wheel bolts DODGE RAM 1500 1998 2.G Repair Manual

(2) Remove the right front wheelhouse splash
shield.
(3) Disconnect the right front fender ground wire.
(4) Remove fasteners from grid heater relay
bracket.
(5) Remove air box.
(6) Remove the remaining battery tray retaining
bolts (Fig. 17).
(7) Remove the battery tray from the vehicle.
INSTALLATION
LEFT SIDE
(1) Position the battery tray assembly and install
the retaining bolts.
(2) Connect the left front fender ground wire.
(3) Install the purge solenoid on its mounting
bracket.
(4) Install the battery temperature sensor in the
battery tray (Refer to 8 - ELECTRICAL/CHARGING/
BATTERY TEMPERATURE SENSOR - INSTALLA-
TION).
(5) Install the cruise servo (if equipped) and
retaining screws.
(6) Install the left front wheelhouse splash shield
(Refer to 23 - BODY/EXTERIOR/LF WHEELHOUSE
SPLASH SHIELD - INSTALLATION).
(7) Install the anti-lock brake controller (if
equipped).
(8) Connect the wire harness retainers on the bat-
tery tray assembly.
(9) Install the integrated power module (Refer to 8
- ELECTRICAL/POWER DISTRIBUTION/INTELLI-
GENT POWER MODULE - INSTALLATION).
(10) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
RIGHT SIDE
(1) Position the battery tray assembly and install
the retaining bolts.
(2) Connect the right front fender ground wire.
(3) Install the air box.
(4) Install the grid heater relay bracket.
(5) Install the right front wheelhouse splash
shield.
(6) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
Fig. 16 Lower Battery Tray Retaining Bolts
1 - BATTERY TRAY ASSEMBLY
2 - BATTERY TRAY RETAINING BOLTS
3 - CRUISE CONTROL SERVO
Fig. 17 RIGHT SIDE BATTERY TRAY
8F - 18 BATTERY SYSTEMDR
BATTERY TRAY (Continued)

(2) Remove the left instrument panel bezel. (Refer
to 23 - BODY/INSTRUMENT PANEL/CLUSTER
BEZEL - REMOVAL).
(3) Disconnect the harness connector.
(4) Remove the screws that secure the headlamp
switch to the instrument panel bezel (Fig. 10).
(5) Remove the headlamp switch from the instru-
ment panel bezel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Position the headlamp switch to the left instru-
ment panel bezal and secure with screws.Tighten the
screws to 2.2 N´m (20 in. lbs.).(2) Reconnect the instrument panel wire harness
connector for the headlamp switch.
(3) Position the left instrument panel bezal on to
the instrument panel.
(4) Install the cluster bezel onto the instrument
panel (Fig. 10).
(5) Connect the battery negative cable.
HEADLAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the push pins attaching the seal to the
fender.
(3) Remove the bolts attaching the headlamp unit
to the fender (Fig. 11).
(4) Remove the bulb sockets from the headlamp
unit
(5) Separate headlamp unit from vehicle.
INSTALLATION
CAUTION: Do not touch the bulb glass with fingers
or other oily surfaces. Reduced bulb life will result.
(1) Install the bulb sockets for the front park/turn
signal and headlamp.
(2) Position headlamp unit in inner fender panel.
Fig. 10 Headlamp Switch Removal
1 - DASH BOARD
2 - HEADLAMP SWITCH
3 - INSTRUMENT PANEL BEZAL
Fig. 11 Headlamp - Typical
1 - SEAL
2 - PUSH PIN
3 - SCREW
4 - HEADLAMP UNIT
DRLAMPS/LIGHTING - EXTERIOR 8L - 15
HEADLAMP SWITCH (Continued)

WARNING: TO AVOID PERSONAL INJURY OR
DEATH ON VEHICLES EQUIPPED WITH AIRBAGS,
BEFORE PERFORMING ANY WELDING OPERA-
TIONS DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE AND DISCONNECT
ALL WIRE HARNESS CONNECTORS FROM THE
AIRBAG CONTROL MODULE (ACM). FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND OTHER POSSIBLE DAMAGE TO THE SUPPLE-
MENTAL RESTRAINT SYSTEM CIRCUITS AND COM-
PONENTS.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DO NOT ATTEMPT TO DISMANTLE AN AIR-
BAG UNIT OR TAMPER WITH ITS INFLATOR. DO
NOT PUNCTURE, INCINERATE, OR BRING INTO
CONTACT WITH ELECTRICITY. DO NOT STORE AT
TEMPERATURES EXCEEDING 93É C (200É F). AN
AIRBAG INFLATOR UNIT MAY CONTAIN SODIUM
AZIDE AND POTASSIUM NITRATE. THESE MATERI-
ALS ARE POISONOUS AND EXTREMELY FLAMMA-
BLE. CONTACT WITH ACID, WATER, OR HEAVY
METALS MAY PRODUCE HARMFUL AND IRRITAT-
ING GASES (SODIUM HYDROXIDE IS FORMED IN
THE PRESENCE OF MOISTURE) OR COMBUSTIBLE
COMPOUNDS. AN AIRBAG INFLATOR UNIT MAY
ALSO CONTAIN A GAS CANISTER PRESSURIZED
TO OVER 2500 PSI.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, WHEN HANDLING A SEAT BELT TEN-
SIONER RETRACTOR, PROPER CARE SHOULD BE
EXERCISED TO KEEP FINGERS OUT FROM UNDER
THE RETRACTOR COVER AND AWAY FROM THE
SEAT BELT WEBBING WHERE IT EXITS FROM THE
RETRACTOR COVER.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, REPLACE ALL RESTRAINT SYSTEM COM-
PONENTS ONLY WITH PARTS SPECIFIED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
SUBSTITUTE PARTS MAY APPEAR INTERCHANGE-
ABLE, BUT INTERNAL DIFFERENCES MAY RESULT
IN INFERIOR OCCUPANT PROTECTION.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, THE FASTENERS, SCREWS, AND BOLTS
ORIGINALLY USED FOR THE RESTRAINT SYSTEM
COMPONENTS MUST NEVER BE REPLACED WITH
ANY SUBSTITUTES. THESE FASTENERS HAVE
SPECIAL COATINGS AND ARE SPECIFICALLY
DESIGNED FOR THE RESTRAINT SYSTEM. ANY
TIME A NEW FASTENER IS NEEDED, REPLACE ITWITH THE CORRECT FASTENERS PROVIDED IN
THE SERVICE PACKAGE OR SPECIFIED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, WHEN A STEERING COLUMN HAS AN AIR-
BAG UNIT ATTACHED, NEVER PLACE THE COL-
UMN ON THE FLOOR OR ANY OTHER SURFACE
WITH THE STEERING WHEEL OR AIRBAG UNIT
FACE DOWN.
DIAGNOSIS AND TESTING - SUPPLEMENTAL
RESTRAINT SYSTEM
Proper diagnosis and testing of the supplemental
restraint system components, the Programmable
Communications Interface (PCI) data bus, the data
bus electronic message inputs to and outputs from
the ElectroMechanical Instrument Cluster (EMIC),
the Airbag Control Module (ACM), as well as the
retrieval or erasure of a Diagnostic Trouble Code
(DTC) from the ACM requires the use of a DRBIIIt
scan tool. Refer to the appropriate diagnostic infor-
mation.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
NON-DEPLOYED SUPPLEMENTAL RESTRAINTS
At no time should any source of electricity be per-
mitted near the inflator on the back of a non-de-
ployed airbag or seat belt tensioner. When carrying a
non-deployed airbag, the trim cover or airbag cushion
side of the unit should be pointed away from the
body to minimize injury in the event of an accidental
deployment. If the airbag unit is placed on a bench or
any other surface, the trim cover or airbag cushion
side of the unit should be face up to minimize move-
8O - 6 RESTRAINTSDR
RESTRAINTS (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)

(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Oil leak or excessive cam bore wear in cylin-
der head.
(11) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head and cam on camshaft at
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
(1) Disconnect battery negative cable.
(2) Raise the vehicle on a hoist.
(3) Disconnect the exhaust pipe at the right 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 cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(8) Remove the fan shroud(Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL).
(9) Remove oil fill housing from cylinder head.
(10) Remove accessory drive belt(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(11) Rotate the crankshaft until the damper timing
mark is aligned with TDC indicator mark.
(12) Verify the V6 mark on the camshaft sprocket
is at the 12 o'clock position. Rotate the crankshaft
one turn if necessary.
(13) Remove the crankshaft damper(Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(14) Remove the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(15) Lock the secondary timing chains to the idler
sprocket using Special Tool 8429 Timing Chain Hold-
ing Fixture.NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(16) Mark the secondary timing chain, one link on
each side of the V6 mark on the camshaft drive gear.
(17) Remove the right side secondary chain ten-
sioner(Refer to 9 - ENGINE/VALVE TIMING/TIM-
ING BELT/CHAIN AND SPROCKETS - REMOVAL).
(18) Remove the cylinder head access plug.
(19) Remove the right side secondary chain
guide(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL).
CAUTION: The nut on the right side camshaft
sprocket should not be removed for any reason, as
the sprocket and camshaft sensor target wheel is
serviced as an assembly. If the nut was removed,
torque nut to 5 N´m (44 in. lbs.).
(20) Remove the retaining bolt and the camshaft
drive gear.
CAUTION: Do not allow the engine to rotate. severe
damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to
remove the cylinder head without removing these
four bolts.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel for any reason. A damaged target wheel
can result in a vehicle no start condition.
NOTE: The cylinder head is attached to the cylinder
block with twelve bolts.
(21) Remove the cylinder head retaining bolts.
(22) Remove the cylinder head and gasket. Discard
the gasket.
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, do to the design of the cylinder
head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
DRENGINE - 3.7L 9 - 33
CYLINDER HEAD - RIGHT (Continued)

(2) Measure the inside diameter of the cylinder
bore at three levels below top of bore. Start perpen-
dicular (across or at 90 degrees) to the axis of the
crankshaft and then take two additional reading.
(3) Measure the cylinder bore diameter crosswise
to the cylinder block near the top of the bore. Repeat
the measurement near the middle of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determine taper by subtracting the smaller
diameter from the larger diameter.
(5) Rotate measuring device 90É and repeat steps
above.
(6) Determine out-of-roundness by comparing the
difference between each measurement.
(7) If cylinder bore taper does not exceed 0.025
mm (0.001 inch) and out-of-roundness does not
exceed 0.025 mm (0.001 inch), the cylinder bore can
be honed. If the cylinder bore taper or out- of-round
condition exceeds these maximum limits, the cylinder
block must be replaced. A slight amount of taper
always exists in the cylinder bore after the engine
has been in use for a period of time.
CRANKSHAFT
DESCRIPTION
The crankshaft is constructed of nodular cast iron.
The crankshaft is a three throw split pin design with
six counterweights for balancing purposes. The
crankshaft is supported by four select fit main bear-
ings with the No. 2 serving as the thrust washer
location. The main journals of the crankshaft are
cross drilled to improve rod bearing lubrication. The
No. 6 counterweight has provisions for crankshaft
position sensor target wheel mounting. The select fit
main bearing markings are located on the rear side
of the target wheel (Fig. 31). The crankshaft oil seals
are one piece design. The front oil seal is retained in
the timing chain cover, and the rear seal is pressed
in to a bore formed by the cylinder block and the
bedplate assembly.
REMOVAL
NOTE: To remove the crankshaft from the engine,
the engine must be removed from the vehicle.
(1) Remove the engine(Refer to 9 - ENGINE -
REMOVAL).
(2) Remove the engine oil pump(Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - REMOVAL).CAUTION: DO NOT pry on the oil pan gasket when
removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when removing oil pan.
Gasket can not be removed with oil pan.
(3) Remove the bedplate mounting bolts. Note the
location of the two stud bolts for installation.
(4) Remove the connecting rods from the crank-
shaft.
CAUTION: The bedplate to cylinder block mating
surface is a critical sealing surface. Do not pry on
or damage this surface in anyway.
NOTE: The bedplate contains the lower main bear-
ing halves. Use care when handling bedplate as not
to drop or damage bearing halves. Installing main
bearing halves in the wrong position will cause
severe damage to the crankshaft.
Fig. 31 CRANKSHAFT AND TARGET RING
1 - CRANKSHAFT
2 - CRANKSHAFT POSITION SENSOR TARGET RING
9 - 40 ENGINE - 3.7LDR
ENGINE BLOCK (Continued)

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-
tons covered during this operation.Pistons and
connecting rods must be removed from top of cylinder
block. When removing piston and connecting rod
assemblies from the engine, rotate crankshaft so the
each connecting rod is centered in cylinder bore.
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods or caps, as damage to
connecting rods could occur
NOTE: Connecting rods and bearing caps are not
interchangeable and should be marked before
removing to ensure correct reassembly.
(4) Mark connecting rod and bearing cap positions
using a permanent ink marker or scribe tool.
CAUTION: Care must be taken not to damage the
fractured rod and cap joint face surfaces, as engine
damage may occur.
(5) Remove connecting rod cap. Install Special Tool
8507 Connecting Rod Guides into the connecting rod
being removed. Remove piston from cylinder bore.
Repeat this procedure for each piston being removed.
CAUTION: Care must be taken not to nick crank-
shaft journals, as engine damage may occur
(6) Immediately after piston and connecting rod
removal, install bearing cap on the mating connect-
ing rod to prevent damage to the fractured cap and
rod surfaces.
CLEANING
CAUTION: DO NOT use a wire wheel or other abra-
sive cleaning devise to clean the pistons or con-
necting rods. The pistons have a Moly coating, this
coating must not be damaged.
(1) Using a suitable cleaning solvent clean the pis-
tons in warm water and towel dry.
(2) Use a wood or plastic scraper to clean the ring
land grooves.
CAUTION: DO NOT remove the piston pin from the
piston and connecting rod assembly.
INSPECTION
Check the connecting rod journal for excessive
wear, taper and scoring (Refer to 9 - ENGINE/EN-
GINE BLOCK/CONNECTING ROD BEARINGS -
STANDARD PROCEDURE).
Check the connecting rod for signs of twist or bend-
ing.
Check the piston for taper and elliptical shape
before it is fitted into the cylinder bore (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECT-
ING ROD - STANDARD PROCEDURE).
Check the piston for scoring, or scraping marks in
the piston skirts. Check the ring lands for cracks
and/or deterioration.
INSTALLATION
(1) Before installing piston and connecting rod
assemblies into the bore, install the piston rings.
(2) Immerse the piston head and rings in clean
engine oil. Position a ring compressor over the piston
and rings. Tighten ring compressor.Ensure posi-
tion of rings do not change during this opera-
tion.
(3) Position bearing onto connecting rod. Ensure
that hole in bearing shell aligns with hole in connect-
ing rod. Lubricate bearing surface with clean engine
oil.
(4) Install Special Tool 8507 Connecting Rod
Guides into connecting rod bolt threads (Fig. 53).
(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. 54).
(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).
9 - 52 ENGINE - 3.7LDR
PISTON & CONNECTING ROD (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

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

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