lubrication DODGE RAM 2003 Service Repair Manual

REAR MOUNT
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Position a transmission jack in place.
(3) Remove support cushion stud nuts (Fig. 110).
(4) Raise rear of transmission and engine
SLIGHTLY.
(5) Remove the bolts holding the support cushion
to the transmission support bracket. Remove the sup-
port cushion.
(6) If necessary, remove the bolts holding the
transmission support bracket to the transmission.
INSTALLATION
(1) If removed, position the transmission support
bracket to the transmission. Install new attaching
bolts and tighten to 102 N´m (75 ft. lbs.) torque.
(2) Position support cushion to transmission sup-
port bracket. Install stud nuts and tighten to 47 N´m
(35 ft. lbs.) torque.
(3) Using the transmission jack, lower the trans-
mission and support cushion onto the crossmember
(Fig. 110).
(4) Install the support cushion bolts and tighten to
47 N´m (35 ft. lbs.) torque.
(5) Remove the transmission jack.
(6) Lower the vehicle.
LUBRICATION
DESCRIPTION
NOTE: Refer to (Fig. 111) and (Fig. 112) for circuit
illustrations.
A gear driven gerotor type oil pump is mounted
behind the front gear cover in the lower right portion
on the engine.
OPERATION
A gerotor style oil pump draws oil from the crank-
case through the suction tube and delivers it through
the block where it enters the oil cooler cover and
pressure regulator valve. When oil pressure exceeds
517 kPa (75 PSI), the valve opens exposing the dump
port, which routes excess oil back to the oil pump.
At the same time, oil is directed to a cast in pas-
sage in the oil cooler cover, leading to the oil cooler
element. As the oil travels through the element
plates, it is cooled by engine coolant traveling past
the outside of the plates. It is then routed to the oil
filter head and through a full flow oil filter. If a
plugged filter is encountered, the filter by-pass valve
opens, allowing unfiltered oil to lubricate the engine.
This condition can be avoided by frequent oil and fil-
ter changes, per the maintenance schedules found in
Fig. 110 Engine Rear Support Cushion Assembly
DRENGINE 5.9L DIESEL 9 - 337

the owners manual. The by-pass valve is calibrated
to open when it sees a pressure drop of more than
345 kPa (50 psi) across the oil filter.
The oil filter head then divides the oil between the
engine and the turbocharger. The turbocharger
receives filtered, cooled and pressurized oil through a
supply line from the filter head. The oil lubricates
the turbocharger and returns to the pan by way of a
drain tube connecting the bottom of the turbocharger
to a pressed in tube in the cylinder block.
Oil is then carried across the block to an angle
drilling which intersects the main oil rifle. The main
oil rifle runs the length of the block and delivers oil
to the crankshaft main journals and valve train. Oil
travels to the crankshaft through a series of transfer
drillings (one for each main bearing) and lubricates a
groove in the main bearing upper shell. From there
another drilling feeds the camshaft main journals.
The saddle jet piston cooling nozzles are also sup-
plied by the main bearing upper shell. J-jet piston
cooling nozzles are supplied by a separate oil rifle.
Plugs are used in place of saddle jets when J-jets are
used. J-jet hole locations are plugged when saddle jet
cooling nozzles are used. Crankshaft internal cross-
drillings supply oil to the connecting rod journals.
Another series of transfer drillings intersecting the
main oil rifle supply the valve train components. Oil
travels up the drilling, through a hole in the head
gasket, and through a drilling in the cylinder head
(one per cylinder), where it enters the rocker arm
pedestal and is divided between the intake and
exhaust rocker arm. Oil travels up and around therocker arm mounting bolt, and lubricates the rocker
shaft by cross drillings that intersect the mounting
bolt hole. Grooves at both ends of the rocker shaft
supply oil through the rocker arm where the oil trav-
els to the push rod and socket balls (Fig. 111) and
(Fig. 112).
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE
(1) Remove the 1/8 npt plug from the top of the oil
filter housing.
(2) Install Oil Pressure Line and Gauge Tool
C-3292 with a suitable adapter.
(3) Start engine and warm to operating tempera-
ture.
(4) Record engine oil pressure and compare with
engine oil pressure chart.
CAUTION: If engine oil pressure is zero at idle, DO
NOT RUN THE ENGINE.
Engine Oil Pressure (MIN)
At Idle 68.9 kPa (10 psi)
At 2500 rpm 206.9 kPa (30 psi)
If minimum engine oil pressure is below these
ranges, (Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
(5) Remove oil pressure gauge and install the 1/8
npt plug.
9 - 338 ENGINE 5.9L DIESELDR
LUBRICATION (Continued)

Fig. 111 Lubrication System Circulation
1 - TO FILTER
2 - FROM FILTER
3 - TO MAIN OIL RIFLE
4 - CLOSED
5 - OPEN
6 - TO COOLER7 - FROM PUMP
8 - CLOSED
9 - OPEN
10 - OIL DRAINS BACK TO THE PUMP
11 - OIL DRAIN
12 - OIL SUPPLY
DRENGINE 5.9L DIESEL 9 - 339
LUBRICATION (Continued)

Fig. 112 Lubrication System CirculationÐCont'd
9 - 340 ENGINE 5.9L DIESELDR
LUBRICATION (Continued)

OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL LEVEL
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
To ensure proper lubrication of an engine, the
engine oil must be maintained at an acceptable level.
The acceptable oil level is in the SAFE RANGE on
the engine oil dipstick (Fig. 113).
Unless the engine has exhibited loss of oil pres-
sure, run the engine for about five minutes before
checking oil level. Checking engine oil level of a cold
engine is not accurate.
(1) Position vehicle on level surface.
(2) With engine OFF, allow approximately ten min-
utes for oil to settle to bottom of crankcase, remove
engine oil dipstick.
(3) Wipe dipstick clean.
(4) Replace dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the SAFE RANGE
area on the dipstick.
(7) Replace dipstick
STANDARD PROCEDURE - ENGINE OIL
SERVICE
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
NOTE: Change engine oil and filter at intervals
specified in the owner's manual.
(1) Operate the engine until the water tempera-
ture reaches 60ÉC (140ÉF). Shut the engine off.
(2) Use a container that can hold at least 14 liters
(15 quarts) to hold the used oil. Remove the oil drain
plug and drain the used engine oil into the container.
(3) Always check the condition of the used oil. This
can give you an indication of engine problems that
might exist.
²Thin, black oil indicates fuel dilution.
²Milky discoloration indicates coolant dilution.
(4) Clean the area around the oil filter head.
Remove the filter (Refer to 9 - ENGINE/LUBRICA-
TION/OIL FILTER - REMOVAL).
(5) Install new oil filter (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION).
(6) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and seal-
ing surface on the oil pan and drain plug.
(7) Install the drain plug. Tighten the plug to 50
N´m (37 ft. lbs.) torque.
(8) Use only High-Quality Multi-Viscosity lubricat-
ing oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(9) Fill the engine with the correct grade of new oil
(Refer to LUBRICATION & MAINTENANCE/FLUID
CAPACITIES - SPECIFICATIONS).
(10) Start the engine and operate it at idle for sev-
eral minutes. Check for leaks at the filter and drain
plug.
(11) Stop engine. Wait several minutes to allow the
oil to drain back to the pan and check the level
again.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing of used
engine oil after it has been drained from a vehicle's
engine.
1 - ROCKER ARM
2 - ROCKER SHAFT
3 - PEDESTAL
4 - FROM MAIN OIL RIFLE
5 - TO VALVE TRAIN
6 - MAIN OIL RIFLE
7 - FROM MAIN OIL RIFLE8 - TO CAMSHAFT
9 - TO PISTON COOLING NOZZLE
10 - FROM OIL COOLER
11 - CRANKSHAFT MAIN JOURNAL
12 - ROD JOURNAL
13 - TO ROD BEARING
14 - MAIN OIL RIFLE
Fig. 113 Oil Level Indicator (Dipstick)
1 - ADD OIL MARK
2 - O-RING
3 - SAFE RANGE
DRENGINE 5.9L DIESEL 9 - 341
OIL (Continued)

ENGINE 8.0L
TABLE OF CONTENTS
page page
ENGINE 8.0L
DESCRIPTION........................353
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION..........353
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - PERFORMANCE..........354
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL............356
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - LUBRICATION............358
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE............359
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.....359
STANDARD PROCEDURE
STANDARD PROCEDUREÐCYLINDER
BORE HONING......................360
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS........360
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS........361
STANDARD PROCEDUREÐHYDROSTATIC
LOCK..............................361
REMOVAL............................361
INSTALLATION........................362
SPECIFICATIONS
TORQUE...........................363
8.OL ENGINE.......................364
SPECIAL TOOLS
8.0L ENGINE........................367
AIR CLEANER ELEMENT
REMOVAL............................370
INSTALLATION........................370
CYLINDER HEAD
DESCRIPTION........................370
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE....................370
REMOVAL............................371
CLEANING...........................372
INSPECTION.........................372
INSTALLATION........................372
CYLINDER HEAD COVER(S)
DESCRIPTION........................373
REMOVAL............................373
CLEANING...........................374
INSPECTION.........................374
INSTALLATION........................374INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................375
STANDARD PROCEDURE
VALVE SERVICE.....................375
REMOVAL
REMOVALÐVALVE STEM SEALS........377
REMOVALÐVALVES AND VALVE SPRINGS . 377
CLEANING...........................378
INSPECTION.........................378
INSTALLATION
INSTALLATIONÐVALVE STEM SEAL......378
INSTALLATIONÐVALVES AND VALVE
SPRINGS...........................379
ROCKER ARM / ADJUSTER ASSY
REMOVAL............................379
INSTALLATION........................379
ENGINE BLOCK
CLEANING...........................380
INSPECTION.........................380
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS......380
REMOVALÐCAMSHAFT...............380
INSTALLATION
INSTALLATIONÐCAMSHAFT BEARINGS . . 381
INSTALLATIONÐCAMSHAFT............381
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING...............382
CRANKSHAFT
REMOVAL............................382
INSTALLATION........................383
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDUREÐFITTING
CRANKSHAFT MAIN BEARINGS.........383
REMOVAL............................383
INSTALLATION........................383
CRANKSHAFT OIL SEAL - FRONT
REMOVAL
REMOVALÐFRONT OIL SEAL - FRONT
COVER INSTALLED...................384
REMOVALÐFRONT OIL SEAL - FRONT
COVER REMOVED...................384
INSTALLATION
INSTALLATIONÐFRONT OIL SEAL ± FRONT
COVER INSTALLED...................384
INSTALLATIONÐFRONT OIL SEAL - FRONT
COVER REMOVED...................384
DRENGINE 8.0L 9 - 351

CRANKSHAFT OIL SEAL - REAR
REMOVAL............................385
INSTALLATION........................385
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................386
INSTALLATION........................386
HYDRAULIC LIFTERS
DIAGNOSIS AND TESTINGÐHYDRAULIC
TAPPETS...........................386
REMOVAL............................387
CLEANING...........................388
INSTALLATION........................388
PISTON & CONNECTING ROD
DESCRIPTION........................388
STANDARD PROCEDUREÐPISTON FITTING . 389
REMOVAL............................389
CLEANING...........................389
INSPECTION.........................389
INSTALLATION........................389
PISTON RINGS
STANDARD PROCEDUREÐFITTING PISTON
RINGS.............................390
VIBRATION DAMPER
REMOVAL............................392
INSTALLATION........................392
FRONT MOUNT
REMOVAL............................392
INSTALLATION........................392
REAR MOUNT
REMOVAL............................393
INSTALLATION........................393
LUBRICATION
DESCRIPTION........................393
OPERATION..........................393
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE OIL
LEAKS.............................394
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE.........................396OIL
STANDARD PROCEDURE - ENGINE OIL....396
OIL FILTER
REMOVAL............................397
INSTALLATION........................397
OIL PAN
REMOVAL............................397
CLEANING...........................397
INSPECTION.........................397
INSTALLATION........................398
OIL PUMP
REMOVAL............................398
CLEANING...........................398
INSPECTION.........................399
INSTALLATION........................400
INTAKE MANIFOLD
DESCRIPTION........................401
DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE.................401
REMOVAL............................401
CLEANING...........................402
INSPECTION.........................402
INSTALLATION........................402
EXHAUST MANIFOLD
DESCRIPTION........................403
OPERATION..........................403
REMOVAL............................404
CLEANING...........................404
INSPECTION.........................404
INSTALLATION........................404
TIMING BELT / CHAIN COVER(S)
REMOVAL............................404
INSTALLATION........................404
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL............................405
INSPECTIONÐMEASURING TIMING CHAIN
STRETCH..........................405
INSTALLATION........................406
9 - 352 ENGINE 8.0LDR

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
DRENGINE 8.0L 9 - 353

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
NOISE1. 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 round 5. Replace crankshaft or grind journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING 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)
3. Thin or diluted oil 3. Change oil to correct viscosity.
9 - 356 ENGINE 8.0LDR
ENGINE 8.0L (Continued)

DIAGNOSIS AND TESTINGÐENGINE DIAGNOSIS - LUBRICATION
CONDITION POSSIBLE CAUSES CORRECTION
OIL LEAKS 1. Gaskets and O-Rings. 1.
(a) Misaligned or damaged. (a) Replace as necessary.
(b) Loose fasteners, broken or
porous metal parts.(b) Tighten fasteners, Repair or
replace metal parts.
2. Crankshaft rear seal 2. Replace as necessary.
3. Crankshaft seal flange.
Scratched, nicked or grooved.3. Polish or replace crankshaft.
4. Oil pan flange cracked. 4. Replace oil pan.
5.Front cover seal, damaged or
misaligned.5. Replace seal.
6. Scratched or damaged vibration
damper hub.6. Polish or replace damper.
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.
2. Faulty oil pressure sending unit. 2. Replace sending unit.
3. Low oil pressure. 3. Check pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter.
5. Worn oil pump. 5. Replace as necessary.
6. Thin or diluted oil. 6. Change oil and filter.
7. Excessive bearing clearance. 7. Replace as necessary.
8. Oil pump relief valve stuck. 8. Replace oil pump.
9. Oil pickup tube loose or
damaged.9. Replace as necessary.
OIL PUMPING AT RINGS; SPARK
PLUGS FOULING1. Worn or damaged rings. 1. Hone cylinder bores and replace
rings.
2. Carbon in oil ring slots. 2. Replace rings.
3. Incorrect ring size installed. 3. Replace rings.
4. Worn valve guides. 4. Ream guides and replace valves.
5. Leaking intake gasket. 5. Replace intake gaskets.
6. Leaking valve guide seals. 6. Replace valve guide seals.
9 - 358 ENGINE 8.0LDR
ENGINE 8.0L (Continued)