2003 DODGE RAM radiator drain

Crankshaft JOURNAL SIZE
SIZE mm (in.)
MARKING
(.0958 - .0960
in.)
Lower Bearing Main919and949
9192.441 - 2.447
mmUse with crankshaft
9R, S9
(.0961 -.0963
in.)
9292.435 - 2.441
mmUse with crankshaft
9T, U9
(.0958 - .0962
in.)
Lower Main Bearing929and939
9392.429 - 2.435
mmUse with crankshaft
9R, S9
(.0956 - .0958
in.)
9492.423 - 2.429
mmUse with crankshaft
9T, U9
(.0953 - .0956
in.)
Bearing Clearances
Main91, 49
Crankshaft
9R9.004 - .034 mm ( .00015 - .0013 in.)
Crankshaft
9S9.004 - .030 mm ( .00015 - .0011 in.)
Crankshaft
9T9.006 - .032 mm (.0002 - .0012 in.)
Crankshaft
9U9.002 - .032 mm (.00007 -. 0012 in.)
Main92, 39
Crankshaft
9R9.016 - .046 mm (.0006 - .0018 in.)
Crankshaft
9S9.016 - .042 mm (.00062 - .016 in.)
Crankshaft
9T9.018 - .044 mm (.0007 - .0017 in.)
Crankshaft
9U9.014 - .044 mm (.0005 - .0017 in.)CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Remove A/C compressor mouning fasteners and
set aside.
(4) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(5) Remove upper radiator hose.
(6) Disconnect electrical connector for fan mounted
inside radiator shroud.
(7) Remove radiator shroud attaching fasteners.
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
(8) Remove radiator cooling fan and shroud (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(9) Remove crankshaft damper bolt.
(10) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 37).
Fig. 37 Crankshaft Damper Removal
1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026
9 - 44 ENGINE - 3.7LDR
CRANKSHAFT MAIN BEARINGS (Continued)

(8) Install the oil ring expander.
(9) Install upper side rail (Fig. 57) by placing one
end between the piston ring groove and the expander
ring. Hold end firmly and press down the portion to
be installed until side rail is in position. Repeat this
step for the lower side rail.
(10) Install No. 2 intermediate piston ring using a
piston ring installer (Fig. 58).
(11) Install No. 1 upper piston ring using a piston
ring installer (Fig. 58).
(12) Position piston ring end gaps as shown in
(Fig. 59). It is important that expander ring gap is at
least 45É from the side rail gaps, but not on the pis-
ton pin center or on the thrust direction.
VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove radiator upper hose.
(5) Remove upper fan shroud.
(6) Using Special Tools 6958 Spanner with Adapter
Pins 8346, loosen fan and viscous assembly from
water pump (Fig. 60).
(7) Remove fan and viscous assembly.
Fig. 57 Side RailÐInstallation
1 - SIDE RAIL END
Fig. 58 Upper and Intermediate RingsÐInstallation
Fig. 59 Piston Ring End Gap Position
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 60 FAN ASSEMBLY-REMOVAL/ASSEMBLY
1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2-FAN
9 - 54 ENGINE - 3.7LDR
PISTON RINGS (Continued)

CAUTION: Use care when removing the idler shaft,
Do not strike the radiator cooling fins with the slide
hammer.
(4) Using Special Tool 8517 Slide Hammer, remove
the idler shaft.
INSTALLATION
(1) Thoroughly clean the idler shaft bore.
(2) Position the idler shaft in the bore.
NOTE: The two lubrication holes in the idler shaft
do not require any special alignment.
NOTE: Before using the retaining bolt to install the
idler shaft, coat the threads and the pilot on the
idler shaft, with clean engine oil.
(3) Using the primary idler sprocket retaining bolt
and washer, carefully draw the idler shaft into the
bore until fully seated.
(4) Coat the idler shaft with clean engine oil.
(5) Install the timing chains and sprockets. Refer
to procedure in this section.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove electric cooling fan and fan shroud
assembly.
(4) Remove fan and fan drive assembly (Refer to 7
- COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL).
(5) Disconnect both heater hoses at timing cover.
(6) Disconnect lower radiator hose at engine.
(7) Remove accessory drive belt tensioner assembly
(Fig. 103).
(8) Remove crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(9) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(10) Remove A/C compressor (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - REMOVAL).
CAUTION: The 3.7L engine uses an anerobic sealer
instead of a gasket to seal the front cover to the
engine block, from the factory. For service, MoparT
Engine RTV sealant must be substituted.NOTE: It is not necessary to remove the water
pump for timing cover removal.
(11) Remove the bolts holding the timing cover to
engine block (Fig. 104).
(12) Remove the timing cover.
Fig. 103 ACCESSORY DRIVE BELT TENSIONER
1 - TENSIONER ASSEMBLY
2 - FASTENER TENSIONER TO FRONT COVER
Fig. 104 TIMING CHAIN COVER FASTENERS
9 - 80 ENGINE - 3.7LDR
IDLER SHAFT (Continued)

INSTALLATION
CAUTION: Do not use oil based liquids to clean tim-
ing cover or block surfaces. Use only rubbing alco-
hol, along with plastic or wooden scrapers. Use no
wire brushes or abrasive wheels or metal scrapers,
or damage to surfaces could result.
(1) Clean timing chain cover and block surface
using rubbing alcohol.
CAUTION: The 3.7L uses a special anerobic sealer
instead of a gasket to seal the timing cover to the
engine block, from the factory. For service repairs,
MoparTEngine RTV must be used as a substitute.
(2) Inspect the water passage o-rings for any dam-
age, and replace as necessary.
(3) Apply MopartEngine RTV sealer to front cover
following the path below usinga3to4mmthick
bead (Fig. 105).
(4) Install cover. Tighten fasteners in sequence as
shown in to 58 N´m (43 ft. lbs.) (Fig. 106).
(5) Install crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(6) Install the A/C compressor (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION).(7) Install the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - INSTALLATION).
(8) Install accessory drive belt tensioner assembly
(Refer to 7 - COOLING/ACCESSORY DRIVE/BELT
TENSIONERS - INSTALLATION).
(9) Install radiator upper and lower hoses.
(10) Install both heater hoses.
(11) Install electric fan shroud and viscous fan
drive assembly (Refer to 7 - COOLING/ENGINE/FAN
DRIVE VISCOUS CLUTCH - INSTALLATION).
(12) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(13) Connect the battery negative cable.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove right and left cylinder head covers(Re-
fer to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - REMOVAL).
(4) Remove radiator fan shroud(Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(5) Rotate engine until timing mark on crankshaft
damper aligns with TDC mark on timing chain cover
(Fig. 108) and the camshaft sprocket ªV6º marks are
at the 12 o'clock position (#1 TDC exhaust stroke)
(Fig. 107).
(6) Remove power steering pump(Refer to 19 -
STEERING/PUMP - REMOVAL).
(7) Remove access plug from left and right cylinder
heads for access to chain guide fasteners (Fig. 109).
Fig. 105 TIMING COVER SEALANT
1 - TIMING CHAIN COVER
2 - WATER PASSAGE ORING
3 - MOPARTENGINE RTV SEALER
Fig. 106 TIMING CHAIN COVER FASTENERS
DRENGINE - 3.7L 9 - 81
TIMING BELT / CHAIN COVER(S) (Continued)

to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
REMOVAL
NOTE: This procedure applies to both the 4X2 and
4X4 vehicles, steps that apply to the 4X4 vehicle
only, are identified.
(1) Disconnect the battery negative and positive
cables.
(2) Remove the battery and the battery tray.
(3) Raise vehicle on hoist.
(4) Remove exhaust crossover pipe from exhaust
manifolds.
(5)4X4 vehiclesDisconnect axle vent tube from
left side engine mount.
(6) Remove the through bolt retaining nut and bolt
from both the left and right side engine mounts.
(7)4X4 vehiclesRemove locknut from left and
right side engine mount brackets.
(8) Disconnect two ground straps from the lower
left hand side and one ground strap from the lower
right hand side of the engine.
(9) Disconnect crankshaft position sensor. (Fig. 1)
NOTE: The following step applies to 4X4 vehicles
equipped with automatic transmission only.
(10)4X4 vehiclesRemove the axle isolator
bracket from the engine, transmission and the axle.
(11) Remove structural cover (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL).(12) Remove starter (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - REMOVAL).
(13) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Remove torque converter bolts (Automatic
Transmission Only).
(15) Remove transmission to engine mounting
bolts.
(16) Disconnect the engine block heater power
cable from the block heater, if equipped.
(17) Lower vehicle.
(18) Remove throttle body resonator assembly and
air inlet hose.
(19) Disconnect throttle and speed control cables.
(20) Disconnect tube from both the left and right
side crankcase breathers (Fig. 2). Remove breathers
(21) Discharge A/C system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/REFRIG-
ERANT - STANDARD PROCEDURE).
(22) Remove A/C compressor (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - REMOVAL).
(23) Remove shroud, fan assembly (Refer to 7 -
COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL) and accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - REMOVAL).
(24) Disconnect transmission oil cooler lines at the
radiator.
Fig. 1 Crankshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
2 - CYLINDER HEAD COVER
3 - CAMSHAFT POSITION SENSOR
4 - RIGHT SIDE CYLINDER BLOCK
9 - 94 ENGINE - 4.7LDR
ENGINE - 4.7L (Continued)

CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Remove A/C compressor mouning fasteners and
set aside.
(4) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(5) Remove upper radiator hose.
(6) Disconnect electrical connector for fan mounted
inside radiator shroud.
(7) Remove radiator shroud attaching fasteners.
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
(8) Remove radiator cooling fan and shroud (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(9) Remove crankshaft damper bolt.
(10) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 64).(11) Using Special Tool 8511, remove crankshaft
front seal (Fig. 65).
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Using Special Tool 8348 and 8512, install
crankshaft front seal (Fig. 66).
(2) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(3) Install radiator cooling fan and shroud (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(4) Install upper radiator hose.
(5) Install A/C compressor and tighten fasteners to
54 N´m (40 ft. lbs.).
(6) Install accessory drive belt refer (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(7) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(8) Connect negative cable to battery.
Fig. 64 Crankshaft Damper Removal
1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026
Fig. 65 Crankshaft Front Seal Removal
1 - SPECIAL TOOL 8511
9 - 134 ENGINE - 4.7LDR

PISTON RING SPECIFICATION CHART
Ring Position Groove Maximum
Clearance Clearance
Upper Ring .051-.094mm 0.11mm
(0.0020- .0037
in.)(0.004 in.)
Intermediate
Ring0.04-0.08mm 0.10mm
(0.0016-0.0031
in.)(0.004 in.)
Oil Control Ring .019-.229mm .25mm
(Steel Rails) (.0007-.0090
in.)(0.010 in.)
Ring Position Ring Gap Wear Limit
Upper Ring 0.20-0.36mm 0.43mm
(0.0079-0.0142
in.)(0.0017 in.)
Intermediate
Ring0.37-0.63mm 0.74mm
(0.0146-0.0249
in.)(0.029 in.)
Oil Control Ring 0.025-0.76mm 1.55mm
(Steel Rail) (0.0099- 0.03
in.)(0.061 in.)
(7) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Ensure No. 2 ring is installed with
manufacturers I.D. mark (Dot) facing up, towards top
of the piston.
NOTE: Piston rings are installed in the following
order:
²Oil ring expander.
²Upper oil ring side rail.
²Lower oil ring side rail.
²No. 2 Intermediate piston ring.
²No. 1 Upper piston ring.
(8) Install the oil ring expander.
(9) Install upper side rail (Fig. 78) by placing one
end between the piston ring groove and the expander
ring. Hold end firmly and press down the portion to
be installed until side rail is in position. Repeat this
step for the lower side rail.
(10) Install No. 2 intermediate piston ring using a
piston ring installer (Fig. 79).
(11) Install No. 1 upper piston ring using a piston
ring installer (Fig. 79).
(12) Position piston ring end gaps as shown in
(Fig. 80). It is important that expander ring gap is atleast 45É from the side rail gaps, but not on the pis-
ton pin center or on the thrust direction.
VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove radiator upper hose.
(5) Remove upper fan shroud.
(6) Using Special Tools 6958 Spanner with Adapter
Pins 8346, loosen fan and viscous assembly from
water pump (Fig. 81).
(7) Remove fan and viscous assembly.
(8) Disconnect electrical connector for fan mounted
inside radiator shroud.
Fig. 78 Side RailÐInstallation
1 - SIDE RAIL END
Fig. 79 Upper and Intermediate RingsÐInstallation
DRENGINE - 4.7L 9 - 141
PISTON RINGS (Continued)

Tighten retaining bolt to 122N´m (90 ft. Lbs.) (Fig.
120) (Fig. 121).
(7) Remove special tool 8350.
(8) Rotate the crankshaft two full revolutions, then
reverify that the camshaft drive gear V8 marks are
in fact aligned.
(9) Install the cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove fan and fan drive assembly (Refer to 7
- COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL).
(4) Disconnect both heater hoses at timing cover.(5) Disconnect lower radiator hose at engine.
(6) Remove crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(7) Remove accessory drive belt tensioner assembly
(Fig. 122).
Fig. 120 Camshaft Sprocket Left Cylinder Head
1 - TORQUE WRENCH
2 - CAMSHAFT SPROCKET
3 - LEFT CYLINDER HEAD
4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
Fig. 121 Camshaft Sprocket InstallationÐRight
Cylinder Head
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
4 - RIGHT CAMSHAFT SPROCKET
Fig. 122 Accessory Drive Belt Tensioner
1 - TENSIONER ASSEMBLY
2 - FASTENER TENSIONER TO FRONT COVER
9 - 168 ENGINE - 4.7LDR
VALVE TIMING (Continued)