cooling DODGE RAM 2001 Service Owners Manual

INSPECTIONÐMEASURING TIMING CHAIN
STRETCH
NOTE: Timing chain tensioner must be removed for
this operation.
(1) Place a scale next to the timing chain so that
any movement of the chain can be measured.
(2) Place a torque wrench and socket over cam-
shaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
N´m (30 ft. lbs.) torque with cylinder head installed
or 20 N´m (15 ft. lbs.) torque with cylinder head
removed. With torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N´m (30 ft. lbs.) torque in the
reverse direction. With the cylinder heads removed,
apply 20 N´m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 76).
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
INSTALLATION
(1) If tensioner assembly is being replaced, install
tensioner and mounting bolts. Torque bolts to 24 N´m
(210 in. lbs.).
(2) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on an exact
imaginary center line through both camshaft and
crankshaft bores.
(3) Place timing chain around both sprockets.
(4) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).(5) Slide both sprockets evenly over their respec-
tive shafts and verify alignment of timing marks
(Fig. 77) with a straight-edge if necessary.
(6) Install the camshaft bolt. Tighten the bolt to 68
N´m (50 ft. lbs.) torque.
(7)Remove tensioner pin.Again, verify align-
ment of timing marks.
(8) Install timing cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION).
(9) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(10) Connect battery negative cable.
(11) Start engine and check for oil and coolant
leaks.
Fig. 76 Measuring Timing Chain Wear and Stretch
1 - TORQUE WRENCH
2 - 3.175 MM
(0.125 IN.)
Fig. 77 Alignment of Timing Marks
1 - TIMING MARKS
9 - 58 ENGINE 3.9LBR/BE
TIMING BELT/CHAIN AND SPROCKETS (Continued)

(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 cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(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,
oil, etc.).
(7) Be sure all fluid has been removed from the
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.
STANDARD PROCEDUREÐCYLINDER 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 20-60strokes, 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 50É to 60É
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 50É to 60É
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.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Recover refrigerant from a/c system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(4) Remove the a/c condenser, if equipped (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - REMOVAL).
Fig. 3 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
BR/BEENGINE 5.2L 9 - 69
ENGINE 5.2L (Continued)

(5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
(6) Remove the washer bottle from the fan shroud.
(7) Remove the viscous fan/drive (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(8) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(9) Remove the upper crossmember and top core
support.
(10) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(11) Remove the A/C compressor with the lines
attached. Secure compressor out of the way.
(12) Remove generator assembly (Refer to 8 -
ELECTRICAL/CHARGING/GENERATOR - REMOV-
AL).
(13) Remove the air cleaner resonator and duct
work as an assembly.
(14) Disconnect the throttle linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL).
(15) Remove throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(16) Remove the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(17) Remove the distributor cap and wiring.
(18) Disconnect the heater hoses.
(19) Disconnect the power steering hoses, if
equipped.
(20) Perform the Fuel System Pressure Release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).
(21) Disconnect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(22) On Manual Transmission vehicles, remove the
shift lever (Refer to 21 - TRANSMISSION/TRAN-
SAXLE/MANUAL/SHIFT COVER - REMOVAL).
(23) Raise and support the vehicle on a hoist and
drain the engine oil.
(24) Remove engine front mount thru-bolt nuts.
(25) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(26) Disconnect exhaust pipe at manifolds.
(27) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
(28) Remove the dust shield and transmission
inspection cover.
(29) Remove drive plate to converter bolts (Auto-
matic transmission equipped vehicles).(30) Remove transmission bell housing to engine
block bolts.
(31) Lower the vehicle.
(32) Install an engine lifting fixture.
(33) Separate engine from transmission, 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 engine lifting device.
(3) Lower engine into compartment and align
engine with transmission:
²Manual Transmission: Align clutch disc assem-
bly (if disturbed). Install transmission input shaft
into clutch disc while mating engine and transmis-
sion surfaces. Install two transmission to engine
block mounting bolts finger tight.
²Automatic Transmission: Mate engine and trans-
mission and install two transmission to engine block
mounting bolts finger tight.
(4) Lower engine assembly until engine mount
through bolts rest in mount perches.
(5) Install remaining transmission to engine block
mounting bolts and tighten.
(6) Tighten engine mount through bolts.
(7) Install drive plate to torque converter bolts.
(Automatic transmission models)
(8) Install the dust shield and transmission cover.
(9) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(10) Install exhaust pipe to manifold.
(11) Install the transmission cooler line brackets to
the oil pan.
(12) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(13) Lower the vehicle.
(14) Remove engine lifting fixture.
(15) On Manual Transmission vehicles, install the
shift lever (Refer to 21 - TRANSMISSION/TRAN-
SAXLE/MANUAL/SHIFT COVER - INSTALLA-
TION).
(16) Connect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(17) Connect the power steering hoses, if equipped.
(18) Connect the heater hoses.
(19) Install the distributor cap and wiring.
(20) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
9 - 70 ENGINE 5.2LBR/BE
ENGINE 5.2L (Continued)

(21) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(22) Connect the throttle linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - INSTALLATION).
(23) Install the air cleaner resonator and duct
work..
(24) Install the generator and wire connections
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION).
(25) Install a/c compressor and lines (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION).
(26) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(27) Install upper radiator support crossmember.
(28) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(29) Connect the radiator lower hose.
(30) Connect the transmission oil cooler lines to
the radiator.
(31) Install the fan shroud.(32) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(33) Connect the radiator upper hose.
(34) Install the washer bottle.
(35) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
(36) Connect the transmission cooler lines.
(37) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - INSTALLATION).
(38) Evacuate and charge the air conditioning sys-
tem, if equipped (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE).
(39) Add engine oil to crankcase (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES - SPEC-
IFICATIONS).
(40) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(41) Connect battery negative cable.
(42) Start engine and inspect for leaks.
(43) Road test vehicle.
BR/BEENGINE 5.2L 9 - 71
ENGINE 5.2L (Continued)

SPECIFICATIONS
5.2L ENGINE
ENGINE SPECIFICATIONS
DESCRIPTION SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type 90É V-8 OHV
Bore and Stroke 99.3 x 84.0 mm
(3.91 x 3.31 in.)
Displacement 5.2L
(318 c.i.)
Compression Ratio 9.1:1
Firing Order 1±8±4±3±6±5±7±2
Lubrication Pressure FeedÐ
Full Flow Filtration
Cooling System Liquid CooledÐ
Forced Circulation
Cylinder Block Cast Iron
Crankshaft Nodular Iron
Cylinder Head Cast Iron
Combustion Chambers Wedge-High Swirl
Valve shrouding
Camshaft Nodular Cast Iron
Pistons Aluminum Alloy w/strut
Connecting Rods Forged Steel
Cylinder Compression 689.5 kPa
Pressure (Min.) (100 psi)
CAMSHAFT
Bearing Diameter
No. 1 50.800 ± 50.825 mm
(2.000 ± 2.001 in.)
No. 2 50.394 ± 50.419 mm
(1.984 ± 1.985 in.)
No. 3 50.013 ± 50.038 mm
(1.969 ± 1.970 in.)
No. 4 49.606 ± 49.632 mm
(1.953 ± 1.954 in.)
DESCRIPTION SPECIFICATION
No. 5 39.688 ± 39.713 mm
(1.5625 ± 1.5635 in.)
Bearing Journal Diameter
No. 1 50.749 ± 50.775 mm
(1.998 ± 1.999 in.)
No. 2 50.343 ± 50.368 mm
(1.982 ± 1.983 in.)
No. 3 49.962 ± 49.987 mm
(1.967 ± 1.968 in.)
No. 4 49.555 ± 49.581 mm
(1.951 ± 1.952 in.)
No. 5 39.637 ± 39.662 mm
(1.5605 ± 1.5615 in.)
Bearing to Journal
Clearance
Standard 0.0254 ± 0.0762 mm
(0.001 ± 0.003 in.)
Service Limit 0.127 mm
(0.005 in.)
End Play 0.051 ± 0.254 mm
(0.002 ± 0.010 in.)
CONNECTING RODS
Piston Pin bore Diameter 24.966 ± 24.978 mm
(0.9829 ± 0.9834 in.)
Side Clearance 0.152 ± 0.356 mm
(0.006 ± 0.014 in.)
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.)
Bearing Clearance 0.013 ± 0.056 mm
(0.0005 ± 0.0022 in.)
Service Limit 0.0762 mm
(0.003 in.)
9 - 72 ENGINE 5.2LBR/BE
ENGINE 5.2L (Continued)

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 (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the air cleaner resonator and duct
work.
(4) Remove the intake manifold-to-generator
bracket support rod. 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 accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(9) Remove distributor cap and wires.
(10) Disconnect the coil wires.
(11) Disconnect heat indicator sending unit wire.
(12) Disconnect heater hoses and bypass hose.
(13) Remove cylinder head covers and gaskets
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(14) Remove intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL) and throttle body as an assembly. Dis-
card the flange side gaskets and the front and rear
cross-over gaskets.
(15) Remove exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
REMOVAL).
(16) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.(17) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(18) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness
exceeds 0.00075mm (0.0001in.) times the span length
in any direction, either replace head or lightly
machine the head surface.
FOR EXAMPLE:ÐA 305 mm (12 in.) span is
0.102 mm (0.004 in.) out-of-flat. The allowable out-of-
flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 mm
(0.009 in.). This amount of out-of-flat is acceptable.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent 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.
(3) Position new cylinder head gaskets onto the
cylinder block.
(4) Position cylinder heads onto head gaskets and
cylinder block.
(5) Starting at top center, tighten all cylinder head
bolts, in sequence (Fig. 6).
Fig. 6 Cylinder Head Bolt Tightening Sequence
9 - 80 ENGINE 5.2LBR/BE
CYLINDER HEAD (Continued)

CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(6) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 N´m
(21 ft. lbs.) torque.
(7) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION) and throttle body assembly.
(8) Install exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSTALLATION).
(9) If required, adjust spark plugs to specifications.
Install the plugs and tighten to 41 N´m (30 ft. lbs.)
torque.
(10) Install coil wire.
(11) Connect heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(15) Install the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(16) Install the generator and drive belt (Refer to 7
- COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION). Tighten generator mounting bolt
to 41 N´m (30 ft. lbs.) torque. Tighten the adjusting
strap bolt to 23 N´m (200 in. lbs.) torque.
(17) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(18) Place the cylinder head cover gaskets in posi-
tion and install cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(19) Install closed crankcase ventilation system.
(20) Connect the evaporation control system.
(21) Install the air cleaner.
(22) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(23) Connect the negative cable to the battery.
(24) Start engine check for leaks.
CYLINDER HEAD COVER(S)
REMOVAL
NOTE: A steel backed silicon gasket is used with
the cylinder head cover (Fig. 7). This gasket can be
used again.
(1) Disconnect the negative cable from the battery.(2) Disconnect the spark plug wires form the spark
plugs and set aside.
(3) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
(4) Remove cylinder head cover and gasket.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
INSTALLATION
(1) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas-
ket. Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(3) Install closed crankcase ventilation system and
evaporation control system.
(4) Connect the spark plug wires to the spark
plugs.
(5) Connect the negative cable to the battery.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
Both the intake and exhaust valves are made of
steel. The intake valve is 48.768 mm (1.92 inches) in
diameter and the exhaust valve is 41.148 mm (1.62
inches) in diameter and has a 2.032 mm (0.080 inch)
wafer interia welded to the tip for durability. These
valves are not splayed.
Fig. 7 Cylinder Head Cover Gasket
1 - CYLINDER HEAD COVER GASKET
BR/BEENGINE 5.2L 9 - 81
CYLINDER HEAD (Continued)

(1) Remove the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL).
(2) Remove the A/C Condenser (if equipped)
(3) Remove the engine cover.
(4) Remove intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(5) Remove cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(6) Remove timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL) and timing chain (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(7) Remove rocker arms.
(8) Remove push rods and tappets. Identify each
part so it can be installed in its original location.
(9) Remove distributor and lift out the oil pump
and distributor drive shaft.
(10) Remove camshaft thrust plate, note location of
oil tab (Fig. 20).
(11) 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.INSTALLATIONÐCAMSHAFT BEARINGS
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
the new camshaft bearing shell over proper adapter.
(2) Position rear bearing in the tool. Install horse-
shoe lock and by reversing removal procedure, care-
fully drive bearing shell into place.
(3) Install remaining bearings in the same man-
ner. 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.
INSTALLATIONÐCAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2
inches) of its final position in cylinder block.
(2) Install Camshaft Holder Tool C-3509 with
tongue back of distributor drive gear (Fig. 21).
(3) Hold tool in position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block.Tool should remain
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower right hole in
thrust plate.Tighten bolts to 24 N´m (210 in. lbs.)
torque. Top edge of tab should be flat against thrust
plate in order to catch oil for chain lubrication.
(5) Install timing chain and gears (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(6) Measure camshaft end play (Refer to 9 -
ENGINE - SPECIFICATIONS). If not within limits
install a new thrust plate.
Fig. 20 Timing Chain Oil
1 - THRUST PLATE FRONT SIDE
2 - CHAIN OIL TAB
3 - THRUST PLATE REAR SIDE
Fig. 21 Camshaft Holding Tool C-3509 (Installed
Position)
1 - SPECIAL TOOL C-3509
2 - DRIVE GEAR
3 - DISTRIBUTOR LOCK BOLT
BR/BEENGINE 5.2L 9 - 87
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

(7) 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.
(8) Install distributor and distributor drive shaft.
(9) Install push rods and tappets.
(10) Install rocker arms.
(11) Install timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(12) Install cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(13) Install intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSTALLA-
TION).
(14) Install the engine cover.
(15) Install the A/C Condenser (if equipped)
(16) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
(17) Start engine check for leaks.
CONNECTING ROD BEARINGS
STANDARD PROCEDUREÐCONNECTING 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 interchangeable and
should be marked at removal to ensure correct
assembly.
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
DESCRIPTION
The crankshaft (Fig. 22) is of a cast nodular steel
splayed type design, with five main bearing journal-
s.The crankshaft is located at the bottom of the
engine block and is held in place with five main bear-
ing caps. The number 3 counterweight is the location
for journal size identification.
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or
flexplate.
REMOVAL
NOTE: This procedure can be done in vehicle. How-
ever the transmission must be removed first.
(1) If crankshaft is to be removed while engine is
in vehicle remove the transmission. Refer to Group
21, for correct procedure.
(2) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(3) Remove the oil pump from the rear main bear-
ing cap (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - REMOVAL).
(4) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(5) Remove the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(6) Identify rod bearing caps before removal.
Remove rod bearing caps with bearings.
Fig. 22 Crankshaft with Journal Size Identification
9 - 88 ENGINE 5.2LBR/BE
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

(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 ªOº, an oval depression, or the
word ªTOPº (Fig. 39) (Fig. 41).
(c) Using a ring installer, install the top com-
pression ring with the chamfer facing up (Fig. 40)
(Fig. 41). An identification mark on the ring is a
drill point, a stamped letter ªOº, an oval depression
or the word ªTOPº facing up.
(d) Measure side clearance between piston ring
and ring land. Clearance should be 0.074-0.097 mm
(0.0029-0.0038 in.) for the compression rings. The
steel rail oil ring should be free in groove, but
should not exceed 0.246 mm (0.0097 in.) side clear-
ance.
(e) Pistons with insufficient, or excessive, side
clearance should be replaced.
(3) Orient the rings:
(a) Arrange top compression ring 90É counter-
clockwise from the oil ring rail gap (Fig. 42).
(b) Arrange second compression ring 90É clock-
wise from the oil ring rail gap (Fig. 42).
VIBRATION DAMPER
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove fan, and fan drive (Refer to 7 - COOL-
ING/ENGINE/FAN DRIVE VISCOUS CLUTCH -
REMOVAL).
(3) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).(4) Remove the vibration damper pulley.
(5) Remove vibration damper bolt and washer from
end of crankshaft.
(6) Install bar and screw from Puller Tool Set
C-3688. Install two bolts with washers through the
puller tool and into the vibration damper (Fig. 43).
(7) Pull vibration damper off of the crankshaft.
INSTALLATION
(1) Position the vibration damper onto the crank-
shaft.
(2) Place installing tool, part of Puller Tool Set
C-3688, in position and press the vibration damper
onto the crankshaft (Fig. 44).
(3) Install the crankshaft bolt and washer. Tighten
the bolt to 244 N´m (180 ft. lbs.) torque.
Fig. 39 Second Compression Ring Identification
(Typical)
1 - SECOND COMPRESSION RING (BLACK CAST IRON)
2 - CHAMFER
3 - TWO DOTS
Fig. 40 Top Compression Ring Identification
(Typical)
1 - TOP COMPRESSION RING (GRAY IN COLOR)
2 - CHAMFER
3 - ONE DOT
Fig. 41 Compression Ring Chamfer Location
(Typical)
1 - CHAMFER
2 - TOP COMPRESSION RING
3 - SECOND COMPRESSION RING
4 - PISTON
5 - CHAMFER
BR/BEENGINE 5.2L 9 - 99
PISTON RINGS (Continued)