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. ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page 4.7L ENGINE.1 5.9L ENGINE. 9 - 2 4.7L ENGINE OIL PUMP.69 CYLINDER HEADS.75 ENGINE OIL PRESSURE SENDING UNIT. 4.7L ENGINE 9 - 3 DESCRIPTION AND OPERATION (Continued) firing order is 1–8–4–3–6–5–7–2. The engine serial number is located at the right front side of the engine block (Fig. 1) ENGINE LUBRICATION SYSTEM DESCRIPTION The lubrication system (Fig. 2) is a full flow filtra- tion pressure feed type.
9 - 4 4.7L ENGINE DESCRIPTION AND OPERATION (Continued) Fig. 2 Engine Oil Lubrication System 1 – LEFT CYLINDER HEAD OIL GALLERY 7 – TO CRANKSHAFT MAIN JOURNALS 2 – OIL PRESSURE SENSOR LOCATION 8 – RIGHT CYLINDER HEAD OIL GALLERY 3 –. 4.7L ENGINE 9 - 5 2000 DN Service Manual DESCRIPTION AND OPERATION (Continued) Publication No.
81-370-0016 TSB 26-12-99 December, 1999 ENGINE LUBRICATION FLOW CHART—CYLINDER HEADS: TABLE 2 FROM Cylinder Head Oil Port (in bolt hole) Diagonal Cross Drilling to Main Oil Gallery Main Oil Gallery (drilled through head from rear to front) 1. 9 - 6 4.7L ENGINE DESCRIPTION AND OPERATION (Continued) VALVE SPRING There are two secondary drive chains, both are inverted tooth type, one to drive the camshaft in each SOHC cylinder head.
There are no shaft speed DESCRIPTION changes in the secondary chain drive system. Each The valve springs are made from high strength secondary chain drives a thirty tooth cam sprocket chrome silicon steel. 4.7L ENGINE 9 - 7 DESCRIPTION AND OPERATION (Continued) OIL PAN mance. The exhaust manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is used to improve DESCRIPTION sealing to the cylinder head. The exhaust manifolds The engine oil pan is made of laminated steel and are covered by a three layer laminated heat shield has a single plane sealing surface.
9 - 8 4.7L ENGINE DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary. Corroded or loose battery 2. Clean and tighten battery connections.
Apply a coat of light mineral grease to the terminals. 4.7L ENGINE 9 - 9 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Incorrect ignition timing.
Refer to Group 8D, Ignition System. Worn or burned distributor rotor. Replace distributor rotor.
Worn distributor shaft. 9 - 10 4.7L ENGINE DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—MECHANICAL CONDITION POSSIBLE CAUSES CORRECTIONS NOISY VALVES 1. High or low oil level in 1. Refer to Group 0, Lubrication and crankcase. Thin or diluted oil.
Change oil and filter. 4.7L ENGINE 9 - 11 DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—LUBRICATION CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1.
Gaskets and O-Rings. (a) Misaligned or damaged. (a) Replace as necessary. (b) Loose fasteners, broken or (b) Tighten fasteners, Repair or porous metal parts.
Replace metal parts. 9 - 12 4.7L ENGINE DIAGNOSIS AND TESTING (Continued) Otherwise the indicated compression pressures may COOLING SYSTEM TESTER METHOD not be valid for diagnosis purposes. (1) Clean the spark plug recesses with compressed WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. 4.7L ENGINE 9 - 13 DIAGNOSIS AND TESTING (Continued) CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION AIR ESCAPES THROUGH Intake valve bent, burnt, or not Inspect valve and valve seat. THROTTLE BODY seated properly Reface or replace, as necessary AIR ESCAPES THROUGH Exhaust valve bent, burnt, or not Inspect valve and valve seat. 9 - 14 4.7L ENGINE DIAGNOSIS AND TESTING (Continued) filter runoff, and main bearing cap to cylinder crankshaft seal surface is damaged.
The seal area on block mating surfaces. The crankshaft could have minor nicks or scratches (4) If no leaks are detected, pressurize the crank- that can be polished out with emery cloth. 4.7L ENGINE 9 - 15 DIAGNOSIS AND TESTING (Continued) CHECKING ENGINE OIL PRESSURE have different properties and cannot be used inter- changeably. (1) Remove oil pressure sending unit (Fig. 3) and install gauge assembly C-3292.
MOPAR SILICONE RUBBER ADHESIVE SEALANT Mopar Silicone Rubber Adhesive Sealant, normally black in color, is available in 3 ounce tubes. 9 - 16 4.7L ENGINE SERVICE PROCEDURES (Continued) locating dowel is recommended during assembly to ENERGY CONSERVING OIL prevent smearing the material off location. An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CON- ENGINE OIL SERVING is located on the label of an engine oil con- tainer. 4.7L ENGINE 9 - 17 SERVICE PROCEDURES (Continued) CRANKCASE OIL LEVEL INSPECTION OIL FILTER REMOVAL (1) Position a drain pan under the oil filter. CAUTION: Do not overfill crankcase with engine oil, (2) Using a suitable oil filter wrench loosen filter. Pressure loss or oil foaming can result.
9 - 18 4.7L ENGINE SERVICE PROCEDURES (Continued) The hone marks should INTERSECT at 50° to 60° for proper seating of rings (Fig. 8 Oil Filter Sealing Surface—Typical 1 – SEALING SURFACE 2 – RUBBER GASKET 3 – OIL FILTER Damaged or worn threads can be repaired. 4.7L ENGINE 9 - 19 SERVICE PROCEDURES (Continued) (6) Identify the fluid in the cylinders (i.e. Coolant, fuel, oil, etc.). (7) Make sure all fluid has been removed from the cylinders.
(8) Repair engine or components as necessary to prevent this problem from occurring again. (9) Squirt engine oil into the cylinders to lubricate the walls. 9 - 20 4.7L ENGINE SERVICE PROCEDURES (Continued) SINGLE CAMSHAFT TIMING NOTE: to adjust the timing on one camshaft, pre- form the following procedure. (1) Using Chain Tensioner Wedge, special tool 8350, stabilize the secondary chain drive.
For refer- ence purposes, mark the chain-to-sprocket position (Fig. 4.7L ENGINE 9 - 21 SERVICE PROCEDURES (Continued) Fig. 12 Camshaft Sprocket V8 Marks 1 – LEFT CYLINDER HEAD 2 – RIGHT CYLINDER HEAD Fig. 13 Securing Timing Chain Tensioners Using Timing Chain Wedge 1 – LEFT CYLINDER HEAD 3 – SPECIAL TOOL 8350 WEDGE 2 –. 9 - 22 4.7L ENGINE SERVICE PROCEDURES (Continued) Fig. 14 Camshaft Dowel To Sprocket Alignment 1 – ADJUSTABLE PLIERS 2 – CAMSHAFT DOWEL TIMING CHAIN—MEASURING WEAR Fig. 15 Camshaft Sprocket Installation—Left NOTE: This procedure must be performed with the Cylinder Head timing chain cover removed.
4.7L ENGINE 9 - 23 SERVICE PROCEDURES (Continued) Fig. 18 Moly Coated Piston 1 – MOLY COATED Fig. 16 Camshaft Sprocket Installation—Right 2 – MOLY COATED Cylinder Head 1 – TORQUE WRENCH 2 – SPECIAL TOOL 6958 WITH ADAPTER PINS 8346 3 –. 9 - 24 4.7L ENGINE 2000 DN Service Manual SERVICE PROCEDURES (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 PISTON RINGS—FITTING RING END GAP Before reinstalling used rings or installing new rings, the ring clearances must be checked. (1) Wipe the cylinder bore clean. (2) Insert the ring in the cylinder bore.
4.7L ENGINE 9 - 25 SERVICE PROCEDURES (Continued) NOTE: Piston rings are installed in the following order:. Oil ring expander. Upper oil ring side rail. Lower oil ring side rail. 2 Intermediate piston ring. 1 Upper piston ring. (8) Install the oil ring expander.
9 - 26 4.7L ENGINE SERVICE PROCEDURES (Continued) Fig. 25 Connecting Rod Bearing Inspection 1 – UPPER BEARING HALF 2 – MATING EDGES 3 – GROOVES CAUSED BY ROD BOLTS SCRATCHING JOURNAL DURING INSTALLATION 4 – WEAR PATTERN — ALWAYS GREATER ON UPPER BEARING 5 –. 4.7L ENGINE 9 - 27 SERVICE PROCEDURES (Continued) Fig.
30 Checking Connecting Rod Side Clearance— Fig. 29 Measuring Bearing Clearance with Typical Plastigage 1 – PLASTIGAGE SCALE 2 – COMPRESSED PLASTIGAGE Bearing SIZE USED WITH Mark JOURNAL SIZE.025 US.025 mm 50.983-50.967 mm (.001 in.). 9 - 28 4.7L ENGINE SERVICE PROCEDURES (Continued) nal diameter specification (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance. Install the crankshaft into the cylinder block. Refer to Crankshaft in this section for procedure.
CRANKSHAFT MAIN BEARING SELECTION (1) Service main bearings are available in three grades. 4.7L ENGINE 9 - 29 REMOVAL AND INSTALLATION (Continued) (4) Remove the four bolts and washers retaining the mount to the transmission (4x4 automatic trans- mission only) (Fig.
(5) Raise the transmission enough to remove the through bolt (Manual transmission and 4x2 auto- matic transmission only) (Fig. 9 - 30 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) STRUCTURAL COVER REMOVAL (1) Raise vehicle on hoist.
(2) Remove the left hand exhaust pipe from exhaust manifold. Refer to Group 11, Exhaust Sys- tem. (3) Loosen the right hand exhaust manifold-to-ex- haust pipe retaining bolts. 4.7L ENGINE 9 - 31 REMOVAL AND INSTALLATION (Continued) SEQUENCE ITEM TORQUE BOLT 54 Nm (Qty 4) (40 ft. Lbs.) BOLT 54 Nm (Qty 2) (40 ft. Lbs.) BOLT 54 Nm (Qty 2) (40 ft. Lbs.) ENGINE ASSEMBLY REMOVAL NOTE: This procedure applies to both the 4X2 and 4X4 vehicles, steps that apply to the 4X4 vehicle only, are identified.
9 - 32 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 41 Engine Mount Through Bolt and Nut Removal / Installation—4X4 Vehicles 1 – ENGINE MOUNT BRACKET (2) Fig.
42 Axle Isolator Bracket Removal / 2 – THROUGH BOLT (2) 3 – LOCKNUT AND WASHER (2) Installation—4X4 Vehicles With Automatic 4 –. 4.7L ENGINE 9 - 33 REMOVAL AND INSTALLATION (Continued) Fig. 45 Heater Hoses and Tubes Removal / Installation Fig. 43 Crankshaft Position Sensor 1 – HEATER HOSES AND TUBES 1 – CRANKSHAFT POSITION SENSOR 2 – ROUTING/RETAINING CLIPS 2 – CYLINDER HEAD COVER 3 –. 9 - 34 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig.
46 Throttle Body Connection Points 1 – THROTTLE BODY 2 – TPS 3 – IAC MOTOR Fig. 47 Engine Lifting Fixture Attachment Locations 4 – IAT SENSOR 1 – ATTACHING LOCATION 5 –. 4.7L ENGINE 9 - 35 REMOVAL AND INSTALLATION (Continued) INTAKE MANIFOLD 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. 9 - 36 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (12) Connect electrical connectors for the following components:. Manifold Absolute Pressure (MAP) Sensor. Intake Air Temperature (IAT) Sensor. Throttle Position (TPS) Sensor.
Coolant Temperature (CTS) Sensor. Idle Air Control (IAC) Motor. 4.7L ENGINE 9 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 52 Exhaust Manifold—Right ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE Stud (Qty 2) Nut (Qty 2) 8 Nm (72 in.
Lbs.), then 25 Nm loosen 45 Bolt (Qty 4) Nut (Qty 2) (18 ft. 9 - 38 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (9) Install A/C compressor and fasteners.
(5) Disconnect the left side breather tube and (10) Install accessory drive belt. Remove the breather tube. (11) Install air cleaner assembly, resonator assem- (6) Remove the cylinder head cover mounting bly and air inlet hose. 4.7L ENGINE 9 - 39 REMOVAL AND INSTALLATION (Continued) Fig. 53 Exhaust Manifold—Left ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE Stud (Qty 2) Nut (Qty 2) 8 Nm (72 in. Lbs.), then loosen 25 Nm (18 ft. Bolt (Qty 4) Nut (Qty 2) 45 degrees lbs.) Stud (Qty 2).
9 - 40 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (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. 4.7L ENGINE 9 - 41 REMOVAL AND INSTALLATION (Continued) (11) Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark (Fig. 56 Rocker Arm—Removal 1 – CAMSHAFT 2 – SPECIAL TOOL 8516 Fig. 57 Engine Top Dead Center (TDC) Indicator Mark (4) For rocker arm installation on cylinders 1 and 1 –.
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9 - 42 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) 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. NOTE: The cylinder head is attached to the cylinder block with fourteen bolts. 4.7L ENGINE 9 - 43 REMOVAL AND INSTALLATION (Continued) (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, due to the design of the cylin- der head gasket any distortion to the cylinder head sealing surface may prevent the gasket from prop- erly sealing resulting in leaks. 9 - 44 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (14) Remove the timing chain cover.
Refer to Tim- ing Chain Cover in this section. (15) Lock the secondary timing chains to the idler sprocket using Special Tool 8515 (Fig. NOTE: Mark the secondary timing chain prior to removal to aid in installation.
4.7L ENGINE 9 - 45 REMOVAL AND INSTALLATION (Continued) NOTE: The cylinder head is attached to the cylinder (2) Position the new cylinder head gasket on the block with fourteen bolts. Locating dowels. (21) Remove the cylinder head retaining bolts. CAUTION: When installing cylinder head, use care (22) Remove the cylinder head and gasket. 9 - 46 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (14) Install crankshaft damper.
Tighten NOTE: All eight valve springs and seals are damper bolt 175 Nm (130 Ft. Removed in the same manner; this procedure only (15) Install accessory drive belt. Covers one valve seal and valve spring. 4.7L ENGINE 9 - 47 REMOVAL AND INSTALLATION (Continued) Fig. 68 Valve Assembly Configuration Fig. 69 Fan Assembly—Removal/Installation 1 – VALVE LOCKS (3–BEAD) 1 – SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER 2 – RETAINER PINS 8346 3 – VALVE STEM OIL SEAL 2 –. 9 - 48 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig.
72 Crankshaft Damper—Installation Fig. 70 Crankshaft Damper—Removal 1 – SPECIAL TOOL 8512 1 – SPECIAL TOOL 8513 INSERT 2 – SPECIAL TOOL 1026 (6) Install radiator upper shroud and tighten fas- teners to 11 Nm (95 in. 4.7L ENGINE 9 - 49 REMOVAL AND INSTALLATION (Continued) (9) Fill cooling system. Refer to Group 7, Cooling System for procedures.
(10) Connect the battery negative cable. TIMING CHAIN AND SPROCKETS REMOVAL (1) Disconnect negative cable from battery. (2) Drain cooling system. Refer to Group 7, Cooling System for procedures. 9 - 50 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 76 Camshaft Sprocket V8 Marks 1 – LEFT CYLINDER HEAD 2 – RIGHT CYLINDER HEAD Fig.
77 Cylinder Head Access Plug Location 1 – RIGHT CYLINDER HEAD ACCESS PLUG 2 – LEFT CYLINDER HEAD ACCESS PLUG Fig. 4.7L ENGINE 9 - 51 REMOVAL AND INSTALLATION (Continued) Fig. 79 Camshaft Position Sensor—Removal Fig. 80 Camshaft Rotation—Left Side 1 – CRANKSHAFT POSITION SENSOR 1 – CAMSHAFT SPROCKET AND CHAIN 2 – CYLINDER HEAD COVER 2 – ADJUSTABLE PLIERS 3 – CAMSHAFT POSITION SENSOR 3 –. 9 - 52 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig.
82 Timing Chain System 1 – RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN 7 – PRIMARY CHAIN 2 – SECONDARY TIMING CHAIN TENSIONER 8 – IDLER SPROCKET 3 – SECONDARY TENSIONER ARM 9 –. 4.7L ENGINE 9 - 53 REMOVAL AND INSTALLATION (Continued) the secondary timing chains are installed, position special tool 8515 to hold chains in place for installa- tion (Fig. (8) Align primary chain double plated links with the timing mark at 12 o’clock on the idler sprocket. Align the primary chain single plated link with the timing mark at 6 o’clock on the crankshaft sprocket (Fig. 9 - 54 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig.
85 Installing Idler Gear, Primary and Secondary Timing Chains 1 – SPECIAL TOOL 8515 2 – PRIMARY CHAIN IDLER SPROCKET 3 – CRANKSHAFT SPROCKET (13) Remove Special Tool 8515, then attach both sprockets to camshafts. 4.7L ENGINE 9 - 55 REMOVAL AND INSTALLATION (Continued) (25) Install the oil fill housing.
(26) Install access plug in left cylinder head (Fig. (27) Install power steering pump.
Refer to Group 19, Steering for procedure. (28) Install radiator fan shroud. Refer to Group 7, Cooling System for procedure. 9 - 56 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) CAUTION: When removing the cam sprocket, tim- ing chains or camshaft, Failure to use Special Tool 8350 will result in hydraulic tensioner ratchet over extension, requiring timing chain cover removal to reset the tensioner ratchet. 4.7L ENGINE 9 - 57 REMOVAL AND INSTALLATION (Continued) Fig. 91 Securing Timing Chain Tensioners Using Timing Chain Wedge 1 – LEFT CYLINDER HEAD 3 – SPECIAL TOOL 8350 WEDGE 2 – RIGHT CYLINDER HEAD 4 – SPECIAL TOOL 8350 WEDGE INSTALLATION (1) Lubricate camshaft journals with clean engine oil. 9 - 58 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (8) Remove excess oil from bolt, then install the camshaft sprocket retaining bolt and hand tighten.
(9) Remove Special Tool 8350 timing chain wedge (Fig. (10) Using Special Tool 6958 spanner wrench with adapter pins 8346 (Fig. 4.7L ENGINE 9 - 59 REMOVAL AND INSTALLATION (Continued) Fig. 95 Camshaft Sprocket Installation 1 – ADJUSTABLE PLIERS 2 – CAMSHAFT DOWEL (2) Set engine to TDC cylinder #1, camshaft sprocket V8 marks at the 12 o’clock position. 96 Tightening Left Side Cam Sprocket (3) Mark one link on the secondary timing chain Retaining Bolt on both sides of the V8 mark on the camshaft. 9 - 60 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig.
97 Securing Timing Chain Tensioners Using Timing Chain Wedge 1 – LEFT CYLINDER HEAD 3 – SPECIAL TOOL 8350 WEDGE 2 – RIGHT CYLINDER HEAD 4 – SPECIAL TOOL 8350 WEDGE Fig. 4.7L ENGINE 9 - 61 REMOVAL AND INSTALLATION (Continued) INSTALLATION (8) Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and (1) Lubricate camshaft journals with clean engine hand tighten. (9) Remove timing chain wedge special tool 8350 NOTE: Position the right side camshaft so that the (Fig. 9 - 62 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig.
101 Timing Chain to Sprocket Alignment 1 – LEFT CYLINDER HEAD 2 – RIGHT CYLINDER HEAD Fig. 103 Tightening Right Side Cam Sprocket Retaining Bolt 1 – TORQUE WRENCH Fig. 102 Camshaft Sprocket Installation 2 –.
4.7L ENGINE 9 - 63 REMOVAL AND INSTALLATION (Continued) Fig. 105 Checking Crankshaft End Play—Typical CRANKSHAFT END PLAY SPECIFICATION CHART Fig. 104 Main Bearing Markings on Target Wheel New Part: 0.052 - 0.282mm 1 – REARMOST CRANKSHAFT COUNTER WEIGHT Specification (0.002 - 0.011 in.) 2 –. 9 - 64 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (15) Start engine and check for leaks. OIL PAN 4X4 VEHICLE REMOVAL NOTE: 4X4 vehicles equipped with a 4.7L engine must have the front axle removed before the oil pan can be removed. (1) Remove the front axle from vehicle.
4.7L ENGINE 9 - 65 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Clean the oil pan gasket mating surface of the bedplate and oil pan. (2) Position the oil pan gasket and pickup tube with new o-ring. Install the mounting bolt and nuts. Tighten bolt and nuts to 28 Nm (20 ft. 9 - 66 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 114 Piston Ring End Gap Position Fig.
112 Side Rail—Installation 1 – SIDE RAIL UPPER 1 – SIDE RAIL END 2 – NO. 1 RING GAP 3 – PISTON PIN 4 –. 4.7L ENGINE 9 - 67 REMOVAL AND INSTALLATION (Continued) CRANKSHAFT REMOVAL NOTE: To remove the crankshaft from the engine, the engine must be removed from the vehicle. (1) Remove the engine. Refer to Engine Assembly in this section for procedure. (2) Remove the engine oil pump. 9 - 68 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (1) Lubricate upper main bearing halves with clean engine oil.
CAUTION: When installing crankshaft, use care not to damage bearing surfaces on the crankshaft. NOTE: Apply sealant to the tone wheel retaining screws prior to installation. 4.7L ENGINE 9 - 69 REMOVAL AND INSTALLATION (Continued). Tighten bolts A1– A6 to 27 Nm (20 ft. Lbs.) (8) Measure crankshaft end play. Refer to Crank- shaft Main Bearings in this section for procedure. (9) Install the connecting rods and measure side clearance.
9 - 70 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 121 Bedplate Tightening Sequence Fig. 122 Oil Pan Tightening Sequence ENGINE OIL PRESSURE SENDING UNIT 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. 4.7L ENGINE 9 - 71 REMOVAL AND INSTALLATION (Continued) (4) Drain cooling system. Refer to Group 7, Cooling System for procedure. (5) Remove upper radiator hose.
(6) Using Special Tools 6958 Spanner with Adapter Pins 8346 loosen fan and viscous assembly from water pump (Fig. 9 - 72 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 127 Crankshaft Damper—Removal Fig. 129 Crankshaft Front Seal—Installation 1 – SPECIAL TOOL 8513 INSERT 1 – TIMING CHAIN COVER 2 – SPECIAL TOOL 1026 2 – SPECIAL TOOL 8348 3 – SPECIAL TOOL 8512 (2) Assemble Special Tool 8512 as follows, The nut is threaded onto the shaft first. 4.7L ENGINE 9 - 73 REMOVAL AND INSTALLATION (Continued) (1) If being preformed in vehicle, remove the transmission. Refer to Group 21, Transmission and Transfer Case. (2) Remove the flexplate.
Refer to procedure in this section. NOTE: The crankshaft oil seal CAN NOT be reused after removal. 9 - 74 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 135 Engine Core Plug Removal 1 – CYLINDER BLOCK 2 – REMOVE PLUG WITH PLIERS Fig. 133 Crankshaft Rear Oil Seal Guide Special 3 – STRIKE HERE WITH HAMMER Tool 8349–2 and Oil Seal 4 –. 4.7L ENGINE 9 - 75 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: Once the oil pressure relief valve, cup plug, (3) Inspect the manifold to exhaust pipe mating and pin are removed, the pump assembly must be surface for cracks, gouges, or other damage that would prevent sealing. 9 - 76 4.7L ENGINE CLEANING AND INSPECTION (Continued) PISTON AND CONNECTING ROD (1) Clean all parts thoroughly.
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Mating surface of the oil pump housing should be smooth. If the pump cover is scratched or grooved the oil pump assembly CLEANING should be replaced. 4.7L ENGINE 9 - 77 CLEANING AND INSPECTION (Continued) Fig. 137 Checking Oil Pump Cover Flatness 1 – STRAIGHT EDGE 2 – FEELER GAUGE 3 – OIL PUMP COVER Fig.
140 Measuring Outer Rotor Clearance in Housing 1 – FEELER GAUGE 2 –. 9 - 78 4.7L ENGINE CLEANING AND INSPECTION (Continued) (4) Determine taper by subtracting the smaller diameter from the larger diameter. (5) Rotate measuring device 90° 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. 4.7L ENGINE 9 - 79 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION No. 3 83.88 - 84.08 mm Bearing Bore Out of 0.004 mm Round (3.302 - 3.310 in.) (MAX) (0.0002 in.) PISTON PINS Total Weight (Less 578 grams (20.388 Type Pressed Fit Bearing) ounces).
9 - 80 4.7L ENGINE 2000 DN Service Manual SPECIFICATIONS (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Spring Force (Valve Exhaust Closed) Opens (BTDC) 232.5° Intake and Exhaust 315.5 - 352.5 N @ 40.89 Closes (ATDC) 21.2°.
4.7L ENGINE 9 - 81 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION Nm OIL PUMP Lbs. Clearance Over Rotors.035.095 mm Flexplate—Bolts — (MAX) Engine Mount Bracket to — (0.0014 - 0.0038 in.) Block—Bolts Cover Out - of -Flat.025 mm (0.001 in.) Rear Mount to —. 9 - 82 4.7L ENGINE SPECIAL TOOLS 4.7L ENGINE Front Crankshaft Seal Remover 8511 Spanner Wrench 6958 Front Crankshaft Seal Installer 8348 Adapter Pins 8346 Engine Lifting Studs 8400 Handle C-4171 Engine Lift Fixture 8347 Rear Crankshaft Seal Installer 8349.
4.7L ENGINE 9 - 83 SPECIAL TOOLS (Continued) Crankshaft Damper Removal Insert 8513 Rear Crankshaft Seal Remover 8506 Connecting Rod Guides 8507 Chain Tensioner Wedge 8350 Crankshaft Damper Installer 8512 Chain Tensioner Pins 8514 Puller 1026 Secondary Chain Holder 8515. 9 - 84 4.7L ENGINE SPECIAL TOOLS (Continued) Valve Spring Tester C-647 Remover, Rocker Arm 8516 Dial Indicator C-3339 Valve Spring Compressor 8387 Valve Spring Compressor C-3422-B Idler Shaft Remover 8517 Bore Size Indicator C-119 Valve Spring Compressor Adapters 8519 Oil Pressure Gauge C-3292. 4.7L ENGINE 9 - 85 SPECIAL TOOLS (Continued) Pressure Tester Kit 7700 Piston Ring Compressor C-385 Bloc–Chek–Kit C-3685–A.
9 - 86 5.2L ENGINE 5.2L ENGINE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION CYLINDER HEAD.107 ENGINE. 5.2L ENGINE 9 - 87 DESCRIPTION AND OPERATION (Continued) Fig. 3 Positive Displacement Oil Pump—Typical 1 – INNER ROTOR AND SHAFT 2 – BODY 3 – DISTRIBUTOR DRIVESHAFT (REFERENCE) Fig. 1 Firing Order 4 – COTTER PIN 5 – RETAINER CAP 6 –. 9 - 88 5.2L ENGINE DESCRIPTION AND OPERATION (Continued). 5.2L ENGINE 9 - 89 DESCRIPTION AND OPERATION (Continued) 1 – OIL DEFLECTOR TAB 14 – OIL PUMP 2 – BOLT 15 – OIL FILTER 3 – ROCKER ARM PIVOT 16 – CRANKSHAFT 4 – ROCKER ARM 17 – FROM OIL PUMP 5 –. 9 - 90 5.2L ENGINE DESCRIPTION AND OPERATION (Continued) CYLINDER HEAD COVER GASKET OPERATION The cylinder head closes the combustion chamber DESCRIPTION allowing the pistons to compress the air fuel mixture to the correct ratio for ignition.
The valves located in The cylinder head cover gasket is a steel-backed the cylinder head open and close to either allow clean silicone gasket, designed for long life usage (Fig. 5.2L ENGINE 9 - 91 DESCRIPTION AND OPERATION (Continued) CRANKSHAFT MAIN BEARINGS DESCRIPTION Main bearings are located in the cylinder block. One half of the main bearing is located in the crank- shaft main bore the other half of the matching bear- ing is located in the main bearing cap (Fig. 9 - 92 5.2L ENGINE SERVICE PROCEDURES (Continued) Scrape or wire brush all gasket surfaces to remove (9) Inspect crankcase ventilation system as out all loose material.
Inspect stamped parts to ensure lined in Group 0, Lubrication and Maintenance. For gasket rails are flat. 5.2L ENGINE 9 - 93 SERVICE PROCEDURES (Continued) particular ambient temperature range and variation To ensure proper lubrication of an engine, the (Fig.
Engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick.
9 - 94 5.2L ENGINE SERVICE PROCEDURES (Continued). Tapping the hole with a special Heli-Coil Tap, or equivalent. Installing an insert into the tapped hole to bring the hole back to its original thread size.
CYLINDER BORE—HONING Before honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area. 5.2L ENGINE 9 - 95 SERVICE PROCEDURES (Continued) (4) A controlled hone motor speed between 200 and (2) Insert a 6.350 mm (1/4 inch) spacer between 300 RPM is necessary to obtain the proper cross- rocker arm pad and stem tip of No.1 intake valve.
9 - 96 5.2L ENGINE SERVICE PROCEDURES (Continued) (2) Attach Dial Indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured (Fig. 18 Measuring Valve Guide Wear Fig. 19 Valve Face and Seat Angles 1 –. 5.2L ENGINE 9 - 97 SERVICE PROCEDURES (Continued) (4) When seat is properly positioned the width of intake seats should be 1.016-1.524 mm (0.040-0.060 inch). The width of the exhaust seats should be 1.524-2.032 mm (0.060-0.080 inch). VALVE SPRING INSPECTION Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested.
9 - 98 5.2L ENGINE SERVICE PROCEDURES (Continued) sprocket bolt, crankshaft should not be permitted to move. It may be necessary to block the crankshaft to prevent rotation. (3) Hold a scale with dimensional reading even with the edge of a chain link. With cylinder heads installed, apply 14 Nm (30 ft.
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5.2L ENGINE 9 - 99 SERVICE PROCEDURES (Continued) PISTON MEASUREMENT CHART up (toward top of piston) and chamfer facing down. An identification mark on the ring is a drill point, a stamped letter “O”, an oval depression or the PISTON A DIA = PISTON BORE word TOP (Fig.
9 - 100 5.2L ENGINE SERVICE PROCEDURES (Continued) The bearing shells must be installed so that the tangs are in the machined grooves in the rods and caps. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Bearings are available in 0.025 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch) under. 5.2L ENGINE 9 - 101 REMOVAL AND INSTALLATION (Continued) (1) Disconnect the negative cable from the battery.
(2) Raise vehicle on hoist. (3) Install engine lifting (support) fixture. (4) Remove front axle assembly. (Refer to Group 3, Differential and Driveline in this publication.) (5) Left mount insulator only. 9 - 102 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 33 Engine Mount Insulator at Frame 1 – NUT 2 – ENGINE SUPPORT BRACKET Fig. 34 Rear Mount Insulator 3 – INSULATOR 4 – NUT 1 – AUTOMATIC TRANSMISSION 5 – THROUGH BOLT 2 –.
5.2L ENGINE 9 - 103 REMOVAL AND INSTALLATION (Continued) (9) Disconnect the accelerator linkage. (11) Install the generator (refer to Group 8B, Bat- (10) Remove throttle body. Tery/Starter/Generator Service). (11) Perform the Fuel System Pressure release (12) Install starter motor (refer to Group 8B, Bat- procedure (refer to Group 14, fuel System).
9 - 104 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) (13) Disconnect the heater hoses and bypass hose. (14) Remove the closed crankcase ventilation and evaporation control systems. (15) Remove intake manifold bolts. (16) Lift the intake manifold and throttle body out of the engine compartment as an assembly.
5.2L ENGINE 9 - 105 REMOVAL AND INSTALLATION (Continued). Step 1—Tighten bolts 1 thru 4, in sequence, to 8 Nm (72 in.
Lbs.) torque. Tighten in alternating steps 1.4 Nm (12 in. Lbs.) torque at a time. Step 2—Tighten bolts 5 thru 12, in sequence, to 8 Nm (72 in. 9 - 106 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) Fig.
Dodge Ram Service Manual
42 Exhaust Manifold Installation—5.9L Engine Fig. 40 Exhaust Manifold Heat Shield—Right Side 1 – EXHAUST MANIFOLD (LEFT) 2 – BOLTS & WASHERS 1 – WASHER 3 – NUTS & WASHERS 2 –. 5.2L ENGINE 9 - 107 REMOVAL AND INSTALLATION (Continued) (2) Position the cylinder head cover onto the gas- (3) Remove coil wire from distributor and secure to ket. Tighten the bolts to 11 Nm (95 in. Lbs.) torque. Good ground to prevent engine from starting. (3) Install closed crankcase ventilation system and (4) Using suitable socket and flex handle at crank- evaporation control system.
9 - 108 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) (15) Remove intake manifold and throttle body as (10) Connect the heater hoses and bypass hose. Discard the flange side gaskets and the (11) Install distributor cap and wires. Front and rear cross-over gaskets. 5.2L ENGINE 9 - 109 REMOVAL AND INSTALLATION (Continued) spring seat in cylinder head to the bottom surface of (3) Remove the cooling system fan. Spring retainer. If spacers are installed, measure (4) Remove the serpentine belt (refer to Group 7, from the top of spacer.
9 - 110 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) (7) Position the fan shroud and install the bolts. Tighten the retainer bolts to 11 Nm (95 in. Lbs.) torque.
(8) Connect the negative cable to the battery. TIMING CHAIN COVER (1) Disconnect the negative cable from the battery. 5.2L ENGINE 9 - 111 REMOVAL AND INSTALLATION (Continued) the crankshaft to align timing marks as shown in (Fig. (4) Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets. INSTALLATION (1) Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. 9 - 112 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 51 mm (2 inches) of its final position in cylinder block.
(2) Install Camshaft Gear Installer Tool C-3509 with tongue back of distributor drive gear (Fig. 5.2L ENGINE 9 - 113 REMOVAL AND INSTALLATION (Continued) Fig. 56 Alignment of Timing Marks Fig. 57 Camshaft Bearings Removal/Installation with 1 – TIMING MARKS Tool C-3132-A 1 – SPECIAL TOOL C-3132–A (13) Install distributor and distributor drive shaft. 2 – MAIN BEARING OIL HOLE (14) Install push rods and tappets. 9 - 114 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION Only one main bearing should be selectively fitted while all other main bearing caps are properly tight- ened. All bearing capbolts removed during service pro- cedures are to be cleaned and oiled before installation.
When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. 5.2L ENGINE 9 - 115 2000 DN Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 Fig. 62 Position of Oil Pump Shaft Slot 1 – DISTRIBUTOR DRIVE After the distributor has been installed, its rota- tional position must be set using the SET SYNC mode of the DRB scan tool. 9 - 115A 5.2L ENGINE 2000 DN Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 (8) Install the drain plug.
Tighten drain plug to 34 Nm (25 ft. Lbs.) torque. (9) Lower transmission onto crossmember. (10) Install rear support cushion mounting bolts. 9 - 116 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) PISTON AND CONNECTING ROD ASSEMBLY (4) Install connecting rod bolt protectors on rod bolts, the long protector should be installed on the numbered side of the connecting rod.
REMOVAL (5) Rotate crankshaft so that the connecting rod (1) Remove the engine from the vehicle. 5.2L ENGINE 9 - 117 REMOVAL AND INSTALLATION (Continued) INSTALLATION Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess seal- (1) Clean Gasket Maker residue and sealant from ant off the oil pan seal groove. The cylinder block and rear cap mating surface.
9 - 118 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) interference. If tool does not fit, the cover must be removed and installed properly. (4) Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal bore of cover. 5.2L ENGINE 9 - 119 REMOVAL AND INSTALLATION (Continued) (2) Lightly oil the new upper seal lips with engine oil. (3) Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. (4) Position the crankshaft into the cylinder block.
9 - 120 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) (6) To align the bearing cap, use cap slot, align- ENGINE CORE OIL AND CAMSHAFT PLUGS ment dowel and cap bolts. DO NOT remove excess Engine core plugs have been pressed into the oil material after assembly. 5.2L ENGINE 9 - 121 REMOVAL AND INSTALLATION (Continued) (2) Attach Dial Indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured (Fig. 74 Core Hole Plug Removal 1 – CYLINDER BLOCK 2 –.
9 - 122 5.2L ENGINE DISASSEMBLY AND ASSEMBLY (Continued) REFACING VALVES AND VALVE SEATS The intake and exhaust valves have a 43-1/4° to 43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle (Fig. 78 Intake and Exhaust Valves 1 –.
5.2L ENGINE 9 - 123 DISASSEMBLY AND ASSEMBLY (Continued) (2) Measure the concentricity of valve seat using a OIL PUMP dial indicator. Total runout should not exceed 0.051 mm (0.002 inch) total indicator reading. DISASSEMBLE (3) Inspect the valve seat with Prussian blue to (1) Remove the relief valve as follows: determine where the valve contacts the seat. 9 - 124 5.2L ENGINE DISASSEMBLY AND ASSEMBLY (Continued) CLEANING AND INSPECTION CYLINDER HEAD COVER CLEANING Clean cylinder head cover gasket surface. Clean head rail, if necessary. INSPECTION Inspect cover for distortion and straighten, if nec- essary.
Check the gasket for use in head cover installation. If damaged, use a new gasket. 5.2L ENGINE 9 - 125 CLEANING AND INSPECTION (Continued) Clean oil pan in solvent and wipe dry with a clean cloth.
Clean oil screen and pipe thoroughly in clean sol- vent. Inspect condition of screen. INSPECTION Inspect oil drain plug and plug hole for stripped or damaged threads.
9 - 126 5.2L ENGINE CLEANING AND INSPECTION (Continued) Fig. 85 Measuring Outer Rotor Thickness Fig. 88 Measuring Clearance Between Rotors 1 – OUTER ROTOR 2 – FEELER GAUGE 3 – INNER ROTOR Place a straightedge across the face of the pump, between bolt holes. 5.2L ENGINE 9 - 127 CLEANING AND INSPECTION (Continued). The cylinder bores show a taper of more than If oil pressure was low and pump is within specifi- cations, inspect for worn engine bearings or other 0.254 mm (0.010 inch). 9 - 128 5.2L ENGINE SPECIFICATIONS DESCRIPTION SPECIFICATION 5.2L ENGINE SPECIFICATIONS No. 5 39.688 – 39.713 mm ENGINE SPECIFICATIONS (1.5625 – 1.5635 in.) Bearing Journal Diameter DESCRIPTION SPECIFICATION No.
1 50.749 – 50.775 mm GENERAL SPECIFICATIONS (1.998 – 1.999 in.) No.
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