2003 DODGE RAM rocker arm

ENGINE LUBRICATION FLOW CHART - BLOCK: TABLE 1
FROM TO
Oil Pickup Tube Oil Pump
Oil Pump Oil Filter
Oil Filter Block Main Oil Gallery
Block Main Oil Gallery 1. Crankshaft Main Journal
2. Left Cylinder Head*
3. Right Cylinder Head*
4. Counterbalance Shaft Rear Journal
Crankshaft Main Journals Crankshaft Rod Journals
Crankshaft Number One Main Journal 1. Front Timing Chain Idler Shaft
2. Counterbalance Shaft - Front Journal
3. Both Secondary Chain Tensioners
Left Cylinder Head Refer to Engine Lubrication Flow Chart - Cylinder
Heads: Table 2
Right Cylinder Head Refer to Engine Lubrication Flow Chart - Cylinder
Heads: Table 2
* The cylinder head gaskets have an oil restricter to control oil flow to the cylinder heads
ENGINE LUBRICATION FLOW CHART - CYLINDER HEADS: TABLE 2
FROM TO
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. Base of Camshaft Towers
2. Lash Adjuster Towers
Base of Camshaft Towers Vertical Drilling Through Tower to Camshaft Bearings**
Lash Adjuster Towers Diagonal Drillings to Hydraulic Lash Adjuster Pockets
** The number three camshaft bearing journal feeds oil into the hollow camshaft tubes. Oil is routed to the intake
lobes, which have oil passages drilled into them to lubricate the rocker arms.
DRENGINE - 3.7L 9 - 61
LUBRICATION (Continued)

ENGINE - 4.7L
TABLE OF CONTENTS
page page
ENGINE - 4.7L
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE...........89
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL.............91
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE.............92
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE......92
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........93
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.........93
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........93
REMOVAL.............................94
INSTALLATION.........................96
SPECIFICATIONS
4.7L ENGINE.........................98
TORQUE...........................101
SPECIAL TOOLS
4.7L ENGINE........................102
AIR CLEANER ELEMENT
REMOVAL............................105
INSTALLATION........................105
CYLINDER HEAD
DESCRIPTION
DESCRIPTION - CYLINDER HEAD.......106
DESCRIPTION - VALVE GUIDES.........106
REMOVAL
REMOVAL - LEFT CYLINDER HEAD......106
REMOVAL - RIGHT CYLINDER HEAD.....108
CLEANING...........................110
INSPECTION..........................110
INSTALLATION
INSTALLATION - LEFT CYLINDER HEAD . . . 110
INSTALLATION - RIGHT CYLINDER HEAD . . 111
CAMSHAFT(S) - LEFT
DESCRIPTION........................113
REMOVAL............................113
INSTALLATION........................114
CAMSHAFT(S) - RIGHT
DESCRIPTION........................117
REMOVAL............................117
INSTALLATION........................118
CYLINDER HEAD COVER(S)
DESCRIPTION........................121REMOVAL
REMOVAL - RIGHT SIDE...............121
REMOVAL - LEFT SIDE................121
CLEANING...........................121
INSTALLATION
INSTALLATION - RIGHT SIDE...........121
INSTALLATIONÐLEFT SIDE............122
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................122
REMOVAL............................122
INSTALLATION........................123
ROCKER ARM / ADJUSTER ASSEMBLY
DESCRIPTION........................124
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER.....................124
REMOVAL............................124
INSTALLATION........................124
VALVE SPRINGS
DESCRIPTION........................125
REMOVAL............................125
INSTALLATION........................126
VALVE STEM SEALS
DESCRIPTION........................126
ENGINE BLOCK
DESCRIPTION........................126
STANDARD PROCEDUREÐCYLINDER BORE
HONING...........................126
CLEANING...........................127
INSPECTION.........................127
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING...............128
CORE PLUGS
REMOVAL............................129
INSTALLATION........................130
CRANKSHAFT
DESCRIPTION........................130
REMOVAL............................130
INSPECTION.........................131
INSTALLATION........................131
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDUREÐCRANKSHAFT
MAIN BEARING - FITTING..............133
INSPECTION.........................133
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................134
INSTALLATION........................134
DRENGINE - 4.7L 9 - 87

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTIONS
NOISY VALVES 1. High or low oil level in
crankcase.1. (Refer to LUBRICATION &
MAINTENANCE -
SPECIFICATIONS)
2. Thin or diluted oil. 2. Change oil and filter.
3. Low oil pressure. 3. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
4. Dirt in lash adjusters. 4. Replace as necessary.
5. Worn rocker arms. 5. Replace as necessary.
6. Worn lash adjusters 6. Replace as necessary.
7. Worn valve guides. 7. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE)
8. Excessive runout of valve seats
on valve faces.8. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE)
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
MAINTENANCE -
SPECIFICATIONS)
2. Low oil pressure. 2. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
3. Thin or diluted oil. 3. Change oil and filter.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Connecting rod journal
out-of-round.5. Service or replace crankshaft.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
MAINTENANCE -
SPECIFICATIONS)
2. Low oil pressure. 2. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
3. Thin or diluted oil. 3. Change oil and filter.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Excessive end play. 5. Check thrust washers for wear.
6. Crankshaft journal out-of round. 6. Service or replace crankshaft.
7. Loose flywheel or torque
converter.7. Tighten to correct torque
DRENGINE - 4.7L 9 - 91
ENGINE - 4.7L (Continued)

Remover, Rocker Arm 8516
Valve Spring Compressor 8387
Idler Shaft Remover 8517
Valve Spring Compressor Adapters 8519
Valve Spring Tester C-647
Dial Indicator C-3339
Valve Spring Compressor C-3422-B
Bore Size Indicator C-119
Oil Pressure Gauge C-3292
9 - 104 ENGINE - 4.7LDR
ENGINE - 4.7L (Continued)

(11) Re-set and install the right side secondary
chain tensioner.
(12) Remove Special Tool 8515.
(13) Install the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(14) Install the crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(15) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(16) Install the fan shroud.
(17) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(18) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(19) Install oil fill housing onto cylinder head.
(20) Refill the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(21) Raise the vehicle.
(22) Install the exhaust pipe onto the right
exhaust manifold.
(23) Lower the vehicle.
(24) Reconnect battery negitive cable.
(25) Start the engine and check for leaks.
CAMSHAFT(S) - LEFT
DESCRIPTION
The camshafts consist of powdered metal steel
lobes which are sinter-bonded to a steel tube. A steel
post or nose piece is friction-welded to the steel cam-
shaft tube. Five bearing journals are machined into
the camshaft, four on the steel tube and one on the
steel nose piece. Camshaft end play is controlled by
two thrust walls that border the nose piece journal.
Engine oil enters the hollow camshafts at the third
journal and lubricates every intake lobe rocker
through a drilled passage in the intake lobe.
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.CAUTION: When removing the cam sprocket, timing
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.
(1) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(2) Set engine to TDC cylinder #1, camshaft
sprocket V8 marks at the 12 o'clock position.
(3) Mark one link on the secondary timing chain
on both sides of the V8 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 8350 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. 25).
NOTE: When gripping the camshaft, place the pliers
on the tube portion of the camshaft only. Do not
grip the lobes or the sprocket areas.
DRENGINE - 4.7L 9 - 113
CYLINDER HEAD (Continued)

(6) Hold the camshaft with adjustable pliers while
removing the camshaft sprocket bolt and sprocket
(Fig. 26).(7) Using the pliers, gently allow the camshaft to
rotate 15É clockwise until the camshaft is in the neu-
tral 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.
INSTALLATION
(1) Lubricate camshaft journals with clean engine
oil.
NOTE: Position the left side camshaft so that the
camshaft sprocket dowel is near the 1 o'clock posi-
tion, 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.
Fig. 25 Securing Timing Chain Tensioners Using Timing Chain Wedge
1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD3 - SPECIAL TOOL 8350 WEDGE
4 - SPECIAL TOOL 8350 WEDGE
Fig. 26 Camshaft Sprocket and Chain
1 - CAMSHAFT SPROCKET AND CHAIN
2 - ADJUSTABLE PLIERS
3 - CAMSHAFT
9 - 114 ENGINE - 4.7LDR
CAMSHAFT(S) - LEFT (Continued)

(5) Position Special Tool 8350 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. 32).
(6) Remove the camshaft position sensor (Fig. 33).
NOTE: When gripping the camshaft, place the pliers
on the tube portion of the camshaft only. Do not
grip the lobes or the sprocket areas.
(7) Hold the camshaft with adjustable pliers while
removing the camshaft sprocket bolt and sprocket
(Fig. 34).
(8) Using the pliers, gently allow the camshaft to
rotate 45É counter-clockwise until the camshaft is in
the neutral position (no valve load).
(9) 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.
(10) Remove the camshaft bearing caps and the
camshaft.
INSTALLATION
(1) Lubricate camshaft journals with clean engine
oil.
Fig. 32 Securing Timing Chain Tensioners Using Timing Chain Wedge
1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD3 - SPECIAL TOOL 8350 WEDGE
4 - SPECIAL TOOL 8350 WEDGE
Fig. 33 Camshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
2 - CYLINDER HEAD COVER
3 - CAMSHAFT POSITION SENSOR
4 - RIGHT SIDE CYLINDER BLOCK
9 - 118 ENGINE - 4.7LDR
CAMSHAFT(S) - RIGHT (Continued)

(11) Fill Cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(12) Install air cleaner assembly, resonator assem-
bly and air inlet hose.
(13) Connect battery negative cable.
INSTALLATIONÐLEFT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the cylin-
der head cover. Prolonged contact with other
objects may wear a hole in the engine cylinder head
cover.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2) Install cylinder head cover and hand start all
fasteners. Verify that all studs are in the correct loca-
tion shown in (Fig. 40).
(3) Tighten cylinder head cover bolts and double
ended studs to 12 N´m (105 in. lbs.).
(4) Install left side breather and connect breather
tube.
(5) Connect injector electrical connectors and injec-
tor harness retaining clips.
(6) Install the resonator and air inlet hose.
(7) Connect negative cable to battery.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves are made of heat resistant steel and
have chrome plated stems to prevent scuffing. Each
valve is actuated by a roller rocker arm which pivots
on a stationary lash adjuster. All valves use three
bead lock keepers to retain the springs and promote
valve rotation.
REMOVAL
NOTE: The cylinder heads must be removed in
order to perform this procedure.
(1) Remove rocker arms and lash adjusters(Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARM /
ADJUSTER ASSY - REMOVAL). (Fig. 41).
(2) Remove the camshaft bearing caps and the
camshaft.
NOTE: All six valve springs and valves are removed
in the same manner; this procedure only covers
one valve and valve spring.
(3) Using Special Tool C-3422±B or C-3422±C
Valve Spring Compressor and Special tool 8519
Adapter, compress the valve spring.
Fig. 40 Cylinder Head CoverÐLeft
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 N´m (105 in. lbs.)
Fig. 41 Rocker Arm Removal
1 - CAMSHAFT
2 - SPECIAL TOOL 8516
9 - 122 ENGINE - 4.7LDR
CYLINDER HEAD COVER(S) (Continued)