DODGE RAM 2003 Service Repair Manual

²Idler sprocket assembly bushing and shaft for
excessive wear.
²Idler sprocket assembly spline joint. The joint
should be tight with no backlash or axial movement.
²Chain guides and tensioner arms. Replace these
parts if grooving in plastic face is more than 1 mm
(0.039 in.) deep. If plastic face is severely grooved or
melted, the tensioner lube jet may be clogged. The
tensioner should be replaced.
²secondary chain tensioner piston and ratcheting
device. Inspect for evidence of heavy contact between
tensioner piston and tensioner arm. If this condition
exist the tensioner and tensioner arm should be
replaced.
²Primary chain tensioner plastic faces. Replace as
required (Fig. 131).
INSTALLATION
(1) Using a vise, lightly compress the secondary
chain tensioner piston until the piston step is flushwith the tensioner body. Using a pin or suitable tool,
release ratchet pawl by pulling pawl back against
spring force through access hole on side of tensioner.
While continuing to hold pawl back, Push ratchet
device to approximately 2 mm from the tensioner
body. Install Special Tool 8514 lock pin into hole on
front of tensioner. Slowly open vise to transfer piston
spring force to lock pin (Fig. 132).
(2) Position primary chain tensioner over oil pump
and insert bolts into lower two holes on tensioner
bracket. Tighten bolts to 28 N´m (250 in. lbs.).
CAUTION: Overtightening the tensioner arm torxT
bolt can cause severe damage to the cylinder head.
Tighten torxTbolt to specified torque only.
(3) Install right side chain tensioner arm. Apply
MopartLock N, Seal to torxtbolt, tighten bolt to 17
N´m (150 in. lbs.).
Fig. 131 Timing Chain System
1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN
2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT
SIDE NOT COMMON)
3 - SECONDARY TENSIONER ARM
4 - LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN
5 - CHAIN GUIDE
6 - TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN7 - PRIMARY CHAIN
8 - IDLER SPROCKET
9 - CRANKSHAFT SPROCKET
10 - PRIMARY CHAIN TENSIONER
11 - TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN
12 - SECONDARY TENSIONER ARM
9 - 172 ENGINE - 4.7LDR
TIMING BELT/CHAIN AND SPROCKETS (Continued)

NOTE: The silver bolts retain the guides to the cyl-
inder heads and the black bolts retain the guides to
the engine block.
(4) Install the left side chain guide. Tighten the
bolts to 28 N´m (250 in. lbs.).
CAUTION: Overtightening the tensioner arm torxT
bolt can cause severe damage to the cylinder head.
Tighten torxTbolt to specified torque only.
(5) Install left side chain tensioner arm. Apply
MopartLock N, Seal to torxtbolt, tighten bolt to 17
N´m (150 in. lbs.).
(6) Install the right side chain guide. Tighten the
bolts to 28 N´m (250 in. lbs.).
(7) Install both secondary chains onto the idler
sprocket. Align two plated links on the secondary
chains to be visible through the two lower openings
on the idler sprocket (4 o'clock and 8 o'clock). Once
the secondary timing chains are installed, position
special tool 8515 to hold chains in place for installa-
tion (Fig. 133).
(8) Align primary chain double plated links with
the timing mark at 12 o'clock on the idler sprocket.
Align the primary chain single plated link with the
timing mark at 6 o'clock on the crankshaft sprocket
(Fig. 131).(9) Lubricate idler shaft and bushings with clean
engine oil.
(10) Install all chains, crankshaft sprocket, and
idler sprocket as an assembly (Fig. 134). After guid-
ing both secondary chains through the block and cyl-
inder head openings, affix chains with a elastic strap
or the equivalent, This will maintain tension on
chains to aid in installation.
NOTE: It will be necessary to slightly rotate cam-
shafts for sprocket installation.
(11) Align left camshaft sprocket ªLº dot to plated
link on chain.
(12) Align right camshaft sprocket ªRº dot to
plated link on chain.
CAUTION: Remove excess oil from the camshaft
sprocket bolt. Failure to do so can result in over-
torque of bolt resulting in bolt failure.
(13) Remove Special Tool 8515, then attach both
sprockets to camshafts. Remove excess oil from bolts,
then Install sprocket bolts, but do not tighten at this
time.
(14) Verify that all plated links are aligned with
the marks on all sprockets and the ªV8º marks on
camshaft sprockets are at the 12 o'clock position (Fig.
131).
Fig. 132 Resetting Secondary Chain Tensioners
1 - VISE
2 - INSERT LOCK PIN
3 - RATCHET PAWL
4 - RATCHET
5 - PISTON
Fig. 133 Installing Secondary Timing Chains on
Idler Sprocket
1 - LOCK ARM
2 - RIGHT CAMSHAFT CHAIN
3 - SECONDARY CHAINS RETAINING PINS (4)
4 - IDLER SPROCKET
5 - LEFT CAMSHAFT CHAIN
6 - SPECIAL TOOL 8515
DRENGINE - 4.7L 9 - 173
TIMING BELT/CHAIN AND SPROCKETS (Continued)

CAUTION: Ensure the plate between the left sec-
ondary chain tensioner and block is correctly
installed.
(15) Install both secondary chain tensioners.
Tighten bolts to 28 N´m (250 in. lbs.).
NOTE: Left and right secondary chain tensioners
are not common.
(16) Before installing idler sprocket bolt, lubricate
washer with oil, and tighten idler sprocket assembly
retaining bolt to 34 N´m (25 ft. lbs.).
(17) Remove all locking pins (3) from tensioners.
CAUTION: After pulling locking pins out of each
tensioner, DO NOT manually extend the tensioner(s)
ratchet. Doing so will over tension the chains,
resulting in noise and/or high timing chain loads.
(18) Using Special Tool 6958, Spanner with Adap-
tor Pins 8346, tighten left (Fig. 135) and right (Fig.
136). camshaft sprocket bolts to 122 N´m (90 ft. lbs.).
(19) Rotate engine two full revolutions. Verify tim-
ing marks are at the follow locations:
²primary chain idler sprocket dot is at 12 o'clock
(Fig. 131)
²primary chain crankshaft sprocket dot is at 6
o'clock (Fig. 131)
²secondary chain camshaft sprockets ªV8º marks
are at 12 o'clock (Fig. 131)
(20) Lubricate all three chains with engine oil.(21) After installing all chains, it is recommended
that the idler gear end play be checked (Fig. 137).
The end play must be within 0.10±0.25 mm (0.004±
0.010 in.). If not within specification, the idler gear
must be replaced.
(22) Install timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION) and crankshaft
damper (Refer to 9 - ENGINE/ENGINE BLOCK/VI-
BRATION DAMPER - INSTALLATION).
(23) Install cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
NOTE: Before installing threaded plug in right cylin-
der head, the plug must be coated with sealant to
prevent leaks.
(24) Coat the large threaded access plug with
MopartThread Sealant with Teflon, then install
into the right cylinder head and tighten to 81 N´m
(60 ft. lbs.) (Fig. 126).
Fig. 134 Installing Idler Gear, Primary and
Secondary Timing Chains
1 - SPECIAL TOOL 8429
2 - PRIMARY CHAIN IDLER SPROCKET
3 - CRANKSHAFT SPROCKET
Fig. 135 Tightening Left Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
2 - CAMSHAFT SPROCKET
3 - LEFT CYLINDER HEAD
4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
9 - 174 ENGINE - 4.7LDR
TIMING BELT/CHAIN AND SPROCKETS (Continued)

(25) Install the oil fill housing.
(26) Install access plug in left cylinder head (Fig.
126).
(27) Install power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(28) Install radiator fan shroud.(29) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(30) Connect negative cable to battery.
IDLER SHAFT
REMOVAL
(1) Remove the primary and secondary timing
chains and sprockets (Refer to 9 - ENGINE/VALVE
TIMING/TIMING BELT/CHAIN AND SPROCKETS -
REMOVAL) .
NOTE: To remove the idler shaft, it is necessary to
tap threads into the shaft, to install the removal
tool.
(2) Using a 12 mm X 1.75 tap, cut threads in the
idler shaft center bore.
(3) Cover the radiator core with a suitable cover.
CAUTION: Use care when removing the idler shaft,
Do not strike the radiator cooling fins with the slide
hammer.
(4) Using Special Tool 8517 Slide Hammer, remove
the idler shaft.
INSTALLATION
(1) Thoroughly clean the idler shaft bore.
(2) Position the idler shaft in the bore.
NOTE: The two lubrication holes in the idler shaft
do not require any special alignment.
NOTE: Before using the retaining bolt to install the
idler shaft, coat the threads and the pilot on the
idler shaft, with clean engine oil.
(3) Using the primary idler sprocket retaining bolt
and washer, carefully draw the idler shaft into the
bore until fully seated.
(4) Coat the idler shaft with clean engine oil.
(5) Install the timing chains and sprockets (Refer
to 9 - ENGINE/VALVE TIMING/TIMING BELT/
CHAIN AND SPROCKETS - INSTALLATION).
Fig. 136 Tightening Right Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
4 - RIGHT CAMSHAFT SPROCKET
Fig. 137 Measuring Idler Gear End Play
1 - IDLER SPROCKET ASSEMBLY
2 - DIAL INDICATOR
DRENGINE - 4.7L 9 - 175
TIMING BELT/CHAIN AND SPROCKETS (Continued)

ENGINE - 5.7L
TABLE OF CONTENTS
page page
ENGINE - 5.7L
DESCRIPTION........................178
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION..........178
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE..........179
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL............181
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE............182
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.....182
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - LUBRICATION............183
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL............184
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS........186
STANDARD PROCEDUREÐHYDROSTATIC
LOCK..............................186
REMOVAL............................186
INSTALLATION........................187
SPECIFICATIONS
5.7L ENGINE........................188
TORQUE...........................191
SPECIAL TOOLS
5.7L ENGINE........................192
AIR INTAKE SYSTEM
REMOVAL............................194
INSTALLATION........................194
CYLINDER HEAD
OPERATIONÐCYLINDER HEAD...........194
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE....................194
REMOVAL............................195
CLEANING...........................195
INSPECTION.........................195
INSTALLATION........................195
CYLINDER HEAD COVER(S)
REMOVAL............................196
INSTALLATION........................196
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION
DESCRIPTION - VALVE GUIDES.........197
DESCRIPTION.......................197
STANDARD PROCEDURE - REFACING.....197
REMOVAL............................198INSTALLATION........................198
ROCKER ARM / ADJUSTER ASSY
REMOVAL............................198
INSTALLATION........................198
VALVE STEM SEALS
DESCRIPTION........................198
VALVE SPRINGS
REMOVAL............................199
INSTALLATION........................199
ENGINE BLOCK
CLEANING...........................200
INSPECTION.........................200
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVAL - CAMSHAFT CORE HOLE PLUG. 200
REMOVAL - CAMSHAFT...............200
INSPECTION.........................201
INSTALLATION
INSTALLATION - CAMSHAFT CORE HOLE
PLUG..............................201
INSTALLATION - CAMSHAFT............201
CRANKSHAFT
REMOVAL............................201
INSTALLATION........................202
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - CRANKSHAFT
MAIN BEARING - FITTING..............202
INSPECTION.........................203
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................203
INSTALLATION........................203
CRANKSHAFT OIL SEAL - REAR
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS........................204
REMOVAL............................204
INSTALLATION........................204
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................204
INSTALLATION........................205
FLEX PLATE
REMOVAL............................205
INSTALLATION........................205
PISTON & CONNECTING ROD
DESCRIPTION........................205
STANDARD PROCEDUREÐPISTON FITTING . 205
REMOVAL............................205
CLEANING...........................206
INSPECTION.........................206
INSTALLATION........................207
9 - 176 ENGINE - 5.7LDR

PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................207
VIBRATION DAMPER
REMOVAL............................209
INSTALLATION........................209
STRUCTURAL COVER
DESCRIPTION........................210
OPERATION..........................210
REMOVAL............................210
INSTALLATION........................210
FRONT MOUNT
REMOVAL............................211
INSTALLATION........................211
REAR MOUNT
REMOVAL............................213
INSTALLATION........................213
LUBRICATION
DESCRIPTION........................214
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE...............214
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK..............................214
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE...........................215
OIL FILTER
REMOVAL............................216
INSTALLATION........................217
OIL PAN
REMOVAL............................217INSTALLATION........................217
OIL PUMP
REMOVAL............................218
CLEANING...........................218
INSPECTION.........................218
INSTALLATION........................219
INTAKE MANIFOLD
DESCRIPTION........................219
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE.................219
REMOVAL............................219
CLEANING...........................219
INSPECTION.........................219
INSTALLATION........................219
EXHAUST MANIFOLD
DESCRIPTION........................220
OPERATION..........................220
REMOVAL............................220
CLEANING...........................220
INSPECTION.........................220
INSTALLATION........................220
TIMING/CHAIN COVER
REMOVAL............................220
INSTALLATION........................221
TIMING/CHAIN AND SPROCKETS
REMOVAL............................221
INSTALLATION........................222
TIMING CHAIN/TENSIONER
DESCRIPTION........................222
OPERATION..........................222
DRENGINE - 5.7L 9 - 177

ENGINE - 5.7L
DESCRIPTION
The 5.7L engine (Fig. 1)(345 CID) eight-cylinder
engine is a 90É V-Type lightweight, deep skirt cast
iron block, aluminum heads, single cam, overhead
valve engine with hydraulic roller tappets. The heads
incorporate splayed valves with a hemispherical style
combustion chamber and dual spark plugs. The cyl-
inders are numbered from front to rear; 1, 3, 5, 7 on
the left bank and 2, 4, 6, 8 on the right bank. The
firing order is 1-8-4-3-6-5-7-2.
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 per-
formance (e.g., engine idles rough and stalls) or
mechanical (e.g., a strange noise).
Fig. 1 5.7L ENGINE
9 - 178 ENGINE - 5.7LDR

(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING)ÐPERFORMANCE and (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)ÐMECHANICAL for
possible causes and corrections of malfunctions.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
DIAGNOSIS AND TESTING) and (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION - DIAGNOSIS
AND TESTING) for the 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 diagnosis:²Cylinder Compression Pressure Test (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING).
²Cylinder Combustion Pressure Leakage Test
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING).
²Engine Cylinder Head Gasket Failure Diagnosis
(Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNO-
SIS AND TESTING).
²Intake Manifold Leakage Diagnosis (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING).
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary.
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to the terminals.
3. Faulty starter. 3. (Refer to 8 - ELECTRICAL/
STARTING - DIAGNOSIS AND
TESTING).
4. Faulty coil or control unit. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
5. Incorrect spark plug gap. 5. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING).
6. Dirt or water in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump, relay or wiring. 7. Repair or replace as necessary.
ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low. 1. (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/IDLE AIR
CONTROL MOTOR - REMOVAL).
2. Idle mixture too lean or too rich. 2. Refer to Powertrain Diagnosis
Information.
3. Vacuum leak. 3. Inspect intake manifold and
vacuum hoses, repair or replace as
necessary.
4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
5. Incorrect engine timing. 5. (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD
PROCEDURE).
DRENGINE - 5.7L 9 - 179
ENGINE - 5.7L (Continued)

CONDITION POSSIBLE CAUSE CORRECTION
1. ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped spark
plugs.1. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING).
2. Dirt or water in fuel system. 2. Clean system and replace fuel
filter.
3. Faulty fuel pump. 3. (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL PUMP -
DIAGNOSIS AND TESTING).
4. Blown cylinder head gasket. 4. Replace cylinder head gasket.
5. Low compression. 5. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING).
6. Burned, warped or pitted valves. 6. Replace as necessary.
7. Plugged or restricted exhaust
system.7. Inspect and replace as
necessary.
8. Faulty coil. 8. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
1. ENGINE MISSES ON
ACCELERATION1. Spark plugs dirty or incorrectly
gapped.1. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING).
2. Dirt in fuel system. 2. Clean fuel system.
3. Burned, warped or pitted valves. 3. Replcae as necessary.
4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
1. ENGINE MISSES AT HIGH
SPEED1. Spark plugs dirty or incorrectly
gapped.1. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING).
2. Faulty coil. 2. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
3. Dirt or water in fuel system. 3. Clean system and replace fuel
filter.
9 - 180 ENGINE - 5.7LDR
ENGINE - 5.7L (Continued)

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTIONS
NOISY VALVES 1. High or low oil level in
crankcase.1. (Refer to LUBRICATION &
MAINTENANCE -
SPECIFICATIONS)
2. Thin or diluted oil. 2. Change oil and filter.
3. Low oil pressure. 3. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
4. Dirt in lash adjusters. 4. Replace as necessary.
5. Worn rocker arms. 5. Replace as necessary.
6. Worn lash adjusters 6. Replace as necessary.
7. Worn valve guides. 7. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE)
8. Excessive runout of valve seats
on valve faces.8. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE)
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
MAINTENANCE -
SPECIFICATIONS)
2. Low oil pressure. 2. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
3. Thin or diluted oil. 3. Change oil and filter.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Connecting rod journal
out-of-round.5. Service or replace crankshaft.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
MAINTENANCE -
SPECIFICATIONS)
2. Low oil pressure. 2. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
3. Thin or diluted oil. 3. Change oil and filter.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Excessive end play. 5. Check thrust washers for wear.
6. Crankshaft journal out-of round. 6. Service or replace crankshaft.
7. Loose flywheel or torque
converter.7. Tighten to correct torque
DRENGINE - 5.7L 9 - 181
ENGINE - 5.7L (Continued)