Removal DODGE RAM 1500 1998 2.G Workshop Manual

DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE
(1) Remove oil pressure sending unit (Fig. 72)and
install gauge assembly C-3292.
(2) Run engine until thermostat opens.
(3) Oil Pressure:
²Curb Idle - 25 kPa (4 psi) minimum
²3000 rpm - 170 - 758 kPa (25 - 110 psi)
(4) If oil pressure is 0 at idle, shut off engine.
Check for a clogged oil pick-up screen or a pressure
relief valve stuck open.
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. Thefollowing 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).
Fig. 72 OIL PRESSURE SENDING UNIT -TYPICAL
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
DRENGINE - 3.7L 9 - 65
LUBRICATION (Continued)

OIL PAN
DESCRIPTION
The engine oil pan is made of laminated steel and
has a single plane sealing surface. The sandwich
style oil pan gasket has an integrated windage tray
and steel carrier (Fig. 73). The sealing area of the
gasket is molded with rubber and is designed to be
reused as long as the gasket is not cut, torn or
ripped.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Install engine support fixture special tool #
8534.Do not raise engine at this time.
(3) Loosen both left and right side engine mount
through bolts. Do not remove bolts.
(4) Remove the structural dust cover, if equipped.
(5) Drain engine oil.
(6) Remove the front crossmember(Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT CROSS-
MEMBER - REMOVAL).
CAUTION: Only raise the engine enough to provide
clearance for oil pan removal. Check for proper
clearance at fan shroud to fan and cowl to intake
manifold.
(7) Raise engine using special tool 8534 to provide
clearance to remove oil pan.
NOTE: Do not pry on oil pan or oil pan gasket. Gas-
ket is integral to engine windage tray and does not
come out with oil pan.
(8) Remove the oil pan mounting bolts and oil pan.
(9) Unbolt oil pump pickup tube and remove tube.
(10) Inspect the integral windage tray (Fig. 73)
and gasket and replace as needed.
CLEANING
(1) Clean oil pan in solvent and wipe dry with a
clean cloth.
(2) Clean the oil pan gasket surface.DO NOTuse
a grinder wheel or other abrasive tool to clean seal-
ing surface.
(3) Clean oil screen and tube thoroughly in clean
solvent.
INSPECTION
(1) Inspect oil drain plug and plug hole for
stripped or damaged threads. Repair as necessary.
(2) Inspect the oil pan mounting flange for bends
or distortion. Straighten flange, if necessary.
INSTALLATION
(1) Clean the oil pan gasket mating surface of the
bedplate and oil pan.
(2) Inspect integrated oil pan gasket, and replace
as necessary.
(3) Position the integrated oil pan gasket/windage
tray assembly.
(4) Install the oil pickup tube
(5) Install the mounting bolt and nuts. Tighten
nuts to 28 N´m (20 ft. lbs.).
(6) If removed, install stud at position No. 9. (Fig.
74).
(7) Position the oil pan and install the mounting
bolts and nut. Tighten the mounting bolts and nut to
15 N´m (11 ft. lbs.) in the sequence shown (Fig. 74).
(8) Lower the engine into mounts using special
tool 8534.
(9) Install both the left and right side engine
mount through bolts. Tighten the nuts to 68 N´m (50
ft. lbs.).
(10) Remove special tool 8534.
(11) Install structural dust cover, if equipped.
Fig. 73 Oil Pan And Gasket
1 - OIL PAN
2 - WINDAGE TRAY AND INTEGRATED OIL PAN GASKET
9 - 66 ENGINE - 3.7LDR

(12) Install the front crossmember(Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT CROSS-
MEMBER - INSTALLATION).
(13) Fill engine oil.
(14) Reconnect the negative battery cable.
(15) Start engine and check for leaks.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 3 wire, solid-state engine oil pressure sensor
(sending unit) is located in an engine oil pressure
gallery.
OPERATION
The oil pressure sensor uses three circuits. They
are:
²A 5 volt power supply from the Powertrain Con-
trol Module (PCM)
²A sensor ground through the PCM's sensor
return
²A signal to the PCM relating to engine oil pres-
sure
The oil pressure sensor has a 3 wire electrical
function very much like the Manifold Absolute Pres-
sure (MAP) sensor. Meaning different pressures
relate to different output voltages.
A 5 volt supply is sent to the sensor from the PCM
to power up the sensor. The sensor returns a voltage
signal back to the PCM relating to engine oil pres-
sure. This signal is then transferred (bussed) to theinstrument panel on either a CCD or PCI bus circuit
(depending on vehicle line) to operate the oil pressure
gauge and the check gauges lamp. Ground for the
sensor is provided by the PCM through a low-noise
sensor return.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise vehicle on hoist.
(3) Remove front splash shield.
(4) Disconnect oil pressure sender wire (Fig. 75).
(5) Remove the pressure sender (Fig. 75).
INSTALLATION
(1) Install oil pressure sender.
(2) Connect oil pressure sender wire.
(3) Install front splash shield.
(4) Lower vehicle.
(5) Connect the negative battery cable.
OIL PUMP
REMOVAL
(1) Remove the oil pan and pick-up tube (Refer to
9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(2) Remove the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
Fig. 74 Oil Pan Mounting Bolt Sequence
Fig. 75 OIL PRESSURE SENDING UNIT
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
DRENGINE - 3.7L 9 - 67
OIL PAN (Continued)

(3) Remove the timing chains and tensioners
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL).
(4) Remove the four bolts, primary timing chain
tensioner and the oil pump.
DISASSEMBLY
(1) Remove oil pump cover screws and lift off cover
plate.
(2) Remove pump inner and outer rotors.
NOTE: Once the oil pressure relief valve, cup plug,
and pin are removed, the pump assembly must be
replaced.
(3) If it is necessary to remove the pressure relief
valve, drive the roll pin from pump housing and
remove cup plug, spring and valve.
INSPECTION
CAUTION: Oil pump pressure relief valve and spring
should not be removed from the oil pump. If these com-
ponents are disassembled and or removed from the
pump the entire oil pump assembly must be replaced.
(1) Clean all parts thoroughly. Mating surface of
the oil pump housing should be smooth. If the pump
cover is scratched or grooved the oil pump assembly
should be replaced.
(2) Lay a straight edge across the pump cover sur-
face (Fig. 76). If a 0.025 mm (0.001 in.) feeler gauge
can be inserted between the cover and the straight
edge the oil pump assembly should be replaced.(3) Measure the thickness of the outer rotor (Fig.
77). If the outer rotor thickness measures at 12.005
mm (0.472 in.) or less the oil pump assembly must be
replaced.
(4) Measure the diameter of the outer rotor. If the
outer rotor diameter measures at 85.925 mm (3.382
in.) or less the oil pump assembly must be replaced.
(5) Measure the thickness of the inner rotor (Fig.
78). If the inner rotor thickness measures at 12.005
mm (0.472 in.) or less then the oil pump assembly
must be replaced.
Fig. 76 Checking Oil Pump Cover Flatness
1 - STRAIGHT EDGE
2 - FEELER GAUGE
3 - OIL PUMP COVER
Fig. 77 Measuring Outer Rotor Thickness
Fig. 78 Measuring Inner Rotor Thickness
9 - 68 ENGINE - 3.7LDR
OIL PUMP (Continued)

(5) Install the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(6) Install the pick-up tube and oil pan (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
OIL FILTER
REMOVAL
All engines are equipped with a high quality full-
flow, disposable type oil filter. DaimlerChrysler Cor-
poration recommends a Mopartor equivalent oil
filter be used.
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
(3) Rotate the oil filter counterclockwise (Fig. 83)
to remove it from the cylinder block oil filter boss.
(4) When filter separates from cylinder block oil
filter boss, tip gasket end upward to minimize oil
spill. Remove filter from vehicle.
NOTE: Make sure filter gasket was removed with fil-
ter.
(5) With a wiping cloth, clean the gasket sealing
surface of oil and grime.
INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, (Fig. 84) hand
tighten filter one full turn, do not over tighten.
(3) Add oil, verify crankcase oil level and start
engine. Inspect for oil leaks.
Fig. 82 Oil Pump And Primary Timing Chain
Tensioner Tightening SequenceFig. 83 OIL FILTER
1 - ENGINE OIL FILTER
Fig. 84 Oil Filter Sealing Surface-Typical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
9 - 70 ENGINE - 3.7LDR
OIL PUMP (Continued)

(1) Start the engine.
(2) Spray a small stream of water (spray bottle) at
the suspected leak area.
(3) If engine RPM'S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove resonator assembly and air inlet hose.
(3) Disconnect throttle and speed control cables.
(4) Disconnect electrical connectors for the follow-
ing components: Refer to FUEL SYSTEM for compo-
nent locations.
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
(5) Disconnect vapor purge hose, brake booster
hose, speed control servo hose, positive crankcase
ventilation (PCV) hose.
(6) Disconnect generator electrical connections.
(7) Disconnect air conditioning compressor electri-
cal connections.
(8) Disconnect left and right radio suppressor
straps.
(9) Disconnect and remove ignition coil towers.
(10) Remove top oil dipstick tube retaining bolt
and ground strap.
(11) Bleed fuel system (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY - STANDARD PROCE-
DURE).
(12) Remove fuel rail.
(13) Remove throttle body assembly and mounting
bracket.
(14) Drain cooling system below coolant tempera-
ture level (Refer to 7 - COOLING - STANDARD
PROCEDURE).
(15) Remove the heater hoses from the engine
front cover and the heater core.
(16) Unclip and remove heater hoses and tubes
from intake manifold.
(17) Remove coolant temperature sensor (Refer to
7 - COOLING/ENGINE/ENGINE COOLANT TEMP
SENSOR - REMOVAL).
(18) Remove intake manifold retaining fasteners in
reverse order of tightening sequence.
(19) Remove intake manifold.
INSTALLATION
(1) Install intake manifold gaskets.
(2) Install intake manifold.
(3) Install intake manifold retaining bolts and
tighten in sequence shown in to 12 N´m (105 in. lbs.)
(Fig. 89).(4) Install left and right radio suppressor straps.
(5) Install throttle body assembly.
(6) Connect throttle cable and speed control cable
to throttle body.
(7) Install fuel rail.
(8) Install ignition coil towers.
(9) Position and install heater hoses and tubes
onto intake manifold.
(10) Install the heater hoses to the heater core and
engine front cover.
(11) Connect electrical connectors for the following
components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
²Ignition coil towers
²Fuel injectors
(12) Install top oil dipstick tube retaining bolt and
ground strap.
(13) Connect generator electrical connections.
(14) Connect Vapor purge hose, Brake booster
hose, Speed control servo hose, Positive crankcase
ventilation (PCV) hose.
(15) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(16) Install resonator assembly and air inlet hose.
(17) Connect negative cable to battery.
Fig. 89 Intake Manifold Tightening Sequence
DRENGINE - 3.7L 9 - 73
INTAKE MANIFOLD (Continued)

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

block. A large washer on the idler shaft bolt and the
rear flange of the idler shaft are used to control
sprocket thrust movement. Pressurized oil is routed
through the center of the idler shaft to provide lubri-
cation for the two bushings used in the idler sprocket
assembly.
There are two secondary drive chains, both are
roller type, one to drive the camshaft in each SOHC
cylinder head. There are no shaft speed changes in
the secondary chain drive system. Each secondary
chain drives a 26 tooth cam sprocket directly from
the 26 tooth sprocket on the idler sprocket assembly.
A fixed chain guide and a hydraulic oil damped ten-
sioner are used to maintain tension in each second-
ary chain system. The hydraulic tensioners for the
secondary chain systems are fed pressurized oil from
oil reservoir pockets in the block. Each tensioner
incorporates a controlled leak path through a device
known as a vent disc located in the nose of the piston
to manage chain loads. Each tensioner also has a
mechanical ratchet system that limits chain slack if
the tensioner piston bleeds down after engine shut
down. The tensioner arms and guides also utilize
nylon wear faces for low friction and long wear. The
secondary timing chains receive lubrication from a
small orifice in the tensioners. This orifice is pro-
tected from clogging by a fine mesh screen which is
located on the back of the hydraulic tensioners.
STANDARD PROCEDURE
MEASURING TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed.
(1) Remove the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(2) To determine if the secondary timing chains
are worn, rotate the engine clockwise until maximum
tensioner piston extension is obtained. Measure the
distance between the secondary timing chain ten-
sioner housing and the step ledge on the piston. The
measurement at point (A) must be less than 15mm
(.5906 inches) (Fig. 95).
(3) If the measurement exceeds the specification
the secondary timing chains are worn and require
replacement (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT/CHAIN AND SPROCKETS -
REMOVAL).
SERVICE PROCEDURE - TIMING VERIFICATION
CAUTION: The 3.7L is a non free-wheeling design
engine. Therefore, correct engine timing is critical.
NOTE: Components referred to as left hand or right
hand are as viewed from the drivers position inside
the vehicle.
NOTE: The blue link plates on the chains and the
dots on the camshaft drive sprockets may not line
up during the timing verification procedure. The
blue link plates are lined up with the sprocket dots
only when re-timing the complete timing drive.
Once the timing drive is rotated blue link-to-dot
alignment is no longer valid.
Engine base timing can be verified by the following
procedure:
(1) Remove the cylinder head covers. Refer to the
procedure in this section.
Fig. 95 Measuring Secondary Timing Chains For
Wear
1 - SECONDARY TENSIONER ARM
2 - SECONDARY CHAIN TENSIONER PISTON
DRENGINE - 3.7L 9 - 77
VALVE TIMING (Continued)

(6) Position the camshaft drive gear onto the cam-
shaft, remove oil from bolt then install the retaining
bolt. Using Special Tools, Spanner Wrench 6958 with
Adapter Pins 8346 and a suitable torque wrench,
Tighten retaining bolt to 122 N´m (90 ft. Lbs.).
(7) Remove Special Tool 8379.Fig. 98 SECURING TIMING CHAIN TENSIONER
USING TIMING CHAIN WEDGE
1 - CYLINDER HEAD
2 -SPECIAL TOOL 8379
3 - TIMING CHAIN
Fig. 99 CAMSHAFT DRIVE GEAR REMOVAL/
INSTALLATION
1 - SPECIAL TOOL 8379 TIMING CHAIN WEDGE
2 - CAMSHAFT DRIVE GEAR
3 - RETAINING BOLT
4 - CYLINDER HEAD
Fig. 100 CAMSHAFT SPROCKET V6 MARKS (#1 TDC, Exhaust stroke)
1 - LEFT CYLINDER HEAD2 - RIGHT CYLINDER HEAD
DRENGINE - 3.7L 9 - 79
VALVE TIMING (Continued)

(8) Rotate the crankshaft two full revolutions, then
verify that the camshaft drive gear V6 marks are in
fact aligned.
(9) Install the cylinder head covers. Refer to Cylin-
der Head Cover in this section.
BALANCE SHAFT
REMOVAL
(1) Remove the primary and secondary timing
chains. Refer to TIMING CHAIN and SPROCKET.
NOTE: The balance shaft and gear are serviced as
an assembly. Do not attempt to remove the gear
from the balance shaft.Remove the retaining bolt
from the counterbalance shaft thrust plate (Fig.
101).
(2) Using Special Tool 8641 Counterbalance shaft
remover/installer tool, remove the counterbalance
shaft from the engine (Fig. 102).
INSTALLATION
NOTE: The balance shaft and gear are serviced as
an assembly. Do not attempt to remove the gear
from the balance shaft.
(1) Coat counterbalance shaft bearing journals
with clean engine oil.
NOTE: The balance shaft is heavy, and care should
be used when installing shaft, so bearings are not
damaged.
(2) Using Special Tool 8641 Counterbalance shaft
remover/installer tool, carefully install counterbal-
ance shaft into engine.
(3) Install Counterbalance shaft thrust plate
retaining bolt finger tight.Do not tighten bolt at this
time.
(4) Position the right side of the thrust plate with
the right chain guide bolt, install bolt finger tight.
(5) Torque the thrust plate retaining bolt to 28
N´m (250 in. lbs.).
(6) Remove the chain guide bolt so that guide can
be installed.
Fig. 101 Counterbalance Shaft Retaining Plate
1 - IDLER SHAFT
2 - COUNTERBALANCE SHAFT THRUST PLATE
3 - COUNTERBALANCE SHAFT DRIVE GEAR
4 - RETAINING BOLT
Fig. 102 Counterbalance Shaft Removal/Installation
Tool
1 - COUNTERBALANCE SHAFT REMOVAL AND INSTALLATION
TOOL
2 - COUNTERBALANCE SHAFT THRUST PLATE
9 - 80 ENGINE - 3.7LDR
VALVE TIMING (Continued)