Battery DODGE RAM 1500 1998 2.G Workshop Manual

(9) Install the left side secondary chain guide
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLA-
TION).
(10) Install the cylinder head access plug (Fig. 20).
(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 8515.
(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).
(15) Install the power steering pump.
(16) Install the fan blade assembly and fan shroud
(Refer to 7 - COOLING/ENGINE/FAN DRIVE VIS-
COUS CLUTCH - INSTALLATION).
(17) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(18) Reinstall the master cylinder and booster
assembly. Refer to section 5 brakes.
(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.INSTALLATION - RIGHT CYLINDER HEAD
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. 21).
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. 22).
(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 ten M10 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.
Fig. 20 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
Fig. 21 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
DRENGINE - 4.7L 9 - 113
CYLINDER HEAD (Continued)

(6) Tighten the bolts in sequence (Fig. 23) using
the following steps and torque values:
²Step 1: Tighten bolts 1±10, 20 N´m (15 ft. lbs.).
²Step 2: Tighten bolts 1±10, 47 N´m (35 ft. lbs.).
Tighten bolts 11±14, 25 N´m (18 ft. lbs.).
²Step 3: Tighten bolts 1±10, 90 degrees. Tighten
bolts 11±14, 30 N´m (22 ft. lbs.).
(7) Position the secondary chain onto the camshaft
drive gear, making sure one marked chain link is on
either side of the V8 mark on the gear and position
the gear onto the camshaft.
(8) Install the camshaft drive gear retaining bolt.
(9) Install the right side secondary chain guide
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION).
(10) Install the right side cylinder head access
plug (Fig. 24).(11) Re-set and install the right side secondary
chain tensioner.
(12) Remove Special Tool 8515.
(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).
(15) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(16) Install the fan shroud.
(17) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(18) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(19) Install oil fill housing onto cylinder head.
(20) Refill the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(21) Raise the vehicle.
(22) Install the exhaust pipe onto the right
exhaust manifold.
(23) Lower the vehicle.
(24) Reconnect battery negitive cable.
(25) Start the engine and check for leaks.
CAMSHAFT(S) - LEFT
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 cam-
shaft tube. Five bearing journals are machined into
Fig. 22 Proper Tool Usage for
1 - PLASTIC/WOOD SCRAPER
Fig. 23 Cylinder Head Tightening Sequence
Fig. 24 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
9 - 114 ENGINE - 4.7LDR
CYLINDER HEAD (Continued)

(10) Using Special Tool 6958 spanner wrench with
adapter pins 8346 (Fig. 38), torque the camshaft
sprocket retaining bolt to 122 N´m (90 ft. lbs.).
(11) Install the camshaft position sensor (Fig. 33).(12) 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 injection
molded thermo-set plastic, and are not interchange-
able from side-to-side. It is imperative that nothing
rest on the cylinder head covers. Prolonged contact
with other items may wear a hole in the cylinder
head cover.
REMOVAL
REMOVAL - RIGHT SIDE
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly, resonator assem-
bly and air inlet hose.
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Remove air conditioning compressor retaining
bolts and move compressor to the left.
(6) Remove heater hoses.
(7) Disconnect injector and ignition coil connectors.
(8) Disconnect and remove positive crankcase ven-
tilation (PCV) hose.
(9) Remove oil fill tube.
(10) Un-clip injector and ignition coil harness and
move away from cylinder head cover.
(11) Remove right rear breather tube and filter
assembly.
(12) Remove cylinder head cover retaining bolts.
(13) Remove cylinder head cover.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
REMOVAL - LEFT SIDE
(1) Disconnect negative cable from battery.
(2) Remove the resonator assemble and air inlet
hose.
(3) Disconnect injector connectors and un-clip the
injector harness.
(4) Route injector harness in front of cylinder head
cover.
(5) Disconnect the left side breather tube and
remove the breather tube.
(6) Remove the cylinder head cover mounting
bolts.
Fig. 37 Camshaft Sprocket Installation
1 - ADJUSTABLE PLIERS
2 - CAMSHAFT DOWEL
Fig. 38 Tightening Right Side Cam Sprocket
Retaining Bolt
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
4 - RIGHT CAMSHAFT SPROCKET
9 - 122 ENGINE - 4.7LDR
CAMSHAFT(S) - RIGHT (Continued)

(7) Remove cylinder head cover and gasket.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSTALLATION
INSTALLATION - RIGHT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2) Install cylinder head cover and hand start all
fasteners. Verify that all double ended studs are in
the correct location shown in (Fig. 39).
(3) Tighten cylinder head cover bolts and double
ended studs to 12 N´m (105 in. lbs).
(4) Install right rear breather tube and filter
assembly.
(5) Connect injector, ignition coil electrical connec-
tors and harness retaining clips.
(6) Install the oil fill tube.
(7) Install PCV hose.
(8) Install heater hoses.
(9) Install air conditioning compressor retaining
bolts.
(10) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Fill Cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).(12) Install air cleaner assembly, resonator assem-
bly and air inlet hose.
(13) Connect battery negative cable.
INSTALLATIONÐLEFT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2) Install cylinder head cover and hand start all
fasteners. Verify that all studs are in the correct loca-
tion shown in (Fig. 40).
(3) Tighten cylinder head cover bolts and double
ended studs to 12 N´m (105 in. lbs.).
(4) Install left side breather and connect breather
tube.
(5) Connect injector electrical connectors and injec-
tor harness retaining clips.
(6) Install the resonator and air inlet hose.
(7) Connect negative cable to battery.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves are made of heat resistant steel and
have chrome plated stems to prevent scuffing. Each
valve is actuated by a roller rocker arm which pivots
on a stationary lash adjuster. All valves use three
bead lock keepers to retain the springs and promote
valve rotation.
Fig. 39 Cylinder Head CoverÐRight
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 N´m (105 in. lbs.)
Fig. 40 Cylinder Head Cover-Left
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 N´m (105 in. lbs.)
DRENGINE - 4.7L 9 - 123
CYLINDER HEAD COVER(S) (Continued)

base circle. Depress part of rocker arm over adjuster.
Normal adjusters should feel very firm. Spongy
adjusters can be bottomed out easily.
b. Remove suspected lash adjusters, and replace.
c. Before installation, make sure adjusters are at
least partially full of oil. This can be verified by little
or no plunger travel when lash adjuster is depressed.
REMOVAL
NOTE: Disconnect the battery negative cable to pre-
vent accidental starter engagement.
(1) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(2) For rocker arm removal on cylinders 3 and 5
Rotate the crankshaft until cylinder #1 is at TDC
exhaust stroke.
(3) For rocker arm removal on cylinders 2 and 8
Rotate the crankshaft until cylinder #1 is at TDC
compression stroke.
(4) For rocker arm removal on cylinders 4 and 6
Rotate the crankshaft until cylinder #3 is at TDC
compression stroke.
(5) For rocker arm removal on cylinders 1 and 7
Rotate the crankshaft until cylinder #2 is at TDC
compression stroke.
(6) Using special tool 8516 Rocker Arm Remover,
press downward on the valve spring, remove rocker
arm (Fig. 45).
INSTALLATION
CAUTION: Make sure the rocker arms are installed
with the concave pocket over the lash adjusters.
Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.
NOTE: Coat the rocker arms with clean engine oil
prior to installation.
(1) For rocker arm installation on cylinders 3 and
5 Rotate the crankshaft until cylinder #1 is at TDC
exhaust stroke.
(2) For rocker arm installation on cylinders 2 and
8 Rotate the crankshaft until cylinder #1 is at TDC
compression stroke.
(3) For rocker arm installation on cylinders 4 and
6 Rotate the crankshaft until cylinder #3 is at TDC
compression stroke.
(4) For rocker arm installation on cylinders 1 and
7 Rotate the crankshaft until cylinder #2 is at TDC
compression stroke.
(5) Using special tool 8516 press downward on the
valve spring, install rocker arm (Fig. 45).
(6) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
VALVE SPRINGS
DESCRIPTION
The valve springs are made from high strength
chrome silicon steel. The springs are common for
intake and exhaust applications. The valve spring
seat is integral with the valve stem seal, which is a
positive type seal to control lubrication.
REMOVAL
(1) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(2) Using Special Tool 8516 Rocker Arm Remover,
remove the rocker arms and the hydraulic lash
adjusters (Fig. 46).
(3) Remove the spark plug for the cylinder the
valve spring and seal are to be removed from.
(4) Apply shop air to the cylinder to hold the
valves in place when the spring is removed
(5) Remove the camshaft (Refer to 9 - ENGINE/
CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: All eight valve springs and seals are
removed in the same manner; this procedure only
covers one valve seal and valve spring.
Fig. 45 Rocker ArmÐRemoval
1 - CAMSHAFT
2 - SPECIAL TOOL 8516
9 - 126 ENGINE - 4.7LDR
ROCKER ARM / ADJUSTER ASSEMBLY (Continued)

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 CHARTÐ4.7L
GRADE SIZE mm
(in.)FOR USE WITH
MARKING JOURNAL SIZE
A0.008 mm
U/S63.488±63.496 mm
(0.0004 in.)
U/S(2.4996±2.4999 in.)
BNOMINAL 63.496±63.504 mm
(2.4999±2.5002 in.)
C0.008 mm
O/S63.504±63.512 mm
(0.0004 in.)
O/S(2.5002±2.5005 in.)
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).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.
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(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
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(9) Remove crankshaft damper bolt.
Fig. 62 Main Bearing Markings on Target Wheel
1 - REARMOST CRANKSHAFT COUNTER WEIGHT
2 - TARGET WHEEL
3 - MAIN BEARING SELECT FIT MARKINGS
Fig. 63 Main Bearing Wear Patterns
1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT
DRENGINE - 4.7L 9 - 135
CRANKSHAFT MAIN BEARINGS (Continued)

(10) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 64).
(11) Using Special Tool 8511, remove crankshaft
front seal (Fig. 65).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
to 7 - COOLING/ENGINE/RADIATOR FAN -
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. 64 Crankshaft Damper Removal
1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026
Fig. 65 Crankshaft Front Seal Removal
1 - SPECIAL TOOL 8511
Fig. 66 Crankshaft Front Seal Installation
1 - TIMING CHAIN COVER
2 - SPECIAL TOOL 8348
3 - SPECIAL TOOL 8512
9 - 136 ENGINE - 4.7LDR
CRANKSHAFT OIL SEAL - FRONT (Continued)

CRANKSHAFT 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)
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 BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL).
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.
(3) Using Special Tool 8506 (Fig. 67), remove the
crankshaft rear oil seal.
Fig. 67 Crankshaft Rear Oil Seal Removal
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8506
DRENGINE - 4.7L 9 - 137

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 ªfractured
capº design. A pressed fit piston pin is used to attach
the piston and connecting rod.
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 isMANDATORY. 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 the 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.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the following components:
²Oil pan and gasket/windage tray (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - REMOVAL).
²Cylinder head covers (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL) and (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - REMOVAL).²Timing chain cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- REMOVAL).
²Cylinder 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-
Fig. 71 DO NOT MEASURE MOLY COATED PISTON
1 - MOLY COATED
2 - MOLY COATED
Fig. 72 BORE GAUGE - TYPICAL
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM (1.5 in)
DRENGINE - 4.7L 9 - 139

(4) Install Special Tool 8507 Connecting Rod
Guides into connecting rod bolt threads (Fig. 74).
(5) The pistons are marked on the piston pin bore
surface with an raised ªFº 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).
(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.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 90É.
(10) Install the following components:
²Cylinder head(s). (Refer to 9 - ENGINE/CYLIN-
DER HEAD - INSTALLATION).
²Timing chain and cover. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION).
²Cylinder head covers (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).
²Oil pan and gasket/windage tray. (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(11) Fill crankcase with proper engine oil to cor-
rect level.
(12) Connect negative cable to battery.
Fig. 74 PISTON AND CONNECTING ROD
INSTALLATION
1 - ªFº TOWARD FRONT OF ENGINE
2 - OIL SLINGER SLOT
3 - RING COMPRESSOR
4 - SPECIAL TOOL 8507
Fig. 75 PISTON AND CONNECTING ROD
ORIENTATION
1 - MAJOR THRUST SIDE OF PISTON
2 - OIL SLINGER SLOT
DRENGINE - 4.7L 9 - 141
PISTON & CONNECTING ROD (Continued)