fuel DODGE RAM 2002 Service Owners Manual

(13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear end seals.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 65). Dis-
card the gasket.
(19) If required, remove the plenum pan and gas-
ket. Discard gasket.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
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) If removed, position new plenum gasket and
install plenum pan (Fig. 66).
(2) Tighten plenum pan mounting bolts as follows:²Step 1. Tighten bolts to 5.4 N´m (48 in. lbs.)
²Step 2. Tighten bolts to 9.5 N´m (84 in. lbs.)
²Step 3. Check all bolts are at 9.5 N´m (84 in.
lbs.)
(3) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 68). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(4) Apply MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, to 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 and 15 mm (0.6 in.)
long.
(5) Install the front and rear end seals (Fig. 67)
Make sure the molded dowel pins on the end seals
fully enter the corresponding holes in the cylinder
block.
(6) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. After intake
manifold is in place, inspect to make sure seals are
in place.
(7) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N´m
(200 in. lbs.) torque.
(8) Install the intake manifold bolts and tighten as
follows (Fig. 69):
Fig. 65 Throttle Body Assembly
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
Fig. 66 Plenum Pan Bolt Tightening Sequence
BR/BEENGINE 5.9L 9 - 51
INTAKE MANIFOLD (Continued)

²Step 1. Tighten bolts 1 through 4 to 8 N´m (72
in. lbs.) Tighten in alternating steps 1.4 N´m (12 in.
lbs.) at a time
²Step 2. Tighten bolts 5 through 12 to 8 N´m (72
in. lbs.)
²Step 3. Check all bolts are torqued to 8 N´m (72
in. lbs.)
²Step 4. Tighten all bolts in sequence to 16 N´m
(12 ft. lbs.)
²Step 5. Check all bolts are torqued to 16 N´m
(12 ft. lbs.)
(9) Install closed crankcase ventilation and evapo-
ration control systems.
(10) Connect the coil wires.
(11) Connect the heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Hook up the return spring.
(15) Connect the accelerator linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - INSTALLATION) and if so
equipped, the speed control and transmission kick-
down cables.
(16) Install the fuel lines (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(17) Install the accessory drive bracket and A/C
compressor (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
INSTALLATION).(18) 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.
(19) Install the air cleaner.
(20) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(21) Connect the negative cable to the battery.
Fig. 67 Front and Rear End Seals
1 - FRONT CROSS-OVER GASKET
2 - REAR CROSS-OVER GASKET
Fig. 68 Intake Manifold Flange Gasket Alignment
1 - FLANGE GASKET
2 - ALIGNMENT TABS
3 - CYLINDER HEAD GASKET
Fig. 69 Intake Manifold Bolt Tightening Sequence
9 - 52 ENGINE 5.9LBR/BE
INTAKE MANIFOLD (Continued)

ENGINE 8.0L
DESCRIPTION
The 8.0 Liter (488 CID) ten-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
Engine lubrication system consists of a gerotor
type oil pump mounted in the timing chain cover and
driven by the crankshaft. The V-10 uses a full flow
oil filter.
The cylinders are numbered from front to rear; 1,
3, 5, 7, 9 on the left bank and 2, 4, 6, 8, 10 on the
right bank. The firing order is 1-10-9-4-3-6-5-8-7-2
(Fig. 1) .
The engine serial number is located on the lower
left front of the cylinder block in front of the engine
mount (Fig. 2) . When component part replacement is
necessary, use the engine type and serial number for
reference.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING - Preformance) or (Refer to 9 - ENGINE - DIAG-
NOSIS AND TESTING - Mechanical). Refer to 14 -
FUEL SYSTEM for fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING)
²Cylinder Combustion Pressure Leakage Test
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
²Cylinder Head Gasket Failure Diagnosis (Refer
to 9 - ENGINE/CYLINDER HEAD - DIAGNOSIS
AND TESTING)
²Intake Manifold Leakage Diagnosis (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING)
²Lash Adjuster (Tappet) Noise Diagnosis (Refer to
9 - ENGINE/ENGINE BLOCK/HYDRAULIC LIFT-
ERS (CAM IN BLOCK) - DIAGNOSIS AND TEST-
ING)
²Engine Oil Leak Inspection (Refer to 9 -
ENGINE/LUBRICATION - DIAGNOSIS AND TEST-
ING)
Fig. 1 Firing Order
Fig. 2 Engine IdentificationÐ(Serial Number)
1 - ENGINE SERIAL NO.
2 - ENGINE MOUNT LOCATION
9 - 58 ENGINE 8.0LBR/BE

DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - PERFORMANCE
PERFORMANCE DIAGNOSIS CHARTÐGASOLINE ENGINES
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. (Refer to
8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD
PROCEDURE). Check charging
system. (Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND
TESTING).
2. Corroded or loose battery
connections2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. (Refer to
8 - ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Seized accessory drive
component4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace seized
component.
5. Engine internal mechanical
failure or hydro-static lock5. Refer to (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
ENGINE CRANKS BUT WILL NOT
START1. No spark 1. Check for spark. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- DESCRIPTION)
2. No fuel 2. Perform fuel pressure test, and if
necessary, inspect fuel injector(s)
and driver circuits. (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/
FUEL PUMP - DIAGNOSIS AND
TESTING).
3. Low or no engine compression 3. Perform cylinder compression
pressure test. (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING).
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/
DISTRIBUTOR - REMOVAL).
3. Worn or incorrect gapped spark
plugs3. Clean plugs and set gap. (Refer
to 8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG -
CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
BR/BEENGINE 8.0L 9 - 59
ENGINE 8.0L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression (Refer
to 9 - ENGINE - DIAGNOSIS AND
TESTING).
9. Burned, warped, or pitted valves 9. Install/Reface valves as
necessary
10. Plugged or restricted exhaust
system10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted
cables
12. Faulty ignition coil 12. Test and replace, as necessary
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/
THROTTLE BODY - REMOVAL).
2. Engine idle speed too low 2. Check Idle Air Control circuit.
(Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/IDLE AIR CONTROL
MOTOR - DESCRIPTION)
3. Worn or incorrectly gapped spark
plugs3. Replace or clean and re-gap
spark plugs (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
SPARK PLUG - CLEANING)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or
crossed5. Check for correct firing order or
replace spark plug cables. (Refer to
8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG CABLE -
DIAGNOSIS AND TESTING)
6. Faulty coil 6. Test and replace, if necessary
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket
and vacuum hoses (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD - DIAGNOSIS AND
TESTING).
ENGINE MISSES ON
ACCELERATION1. Worn or incorrectly gapped spark
plugs1. Replace spark plugs or clean and
set gap. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING)
2. Spark plug cables defective or
crossed2. Replace or rewire secondary
ignition cables. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
SPARK PLUG CABLE - REMOVAL)
9 - 60 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL)
DIAGNOSIS AND TESTINGÐ 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
BR/BEENGINE 8.0L 9 - 61
ENGINE 8.0L (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.
REMOVAL
(1) Remove the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Discharge the air conditioning system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(4) Remove the upper crossmember.
(5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
(6) Remove the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).
(7) Remove the A/C compressor with the lines
attached (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
REMOVAL). Set aside.
(8) If equipped, remove the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - REMOVAL).(9) Remove the washer fluid reservoir bottle (Refer
to 8 - ELECTRICAL/WIPERS/WASHERS -
REMOVAL AND INSTALLATION).
(10) Disconnect the top radiator hose.
(11) Remove the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - REMOVAL).
(12) Remove the fan shroud.
(13) Disconnect the lower radiator hose.
(14) Disconnect the transmission cooler lines.
(15) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(16) Remove the generator with the wire connec-
tions (Refer to 8 - ELECTRICAL/CHARGING/GEN-
ERATOR - REMOVAL).
(17) Remove the air cleaner.
(18) Disconnect the throttle linkage.
(19) Remove throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(20) Remove the upper intake manifold (Refer to 9
- ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(21) Remove the coil assemblies with the ignition
cables.
(22) Disconnect the heater hoses.
(23) Disconnect the power steering hoses, if
equipped.
(24) Perform the Fuel System Pressure release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE). Disconnect
the fuel line (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(25) On Manual Transmission vehicles, remove the
shift lever.
(26) Raise and support the vehicle on a hoist.
(27) Remove the drain plug and drain the engine
oil.
(28) Loosen front engine mount thru-bolt nuts.
(29) Remove the transmission cooler line brackets
from oil pan.
(30) Disconnect exhaust pipe at manifold.
(31) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
(32) Remove transmission.
(33) Lower vehicle.
CAUTION: DO NOT lift the engine by the intake
manifold.
(34) Install an engine lifting fixture.
(35) Remove engine from vehicle and install
engine assembly on a repair stand.
BR/BEENGINE 8.0L 9 - 67
ENGINE 8.0L (Continued)

INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment. Position the thru-
bolt into the support cushion brackets.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4) Install Transmission.
(5) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(6) Install exhaust pipe to manifold.
(7) Install the transmission cooler line brackets
from oil pan.
(8) Tighten the Front mount thru-bolts and nuts to
102N´m (75 ft. lbs.).
(9) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(10) Prime oil pump by squirting oil in the oil fil-
ter mounting hole and filling the J-trap of the front
timing cover. When oil is running out, install oil filter
that has been filled with oil.
(11) Lower the vehicle.
(12) Remove engine lifting fixture.
(13) On Manual Transmission vehicles, install the
shift lever.
(14) Connect the fuel lines (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(15) Connect the heater hoses.
(16) Install the upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(17) Install the coil assemblies with the ignition
cables.
(18) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(19) Connect the throttle linkage.
(20) Install the air cleaner box.
(21) Install the generator and wire connections
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION).
(22) Install the upper crossmember.
(23) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(24) Connect the lower radiator hose.
(25) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
(26) Connect the transmission cooler lines.
(27) Connect the power steering hoses, if equipped.
(28) Install the fan shroud.
(29) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(30) Connect the top radiator hose.(31) Install the washer fluid reservoir bottle (Refer
to 8 - ELECTRICAL/WIPERS/WASHERS - INSTAL-
LATION).
(32) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - INSTALLATION).
(33) Install the A/C compressor with the lines
attached (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
INSTALLATION).
(34) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(35) Evacuate (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE) and charge the air conditioning system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(36) Add coolant to the cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(37) Install the battery.
(38) Warm engine and adjust as required.
(39) Road test vehicle.
SPECIFICATIONS
8.OL ENGINE
DESCRIPTION SPECIFICATION
CAMSHAFT
Bearing Diameter
No. 1 53.16 ± 53.19 mm
(2.093 ± 2.094 in.)
No. 2 52.76 ± 52.78 mm
(2.077 ± 2.078 in.)
No. 3 52.35 ± 52.37 mm
No. 4 51.94 ± 51.97 mm
(2.045 ± 2.046 in.)
No. 5 51.54 ± 51.56 mm
(2.029 ± 2.030 in.)
No. 6 48.74 ± 48.77 mm
(1.919 ± 1.920 in.)
Bearing Journal Diameter
No. 1 53.11 ± 53.14 mm
(2.091 ± 2.092 in.)
No. 2 52.69 ± 52.72 mm
9 - 68 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)

CYLINDER HEAD
DESCRIPTION
The alloy cast iron cylinder heads (Fig. 7) are held
in place by 12 bolts. The spark plugs are located in
the peak of the wedge between the valves.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
²Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
²Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant 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 negative cable from the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the heat shields (Fig. 8).
(4) Remove the intake manifold-to-generator
bracket support rod. Remove the generator (Refer to
8 - ELECTRICAL/CHARGING/GENERATOR -
REMOVAL).
(5) Remove closed crankcase ventilation system.
(6) Disconnect the evaporation control system.
(7) Remove the air cleaner.
(8) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
Fig. 7 Cylinder Head Assembly
1 - SPARK PLUG
2 - INTAKE VALVES
3 - SPARK PLUG
4 - INTAKE VALVES
5 - SPARK PLUG
6 - SPARK PLUG
7 - INTAKE VALVE
8 - SPARK PLUG
9 - EXHAUST VALVE
10 - EXHAUST VALVES
11 - EXHAUST VALVES
9 - 76 ENGINE 8.0LBR/BE

ERY - STANDARD PROCEDURE). Disconnect the
fuel line (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/QUICK CONNECT FITTING - STANDARD
PROCEDURE).
(9) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(10) Remove coil pack and bracket (Fig. 9).
(11) Disconnect the coil wires.(12) Disconnect heat indicator sending unit wire.
(13) Disconnect heater hoses and bypass hose.
(14) Remove upper intake manifold and throttle
body as an assembly (Refer to 9 - ENGINE/MANI-
FOLDS/INTAKE MANIFOLD - REMOVAL).
(15) Remove cylinder head covers and gaskets
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(16) Remove the EGR tube. Discard the gasket, for
right side only.
(17) Remove lower intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL). Discard the flange side gaskets and the
front and rear cross-over gaskets.
(18) Disconnect exhaust pipe from exhaust mani-
fold.
(19) Remove exhaust manifolds and gaskets (Refer
to 9 - ENGINE/MANIFOLDS/EXHAUST MANIFOLD
- REMOVAL).
(20) Remove rocker arm assemblies and push rods
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARM / ADJUSTER ASSY - REMOVAL). Identify to
ensure installation in original locations.
(21) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(22) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads. Be sure material does not fall into the lifters
and surrounding valley.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
Clean the exhaust manifold to cylinder head mat-
ing areas.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. The out-of-flatness
specifications are 0.0007 mm/mm (0.0004 inch/inch),
0.127 mm/152 mm (0.005 inch/6 inches) any direction
or 0.254 mm (0.010 inch) overall across head. If
exceeded, either replace head or lightly machine the
head surface.
The cylinder head surface finish should be
1.78-4.57 microns (15-80 microinches).
Inspect push rods. Replace worn or bent rods.
Inspect rocker arms. Replace if worn or scored.
INSTALLATION
(1) Position the new cylinder head gaskets onto
the cylinder block.
(2) Position the cylinder heads onto head gaskets
and cylinder block.
Fig. 8 Spark Plug Wire Heat Shields (Left Side
Shown)
1 - EXHAUST MANIFOLD
2 - HEAT SHIELD
Fig. 9 Coil Pack and Bracket
1 - COIL PACKS AND BRACKET
2 - MOUNTING BOLTS (4)
BR/BEENGINE 8.0L 9 - 77
CYLINDER HEAD (Continued)