMOVAL.............................61
INSTALLATION.........................61
LUBRICATION
DESCRIPTION.........................61
OPERATION...........................61
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK...............................64DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE................65
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS.........................65
OIL PAN
DESCRIPTION.........................66
REMOVAL.............................66
CLEANING............................66
INSPECTION..........................66
INSTALLATION.........................66
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION.........................67
OPERATION...........................67
REMOVAL.............................67
INSTALLATION.........................67
OIL PUMP
REMOVAL.............................67
DISASSEMBLY.........................68
INSPECTION..........................68
ASSEMBLY............................69
INSTALLATION.........................69
OIL FILTER
REMOVAL.............................70
INSTALLATION.........................70
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE............................71
INTAKE MANIFOLD
DESCRIPTION.........................72
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS.....................72
REMOVAL.............................73
INSTALLATION.........................73
EXHAUST MANIFOLD
DESCRIPTION.........................74
REMOVAL.............................74
INSTALLATION.........................74
VALVE TIMING
DESCRIPTION.........................76
OPERATION...........................76
STANDARD PROCEDURE
MEASURING TIMING CHAIN WEAR.......77
SERVICE PROCEDURE - TIMING
VERIFICATION........................77
BALANCE SHAFT
REMOVAL.............................80
INSTALLATION.........................80
IDLER SHAFT
REMOVAL.............................81
INSTALLATION.........................81
TIMING BELT / CHAIN COVER(S)
REMOVAL.............................81
INSTALLATION.........................81
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL.............................83
INSPECTION..........................84
INSTALLATION.........................85
9 - 2 ENGINE - 3.7LDR
Page 1227 of 2627
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either per-
formance (e.g., engine idles rough and stalls) or
mechanical (e.g., a strange noise).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING) - PERFORMANCE and (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)ÐMECHANICAL for
possible causes and corrections of malfunctions.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
DIAGNOSIS AND TESTING) and (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION - DIAGNOSIS
AND TESTING) for the fuel system diagnosis.Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following diagnosis:
²Cylinder Compression Pressure Test (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING).
²Cylinder Combustion Pressure Leakage Test
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING).
²Engine Cylinder Head Gasket Failure Diagnosis
(Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNO-
SIS AND TESTING).
²Intake Manifold Leakage Diagnosis (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING).
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary.
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to the terminals.
3. Faulty starter. 3. (Refer to 8 - ELECTRICAL/
STARTING - DIAGNOSIS AND
TESTING).
4. Faulty coil or control unit. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
5. Incorrect spark plug gap. 5. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING).
6. Incorrect right bank cam timing. 6. Refer to engine timing in this
section.
7. Dirt or water in fuel system. 7. Clean system and replace fuel
filter.
8.Faulty fuel pump, relay or wiring. 8.Repair or replace as necessary.
9. Faulty cam or crank sensor 9. Refer to Ignition system.
ENGINE STALLS OR ROUGH IDLE 1. Vacuum leak. 1. Inspect intake manifold and
vacuum hoses, repair or replace as
necessary.
2. Faulty crank position sensor 2. Replace crank position sensor.
3. Faulty coil. 3. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
9 - 4 ENGINE - 3.7LDR
ENGINE - 3.7L (Continued)
Page 1230 of 2627
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION
CONDITION POSSIBLE CAUSES CORRECTION
OIL LEAKS 1. Gaskets and O-Rings. 1.
(a) Misaligned or damaged. (a) Replace as necessary.
(b) Loose fasteners, broken or
porous metal parts.(b) Tighten fasteners, Repair or
replace metal parts.
2. Crankshaft rear seal 2. Replace as necessary (Refer to 9
- ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - REAR -
REMOVAL).
3. Crankshaft seal flange.
Scratched, nicked or grooved.3. Polish or replace crankshaft.
4. Oil pan flange cracked. 4. Replace oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN -
REMOVAL).
5. Timing chain cover seal,
damaged or misaligned.5. Replace seal (Refer to 9 -
ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - FRONT
- REMOVAL).
6. Scratched or damaged vibration
damper hub.6. Polish or replace damper.
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.
2. Faulty oil pressure sending unit. 2. Replace sending unit (Refer to 9
- ENGINE/LUBRICATION/OIL
PRESSURE SENSOR/SWITCH -
REMOVAL).
3. Low oil pressure. 3. Check oil pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER
- REMOVAL).
5. Worn oil pump. 5. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
6. Thin or diluted oil. 6. Change oil and filter.
7. Excessive bearing clearance. 7. Replace as necessary.
8. Oil pump relief valve stuck. 8. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
9. Oil pick up tube loose, damaged
or clogged.9. Replace as necessary.
DRENGINE - 3.7L 9 - 7
ENGINE - 3.7L (Continued)
Page 1231 of 2627
CONDITION POSSIBLE CAUSES CORRECTION
OIL PUMPING AT RINGS; SPARK
PLUGS FOULING1. Worn or damaged rings. 1. Hone cylinder bores and replace
rings.
2. Carbon in oil ring slots. 2. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
3. Incorrect ring size installed. 3. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
4. Worn valve guides. 4. Ream guides and replace valves
(Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE).
5. Leaking valve guide seals. 5. Replace valve guide seals.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs.
(3) Disable the fuel system (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DESCRIPTION).
(4) Remove the ASD relay (Refer to 8 - ELECTRI-
CAL/IGNITION CONTROL/AUTO SHUT DOWN
RELAY - REMOVAL).
(5) Insert a compression pressure gauge and rotate
the engine with the engine starter motor for three
revolutions.
(6) Record the compression pressure on the 3rd
revolution. Continue the test for the remaining cylin-
ders.
(7) (Refer to 9 - ENGINE - SPECIFICATIONS) for
the correct engine compression pressures.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
(1) Check the coolant level and fill as required. DO
NOT install the radiator cap.
(2) Start and operate the engine until it attains
normal operating temperature, then turn the engine
OFF.
(3) Remove the spark plugs.
(4) Remove the oil filler cap.
(5) Remove the air cleaner hose.
(6) Calibrate the tester according to the manufac-
turer's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.
(7) Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
Set piston of cylinder to be tested at TDC compres-
sion,While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
Refer to CYLINDER COMBUSTION PRESSURE
LEAKAGE DIAGNOSIS CHART.
9 - 8 ENGINE - 3.7LDR
ENGINE - 3.7L (Continued)
Page 1232 of 2627
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODYIntake valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
TAILPIPEExhaust valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
RADIATORHead gasket leaking or cracked
cylinder head or blockRemove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERSHead gasket leaking or crack in
cylinder head or block between
adjacent cylindersRemove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLYStuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wallInspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and MopartGasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtGASKET SEALANT
MopartGasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
DRENGINE - 3.7L 9 - 9
ENGINE - 3.7L (Continued)
Page 1234 of 2627
(12) Disconnect heater hoses from heater core and
remove hose assembly.
(13) Disconnect throttle and speed control cables.
(14) Remove upper radiator hose from engine.
(15) Remove lower radiator hose from engine.
(16) Remove radiator/cooling module assembly.
(17) Disconnect the engine to body ground straps
at the left side of cowl.
(18) Disconnect the engine wiring harness at the
following points:
²Intake air temperature (IAT) sensor
²Fuel Injectors
²Throttle Position (TPS) Switch
²Idle Air Control (IAC) Motor
²Engine Oil Pressure Switch
²Engine Coolant Temperature (ECT) Sensor
²Manifold Absolute Pressure MAP) Sensor
²Camshaft Position (CMP) Sensor
²Coil Over Plugs
²Crankshaft Position Sensor
(19) Remove coil over plugs.
(20) Release fuel rail pressure.
(21) Remove fuel rail and secure away from
engine.
NOTE: It is not necessary to release the quick con-
nect fitting from the fuel supply line for engine
removal.
(22) Remove the PCV hose.
(23) Remove the breather hoses.
(24) Remove the vacuum hose for the power brake
booster.
(25) Disconnect knock sensors.
(26) Remove engine oil dipstick tube.
(27) Remove intake manifold.
(28) Install engine lifting fixture,special tool#8247,
using original fasteners from the removed intake
manifold, and fuel rail. Torque to factory specifica-
tions.
NOTE: Recheck bolt torque for engine lift plate
before removing engine.
(29) Secure the left and right engine wiring har-
nesses away from engine.
(30) Raise vehicle.
(31) Disconnect oxygen sensor wiring.
(32) Disconnect crankshaft postion sensor.
(33) Disconnect the engine block heater power
cable, if equipped.
(34) Disconnect the front propshaft at the front
differential and secure out of way.
NOTE: It is necessary to disconnect the front prop-
shaft for access to the starter and left side exhaust
flange.(35) Remove the starter.
(36) Remove the ground straps from the left and
right side of the block.
(37) Disconnect the right and left exhaust pipes at
the manifolds and from the crossover, and remove
from the vehicle.
NOTE: The exhaust clamps at the manifolds cannot
be reused. New clamps must be used or leaks may
occur.
(38) Remove the structural cover.
(39) Remove torque convertor bolts, and mark
location for reassembly.
(40) Remove transmission bellhousing to engine
bolts.
(41) Remove left and right engine mount thru
bolts.
(42) Lower the vehicle.
(43) Support the transmission with a suitable jack.
(44) Connect a suitable engine hoist to the engine
lift plate.
(45) Remove engine from vehicle.
INSTALLATION
(1) Position the engine in the vehicle.
(2) Install both left and right side engine mounts
onto engine.
(3) Raise the vehicle.
(4) Install the transmission bellhousing to engine
mounting bolts. Tighten the bolts to 41 N´m (30ft.
lbs.).
(5) Tighten the engine mount thru bolts.
(6) Install the torque convertor bolts.
(7) Connect the ground straps on the left and right
side of the engine.
(8) Install the starter.
(9) Connect the crankshaft position sensor.
(10) Install the engine block heater power cable, if
equipped.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(11) Install the structural cover.
NOTE: New clamps must be used on exhaust man-
ifold flanges. Failure to use new clamps may result
in exhaust leaks.
(12) Install the left and right exhaust pipes.
(13) Connect the left and right oxygen sensors.
(14) Lower vehicle.
(15) Remove the engine lift plate.
(16) Connect the knock sensors.
DRENGINE - 3.7L 9 - 11
ENGINE - 3.7L (Continued)