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Fig.24CylinderHeadCovers
1 - CYLINDER HEAD COVER 2 - CYLINDER HEAD COVER GASKET
(10) Install closed crankcase ventilation system. (11) Connect the evaporation control system. (12) Install air cleaner. (13) Connect the negative cable to the battery. (14) Road test vehicle and check for leaks.
INSTALLATION—VALVES AND VALVE SPRINGS thoroughly. Discard burned,
(1) Clean valves
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) Make sure there are no burrs on valve stems. (5) Coat valve stems with lubrication oil. Insert
valves into valve guides in cylinder head.
(6) Install new seals on all valve guides (BLACK on intake and BROWN on exhaust). Install valve springs and valve retainers.
(7) Compress valve springs with Valve Spring Compressor Tool MD-998772A and adapter 6716A, install locks and release tool. Tap the retainer with a brass or heavy plastic hammer to ensure locks have been seated.
(8) If valves and/or seats were ground, measure the installed height of springs. Make sure the mea- surement is taken from bottom of spring seat in cyl- inder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer. If height is greater than 42.86 mm (1-11/16 inches), install a 1.587 mm (1/16 inch) spacer in head coun- terbore. Ensure this brings spring height back to nor- mal, 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
(9) Install the cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
ROCKER ARM / ADJUSTER ASSY REMOVAL
(1) Disconnect spark plug wires by pulling the boot
straight out in line with plug.
(2) Remove cylinder head cover and gasket (Refer - ENGINE/CYLINDER HEAD/CYLINDER
to HEAD COVER(S) - REMOVAL).
(3) Remove the rocker arm bolts and the rocker arm assembly (Fig. 25). Place rocker arm assemblies on a bench in the same order as removed.
(4) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
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).
ENGINE 8.0L
9 - 380
ROCKER ARM / ADJUSTER ASSY (Continued)DR
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVAL—CAMSHAFT BEARINGS
This procedure requires that the engine is removed
from the vehicle.
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
NOTE: It is not advisable to attempt to replace cam- shaft bearings unless special removal and installa- tion tools are available, such as recommended tool 8544 Camshaft Bushing Remover Installer.
(2) Using recommended tool 8544 Camshaft Bush-
ing Remover Installer, Drive out bearing shells.
REMOVAL—CAMSHAFT
(1) Remove rocker arms and push rods (Refer to 9
- ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - REMOVAL). Identify each part so it can be installed in its original location.NOTE: The 4 corner tappets can not be removed without removing the cylinder heads and gaskets. However, they can be lifted and retained for cam- shaft removal.
(2) Remove the Bolts retaining the yoke retaining spider. Remove the yoke retaining spider, tappet aligning yokes and tappets.
(3) Remove upper and lower intake manifolds (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI- FOLD - REMOVAL).
(4) Remove timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL) and timing chain and sprockets (Refer to 9 - ENGINE/VALVE TIMING/ TIMING BELT/CHAIN AND SPROCKETS REMOVAL).
Fig.25RockerArm-Typical
1 - ROCKER ARMS 2 - ROCKER ARM PEDESTALS 3 - RETAINER
(1) Install the push rods in the same order as
removed.
(2) Install rocker arm assemblies in the same order as removed. Tighten the rocker arm bolts to 53
N·m (40 ft. lbs.) torque.(3) Install cylinder head cover and gasket (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(4) Connect spark plug wires.
ENGINE BLOCK CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures. The cylinder walls should be checked for out-of- round and taper with Cylinder Bore Indicator Tool, Special tool 6879 or equivalent. The cylinder block should be bored and honed with new pistons and rings fitted if: † The cylinder bores show more than 0.127 mm † The cylinder bores show a taper of more than † The cylinder walls are badly scuffed or scored. Boring and honing operation should be closely coor- dinated with the fitting of pistons and rings so spec- ified clearances may be maintained.
(0.005 inch) out-of-round.
0.254 mm (0.010 inch).
DR CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
ENGINE 8.0L
9 - 381
(5) Remove camshaft thrust plate (Fig. 26).
(4) Line up key with keyway in sprocket, then using Special Tools C-3688, C-3718 and MB990799
install crankshaft timing sprocket. Make sure the sprocket seats against the crankshaft shoulder (Fig. 27).Fig.26Camshaft
1 - CAMSHAFT 2 - THRUST PLATE
(6) 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.
INSTALLATION
INSTALLATION—CAMSHAFT BEARINGS
(1) Install new camshaft bearings using recom- mended Tool 8544 Camshaft Bushing Remover Installer, by sliding the new camshaft bearing shell over proper adapter.
(2) Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing. If the camshaft bearing shell oil holes are not in exact alignment, remove and install them correctly. Install a new core hole plug at the rear of camshaft. Be sure this plug does not leak.
INSTALLATION—CAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing journals. Using a long bolt, insert the camshaft into the cylinder block.
NOTE: Whenever an engine has been rebuilt, a new camshaft and/or new tappets installed, add 1 pint of MoparT Crankcase Conditioner, or equivalent. The oil mixture should be left in engine for a minimum of 805 km (500 miles). Drain at the next normal oil change.
(2) Install camshaft thrust plate. Tighten the torx
bolts to 22 N·m (16 ft. lbs.) torque.
(3) Check camshaft end play. The end play should be 0.051-0.152 mm (0.002-0.006 inch) with a new thrust plate and up to 0.254 mm (0.010 inch) with a used thrust plate. If not within these limits install a new thrust plate.
Fig.27CrankshaftSprocketInstallation
1 - SPECIAL TOOL C-3688
2 - SPECIAL TOOL C-3718
3 - SPECIAL TOOL MD990799(5) Install timing chain and sprocket (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).
(6) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(7) Install the crankshaft pulley/damper (Refer to BLOCK/VIBRATION
ENGINE/ENGINE
DAMPER - INSTALLATION).
(8) Prime oil pump by squirting oil in the oil filter mounting hole and filling the J-trap of the front tim- ing cover. When oil is running out, install oil filter that has been filled with oil.
(9) Each tappet reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the tappets must be replaced.
(10) Install tappets and push rods in their original
location.
retaing spider.
(11) Position the tappet aligning yokes and yoke
(12) Install the retaining spider mounting bolts.
Tighten bolts to 22 N·m (16 ft. lbs.).
ENGINE 8.0L
9 - 382
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)DR
(13) Install the rocker arms (Refer to 9 - ENGINE/ CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - INSTALLATION).
(14) The cylinder head cover gasket can be used again. Install the gasket onto the head rail. For the left side the number tab is at the front of engine with the number up. For the right side the number tab is at the rear of engine with the number up.
Fig.28CylinderHeadCover
1 - CYLINDER HEAD COVER 2 - CYLINDER HEAD COVER GASKET
CAUTION: The cylinder head cover fasteners have a special plating. DO NOT use alternative fasteners.
(15) Install cylinder head cover (Fig. 28) (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(16) Install the intake manifolds (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE INSTALLATION).
(17) Start engine and check for leaks.
CONNECTING ROD BEARINGS STANDARD PROCEDURE - CONNECTING ROD BEARING FITTING
Fit all rods on a bank until completed. DO NOT alternate from one bank to another, because connect- ing rods and pistons are not interchangeable from one bank to another.
The bearing caps are not
should be marked at removal assembly.
interchangeable and to ensure correct
Each bearing cap has a small V-groove across the parting face. When installing the lower bearing shell, be certain that the V-groove in the shell is in line with the V-groove in the cap. This provides lubrica- tion of the cylinder wall in the opposite bank.
The bearing shells must be installed so that the tangs are in the machined grooves in the rods and caps.
Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 in.). Bearings are available in 0.025 mm (0.001 in.), 0.051
mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 mm (0.010 in.) and 0.305 mm (0.012 in.) undersize. Install the bearings in pairs. DO NOT use a new bearing half with an old bearing half. DO NOT file the rods or bearing caps.CRANKSHAFT REMOVAL
When a crankshaft is replaced, all main and con- necting rod bearings should be replaced with new bearings. Therefore, selective fitting of the bearings is not required when a crankshaft and bearings are replaced.
(1) Remove the oil pan and oil pickup tube (refer
to Oil Pan in this section for correct procedure).
(2) Remove the timing chain cover and gasket. Remove and discard the front crankshaft oil seal and cover gasket.
(3) Remove Transmission (refer
to Group 21,
Transmission).
(4) Remove the rear seal retainer (refer to Crank- shaft Rear Seal Retainer in this section for correct procedure).
(5) Identify main bearing caps before removal (Fig. 29). Remove bearing caps and lower bearings one at a time.
(6) Remove the connecting rod bearing caps. (7) Lift the crankshaft straight out of the block. (8) Remove the upper main bearings from the
block.
DR CRANKSHAFT (Continued)
ENGINE 8.0L
9 - 383
(9) Apply a rearward axial
load of 667 N (150
lbs-f) on crankshaft centerline, driving No.3 main cap and thrust bearing against No.3 bulkhead. Repeat procedure, driving crankshaft forward to align rear flange of thrust bearings in a common plane. Front face of No.1 main cap must not extend forward in front of face of No.1 bulkhead.(10) Install the oil pickup tube. Tighten the bolts
to 16 N·m (144 in. lbs.) torque.
(11) Install the oil pan.
CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE—FITTING CRANKSHAFT MAIN BEARINGS
Bearing caps are not interchangeable and should be marked at removal to ensure correct assembly. Upper and lower bearing halves are NOT inter- changeable. All lower main bearing halves are inter- changeable. Upper main bearing halves of No. 2, 4, and 5 are interchangeable. Upper main bearing halves of No. 1 and 6 are interchangeable, this also applies to the lower bearing halves.
The No.3 main bearing is flanged to carry the crankshaft thrust loads. This bearing is NOT inter- changeable with any other bearing halves in the engine. Bearing shells are available in standard and the following undersizes: 0.25 mm (0.001 inch), 0.051
mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch). Never install an undersize bearing that will reduce clearance below specifications.REMOVAL
(1) Remove the oil pan and oil pump pick-up tube (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(2) Identify bearing caps before removal. Remove
bearing caps one at a time.
(3) Remove upper half of bearing by inserting Crankshaft Main Bearing Remover/Installer Tool C-3059 into the oil hole of crankshaft (Fig. 30).
(4) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
INSTALLATION
Only one main bearing should be selectively fitted while all other main bearing caps are properly tight- ened. All bearing capbolts removed during service procedures are to be cleaned and oiled before instal- lation.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
Fig.29MainBearingIdentification
1 - MAIN BEARING CAP 2 - UPPER MAIN BEARINGS 3 - CRANKSHAFT 4 - LOWER MAIN BEARINGS
INSTALLATION
When a crankshaft is replaced, all main and con- necting rod bearings should be replaced with new bearings. Therefore, selective fitting of the bearings is not required when a crankshaft and bearings are replaced.
NOTE: Lubricate crankshaft main bearings with clean engine oil.
(1) Position upper main bearings into block. (2) Position the crankshaft into the cylinder block. (3) Lubricate the main journals with clean engine oil. Install upper main bearings, caps and bolts. Fol- low the 2 step tightening sequence, starting with main bearing cap 1.
(4) Lubricate the connecting rod bearings and jour- nals with clean engine oil. Carefully install connect- ing rods to the crankshaft.
(5) Using Special Tool 8359 Seal Installer install
new oil into oil seal retainer.
(6) Using Special Tool 6687 Guide, install the rear
seal retainer with a new gasket.
(7) Install the timing chain cover with a new gas-
ket and oil seal.
(8) Prime oil pump by squirt oil in the oil filter mounting hole and filling the J-trap of the front tim- ing cover. When oil is running out, install oil filter that has been filled with oil.
ENGINE 8.0L
9 - 384
CRANKSHAFT MAIN BEARINGS (Continued)DR
(3) Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal surface of the cover (Fig. 31).
Fig.30UpperMainBearingRemovaland
InstallationwithToolC-3059
1 - SPECIAL TOOL C-3059
2 - BEARING 3 - SPECIAL TOOL C-3059
4 - BEARING(1) Start bearing in place, and insert Crankshaft Main Bearing Remover/Installer Tool C-3059 into oil hole of crankshaft (Fig. 30).
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Tool C-3059.
(3) Lubricate the main journals with clean engine oil. Install main bearing caps and bolts. Follow the 2
step tightening sequence, starting with No. 1 main bearing cap.(4) Apply a rearward axial
load of 667 N (150
lbs-f) on crankshaft centerline, driving No.3 main cap and thrust bearing against No.3 bulkhead. Repeat procedure, driving crankshaft forward to align rear flange of thrust bearings in a common plane. Front face of No.1 main cap must not extend forward in front of face of No.1 bulkhead.(5) Install the oil pump pick-up tube and oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION).
CRANKSHAFT OIL SEAL - FRONT
REMOVAL
REMOVAL—FRONT OIL SEAL - FRONT COVER INSTALLED
(1) Disconnect the negative cable from the battery. (2) Remove vibration damper from the crankshaft (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
Fig.31TimingChainCoverandOilSeal
1 - TIMING CHAIN COVER 2 - OIL SEAL
REMOVAL—FRONT OIL SEAL - FRONT COVER REMOVED
(1) Remove engine front
to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(Refer
cover
(2) Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal surface of the cover.
INSTALLATION
INSTALLATION—FRONT OIL SEAL – FRONT COVER INSTALLED
(1) Position the crankshaft front oil seal onto seal installer special tool 6806 and C-3688 (Fig. 32). Install seal.
(2) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTAL- LATION).
(3) Install serpentine belt (Refer to 7 - COOLING/ ACCESSORY DRIVE/DRIVE BELTS - INSTALLA- TION).
(4) Install cooling fan and shroud (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA- TION).
(5) Connect negative cable to the battery. (6) Start engine and check for leaks.
INSTALLATION—FRONT OIL SEAL - FRONT COVER REMOVED
(1) Position the crankshaft front oil seal onto seal
installer special tool 6806.
DR CRANKSHAFT OIL SEAL - FRONT (Continued)
ENGINE 8.0L
9 - 385
Fig.32TimingChainCoverandOilSeal
1 - SPECIAL TOOL C-3688
2 - SPECIAL TOOL 6806(2) Use tool 6761 to support timing chain cover when installing oil seal with tool 6806 (Fig. 33), install seal (Fig. 34).
Fig.33OilSeal,Tools—6806and6761
1 - FRONT COVER 2 - SPECIAL TOOL 6761
3 - FRONT OIL SEAL 4 - SPECIAL TOOL 6806Fig.34OilSealInstalled
1 - SPECIAL TOOL 6806
2 - SPECIAL TOOL 6761(3) Install engine front
to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(Refer
cover
CRANKSHAFT OIL SEAL - REAR REMOVAL
NOTE: This procedure does not require the removal of the seal retainer from the engine block.
(1) Remove the transmission. (2) Carefully,
remove the rear
retainer. Discard the oil seal.
seal
from the
INSTALLATION
(1) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
(2) Position Special Tool 6687 Seal Guide, onto the
crankshaft.
(3) Position the oil seal onto the Seal guide, then using Special Tool 8359 Seal Installer and C–4171
Driver Handle, Install the oil seal.(4) The seal face surface must be countersunk into
the retainer .762–1.27mm (0.030–0.050 in.).
(5) Install the transmission. (6) Check and verify engine oil is at correct level. (7) Start engine and check for leaks.
9 - 386
ENGINE 8.0L
DR
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.
INSTALLATION
engine block.
from the retainer.
(1) Throughly clean all gasket resdue from the
(2) Use extream care and clean all gasket resdue
(3) Apply a small amount of Mopart Silicone Rub- ber Adhesive Sealant to the retainer gasket. Position the gasket onto the retainer.
(4) Position Special Tool 6687 Seal Guide onto the
crankshaft.
(5) Position the retainer and seal over the guide
and onto the engine block.
(6) Install the retainer mounting bolts. Tighten the
bolts to 22 N·m (16 ft. lbs.).
(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.
HYDRAULIC LIFTERS DIAGNOSIS AND TESTING—HYDRAULIC TAPPETS
Before disassembling any part of the engine to cor- rect tappet noise, check the oil pressure. If vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending-unit. The pressure should be between 207-552 kPa (30-80 psi) at 3,000 RPM.
level, check dipstick. The oil
Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick. Either of these two con- ditions could be responsible for noisy tappets.
level
OIL LEVEL
HIGH
If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine running, this condition could create foam in the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily.
LOW
Low oil level may allow oil pump to take in air. When air is fed to the tappets, they lose length, which allows valves to seat noisily. Any leaks on intake side of oil pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be noisy. When oil level and leaks have been corrected, operate the engine at fast idle. Run engine for a sufficient time to allow all of the air inside the tappets to be bled out.
TAPPET NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate
engine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation.
NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not apprecia- bly reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear.
(3) Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by exces- sive leak-down around the unit plunger, or by the plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is caused by a tappet check valve not seating, or by for- eign particles wedged between the plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy click will be accompa- nied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and clean- ing.
DR HYDRAULIC LIFTERS (Continued)
(4) The valve train generates a noise very much like a light tappet noise during normal operation. Care must be taken to ensure that tappets are mak- ing the noise. If more than one tappet seems to be noisy, it’s probably not the tappets.
LEAK-DOWN TEST
ENGINE 8.0L
9 - 387
After cleaning and inspection, test each tappet for specified leak-down rate tolerance to ensure zero-lash operation (Fig. 35).
Swing the weighted arm of the hydraulic valve tap- pet tester away from the ram of the Universal Leak- Down Tester.
(1) Place a 7.925-7.950 mm (0.312-0.313 inch) diameter ball bearing on the plunger cap of the tap- pet.
(2) Lift the ram and position the tappet (with the
ball bearing) inside the tester cup.
(3) Lower the ram, then adjust the nose of the ram until it contacts the ball bearing. DO NOT tighten the hex nut on the ram.
(4) Fill the tester cup with hydraulic valve tappet
test oil until the tappet is completely submerged.
(5) Swing the weighted arm onto the push rod and pump the tappet plunger up and down to remove air. When the air bubbles cease, swing the weighted arm away and allow the plunger to rise to the normal position.
(6) Adjust the nose of the ram to align the pointer with the SET mark on the scale of the tester and tighten the hex nut.
(7) Slowly swing the weighted arm onto the push
rod.
(8) Rotate the cup by turning the handle at the base of the tester clockwise one revolution every 2
seconds.(9) Observe the leak-down time interval from the instant the pointer aligns with the START mark on the scale until the pointer aligns with the 0.125
mark. A normally functioning tappet will require 20-110 seconds to leak-down. Discard tappets with leak-down time interval not within this specification.Fig.35Leak-DownTester
1 - POINTER 2 - WEIGHTED ARM 3 - RAM 4 - CUP 5 - HANDLE 6 - PUSH ROD
(6) Cut the cylinder head gasket for accessibility if
the end tappets are to be removed.
(7) Remove yoke retainer spider and tappet align-
ing yokes (Fig. 36).
REMOVAL
(1) Disconnect the negative cable from the battery. (2) Remove the air cleaner. (3) Remove cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(4) Remove rocker arm assembly and push rods (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - REMOVAL). Identify push rods to ensure installation in original location. intake manifold (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI- FOLD - REMOVAL).
(5) Remove upper and lower
Fig.36Tappets,AligningYokeandYokeRetaining
Spider
1 - TAPPET ALIGNING YOLK 2 - YOKE RETAINING SPIDER 3 - TAPPET
DR
PISTON & CONNECTING ROD DESCRIPTION
The pistons (Fig. 37) are elliptically turned so that the diameter at the pin boss is less than its diameter across the thrust face. This allows for expansion under normal operating conditions. Under operating temperatures, expansion forces the pin bosses away from each other, causing the piston to assume a more nearly round shape.
All pistons are machined to the same weight,
regardless of size, to maintain piston balance.
The piston pin rotates in the piston only and is retained by the press interference fit of the piston pin in the connecting rod.
The pistons have a unique dry-film lubricant coat- ing baked onto the skirts to reduce friction. The lubricant is particularly effective during engine break-in, but with time, the material becomes embed- ded into cylinder bore walls and continues to reduce friction.
The pistons are LH and RH bank specific.
ENGINE 8.0L
9 - 388
HYDRAULIC LIFTERS (Continued)(8) Pull tappet out of bore with a twisting motion. If all tappets are to be removed, identify tappets to ensure installation in original location.
(9) If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize. Replace with oversize tappet.
(10) Check camshaft lobes for abnormal wear.
CLEANING
Clean tappet with a suitable solvent. Rinse in hot water and blow dry with a clean shop rag or com- pressed air.
INSTALLATION
(1) Lubricate tappets. (2) Install
tappets
in their original positions. Ensure that the oil bleed hole (if so equipped) faces forward.
(3) Install tappet aligning yokes. Position the yoke retainer spider over the tappet aligning yokes (Fig. 36)Install the yoke retaining spider bolts and tighten to 22 N·m (16 ft. lbs.) torque.
(4) Install the push rods in their original location. (5) Install the rocker arms (Refer to 9 - ENGINE/ CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - INSTALLATION).
(6) Install lower and upper intake manifold (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION).
(7) The cylinder head cover gasket can be used again. Install the gasket onto the head rail. For the left side the number tab is at the front of engine with the number up. For the right side the number tab is at the rear of engine with the number up. (8) Install
to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
cylinder head cover
(Refer
(9) Install the air cleaner.
CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet.
(10) Connect the negative cable to the battery. (11) Road test vehicle and check for leaks.
Fig.37PistonandConnectingRod—8.0LEngine 1 - FRONT I.D. TOWARDS THIS SIDE 2 - ORIENTATION BUTTON TOWARDS REAR (R.H. ONLY) 2, 4, 6, 8, 10
3 - ORIENTATION BUTTON TOWARDS FRONT (L.H. ONLY) 1, 3, 5, 7, 9DR PISTON & CONNECTING ROD (Continued) STANDARD PROCEDURE—PISTON FITTING
REMOVAL
ENGINE 8.0L
9 - 389
Piston and cylinder wall must be clean and dry. Specified clearance between the piston and the cylin- der wall is 0.013-0.038 mm (0.0005-0.0015 inch). The max. allowable clearance is 0.0762 mm (0.003 in.).
Piston diameter should be measured at the top of skirt, 90° to piston pin axis. Cylinder bores should be measured halfway down the cylinder bore and trans- verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21°C (70°F).
(1) To correctly select the proper size piston, a cyl- inder bore gauge, capable of reading in .00019
INCREMENTS is required (Fig. 38). If a bore gauge is not available, do not use an inside micrometer.The coating material is applied to the piston after the final piston machining process. Measuring the out- side diameter of a coated piston will not provide accurate results. 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 .00019 increments is required.Piston installation into the cylinder bore require 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.Fig.38BoreGauge
1 - BORE GAUGE 2 - CYLINDER BORE 3 - 2-5/16 in.
(1) Remove the engine from the vehicle (Refer to 9
- ENGINE - REMOVAL).
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(3) Remove the oil pan and oil pump pick-up tube (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(4) Remove top ridge of cylinder bores with a reli- able ridge reamer before removing pistons from cyl- inder block. Be sure to keep tops of pistons covered during this operation.
(5) Be sure the connecting rod and connecting rod cap are identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts.
(6) Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies, rotate crankshaft center the connecting rod in the cylinder bore and at BDC. Be careful not to nick crankshaft journals. DO NOT try to remove black coating on skirt. This is the dry film lubricant.
(7) After removal, install bearing cap on the mat-
ing rod.
CLEANING
Clean the piston and connecting rod assembly
using a suitable solvent.
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).
Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration.
INSTALLATION
(1) Check the crankshaft connecting rod journal
for excessive wear, taper and scoring.
(2) Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.
(3) Be sure that compression ring gaps are stag- gered so that neither is in line with oil ring rail gap. (4) Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located properly (Fig. 39).
ENGINE 8.0L
9 - 390
PISTON & CONNECTING ROD (Continued)NOTE: Be sure position of rings does not change during the following step.
(5) Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench (part of Tool C-385).DR
Fig.39ProperRingInstallation
1 - TOP COMPRESSION RING GAP UPPER OIL RING GAP 2 - 2ND COMPRESSION RING GAP LOWER OIL RAIL GAP 3 - SPACER GAP
(6) Install connecting rod bolt protectors on rod bolts, a long protector should be installed on the numbered side of the connecting rod.
(7) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore in the bottom dead center (BDC) position. Be sure connect- ing rod and cylinder bore number are the same. Insert rod and piston into cylinder bore. Be sure the piston and rod assemblies are installed in the proper orientation (Fig. 40).
(8) The notch, groove or arrow on top of piston must be pointing toward front of engine. The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet.
(9) While tapping the piston down in cylinder bore with the handle of a hammer, guide the connecting rod over the crankshaft journal.
(10) Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 N·m (45 ft. lbs.) torque.
(11) Install the oil pump pick-up tube and oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION).
(12) Install
the cylinder head (Refer
to 9 - ENGINE/CYLINDER HEAD - INSTALLATION) and cylinder head cover (Refer to 9 - ENGINE/CYLIN- DER HEAD/CYLINDER HEAD COVER(S) INSTALLATION).
Fig.40PistonandRodOrientation
1 - FRONT I.D. TOWARDS THIS SIDE 2 - ORIENTATION BUTTON TOWARDS REAR (R.H. ONLY) 2, 4, 6, 8, 10
3 - ORIENTATION BUTTON TOWARDS FRONT (L.H. ONLY) 1, 3, 5, 7, 9(13) Install intake manifold (Refer to 9 - ENGINE/ INSTALLA-
MANIFOLDS/INTAKE MANIFOLD - TION).
(14) Install the engine into the vehicle (Refer to 9 -
ENGINE - INSTALLATION).
PISTON RINGS STANDARD PROCEDURE—FITTING PISTON RINGS
(1) Measurement of end gaps:
(a) Measure piston ring gap 2 inches from bot- tom of cylinder bore. An inverted piston can be used to push the rings down to ensure positioning rings squarely in the cylinder bore before measur- ing.
(b) Insert feeler stock in the gap. Gap for com- pression rings should be between 0.254-0.508 mm (0.010-0.020 inch). The oil ring gap should be 0.381- 1.397 mm (0.015-0.055 inch).
DR PISTON RINGS (Continued)
ENGINE 8.0L
9 - 391
(c) Rings with insufficient end gap may be prop- erly filed to the correct dimension. Ends should be stoned smooth after filing with Arkansas White Stone. Rings with excess gaps should not be used. (2) Install rings and confirm ring side clearance:
(a) Install oil rings being careful not to nick or scratch the piston. Install the oil control rings according to instructions in the package. It is not necessary to use a tool to install the upper and lower rails. Insert oil rail spacer first, then side rails.
(b) Install the second compression rings using Installation Tool C-4184. The compression rings must be installed with the identification mark face up (toward top of piston) and chamfer facing down. An identification mark on the ring is a drill point, a stamped letter O, an oval depression or the word TOP (Fig. 41) (Fig. 43).
(c) Using a ring installer, install the top com- pression ring with the chamfer facing up (Fig. 43). An identification mark on the ring is a drill point, a stamped letter O, an oval depression or the word TOP facing up (Fig. 42).
(d) Measure side clearance between piston ring and ring land. Clearance should be 0.074-0.097 mm (0.0029-0.0038 inch) for the compression rings. The steel rail oil ring should be free in groove, but should not exceed 0.246 mm (0.0097 inch) side clearance.
(e) Pistons with insufficient or excessive side
clearance should be replaced.
Fig.42TopCompressionRingIdentification—Typical 1 - TOP COMPRESSION RING (GRAY IN COLOR) 2 - CHAMFER 3 - ONE DOT
Fig.43CompressionRingChamferLocation—Typical 1 - CHAMFER 2 - TOP COMPRESSION RING 3 - SECOND COMPRESSION RING 4 - PISTON 5 - CHAMFER
Fig.41SecondCompressionRingIdentification—
Typical
1 - SECOND COMPRESSION RING (BLACK CAST IRON) 2 - CHAMFER 3 - TWO DOTS
(3) Arrange ring gaps 180° apart as shown in (Fig.
44).
Fig.44ProperRingInstallation
1 - TOP COMPRESSION RING GAP UPPER OIL RING GAP 2 - 2ND COMPRESSION RING GAP LOWER OIL RAIL GAP 3 - SPACER GAP
9 - 392
ENGINE 8.0L
VIBRATION DAMPER REMOVAL
(1) Disconnect the negative cable from the battery. (2) Remove the following: † Radiator fan (Refer to 7 - COOLING/ENGINE/ RADIATOR FAN - REMOVAL) † Accessory drive belt (Refer to 7 - COOLING/AC- CESSORY DRIVE/DRIVE BELTS - REMOVAL) † Radiator (Refer to 7 - COOLING/ENGINE/RA-
DIATOR - REMOVAL)
(3) Remove crankshaft pulley/damper bolt and
washer from end of crankshaft.
(4) Using Special Tool, 1026 3 Jaw Puller and Spe- cial Tool 8513 Insert, remove pulley—damper from the crankshaft (Fig. 45).
Fig.45CrankshaftPulley—DamperRemoval
1 - 3 JAW PULLER
(5) Inspect crankshaft oil seal.
If damaged or worn, replace the front oil seal (Refer to 9 - ENGINE/ ENGINE BLOCK/CRANKSHAFT OIL SEAL - FRONT - REMOVAL).
INSTALLATION
(1) Position the crankshaft pulley/damper onto the
crankshaft.
(2) Use Special Tool, C-3688 Crankshaft Pulley/ Damper Installer to press the pulley—damper onto the crankshaft. Install crankshaft bolt and washer and tighten to 312 N·m (230 ft. lbs.) torque (Fig. 46). (3) Install the following: † Radiator (Refer to 7 - COOLING/ENGINE/RA-
DIATOR - INSTALLATION)
DR
† Accessory drive belt (Refer to 7 - COOLING/AC- CESSORY DRIVE/DRIVE BELTS - INSTALLATION) † Radiator fan (Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - INSTALLATION)
(4) Connect the negative cable to the battery.
Fig.46InstallingCrankshaftPulley—Damper
1 - SPECIAL TOOL C-3688
FRONT MOUNT REMOVAL
(1) Disconnect the negative cable from the battery. (2) Position fan to assure clearance for radiator top
tank and hose.
CAUTION: DO NOT lift the engine by the intake manifold.
(3) Install engine support/lifting fixture. (4) Raise vehicle on hoist. (5) Lift the engine SLIGHTLY and remove the
thru-bolt and nut.
Remove shields.
(6) Remove engine support bracket/cushion bolts. support bracket/cushion and heat
the
INSTALLATION
(1) With engine raised SLIGHTLY, position the engine support bracket/cushion and heat shields to the block. Install new bolts and tighten to 81 N·m (60
ft. lbs.) torque.(2) Install the thru-bolt and 2 piece rubber engine rubber restrictors onto the engine support bracket/ cushion.
DR FRONT MOUNT (Continued)
ENGINE 8.0L
9 - 393
(3) Lower engine with support/lifting fixture while guiding the engine bracket/cushion and thru-bolt into support cushion brackets.
(4) Install thru-bolt nuts and tighten the nuts to
68 N·m (50 ft. lbs.) torque.
(5) Lower the vehicle. (6) Remove lifting fixture.
REAR MOUNT REMOVAL
(1) Raise the vehicle on a hoist. (2) Position a transmission jack in place. (3) Remove support cushion stud nuts (Fig. 47). (4) Raise SLIGHTLY.
transmission
rear
and
of
engine
(5) Remove the bolts holding the support cushion to the transmission support bracket. Remove the sup- port cushion.
(6) If necessary, remove the bolts holding the
transmission support bracket to the transmission.
INSTALLATION
(1) If removed, position the transmission support bracket to the transmission. Install new attaching bolts and tighten to 102 N·m (75 ft. lbs.) torque.
(2) Position support cushion to transmission sup- port bracket. Install stud nuts and tighten to 47 N·m (35 ft. lbs.) torque.
(3) Using the transmission jack, lower the trans- mission and support cushion onto the crossmember (Fig. 110).
(4) Install the support cushion bolts and tighten to
47 N·m (35 ft. lbs.) torque.
(5) Remove the transmission jack. (6) Lower the vehicle.
LUBRICATION DESCRIPTION
A pressure feed type (gerotor) oil pump is located in the engine front cover. The pump uses a pick-up tube and screen assembly to gather engine oil from the oil pan (Fig. 48).
OPERATION
The pump draws oil through the screen and inlet tube from the sump at the rear of the oil pan. The oil is driven between the inner and outer gears of the oil pump, then forced through the outlet in the engine front cover. An oil gallery in the front cover channels the oil to the inlet side of the full flow oil filter. After passing through the filter element, the oil passes
Fig.47EngineRearSupportCushionAsse
ENGINE 8.0L
9 - 394
LUBRICATION (Continued)DR
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING—ENGINE OIL LEAKS
Begin with a through visual
inspection of the engine, particularly at the area of the suspected leak. 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 be sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light source. (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 24km (15 miles), and repeat previous step.
(5) If the oil leak source is not positively identified at this time, proceed with the air leak detection test method as follows:
(6) Disconnect the breather cap to air cleaner hose at the breather cap end. Cap or plug breather cap nipple.
(7) Remove the PCV valve from the cylinder head
cover. Cap or plug the PCV valve grommet.
(8) 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.
(9) 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.(10) If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak.
(11) If no leaks are detected, turn off the air sup- ply and remove the air hose and all plugs and caps. Install the PCV valve and breather cap hose. Proceed to next step.
(12) 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.
Fig.48PressureFeedType(Gerotor)OilPump—
Typical
1 - OUTER ROTOR 2 - INNER ROTOR 3 - OIL PUMP COVER 4 - TIMING CHAIN COVER
from the center outlet of the filter through an oil gal- lery that channels the oil up to the tappet galleries, which extends the entire length of block.
Galleries extend downward from the main oil gal- lery to the upper shell of each main bearing. The crankshaft is drilled internally to pass oil from the main bearing journals to the connecting rod journals. Each connecting rod bearing has half a hole in it, oil passes through the hole when the rods rotate and the is then thrown off as the rod hole lines up, oil rotates. This oil throwoff lubricates the camshaft lobes, cylinder walls, and piston pins.
The hydraulic valve tappets receive oil directly from the main oil gallery. The camshaft bearings receive oil from the main bearing galleries. The front camshaft bearing journal passes oil through the cam- shaft sprocket to the timing chain. Oil drains back to the oil pan under the No. 1 main bearing cap.
The oil supply for the rocker arms and bridged pivot assemblies is provided by the hydraulic valve tappets, which pass oil through hollow push rods to a hole in the corresponding rocker arm. Oil from the rocker arm lubricates the valve train components. The oil then passes down through the push rod guide holes and the oil drain-back passages in the cylinder head, past the valve tappet area, and then returns to the oil pan (Fig. 49).
DR LUBRICATION (Continued)
ENGINE 8.0L
9 - 395
Fig.49EngineLubricationSystem
ENGINE 8.0L
9 - 396
LUBRICATION (Continued)1 - OIL TO MAIN OIL GALLERIES 2 - RELIEF VALVE 3 - OIL GALLERY FOR TAPPETS 4 - MAIN OIL GALLERY 5 - TAPPET OIL GALLERY 6 - HOLLOW PUSH ROD 7 - ROCKER ARM 8 - PLUG 9 - GASKET 10 - SPRING 11 - TIMING CHAIN COVER 12 - CAM BEARINGS 13 - HYDRAULIC TAPPET GALLERIES 14 - CAMSHAFT 15 - CRANKSHAFT
DR
16 - OIL PASSAGE TO CONNECTING ROD JOURNALS 17 - OIL PICKUP 18 - CONNECTING ROD JOURNALS 19 - CRANKSHAFT BEARINGS 20 - MAIN OIL GALLERY 21 - CRANKSHAFT 22 - OIL PICKUP TUBE 23 - CONNECT ROD JOURNALS 24 - CAMSHAFT BEARINGS 25 - TAPPET OIL GALLERY 26 - OIL FROM PICKUP TUBE 27 - CAMSHAFT 28 - TAPPET 29 - VALVE 30 - OIL PUMP RELIEF VALVE
DIAGNOSIS AND TESTING—ENGINE OIL PRESSURE
(1) Remove oil pressure sending unit. (2) Install Oil Pressure Line and Gauge Tool C-3292. Start engine and record pressure. (Refer to 9
- ENGINE - SPECIFICATIONS).OIL STANDARD PROCEDURE - ENGINE OIL
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the right
front of the engine, left of the generator (Fig. 50).
Fig.50OilLevelIndicatorLocation
1 - CYLINDER HEAD COVER 2 - ENGINE OIL FILL CAP 3 - DIPSTICK 4 - ENGINE OIL FILTER 5 - FILTER BOSS
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result.
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 ten min- utes 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 tube. (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
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals described in the Maintenance Schedule. This infor- mation can be found in the owner’s manual.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
engine off.
(1) Position the vehicle on a level surface and turn
(2) Hoist vehicle. (3) Remove oil fill cap. (4) Place a suitable drain pan under crankcase drain. (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 and gasket if damaged.
(6) Install drain plug in crankcase. (7) Change oil filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL).
(8) Lower vehicle and fill crankcase with specified type (Refer to LUBRICATION & MAINTENANCE/ FLUID TYPES - DESCRIPTION) and amount of engine oil (Refer to LUBRICATION & MAINTE- NANCE - SPECIFICATIONS).
(9) Install oil fill cap. (10) Start engine and inspect for leaks. (11) Stop engine and inspect oil level.
DR
OIL FILTER REMOVAL
ENGINE 8.0L
9 - 397
All engines are equipped with a high quality full- flow, disposable type oil filter. DaimlerChrysler Cor- 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 (Fig. 51).
Fig.52OilFilterSealingSurface—Typical
1 - SEALING SURFACE 2 - RUBBER GASKET 3 - OIL FILTER
(6) Remove the oil pick-up tube assembly (Fig. 53).
Discard the gasket.
Fig.51OilFilterRemoval—Typical
1 - ENGINE OIL FILTER 2 - OIL FILTER WRENCH
(4) When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove fil- ter from vehicle.
(5) With a wiping cloth, clean the gasket sealing
surface (Fig. 52) of oil and grime.
(6) Install new filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - INSTALLATION).
INSTALLATION
Fig.53OilPick-UpTube
(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
(2) Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Fig. 52) hand tighten filter one full turn, do not over tighten.
(3) Add oil (Refer to 9 - ENGINE/LUBRICATION/
OIL - STANDARD PROCEDURE).
OIL PAN REMOVAL
(1) Disconnect the negative cable from the battery. (2) Raise vehicle. (3) Drain engine oil. (4) Remove left engine to transmission strut. (5) Remove oil pan mounting bolts, pan and one- piece gasket. The engine may have to be raised slightly on 2WD vehicles.
1 - PICK—UP TUBE 2 - SEALANT AT SPLIT-LINES 3 - SEALANT AT SPLIT-LINE
CLEANING
Clean the block and pan gasket surfaces. If present, trim excess sealant from inside the
Clean oil pan in solvent and wipe dry with a clean
engine.
cloth.
Clean oil screen and pipe thoroughly in clean sol-
vent. Inspect condition of screen.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor-
tion. Straighten flange, if necessary.
9 - 398
ENGINE 8.0L OIL PAN (Continued) INSTALLATION(1) Fabricate 4 alignment dowels from 5/16 x 1 1/2
inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver (Fig. 54). (2) Install the dowels in the cylinder block at theFig.54FabricationofAlignmentDowels
1 - 5/16” X 11⁄2” BOLT 2 - DOWEL 3 - SLOT
four corners.
(3) Apply small amount of Mopart Silicone Rubber Adhesive Sealant, or equivalent at the split lines. The split lines are between the cylinder block, the timing chain cover and the rear crankshaft seal assembly (Fig. 53). After the sealant is applied you have 3 minutes to install the gasket and oil pan.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto the gasket. The engine may have to be slightly raised on 2WD vehicles.
(6) Install the oil pan bolts (Fig. 55). Tighten the
bolts to as shown in Oil Pan Bolts Torque Chart.
DR
(7) Remove the dowels. Install the remaining 5/16
inch oil pan bolts. Torque these bolts as shown in Oil Pan Bolts Torque Chart.(8) Install the drain plug. Tighten drain plug to 34
N·m (25 ft. lbs.) torque.
(9) Install the engine to transmission strut. (10) Lower vehicle. (11) Connect the negative cable to the battery. (12) Fill crankcase with oil to proper level. (13) Start engine and check for leaks.
OIL PUMP REMOVAL
(1) Remove the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(2) Remove the relief valve plug, gasket, spring
and valve (Fig. 56). Discard the gasket.
Fig.56OilPressureReliefValve
1 - TIMING CHAIN COVER 2 - OIL PUMP RELIEF VALVE 3 - SPRING 4 - GASKET 5 - PLUG
(3) Remove mounting screws and oil pump cover
(4) Remove oil pump inner and outer rotors (Fig.
(Fig. 57).
57).
(5) Inspect oil pump for wear (Refer to 9 - INSPEC-
ENGINE/LUBRICATION/OIL PUMP - TION).
Fig.55OilPanBoltLocation
1 - OIL PAN 2 - OIL FILTER 3 - STUD BOLTS 4 - DRAIN PLUG
CLEANING
Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
DR OIL PUMP (Continued)
ENGINE 8.0L
9 - 399
mm (0.5876 inch) or less, or if the diameter is 82.45
mm (3.246 inches) or less, replace rotor set.Fig.57OilPump
1 - OUTER ROTOR 2 - INNER ROTOR 3 - OIL PUMP COVER 4 - TIMING CHAIN COVER
INSPECTION
Mating surface of the oil pump cover should be smooth. Replace pump cover if scratched or grooved. Lay a straightedge across the pump cover surface (Fig. 58). If a 0.076 mm (0.003 inch) feeler gauge can be inserted between cover and straightedge, cover should be replaced.
Fig.59MeasuringOuterRotorThickness
Fig.60MeasuringInnerRotorThickness
Slide outer rotor into timing chain cover pump body. Press rotor to the side with your fingers and measure clearance between rotor and pump body (Fig. 61). If clearance is 0.19 mm (0.007 inch) or more, and outer rotor is within specifications, replace timing chain cover.
Install inner rotor into timing chain cover pump body (Fig. 62). Inner rotor should be positioned with chamfer up or toward engine when cover is installed. This allows easy installation over crankshaft. If clearance between inner and outer rotors is 0.150
mm (0.006 inch) or more, replace both rotors.Place a straightedge across the face of the timing chain cover pump body, between bolt holes (Fig. 63). If a feeler gauge of 0.077 mm (0.003 inch) or more can be inserted between rotors and the straightedge, and the rotors are within specifications, replace tim- ing chain cover.
Fig.58CheckingOilPumpCoverFlatness
1 - FEELER GAUGE 2 - STRAIGHT EDGE 3 - OIL PUMP COVER
Measure thickness (Fig. 59) (Fig. 60) and diameter of rotors. If either rotor thickness measures 14.956
ENGINE 8.0L
9 - 400
OIL PUMP (Continued)DR
Fig.61MeasuringOuterRotorClearanceinCover 1 - FEELER GAUGE 2 - OUTER ROTOR
Fig.63MeasuringClearanceOverRotors
1 - FEELER GAUGE 2 - STRAIGHT EDGE
Fig.62MeasuringInnerRotorClearanceinCover 1 - FEELER GAUGE 2 - OUTER ROTOR 3 - INNER ROTOR
Inspect oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400-grit wet or dry sandpaper.
The relief valve spring has a free length of approx- imately 49.5 mm (1.95 inches). The spring should test between 100 and 109 N (22.5 and 24.5 pounds) when compressed to 34 mm (1-11/32 inches). Replace spring that fails to meet these specifications.
If oil pressure was low and pump is within specifi- cations, inspect for worn engine bearings or other reasons for oil pressure loss.
INSTALLATION
(1) Lubricate both oil pump rotors using petroleum jelly or lubriplate and install in the timing chain cover. Use new parts as required (Fig. 64).
Fig.64PrimingOilPump.
1 - FILL WITH PETROLEUM JELLY OR LUBER PLATE
(2) Position the oil pump cover onto the timing chain cover. Tighten cover screws to 14 N·m (125 in. lbs.) torque.
(3) Make sure that inner ring moves freely after
cover is installed.
(4) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(5) Squirt oil into relief valve hole until oil runs
out.
(6) Install the relief valve and spring.
DR OIL PUMP (Continued)
(7) Using a new pressure relief valve gasket, install the relief valve plug. Tighten the plug to 20
N·m (15 ft. lbs.) torque.(8) Install oil filter that has been filled with oil.
INTAKE MANIFOLD DESCRIPTION
The aluminum intake manifold (Fig. 65) has two plenum chambers an upper and lower which supply air to five runners each. Passages across the longitu- dinal center of the manifold feed air from the throttle body to the plenum chambers.
Fig.65UpperandLowerIntakeManifold—8.0L
Engine
1 - UPPER INTAKE MANIFOLD 2 - THROTTLE BODY (MPI) 3 - LOWER INTAKE MANIFOLD
DIAGNOSIS AND TESTING—INTAKE MANIFOLD LEAKAGE
An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS, OR THE FAN. DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine. (2) Spray a small stream of water at the suspected
leak area.
ENGINE 8.0L
9 - 401
(3) If a change in RPMs occur, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect the negative cable from the battery. (2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(4) Remove the generator brace and generator
(Fig. 66).
(5) Remove the A/C compressor brace (Fig. 66).
Remove the compressor and set aside.
Fig.66GeneratorandA/CCompressorBraces
1 - GENERATOR 2 - INTAKE MANIFOLD TO GENERATOR BRACE 3 - A/C COMPRESSOR 4 - INTAKE MANIFOLD TO A/C COMPRESSOR BRACE
(6) Remove the air
cover and filter. Remove the air cleaner housing (Fig. 67). Discard the gasket.
cleaner
(7) Perform the Fuel System Pressure release pro- cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV- ERY - STANDARD PROCEDURE). Disconnect the fuel lines (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STAN- DARD PROCEDURE).
(8) Disconnect the accelerator linkage and if so equipped, the speed control and transmission kick- down cables.
(9) Remove the coil assemblies with the ignition
wires.
(10) Disconnect the vacuum lines. (11) Disconnect the heater hoses and bypass hose. (12) Remove the closed crankcase ventilation and
evaporation control systems.
ENGINE 8.0L
9 - 402
INTAKE MANIFOLD (Continued)DR
Fig.67AirIntakeHousing
1 - AIR INTAKE HOUSING
Fig.69LowerIntakeManifold
(13) Remove the throttle body bolts and lift the throttle body off the upper intake manifold (Fig. 68). Discard the gasket.
(14) Remove upper intake manifold bolts. (15) Lift the upper intake manifold out of the
engine compartment (Fig. 68). Discard the gasket.
Fig.68UpperIntakeManifoldandThrottleBody
1 - UPPER INTAKE MANIFOLD 2 - THROTTLE BODY (MPI) 3 - LOWER INTAKE MANIFOLD
1 - INTAKE MANIFOLD GASKET 2 - SEALANT 3 - CROSS-OVER GASKETS 4 - SEALANT 5 - LOCATOR DOWELS
Fig.70LowerIntakeManifoldGaskets
(16) Remove the lower intake manifold bolts and
remove the manifold (Fig. 69).
(17) Discard the lower intake manifold gaskets
(Fig. 70).
CLEANING
pressed air.
able solvent.
Clean manifold in solvent and blow dry with com-
Clean cylinder block gasket surfaces using a suit-
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) Install the intake manifold side gaskets. Be sure that the locator dowels are positioned in the head (Fig. 71).
DR INTAKE MANIFOLD (Continued)
ENGINE 8.0L
9 - 403
(15) Install the fuel lines (Refer to 14 - FUEL SYS- TEM/FUEL DELIVERY/QUICK CONNECT FIT- TING - STANDARD PROCEDURE).
(16) Using a new gasket, install the air cleaner housing. Tighten the nuts to 11 N·m (96 in. lbs.) torque. Install the air cleaner filter and cover.
(17) Install the A/C compressor (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION). Position the com- pressor brace and install the bolts. Tighten the brace bolts to 41 N·m (30 ft. lbs.) torque.
(18) Install the generator (Refer to 8 - ELECTRI- CAL/CHARGING/GENERATOR - INSTALLATION). Position the generator brace and install the bolts. Tighten the brace bolts to 41 N·m (30 ft. lbs.) torque. (19) Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(20) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(21) Connect the negative cable to the battery. (22) Start engine check for leaks.
EXHAUST MANIFOLD DESCRIPTION
Engine exhaust manifolds (Fig. 72) are made of high molybdenum ductile cast iron. A special ribbed design helps control permanent dimensional changes during heat cycles.
Fig.72ExhaustManifold—8.0LEngine
1 - EXHAUST MANIFOLD
OPERATION
The exhaust manifolds collect the engine exhaust exiting the combustion chambers, then channels the exhaust gases to the exhaust pipes attached to the manifolds.
Fig.71IntakeManifoldFlange
1 - LOCATOR DOWELS 2 - INTAKE MANIFOLD GASKETS 3 - LOCATOR DOWELS
(2) Insert Mopart GEN II Silicone Rubber Adhe- sive Sealant, or equivalent, into the four corner joints an excessive amount of sealant is not required to ensure a leak proof seal. However, an excessive amount of sealant may reduce the effectiveness of the flange gasket. The sealant should be approxi- mately 5 mm (0.2 in.) in diameter. (Fig. 70).
(3) Position the cross-over gaskets and press firmly onto the block (Fig. 70). BE SURE THE BLOCK IS OIL FREE..
(4) The lower intake manifold MUST be installed within 3 minutes of sealant application. Carefully lower intake manifold into position on the cylinder block and heads. After intake manifold is in place, inspect to make sure seals and gaskets are in place. Finger start all the lower intake bolts.
(5) Tighten the lower intake manifold bolts in lbs.) torque (Fig. 69). sequence to 54 N·m (40 ft. Recheck all bolts are tightened to 54 N·m (40 ft. lbs.) torque.
(6) Using a new gasket, position the upper intake
manifold onto the lower intake manifold.
(7) Finger start all bolts, alternate one side to the
other.
(8) Tighten upper
bolts sequence to 22 N·m (16 ft. lbs.) torque (Fig. 68).
intake manifold
in
(9) Using a new gasket, install the throttle body onto the upper intake manifold. Tighten the bolts to 23 N·m (200 in. lbs.) torque.
(10) Install closed crankcase ventilation and evap-
oration control systems.
(11) Connect the heater hoses and bypass hose. (12) Connect the vacuum lines. (13) Install the coil assemblies and the ignition
wires.
(14) Connect
the accelerator linkage and if so equipped, the speed control and transmission kick- down cables.
ENGINE 8.0L
9 - 404
EXHAUST MANIFOLD (Continued) REMOVAL(1) Disconnect the negative cable from the battery. (2) Raise and support the vehicle. (3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold..
(4) Lower the vehicle. (5) Remove the exhaust heat shields (Fig. 73).
Fig.738.0LEngineExhaustManifold—Typical
1 - EXHAUST MANIFOLD 2 - HEAT SHIELD
(6) Remove the dipstick bracket from the exhaust
manifold (right side only).
(7) Remove bolts attaching manifold to cylinder head. (8) Remove manifold from the cylinder head. Dis-
card the gasket.
CLEANING
