2003 DODGE RAM oil level

(4) Install the cluster bezel onto the instrument
panel (Fig. 9).
(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. 10).
(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.
(3) Install the bolts attaching headlamp unit to the
fender (Fig. 10).
(4) Align the seal and install the push pins.
(5) Connect the battery negative cable.
ADJUSTMENTS
Headlamps can be aligned using the screen method
provided in this section. Alignment Tool C-4466-A or
equivalent can also be used. Refer to instructions
provided with the tool for proper procedures.
LAMP ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft) away from front
of headlamp lens (Fig. 11).
(2) If necessary, tape a line on the floor 7.62
meters (25 ft) away from and parallel to the wall.
(3) Up 1.27 meters (5 feet) from the floor, tape a
line on the wall at the centerline of the vehicle. Sight
along the centerline of the vehicle (from rear of vehi-
cle forward) to verify accuracy of the line placement.
(4) Rock vehicle side-to-side three times to allow
suspension to stabilize.
(5) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(6) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
(7) Measure distance from the centerline of the
vehicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
side of vehicle centerline. Use these lines for left/
right adjustment reference.
VEHICLE PREPARATION FOR HEADLAMP
ALIGNMENT
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Correct defective components that could hinder
proper headlamp alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is not heavily loaded.
(6) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
HEADLAMP ALIGNMENT
A properly aimed low beam headlamp will project
top edge of high intensity pattern on screen from 50
mm (2 in.) above to 50 mm (2 in.) below headlamp
centerline. The side-to-side outboard edge of high
intensity pattern should be from 50 mm (2 in.) left to
50 mm (2 in.) right of headlamp centerline (Fig. 11).
The preferred headlamp alignment is 1(down
for the up/down adjustment and 0 for the left/
right adjustment.The high beam pattern should be
correct when the low beams are aligned properly.
To adjust low beam headlamp, rotate alignment
screws to achieve the specified aim.
Fig. 10 HEADLAMP Ð TYPICAL
1 - SEAL
2 - PUSH PIN
3 - SCREW
4 - HEADLAMP UNIT
DRLAMPS/LIGHTING - EXTERIOR 8L - 15
HEADLAMP SWITCH (Continued)

8W-10 POWER DISTRIBUTION
Component PageA/C Compressor Clutch....................8W-10-16, 43, 44
A/C Compressor Clutch Relay.................8W-10-16, 43, 44
A/C-Heater Control......................8W-10-46, 47, 58
Adjustable Pedal Relay......................8W-10-14, 34
Adjustable Pedal Switch.................8W-10-14, 34, 46, 58
Airbag Control Module......................8W-10-46, 48
Airbag Control Module-Left Side Impact...............8W-10-46
Airbag Control Module-Right Side Impact..............8W-10-46
Ambient Temperature Sensor...................8W-10-52, 54
Amplifier Audio...........................8W-10-33
Auto Shut Down Relay......................8W-10-11, 18
Automatic Day/Night Mirror...................8W-10-45, 52
Auxiliary Battery...........................8W-10-11
Backup Lamp Switch.......................8W-10-48, 53
Battery..............................8W-10-11, 18
Blower Motor.............................8W-10-56
Brake Lamp Switch....................8W-10-13, 32, 43, 44
Capacitor.............................8W-10-21, 23
Center High Mounted Stop Lamp/Cargo Lamp............8W-10-42
Cigar Lighter Outlet.........................8W-10-50
Circuit Breaker............................8W-10-56
Clearance Lamp No. 1........................8W-10-37
Clearance Lamp No. 2........................8W-10-37
Clearance Lamp No. 3........................8W-10-37
Clearance Lamp No. 4........................8W-10-37
Clearance Lamp No. 5........................8W-10-37
Clutch Interlock Brake Switch....................8W-10-39
Coil On Plug No. 1........................8W-10-19, 22
Coil On Plug No. 2........................8W-10-20, 21
Coil On Plug No. 3........................8W-10-19, 22
Coil On Plug No. 4........................8W-10-20, 21
Coil On Plug No. 5........................8W-10-19, 22
Coil On Plug No. 6........................8W-10-20, 21
Coil On Plug No. 7........................8W-10-19, 22
Coil On Plug No. 8........................8W-10-20, 21
Compass/Mini-Trip Computer...................8W-10-42, 45
Condenser Fan..........................8W-10-17, 49
Condenser Fan Relay.......................8W-10-17, 49
Controller Antilock Brake...................8W-10-13, 30, 48
Data Link Connector.......................8W-10-32, 54
Dome Lamp.............................8W-10-42
Door Lock Switch-Passenger.....................8W-10-45
Driver Door Module.......................8W-10-42, 56
Electric Brake Provision.......................8W-10-18
Engine Control Module........................8W-10-43
EVAP/Purge Solenoid.........................8W-10-45
Fender Lamp-Front Left.......................8W-10-37
Fender Lamp-Front Right......................8W-10-37
Fender Lamp-Rear Left.......................8W-10-37
Fender Lamp-Rear Right.......................8W-10-37
Fog Lamp Relay.........................8W-10-15, 38
Fog Lamp-Left............................8W-10-38
Fog Lamp-Right...........................8W-10-38
Front Control Module....8W-10-12, 31, 32, 34, 35, 36, 48, 45, 51, 52, 54 , 55
Fuel Heater.............................8W-10-57
Fuel Heater Relay........................8W-10-17, 57
Fuel Injector No. 1........................8W-10-22, 24
Fuel Injector No. 2....................8W-10-20, 21, 23, 24
Fuel Injector No. 3........................8W-10-22, 24
Fuel Injector No. 4....................8W-10-20, 21, 23, 24
Fuel Injector No. 5........................8W-10-22, 24
Fuel Injector No. 6....................8W-10-20, 21, 23, 24
Fuel Injector No. 7........................8W-10-22, 24
Fuel Injector No. 8....................8W-10-20, 21, 23, 24
Fuel Injector No. 9..........................8W-10-24
Fuel Injector No. 10.........................8W-10-23
Fuel Pump Module........................8W-10-16, 42
Fuel Pump Relay.....................8W-10-16, 42, 43, 44
Fuse 1..............................8W-10-11, 18
Fuse 2............................8W-10-11, 12, 18
Fuse 3..............................8W-10-12, 26
Fuse 4..............................8W-10-12, 26
Fuse 5.......................8W-10-11, 12, 13, 27, 28, 29
Fuse 6............................8W-10-12, 13, 30
Fuse 7..............................8W-10-13, 30
Fuse 8..............................8W-10-14, 31
Fuse 9..............................8W-10-12, 26
Fuse 10..............................8W-10-12, 26
Fuse 11............................8W-10-12, 13, 32
Fuse 12............................8W-10-17, 49, 57
Fuse 13..............................8W-10-12, 32
Fuse 14..............................8W-10-14, 39
Fuse 15............................8W-10-15, 16, 36
Fuse 16............................8W-10-16, 43, 44
Fuse 17............................8W-10-16, 17, 42
Fuse 18..............................8W-10-13, 32
Fuse 19..............................8W-10-13, 33
Fuse 20..............................8W-10-12, 26
Fuse 21..............................8W-10-13, 33
Fuse 22..............................8W-10-13, 33
Fuse 24..............................8W-10-13, 32
Fuse 25..............................8W-10-13, 33
Fuse 27............................8W-10-16, 17, 47
Fuse 28............................8W-10-43, 44, 45
Fuse 32..............................8W-10-16, 36
Fuse 33..............................8W-10-16, 36Component PageFuse 34..............................8W-10-16, 36
Fuse 35...............................8W-10-48
Fuse 36..............................8W-10-47, 58
Fuse 37...............................8W-10-48
Fuse 38..............................8W-10-47, 48
Fuse 40............................8W-10-14, 15, 34
Fuse 41..............................8W-10-15, 38
Fuse 42..............................8W-10-13, 34
Fuse 43..............................8W-10-13, 34
Fuse 45............................8W-10-15, 16, 38
Fuse 46............................8W-10-14, 15, 35
Fuse 47..............................8W-10-15, 35
Fuse 48..............................8W-10-14, 34
Fuse 49..............................8W-10-11, 18
Fuse 50...............................8W-10-45
Fuse 51............................8W-10-13, 14, 32
Fuse 52..............................8W-10-47, 48
Fuse 53...............................8W-10-45
Fusible Link.............................8W-10-11
G103...............................8W-10-51, 52
G106...........................8W-10-31, 51, 55, 57
G107...............................8W-10-27, 29
G201.................................8W-10-26
Generator.............................8W-10-11, 28
Glove Box Lamp And Switch.....................8W-10-42
Headlamp Switch..........................8W-10-38
Headlamp-Left............................8W-10-55
Headlamp-Right...........................8W-10-55
Heated Mirror Relay.......................8W-10-17, 47
Horn Relay............................8W-10-15, 38
Horn-High Note...........................8W-10-38
Horn-Low Note............................8W-10-38
Ignition Coil.............................8W-10-24
Ignition Coil-Left...........................8W-10-23
Ignition Coil-Right..........................8W-10-23
Ignition Switch................8W-10-12, 26, 39, 45, 48, 50, 56
Instrument Cluster................8W-10-13, 26, 32, 33, 45, 50
Integrated Power Module . 8W-10-2, 3, 5, 11, 12, 13,, 14, 15, 16, 17, 18, 26, 27,
28, 29, 30, 31, 32, 33, 34, 35, 36, 38, 39, 42, 43, 44, 45, 46, 47, 48, 49, 50, 52,
54, 55, 57, 58
Leak Detection Pump........................8W-10-28
License Lamp-Left..........................8W-10-36
License Lamp-Right.........................8W-10-37
Overhead Map/Reading Lamp....................8W-10-42
Oxygen Sensor 1/1 Upstream.....................8W-10-25
Oxygen Sensor 1/2 Downstream...................8W-10-25
Oxygen Sensor 2/1 Upstream.....................8W-10-25
Oxygen Sensor 2/2 Downstream...................8W-10-25
Oxygen Sensor Downstream Relay................8W-10-11, 18
Park Lamp Relay.........................8W-10-16, 36
Park/Turn Signal Lamp-Left Front................8W-10-36, 51
Park/Turn Signal Lamp-Right Front...............8W-10-36, 51
Passenger Airbag On/Off Switch...................8W-10-46
Passenger Lumbar Switch......................8W-10-30
Power Mirror-Left..........................8W-10-47
Power Mirror-Right.........................8W-10-47
Power Outlet...........................8W-10-13, 33
Power Outlet-Console........................8W-10-34
Power Seat Switch-Driver......................8W-10-30
Power Seat Switch-Passenger....................8W-10-30
Power Window Circuit Breaker....................8W-10-56
Powertrain Control Module . 8W-10-17, 18, 19, 21, 23, 24, 28, 29, 33, 39, 40, 41,
42, 43, 44, 49, 57
PTCNo.1.........................8W-10-42, 43, 44, 45
PTCNo.2 ..............................8W-10-50
PTCNo.5 ..............................8W-10-35
Radio...............................8W-10-32, 50
Seat Belt Tensioner Reducer.....................8W-10-50
Seat Heater Interface Module....................8W-10-34
Sentry Key Immobilizer Module...............8W-10-33, 43, 44
Spare Relay.............................8W-10-58
Starter Motor...........................8W-10-14, 39
Starter Motor Relay.......................8W-10-14, 39
Tail/Stop/Turn Signal Lamp-Left.............8W-10-36, 51, 52, 54
Tail/Stop/Turn Signal Lamp-Right.............8W-10-37, 51, 52, 54
Tailgate Lamp Assembly.....................8W-10-36, 41
Trailer Tow Connector...................8W-10-15, 16, 35, 36
Trailer Tow Connector-Add On..............8W-10-18, 35, 36, 52
Trailer Tow Left Turn Relay...................8W-10-15, 35
Trailer Tow Right Turn Relay...................8W-10-15, 35
Transfer Case Control Module................8W-10-13, 34, 39
Transmission Control Module...............8W-10-12, 27, 41, 56
Transmission Control Relay................8W-10-12, 27, 28, 29
Transmission Range Sensor..................8W-10-40, 48, 53
Transmission Solenoid Assembly.................8W-10-12, 28
Transmission Solenoid/TRS Assembly.........8W-10-27, 29, 40, 48, 53
Underhood Lamp...........................8W-10-32
Vacuum Pump............................8W-10-43
Vistronic Fan Drive.........................8W-10-58
Washer Fluid Level Switch....................8W-10-52, 54
Washer Pump Motor-Front......................8W-10-52
Wiper High/Low Relay......................8W-10-14, 31
Wiper Motor-Front........................8W-10-31, 52
Wiper On/Off Relay........................8W-10-14, 31
DR8W-10 POWER DISTRIBUTION 8W - 10 - 1

ENGINE CONTROL MODULE - C1 (DIESEL) - 60 WAY
CAV CIRCUIT FUNCTION
38 - -
39 - -
40 K13 16TN FUEL INJECTOR NO. 3 DRIVER
41 - -
42 K900 18DB/DG 5 VOLT SUPPLY
43 K9 18LB 5 VOLT SUPPLY
44 K101 18WT APPS NOT IDLE SWITCH
45 K62 18BR/DB LETF PUMP
46 K58 16BR/DB FUEL INJECTOR NO. 6 DRIVER
47 - -
48 - -
49 - -
50 K12 16YL/WT FUEL INJECTOR NO. 2 DRIVER
51 - -
52 K167 18BR/YL ACCELERATOR PEDAL POSITION SENSOR GROUND
NO. 1
53 G910 18VT/RD FUEL PRESSURE SENSOR SIGNAL RETURN
54 K72 18DG/OR MAP SENSOR SIGNAL
55 - -
56 K38 16GY FUEL INJECTOR NO. 5 DRIVER
57 K92 16TN/PK COIL ON PLUG DRIVER NO. 2
58 - -
59 K91 16TN/RD COIL ON PLUG DRIVER NO. 1
60 - -
ENGINE CONTROL MODULE - C2 (DIESEL) - 50 WAY
CAV CIRCUIT FUNCTION
1 K22 18DR/DB THROTTLE POSITION SENSOR SIGNAL
2 K24 18WT/DG CRANKSHAFT POSITION SENSOR SIGNAL
3 K69 18 BR/LB INJECTOR CONTROL SIGNAL NO.1
4- -
5 K154 18GY GLOW PLUG RELAY NO. 1 OUTPUT
6 K152 18WT GLOW PLUG RELAY NO. 1 CONTROL
7- -
8- -
9- -
10 Y5 18OR FAN SPEED SENSOR
11 G7 18WT/OR VEHICLE SPEED SIGNAL
12 G60 18GY/YL ENGINE OIL PRESSURE SWITCH SENSE
13 - -
14 - -
15 - -
16 D21 18PK SCI TRANSMIT
17 - -
18 - -
19 D20 18LG SCI RECEIVE
20 A140 16DG/WT FUSED B(+)
21 Z816 16BK/TN GROUND
22 - -
23 Y3 18WT -
24 K4 18BK/LB SENSOR GROUND
25 - -
26 G8 18 LB/BK FUEL LEVEL SENSOR SIGNAL
27 K77 18 BR/WT TRANSFER CASE POSITION SENSOR INPUT
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55

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
9 - 6 ENGINE - 3.7LDR
ENGINE - 3.7L (Continued)

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION
CONDITION POSSIBLE CAUSES CORRECTION
OIL LEAKS 1. Gaskets and O-Rings. 1.
(a) Misaligned or damaged. (a) Replace as necessary.
(b) Loose fasteners, broken or
porous metal parts.(b) Tighten fasteners, Repair or
replace metal parts.
2. Crankshaft rear seal 2. Replace as necessary (Refer to 9
- ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - REAR -
REMOVAL).
3. Crankshaft seal flange.
Scratched, nicked or grooved.3. Polish or replace crankshaft.
4. Oil pan flange cracked. 4. Replace oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN -
REMOVAL).
5. Timing chain cover seal,
damaged or misaligned.5. Replace seal (Refer to 9 -
ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - FRONT
- REMOVAL).
6. Scratched or damaged vibration
damper hub.6. Polish or replace damper.
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.
2. Faulty oil pressure sending unit. 2. Replace sending unit (Refer to 9
- ENGINE/LUBRICATION/OIL
PRESSURE SENSOR/SWITCH -
REMOVAL).
3. Low oil pressure. 3. Check oil pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER
- REMOVAL).
5. Worn oil pump. 5. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
6. Thin or diluted oil. 6. Change oil and filter.
7. Excessive bearing clearance. 7. Replace as necessary.
8. Oil pump relief valve stuck. 8. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
9. Oil pick up tube loose, damaged
or clogged.9. Replace as necessary.
DRENGINE - 3.7L 9 - 7
ENGINE - 3.7L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
OIL PUMPING AT RINGS; SPARK
PLUGS FOULING1. Worn or damaged rings. 1. Hone cylinder bores and replace
rings.
2. Carbon in oil ring slots. 2. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
3. Incorrect ring size installed. 3. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
4. Worn valve guides. 4. Ream guides and replace valves
(Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE).
5. Leaking valve guide seals. 5. Replace valve guide seals.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs.
(3) Secure the throttle in the wide-open position.
(4) Disable the fuel system (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DESCRIPTION).
(5) Remove the ASD relay (Refer to 8 - ELECTRI-
CAL/IGNITION CONTROL/AUTO SHUT DOWN
RELAY - REMOVAL).
(6) Insert a compression pressure gauge and rotate
the engine with the engine starter motor for three
revolutions.
(7) Record the compression pressure on the 3rd
revolution. Continue the test for the remaining cylin-
ders.
(8) (Refer to 9 - ENGINE - SPECIFICATIONS) for
the correct engine compression pressures.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
(1) Check the coolant level and fill as required. DO
NOT install the radiator cap.
(2) Start and operate the engine until it attains
normal operating temperature, then turn the engine
OFF.
(3) Remove the spark plugs.
(4) Remove the oil filler cap.
(5) Remove the air cleaner hose.
(6) Calibrate the tester according to the manufac-
turer's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.
(7) Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
Set piston of cylinder to be tested at TDC compres-
sion,While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
Refer to CYLINDER COMBUSTION PRESSURE
LEAKAGE DIAGNOSIS CHART.
9 - 8 ENGINE - 3.7LDR
ENGINE - 3.7L (Continued)

VALVE GUIDE SEALS
DESCRIPTION
The valve guide seals are made of rubber and
incorporate an integral steel valve spring seat. The
integral garter spring maintains consistent lubrica-
tion control to the valve stems.
VALVE SPRINGS
DESCRIPTION
The valve springs are made from high strength
chrome silicon steel. The springs are NOT common
for intake and exhaust applications. The valve spring
seat is integral with the valve stem seal, which is a
positive type seal to control lubrication.
REMOVAL
(1) Remove the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(2) Using Special Tool 8516 Valve Spring Compres-
sor, remove the rocker arms and the hydraulic lash
adjusters.
(3) Remove the spark plug for the cylinder the
valve spring and seal are to be removed from.
(4) Apply shop air to the cylinder to hold the
valves in place when the spring is removed.
NOTE: All six valve springs and seals are removed
in the same manner; this procedure only covers
one valve seal and valve spring.
(5) Using Special Tool 8387 Valve Spring Compres-
sor, compress the valve spring.
NOTE: It may be necessary to tap the top of the
valve spring to loosen the spring retainers locks
enough to be removed.
(6) Remove the two spring retainer lock halves.
NOTE: the valve spring is under tension use care
when releasing the valve spring compressor.
(7) Remove the valve spring compressor.
NOTE: The valve springs are NOT common between
intake and exhaust.
(8) Remove the spring retainer, and the spring.
(9) Remove the valve stem seal.
NOTE: The valve stem seals are common between
intake and exhaust.
INSTALLATION
NOTE: All six valve springs and seals are removed
in the same manner; this procedure only covers
one valve seal and valve spring.
(1) Apply shop air to the cylinder to hold the
valves in place while the spring is installed.
NOTE: The valve stem seals are common between
intake and exhaust.
(2) Install the valve stem seal.
NOTE: The valve springs are NOT common between
intake and exhaust.
(3) Install the spring retainer, and the spring.
(4) Using Special Tool 8387 Valve Spring Compres-
sor, compress the valve spring.
(5) Install the two spring retainer lock halves.
NOTE: the valve spring is under tension use care
when releasing the valve spring compressor.
(6) Remove the valve spring compressor.
(7) Disconnect the shop air to the cylinder.
(8) Install the spark plug for the cylinder the valve
spring and seal was installed on.
(9) Using Special Tool 8516 Valve Spring Compres-
sor, install the rocker arms and the hydraulic lash
adjusters.
(10) Install the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
CYLINDER HEAD - RIGHT
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) Turn engine off and let set for a few minutes
before restarting. Repeat this several times after
engine has reached normal operating temperature.
(4) Low oil pressure.
(5) The oil restrictor in cylinder head gasket or the
oil passage to the cylinder head is plugged with
debris.
DRENGINE - 3.7L 9 - 31

(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)