tow DODGE RAM 2003 Service Repair Manual

(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 cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(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.
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.
Fig. 37 Piston and Connecting RodÐ8.0L Engine
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
9 - 388 ENGINE 8.0LDR
HYDRAULIC LIFTERS (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).
(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).(13) Install intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSTALLA-
TION).
(14) Install the engine into the vehicle (Refer to 9 -
ENGINE - INSTALLATION).
PISTON RINGS
STANDARD PROCEDUREÐFITTING 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).
Fig. 39 Proper Ring Installation
1 - TOP COMPRESSION RING GAP
UPPER OIL RING GAP
2 - 2ND COMPRESSION RING GAP
LOWER OIL RAIL GAP
3 - SPACER GAP
Fig. 40 Piston and Rod Orientation
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
9 - 390 ENGINE 8.0LDR
PISTON & CONNECTING ROD (Continued)

(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.
(3) Arrange ring gaps 180É apart as shown in (Fig.
44).
Fig. 41 Second Compression Ring IdentificationÐ
Typical
1 - SECOND COMPRESSION RING (BLACK CAST IRON)
2 - CHAMFER
3 - TWO DOTS
Fig. 42 Top Compression Ring IdentificationÐTypical
1 - TOP COMPRESSION RING (GRAY IN COLOR)
2 - CHAMFER
3 - ONE DOT
Fig. 43 Compression Ring Chamfer LocationÐTypical
1 - CHAMFER
2 - TOP COMPRESSION RING
3 - SECOND COMPRESSION RING
4 - PISTON
5 - CHAMFER
Fig. 44 Proper Ring Installation
1 - TOP COMPRESSION RING GAP UPPER OIL RING GAP
2 - 2ND COMPRESSION RING GAP LOWER OIL RAIL GAP
3 - SPACER GAP
DRENGINE 8.0L 9 - 391
PISTON RINGS (Continued)

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.
Measure thickness (Fig. 59) (Fig. 60) and diameter
of rotors. If either rotor thickness measures 14.956mm (0.5876 inch) or less, or if the diameter is 82.45
mm (3.246 inches) or less, replace rotor set.
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. 57 Oil Pump
1 - OUTER ROTOR
2 - INNER ROTOR
3 - OIL PUMP COVER
4 - TIMING CHAIN COVER
Fig. 58 Checking Oil Pump Cover Flatness
1 - FEELER GAUGE
2 - STRAIGHT EDGE
3 - OIL PUMP COVER
Fig. 59 Measuring Outer Rotor Thickness
Fig. 60 Measuring Inner Rotor Thickness
DRENGINE 8.0L 9 - 399
OIL PUMP (Continued)

(9) If the turbocharger is not to be installed imme-
diately, cover the opening to prevent material from
entering into the manifold.
(10) If replacing the turbocharger, transfer the
compressor outlet and clamp to the new assembly.
(11) Clean and inspect the sealing surface.
CAUTION: The turbocharger is only serviced as an
assembly. Do not attempt to repair the turbocharger
as turbocharger and/or engine damage can result.
CLEANING
Clean the turbocharger and exhaust manifold
mounting surfaces with a suitable scraper.
INSPECTION
Visually inspect the turbocharger and exhaust
manifold gasket surfaces. Replace stripped or eroded
mounting studs.
(1) Visually inspect the turbocharger for cracks.
The following cracks are NOT acceptable:
²Cracks in the turbine and compressor housing
that go completely through.
²Cracks in the mounting flange that are longer
than 15 mm (0.6 in.).
²Cracks in the mounting flange that intersect
bolt through-holes.
²Two (2) Cracks in the mounting flange that are
closer than 6.4 mm (0.25 in.) together.
(2) Visually inspect the impeller and compressor
wheel fins for nicks, cracks, or chips. Note: Some
impellers may have a factory placed paint mark
which, after normal operation, appears to be a crack.
Remove this mark with a suitable solvent to verify
that it is not a crack.
(3) Visually inspect the turbocharger compressor
housing for an impeller rubbing condition (Fig. 20).
Replace the turbocharger if the condition exists.
(4) Measure the turbocharger axial end play:
(a) Install a dial indicator as shown in (Fig. 21).
Zero the indicator at one end of travel.
(b) Move the impeller shaft fore and aft and
record the measurement. Allowable end play is
0.026 mm (0.0001 in.) MIN. and 0.127 mm (0.005
in.) MAX. If the recorded measurement falls out-
side these parameters, replace the turbocharger
assembly.
(5) Measure the turbocharger bearing radial clear-
ance:
(a) Insert a narrow blade or wire style feeler
gauge between the compressor wheel and the hous-
ing (Fig. 22).
(b) Gently push the compressor wheel toward
the housing and record the clearance.(c) With the feeler gauge in the same location,
gently push the compressor wheel away from the
housing and again record the clearance.
(d) Subtract the smaller clearance from the
larger clearance. This is the radial bearing clear-
ance.
(e) Allowable radial bearing clearance is 0.33
mm (0.013 in.) MIN. and 0.50 mm (0.020 in.) MAX.
If the recorded measurement falls outside these
specifications, replace the turbocharger assembly.
INSTALLATION
(1) Install the turbocharger. Apply anti-seize to the
studs and then tighten the turbocharger mounting
nuts to 43 N´m (32 ft. lbs.) torque.
(2) Install the oil drain tube to the turbocharger
(Fig. 19). Tighten the drain tube bolts to 24 N´m (18
ft. lbs.) torque.
Fig. 20 Inspect Compressor Housing for Impeller
Rubbing Condition
Fig. 21 Measure Turbocharger Axial End Play
11 - 14 EXHAUST SYSTEMDR
TURBOCHARGER (Continued)

FRAMES & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT AIR DAM
REMOVAL.............................2
INSTALLATION..........................2
FRONT BUMPER
REMOVAL.............................2
INSTALLATION..........................2
FRONT FASCIA
REMOVAL.............................3
INSTALLATION..........................3
REAR BUMPER
REMOVAL.............................4
INSTALLATION..........................4
FRAME
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY
FRONT FRAME RAIL TIP REPLACEMENT....4
STANDARD PROCEDURE - HYDROFORM
FENDER RAIL REPAIR.................12
STANDARD PROCEDURE - REAR FRAME
H-SECTION REPLACEMENT.............15SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS . . . 17
SPECIFICATIONS - TORQUE............23
FRONT CROSSMEMBER
REMOVAL.............................23
INSTALLATION.........................23
FRONT SKID PLATE
REMOVAL.............................24
INSTALLATION.........................24
TRANSMISSION CROSSMEMBER
REMOVAL.............................24
INSTALLATION.........................25
TRAILER HITCH
REMOVAL.............................25
INSTALLATION.........................25
TRANSFER CASE SKID PLATE
REMOVAL.............................26
INSTALLATION.........................26
FRONT TOW HOOK ASSEMBLY
REMOVAL.............................26
INSTALLATION.........................26
BUMPERS
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper center bracket nuts 95 70 Ð
Front bumper stud plate nuts 95 70 Ð
License plate hitch reinforcement bolts 54 40 Ð
Rear bumper support bracket stud plate nuts 54 40 Ð
Rear bumper support bracket to hitch bolts 54 40 Ð
Rear bumper to hitch bolts 54 40 Ð
DRFRAMES & BUMPERS 13 - 1

TRANSFER CASE SKID PLATE
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Support the skid plate and remove the bolts.
(Fig. 35)
(3) Remove the skid plate.
(4) Support the skid plate crossmember and
remove the bolts.
(5) Remove the skid plate crossmember.
INSTALLATION
(1) Install the skid plate crossmember and install
the bolts.
(2) Tighten the bolts to 34 N´m (25 ft. lbs.).
(3) Install the skid plate and install the bolts.
(4) Tighten the bolts to 34 N´m (25 ft. lbs.).
FRONT TOW HOOK ASSEMBLY
REMOVAL
(1) Remove front bumper. (Refer to 13 - FRAME &
BUMPERS/BUMPERS/FRONT BUMPER -
REMOVAL)
(2) Remove the bolts and remove the tow hook
assembly. (Fig. 36)
INSTALLATION
(1) Install the tow hook assembly and bolts hand
tight.
(2) Install the front bumper. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/FRONT BUMPER -
INSTALLATION)
(3) Tighten the tow hook bolts to 68 N´m (50 ft.
lbs.).
Fig. 35 TRANSFER CASE SKID PLATE
1 - CROSSMEMBER BOLTS (4)
2 - SKID PLATE CROSSMEMBER
3 - SKID PLATE
4 - SKID PLATE BOLTS (4)
Fig. 36 FRONT TOW HOOK ASSEMBLY
1 - BUMPER CENTER SUPPORT BRACKET
2 - BOLTS (6)
3 - TOW HOOK ASSEMBLY
13 - 26 FRAMES & BUMPERSDR

(2) Remove fuel pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(3) Start and run engine until it stalls.
(4) Attempt restarting engine until it will no
longer run.
(5) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unplug connector from any fuel injector.
(7) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.
(8) Connect other end of jumper wire to positive
side of battery.(9) Connect one end of a second jumper wire to
remaining injector terminal.
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentarily touch other end of jumper wire
to negative terminal of battery for no more than a
few seconds.
(11) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(12) Disconnect quick-connect fitting at fuel rail.
Refer to Quick-Connect Fittings.
(13) Return fuel pump relay to PDC.
(14) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRBtscan tool must be
used to erase a DTC.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
339 kPa +/- 34 kPa (49.2 psi +/- 2 psi).
TORQUE - FUEL SYSTEM
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Accelerator Pedal Bracket
Mounting12 - 105
Accelerator Pedal Position
Sensor Bracket-to-Battery
Tray Bolts3-30
Crankshaft Position
Sensor - 3.7L28 21 -
Crankshaft Position
Sensor - 4.7L28 21 -
Crankshaft Position
Sensor - 5.7L12 - 105 (+/-20)
Crankshaft Position
Sensor - 5.9L8-70
Crankshaft Position
Sensor - 8.0L8-70
Camshaft Position Sensor
- 3.7L12 - 106
Camshaft Position Sensor
- 4.7L12 - 106
Camshaft Position Sensor
- 5.7L12 9 105 (+/-) 20
Camshaft Position Sensor
- 8.0L6-50
DRFUEL DELIVERY - GAS 14 - 3
FUEL DELIVERY - GAS (Continued)

(8)Plastic Retainer Ring Type Fitting:This
type of fitting can be identified by the use of a full-
round plastic retainer ring (Fig. 11) usually black in
color.
(a) To release fuel system component from quick-
connect fitting, firmly push fitting towards compo-
nent being serviced while firmly pushing plastic
retainer ring into fitting (Fig. 11). With plastic ring
depressed, pull fitting from component.The plas-
tic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked
during removal, it may be difficult to discon-
nect fitting. Use an open-end wrench on
shoulder of plastic retainer ring to aid in dis-
connection.(b) After disconnection, plastic retainer ring will
remain with quick-connect fitting connector body.
(c) Inspect fitting connector body, plastic retainer
ring and fuel system component for damage.
Replace as necessary.
(9)Latch Clips:Depending on vehicle model and
engine, 2 different types of safety latch clips are used
Fig. 8 DISCONNECTING SINGLE-TAB TYPE FITTING
1 - PULL TAB
2 - SCREWDRIVER
3 - QUICK-CONNECT FITTING
Fig. 9 REMOVING PULL TAB
1 - FUEL TUBE OR FUEL SYSTEM COMPONENT
2 - PULL TAB
3 - QUICK-CONNECT FITTING
4 - FUEL TUBE STOP
Fig. 10 TYPICAL 2±TAB TYPE FITTING
1 - TAB(S)
2 - QUICK-CONNECT FITTING
Fig. 11 PLASTIC RETAINER RING TYPE FITTING
1 - FUEL TUBE
2 - QUICK CONNECT FITTING
3 - PUSH
4 - PLASTIC RETAINER
5 - PUSH
6 - PUSH
7 - PUSH
8 - PUSH
14 - 10 FUEL DELIVERY - GASDR
QUICK CONNECT FITTING (Continued)

(Fig. 12) or (Fig. 13). Type-1 is tethered to fuel line
and type-2 is not. A special tool will be necessary to
disconnect fuel line after latch clip is removed. The
latch clip may be used on certain fuel line/fuel rail
connection, or to join fuel lines together.
(a) Type 1: Pry up on latch clip with a screw-
driver (Fig. 12).
(b) Type 2: Separate and unlatch 2 small arms
on end of clip (Fig. 13) and swing away from fuel
line.(c) Slide latch clip toward fuel rail while lifting
with screwdriver.
(d) Insert special fuel line removal tool (Snap-On
number FIH 9055-1 or equivalent) into fuel line
(Fig. 14). Use tool to release locking fingers in end
of line.
(e) With special tool still inserted, pull fuel line
from fuel rail.
(f)
After disconnection, locking fingers will remain
within quick-connect fitting at end of fuel line.
(10) Disconnect quick-connect fitting from fuel sys-
tem component being serviced.
CONNECTING
(1) Inspect quick-connect fitting body and fuel sys-
tem component for damage. Replace as necessary.
(2) Prior to connecting quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
(3) Insert quick-connect fitting into fuel tube or
fuel system component until built-on stop on fuel
tube or component rests against back of fitting.
(4) Continue pushing until a click is felt.
(5) Single-tab type fitting: Push new tab down
until it locks into place in quick-connect fitting.
(6) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(7) Latch Clip Equipped: Install latch clip (snaps
into position).If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.
(8) Connect negative cable to battery.
(9) Start engine and check for leaks.
Fig. 12 LATCH CLIP-TYPE 1
1 - TETHER STRAP
2 - FUEL LINE
3 - SCREWDRIVER
4 - LATCH CLIP
5 - FUEL RAIL
Fig. 13 LATCH CLIP-TYPE 2
1 - LATCH CLIP
Fig. 14 FUEL LINE DISCONNECTION USING
SPECIAL TOOL
1 - SPECIAL FUEL LINE TOOL
2 - FUEL LINE
3 - FUEL RAIL
DRFUEL DELIVERY - GAS 14 - 11
QUICK CONNECT FITTING (Continued)