2003 DODGE RAM lock

(9) Remove the spring retainer, and the spring.
(10) Remove the valve stem seal.
NOTE: The valve stem seals are common between
intake and exhaust.
INSTALLATION
(1) coat the valve stem with clean engine oil and
install the valve stem seal. Make sure the seal is
fully seated and that the garter spring at the top of
the seal is intact.
(2) Install the spring and the spring retainer (Fig.
47).
(3) Using Special Tool 8387 Valve Spring Compres-
sor, compress the spring and install the two valve
spring retainer halves.
(4) Release the valve spring compressor and make
sure the two spring retainer halves and the spring
retainer are fully seated.
(5) Install the camshaft (Refer to 9 - ENGINE/
CYLINDER HEAD/CAMSHAFT(S) - INSTALLA-
TION).
(6) Position the hydraulic lash adjusters and
rocker arms (Fig. 46).
(7) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
VALVE STEM SEALS
DESCRIPTION
The valve stem seals are made of rubber and incor-
porate an integral steel valve spring seat. The inte-
gral garter spring maintains consistent lubrication
control to the valve stems.
ENGINE BLOCK
DESCRIPTION
The cylinder block is made of cast iron. The block
is a closed deck design with the left bank forward. To
provide high rigidity and improved NVH an
enhanced compacted graphite bedplate is bolted to
the block. The block design allows coolant flow
between the cylinders bores, and an internal coolant
bypass to a single poppet inlet thermostat is included
in the cast aluminum front cover.
STANDARD PROCEDUREÐCYLINDER 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.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
Fig. 47 Valve Assembly Configuration
1 - VALVE LOCKS (3±BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
9 - 126 ENGINE - 4.7LDR
VALVE SPRINGS (Continued)

(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.
The hone marks should INTERSECT at 50É to 60É
for proper seating of rings (Fig. 48).
(4) A controlled hone motor speed between 200 and
300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50É to 60É
angle. Faster up and down strokes increase the cross-
hatch angle.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
CLEANING
Thoroughly clean the oil pan and engine block gas-
ket surfaces.
Use compressed air to clean out:
²The galley at the oil filter adaptor hole.
²The front and rear oil galley holes.
²The feed holes for the crankshaft main bearings.
Once the block has been completely cleaned, apply
Loctite PST pipe sealant with Teflon 592 to the
threads of the front and rear oil galley plugs. Tighten
the 1/4 inch NPT plugs to 20 N´m (177 in. lbs.)
torque. Tighten the 3/8 inch NPT plugs to 27 N´m
(240 in. lbs.) torque.
INSPECTION
(1) It is mandatory to use a dial bore gauge to
measure each cylinder bore diameter. To correctly
select the proper size piston, a cylinder bore gauge,
capable of reading in 0.003 mm (.0001 in.) INCRE-
MENTS is required. If a bore gauge is not available,
do not use an inside micrometer (Fig. 49).
(2) Measure the inside diameter of the cylinder
bore at three levels below top of bore. Start perpen-
dicular (across or at 90 degrees) to the axis of the
crankshaft and then take two additional reading.
(3) Measure the cylinder bore diameter crosswise
to the cylinder block near the top of the bore. Repeat
the measurement near the middle of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determine taper by subtracting the smaller
diameter from the larger diameter.
(5) Rotate measuring device 90É and repeat steps
above.
(6) Determine out-of-roundness by comparing the
difference between each measurement.
(7) If cylinder bore taper does not exceed 0.025
mm (0.001 inch) and out-of-roundness does not
exceed 0.025 mm (0.001 inch), the cylinder bore can
be honed. If the cylinder bore taper or out- of-round
condition exceeds these maximum limits, the cylinder
block must be replaced. A slight amount of taper
always exists in the cylinder bore after the engine
has been in use for a period of time.
Fig. 48 CYLINDER BORE CROSSHATCH PATTERN
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
Fig. 49 BORE GAUGE-TYPICAL
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM (1.5 in)
DRENGINE - 4.7L 9 - 127
ENGINE BLOCK (Continued)

CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING ROD
BEARING FITTING
Inspect the connecting rod bearings for scoring and
bent alignment tabs (Fig. 50). Check the bearings for
normal wear patterns, scoring, grooving, fatigue and
pitting (Fig. 51). Replace any bearing that shows
abnormal wear.
Inspect the connecting rod journals for signs of
scoring, nicks and burrs.
Misaligned or bent connecting rods can cause
abnormal wear on pistons, piston rings, cylinder
walls, connecting rod bearings and crankshaft con-
necting rod journals. If wear patterns or damage to
any of these components indicate the probability of a
misaligned connecting rod, inspect it for correct rod
alignment. Replace misaligned, bent or twisted con-
necting rods.
(1) Wipe the oil from the connecting rod journal.
(2) Lubricate the upper bearing insert and install
in connecting rod.(3) Use piston ring compressor and Guide Pins
Special Tool 8507 (Fig. 52) to install the rod and pis-
ton assemblies. The oil slinger slots in the rods must
face front of the engine. The ªFº's near the piston
wrist pin bore should point to the front of the engine.
(4) Install the lower bearing insert in the bearing
cap. The lower insert must be dry. Place strip of Plas-
tigage across full width of the lower insert at the cen-
ter of bearing cap. Plastigage must not crumble in
use. If brittle, obtain fresh stock.
(5) Install bearing cap and connecting rod on the
journal and tighten bolts to 27 N´m (20 ft. lbs.) plus a
90É turn. DO NOT rotate crankshaft. Plastigage will
smear, resulting in inaccurate indication.
(6) Remove the bearing cap and determine amount
of bearing-to-journal clearance by measuring the
width of compressed Plastigage (Fig. 53). Refer to
Engine Specifications for the proper clearance.Plas-
tigage should indicate the same clearance
across the entire width of the insert. If the
clearance varies, it may be caused by either a
Fig. 50 Locking Tab Inspection
1 - ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 51 Scoring Caused by Insufficient Lubrication
or Damaged Crankshaft Journal
Fig. 52 Piston and Connecting Rod - Installation
1 - ªFº TOWARD FRONT OF ENGINE
2 - OIL SLINGER SLOT
3 - RING COMPRESSOR
4 - SPECIAL TOOL 8507
9 - 128 ENGINE - 4.7LDR

tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(7) If the correct clearance is indicated, replace-
ment of the bearing inserts is not necessary. Remove
the Plastigage from crankshaft journal and bearing
insert. Proceed with installation.
(8) If bearing-to-journal clearance exceeds the
specification, determin which services bearing set to
use the bearing sizes are as follows:
Bearing
MarkSIZE USED WITH
JOURNAL SIZE
.025 US.025 mm 50.983-50.967 mm
(.001 in.) (2.0073-2.0066 in.)
Std.STANDARD 50.992-51.008 mm
(2.0076-2.0082 in.)
.250 US.250 mm 50.758-50.742 mm
(.010 in.) (1.9984-1.9978 in.)
(9) Repeat the Plastigage measurement to verify
your bearing selection prior to final assembly.
(10) Once you have selected the proper insert,
install the insert and cap. Tighten the connecting rod
bolts to 27 N´m (20 ft. lbs.) plus a 90É turn.
Slide snug-fitting feeler gauge between the con-
necting rod and crankshaft journal flange (Fig. 54).
Refer to Engine Specifications for the proper clear-
ance. Replace the connecting rod if the side clearance
is not within specification.
CORE PLUGS
REMOVAL
(1) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(2) Using a blunt tool such as a drift or a screw
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 55)
(3) Using a suitable pair of pliers, grasp the core
plug and remove.
Fig. 53 Measuring Bearing Clearance with
Plastigage
1 - PLASTIGAGE SCALE
2 - COMPRESSED PLASTIGAGE
Fig. 54 Checking Connecting Rod Side Clearance -
Typical
Fig. 55 Engine Core Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
DRENGINE - 4.7L 9 - 129
CONNECTING ROD BEARINGS (Continued)

INSTALLATION
NOTE: Thoroughly clean core plug bore, remove all
of the old sealer.
(1)
Coat the edges of the engine core plug and the
core plug bore with Mopar Gasket Maker, or equivalent.
NOTE: It is not necessary to wait for the sealant to
cure on the core plugs. The cooling system can be
filled and the vehicle returned to service immediately.
(2) Using proper plug driver, drive core plug into
the core plug bore. The sharp edge of the core plug
should be at least 0.50 mm (0.020 in.) inside the lead
in chamfer.
(3) Refill the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
CRANKSHAFT
DESCRIPTION
The crankshaft is constructed of nodular cast iron.
The crankshaft is a crosshaped four throw design with
eight counterweights for balancing purposes. The crank-
shaft is supported by five select fit main bearings with
the number three serving as the thrust washer location.
The main journals of the crankshaft are cross drilled to
improve rod bearing lubrication. The number eight
counterweight has provisions for crankshaft position
sensor target wheel mounting. The select fit main bear-
ing markings are located on the rear side of the target
wheel. The crankshaft oil seals are one piece design.
The front oil seal is retained in the timing chain cover,
and the rear seal is pressed in to a bore formed by the
cylinder block and the bedplate assembly.
REMOVAL
NOTE: To remove the crankshaft from the engine,
the engine must be removed from the vehicle.
(1) Remove the engine. (Refer to 9 - ENGINE -
REMOVAL).
(2) Remove the engine oil pump.(Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - REMOVAL).
CAUTION: DO NOT pry on the oil pan gasket when
removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when removing oil pan.
Gasket can not be removed with oil pan.
(3) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).(4) Remove the oil pump pickup tube and oil pan
gasket /windage tray.
(5) Remove the bedplate mounting bolts. Note the
location of the three stud bolts for installation.
(6)
Remove the connecting rods from the crankshaft.
CAUTION: The bedplate to cylinder block mating
surface is a critical sealing surface. Do not pry on
or damage this surface in anyway.
NOTE: The bedplate contains the lower main bear-
ing halves. Use care when handling bedplate as not
to drop or damage bearing halves. Installing main
bearing halves in the wrong position will cause
sever damage to the crankshaft.
NOTE: The bedplate has pry points cast into it. Use
these points only. The pry points are on both the
left and right sides, only the left side is shown.
(7) Carefully pry on the pry points (Fig. 56) to
loosen the bedplate then remove the bedplate.
CAUTION: When removing the crankshaft, use care
not to damage bearing surfaces on the crankshaft.
(8) Remove the crankshaft.
(9) Remove the crankshaft target wheel.
Fig. 56 Bedplate Pry Point Location
1 - CYLINDER BLOCK
2 - BEDPLATE
3 - PRY POINT
9 - 130 ENGINE - 4.7LDR
CORE PLUGS (Continued)

INSPECTION
NOTE: Thoroughly inspect the connecting rod bear-
ing bores and main bearing bores for scoring, blue-
ing or severe scratches. Further disassembly may
be required.
If connecting rod bearing bores show damage, the
cylinder heads must be removed to service the piston
and rod assemblies. If the bedplate or the cylinder
block main bearing bores show damage the engine
must be replaced.
(1) If required, remove the main bearing halves
from the cylinder block and bedplate.
(2) Thoroughly clean the bedplate to cylinder block
sealing surfaces and main bearing bores. Remove all
oil and sealant residue.
(3) Inspect the bedplate main bearing bores for
cracks, scoring or severe blueing. If either condition
exists the engine must be replaced.
(4) Inspect the crankshaft thrust washers for scor-
ing, scratches, wear or blueing. If either condition
exist replace the thrust washer.
(5) Inspect the oil pan gasket/windage tray for
splits, tears or cracks in the gasket sealing surfaces.
Replace gasket as necessary.
INSTALLATION
CAUTION: Main bearings are select fit. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE) for proper
bearing selections.
(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 target wheel retaining
screws prior to installation.
(2) Install the crankshaft target wheel. Torque the
mounting screws to 15 N´m (12 ft. lbs.).
(3) Position crankshaft in cylinder block.
(4) Install the thrust washers (Fig. 57).
CAUTION: The bedplate to cylinder block mateing
surface must be coated with sealant prior to instal-
lation. Failure to do so will cause severe oil leaks.
NOTE: The installation time to install the bedplate
after the sealant has been applied is critical.NOTE: Make sure that the bedplate and cylinder
block sealing surfaces are clean and free of oil or
other contaminants. Contaminants on the sealing
surfaces may cause main bearing distortion and/or
oil leaks.
(5) Apply a 2.5mm (0.100 inch) (Fig. 58) bead of
MopartGen II Silicone Rubber Adhesive sealant to
the cylinder block-to-bedplate mating surface as
shown (Fig. 59).
Fig. 58 Cutting Aplicator to Achieve 2.5mm (0.100 in.)
Bead
1 - CUT HERE
Fig. 57 Crankshaft Thrust Washer Installation
1 - CRANKSHAFT THRUST WASHER
DRENGINE - 4.7L 9 - 131
CRANKSHAFT (Continued)

(6) Coat the crankshaft main bearing journals
with clean engine oil and position the bedplate onto
the cylinder block.
NOTE: Lubricate the bedplate retaining bolts with
clean engine oil prior to installation.
(7) Install the bedplate retaining bolts, making
sure to place the stud bolts in the correct location,
Torque the bolts in the sequence shown (Fig. 60).
²Tighten boltsA± Lto 54 N´m (40 ft. lbs.)
²Tighten bolts1±10to 2.8 N´m (25 in. lbs.)
²Turn bolts1±10an additional 90É.
²Tighten boltsA1± A6to 27 N´m (20 ft. lbs.)(8) Measure crankshaft end play. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT - STAN-
DARD PROCEDURE).
(9) Install the connecting rods and measure side
clearance. (Refer to 9 - ENGINE/ENGINE BLOCK/
CONNECTING ROD BEARINGS - STANDARD
PROCEDURE).
(10) Position the oil pan gasket/windage tray,
using a new o-ring, install the oil pickup tube.
Torque the bolt to 28N´n (20 ft. lbs.) torque the nuts
to 28N´m (20 ft. lbs.).
(11)
Install the oil pan. Torque the retaining bolts to
15 N´m (11 ft. lbs.) in the sequence shown (Fig. 61).
(12) Install the engine (Refer to 9 - ENGINE -
INSTALLATION).
Fig. 60 Bedplate Tightening Sequence
1 - BEDPLATE2 - CYLINDER BLOCK
Fig. 59 Cylinder Block-to-Bedplate
Sealent Bead Location
1 - CYLINDER BLOCK
2 - SEALANT BEAD LOCATION
Fig. 61 Oil Pan Tightening Sequence
9 - 132 ENGINE - 4.7LDR
CRANKSHAFT (Continued)

CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDUREÐCRANKSHAFT MAIN
BEARING - FITTING
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Crankshaft removed from the cylinder block.
Clean the oil off the main bearing journal.
Determine the maximum diameter of the journal
with a micrometer. Measure at two locations 90É
apart at each end of the journal.
The maximum allowable taper is 0.008mm (0.0004
inch.) and maximum out of round is 0.005mm (0.002
inch). Compare the measured diameter with the jour-
nal diameter specification (Main Bearing Fitting
Chart). Select inserts required to obtain the specified
bearing-to-journal clearance.
CRANKSHAFT MAIN BEARING SELECTION
The main bearings are ªselect fitº to achieve proper
oil clearances. For main bearing selection, the crank-
shaft position sensor target wheel has grade identifi-
cation marks stamped into it (Fig. 62). These marks
are read from left to right, corresponding with jour-
nal number 1, 2, 3, 4 and 5. The crankshaft position
sensor target wheel is mounted to the number 8
counter weight on the crankshaft.NOTE: Service main bearings are coded. These
codes identify what size (grade) the bearing is.
MAIN BEARING SELECTION CHARTÐ4.7L
GRADE SIZE mm
(in.)FOR USE WITH
MARKING JOURNAL SIZE
A0.008 mm
U/S63.488±63.496 mm
(0.0004 in.)
U/S(2.4996±2.4999 in.)
BNOMINAL 63.496±63.504 mm
(2.4999±2.5002 in.)
C0.008 mm
O/S63.504±63.512 mm
(0.0004 in.)
O/S(2.5002±2.5005 in.)
INSPECTION
Wipe the inserts clean and inspect for abnormal
wear patterns and for metal or other foreign material
imbedded in the lining. Normal main bearing insert
wear patterns are illustrated (Fig. 63).
NOTE: If any of the crankshaft journals are scored,
the crankshaft must be repaired or replaced.
Inspect the back of the inserts for fractures, scrap-
ings or irregular wear patterns.
Inspect the upper insert locking tabs for damage.
Replace all damaged or worn bearing inserts.
Fig. 62 Main Bearing Markings on Target Wheel
1 - REARMOST CRANKSHAFT COUNTER WEIGHT
2 - TARGET WHEEL
3 - MAIN BEARING SELECT FIT MARKINGS
Fig. 63 Main Bearing Wear Patterns
1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT
DRENGINE - 4.7L 9 - 133