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(17) Add coolant (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(18) Connect the battery cables. (19) Start engine and inspect for leaks.
DR
ENGINE 8.0L
9 - 351
ENGINE 8.0L
TABLE OF CONTENTS
page
page
ENGINE 8.0L
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 353
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - ENGINE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 375
STANDARD PROCEDUREVALVE SERVICE . . . . . . . . . . . . . . . . . . . . . 375
DIAGNOSIS - INTRODUCTION . . . . . . . . . . 353
REMOVAL
DIAGNOSIS AND TESTING—ENGINE
DIAGNOSIS - PERFORMANCE . . . . . . . . . . 354
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . 356
DIAGNOSIS AND TESTING—ENGINE
DIAGNOSIS - LUBRICATION . . . . . . . . . . . . 358
DIAGNOSIS AND TESTING—CYLINDER
COMPRESSION PRESSURE . . . . . . . . . . . . 359
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE . . . . . 359
STANDARD PROCEDURE
STANDARD PROCEDURE—CYLINDER
BORE HONING . . . . . . . . . . . . . . . . . . . . . . 360
STANDARD PROCEDURE - FORM-IN-
REMOVAL—VALVE STEM SEALS . . . . . . . . 377
REMOVAL—VALVES AND VALVE SPRINGS . 377
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 378
INSTALLATIONINSTALLATION—VALVE STEM SEAL . . . . . . 378
INSTALLATION—VALVES AND VALVESPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
ROCKER ARM / ADJUSTER ASSY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 379ENGINE BLOCK
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 380PLACE GASKETS AND SEALERS . . . . . . . . 360
CAMSHAFT & BEARINGS (IN BLOCK)
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS . . . . . . . . 361
STANDARD PROCEDURE—HYDROSTATIC
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 362
SPECIFICATIONSTORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
8.OL ENGINE . . . . . . . . . . . . . . . . . . . . . . . 364
SPECIAL TOOLS8.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 367
AIR CLEANER ELEMENT
REMOVAL
REMOVAL—CAMSHAFT BEARINGS . . . . . . 380
REMOVAL—CAMSHAFT . . . . . . . . . . . . . . . 380INSTALLATION
INSTALLATION—CAMSHAFT BEARINGS . . 381
INSTALLATION—CAMSHAFT . . . . . . . . . . . . 381CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING . . . . . . . . . . . . . . . 382
CRANKSHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 383REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 370CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE—FITTING
CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 370
DIAGNOSIS AND TESTING—CYLINDER HEADGASKET FAILURE . . . . . . . . . . . . . . . . . . . . 370
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 372
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 372CYLINDER HEAD COVER(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 373
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 374
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 374CRANKSHAFT MAIN BEARINGS . . . . . . . . . 383
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 383CRANKSHAFT OIL SEAL - FRONT
REMOVAL
REMOVAL—FRONT OIL SEAL - FRONT
COVER INSTALLED . . . . . . . . . . . . . . . . . . . 384
REMOVAL—FRONT OIL SEAL - FRONT
COVER REMOVED . . . . . . . . . . . . . . . . . . . 384
INSTALLATION
INSTALLATION—FRONT OIL SEAL – FRONT
COVER INSTALLED . . . . . . . . . . . . . . . . . . . 384
INSTALLATION—FRONT OIL SEAL - FRONT
COVER REMOVED . . . . . . . . . . . . . . . . . . . 384
9 - 352
ENGINE 8.0L
DR
CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 385CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 386HYDRAULIC LIFTERS
DIAGNOSIS AND TESTING—HYDRAULIC
TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 388PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 388
STANDARD PROCEDURE—PISTON FITTING . 389
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 389
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 389PISTON RINGS
STANDARD PROCEDURE—FITTING PISTON
RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 392FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 392REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 393LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 393
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 393
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING—ENGINE OIL
LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
DIAGNOSIS AND TESTING—ENGINE OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 396
OIL
STANDARD PROCEDURE - ENGINE OIL
. . . . 396
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 397OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 397
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 398OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 399
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 400INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 401
DIAGNOSIS AND TESTING—INTAKEMANIFOLD LEAKAGE
. . . . . . . . . . . . . . . . . 401
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 402
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 402EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 403
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 403
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 404
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 404TIMING BELT / CHAIN COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 404TIMING BELT/CHAIN AND SPROCKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
INSPECTION—MEASURING TIMING CHAINSTRETCH
. . . . . . . . . . . . . . . . . . . . . . . . . . 405
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 406DR
ENGINE 8.0L DESCRIPTION
ENGINE 8.0L
9 - 353
The 8.0 Liter (488 CID) ten-cylinder engine is a V-Type lightweight, single cam, overhead valve engine with hydraulic roller tappets. This engine is designed for unleaded fuel.
Engine lubrication system consists of a gerotor type oil pump mounted in the timing chain cover and driven by the crankshaft. The V-10 uses a full flow oil filter.
The cylinders are numbered from front to rear; 1, 3, 5, 7, 9 on the left bank and 2, 4, 6, 8, 10 on the right bank. The firing order is 1-10-9-4-3-6-5-8-7-2
(Fig. 1).The engine serial number is located on the lower left front of the cylinder block in front of the engine mount (Fig. 2). When component part replacement is necessary, use the engine type and serial number for reference.
Fig.1FiringOrder
Fig.2EngineIdentification—(SerialNumber)
1 - ENGINE SERIAL NO. 2 - ENGINE MOUNT LOCATION
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION Engine diagnosis is helpful
in determining the causes of malfunctions not detected and remedied by routine maintenance.
These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST- ING - Preformance) or (Refer to 9 - ENGINE - DIAG- NOSIS AND TESTING - Mechanical). Refer to 14 - FUEL SYSTEM for fuel system diagnosis.
ENGINE - DIAGNOSIS AND TESTING)
Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can- not be isolated with the Service Diagnosis charts. Information concerning additional tests and diagno- sis is provided within the following: † Cylinder Compression Pressure Test (Refer to 9 - † Cylinder Combustion Pressure Leakage Test (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING) † Cylinder Head Gasket Failure Diagnosis (Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNOSIS AND TESTING) † Intake Manifold Leakage Diagnosis (Refer to 9 - † Lash Adjuster (Tappet) Noise Diagnosis (Refer to 9 - ENGINE/ENGINE BLOCK/HYDRAULIC LIFT- ERS (CAM IN BLOCK) - DIAGNOSIS AND TEST- ING)† Engine Oil Leak Inspection (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TEST- ING)
ENGINE/MANIFOLDS/INTAKE DIAGNOSIS AND TESTING)
MANIFOLD
ENGINE 8.0L
9 - 354
ENGINE 8.0L (Continued) DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - PERFORMANCEPERFORMANCE DIAGNOSIS CHART—GASOLINE ENGINES
DR
CONDITION
POSSIBLE CAUSES
CORRECTION
ENGINE WILL NOT CRANK
1. Weak or dead battery
2. Corroded or loose battery connections
3. Faulty starter or related circuit(s)
4. Seized accessory drive component
5. Engine internal mechanical failure or hydro-static lock
ENGINE CRANKS BUT WILL NOT START
1. No spark
2. No fuel
3. Low or no engine compression
ENGINE LOSS OF POWER
1. Worn or burned distributor rotor 2. Worn distributor shaft
3. Worn or incorrect gapped spark plugs
4. Dirt or water in fuel system 5. Faulty fuel pump 6. Incorrect valve timing 7. Blown cylinder head gasket 8. Low compression
9. Burned, warped, or pitted valves 10. Plugged or restricted exhaust system 11. Faulty ignition cables
1. Charge/Replace Battery. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/ BATTERY - STANDARD PROCEDURE). Check charging system. (Refer to 8 - ELECTRICAL/CHARGING - DIAGNOSIS AND TESTING).
2. Clean/tighten suspect battery/starter connections 3. Check starting system. (Refer to 8 - ELECTRICAL/STARTING - DIAGNOSIS AND TESTING) 4. Remove accessory drive belt and attempt to start engine. If engine starts, repair/replace seized component. 5. Refer to (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
1. Check for spark. (Refer to 8 - ELECTRICAL/IGNITION CONTROL - DESCRIPTION)
2. Perform fuel pressure test, and if necessary, inspect fuel injector(s) and driver circuits. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP - DIAGNOSIS AND TESTING). 3. Perform cylinder compression pressure test. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).
1. Install new distributor rotor 2. Remove and repair distributor (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ DISTRIBUTOR - REMOVAL). 3. Clean plugs and set gap. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ SPARK PLUG - CLEANING). 4. Clean system and replace fuel filter 5. Install new fuel pump 6. Correct valve timing 7. Install new cylinder head gasket 8. Test cylinder compression (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING). 9. Install/Reface valves as necessary 10. Install new parts as necessary 11. Replace any cracked or shorted cables
DR ENGINE 8.0L (Continued)
ENGINE 8.0L
9 - 355
CONDITION
POSSIBLE CAUSES
CORRECTION
12. Faulty ignition coil
ENGINE STALLS OR ROUGH IDLE
1. Carbon build-up on throttle plate
2. Engine idle speed too low
3. Worn or incorrectly gapped spark plugs
4. Worn or burned distributor rotor 5. Spark plug cables defective or crossed
6. Faulty coil
7. Intake manifold vacuum leak
ENGINE MISSES ON ACCELERATION
1. Worn or incorrectly gapped spark plugs
2. Spark plug cables defective or crossed
3. Dirt in fuel system 4. Burned, warped or pitted valves 5. Faulty coil
12. Test and replace, as necessary (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ IGNITION COIL - REMOVAL).
1. Remove throttle body and de-carbon. (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/THROTTLE BODY - REMOVAL). 2. Check Idle Air Control circuit. (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ IDLE AIR CONTROL MOTOR - DESCRIPTION) 3. Replace or clean and re-gap spark plugs (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING) 4. Install new distributor rotor 5. Check for correct firing order or replace spark plug cables. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ SPARK PLUG CABLE - DIAGNOSIS AND TESTING) 6. Test and replace, if necessary (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ IGNITION COIL - REMOVAL) 7. Inspect intake manifold gasket and vacuum hoses (Refer to 9 - ENGINE/ MANIFOLDS/INTAKE MANIFOLD - DIAGNOSIS AND TESTING).
1. Replace spark plugs or clean and set gap. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/SPARK PLUG - CLEANING) 2. Replace or rewire secondary ignition cables. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG CABLE - REMOVAL) 3. Clean fuel system 4. Install new valves 5. Test and replace as necessary (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ IGNITION COIL - REMOVAL)
ENGINE 8.0L
9 - 356
ENGINE 8.0L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICALENGINE MECHANICAL DIAGNOSIS CHART
DR
CONDITION
POSSIBLE CAUSES
CORRECTION
NOISY VALVES/LIFTERS
1. High or low oil level in crankcase
2. Thin or diluted oil
3. Low oil pressure
4. Dirt in tappets/lash adjusters
5. Bent push rod(s) 6. Worn rocker arms
7. Worn tappets/lash adjusters
8. Worn valve guides
9. Excessive runout of valve seats or valve faces
1. Check for correct oil level. Adjust oil level by draining or adding as needed 2. Change oil. (Refer to 9 - ENGINE/ LUBRICATION/OIL - STANDARD PROCEDURE) 3. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/ LUBRICATION - DIAGNOSIS AND TESTING) for engine oil pressure test/specifications 4. Clean/replace hydraulic tappets/lash adjusters 5. Install new push rods 6. Inspect oil supply to rocker arms and replace worn arms as needed 7. Install new hydraulic tappets/lash adjusters 8. Inspect all valve guides and replace as necessary 9. Grind valves and seats
CONNECTING ROD NOISE
1. Insufficient oil supply
1. Check engine oil level.
2. Low oil pressure
3. Thin or diluted oil
4. Excessive connecting rod bearing clearance
5. Connecting rod journal out of round 6. Misaligned connecting rods
MAIN BEARING NOISE
1. Insufficient oil supply 2. Low oil pressure
3. Thin or diluted oil
2. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/ LUBRICATION - DIAGNOSIS AND TESTING) engine oil pressure test/specifications 3. Change oil to correct viscosity. (Refer to 9 - ENGINE/LUBRICATION/OIL - STANDARD PROCEDURE) for correct procedure/engine oil specifications 4. Measure bearings for correct clearance with plasti-gage. Repair as necessary 5. Replace crankshaft or grind journals 6. Replace bent connecting rods
1. Check engine oil level. 2. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/ LUBRICATION - DIAGNOSIS AND TESTING) 3. Change oil to correct viscosity.
DR ENGINE 8.0L (Continued)
ENGINE 8.0L
9 - 357
CONDITION
POSSIBLE CAUSES
CORRECTION
LOW OIL PRESSURE
OIL LEAKS
EXCESSIVE OIL CONSUMPTION OR SPARK PLUGS OIL FOULED
4. Excessive main bearing clearance
5. Excessive end play
6. Crankshaft main journal out of round or worn 7. Loose flywheel or torque converter
1. Low oil level 2. Faulty oil pressure sending unit 3. Clogged oil filter 4. Worn oil pump 5. Thin or diluted oil 6. Excessive bearing clearance
7. Oil pump relief valve stuck
8. Oil pickup tube loose, broken, bent or clogged 9. Oil pump cover warped or cracked
1. Misaligned or deteriorated gaskets 2. Loose fastener, broken or porous metal part 3. Front or rear crankshaft oil seal leaking 4. Leaking oil gallery plug or cup plug
1. CCV System malfunction
2. Defective valve stem seal(s) 3. Worn or broken piston rings 4. Scuffed pistons/cylinder walls
5. Carbon in oil control ring groove 6. Worn valve guides
7. Piston rings fitted too tightly in grooves
4. Measure bearings for correct clearance. Repair as necessary 5. Check crankshaft thrust bearing for excessive wear on flanges 6. Grind journals or replace crankshaft
7. Inspect crankshaft, flexplate/flywheel and bolts for damage. Tighten to correct torque
1. Check oil level and fill if necessary 2. Install new sending unit 3. Install new oil filter 4. Replace oil pump assembly. 5. Change oil to correct viscosity. 6. Measure bearings for correct clearance 7. Remove valve to inspect, clean and reinstall 8. Inspect oil pickup tube and pump, and clean or replace if necessary 9. Install new oil pump
1. Replace gasket 2. Tighten, repair or replace the part
3. Replace seal
4. Remove and reseal threaded plug. Replace cup style plug
1. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS - DESCRIPTION) for correct operation
2. Repair or replace seal(s) 3. Hone cylinder bores. Install new rings 4. Hone cylinder bores and replace pistons as required 5. Remove rings and de-carbon piston 6. Inspect/replace valve guides as necessary 7. Remove rings and check ring end gap and side clearance. Replace if necessary
ENGINE 8.0L
9 - 358
ENGINE 8.0L (Continued) DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - LUBRICATIONDR
CONDITION
OIL LEAKS
POSSIBLE CAUSES
CORRECTION
1. Gaskets and O-Rings.
1.
(a) Misaligned or damaged. (b) Loose fasteners, broken or porous metal parts. 2. Crankshaft rear seal 3. Crankshaft seal flange. Scratched, nicked or grooved. 4. Oil pan flange cracked. 5.Front cover seal, damaged or misaligned. 6. Scratched or damaged vibration damper hub.
(a) Replace as necessary. (b) Tighten fasteners, Repair or replace metal parts. 2. Replace as necessary. 3. Polish or replace crankshaft.
4. Replace oil pan. 5. Replace seal.
6. Polish or replace damper.
OIL PRESSURE DROP
1. Low oil level.
1. Check and correct oil level.
2. Faulty oil pressure sending unit. 3. Low oil pressure.
4. Clogged oil filter. 5. Worn oil pump. 6. Thin or diluted oil. 7. Excessive bearing clearance. 8. Oil pump relief valve stuck. 9. Oil pickup tube loose or damaged.
2. Replace sending unit. 3. Check pump and bearing clearance. 4. Replace oil filter. 5. Replace as necessary. 6. Change oil and filter. 7. Replace as necessary. 8. Replace oil pump. 9. Replace as necessary.
OIL PUMPING AT RINGS; SPARK
1. Worn or damaged rings.
PLUGS FOULING
2. Carbon in oil ring slots. 3. Incorrect ring size installed. 4. Worn valve guides. 5. Leaking intake gasket. 6. Leaking valve guide seals.
1. Hone cylinder bores and replace rings. 2. Replace rings. 3. Replace rings. 4. Ream guides and replace valves. 5. Replace intake gaskets. 6. Replace valve guide seals.
DR ENGINE 8.0L (Continued) 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 (Refer to 8 - ELEC- TRICAL/IGNITION CONTROL/SPARK PLUG - REMOVAL).
(3) Secure the throttle in the wide-open position. (4) Disconnect the ignition coil. (5) Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
(6) Record the compression pressure on the third revolution. Continue the test for the remaining cylin- ders.
(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: † Exhaust and intake valve leaks (improper seat- ing)† Leaks between adjacent cylinders or into water jacket
ENGINE 8.0L
9 - 359
† Any causes for combustion/compression pressure
loss
WARNING: DO NOT REMOVE THE RADIATOR CAP WITH THE SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM HOT COOLANT CAN OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor- then turn OFF the
mal operating temperature, engine.
Remove the spark plugs. Remove the oil filler cap. Remove the air cleaner. Calibrate the tester according to the manufactur- er’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.Perform the test procedure on each cylinder accord- ing to the tester manufacturer’s instructions. While testing, listen for pressurized air escaping through the throttle body, tailpipe or 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 CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART.
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSE
CORRECTION
AIR ESCAPES THROUGH THROTTLE BODY AIR ESCAPES THROUGH TAILPIPE AIR ESCAPES THROUGH RADIATOR MORE THAN 50% LEAKAGE FROM ADJACENT CYLINDERS
MORE THAN 25% LEAKAGE AND AIR ESCAPES THROUGH OIL FILLER CAP OPENING ONLY
Intake valve bent, burnt, or not seated properly Exhaust valve bent, burnt, or not seated properly Head gasket leaking or cracked cylinder head or block Head gasket leaking or crack in cylinder head or block between adjacent cylinders Stuck or broken piston rings; cracked piston; worn rings and/or cylinder wall
Inspect valve and valve seat. Reface or replace, as necessary Inspect valve and valve seat. Reface or replace, as necessary Remove cylinder head and inspect. Replace defective part Remove cylinder head and inspect. Replace gasket, head, or block as necessary Inspect for broken rings or piston. Measure ring gap and cylinder diameter, taper and out-of-round. Replace defective part as necessary
ENGINE 8.0L
9 - 360
ENGINE 8.0L (Continued) STANDARD PROCEDURESTANDARD PROCEDURE—CYLINDER 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.
(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 50° to 60° for proper seating of rings (Fig. 3).
(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 50° to 60° 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.
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in- place gasket material unless specified. Bead size, continuity, and location are of great importance. Too
DR
Fig.3CylinderBoreCrosshatchPattern
1 - CROSSHATCH PATTERN 2 - INTERSECT ANGLE
thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket materials that are used in the engine area. Mopart Engine RTV GEN II, Mopart ATF-RTV, and Mopart Gasket Maker gasket materials, each have different properties and can not be used in place of the other.
MOPARt ENGINE RTV GEN II Mopart Engine RTV GEN II is used to seal com- ponents exposed to engine oil. This material is a spe- cially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
MOPARt ATF RTV Mopart ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and seal- ing properties to seal components exposed to auto- matic coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
transmission fluid,
engine
MOPARt GASKET MAKER
DR ENGINE 8.0L (Continued)
Mopart Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.
MOPARt GASKET SEALANT Mopart Gasket Sealant is a slow drying, perma- nently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This mate- rial is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will pre- vent corrosion. Mopart Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER APPLICATION
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gas- kets.
Mopart Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant 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.
Mopart Engine 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.
Mopart Gasket 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.
STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain the original center line.
ENGINE 8.0L
9 - 361
tially, this repair consists of:
Damaged or worn threads can be repaired. Essen- † Drilling out worn or damaged threads. † Tapping the hole with a special Heli-Coil Tap, or † Installing an insert into the tapped hole to bring
equivalent.
the hole back to its original thread size.
STANDARD PROCEDURE—HYDROSTATIC LOCK
CAUTION: DO NOT use the starter motor to rotate the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps below.
(1) Perform the Fuel Pressure Release Procedure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air
induction system, and intake manifold to ensure system is dry and clear of foreign material.
cleaner,
(4) Place a shop towel around the spark plugs to catch any fluid that may possibly be under pressure in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
(7) Be sure all fluid has been removed from the
oil, etc.).
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N·m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N·m (25 ft. lbs.) torque.
(13) Install a new oil filter. (14) Fill engine crankcase with the specified amount and grade of oil. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery. (16) Start the engine and check for any leaks.
REMOVAL
(1) Remove the battery. (2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
ENGINE 8.0L
9 - 362
ENGINE 8.0L (Continued)DR
(3) Discharge
if equipped (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE).
conditioning system,
the air
(4) Remove the upper crossmember. (5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS REMOVAL).
COOLER
(6) Remove the serpentine belt (Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV- AL).
(7) Remove the A/C compressor with the lines attached (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING/A/C REMOVAL). Set aside.
COMPRESSOR
(8) If equipped, remove the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/ A/C CONDENSER - REMOVAL).(9) Remove the washer fluid reservoir bottle (Refer
ELECTRICAL/WIPERS/WASHERS
to REMOVAL AND INSTALLATION).
(10) Disconnect the top radiator hose. (11) Remove the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - REMOVAL).
(12) Remove the fan shroud. (13) Disconnect the lower radiator hose. (14) Disconnect the transmission cooler lines. (15) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(16) Remove the generator with the wire connec- tions (Refer to 8 - ELECTRICAL/CHARGING/GEN- ERATOR - REMOVAL).
(17) Remove the air cleaner. (18) Disconnect the throttle linkage. (19) Remove throttle body (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/THROTTLE BODY - REMOVAL).
(20) Remove the upper intake manifold (Refer to 9
- ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL).(21) Remove the coil assemblies with the ignition
cables.
equipped.
(22) Disconnect the heater hoses. (23) Disconnect
the power
steering hoses,
if
(24) Perform the Fuel System Pressure release procedure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE). Disconnect the fuel line (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STAN- DARD PROCEDURE).
(25) On Manual Transmission vehicles, remove the
shift lever.
oil.
(26) Raise and support the vehicle on a hoist. (27) Remove the drain plug and drain the engine
(28) Loosen front engine mount thru-bolt nuts.
(29) Remove the transmission cooler line brackets
from oil pan.
(30) Disconnect exhaust pipe at manifold. (31) Disconnect the starter wires. Remove starter to 8 - ELECTRICAL/STARTING/
motor STARTER MOTOR - REMOVAL).
(Refer
(32) Remove transmission. (33) Lower vehicle.
CAUTION: DO NOT lift the engine by the intake manifold.
(34) Install an engine lifting fixture. (35) Remove
engine
from vehicle and install
engine assembly on a repair stand.
INSTALLATION
(1) Remove engine from the repair stand and posi- tion in the engine compartment. Position the thru- bolt into the support cushion brackets. (2) Install an engine support fixture. (3) Raise and support the vehicle on a hoist. (4) Install Transmission. (5) Install (Refer
the starter to 8 - ELECTRICAL/STARTING/
wires STARTER MOTOR - INSTALLATION). (6) Install exhaust pipe to manifold. (7) Install the transmission cooler line brackets
the starter and connect
from oil pan.
102N·m (75 ft. lbs.).
(25 ft. lbs.) torque.
(8) Tighten the Front mount thru-bolts and nuts to
(9) Install the drain plug and tighten to 34 N·m
(10) Prime oil pump by squirting oil in the oil fil- ter mounting hole and filling the J-trap of the front timing cover. When oil is running out, install oil filter that has been filled with oil.
(11) Lower the vehicle. (12) Remove engine lifting fixture. (13) On Manual Transmission vehicles, install the
shift lever.
(14) Connect the fuel lines (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT- TING - STANDARD PROCEDURE).
(15) Connect the heater hoses. (16) Install the upper intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE INSTALLATION).
(17) Install the coil assemblies with the ignition
cables.
(18) Using a new gasket,
throttle body (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ THROTTLE BODY - INSTALLATION).
install
(19) Connect the throttle linkage. (20) Install the air cleaner box.
DR ENGINE 8.0L (Continued)
(21) Install the generator and wire connections (Refer to 8 - ELECTRICAL/CHARGING/GENERA- TOR - INSTALLATION).
(22) Install the upper crossmember. (23) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(24) Connect the lower radiator hose. (25) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS INSTALLATION).
COOLER
(26) Connect the transmission cooler lines. (27) Connect the power steering hoses, if equipped. (28) Install the fan shroud. (29) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(30) Connect the top radiator hose. (31) Install the washer fluid reservoir bottle (Refer to 8 - ELECTRICAL/WIPERS/WASHERS - INSTAL- LATION).
(32) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/ A/C CONDENSER - INSTALLATION).(33) Install the A/C compressor with the lines attached (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING/A/C INSTALLATION).
COMPRESSOR
(34) Install the serpentine belt (Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- LATION).
(35) Evacuate (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO- CEDURE) and charge the air conditioning system, if equipped (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE). (36) Add coolant to the cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(37) Install the battery. (38) Warm engine and adjust as required. (39) Road test vehicle.
ENGINE 8.0L
9 - 363
SPECIFICATIONS
TORQUE
TORQUE CHART 8.0L ENGINE
DESCRIPTION
N·m
Ft. Lbs. 55
16— 45
20
85
23075
2221
6127
115
31222
16
In. Lbs. — —
190
—— — —
—
58
143
16
7543
105
— 55— — 144
—47
35
—
34
20
6825
— 50— 174
—47
35
—
22
16
—
41
4130
30— —
Camshaft Sprocket—Bolt Camshaft Thrust Plate— Bolts Coil Pack Bracket—Bolts Connecting Rod Cap—Bolts Main Bearing—Bolts
Step 1
Step 2
Crankshaft Pulley/Damper— Bolt Crankshaft Rear Seal Retainer— Bolts Cylinder Head—BoltsStep 1
Step 2
Cylinder Head Cover—Bolts Drive Plate to Crankshaft— Bolts Drive Plate to Torque Converter— Bolts EGR Tube—Nut EGR Valve—Bolts Engine Support Bracket/ Insulator— Through Bolt Engine Support Bracket/ Insulator to Block—Bolts Exhaust Manifold to Cylinder Head— Bolt Generator Mounting—Bolt Generator to Intake Manifold Bracket —BoltsN·m 20
2254
22
46
11
16
16
34
16
41
14
2054
41
68
47
25
11
204Ft. — 16
40
16
—
34
— — — 25
— 30
— 1540
30
50
35
— — 150In. 175
——
—
80 + 45° —
96
144
144
— 144
— 125
—— — — — 220
96
—ENGINE 8.0L
9 - 364
ENGINE 8.0L (Continued)DESCRIPTION
Heat Shield—Nuts Hydraulic Tappet Yoke Retaining Spider—Bolts Intake Manifold (Lower)— Bolts Intake Manifold (Upper)— Bolts Oil Filter
Oil Filter Connector Oil Pan
—1/4 - 20 Bolts —5/16 - 18 Bolts —Stud Bolts —Drain Plug Oil Pan Pick Up Tube—Bolts Oil Pump Attaching—Bolts Oil Pump Cover—Bolts Oil Pump Pressure Relief—Plug Rocker Arm—Bolts Spark Plugs Starter Mounting—Bolts Timing Chain Cover—Bolts Thermostat Housing—Bolts Throttle Body—Nuts Transfer Case to Insulator Mounting Plate—Nuts Transmission Support Bracket— Bolts Transmission Support Cushion— Bolts Transmission Support Cushion Stud—Nuts Water Pump to Chain Case Cover— Bolts
DR
8.OL ENGINE
DESCRIPTION
SPECIFICATION
CAMSHAFT
Bearing Diameter
No. 1
No. 2
No. 3
No. 4
No. 5
No. 6
Bearing Journal Diameter No. 1
No. 2
No. 3
No. 4
No. 5
No. 6
53.16 – 53.19 mm (2.093 – 2.094 in.) 52.76 – 52.78 mm (2.077 – 2.078 in.) 52.35 – 52.37 mm (2.061 – 2.062 in.) 51.94 – 51.97 mm (2.045 – 2.046 in.) 51.54 – 51.56 mm (2.029 – 2.030 in.) 48.74 – 48.77 mm (1.919 – 1.920 in.)
53.11 – 53.14 mm (2.091 – 2.092 in.) 52.69 – 52.72 mm
(2.0745 – 2.0755 in.)
52.30 – 52.32 mm (2.059 – 2.060 in.) 51.89 – 51.92 mm (2.043 – 2.044 in.) 51.49 – 51.51 mm (2.027 – 2.028 in.) 48.69 – 48.72 mm (1.917 – 1.918 in.)
0.0254 – 0.0762 mm (0.001 – 0.003 in.) 0.0381 – 0.0889 mm (0.0005 – 0.0035 in.)
0.127 mm (0.005 in.)
0.127 – 0.381 mm (0.005 – 0.015 in.)
102
75
—
Bearing to Journal Clearance
47
35
—
No. 1,3,4,5,6
47
35
—
Service Limit
41
30
—
End Play
No. 2
DR ENGINE 8.0L (Continued)
ENGINE 8.0L
9 - 365
DESCRIPTION
SPECIFICATION
DESCRIPTION
SPECIFICATION
CONNECTING RODS
CYLINDER HEAD AND VALVES
Valve Seat Angle
44.5°
Runout (Max.)
0.0762 mm (0.003 in.)
Piston Pin bore Diameter
Side Clearance
Total Weight (Less Bearing)
24.940 – 24.978 mm (0.9819 – 0.9834 in.)
0.25 – 0.46 mm
(0.010 – 0.018 in.)
744 gms. (26.24 oz.)
CRANKSHAFT
Rod Journal Diameter
53.950 – 53.975 mm (2.124 – 2.125 in.)
Out of Round (Max.)
0.0254 mm (0.001 in.)
Taper (Max.)
0.0254 mm (0.001 in.)
Overall Length
Bearing Clearance
0.005 – 0.074 mm
(0.0002 – 0.0029 in.)
Service Limit
0.0762 mm (0.003 in.)
Main Bearing Journal Diameter
76.187 – 76.213 mm
Lift (@ zero lash)
(2.8995 – 3.0005 in.)
Out of Round (Max.)
0.0254 mm (0.001 in.)
Stem Diameter
Taper (Max.)
0.0254 mm (0.001 in.)
Width (Finish) – Intake
Valve Face Angle
Valve Head Diameter
Intake
Exhaust
Intake
Exhaust
1.016 – 1.524 mm (0.040 – 0.060 in.)
45°
48.640 – 48.900 mm (1.915 – 1.925 in.) 41.123 – 41.377 mm (1.619 – 1.629 in.)
145.19 – 145.82 mm (5.716 – 5.741 in.) 145.54 – 146.18 mm (5.730 – 5.755 in.)
7.900 – 7.920 mm (0.311 – 0.312 in.)
9.500 – 9.525 mm (0.374 – 0.375 on.)
0.025 – 0.076 mm (0.001 – 0..003 in.)
Intake Exhaust
9.91 mm (0.390 in.) 10.34 mm (0.407 in.)
Bearing Clearance
Service Limit
End Play
0.0051 – 0.058 mm (0.0002 – 0.0023 in.)
Guide Bore
0.071 mm (0.0028 in.)
Stem to Guide Clearance
0.076 – 0.305 mm (0.003 – 0.012 in.)
Service Limit ( Runout)
0.4318 (0.017 in.)
Service Limit—End Play
0.381 mm (0.015 in.)
Valve Spring Free Length
49.962 mm (1.967 in.)
CYLINDER BLOCK
Cylinder Bore Diameter
101.60 – 101.65 mm (4.0003 – 4.0008 in.)
Out of Round (Max.)
0.0762 mm (0.003 in.)
Spring Tension
Valve Closed
Valve Open
378 N @ 41.66 mm (85 lbs. @ 1.64 in.) 890 N @ 30.89 mm (200 lbs. @ 1.212 in.)
Taper (Max.)
0.127 mm (0.005 in.)
Number of Coils
6.8
Lifter Bore Diameter
22.982 – 23.010 mm (0.9048 – 0.9059 in.)
Installed Height
Wire Diameter
41.66 mm (1.64 in.)
4.50 mm (0.177 in.)
ENGINE 8.0L
9 - 366
ENGINE 8.0L (Continued)DR
DESCRIPTION
SPECIFICATION
DESCRIPTION
SPECIFICATION
HYDRAULIC TAPPETS
Body Diameter
Clearance (to bore)
Dry Lash
Push Rod Length
22.949 – 22.962 mm (0.9035 – 0.9040 in.)
0.0203 – 0.0610 mm (0.0008 – 0.0024 in.)
1.524 – 5.334 mm (0.060 – 0.210 in.)
195.52 – 196.02 mm (7.698 – 7.717 in.)
OIL PRESSURE
Curb Idle (Min.*)
83 kPa (12 psi)
@ 3000 rpm
345 – 414 kPa (50 – 60
psi)
* If oil pressure is zero at curb idle, DO NOT RUN ENGINE.
OIL PUMP
Clearance over Rotors (Max.)
0.1906 mm (0.0075 in.)
Cover Out of Flat (Max.)
0.051 mm (0.002 in.)
Weight
(3.657 – 3.667 in.)
463 – 473 grams (16.33
– 16.68 oz.)
Piston to Bore Clearance
0.013 – 0.038 mm
Service Limit
Clearance in Piston
Diameter
End Play
Length
(0.0005 – 0.0015 in.)
0.0762 mm (0.003 in.)
PISTON PINS
0.010 – 0.020 mm
(0.0004 – 0.0008 in.)
24.996 – 25.001 mm (0.9841 – 0.9843 in.)
NONE
67.8 – 68.3 mm (2.67 – 2.69 in.)
PISTON RINGS
Ring Gap
Compression Rings
Oil Control (Steel Rails)
0.254 – 0.508 mm (0.010 – 0.020 in.) 0.381 – 1.397 mm (0.015 – 0.055 in.)
Inner Rotor Thickness (Min.)
Outer Rotor
14.925 – 14.950 mm
Ring Side Clearance
(0.5876 – 0.5886 in.)
Compression Rings
0.074 – 0.097 mm
Oil Ring (Steel Rails)
(0.0029 – 0.0038 in.)
2.591 – 2.743 mm (0.102 – 0.108 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) Opens (BBDC) Duration
Intake Valve
Closes (ATDC) Opens (BBDC) Duration
Valve Overlap
25° 60° 265°
61° 6° 246°
31°
Clearance (Max.) Diameter (Min.) Thickness (Min.)
0.1626 mm (0.006 in.) 82.461 mm (3.246 in.) 14.925 mm (0.5876 in.)
Tip Clearance between Rotors (Max.)
0.584 mm (0.0230 in.)
PISTONS
Clearance at Top of Skirt
0.013 – 0.038 mm
Piston Length
Piston Ring Groove Depth
(0.0005 – 0.0015 in.)
82.5 mm (3.25 in.)
#1&2
#3
91.30 – 91.55 mm (3.594 – 3.604 in.) 92.90 – 93.15 mm
DR ENGINE 8.0L (Continued)
CRANKSHAFT JOURNAL MARKING
LOCATION
SPECIAL TOOLS
8.0L ENGINE
ENGINE 8.0L
9 - 367
MEASURE-
MENT
ITEM
IDENTIFI- CATION
0.0254 mm (0.001 in.)
Crankshaft Journals
U/S
0.508 mm (0.020 in.)
O/S
0.2032 mm (0.008 in.)
O/S
Cylinder Bores
Hydraulic Tappets
R or M
M-2-3 ect. (indicating No. 2 and
3 main bearing journal) and/or
R-1-4 ect. (indicating No. 1 and
connecting
rod
journal)
0.127 mm (0.005 in.)
Valve Stems
LOCATION
OF
IDENTIFI- CATION Milled flat on No. 8
crankshaft counter- weight.Following
engine serial
number. Diamond- shaped
stamp top pad - front of engine and flat
ground on
