seats DODGE RAM 1500 1998 2.G Repair Manual

REMOVAL
NOTE: The cylinder heads must be removed in
order to perform this procedure.
(1) Remove rocker arms and lash adjusters(Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARM /
ADJUSTER ASSY - REMOVAL). (Fig. 41).
(2) Remove the camshaft bearing caps and the
camshaft.
NOTE: All six valve springs and valves are removed
in the same manner; this procedure only covers
one valve and valve spring.
(3) Using Special Tool C-3422±B or C-3422±C
Valve Spring Compressor and Special tool 8519
Adapter, compress the valve spring.
NOTE: It may be necessary to tap the top of the
valve spring to loosen the spring retainers locks
enough to be removed.
(4) Remove the two spring retainer lock halves.
NOTE: the valve spring is under tension use care
when releasing the valve spring compressor.
(5) Remove the valve spring compressor.
(6) Remove the spring retainer, and the spring.NOTE: Check for sharp edges on the keeper
grooves. Remove any burrs from the valve stem
before removing the valve from the cylinder head.
(7) Remove the valve from the cylinder head.
NOTE: The valve stem seals are common between
intake and exhaust.
(8) Remove the valve stem seal. Mark the valve for
proper installation.
TESTING VALVE SPRINGS
NOTE: Whenever the valves are removed from the
cylinder head it is recommended that the valve
springs be inspected and tested for reuse.
Inspect the valve springs for physical signs of wear
or damage. Turn table of tool C-647 until surface is
in line with the 40.12 mm (1.579 in.) mark on the
threaded stud and the zero mark on the front. Place
spring over the stud on the table and lift compress-
ing lever to set tone device. Pull on torque wrench
until a Ping is heard. Take reading on torque wrench
at this instant. Multiply this reading by two. This
will give the spring load at test length. Fractional
measurements are indicated on the table for finer
adjustments. Refer to Specifications Section to obtain
specified height and allowable tensions. Replace any
springs that do not meet specifications (Fig. 42).
INSTALLATION
(1) coat the valve stem with clean engine oil and
insert it into the cylinder head.
(2) Install the valve stem seal. make sure the seal
is fully seated and that the garter spring at the top
of the seal is intact.
Fig. 41 Rocker Arm Removal
1 - CAMSHAFT
2 - SPECIAL TOOL 8516
Fig. 42 Testing Valve Springs
1 - SPECIAL TOOL C-647
9 - 124 ENGINE - 4.7LDR
INTAKE/EXHAUST VALVES & SEATS (Continued)

(3) Install the spring and the spring retainer (Fig.
43).
(4) Using the valve spring compressor, compress
the spring and install the two valve spring retainer
halves.
(5) Release the valve spring compressor and make
sure the two spring retainer halves and the spring
retainer are fully seated.
(6) lubricate the camshaft journal with clean
engine oil then Position the camshaft (with the
sprocket dowel on the left camshaft at 11 o'clock and
the right camshaft at 12 o'clock), then position the
camshaft bearing caps.
(7) Install the camshaft bearing cap retaining
bolts. Tighten the bolts 9±13 N´m (100 in. lbs.) in
1¤2
turn increments in the sequence shown (Fig. 44).
(8) Position the hydraulic lash adjusters and
rocker arms.
ROCKER ARM / ADJUSTER
ASSEMBLY
DESCRIPTION
The rocker arms are steel stampings with an inte-
gral roller bearing. The rocker arms incorporate a 2.8mm (0.11 inch) oil hole in the lash adjuster socket for
roller and camshaft lubrication.
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) Turn engine off and let set for a few minutes
before restarting. Repeat this several times after
engine has reached normal operating temperature.
(4) Low oil pressure.
(5) The oil restrictor in cylinder head gasket or the
oil passage to the cylinder head is plugged with
debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Oil leak or excessive cam bore wear in cylin-
der head.
(11) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head and cam on camshaft atFig. 43 Valve Assembly Configuration
1 - VALVE LOCKS (3±BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 44 Camshaft Bearing Caps Tightening
Sequence
DRENGINE - 4.7L 9 - 125
INTAKE/EXHAUST VALVES & SEATS (Continued)

INSTALLATION
(1) Lubricate the crankshaft flange with engine oil.
(2) Position the magnetic seal guide Special Tool
8349-2 (Fig. 68) onto the crankshaft rear face. Then
position the crankshaft rear oil seal onto the guide.
(3) Using Special Tools 8349 Crankshaft Rear Oil
Seal Installer and C-4171 Driver Handle (Fig. 69),
with a hammer, tap the seal into place. Continue to
tap on the driver handle until the seal installer seats
against the cylinder block crankshaft bore.
(4) Install the flexplate.
(5) Install the transmission.
FLEX PLATE
REMOVAL
(1) Remove the transmission.
(2) Remove the bolts and flexplate.
INSTALLATION
(1) Position the flexplate onto the crankshaft and
install the bolts hand tight.
(2) Tighten the flexplate retaining bolts to 60 N´m
(45 ft. lbs.) in the sequence shown (Fig. 70).
(3) Install the transmission.
Fig. 68 Crankshaft Rear Oil Seal Guide Special Tool
8349-2 and Oil
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8349-2 GUIDE
Fig. 69 Crankshaft Rear Oil Seal Installation
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8349-1 INSTALLER
3 - SPECIAL TOOL C-4171 HANDLE
Fig. 70 Flexplate Tightening Sequence
1 - FLEXPLATE
9 - 138 ENGINE - 4.7LDR
CRANKSHAFT OIL SEAL - REAR (Continued)

ENGINE - 5.7L
TABLE OF CONTENTS
page page
ENGINE - 5.7L
DESCRIPTION........................182
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION..........183
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE..........183
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL............185
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE............186
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.....186
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - LUBRICATION............187
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL............188
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS........190
STANDARD PROCEDUREÐHYDROSTATIC
LOCK..............................190
REMOVAL............................190
INSTALLATION........................191
SPECIFICATIONS
5.7L ENGINE........................192
TORQUE...........................195
SPECIAL TOOLS
5.7L ENGINE........................196
AIR INTAKE SYSTEM
REMOVAL............................199
INSTALLATION........................199
CYLINDER HEAD
OPERATIONÐCYLINDER HEAD...........199
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE....................199
REMOVAL............................200
CLEANING...........................200
INSPECTION.........................200
INSTALLATION........................200
CYLINDER HEAD COVER(S)
REMOVAL............................201
INSTALLATION........................201
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION
DESCRIPTION - VALVE GUIDES.........202
DESCRIPTION.......................202
STANDARD PROCEDURE - REFACING.....202
REMOVAL............................203INSTALLATION........................203
ROCKER ARM / ADJUSTER ASSY
REMOVAL............................203
INSTALLATION........................203
VALVE STEM SEALS
DESCRIPTION........................203
VALVE SPRINGS
REMOVAL............................204
INSTALLATION........................204
ENGINE BLOCK
CLEANING...........................205
INSPECTION.........................205
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVAL - CAMSHAFT CORE HOLE PLUG. 205
REMOVAL - CAMSHAFT...............205
INSPECTION.........................206
INSTALLATION
INSTALLATION - CAMSHAFT CORE HOLE
PLUG..............................206
INSTALLATION - CAMSHAFT............206
CRANKSHAFT
REMOVAL............................206
INSTALLATION........................207
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - CRANKSHAFT
MAIN BEARING - FITTING..............207
INSPECTION.........................208
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................208
INSTALLATION........................208
CRANKSHAFT OIL SEAL - REAR
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS........................209
REMOVAL............................209
INSTALLATION........................209
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................209
INSTALLATION........................210
FLEX PLATE
REMOVAL............................210
INSTALLATION........................210
HYDRAULIC TAPPETS
DIAGNOSIS AND TESTING - HYDRAULIC
TAPPETS...........................210
REMOVAL............................211
INSTALLATION........................211
PISTON & CONNECTING ROD
DESCRIPTION........................211
9 - 180 ENGINE - 5.7LDR

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTIONS
NOISY VALVES 1. High or low oil level in
crankcase.1. (Refer to LUBRICATION &
MAINTENANCE -
SPECIFICATIONS)
2. Thin or diluted oil. 2. Change oil and filter.
3. Low oil pressure. 3. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
4. Dirt in lash adjusters. 4. Replace as necessary.
5. Worn rocker arms. 5. Replace as necessary.
6. Worn lash adjusters 6. Replace as necessary.
7. Worn valve guides. 7. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE)
8. Excessive runout of valve seats
on valve faces.8. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE)
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
MAINTENANCE -
SPECIFICATIONS)
2. Low oil pressure. 2. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
3. Thin or diluted oil. 3. Change oil and filter.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Connecting rod journal
out-of-round.5. Service or replace crankshaft.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
MAINTENANCE -
SPECIFICATIONS)
2. Low oil pressure. 2. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
3. Thin or diluted oil. 3. Change oil and filter.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Excessive end play. 5. Check thrust washers for wear.
6. Crankshaft journal out-of round. 6. Service or replace crankshaft.
7. Loose flywheel or torque
converter.7. Tighten to correct torque
DRENGINE - 5.7L 9 - 185
ENGINE - 5.7L (Continued)

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil. (Refer to 9 -
ENGINE/LUBRICATION/OIL -
STANDARD PROCEDURE)
3. Low oil pressure 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. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic
tappets/lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats
or valve faces9. Grind valves and seats
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level.
2. Low oil pressure 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. Thin or diluted oil 3. Change oil to correct viscosity.
(Refer to 9 - ENGINE/
LUBRICATION/OIL - STANDARD
PROCEDURE) for correct
procedure/engine oil specifications
4. Excessive connecting rod
bearing clearance4. Measure bearings for correct
clearance with plasti-gage. Repair
as necessary
5. Connecting rod journal out of
round5. Replace crankshaft or grind
journals
6. Misaligned connecting rods 6. Replace bent connecting rods
9 - 188 ENGINE - 5.7LDR
ENGINE - 5.7L (Continued)

þ Loss of engine power
þ Engine misfiring
þ Poor fuel economy
²Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
þ Engine overheating
þ Loss of coolant
þ Excessive steam (white smoke) emitting from
exhaust
þ Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test in this
section. An engine cylinder head gasket leaking
between adjacent cylinders will result in approxi-
mately a 50±70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system.
(3) Remove the air cleaner resonator and duct
work.
(4) Remove the generator.
(5) Remove closed crankcase ventilation system.
(6) Disconnect the evaporation control system.
(7) Perform the Fuel System Pressure Release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect heater hoses.
(9) Remove cylinder head covers and gaskets.
(10) Remove intake manifold and throttle body as
an assembly.
(11) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(12) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
(1) Inspect the cylinder head for out-of-flatness,
using a straightedge and a feeler gauge. If tolerances
exceed 0.0508 mm (0.002 in.) replace the cylinder
head.
(2) Inspect the valve seats for damage. Service the
valve seats as necessary.
(3) Inspect the valve guides for wear, cracks or
looseness. If either condition exist, replace the cylin-
der head.
(4) Inspect pushrods. Replace worn or bent push-
rods.
INSTALLATION
(1) Clean all surfaces of cylinder block and cylin-
der heads.
(2) Clean cylinder block front and rear gasket sur-
faces using a suitable solvent.
CAUTION: The head gaskets are not interchange-
able between left and right sides. They are marked
ªLº and ªRº to indicate left and right sides.
(3) Position new cylinder head gaskets onto the
cylinder block.
9 - 200 ENGINE - 5.7LDR
CYLINDER HEAD (Continued)

INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
DESCRIPTION - VALVE GUIDES
The valve guides are made of powered metal and
are pressed into the cylinder head. The guides are
not replaceable or serviceable, and valve guide ream-
ing is not recommended. If the guides are worn
beyond acceptable limits, replace the cylinder heads.
DESCRIPTION
Both the intake and exhaust valves are made of
steel. The intake valve is 50.93 mm (2.00 inches) in
diameter and the exhaust valve is 39.53 mm (1.55
inches) in diameter. All valves use three bead lock
keepers to retain the springs and promote valve rota-
tion.
STANDARD PROCEDURE - REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.
NOTE: When refacing valves and valve seats, it is
important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained.
(1) Using a suitable dial indicator measure the
center of the valve seat Total run out must not
exceed 0.051 mm (0.002 in).
(2) Apply a small amount of Prussian blue to the
valve seat, insert the valve into the cylinder head,
while applying light pressure on the valve rotate the
valve. Remove the valve and examine the valve face.
If the blue is transferred below the top edge of the
valve face, lower the valve seat using a 15 degree
stone. If the blue is transferred to the bottom edge of
the valve face, raise the valve seat using a 65 degree
stone.
(3) When the seat is properly positioned the width
of the intake seat must be 1.018 - 1.62 mm (0.0464 -
0.0637 in.) and the exhaust seat must be 1.48 - 1.92
mm (0.058 - 0.075 in.).
(4) Check the valve spring installed height after
refacing the valve and seat. The installed height for
both intake and exhaust valve springs must not
exceed 46.0 mm (1.81 in.).
VALVE FACE AND VALVE SEAT ANGLE CHART
DESCRIPTION SPECIFICATION
SEAT WIDTH
INTAKE 1.018 - 1.62 mm
(0.0464 - 0.0637 in.)
EXHAUST 1.48 - 1.92 mm
(0.058 - 0.075 in.)
FACE ANGLE
(INT. AND EXT.) 45É - 45
1¤2É
SEAT ANGLE
(INT. AND EXT.) 44
1¤2É - 45É
(5)
The valve seat must maintain an angle of 44.5 ±
45.0 degrees angle.
(6) The valve face must maintain a face angle of
45.0 ± 45.5 degrees angle (Fig. 5).
Fig. 5 Valve Assembly Configuration
1 - VALVE LOCKS (3±BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
9 - 202 ENGINE - 5.7LDR

REMOVAL
(1) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(2) Compress valve springs using Valve Spring
Compressor Tool special tool # C-3422and adapter
8464.
(3) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original location.
INSTALLATION
(1) Clean valves thoroughly. Discard burned,
warped and cracked valves.
(2) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(3) Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve.
(4) Coat valve stems with lubrication oil and insert
them in cylinder head.
(5) If valves or seats are reground, check valve
stem height. If valve is too long, replace cylinder
head.
(6) Install new seals on all valve guides. Install
valve springs and valve retainers.
(7) Compress valve springs with Valve Spring
Compressor Tool special tool # C- 3422and adapter
8464, install locks and release tool. If valves and/or
seats are ground, measure the installed height of
springs. Make sure the measurement is taken from
bottom of spring seat in cylinder head to the bottom
surface of spring retainer.
(8) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
ROCKER ARM / ADJUSTER
ASSY
REMOVAL
(1) Remove cylinder head cover.(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(2) Loosen the rocker shafts using the following
sequence:Center, center-left, center-right, left,
right,.
CAUTION: The rocker shaft assemblies are not
interchangeable between intake and exhaust. The
intake rocker arms are marked with an ªIº.
(3) Remove the rocker shafts. Note location for
reassembly.CAUTION: The longer push rods are for the exhaust
side, and the shorter push rods are for intake side.
(4) Remove the pushrods. Note pushrod location
for reassembly.
INSTALLATION
CAUTION: The longer push rods are for the exhaust
side, and the shorter push rods are for intake side.
(1) Install the push rods in the same order as
removed.
CAUTION: Verify that pushrod is installed into
rocker arm and lifter correctly while installing
rocker shaft assembly. Recheck after rocker shaft
has been torqued to specification.
CAUTION: The rocker shaft assemblies are not
interchangeable between intake and exhaust. The
intake rocker arms are marked with the letter ªIº.
(2) Install rocker shaft assemblies in the same
order as removed.
CAUTION: Ensure that hold downs and rocker arms
are not overlapped when torquing bolts.
(3) Tighten the rocker shaft bolts to 22 N´m (195
in. lbs.) torque,using the following sequence:Center,
center-right, center-left, right, left.
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(4) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
VALVE STEM SEALS
DESCRIPTION
The valve guide seals are made of rubber and
incorporate an integral steel valve spring seat. The
integral garter spring maintains consistent lubrica-
tion control to the valve stems.
DRENGINE - 5.7L 9 - 203
INTAKE/EXHAUST VALVES & SEATS (Continued)

CRANKSHAFT OIL SEAL -
REAR
DIAGNOSIS AND TESTING - REAR SEAL AREA
LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, camshaft bore
cup plugs, oil galley pipe plugs, oil filter runoff,
and main bearing cap to cylinder block mating sur-
faces. See Engine, for proper repair procedures of
these items.
(4) If no leaks are detected, pressurized the crank-
case as outlined in the section, Inspection (Engine oil
Leaks in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled. (Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING), under the Oil Leak row, for components
inspections on possible causes and corrections.
(7) After the oil leak root cause and appropriate
corrective action have been identified, (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL).
REMOVAL
NOTE: This procedure can be performed in vehicle.
(1) If being preformed in vehicle, remove the
transmission.
(2) Remove the flexplate (Refer to 9 - ENGINE/
ENGINE BLOCK/FLEX PLATE - REMOVAL).
NOTE: The crankshaft oil seal CAN NOT be reused
after removal.
NOTE: The crankshaft rear oil seal remover Special
Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.
(3) Using Special Tool 8506, remove the crankshaft
rear oil seal.
INSTALLATION
CAUTION: The rear seal must be installed dry for
proper operation. Do not lubricate the seal lip or
outer edge.
(1) Position the plastic seal guide onto the crank-
shaft rear face. Then position the crankshaft rear oil
seal onto the guide.
(2) Using Special Tools 8349 Crankshaft Rear Oil
Seal Installer and C-4171 Driver Handle, with a
hammer, tap the seal into place. Continue to tap on
the driver handle until the seal installer seats
against the cylinder block crankshaft bore.
(3) Install the flexplate.
(4) Install the transmission.
CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the transmission.
(3) Remove the drive plate / flywheel.
(4) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(5) Remove the rear oil seal retainer mounting
bolts.
(6) Carefully remove the retainer from the engine
block.
DRENGINE - 5.7L 9 - 209