drain bolt DODGE RAM 2003 Service Owner's Manual

radiator core, cooling system hoses and heater core,
this coolant absorbs the heat generated when the
engine is running. The pump is driven by the engine
crankshaft via a drive belt.
OPERATIONÐWATER PUMP BYPASS
When the thermostat is in the closed position the
bypass gallery is not obstructed allowing 100% flow.
When the thermostat is in the open position the stub
shaft enters the bypass gallery obstructing bypass
coolant flow by 50%. This design allows the coolant
to reach operating temperature quickly when cold,
while adding extra cooling during normal tempera-
ture operation.
REMOVAL
The water pump on 3.7L/4.7L engines is bolted
directly to the engine timing chain case cover.
(1) Disconnect the negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove fan/viscous fan drive assembly from
water pump (Fig. 46) (Refer to 7 - COOLING/EN-
GINE/FAN DRIVE VISCOUS CLUTCH - REMOV-
AL). Do not attempt to remove fan/viscous fan drive
assembly from vehicle at this time.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN
SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter and width.
(4) If the water pump is being replaced, do not
unbolt the fan blade assembly from the thermal vis-
cous fan drive.
(5) Remove the radiator fan (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(6) Remove accessory drive belt (Fig. 47) (Refer to
7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove the lower radiator hose clamp and
remove the lower hose at the water pump.
(8) Remove the water pump mounting bolts.
Fig. 44 Water Pump and Timing Chain Cover
1 - INTEGRAL WATER PUMP PULLEY
2 - TIMING CHAIN COVER
3 - THERMOSTAT HOUSING
4 - HEATER HOSE FITTINGS
5 - WATER PUMP
Fig. 45 Water/Coolant Bypass Flow and Thermostat
1 - FROM HEATER AND DEGAS CONTAINER
2 - FROM RADIATOR
3 - TO WATER PUMP
4 - ENGINE BYPASS
5 - THERMOSTAT
DRENGINE 7 - 65
WATER PUMP - 3.7L/4.7L (Continued)

CAUTION: When installing the serpentine accessory
drive belt, the belt must be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction. Refer to (Fig. 49) for
the correct belt routing. Or, refer to the Belt Routing
Label located in the engine compartment. The cor-
rect belt with correct length must be used.
(6) Install the radiator fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
(7) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(8) Connect the negative battery cable.
(9) Start and warm the engine. Check for leaks.
WATER PUMP - 5.9L DIESEL
DESCRIPTION
The water pump is mounted to the front of the
engine block between the automatic belt tensioner
and the fan drive pulley.
The water pump impeller is pressed onto the rear
of a shaft that rotates in a bearing pressed into the
water pump body. The body has a small hole for ven-
tilation. The water pump seals are lubricated byantifreeze in the coolant mixture. Additional lubrica-
tion is not necessary.
OPERATION
The diesel engine water pump draws coolant from
radiator outlet and circulates it through engine,
heater core and back to radiator inlet. The crank-
shaft pulley drives the water pump with a serpentine
drive belt.
DIAGNOSIS AND TESTINGÐWATER PUMP
A quick test to determine if pump is working is to
check if heater warms properly. A defective water
pump will not be able to circulate heated coolant
through the long heater hose to the heater core.
REMOVAL
(1) Disconnect battery negative cables.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove water pump mounting bolts (Fig. 50).
(5) Clean water pump sealing surface on cylinder
block.
CLEANING
Clean gasket mating surfaces as necessary.
Fig. 49 Belt Routing 3.7L
1 - GENERATOR PULLEY
2 - ACCESSORY DRIVE BELT
3 - POWER STEERING PUMP PULLEY
4 - CRANKSHAFT PULLEY
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - WATER PUMP PULLEY
Fig. 50 Water Pump Removal/Installation
1 - O-RING SEAL (SQUARE)
2 - WATER PUMP
3 - BOLT (2)
DRENGINE 7 - 67
WATER PUMP - 3.7L/4.7L (Continued)

INSPECTION
Visually inspect the water pump and replace if it
has any of the following conditions:
²The body is cracked or damaged
²Water leaks from the shaft seal. This is evident
by traces of coolant below the vent hole
²Loose or rough turning bearing.
²Impeller rubbing the pump body
INSTALLATION
(1) Install new O-ring seal in groove on water
pump (Fig. 51).
(2) Install water pump. Tighten mounting bolts to
24 N´m (18 ft. lbs.) torque.
(3) Install accessory drive belt. Refer to procedure
in this group.
(4) Install the bolt retaining the wiring harness
near top of water pump.
(5) Fill cooling system. Refer to Refilling Cooling
System in this section.
(6) Connect both battery cables.
(7) Start and warm the engine. Check for leaks.
WATER PUMP INLET TUBE -
5.9L
REMOVAL
REMOVAL - WATER PUMP BYPASS HOSE
WITH AIR CONDITIONING
If equipped with A/C, the generator and A/C com-
pressor along with their common mounting bracket
(Fig. 52) must be partially removed. Removing thegenerator or A/C compressor from their mounting
bracket is not necessary. Also, discharging the A/C
system is not necessary.Do notremove any refriger-
ant lines from A/C compressor.
WARNING: THE A/C SYSTEM IS UNDER PRESSURE
EVEN WITH THE ENGINE OFF. REFER TO REFRIG-
ERANT WARNINGS IN SECTION 24 - HEATING AND
AIR CONDITIONING.
(1) Disconnect the negative battery cable.
(2) Partially drain the cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).Do not
waste reusable coolant. If the solution is clean, drain
the coolant into a clean container for reuse.
(3) Remove the upper radiator hose clamp at the
radiator. A special clamp tool must be used to remove
the constant tension clamps. Removethe hose at the
radiator.
(4) Unplug the wiring harness from the A/C com-
pressor.
(5) Remove the air cleaner assembly.
(6) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) The drive belt idler pulley must be removed to
gain access to one of the A/C compressor/generator
bracket mounting bolts. Remove the idler pulley bolt
and remove idler pulley (Fig. 53).
(8) Remove the engine oil dipstick tube mounting
bolt at the side of the A/C-generator mounting
bracket.
(9) Disconnect the throttle body control cables.
Fig. 51 Pump O-ring Seal
1 - O-RING SEAL
2 - GROOVE
3 - WATER PUMP
Fig. 52 Generator - A/C Compressor Mounting
Bracket - Typical
7 - 68 ENGINEDR
WATER PUMP - 5.9L DIESEL (Continued)

(10) Remove the heater hose coolant return tube
mounting bolt (Fig. 54) (Fig. 55) and remove the tube
from the engine. Discard the old tube O-ring.
(11) Remove the bracket-to-intake manifold bolts
(number 1 and 2 (Fig. 52).(12) Remove the remaining bracket-to-engine bolts
(Fig. 55).
(13) Lift and position the generator and A/C com-
pressor (along with their common mounting bracket)
to gain access to the bypass hose. A block of wood
may be used to hold the assembly in position.
(14) Loosen and position both hose clamps to the
center of the bypass hose. A special clamp tool must
be used to remove the constant tension clamps.
Remove the hose from the vehicle.
REMOVAL - WATER PUMP BYPASS HOSE
WITHOUT AIR CONDITIONING
A water pump bypass hose (Fig. 56) is used
between the intake manifold and water pump on all
gas powered engines. To test for leaks, (Refer to 7 -
COOLING - DIAGNOSIS AND TESTING).
(1) Partially drain the cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE). Do not
waste reusable coolant. If the solution is clean, drain
the coolant into a clean container for reuse.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN
SERVICING CONSTANT TENSION CLAMPS.
Fig. 53 Idler Pulley - 5.9L V-8 Gas Engine
Fig. 54 Coolant Return
1 - COOLANT RETURN TUBE
2 - WATER PUMP
3 - TUBE MOUNTING BOLT
4 - O-RING
Fig. 55 Bracket Bolts - 5.9L V-8 Gas
1 - COOLANT TUBE MOUNTING BOLT
2 - BRACKET MOUNTING BOLTS
DRENGINE 7 - 69
WATER PUMP INLET TUBE - 5.9L (Continued)

CAUTION: A number or letter is stamped into the
tongue of the constant tension clamps. If replace-
ment is necessary, use only an original equipment
clamp with a matching number or letter and width.
(2) Loosen both of the bypass hose clamps and
position them to the center of the hose.
(3) Removethe hose from the vehicle.
INSTALLATION
INSTALLATION - WATER PUMP BYPASS HOSE
WITH AIR CONDITIONING
(1) Position the bypass hose clamps to the center
of the bypass hose.
(2) Install the bypass hose to the engine.
(3) Secure both of the hose clamps.
(4) Install the generator-A/C mounting bracket
assembly to the engine. Tighten bolt number 1 (Fig.
53) to 41 N´m (30 ft. lbs.). Tighten bolt number 2
(Fig. 53) to 28 N´m (20 ft. lbs.). Tighten bracket
mounting bolts (Fig. 53) (Fig. 53) to 40 N´m (30 ft.
lbs.).
(5) Install a new O-ring to the heater hose coolant
return tube. Coat the new O-ring with antifreeze
before installation.
(6) Install the coolant return tube and its mount-
ing bolt to the engine.
(7) Connect the throttle body control cables.
(8) Install the oil dipstick mounting bolt.
(9) Install the idler pulley. Tighten the bolt to 41
N´m (30 ft. lbs.) (Fig. 57).
(10) Install the drive belt (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION).CAUTION: When installing the serpentine accessory
drive belt, the belt must be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION). The correct belt with the correct length must
be used.
(11) Install the air cleaner assembly.
(12) Install the upper radiator hose to the radiator.
(13) Connect the throttle cable to the clip at the
radiator fan shroud.
(14) Connect the wiring harness to the A/C com-
pressor.
(15) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(16) Start and warm the engine. Check for leaks.
INSTALLATION - WATER PUMP BYPASS HOSE
WITHOUT AIR CONDITIONING
(1) Position the bypass hose clamps to the center
of the bypass hose.
(2) Install the bypass hose tothe engine.
(3) Secure both of the hose clamps.
(4) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(5) Start and warm the engine. Check for leaks.
WATER PUMP - 5.7L
REMOVAL
(1) Disconnect negative battery cable.
(2) Drain coolant.
(3) Remove serpentine belt.
(4) Remove fan clutch assembly.
(5) Remove coolant fill bottle.
Fig. 56 Water Pump Bypass Hose - Typical
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY
Fig. 57 Tensioner Mounting
1 - DOWEL PIN HOLE
2 - TENSIONER MOUNTING BRACKET
7 - 70 ENGINEDR
WATER PUMP INLET TUBE - 5.9L (Continued)

TRANSMISSION
TABLE OF CONTENTS
page page
TRANS COOLER
DESCRIPTION
DESCRIPTION........................72
DESCRIPTION........................72
OPERATION...........................72
REMOVAL.............................72
DISASSEMBLY - 5.9L ONLY...............73
ASSEMBLY - 5.9L ONLY..................73
INSTALLATION.........................73TRANS COOLER - 5.9L DIESEL
DESCRIPTION.........................73
OPERATION...........................74
REMOVAL
REMOVALÐAIR TO OIL COOLER.........74
REMOVALÐWATER TO OIL COOLER......74
INSTALLATION
INSTALLATIONÐAIR TO OIL COOLER.....75
INSTALLATION.......................75
TRANS COOLER
DESCRIPTION
DESCRIPTION
An air-to-oil transmission oil cooler is standard on
all engine packages. The transmission oil cooler is
mounted to the front of the radiator above the power
steering cooler (Fig. 1).
DESCRIPTION
An air-to-oil transmission oil cooler is standard on
all engine packages. The transmission oil cooler is
mounted to the front of the radiator above the power
steering cooler (Fig. 2).
OPERATION
Transmission oil is routed through the cooler
where heat is removed from the transmission oil
before returning to the transmission. Vehicles
equipped with the 5.9L engine have an internal ther-
mostat that controls fluid flow through the cooler-
.When the transmission fluid is cold ( less than
operating temperature) the fluid is routed through
the cooler bypass. when the transmission fluid
reaches operating temperatures and above, the ther-
mostat closes off the bypass allowing fluid flow
through the cooler. The thermostat is serviceable.
NOTE: Vehicles with the 3.7L/4.7L engines are not
equipped with the oil cooler thermostat.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Place a drain pan under the oil cooler lines.(3) Disconnect the transmission oil cooler line
quick-connect fitting at the cooler outlet using the
quick connect release tool 6935. Plug the cooler lines
to prevent oil leakage.
(4) Unsnap the transmission cooler tubes from the
radiator tank clips.
Fig. 1 Cooling Module Ð 5.9L Gas
1 - TRANS OIL COOLER BYPASS (5.9L only)
2 - OIL COOLER THERMOSTATIC BYPASS VALVE (5.9L only)
3 -TRANS OIL COOLER
4 - OIL COOLER MOUNTING BOLT (4)
5 - POWER STEERING COOLER
6 - POWER STEERING COOLER MOUNTING BOLT(2)
7 - TRANS OIL COOLER OUTLET
8 - TRANS OIL COOLER INLET
9 - COOLER LINE CLIP
10 - COOLER LINE CLIP
11 - RADIATOR
7 - 72 TRANSMISSIONDR

ers are supplied as standard equipment on diesel
engine powered models when equipped with an auto-
matic transmission.
The main water-to-oil transmission oil cooler is
mounted to a bracket on the intake side of the engine
(Fig. 4).
The air-to-oil cooler is located in front of and to the
left side of the radiator (Fig. 5).
OPERATION
The transmission oil is routed through the main
cooler first, then the auxiliary cooler where addi-
tional heat is removed from the transmission oil
before returning to the transmission. The cooler has
an internal thermostat that controls fluid flow
through the cooler. When the transmission fluid is
cold (less then operating temperature), the fluid is
routed through the cooler bypass. When the trans-
mission fluid reaches operating temperatures and
above, the thermostat closes off the bypass allowing
fluid flow through the cooler. The thermostat is ser-
vicable.
REMOVAL
REMOVALÐAIR TO OIL COOLER
(1) Remove Charge Air Cooler (Refer to 11 -
EXHAUST SYSTEM/TURBOCHARGER SYSTEM/
CHARGE AIR COOLER AND PLUMBING -
REMOVAL).(2) Place a drain pan under the oil cooler.
(3) Raise the vehicle.
(4) Disconnect the oil cooler quick-connect fittings
from the transmission lines.
(5) Remove the charge air cooler-to-oil cooler bolt
(Fig. 6).
(6) Remove two mounting nuts.
(7) Remove the oil cooler and line assembly
towards the front of vehicle. Cooler must be rotated
and tilted into position while removing.
REMOVALÐWATER TO OIL COOLER
CAUTION: If a leak should occur in the water-to-oil
cooler mounted to the side of the engine block,
engine coolant may become mixed with transmis-
sion fluid. Transmission fluid may also enter engine
cooling system. Both cooling system and transmis-
sion should be drained and inspected in case of oil
cooler leakage.
(1) Disconnect both battery negative cables.
(2) Remove starter (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - REMOVAL).
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Disconnect coolant lines from cooler.
Fig. 4 Transmission Water-To-Oil CoolerÐDiesel
EngineÐTypical
1 - TRANSMISSION WATER-TO-OIL COOLER
Fig. 5 Auxiliary Transmission Oil CoolerÐDiesel
Engine
1 - MOUNTING BOLTS
2 - RADIATOR
3 - QUICK-CONNECT FITTINGS
4 - TRANSMISSION OIL COOLER
7 - 74 TRANSMISSIONDR
TRANS COOLER - 5.9L DIESEL (Continued)

DESCRIPTION SPECIFICATION
Cover Out - of -Flat
(MAX)0.025 mm (0.001 in.)
Inner and Outer Rotor
Thickness 12.02 mm (0.4731 in.)
Outer Rotor to pocket
(Diametral) clearance
(MAX).235 mm (.0093 in.)
Outer Rotor Diameter
(MIN)85.925 mm (0.400 in.)
Tip Clearance Between
Rotors
(MAX) 0.150 mm (0.006 in.)
OIL PRESSURE
At Curb Idle Speed
(MIN)*25 kPa (4 psi)
@ 3000 rpm 170 - 758 kPa (25 - 110
psi)
* CAUTION: If pressure is zero at curb idle, DO
NOT run engine at 3000 rpm.
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft
Non - Oiled Sprocket Bolt 122 90 Ð
Bearing Cap Bolts 11 Ð 100
Counterbalance shaft
retaining bolt28 Ð 250
Timing Chain CoverÐBolts 58 43 Ð
Connecting Rod CapÐBolts 27 20 Ð
PLUS 90É TURN
Bed PlateÐBolts Refer to Procedure
Crankshaft DamperÐBolt 175 130 Ð
Cylinder HeadÐBolts
M11 Bolts Refer ToProcedure
M8 Bolts - - -
Cylinder Head CoverÐBolts 12 Ð 105
Exhaust ManifoldÐBolts 25 18 Ð
Exhaust Manifold Heat
ShieldÐNuts8Ð72
Then loosen 45É
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
FlexplateÐBolts 95 70 Ð
Engine Mount Bracket to
BlockÐBolts61 45 Ð
Rear Mount to
TransmissionÐBolts46 34 Ð
Generator MountingÐBolts
M10 Bolts 54 40 Ð
M8 Bolts 28 Ð 250
Intake ManifoldÐBolts 12 Ð 105
Refer to Procedure
for
Tightening Sequence
Oil PanÐBolts 15 Ð 130
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐBolts 28 Ð 250
Oil Pump CoverÐBolts 12 Ð 105
Oil Pickup TubeÐBolt and
Nut28 Ð 250
Oil Dipstick Tube to Engine
BlockÐBolt 15 Ð 130
Oil Fill TubeÐBolts 12 Ð 105
Timing Chain GuideÐBolts 28 Ð 250
Timing Chain Tensioner Arm 28 Ð 250
Hydraulic TensionerÐBolts 28 Ð 250
Timing Chain Primary
TensionerÐBolts28 Ð 250
Timing Drive Idler SprocketÐ
Bolt34 25 Ð
Thermostat HousingÐBolts 12 Ð 105
Water PumpÐBolts 58 43 Ð
DRENGINE - 3.7L 9 - 15
ENGINE - 3.7L (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
retorque 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.
INSTALLATION
NOTE: The cylinder head bolts are tightened using
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced.
Necking can be checked by holding a straight edge
against the threads (Fig. 24). If all the threads do not
contact the scale, the bolt should be replaced.
9 - 32 ENGINE - 3.7LDR
CYLINDER HEAD - RIGHT (Continued)

(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.
INSTALLATION
(1) Lubricate camshaft journals with clean engine
oil.
NOTE: Position the right side camshaft so that the
camshaft sprocket dowel is near the 10 o'clock
position, This will place the camshaft at the neutral
position easing the installation of the camshaft
bearing caps.
(2) Position the camshaft into the cylinder head.
(3) Install the camshaft bearing caps, hand tighten
the retaining bolts.
NOTE: Caps should be installed so that the
stamped numbers on the caps are in numerical
order, ( 1 thru 4 ) from the front to the rear of the
engine. All caps should be installed so that the
stamped arrows on the caps point toward the front
of the engine.
(4) Working in 1/2 turn increments, tighten the
bearing cap retaining bolts starting with the middle
cap working outward (Fig. 27).
(5) Torque the camshaft bearing cap retaining
bolts to 11 N´m (100 in. lbs.).
(6) Position the camshaft drive gear into the tim-
ing chain aligning the V6 mark between the two
marked chain links (Two links marked during remov-
al).
(7) Using Special Tool 8428 Camshaft Wrench,
rotate the camshaft until the camshaft sprocket
dowel is aligned with the slot in the camshaft
sprocket. Install the sprocket onto the camshaft.
CAUTION: Remove excess oil from camshaft
sprocket bolt. Failure to do so can cause bolt over-
torque resulting in bolt failure.
(8) Remove excess oil from camshaft sprocket bolt,
then install the camshaft sprocket retaining bolt and
hand tighten.(9) Remove timing chain wedge special tool 8379.
(10) Using Special Tool 6958 spanner wrench with
adapter pins 8346, torque the camshaft sprocket
retaining bolt to 122 N´m (90 ft. lbs.).
(11) Install the camshaft position sensor.
(12) Install the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
CYLINDER HEAD COVER(S)
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly, resonator assem-
bly and air inlet hose.
(3) Drain cooling system, below the level of the
heater hoses(Refer to 7 - COOLING - STANDARD
PROCEDURE).
(4) Remove accessory drive belt(Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).
(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.
Fig. 27 CAMSHAFT BEARING CAPS TIGHTENING
DRENGINE - 3.7L 9 - 35
CAMSHAFT(S) (Continued)