torque DODGE RAM 2003 Service Repair Manual

(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
TORQUE
TORQUE CHART 8.0L ENGINE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft SprocketÐBolt 75 55 Ð
Camshaft Thrust PlateÐ
Bolts22 16 Ð
Coil Pack BracketÐBolts 21 Ð 190
Connecting Rod CapÐBolts 61 45 Ð
Main BearingÐBolts
Step 1 27 20 Ð
Step 2 115 85 Ð
Crankshaft Pulley/DamperÐ
Bolt312 230 Ð
Crankshaft Rear Seal
RetainerÐ22 16 Ð
Bolts
Cylinder HeadÐBolts
Step 1 58 43 Ð
Step 2 143 105 Ð
Cylinder Head CoverÐBolts 16 Ð 144
Drive Plate to CrankshaftÐ
Bolts75 55 Ð
Drive Plate to Torque
ConverterÐ47 35 Ð
Bolts
EGR TubeÐNut 34 25 Ð
EGR ValveÐBolts 20 Ð 174
Engine Support Bracket/
InsulatorÐ68 50 Ð
Through Bolt
Engine Support Bracket/
Insulator to47 35 Ð
BlockÐBolts
Exhaust Manifold to Cylinder
HeadÐ22 16 Ð
Bolt
Generator MountingÐBolt 41 30 Ð
Generator to Intake Manifold
Bracket41 30 Ð
ÐBolts
DRENGINE 8.0L 9 - 363
ENGINE 8.0L (Continued)

AIR CLEANER ELEMENT
REMOVAL
Filter Element Only
Housing removal is not necessary for element (fil-
ter) replacement.
(1) Loosen clamp (Fig. 4) and disconnect air duct
at air cleaner cover.
(2) Pry over 4 spring clips (Fig. 4) from housing
cover (spring clips retain cover to housing).
(3) Release housing cover from locating tabs on
housing (Fig. 4) and remove cover.
(4) Remove air cleaner element (filter) from hous-
ing.
(5) Clean inside of housing before replacing ele-
ment.
Housing Assembly
(1) Loosen clamp (Fig. 4) and disconnect air duct
at air cleaner cover.
(2) Lift entire housing assembly from 4 locating
pins (Fig. 5).
INSTALLATION
(1) Install filter element into housing.
(2) Position housing cover into housing locating
tabs (Fig. 4).(3) Pry up 4 spring clips (Fig. 4) and lock cover to
housing.
(4) Install air duct to air cleaner cover and tighten
hose clamp to 3 N´m (30 in. lbs.) torque.
(5) If any other hose clamps were removed from
air intake system, tighten them to 3.4 N´m (30 in.
lbs.) torque.
(6) If any bolts were removed from air resonator
housing or air intake tubing, tighten them to 4.5 N´m
(40 in. lbs.) torque.
CYLINDER HEAD
DESCRIPTION
The alloy cast iron cylinder heads (Fig. 6) 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:
þ Loss of engine power
þ Engine misfiring
þ Poor fuel economy
Fig. 4 AIR CLEANER HOUSING COVER
1 - CLAMP
2 - AIR DUCT
3 - AIR CLEANER COVER
4 - LOCATING TABS
5 - CLIPS (4)
Fig. 5 AIR CLEANER HOUSING
1 - AIR CLEANER HOUSING ASSEMBLY
2 - LOCATING PINS (4)
9 - 370 ENGINE 8.0LDR

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. 8).
(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.
(3) Tighten the cylinder head bolts in two steps
(Fig. 9):
²Step 1ÐTighten all cylinder head bolts, in
sequence, to 58 N´m (43 ft. lbs.) torque.
²Step 2ÐTighten all cylinder head bolts, in
sequence, to 143 N´m (105 ft. lbs.) torque.
²
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
Fig. 8 Coil Pack and Bracket
1 - COIL PACKS AND BRACKET
2 - MOUNTING BOLTS (4)
Fig. 9 Cylinder Head Bolt Tightening Sequence
9 - 372 ENGINE 8.0LDR
CYLINDER HEAD (Continued)

(4) Install push rods and rocker arm assemblies in
their original position (Refer to 9 - ENGINE/CYLIN-
DER HEAD/ROCKER ARM / ADJUSTER ASSY -
INSTALLATION).
(5) Install lower intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(6) Install the upper intake manifold onto the
lower intake manifold (Refer to 9 - ENGINE/MANI-
FOLDS/INTAKE MANIFOLD - INSTALLATION).
(7) Install the exhaust manifolds and new gaskets
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - INSTALLATION).
(8) Install exhaust pipe to the exhaust manifold.
Tighten the bolts to 34 n´m (25 ft. lbs.) torque.
(9) Using a new gasket, position the EGR tube to
the intake manifold and the exhaust manifold.
Tighten the EGR tube nut to 34 N´m (25 ft. lbs.)
torque. Tighten the bolts to 20 N´m (174 in. lbs.)
torque.
(10) Install the heat shields and the washers.
Make sure that heat shields tabs hook over the
exhaust gasket.Tighten the nuts to 15 N´m (132 in.
lbs.) torque.
(11) Adjust and Install the spark plugs (Refer to 8
- ELECTRICAL/IGNITION CONTROL/SPARK
PLUG - INSTALLATION).
(12) Install coil packs and bracket. Tighten the
bracket bolts to 21 N´m (190 in. lbs.) torque. Connect
the coil wires.
(13) Connect heat indicator sending unit wire.
(14) Connect the heater hoses and bypass hose.
(15) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(16) Install the fuel line (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(17) Install the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - INSTALLATION)
and drive belt (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - INSTALLATION).
(18) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts to 41 N´m (30
ft. lbs.) torque.
(19) 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.
CAUTION: The cylinder head cover fasteners have a
special plating. DO NOT use alternative fasteners.(20) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(21) Install closed crankcase ventilation system.
(22) Connect the evaporation control system.
(23) Install the air cleaner.
(24) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(25) Connect the negative cable to the battery.
(26) Check for leaks (fuel, oil, antifreeze, etc.).
CYLINDER HEAD COVER(S)
DESCRIPTION
Die-cast magnesium cylinder head covers (Fig. 10)
reduce noise and provide a good sealing surface. A
steel backed silicon gasket is used with the cylinder
head cover. This gasket can be used again.
REMOVAL
Die-cast magnesium cylinder head covers (Fig. 12)
reduce noise and provide a good sealing surface. A
steel backed silicon gasket is used with the cylinder
head cover (Fig. 11).
(1) Disconnect the negative cable from the battery.
(2) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
Identify each system for installation.
(3) Remove the upper intake manifold to remove
the right side head cover (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
Fig. 10 Cylinder Head Cover
1 - CYLINDER HEAD COVER
DRENGINE 8.0L 9 - 373
CYLINDER HEAD (Continued)

(4) Remove cylinder head cover bolts and stud
bolts. Remove the covers and gaskets (Fig. 11). The
gasket may be used again.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
INSTALLATION
(1) Check the gasket for use in head cover instal-
lation. If damaged, use a new gasket.
(2) 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.
CAUTION: The cylinder head cover fasteners have a
special plating. DO NOT use alternative fasteners.
(3) Position the cylinder head cover onto the gas-
ket. Install the stud bolts and hex head bolts in theproper positions (Fig. 12). Tighten the stud bolts and
the bolts to 16 N´m (144 in. lbs.) torque.
(4) If removed, install the upper intake manifold
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - INSTALLATION).
(5) Install closed crankcase ventilation system and
evaporation control system onto the proper head
cover. DO NOT switch the systems.
(6) Connect the negative cable to the battery.
(7) Start engine and check for leaks.
Fig. 11 Cylinder Head Cover Gaskets
1 - CYLINDER HEAD COVER GASKETS
2 - TAB WITH NUMBER UP
Fig. 12 Cylinder Head Covers
1 - CYLINDER HEAD COVER
2 - CYLINDER HEAD COVER GASKET
9 - 374 ENGINE 8.0LDR
CYLINDER HEAD COVER(S) (Continued)

REFACING VALVES AND VALVE SEATS
The intake and exhaust valves have a 45É face
angle and a 45É to 44 1/2É seat angle (Fig. 16).
VALVE FACE AND SEAT ANGLES CHART
ITEM DESCRIPTION SPECIFICATION
ASEAT WIDTH 1.016 - 1.524
mm
INTAKE (0.040 - 0.060
in.)
SEAT WIDTH 1.016 - 1.524
mm
EXHAUST (0.040 - 0.060
in.)
BFACE ANGLE
(INT. and EXT.) 45É
CSEAT ANGLE
(INT. and EXT.) 44
1¤2É
DCONTACT
SURFACE Ð
VALVES
Inspect the remaining margin after the valves are
refaced (Fig. 17). Valves with less than 1.190 mm
(0.047 inch) margin should be discarded.
VALVE SEATS
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained.(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.038
mm (0.0015 inch) total indicator reading.
(3) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to the top edge of valve face, lower valve seat
with a 15É stone. If the blue is transferred to bottom
edge of valve face raise valve seat with a 60É stone.
(4) When seat is properly positioned the width of
valve seats should be 1.016-1.524 mm (0.040-0.060
inch).
VALVE SPRING INSPECTION
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested. As an example the compression length of
the spring to be tested is 1-5/16 inch. Turn table of
Universal Valve Spring Tester Tool until surface is in
line with the 1-5/16 inch mark on the threaded stud.
Be sure the zero mark is to the front (Fig. 18). Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by 2. This will give the
spring load at test length. Fractional measurements
are indicated on the table for finer adjustments.
Refer to specifications to obtain specified height and
allowable tensions. Discard the springs that do not
meet specifications.
Fig. 16 Valve Face and Seat Angles
1 - CONTACT POINT
Fig. 17 Intake and Exhaust Valves
1 - MARGIN
2 - VALVE SPRING RETAINER LOCK GROOVE
3 - STEM
4-FACE
9 - 376 ENGINE 8.0LDR
INTAKE/EXHAUST VALVES & SEATS (Continued)

REMOVAL
REMOVALÐVALVE STEM SEALS
NOTE: This procedure is done with the cylinder
head installed.
(1) Disconnect the negative cable from the battery.
(2) Set engine basic timing to Top Dead Center
(TDC) and remove air cleaner.
(3) Remove cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL) and spark plugs (Refer to 8
- ELECTRICAL/IGNITION CONTROL/SPARK
PLUG - REMOVAL).
(4) Using suitable socket and flex handle at crank-
shaft retaining bolt, turn engine so that the piston of
the cylinder to be worked on, is at TDC on the com-
pression stroke.
(5) Remove rocker arms (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARM / ADJUSTER
ASSY - REMOVAL).
(6) With air hose attached to an adapter installed
in the spark plug hole, apply 620-689 kPa (90-100
psi) air pressure.
(7) Using Valve Spring Compressor Tool
MD-998772A with adapter 6716A (Fig. 19), compress
valve spring and remove retainer valve locks and
valve spring.
(8) Remove the valve stem seal.
REMOVALÐVALVES AND VALVE SPRINGS
(1) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(2) Special studs must be used to adapt the Valve
Spring Compressor Tool to the V-10 cylinder head
(Fig. 20). Install the metric end into the Special Tool
MD998772A and the 5/16 end into the cylinder head.
Fig. 18 Testing Valve Spring for Compressed
1 - TORQUE WRENCH
2 - VALVE SPRING TESTER
Fig. 19 Valve Spring Compressor MD-998772A with
Adaptor 6716-A and Screw 6765
1 - SPECIAL TOOL MD 998772A
2 - SPECIAL TOOL 6765
3 - SPECIAL TOOL 6716A
4 - AIR HOSE
Fig. 20 Special Studs 6715 for V-10 Engine
1 - SPECIAL TOOL 6715
DRENGINE 8.0L 9 - 377
INTAKE/EXHAUST VALVES & SEATS (Continued)

(1) Install the push rods in the same order as
removed.
(2) Install rocker arm assemblies in the same
order as removed. Tighten the rocker arm bolts to 53
N´m (40 ft. lbs.) torque.
(3) Install cylinder head cover and gasket (Refer to
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(4) Connect spark plug wires.
ENGINE BLOCK
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool,
Special tool 6879 or equivalent. The cylinder block
should be bored and honed with new pistons and
rings fitted if:
²The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
²The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
²The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coor-
dinated with the fitting of pistons and rings so spec-
ified clearances may be maintained.
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS
This procedure requires that the engine is removed
from the vehicle.
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
NOTE: It is not advisable to attempt to replace cam-
shaft bearings unless special removal and installa-
tion tools are available, such as recommended tool
8544 Camshaft Bushing Remover Installer.
(2) Using recommended tool 8544 Camshaft Bush-
ing Remover Installer, Drive out bearing shells.
REMOVALÐCAMSHAFT
(1) Remove rocker arms and push rods (Refer to 9
- ENGINE/CYLINDER HEAD/ROCKER ARM /
ADJUSTER ASSY - REMOVAL). Identify each part
so it can be installed in its original location.
NOTE: The 4 corner tappets can not be removed
without removing the cylinder heads and gaskets.
However, they can be lifted and retained for cam-
shaft removal.
(2) Remove the Bolts retaining the yoke retaining
spider. Remove the yoke retaining spider, tappet
aligning yokes and tappets.
(3) Remove upper and lower intake manifolds
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - REMOVAL).
(4) Remove timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL) and timing chain and
sprockets (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT/CHAIN AND SPROCKETS -
REMOVAL).
Fig. 25 Rocker Arm - Typical
1 - ROCKER ARMS
2 - ROCKER ARM PEDESTALS
3 - RETAINER
9 - 380 ENGINE 8.0LDR
ROCKER ARM / ADJUSTER ASSY (Continued)

(5) Remove camshaft thrust plate (Fig. 26).
(6) Install a long bolt into front of camshaft to aid
in removal of the camshaft. Remove camshaft, being
careful not to damage cam bearings with the cam
lobes.
INSTALLATION
INSTALLATIONÐCAMSHAFT BEARINGS
(1) Install new camshaft bearings using recom-
mended Tool 8544 Camshaft Bushing Remover
Installer, by sliding the new camshaft bearing shell
over proper adapter.
(2) Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft.Be sure this plug does not leak.
INSTALLATIONÐCAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing
journals. Using a long bolt, insert the camshaft into
the cylinder block.
NOTE: Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1 pint of
MoparTCrankcase Conditioner, or equivalent. The
oil mixture should be left in engine for a minimum
of 805 km (500 miles). Drain at the next normal oil
change.
(2) Install camshaft thrust plate. Tighten the torx
bolts to 22 N´m (16 ft. lbs.) torque.
(3) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 mm (0.010 inch) with a
used thrust plate. If not within these limits install a
new thrust plate.(4) Line up key with keyway in sprocket, then
using Special Tools C-3688, C-3718 and MB990799
install crankshaft timing sprocket. Make sure the
sprocket seats against the crankshaft shoulder (Fig.
27).
(5) Install timing chain and sprocket (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(6) Install the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install the crankshaft pulley/damper (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(8) 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.
(9) Each tappet reused must be installed in the
same position from which it was removed.When
camshaft is replaced, all of the tappets must be
replaced.
(10) Install tappets and push rods in their original
location.
(11) Position the tappet aligning yokes and yoke
retaing spider.
(12) Install the retaining spider mounting bolts.
Tighten bolts to 22 N´m (16 ft. lbs.).
Fig. 26 Camshaft
1 - CAMSHAFT
2 - THRUST PLATE
Fig. 27 Crankshaft Sprocket Installation
1 - SPECIAL TOOL C-3688
2 - SPECIAL TOOL C-3718
3 - SPECIAL TOOL MD990799
DRENGINE 8.0L 9 - 381
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

INSTALLATION
When a crankshaft is replaced, all main and con-
necting rod bearings should be replaced with new
bearings. Therefore, selective fitting of the bearings
is not required when a crankshaft and bearings are
replaced.
NOTE: Lubricate crankshaft main bearings with
clean engine oil.
(1) Position upper main bearings into block.
(2) Position the crankshaft into the cylinder block.
(3) Lubricate the main journals with clean engine
oil. Install upper main bearings, caps and bolts. Fol-
low the 2 step tightening sequence, starting with
main bearing cap 1.
(4) Lubricate the connecting rod bearings and jour-
nals with clean engine oil. Carefully install connect-
ing rods to the crankshaft.
(5) Using Special Tool 8359 Seal Installer install
new oil into oil seal retainer.
(6) Using Special Tool 6687 Guide, install the rear
seal retainer with a new gasket.
(7) Install the timing chain cover with a new gas-
ket and oil seal.
(8) Prime oil pump by squirt 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.(9) Apply a rearward axial load of 667 N (150
lbs-f) on crankshaft centerline, driving No.3 main cap
and thrust bearing against No.3 bulkhead. Repeat
procedure, driving crankshaft forward to align rear
flange of thrust bearings in a common plane. Front
face of No.1 main cap must not extend forward in
front of face of No.1 bulkhead.
(10) Install the oil pickup tube. Tighten the bolts
to 16 N´m (144 in. lbs.) torque.
(11) Install the oil pan.
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDUREÐFITTING
CRANKSHAFT MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter-
changeable. All lower main bearing halves are inter-
changeable. Upper main bearing halves of No. 2, 4,
and 5 are interchangeable. Upper main bearing
halves of No. 1 and 6 are interchangeable, this also
applies to the lower bearing halves.
The No.3 main bearing is flanged to carry the
crankshaft thrust loads. This bearing is NOT inter-
changeable with any other bearing halves in the
engine. Bearing shells are available in standard and
the following undersizes: 0.25 mm (0.001 inch), 0.051
mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm
(0.010 inch) and 0.305 mm (0.012 inch). Never install
an undersize bearing that will reduce clearance
below specifications.
REMOVAL
(1) Remove the oil pan and oil pump pick-up tube
(Refer to 9 - ENGINE/LUBRICATION/OIL PAN -
REMOVAL).
(2) Identify bearing caps before removal. Remove
bearing caps one at a time.
(3) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 30).
(4) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
INSTALLATION
Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight-
ened. All bearing capbolts removed during service
procedures are to be cleaned and oiled before instal-
lation.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
Fig. 29 Main Bearing Identification
1 - MAIN BEARING CAP
2 - UPPER MAIN BEARINGS
3 - CRANKSHAFT
4 - LOWER MAIN BEARINGS
DRENGINE 8.0L 9 - 383
CRANKSHAFT (Continued)