Oil pump DODGE RAM 2003 Service Repair Manual

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)

(3) Lower engine with support/lifting fixture while
guiding the engine bracket/cushion and thru-bolt into
support cushion brackets.
(4) Install thru-bolt nuts and tighten the nuts to
68 N´m (50 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Remove lifting fixture.
REAR MOUNT
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Position a transmission jack in place.
(3) Remove support cushion stud nuts (Fig. 47).
(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
A pressure feed type (gerotor) oil pump is located
in the engine front cover. The pump uses a pick-up
tube and screen assembly to gather engine oil from
the oil pan (Fig. 48).
OPERATION
The pump draws oil through the screen and inlet
tube from the sump at the rear of the oil pan. The oil
is driven between the inner and outer gears of the oil
pump, then forced through the outlet in the engine
front cover. An oil gallery in the front cover channels
the oil to the inlet side of the full flow oil filter. After
passing through the filter element, the oil passes
Fig. 47 Engine Rear Support Cushion Asse
DRENGINE 8.0L 9 - 393
FRONT MOUNT (Continued)

from the center outlet of the filter through an oil gal-
lery that channels the oil up to the tappet galleries,
which extends the entire length of block.
Galleries extend downward from the main oil gal-
lery to the upper shell of each main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Each connecting rod bearing has half a hole in it, oil
passes through the hole when the rods rotate and the
hole lines up, oil is then thrown off as the rod
rotates. This oil throwoff lubricates the camshaft
lobes, cylinder walls, and piston pins.
The hydraulic valve tappets receive oil directly
from the main oil gallery. The camshaft bearings
receive oil from the main bearing galleries. The front
camshaft bearing journal passes oil through the cam-
shaft sprocket to the timing chain. Oil drains back to
the oil pan under the No. 1 main bearing cap.
The oil supply for the rocker arms and bridged
pivot assemblies is provided by the hydraulic valve
tappets, which pass oil through hollow push rods to a
hole in the corresponding rocker arm. Oil from the
rocker arm lubricates the valve train components.
The oil then passes down through the push rod guide
holes and the oil drain-back passages in the cylinder
head, past the valve tappet area, and then returns to
the oil pan (Fig. 49).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE OIL
LEAKS
Begin with a through visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil-soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
be sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light source.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24km (15 miles), and
repeat previous step.
(5) If the oil leak source is not positively identified
at this time, proceed with the air leak detection test
method as follows:
(6) Disconnect the breather cap to air cleaner hose
at the breather cap end. Cap or plug breather cap
nipple.
(7) Remove the PCV valve from the cylinder head
cover. Cap or plug the PCV valve grommet.
(8) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(9) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provide the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
(10) If the leakage occurs at the rear oil seal area,
refer to the section, Inspection for Rear Seal Area
Leak.
(11) If no leaks are detected, turn off the air sup-
ply and remove the air hose and all plugs and caps.
Install the PCV valve and breather cap hose. Proceed
to next step.
(12) Clean the oil off the suspect oil leak area
using a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
Fig. 48 Pressure Feed Type (Gerotor) Oil PumpÐ
Typical
1 - OUTER ROTOR
2 - INNER ROTOR
3 - OIL PUMP COVER
4 - TIMING CHAIN COVER
9 - 394 ENGINE 8.0LDR
LUBRICATION (Continued)

DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE
(1) Remove oil pressure sending unit.
(2) Install Oil Pressure Line and Gauge Tool
C-3292. Start engine and record pressure. (Refer to 9
- ENGINE - SPECIFICATIONS).
OIL
STANDARD PROCEDURE - ENGINE OIL
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the right
front of the engine, left of the generator (Fig. 50).
CRANKCASE OIL LEVEL INSPECTION
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 levels are indicated between the ADD
and SAFE marks on the engine oil dipstick.
(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)
Install 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 ADD mark on
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. This infor-
mation can be found in the owner's manual.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist vehicle.
(3) Remove oil fill cap.
(4)
Place a suitable drain pan under crankcase drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Install drain plug in crankcase.
(7) Change oil filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL).
(8) Lower vehicle and fill crankcase with specified
type (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION) and amount of
engine oil (Refer to LUBRICATION & MAINTE-
NANCE - SPECIFICATIONS).
(9) Install oil fill cap.
(10) Start engine and inspect for leaks.
(11) Stop engine and inspect oil level.
1 - OIL TO MAIN OIL GALLERIES
2 - RELIEF VALVE
3 - OIL GALLERY FOR TAPPETS
4 - MAIN OIL GALLERY
5 - TAPPET OIL GALLERY
6 - HOLLOW PUSH ROD
7 - ROCKER ARM
8 - PLUG
9 - GASKET
10 - SPRING
11 - TIMING CHAIN COVER
12 - CAM BEARINGS
13 - HYDRAULIC TAPPET GALLERIES
14 - CAMSHAFT
15 - CRANKSHAFT16 - OIL PASSAGE TO CONNECTING ROD JOURNALS
17 - OIL PICKUP
18 - CONNECTING ROD JOURNALS
19 - CRANKSHAFT BEARINGS
20 - MAIN OIL GALLERY
21 - CRANKSHAFT
22 - OIL PICKUP TUBE
23 - CONNECT ROD JOURNALS
24 - CAMSHAFT BEARINGS
25 - TAPPET OIL GALLERY
26 - OIL FROM PICKUP TUBE
27 - CAMSHAFT
28 - TAPPET
29 - VALVE
30 - OIL PUMP RELIEF VALVE
Fig. 50 Oil Level Indicator Location
1 - CYLINDER HEAD COVER
2 - ENGINE OIL FILL CAP
3 - DIPSTICK
4 - ENGINE OIL FILTER
5 - FILTER BOSS
9 - 396 ENGINE 8.0LDR
LUBRICATION (Continued)

INSTALLATION
(1) Fabricate 4 alignment dowels from 5/16x11/2
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier
installation and removal with a screwdriver (Fig. 54).
(2) Install the dowels in the cylinder block at the
four corners.
(3) Apply small amount of MopartSilicone Rubber
Adhesive Sealant, or equivalent at the split lines.
The split lines are between the cylinder block, the
timing chain cover and the rear crankshaft seal
assembly (Fig. 53).After the sealant is applied
you have 3 minutes to install the gasket and oil
pan.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket. The engine may have to be slightly raised
on 2WD vehicles.
(6) Install the oil pan bolts (Fig. 55). Tighten the
bolts to as shown in Oil Pan Bolts Torque Chart.(7) Remove the dowels. Install the remaining 5/16
inch oil pan bolts. Torque these bolts as shown in Oil
Pan Bolts Torque Chart.
(8) Install the drain plug. Tighten drain plug to 34
N´m (25 ft. lbs.) torque.
(9) Install the engine to transmission strut.
(10) Lower vehicle.
(11) Connect the negative cable to the battery.
(12) Fill crankcase with oil to proper level.
(13) Start engine and check for leaks.
OIL PUMP
REMOVAL
(1) Remove the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(2) Remove the relief valve plug, gasket, spring
and valve (Fig. 56). Discard the gasket.
(3) Remove mounting screws and oil pump cover
(Fig. 57).
(4) Remove oil pump inner and outer rotors (Fig.
57).
(5) Inspect oil pump for wear (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - INSPEC-
TION).
CLEANING
Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
Fig. 54 Fabrication of Alignment Dowels
1 - 5/16º X 11¤2º BOLT
2 - DOWEL
3 - SLOT
Fig. 55 Oil Pan Bolt Location
1 - OIL PAN
2 - OIL FILTER
3 - STUD BOLTS
4 - DRAIN PLUG
Fig. 56 Oil Pressure Relief Valve
1 - TIMING CHAIN COVER
2 - OIL PUMP RELIEF VALVE
3 - SPRING
4 - GASKET
5 - PLUG
9 - 398 ENGINE 8.0LDR
OIL PAN (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)

Inspect oil pressure relief valve plunger for scoring
and free operation in its bore. Small marks may be
removed with 400-grit wet or dry sandpaper.
The relief valve spring has a free length of approx-
imately 49.5 mm (1.95 inches). The spring should
test between 100 and 109 N (22.5 and 24.5 pounds)
when compressed to 34 mm (1-11/32 inches). Replace
spring that fails to meet these specifications.
If oil pressure was low and pump is within specifi-
cations, inspect for worn engine bearings or other
reasons for oil pressure loss.
INSTALLATION
(1) Lubricate both oil pump rotors using petroleum
jelly or lubriplate and install in the timing chain
cover. Use new parts as required (Fig. 64).(2) Position the oil pump cover onto the timing
chain cover. Tighten cover screws to 14 N´m (125 in.
lbs.) torque.
(3) Make sure that inner ring moves freely after
cover is installed.
(4) Install the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(5) Squirt oil into relief valve hole until oil runs
out.
(6) Install the relief valve and spring.
Fig. 61 Measuring Outer Rotor Clearance in Cover
1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 62 Measuring Inner Rotor Clearance in Cover
1 - FEELER GAUGE
2 - OUTER ROTOR
3 - INNER ROTOR
Fig. 63 Measuring Clearance Over Rotors
1 - FEELER GAUGE
2 - STRAIGHT EDGE
Fig. 64 Priming Oil Pump.
1 - FILL WITH PETROLEUM JELLY OR LUBER PLATE
9 - 400 ENGINE 8.0LDR
OIL PUMP (Continued)

(7) Using a new pressure relief valve gasket,
install the relief valve plug. Tighten the plug to 20
N´m (15 ft. lbs.) torque.
(8) Install oil filter that has been filled with oil.
INTAKE MANIFOLD
DESCRIPTION
The aluminum intake manifold (Fig. 65) has two
plenum chambers an upper and lower which supply
air to five runners each. Passages across the longitu-
dinal center of the manifold feed air from the throttle
body to the plenum chambers.
DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.(3) If a change in RPMs occur, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove the generator brace and generator
(Fig. 66).
(5) Remove the A/C compressor brace (Fig. 66).
Remove the compressor and set aside.
(6) Remove the air cleaner cover and filter.
Remove the air cleaner housing (Fig. 67). Discard the
gasket.
(7) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel lines (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(9) Remove the coil assemblies with the ignition
wires.
(10) Disconnect the vacuum lines.
(11) Disconnect the heater hoses and bypass hose.
(12) Remove the closed crankcase ventilation and
evaporation control systems.
Fig. 65 Upper and Lower Intake ManifoldÐ8.0L
Engine
1 - UPPER INTAKE MANIFOLD
2 - THROTTLE BODY (MPI)
3 - LOWER INTAKE MANIFOLD
Fig. 66 Generator and A/C Compressor Braces
1 - GENERATOR
2 - INTAKE MANIFOLD TO GENERATOR BRACE
3 - A/C COMPRESSOR
4 - INTAKE MANIFOLD TO A/C COMPRESSOR BRACE
DRENGINE 8.0L 9 - 401
OIL PUMP (Continued)

REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise and support the vehicle.
(3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold..
(4) Lower the vehicle.
(5) Remove the exhaust heat shields (Fig. 73).
(6) Remove the dipstick bracket from the exhaust
manifold (right side only).
(7)
Remove bolts attaching manifold to cylinder head.
(8) Remove manifold from the cylinder head. Dis-
card the gasket.
CLEANING
Clean mating surfaces on cylinder head and mani-
fold. Wash with solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straight edge. Gasket surfaces must be flat
within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
(1) Using a new gasket position the engine
exhaust manifold onto the cylinder head. Install bolts
and stud bolts in the proper position. (Fig. 73)
Tighten the bolts to 22 N´m (16 ft. lbs.) torque.
(2) Install the dipstick bracket on to the exhaust
manifold (right side only).(3) Position washers and exhaust heat shields onto
the manifold stud bolts (Fig. 73). Be sure the tabs on
the heat shields are hooked over the top of the
exhaust gasket. Install the nuts and tighten to 20
N´m (175 in. lbs.) torque.
(4) Raise and support the vehicle.
(5) Assemble exhaust pipe to manifold.
(6) Lower the vehicle.
(7) Connect the negative cable to the battery.
(8) Start engine check for leaks.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).
(4) Remove fan and fan shroud (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(5) Unbolt A/C compressor and set on top of
engine.
(6) Remove generator, air pump, and bracket
assembly.
(7) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(8) Remove damper bolt and washer.
(9) Using Special Tool 1026 3-Jaw Puller remove
pulley/damper from the crankshaft. (Fig. 74)
(10)
Loosen oil pan bolts and remove the front oil
pan bolts that mount the pan to the timing chain cover.
(11) Remove the cover bolts.
(12) Remove timing chain cover and gasket using
extreme caution to avoid damaging oil pan gasket.
(13) Inspect surface of cover. Remove any burrs or
high spots.
INSTALLATION
(1) Be sure mating surfaces of timing chain cover
and cylinder block are clean and free from burrs.
(2) Lubricate the pump rotors using petroleum
jelly or lubriplate (Refer to 9 - ENGINE/LUBRICA-
TION/OIL PUMP - INSTALLATION).
(3) Using a new cover gasket, carefully install tim-
ing chain cover to avoid damaging oil pan gasket.
Use a small amount of MopartSilicone Rubber Adhe-
sive Sealant, or equivalent, at the joint between tim-
ing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.
(4) Tighten timing chain cover bolts to 47 N´m (35
ft. lbs.) torque. Tighten oil pan bolts to 24 N´m (215
in. lbs.) torque.
Fig. 73 8.0L Engine Exhaust ManifoldÐTypical
1 - EXHAUST MANIFOLD
2 - HEAT SHIELD
9 - 404 ENGINE 8.0LDR
EXHAUST MANIFOLD (Continued)

(5) Using Special Tool C-3688 Crankshaft Pulley/
Damper Installer Install pulley/vibration damper
(Fig. 75)
(6) Prime oil pump by squirting oil in the oil filter
mounting hole and filling the J-trap of the front tim-
ing cover. When oil is running out, install oil filter
that has been filled with oil.(7) Install water pump and housing assembly
using new o-ring (Refer to 7 - COOLING/ENGINE/
WATER PUMP - INSTALLATION).
(8) Install generator, air pump, and bracket assem-
bly.
(9) Install A/C compressor (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION).
(10) (10) Install the radiator fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(11) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(12) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(13) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect the negative cable to the battery.
(15) Road test vehicle and check for leaks.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Remove timing chain cover and gasket using
extreme caution to avoid damaging oil pan gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
(2) Aline camshaft and crankshaft centerline.
Remove camshaft sprocket attaching bolt and remove
timing chain and camshaft sprockets.
(3) Use puller 6444 and jaws 6820 to remove
crankshaft sprocket (Fig. 76).
INSPECTIONÐMEASURING TIMING CHAIN
STRETCH
(1) Place a scale next to the timing chain so that
any movement of the chain may 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 a 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. 77).
Fig. 74 PulleyÐDamper Removal
1-3JAWPULLER
Fig. 75 Installing Crankshaft
1 - SPECIAL TOOL C-3688
DRENGINE 8.0L 9 - 405
TIMING BELT / CHAIN COVER(S) (Continued)