DODGE TRUCK 1993 Service Repair Manual

•
5.21 ENGINE 9 - 49

TRANSMISSION
SUPPORT
BRACKET
TRANSMISSION
TRANSMISSION SUPPORT BRACKET

INSULATOR
CROSSMEMBER

(SPORT
UTILITY)
J9109-240
l^^^U.TRANSFERJCASE
.

SKIDRATlf
~—l!pW;;^
ni ®p
ATTACHING
BOLTS
1|BS^ID
PLATE|
Fig.
5 Rear
Engine

iSKID PLATE

I
ATTACHING
BOLTS

PU873

Fig.
6
Skid
Plate

(5) MANUAL TRANSMISSION-Remove the
nuts and bolts holding the insulator mounting plate
to the transfer case (Fig. 8).
(6) Remove insulator mounting bolts, spacers,
washers and upper/lower insulators (Figs. 7 and 8).
(7) Remove the insulator mounting plate (Figs. 7
and 8). (8) If necessary, remove the transmission support
spacer (automatic transmission) from the extension
assembly (Fig. 7).
(9) If necessary, remove the engine rear support
bracket (automatic transmission) from the transfer case (Fig. 7).
Supports—2WD

mSYALLATION-4WD
(1) If removed, position the engine rear support
bracket (automatic transmission) to the transfer case (Fig. 7). Install the bolts and tighten to 41 N-m (30
ft. lbs.) torque.
(2) If removed, position the transmission support
spacer (automatic transmission) to the extension as­
sembly (Fig. 7). Install the bolts and tighten to 68
Nnn (50 ft. lbs.) torque.
(3) Install insulator mounting plate, mounting

bolts,
spacers, washers and upper/lower insulators to the rail assembly (Figs. 7 and 8). Tighten the mount­ing bolt nuts to 204 N-m (150 ft. lbs.) torque.
(4) AUTOMATIC TRANSMISSION—Align the
engine rear support plate and the transmission sup­
port spacer to the insulator mounting plate (Fig. 7). Lower the engine and transmission onto the insula­
tor mounting plate and install the bolts. Tighten the
transmission support spacer nuts to 204 N-m (150 ft. lbs.) torque. Tighten the engine rear support plate to
41 N-m (30 ft. lbs.) torque. (5) MANUAL TRANSMISSION—Align the
transfer case to the insulator mounting plate and lower the engine and transmission. Install the bolts and tighten the nuts (Fig. 8 - nut A) to 204 N-m (150
ft. lbs.) torque. Install the bolts and tighten the nuts (Fig. 8 - nut B) to 41 N-m (30 ft. lbs.) torque. (6) Install the skid plate.

TRANSFER

CASE
TRANSFER

CASE
ENGINE
REAR

SUPPORT PLATE
EXTENSION

ASSEMBLY

TRANSMISSION
SUPPORT
SPACER
SPACER

UPPER

INSULATOR
INSULATOR
MOUNTING

PLATE

LOWER

INSULATOR

fT^RAIL
J9109-244
Fig,
7 Rear Engine Support—4WD
with
Automatic
Transmission

(7)
Lower the vehicle.

ENGINE
ASSEMBLY

REMOVAL
(1) Scribe hood hinge outlines on hood. Remove the
hood. (2) Remove the battery.
(3) Drain cooling system (refer to Group 7, Cooling
System for the proper procedure). (4) Remove the air cleaner.
(5) Disconnect the radiator and heater hoses. Re­
move radiator (refer to Group 7, Cooling System). (6) Set fan shroud aside.

(7)
Remove the vacuum lines.
(8) Remove the distributor cap and wiring.
(9) Disconnect the accelerator linkage.
(10) Remove MPI throttle body.
(11) Disconnect the fuel lines.
(12) Disconnect the starter wires.
(13) Disconnect the oil pressure wire.
(14) Discharge the air conditioning system, if
equipped (refer to Group 24, Heating and Air Condi­
tioning for service procedures).
(15) Disconnect the air conditioning hoses.
(16) Disconnect the power steering hoses, if
equipped.
INSULATOR
MOUNTING
PLATE
SPACER

UPPER

L\ f
INSULATOR

NUT®

RAIL

ASSEMBLY
LOWER
INSULATOR

l6ff
RAIL
I
J9109-245

Fig.
8 Rear
Engine
Support—4WD
with
Manual

Transmission
(17) Remove starter motor (refer to Group 8B, Bat­
tery/Starter/Generator Service).
(18) Remove the generator (refer to Group 8B, Bat­
tery/Starter/Generator Service).
(19) Raise and support the vehicle on a hoist.
(20) Disconnect exhaust pipe at manifold.

(21)
AUTOMATIC TRANSMISSION: (a) Support transmission. This will assure that
the torque converter will remain in proper position in the transmission housing. (b) Remove bell housing bolts and inspection
plate. (c) Attach a C-clamp on front bottom of trans­
mission torque converter housing to prevent torque
converter from falling out. (d) Remove torque converter drive plate bolts
from torque converter drive plate. Mark converter and drive plate to aid in assembly.
(22)
MANUAL TRANSMISSION; (a) Support transmission.
(b) Disconnect clutch release mechanism and re­
move transmission to clutch housing bolts.
CAUTION:

manifold.
DO
NOT lift the
engine
by the
intake

(23) Install an engine lifting fixture.
(24) Remove engine front mount bolts.

•

5.2L
ENGINE
9 - 51 (25) Lower the vehicle.
(26) On automatic transmission vehicles, discon­
nect the engine from the torque converter drive
plate. On manual transmission vehicles, move engine forward until drive pinion shaft clears the clutch
disc.
Remove engine from engine compartment.
(27) Install engine assembly on engine repair
stand.

INSTALLATION
(1) Remove engine from the repair stand and posi­
tion in the engine compartment.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4) AUTOMATIC TRANSMISSION: (a) Position the torque converter and drive plate.
Install torque converter drive plate bolts. Tighten
the bolts to 31 N-m (270 in. lbs.) torque.
(b) Install the engine front mounts.
(c) Install bell housing bolts. Tighten the bolts to
41 N-m (30 ft. lbs.) torque.
(d) Remove C-clamp.
(e) Install the inspection plate.
(5) MANUAL TRANSMISSION: (a) Position the drive pinion shaft to the clutch

disc.
(b) Connect the clutch release mechanism and
install the transmission to clutch bolts. Tighten the
bolts to 68 N-m (50 ft. lbs.) torque.
(c) Install the engine front mounts.
(6) Remove transmission support.
(7) Install exhaust pipe to manifold. (8) Lower the vehicle.
(9) Remove engine lifting fixture. (10) Install the generator (refer to Group 8B, Bat­
tery/Starter/ Generator Service). (11) Install the starter motor (refer to Group 8B,
Battery/Starter/Generator Service). (12) Connect power steering hoses, if so equipped.
(13) Connect air conditioning hoses.
(14) Evacuate and charge the air conditioning sys­
tem, if equipped (refer to Group 24, Heater and Air Conditioning for service procedures).
(15) Using a new gasket, install MPI throttle body.
Tighten the throttle body bolts to 23 N-m (200 in. lbs.) torque. (16) Connect the accelerator linkage.
(17) Connect the starter wires.
(18) Connect the oil pressure wire. (19) Install the distributor cap and wiring.
(20) Connect the vacuum lines.
(21) Connect the fuel lines,
(22) Install the radiator (refer to Group 7, Cooling
System). Connect the radiator hoses and heater

hoses.

(23) Install fan shroud in position.
(24) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure). (25) Install the air cleaner.
(26) Install the battery. (27) Warm engine and adjust.
(28) Install hood and line up with the scribe
marks. (29) Road test vehicle.

CYLIiiER
HEAD
COVER
A steel backed silicon gasket is used with the cyl­
inder head cover (Fig. 1). This gasket can be used
again.

CYLINDER HEAD

J9209-105

Fig.
1 Cylinder Head
Cover
Gasket

REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Disconnect closed ventilation system and evap­
oration control system from cylinder head cover.
(3) Remove cylinder head cover and gasket. 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) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas­
ket. Tighten the bolts to 11 N-m (95 in. lbs.) torque.
(3) Install closed crankcase ventilation system and
evaporation control system.
(4) Connect the negative cable to the battery.

ROCKER ARMS

REMOVAL
(1) Disconnect spark plug wires by pulling on the
boot straight out in line with plug. (2) Remove cylinder head cover and gasket.

9
- 52 5.2L
ENGINE

• (3) Remove the rocker arm bolts and pivots (Fig,

2).
Place them on a bench in the same order as re­
moved.
(4) Remove the push rods and place them on a
bench in the same order as removed.
ROCKER
CYLINDER

J9209-65

Fig.
2
Rocker
Arms INSTALLATION

(1) Rotate the crankshaft until the "V8" mark
lines up with the TDC mark on the timing chain
case cover. This mark is located 147° ATDC from the
No.l firing position.

CAUTION:
DO NOT
rotate
or crank the engine dur­
ing
or immediately
after
rocker arm installation. Al­

low
the hydraulic roller tappets adequate
time
to
bleed
down
(about 5 minutes).
(2) Install the push rods in the same order as re­
moved.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker arm bolts
to 28 N-m (21 ft. lbs.) torque. (4) Install cylinder head cover.
(5) Connect spark plug wires.

CYLINDER HEADS
The alloy cast iron cylinder heads (Fig. 3) are held
in place by 10 bolts. The spark plugs are located in
the peak of the wedge between the valves. The 5.2L cylinder head is identified by the foundry
mark NH.
REMOVAL (1) Disconnect the negative cable from the battery.
(2) Drain cooling system (refer to Group 7, Cooling
System for the proper procedures).
(3) Remove the heat shields (Fig. 4).
(4) Remove the intake manifold-to-generator
bracket support rod. Remove the generator. (5) Remove closed crankcase ventilation system. (6) Disconnect the evaporation control system. (7) Remove the air cleaner.
(8) Disconnect the fuel lines. (9) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick- down cables.
EXHAUST SPARK EXHAUST SPARK EXHAUST
VALVE PLUGS VALVES PLUGS VALVE
INTAKE INTAKE
VALVES VALVES
J9309-37

Fig.
3 Cylinder Head
Assembly
Fig.
4
Exhaust
Manifold Heat
Shields
(10) Remove the return spring.
(11) Remove distributor cap and wires.
(12) Disconnect the coil wires.
(13) Disconnect heat indicator sending unit wire.
(14) Disconnect heater hoses and bypass hose. (15) Remove cylinder head covers and gaskets. (16) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(17) Remove exhaust manifolds.
(18) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(19) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin­ der head gasket.
(20) Remove spark plugs.

CLEANING
Clean all surfaces of cylinder block and cylinder

heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.

•

5.2L ENGINE
9 - 53
INSPECTION

Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness ex­
ceeds 0.00075 mm/mm (0.00075 inch/inch) times the span length in inches in any direction, either replace
head or lightly machine the head surface.
FOR EXAMPLE: A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept­

able.

The cylinder head surface finish should be 1.78-
3.00 microns (70-125 microinches). Inspect push rods. Replace worn or bent rods.

INSTALLATION
(1) Apply Perfect Sealant No.5, or equivalent, to
both sides of the gasket (Fig. 5).

Fig.
5 Sealant Location on Cylinder Head
Gasket

(2) Position the new cylinder head gaskets onto the
cylinder block. (3) Position the cylinder heads onto head gaskets
and cylinder block. (4) Starting at top center, tighten all cylinder head

bolts,
in sequence, to 68 N»m (50 ft. lbs.) torque (Fig.
6).
Repeat procedure, tighten all cylinder head bolts
to 143 N®m (105 ft. lbs.) torque. Repeat procedure to confirm that all bolts are at 143 N-m (105 ft. lbs.)
torque.

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.

(5) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 N»m (21 ft. lbs.) torque. (6) Place the 4 plastic locator dowels into the holes
in the block Fig. 7).
Fig.
6 Cylinder Head
Bolt
Tightening
Sequence

(7) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, to the four corner joints. An ex­
cessive amount of sealant is not required to ensure a
leak proof seal. However, an excessive amount of sealant may reduce the effectiveness of the flange
gasket. The sealant should be slightly higher than
the cross-over gaskets, approx. 5 mm (0.2 in).
(8) Install the front and rear cross-over gaskets
onto the dowels (Fig. 7).

FRONT
CROSS-OVER GASKET
REAR CROSS-OVER GASKET
J9209-99

Fig.
7
Cross-Over
Gaskets
and Locator
Dowels

(9) Install the flange gaskets. Be sure that the ver­
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must
be in position with the mating cylinder head gasket
tabs (Fig. 8). The words MANIFOLD SIDE should be visible on the center of each flange gasket.
(10) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. Use the

FLANGE GASKET

X
Fig. 8 intake Manifold Flange Gasket Alignment alignment dowels in the cross-over gaskets to posi­
tion the intake manifold. After intake manifold is in
place, inspect to make sure seals are in place. (11) The following torque sequence duplicates the
expected results of the automated assembly system (Fig. 9).
J9209-60
Fig. 9 Intake Manifold Bolt Tightening Sequence
• Step
1—Tighten
bolts 1 through 4, in sequence, to
8 N-m (72 in. lbs.) torque. Tighten in alternating
steps 1.4 N-m (12 in. lbs.) torque at a time.
• Step 2—Tighten bolts 5 through 12, in sequence,
to 8 N-m (72 in. lbs.) torque.
• Step 3—Check that all bolts are tighten to 8 N-m (72 in. lbs.) torque.
• Step 4—Tighten all bolts, in sequence, to 16 N-m (12 ft. lbs.) torque.
• Step
5—Check
that all bolts are tighten to 16 N-m (12 ft. lbs.) torque.
(12) Install exhaust manifolds. Tighten the bolts
and nuts to 34 N-m (25 ft. lbs.) torque.
(13) Adjust spark plugs to specifications (refer to
Group 8D, Ignition System). Install the plugs and
tighten to 41 N-m (30 ft. lbs.) torque. (14) Install coil wires. (15) Connect heat indicator sending unit wire.
(16) Connect the heater hoses and bypass hose.
(17) Install distributor cap and wires. (18) Hook up the return spring.
(19) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(20) Install the fuel lines.
(21) Install the generator and drive belt. Tighten
generator mounting bolt to 41 N-m (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 N-m (200 in. lbs.) torque. Refer to Group 7, Cooling Sys­
tem for adjusting the belt tension.
(22) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts. (23) Place the cylinder head cover gaskets in posi­
tion and install cylinder head covers. Tighten the
bolts to 11 N-m (95 in. lbs.) torque.
(24) Install closed crankcase ventilation system.
(25) Connect the evaporation control system.
(26) Install the air cleaner.
(27) Install the heat shields. Tighten the bolts to
41 N-m (30 ft. lbs.) torque. (28) Fill cooling system (refer to Group 7, Cooling
System for proper procedure).
(29) Connect the negative cable to the battery.

VALVES
/
VALVE
SPRINGS
The valves are arranged in-line and inclined 18°.
The rocker pivot support and the valve guides are cast integral with the heads. This procedure requires the removal of the cylinder
head.
REMOVAL (1) Remove the cylinder head.
(2) Compress valve springs using Valve Spring
Compressor Tool MD-998772A.
(3) Remove valve retaining locks, valve spring re­
tainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original location.
VALVE CLEANING Clean valves thoroughly. Discard burned, warped
and cracked valves. Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
VAL VE INSPECTION Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve. Measure valve stem guide clearance as follows:
(a) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 10). The special

•
5.2L
ENGINE
I - 55
Fig. 10 Positioning Valve with Tool C-3973 sleeve places the valve at the correct height for
checking with a dial indicator.
(b) Attach Dial Indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being measured (Fig. 11).
Fig. 11 Measuring Valve Guide Wear
(c) Move valve to and from the indicator. The to­
tal dial indicator reading should not exceed
0.432

mm
(0.017
inch). Ream the guides for valves with
oversize stems if dial indicator reading is excessive
or if the stems are scuffed or scored. Service valves with oversize stems are available
(Fig. 12).

Reamer
O/S
Valve
Guide
Size

0.076
mm
8.026
-
8.052
mm

(0.003
in.)
(0.316-0.317in.)

0.381
mm
8.331
-
8.357
mm

(0.015
In.)
(0.328-0.329
In.)

J9309-30

Fig. 12 Reamer Sizes
Slowly turn reamer
by
hand
and
clean guide thor­
oughly before installing
new
valve. Ream
the valve

guides from standard
to 0,381 mm
(0.015 Inch).
Use
a 2
step procedure
so the
valve guides
are

reamed true
in
relation
to the
valve seat:

• Step
1-Ream
to 0.0763 mm (0.003 inch),
• Step 2—Ream, to 0.381 mm (0.015 inch).

REFACING
VAL
WES
/
WAL
WE
SEATS
The intake and exhaust valves have a 43-1/4° to
43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle
(Fig.
13).
CONTACT

A
-
SEAT
WIDTH
-
INTAKE
1.016-1.524
mm
(0.040
-
0.060
in.)
EXHAUST
1.524 -
2.032
mm
(0.060
-
0.080
in.)

B
-
FACE ANGLE (INTAKE
&
EXHAUST)
437.°
-433//

C
-
SEAT ANGLE (INTAKE
&
EXHAUST)
447/ - 447/
D
-
CONTACT SURFACE
J9309-95

Fig. 13 Valve Face and Seat Angles

VALVES
Inspect the remaining margin after the valves are
refaced (Fig. 14). Valves with less than 1.190 mm (0.047 inch) margin should be discarded.

VALVE
SEATS

CAUTION:
DO NOT
un-shroud valves
during
valve

seat
refacing (Fig.
15).
(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 ob­
tained.
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 inch) total indicator reading. (3) Inspect the valve seat with Prussian blue to de­
termine 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