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(8) If required, adjust spark plugs to specifications.
assembly.
Install the plugs.
(9) Connect the heater hoses. (10) Install the fuel supply line. (11) Install the generator and drive belt. (12) Install cylinder head covers(Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(13) Connect the evaporation control system. (14) Install the air cleaner. (15) Fill cooling system. (16) Connect the negative cable to the battery. (17) Start engine check for leaks.
DR
CYLINDER HEAD COVER(S) REMOVAL
(1) Disconnect battery negative cable. (2) Disconnect coil on plug connectors.
CAUTION: The ground straps must be installed in the same location as removed. The covers are machined to accept the ground straps in those locations only.
(3) Remove cylinder head cover retaining bolts,
and ground straps.
(4) Remove cylinder head cover.
NOTE: The gasket may be used again, provided no cuts, tears, or deformation has occurred.
INSTALLATION
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 engine cylinder head cover. Prolonged contact with other objects may wear a hole in the 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 fas- teners. Verify that all double ended studs are in the cor- rect location and install left and right ground straps.
CAUTION: The ground straps must be installed in the same location as removed. The covers are machined to accept the ground straps in those locations only.
NOTE: The right hand ground strap is located on the front inboard stud. The left hand ground strap is located on the rear inboard stud.
(3) Tighten cylinder head cover bolts and double ended studs to 8 N·m (70 in. lbs). Begin torque sequence in the middle of head cover and torque bolts moving outward in a crisscross pattern from top to bottom.
(4) Install ignition coil on plug, and torque fasten-
ers to 12 N·m (105 in. lbs)
(5) Connect, ignition coil electrical connectors. (6) Install PCV hose. (7) Connect battery negative cable.
DR
ENGINE - 5.7L
9 - 197
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION
DESCRIPTION - VALVE GUIDES
The valve guides are made of powered metal and are pressed into the cylinder head. The guides are not replaceable or serviceable, and valve guide ream- ing is not recommended. If the guides are worn beyond acceptable limits, replace the cylinder heads.
DESCRIPTION
Both the intake and exhaust valves are made of steel. The intake valve is 50.93 mm (2.00 inches) in diameter and the exhaust valve is 39.53 mm (1.55
inches) in diameter. All valves use three bead lock keepers to retain the springs and promote valve rota- tion.STANDARD PROCEDURE - REFACING
NOTE: Valve seats that are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced.
NOTE: When refacing valves and valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete sur- face must be obtained.
(1) Using a suitable dial
indicator measure the center of the valve seat Total run out must not exceed 0.051 mm (0.002 in).
(2) Apply a small amount of Prussian blue to the valve seat, insert the valve into the cylinder head, while applying light pressure on the valve rotate the valve. Remove the valve and examine the valve face. If the blue is transferred below the top edge of the valve face, lower the valve seat using a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, raise the valve seat using a 65 degree stone.
(3) When the seat is properly positioned the width of the intake seat must be 1.018 - 1.62 mm (0.0464 - 0.0637 in.) and the exhaust seat must be 1.48 - 1.92
mm (0.058 - 0.075 in.).(4) Check the valve spring installed height after refacing the valve and seat. The installed height for both intake and exhaust valve springs must not exceed 46.0 mm (1.81 in.).
VALVE FACE AND VALVE SEAT ANGLE CHART
DESCRIPTION
SPECIFICATION
SEAT WIDTH
INTAKE
1.018 - 1.62 mm
EXHAUST
(0.0464 - 0.0637 in.)
1.48 - 1.92 mm
(0.058 - 0.075 in.)
FACE ANGLE (INT. AND EXT.)
SEAT ANGLE (INT. AND EXT.)
45° - 451⁄2°
441⁄2° - 45°
(5) The valve seat must maintain an angle of 44.5
– 45.0 degrees angle.
(6) The valve face must maintain a face angle of
45.0 – 45.5 degrees angle (Fig. 5).
Fig.5ValveAssemblyConfiguration
1 - VALVE LOCKS (3–BEAD) 2 - RETAINER 3 - VALVE STEM OIL SEAL 4 - INTAKE VALVE 5 - EXHAUST VALVE 6 - VALVE SPRING
ENGINE - 5.7L
9 - 198
INTAKE/EXHAUST VALVES & SEATS (Continued) REMOVAL(3) Remove the rocker shafts. Note location for
to 9 -
reassembly.
DR
(1) Remove the cylinder head (Refer ENGINE/CYLINDER HEAD - REMOVAL).
(2) Compress valve springs using Valve Spring Compressor Tool special tool # C-3422and adapter 8464.
(3) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location.
INSTALLATION
(1) Clean valves
thoroughly. Discard burned,
warped and cracked valves.
(2) Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. (3) Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve.
(4) Coat valve stems with lubrication oil and insert
them in cylinder head.
(5) If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head.
(6) Install new seals on all valve guides. Install
valve springs and valve retainers.
(7) Compress valve springs with Valve Spring Compressor Tool special tool # C- 3422and adapter 8464, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer.
(8) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
ROCKER ARM / ADJUSTER ASSY REMOVAL
(1) Remove cylinder head cover.(Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL)
(2) Loosen the rocker shafts using the following sequence: Center, center-left, center-right, left, right,.
CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with an “I”.
CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side.
(4) Remove the pushrods. Note pushrod location
for reassembly.
INSTALLATION
CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side.
(1) Install the push rods in the same order as
removed.
CAUTION: Verify that pushrod is installed into rocker arm and lifter correctly while installing rocker shaft assembly. Recheck after rocker shaft has been torqued to specification.
CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with the letter “I”.
(2) Install rocker shaft assemblies in the same
order as removed.
CAUTION: Ensure that hold downs and rocker arms are not overlapped when torquing bolts.
(3) Tighten the rocker shaft bolts to 22 N·m (195
in. lbs.) torque,using the following sequence: Center, center-right, center-left, right, left.CAUTION: DO NOT rotate or crank the engine dur- ing or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes).
(4) Install
cylinder head cover
to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(Refer
VALVE STEM 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.
DR
ENGINE - 5.7L
9 - 199
VALVE SPRINGS REMOVAL
(1) Disconnect negative battery cable. (2) Remove air cleaner assembly. (3) Remove air intake resonator. (4) Remove spark plug cables. (5) Remove ignition coil connectors (Fig. 6).
Fig.6IGNITIONCOILR/I—5.7LV-8
1 - SLIDE LOCK (SLIDE OUTWARD TO UNLOCK) 2 - SPARK PLUG CABLE (TO OPPOSITE CYLINDER BANK SPARK PLUG) 3 - RELEASE LOCK / TAB (PUSH HERE) 4 - ELEC. CONNECTOR 5 - IGNITION COIL 6 - COIL MOUNTING BOLTS (2) 7 - SPARK PLUG CABLE (TO OPPOSITE CYLINDER BANK IGNITION COIL)
(6) Remove ignition coils. (7) Remove one spark plug. (8) Remove valve cover.
CAUTION: The piston must be at TDC, and both valves closed on the cylinder to be serviced.
(9) Remove exhaust/intake rocker arm shafts. (10) Install spring compressor, special tool# 9065.
NOTE: All valve springs and seals are removed in the same manner.
(11) Charge cylinder with air.
NOTE: Tap the top of the valve spring retainer to loosen the spring retainers locks.
(12) Compress valve spring and remove valve
(13) Release spring compressor and remove valve
retainer locks.
spring.
NOTE: The valve springs are interchangeable between intake and exhaust.
(14) Remove valve seal.
INSTALLATION
(1) Install valve seal. (2) Install valve spring. (3) Using special tool# 9065, compress valve spring
and install valve spring retainer and locks.
(4) Release air charge in cylinder. (5) Remove spring compressor tool # 9065.
CAUTION: Verify that the pushrods are fully seated into lifter and rocker arm. Recheck after rocker arm shaft has been torqued to specification.
(6) Install rocker arm shaft and pushrods(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - INSTALLATION).
(7) Tighten the rocker shaft bolts to 22 N·m (195
in. lbs.) torque,using the following sequence: Center, center-right, center-left, right, left.(8) Install cylinder head cover. (9) Tighten cylinder head cover bolts and double ended studs(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLA- TION) .
(10) Install spark plugs. (11) Install ignition coil on plug, and torque fasten-
ers to 12 N·m (105 in. lbs)
(12) Install ignition coil connectors. (13) Install spark plug cables. (14) Install air intake resonator. (15) Install air cleaner assembly. (16) Connect negative battery cable.
9 - 200
ENGINE - 5.7L
ENGINE BLOCK CLEANING
Thoroughly clean the oil pan and engine block gas-
ket surfaces. Use compressed air to clean out: † The galley at the oil filter adaptor hole. † The front and rear oil galley holes. † The 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. 7).
Fig.7BOREGAUGE-TYPICAL
1 - FRONT 2 - BORE GAUGE 3 - CYLINDER BORE 4 - 38 MM (1.5 in)
(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.
DR
(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 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 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.CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVAL - CAMSHAFT CORE HOLE PLUG
CAUTION: Do not damage the rear surface of the camshaft or the core plug sealing surface, when removing the core plug.
(1) Remove the rear cam bearing core plug.
REMOVAL - CAMSHAFT
(1) Remove the battery negative cable. (2) Remove the air cleaner assembly. (3) Drain coolant. (4) Remove the accessory drive belt. (5) Remove the generator. (6) Remove the A/C compressor, and set aside (7) Remove the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL).
(8) Remove intake manifold(Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(9) Remove cylinder head covers(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(10) Remove both left and right cylinder heads(Re- fer to 9 - ENGINE/CYLINDER HEAD - REMOVAL). (11) Remove the oil pan(Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(12) Remove
to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
timing case
cover(Refer
(13) Remove the oil pick up tube.
DR CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
ENGINE - 5.7L
9 - 201
(14) Remove the oil pump(Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL).
(15) Remove timing chain(Refer to 9 - ENGINE/ BELT/CHAIN AND
VALVE TIMING/TIMING SPROCKETS - REMOVAL).
(16) Remove
camshaft
tensioner/thrust
plate
assembly.
NOTE: Identify lifters to ensure installation in origi- nal location.
(17) Remove the lifters and retainer assembly. (18) Install a long bolt into front of camshaft to aid in removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes.
INSPECTION
(1) The cam bearings are not serviceable. Do not
attempt to replace cam bearings for any reason.
INSTALLATION
INSTALLATION - CAMSHAFT CORE HOLE PLUG
CAUTION: The new core hole plug must be installed to the proper depth or camshaft damage could develope. The plug must be installed squarely in the bore.
(1) Install a new core hole plug at the rear of cam- shaft, using special tool # 9048. Clean plug and apply mopart lock and seal adhesive to the edge of the plug, before installing. The plug must be installed to a depth of + / - 0.25mm from the end of the machined bevel, that is the end of the bevel that is closest to the cam bearing.
INSTALLATION - CAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft
(2) Install
camshaft Tensioner plate assembly.
Tighten bolts to 28 N·m (250 in. lbs.) torque.
(3) Install timing chain and sprockets(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).
(4) Measure camshaft end play(Refer
to 9 - ENGINE - SPECIFICATIONS). If not within limits install a new thrust plate.
(5) Install the oil pump(Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(6) Install the oil pick up tube. (7) Each lifter reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the lifters must be replaced.
(8) Install lifters and retainer assembly. (9) Install both left and right cylinder heads(Refer to 9 - ENGINE/CYLINDER HEAD - INSTALLA- TION).
(10) Install pushrods (11) Install rocker arms(Refer to 9 - ENGINE/CYL- INDER HEAD/ROCKER ARM / ADJUSTER ASSY - INSTALLATION).
(12) Install
ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
cover(Refer
timing
case
to
(13) Install the oil pan(Refer to 9 - ENGINE/LU-
(14) Install
BRICATION/OIL PAN - INSTALLATION). cylinder head covers(Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(15) Install intake manifold(Refer to 9 - ENGINE/ INSTALLA-
MANIFOLDS/INTAKE MANIFOLD - TION).
(16) Install the A/C compressor, and set aside (17) Install the generator. (18) Install the accessory drive belt. (19) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
(20) Install the air cleaner assembly. (21) Install the battery negative cable. (22) Refill coolant. (23) Refill engine oil. (24) Start engine and check for leaks.
CRANKSHAFT REMOVAL
(1) Remove the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(2) Remove the timing chain cover(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(3) Remove the oil pan(Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(4) Remove the oil pump pickup. (5) Remove the oil pump(Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - REMOVAL).
(6) Remove the timing drive(Refer to 9 - ENGINE/ BELT/CHAIN AND
TIMING/TIMING VALVE SPROCKETS - REMOVAL).
(7) Identify rod bearing caps before removal.
Remove rod bearing caps with bearings.
(8) Identify main bearing caps before removal. Remove main bearing caps and bearings one at a time.
(9) Remove the thrust washers. (10) Remove the crankshaft out of the block.
ENGINE - 5.7L
9 - 202
CRANKSHAFT (Continued)DR
(11) Remove the rear oil seal retainer(Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT REAR OIL SEAL RETAINE - REMOVAL).
(12) Remove and discard the crankshaft rear oil
(13) Remove and discard the front crankshaft oil
seal.
seal.
INSTALLATION
(1) Select the proper main bearings(Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN BEARINGS - STANDARD PROCEDURE).
(2) Install main bearings in block and caps, and
lubricate bearings.
(3) Position the crankshaft into the cylinder block. (4) Install the thrust washers.
NOTE: The main cap crossbolts are torqued after final torque of the main cap bolts. Always use a new washer/seal on crossbolts.
(5) Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten in two steps using the following sequence (Fig. 8). † Step 1 – 27 N·m ( 20ft. lbs.) torque. † Step 2 – Turn main cap bolts an additional 90°. (6) Install the crossbolts with new washer/gasket.
Fig.8MAINCAPTIGHTENINGSEQUENCE
1 - Stud Location
Starting with crossbolt A (Fig. 8) torque each cross- bolt to 28 N·m torque.
(7) Repeat crossbolt torque procedure.
(8) Measure crankshaft end play(Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN BEARINGS - STANDARD PROCEDURE).
(9) Position the connecting rods onto the crank- shaft and install the rod bearing caps(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECT- ING ROD - INSTALLATION).
(10) Install timing drive(Refer to 9 - ENGINE/ BELT/CHAIN AND
TIMING/TIMING
VALVE SPROCKETS - INSTALLATION).
(11) Install oil pump and pickup(Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - INSTALLA- TION).
(12) Install the timing chain cover(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(13) Install the oil pan(Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(14) Install the rear main seal and retainer. (15) Install the vibration damper. (16) Install the engine(Refer to 9 - ENGINE -
INSTALLATION).
CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE - CRANKSHAFT 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 90° 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 (0.0002
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 “select fit” to achieve proper oil clearances. For main bearing selection, the crank- shaft counterweight has grade identification marks stamped into it. These marks are read from left to right, corresponding with journal number 1, 2, 3, 4
and 5.NOTE: Service main bearings are coded. These codes identify what size (grade) the bearing is.
DR CRANKSHAFT MAIN BEARINGS (Continued)
MAIN BEARING SELECTION CHART - 5.7L
GRADE
MARKING
SIZE mm
(in.)
FOR USE WITH
JOURNAL SIZE
0.008 mm
64.988–64.995 mm
U/S
(0.0004 in.)
(2.5585– 2.5588in.)
U/S
NOMINAL
64.996–65.004 mm (2.5588–2.5592 in.)
0.008 mm
65.005–65.012 mm
O/S
(0.0004 in.)
(2.5592–2.5595 in.)
O/S
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. 9).
Fig.9MainBearingWearPatterns
1 - UPPER INSERT 2 - NO WEAR IN THIS AREA 3 - LOW AREA IN BEARING LINING 4 - LOWER INSERT
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.
ENGINE - 5.7L
9 - 203
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) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove upper radiator hose. (5) Remove radiator shroud attaching fasteners. (6) Remove radiator cooling fan and shroud (Refer - COOLING/ENGINE/RADIATOR FAN -
to REMOVAL).
(7) Remove crankshaft damper bolt. (8) Remove damper using Special Tools 8513A
Insert and 8454 Three Jaw Puller.
(9) Using Special Tool 9071, remove crankshaft
front seal.
INSTALLATION
CAUTION: The front crankshaft seal must be installed dry. Do not apply lubricant to sealing lip or to outer edge.
(1) Using Special Tool 8348 and 8512A,
crankshaft front seal.
install
CAUTION: To prevent severe damage to the Crank- shaft or Damper, thoroughly clean the damper bore and the crankshaft nose before installing Damper.
(2) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTAL- LATION).
(3) Install radiator cooling fan and shroud (Refer - COOLING/ENGINE/RADIATOR FAN -
to INSTALLATION).
(4) Install upper radiator hose. (5) Install accessory drive belt refer (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(6) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(7) Connect negative cable to battery.
9 - 204
ENGINE - 5.7L
DR
CRANKSHAFT OIL SEAL - REAR DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery. (2) Raise the vehicle. (3) Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down, possible causes are a porous block, camshaft bore cup plugs, oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating sur- faces. See Engine, for proper repair procedures of these items. (4) If no leaks are detected, pressurized the crank- case as outlined in the section, Inspection (Engine oil Leaks in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks or scratches. The crankshaft seal flange is specially machined to complement the function of the rear oil seal.
(6) For bubbles that remain steady with shaft rotation, no further inspection can be done until dis- assembled. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING), under the Oil Leak row, for components inspections on possible causes and corrections.
(7) After the oil leak root cause and appropriate corrective action have been identified, (Refer to 9 - ENGINE/ENGINE OIL SEAL - REAR - REMOVAL).
BLOCK/CRANKSHAFT
REMOVAL
NOTE: This procedure can be performed in vehicle.
(1) If being preformed in vehicle, remove the
transmission.
(2) Remove the flexplate (Refer to 9 - ENGINE/
ENGINE BLOCK/FLEX PLATE - REMOVAL).
NOTE: The crankshaft oil seal CAN NOT be reused after removal.
NOTE: The crankshaft rear oil seal remover Special Tool 8506 must be installed deeply into the seal. Continue to tighten the removal tool into the seal until the tool can not be turned farther. Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine.
(3) Using Special Tool 8506, remove the crankshaft
rear oil seal.
INSTALLATION
CAUTION: The rear seal must be installed dry for proper operation. Do not lubricate the seal lip or outer edge.
(1) Position the plastic seal guide onto the crank- shaft rear face. Then position the crankshaft rear oil seal onto the guide.
(2) Using Special Tools 8349 Crankshaft Rear Oil Seal Installer and C-4171 Driver Handle, with a hammer, tap the seal into place. Continue to tap on the driver handle until installer seats against the cylinder block crankshaft bore.
the seal
(3) Install the flexplate. (4) Install the transmission.
CRANKSHAFT REAR OIL SEAL RETAINER REMOVAL
(1) Disconnect negative cable from battery. (2) Remove the transmission. (3) Remove the drive plate / flywheel. (4) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(5) Remove the rear oil seal retainer mounting
(6) Carefully remove the retainer from the engine
bolts.
block.
ENGINE - 5.7L
9 - 205
.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer.
(2) Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B (Fig. 11).
(3) The coated pistons will be serviced with the
piston pin and connecting rod pre-assembled.
(4) The coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston will not pro- vide accurate results (Fig. 10). Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY. To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (.0001 in.) increments is required.
(5) Piston installation into
cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.
the
DR CRANKSHAFT REAR OIL SEAL RETAINER (Continued) INSTALLATION
(1) Throughly clean all gasket resdue from the
engine block.
from the retainer.
(2) Use extream care and clean all gasket resdue
(3) Position the gasket onto the retainer. (4) Position the retainer onto the engine block. (5) Install the retainer mounting bolts. Tighten the bolts to 15 N·m (132 in. lbs.) using a crisscross pat- tern, starting with the bolt on the lower right.
(6) Install a new rear seal(Refer to 9 - ENGINE/ ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - INSTALLATION).
(7) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(8) Install the drive plate / flywheel. (9) Install the transmission. (10) Check and verify engine oil level. (11) Start engine and check for leaks.
FLEX PLATE REMOVAL
(1) Remove the transmission. (2) Remove the bolts and flexplate.
INSTALLATION
(1) Position the flexplate onto the crankshaft and
install the bolts hand tight.
(2) Tighten the flexplate retaining bolts to 95 N·m
(70 ft. lbs.).
(3) Install the transmission.
PISTON & CONNECTING ROD DESCRIPTION
CAUTION: Do not use a metal stamp to mark con- necting rods as damage may result, instead use ink or a scratch awl.
The pistons are made of a high strength aluminum alloy. Piston skirts are coated with a solid lubricant (Molykote) to reduce friction and provide scuff resis- tance. The piston top ring groove and land is anod- ized. The connecting rods are made of forged powdered metal, with a “fractured cap” design. A pressed fit piston pin is used to attach the piston and connecting rod.
STANDARD PROCEDURE—PISTON FITTING
(1) To correctly select the proper size piston, a cyl- inder bore gauge, capable of reading in 0.003 mm (
Fig.10MolyCoatedPiston
1 - MOLY COATED 2 - MOLY COATED
REMOVAL
ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(1) Disconnect negative cable from battery. (2) Remove the following components: † Oil pan and gasket/windage tray (Refer to 9 - † Cylinder head covers (Refer to 9 - ENGINE/ CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) and (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL). † Timing chain cover (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
ENGINE - 5.7L
9 - 206
PISTON & CONNECTING ROD (Continued)DR
Fig.12IdentifyConnectingRodtoCylinder
Position—Typical
(5) Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed.
CAUTION: Care must be taken not to nick crank- shaft journals, as engine damage may occur
Fig.11BoreGauge—Typical
1 - FRONT 2 - BORE GAUGE 3 - CYLINDER BORE 4 - 38 MM (1.5 in)
† Cylinder head(s) (Refer to 9 - ENGINE/CYLIN- DER HEAD - REMOVAL) and (Refer to 9 - ENGINE/ CYLINDER HEAD - REMOVAL).
(3) If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pis- tons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore.
CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur
NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
(4) Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool (Fig. 12).
CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
(6) Immediately after piston and connecting rod removal, install bearing cap on the mating connect- ing rod to prevent damage to the fractured cap and rod surfaces.
(7) Carefully remove piston rings from piston(s),
starting from the top ring down.
CLEANING
CAUTION: DO NOT use a wire wheel or other abra- sive cleaning devise to clean the pistons or con- necting rods. The pistons have a Moly coating, this coating must not be damaged.
(1) Using a suitable cleaning solvent clean the pis-
tons in warm water and towel dry.
(2) Use a wood or plastic scraper to clean the ring
land grooves.
CAUTION: DO NOT remove the piston pin from the piston and connecting rod assembly.
INSPECTION
Check the connecting rod journal
for excessive wear, taper and scoring (Refer to 9 - ENGINE/EN- GINE BLOCK/CONNECTING ROD BEARINGS - STANDARD PROCEDURE).
Check the connecting rod for signs of twist or bend-
ing.
Check the piston for taper and elliptical shape before it is fitted into the cylinder bore (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECT- ING ROD - STANDARD PROCEDURE).
DR PISTON & CONNECTING ROD (Continued)
Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration.
INSTALLATION
(1) Before installing piston and connecting rod assemblies into the bore, install the piston rings(Re- fer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS - STANDARD PROCEDURE).
(2) Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure posi- tion of rings do not change during this opera- tion.
(3) Position bearing onto connecting rod. Lubricate
bearing surface with clean engine oil.
(4) Install Special Tool 8507 Connecting Rod
Guides into connecting rod bolt threads.
(5) The pistons are marked on the piston pin bore surface with an raised “F” or arrow on top of piston indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks. The connecting rod oil slinger slot faces the front of the engine.
(6) Wipe cylinder bore clean and lubricate with
engine oil.
(7) Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and pis- ton into cylinder bore and carefully position connect- ing rod guides over crankshaft journal.
(8) Tap piston down in cylinder bore using a ham- mer handle. While at the same time, guide connect- ing rod into position on rod journal.
ENGINE - 5.7L
9 - 207
† Install the intake manifold. † Oil pan and gasket/windage tray. (Refer to 9 - INSTALLA-
ENGINE/LUBRICATION/OIL PAN - TION).
(11) Fill crankcase with proper engine oil to cor-
rect level.
(12) Connect negative cable to battery.
PISTON RINGS STANDARD PROCEDURE - PISTON RING FITTING
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.
NOTE: The ring gap measurement must be made with the ring positioned at least 12mm (0.50 inch.) from bottom of cylinder bore.
(3) Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder.
(4) Using a feeler gauge check the ring end gap (Fig. 13). Replace any rings not within specification.
CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed.
(9) Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 21 N·m (15 ft. lbs.) plus a 90° turn. (10) Install the following components: † Cylinder head(s). (Refer to 9 - ENGINE/CYLIN- † Cylinder head covers (Refer to 9 - ENGINE/ CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
DER HEAD - INSTALLATION).
1 - FEELER GAUGE
Fig.13Ring
ENGINE - 5.7L
9 - 208
PISTON RINGS (Continued)DR
PISTON RING SIDE CLEARANCE
PISTON RING SPECIFICATION CHART
NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs.
Ring Position
(5) Measure the ring side clearance as shown (Fig. 14)make sure the feeler gauge fits snugly between the ring land and the ring. Replace any ring not within specification.
Upper Ring
Intermediate
Ring
Groove
Clearance
0.6715- .0.7105mm (0.0264- 0.0279
in.)
0.5455-
0.6245mm
Maximum Clearance
0.11mm
(0.004 in.)
0.10mm
(0.0214-0.0245
(0.004 in.)
in.)
Ring Position
Ring Gap
Upper Ring
0.23-0.38mm (0.0090-0.0149
in.)
Wear Limit
0.43mm (0.017 in.)
Intermediate
0.35-0.60mm
0.74mm
Ring
(0.0137-0.0236
(0.029 in.)
in.)
Oil Control Ring
(Steel Rail)
0.015-0.66mm (0.0059- 0.0259
1.55mm (0.061 in.)
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:† Oil ring expander. † Upper oil ring side rail. † Lower oil ring side rail. † No. 2 Intermediate piston ring. † No. 1 Upper piston ring.
Fig.14MeasuringPistonRingSideClearance
1 - FEELER GAUGE
(6) Rotate the ring around the piston, the ring
must rotate in the groove with out binding.
DR PISTON RINGS (Continued)
ENGINE - 5.7L
9 - 209
(8) Install the oil ring expander. (9) Install upper side rail (Fig. 15) 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. 16).
(11) Install No. 1 upper piston ring using a piston
ring installer (Fig. 16).
(12) Position piston ring end gaps as shown in (Fig. 17). It is important that expander ring gap is at least 45° from the side rail gaps, but not on the pis- ton pin center or on the thrust direction.
Fig.15SIDERAIL-INSTALLATION
1 - SIDE RAIL END
Fig.17PISTONRINGENDGAPPOSITION
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
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 loosen fan and viscous assembly from
Pins 8346, water pump.
(7) Remove fan and viscous assembly. (8) Remove crankshaft damper bolt. (9) Remove damper using Special Tools 8513A
Insert and 8454 Three Jaw Puller.
Fig.16UPPERANDINTERMEDIATERINGS
INSTALLATION
CAUTION: To prevent severe damage to the Crank- shaft, Damper or Special Tool 8512–A, thoroughly clean the damper bore and the crankshaft nose before installing Damper.
(1) Slide damper onto crankshaft slightly.
CAUTION: Special Tool 8512–A, is assembled in a specific sequence. Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft.
(2) Assemble Special Tool 8512–A as follows, The nut is threaded onto the shaft first. Then the roller
ENGINE - 5.7L
9 - 210
VIBRATION DAMPER (Continued)bearing is placed onto the threaded rod (The hard- ened bearing surface of the bearing MUSTface the nut). Then the hardened washer slides onto the threaded rod (Fig. 18). Once assembled coat the threaded rod’s threads with Mopart Nickel Anti- Seize or (Loctite No. 771).
Fig.18ProperAssemblyMethodforSpecialTool
8512
1 - BEARING 2 - NUT 3 - THREADED ROD 4 - BEARING HARDENED SURFACE (FACING NUT) 5 - HARDENED WASHER
(3) Using Special Tool 8512–A, press damper onto
crankshaft.
(4) Install then tighten crankshaft damper bolt to
176 N·m (129 ft. lbs.).
(5) Install fan blade assembly (Refer to 7 - COOL- ING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).
(6) Install radiator upper shroud and tighten fas-
teners to 11 N·m (95 in. lbs.).
(7) Install radiator upper hose. (8) Install accessory drive belt (Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- LATION).
(9) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(10) Connect negative cable to battery.
DR
STRUCTURAL COVER DESCRIPTION
The structural dust cover is made of die cast alu- minum and joins the lower half of the transmission bell housing to the engine.
OPERATION
The structural cover provides additional power-
train stiffness and reduces noise and vibration.
REMOVAL
(1) Raise vehicle on hoist. (2) Remove the bolts retaining structural cover. (3) Remove the structural cover.
INSTALLATION
CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will cause severe damage to the cover, and engine noise.
(1) Position the structural cover in the vehicle. (2) Install all bolts retaining the cover-to-engine.
DO NOT tighten the bolts at this time.
(3) Install the cover-to-transmission bolts. Do NOT
tighten at this time.
CAUTION: The structural cover must be held tightly against the corner formed by the engine and the transmission tightening sequence. Failure to do so may cause damage to the cover and engine noise.
housing
during
bell
(4) Torque the structural cover bolt that is closest to the front face of block on the passenger side of block to 54 N·m (40 ft. lbs.).
(5) Torque the structural cover bolt that is closest to the rear face of block on the drivers side to 54 N·m (40 ft. lbs.).
(6) Torque the remaining structural cover bolts that go into the block in an “X” pattern to 54 N·m (40 ft. lbs.).
(7) Torque the structural cover bolts that go into the transmission in an “X” pattern to 54 N·m (40 ft. lbs.).
DR
FRONT MOUNT REMOVAL
2WD
ENGINE - 5.7L
9 - 211
(1) Disconnect negative battery cable. (2) Raise vehicle. (3) Remove engine mount through bolts. (4) Raise engine using engine support fixture spe-
(5) Remove engine mount to insulator bolts (Fig.
cial tool # 8534.
19), (Fig. 20).
(6) Remove insulator from engine.
Fig.20LHINSULATOR
1 - BOLT 2 - INSULATOR
(12) Raise the engine far enough to be able to
remove the left and right engine mounts.
(13) Remove the engine mounts.
INSTALLATION
2WD
(1) Install insulator on the engine (Fig. 22).
NOTE: For mount to engine block and left engine bracket to front axle bolts, apply MoparT Lock and Seal Adhesive, Medium Strength Threadlocker.
(2) Install upper and lower mount mounting bolts.
Tighten bolts to 61 N·m (45 ft. lbs.).
(3) Lower the engine using engine support fixture
special tool # 8534.
(4) Install mount through bolts. (5) Tighten through bolts on both sides to 61 N·m
(45 ft. lbs.).
(6) Lower vehicle. (7) Connect negative battery cable.
4WD
NOTE: For mount to engine block and left engine bracket to front axle bolts, apply MoparT Lock and Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to
the front axle. Torque nuts to 94 N·m (70 ft. lbs.).
Fig.19RHINSULATOR
1 - BOLT 2 - INSULATOR
4WD
(1) Disconnect the negative cable from the battery. (2) Raise the vehicle. (3) Remove the skid plate. (4) Remove the front crossmember(Refer to 13 - FRAME & BUMPERS/FRAME/FRONT CROSS- MEMBER - REMOVAL).
(5) Remove the engine oil filter. (6) Support the engine using engine support fix-
ture, special tool # 8534.
(7) Support the front axle with a suitable jack. (8) Remove the (4) bolts that attach the engine
mounts to the front axle (Fig. 21).
(9) Remove the (3) bolts that attach the front axle
to the left engine bracket.
(10) Lower the front axle. (11) Remove the (6) through bolts
ENGINE - 5.7L
9 - 212
FRONT MOUNT (Continued)DR
Fig.21ENGINEINSULATORMOUNTS4X4
1 - RH INSULATOR TO AXLE BOLT 2 - NUT 3 - PINION SUPPORT MOUNT 4 - LH INSULATOR MOUNT
5 - LH INSULATOR TO AXLE BOLT 6 - FRONT AXLE 7 - NUT 8 - RH INSULATOR MOUNT
(2) Raise the front axle into the frame and install the left and right side through bolts. Torque nuts to 94 N·m (70 ft. lbs.).
(3) Insert the two upper through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts.
(4) Lower the engine using engine support fixture special tool # 8534, until the left and right side engine brackets rest on the through bolts, and the lower engine bracket through holes align with the engine mounts, and the left engine bracket holes align with the front axle slots (Fig. 23).
(5) Loose assemble the (3) bolts that attach the
front axle to the left engine bracket.
(6) Loose assemble the lower through bolts. (7) Torque the nuts for the (4) through bolts to 101
N·m (75 ft. lbs.).
(8) Torque the (3) bolts that attach the front axle
to the left engine bracket to 101 N·m (75 ft. lbs.).
(9) Install the engine oil filter, if removed. (10) Install the front crossmember(Refer to 13 - FRAME & BUMPERS/FRAME/FRONT CROSS- MEMBER - INSTALLATION).
(11) Install the skid plate. (12) Lower the vehicle.
Fig.22RHINSULATOR
1 - BOLT 2 - INSULATOR
DR FRONT MOUNT (Continued)
ENGINE - 5.7L
9 - 213
Fig.23ENGINEINSULATORMOUNTS4X4
1 - RH INSULATOR TO AXLE BOLT 2 - NUT 3 - PINION SUPPORT MOUNT 4 - LH INSULATOR MOUNT
5 - LH INSULATOR TO AXLE BOLT 6 - FRONT AXLE 7 - NUT 8 - RH INSULATOR MOUNT
(13) Reconnect the negative battery cable.
REAR MOUNT REMOVAL
(1) Raise the vehicle on a hoist. (2) Using a suitable jack, support transmission. (3) Remove the nuts from the transmission mount
(Fig. 24).
(4) Remove the two bolts that attach the transmis-
sion mount to the engine bracket.
(5) Raise the transmission enough to remove the
mount from the crossmember.
(6) Remove the mount.
INSTALLATION
NOTE: Threadlocking compound must be applied to the bolts before installation.
(1) Install the two bolts that attach the transmis-
sion mount to the transmission bracket.
(2) Torque the bolts to 61N·m (45 ft.lbs.) torque.
Fig.24TRANSMISSIONMOUNT
1 - MOUNT 2 - CROSSMEMBER 3 - NUT 4 - BOLT
ENGINE - 5.7L
9 - 214
REAR MOUNT (Continued)DR
(3) Lower the transmission so the transmission mount rests on the crossmember, and the studs of the transmission mount are aligned in the slots in the crossmember.
(4) Install the nuts onto the transmission mount
studs through the crossmember access slot. (5) Torque the nuts to 54N·m (40 ft. lbs.).
LUBRICATION DESCRIPTION
The lubrication system (Fig. 25) is a full flow fil-
tration pressure feed type.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE
(1) Remove oil pressure sending unit and install
gauge assembly C-3292.
(2) Run engine until thermostat opens. (3) Oil Pressure: † Curb Idle–25 kPa (4 psi) minimum † 3000 rpm–170 - 758 kPa (25 - 110 psi) (4) If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck open.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK inspection of the engine, particularly at the area of the suspected leak.
Begin with a thorough visual
Fig.25EngineOilLubricationSystem
DR LUBRICATION (Continued)
ENGINE - 5.7L
9 - 215
If an oil leak source is not readily identifiable, the following steps should be followed:
(1) Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var- ious speeds for approximately 24 km (15 miles), and repeat inspection. If the oil leak source is not pos- itively identified at this time, proceed with the air leak detection test method.
Air Leak Detection Test Method
(1) Remove the PCV valve from the IAFM. Cap or
plug the PCV valve grommet.
(2) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.
(3) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus- pected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual procedures.(4) If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak.
(5) If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve.
(6) Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery. (2) Raise the vehicle.
(3) Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down, possible causes are a porous block, distributor seal, camshaft bore cup plugs oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. (4) If no leaks are detected, pressurize the crank- case as outlined in the, Inspection (Engine oil Leaks in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the If a leak is crankshaft and watch for leakage. detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal.
(6) For bubbles that remain steady with shaft rotation, no further inspection can be done until dis- assembled.
OIL STANDARD PROCEDURE - ENGINE OIL SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY.
ENGINE - 5.7L
9 - 216
OIL (Continued) ENGINE OIL SPECIFICATIONCAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi- fied. MOPARt provides engine oils that conform to this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis- cosity of engine oil. Use only engine oils with multi- ple viscosities such as 5W-30 in the 5.7L engines. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation.
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CON- SERVING is located on the label of an engine oil con- tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans (Fig. 26).
Fig.26APISYMBOL
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the left
hand of the engine on the 5.7L engines.
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result.
Inspect engine oil level approximately every 800
kilometers (500 miles). Unless the engine has exhib- ited loss of oil pressure, run the engine for about tenDR
minutes before checking oil level. Checking engine oil level on a cold engine is not accurate.
To ensure proper lubrication of an engine, the 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.
(1) Position vehicle on level surface. (2) With engine OFF, allow approximately five minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. (3) Wipe dipstick clean. (4) Install dipstick and verify it is seated in the
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the ADD mark on
tube.
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals described in Maintenance Schedules(Refer to LUBRI- CATION MAINTENANCE/MAINTENANCE SCHEDULES - DESCRIPTION).
Run engine until achieving normal operating tem-
perature.
engine off.
drain.
(1) Position the vehicle on a level surface and turn
(2) Hoist and support vehicle on safety stands. (3) Remove oil fill cap. (4) Place a suitable drain pan under crankcase
(5) Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged.
(6) Install drain plug in crankcase. Torque to 34
N·m ( 25 ft. lbs.).
(7) Lower vehicle and fill crankcase with specified type and amount of engine oil described in this sec- tion.
(8) Install oil fill cap. (9) Start engine and inspect for leaks. (10) Stop engine and inspect oil level.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING at beginning of this section.
OIL FILTER REMOVAL
All engines are equipped with a high quality full- flow, disposable type oil filter. DaimlerChrysler Cor-
DR OIL FILTER (Continued)
poration recommends a Mopart or equivalent oil filter be used.
(1) Position a drain pan under the oil filter. (2) Using a suitable oil filter wrench loosen filter. (3) Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss.
(4) When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle.
NOTE: Make sure filter gasket was removed with fil- ter.
(5) With a wiping cloth, clean the gasket sealing
surface of oil and grime.
INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil.
(2) Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Fig. 27) hand tighten filter one half turn, or 180°,do not over tighten.
(3) Add oil, verify crankcase oil
level and start
engine. Inspect for oil leaks.
Fig.27OilFilterSealingSurface-Typical
1 - SEALING SURFACE 2 - RUBBER GASKET 3 - OIL FILTER
OIL PAN REMOVAL
(1) Disconnect the negative battery cable. (2) Install engine support fixture special tool #
8534. Do not raise engine at this time.
(3) Loosen both left and right side engine mount
through bolts. Do not remove bolts.
(4) Remove the structural dust cover, if equipped. (5) Drain engine oil. (6) Remove the front crossmember(Refer to 13 - FRAME & BUMPERS/FRAME/FRONT CROSS- MEMBER - REMOVAL).
ENGINE - 5.7L
9 - 217
CAUTION: Only raise the engine enough to provide clearance for oil pan removal. Check for proper clearance at fan shroud to fan and cowl to intake manifold.
(7) Raise engine using special tool # 8534 to pro-
vide clearance to remove oil pan.
NOTE: Do not pry on oil pan or oil pan gasket. Gas- ket is integral to engine windage tray and does not come out with oil pan.
(8) Remove the oil pan mounting bolts and oil pan.
NOTE: The double ended oil pan studs must be installed in the same location that they were removed from.
(9) Unbolt oil pump pickup tube and remove tube. (10) Inspect the integral windage tray and gasket
and replace as needed.
INSTALLATION
(1) Clean the oil pan gasket mating surface of the
block and oil pan.
and replace as needed.
(2) Inspect the integral windage tray and gasket
(3) Reinstall the oil pump pickup tube with new o-ring. Tighten tube to pump fasteners to 28 N·m (250 in. lbs.).
NOTE: The double ended oil pan studs must be installed in the same location that they were removed from.
(4) Position the oil pan and install the mounting bolts and studs.. Tighten the mounting bolts to 12
N·m (105 in.lbs.).(5) Lower the engine into mounts using special
tool # 8534.
(6) Install both the left and right side engine mount through bolts. Tighten the nuts to 68 N·m (50
ft. lbs.).(7) Remove special tool # 8534. (8) Install structural dust cover, if equipped.
