DODGE TRUCK 1993 Service Repair Manual

9
- 56 5.2L
ENGINE

•

VALVE
SPRING
RETAINER LOCK GROOVE
EXHAUST

VALVE

J9209-127 the spring load at test length. Fractional measure­
ments are indicated on the table for finer adjust­
ments. Refer to specifications to obtain specified
height and allowable tensions. Discard the springs
that do not meet specifications.
SPECIAL

TOOL
C-647

Fig.
14 Intake and
Exhaust
Valves

Fig.
15 Refacing
Valve
Seats
valve face, contact is satisfactory. If the blue is trans­
ferred to the top edge of valve face, lower valve seat
with a 15° stone. If the blue is transferred to bottom edge of valve face raise valve seat with a 60° stone.
(4) When seat is properly positioned the width of
intake seats should be
1.016-1.524
mm (0.040-0.060

inch).
The width of the exhaust seats should be
1.524-2.032
mm (0.060-0.080 inch).
WALVE 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 Valve Spring Tester Tool C-647 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. 16). Place spring over stud on the table and lift compressing le­
ver 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 ^
9209-37

Fig.
16 Testing
Valve
Spring
for
Compressed
Length
with
Tool
C-647

INSTALLATION
(1) Coat valve stems with lubrication oil and insert
them in cylinder head.
(2) If valves or seats are reground, check valve
stem height. If valve is too long, replace cylinder
head.
(3) Install new seals on all valve guides. Install
valve springs and valve retainers.
(4) Compress valve springs with Valve Spring
Compressor Tool MD-998772A, install locks and re­
lease tool. If valves and/or seats are ground, measure
the installed height of springs. Make sure the mea­ surement is taken from bottom of spring seat in cyl­
inder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer.
If height is greater than 42.86 mm (1-11/16 inches),
install a 1.587 mm (1/16 inch) spacer in head coun-
terbore. This should bring spring height back to nor­ mal 41.27 to 42.86 mm (1-5/8 to
1-11/16
inch).

VALVE STEM SHIELD
/
SPRING REPLACEMENT
# This procedure is done with the cylinder head in­
stalled. (1) Set engine basic timing to Top Dead Center
(TDC) and remove air cleaner. (2) Remove cylinder head covers and spark plugs.
(3) Remove coil wire from distributor and secure to
good ground to prevent engine from starting. (4) Using suitable socket and flex handle at crank­
shaft retaining bolt, turn engine so the No.l piston is
at TDC on the compression stroke. (5) Remove rocker arms.

•
5.2L
ENGINE
9 - 57 (6) With air hose attached to an adapter installed
in No.l spark plug hole, apply 620-689 kPa (90-100
psi) air pressure.
(7) Using Valve Spring Compressor Tool
MD-998772A, compress valve spring and remove re­
tainer valve locks and valve spring.
(8) Install seals on the exhaust valve stem and po­
sition down against valve guides.
(9) The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the valve stem as a guide. DO NOT force seal against
top of guide. When installing the valve retainer
locks,
compress the spring only enough to install the

locks.
(10) Follow the same procedure on the remaining 7
cylinders using the firing sequence 1-8-4-3-6-5-7-2.
Make sure piston in cylinder is at TDC on the valve
spring that is being removed. (11) Remove adapter from the No.l spark plug

hole.
(12) Install rocker arms.
(13) Install covers and coil wire to distributor.
(14) Install air cleaner. (15) Road test vehicle.

HYDRAULIC TAPPETS
Before disassembling any part of the engine to cor­
rect tappet noise, check the oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at the pressure sending unit. The pressure should be be­
tween 207-552 kPa (30-80 psi) at 3,000 RPM. Check the oil level after the engine reaches normal
operating temperature. Allow 5 minutes to stabilize oil level, check dipstick. The oil level in the pan should never be above the
FULL mark or below the ADD OIL mark on dipstick.
Either of these 2 conditions could be responsible for
noisy tappets.

OIL LEWEL
HIGH
If oil level is above the FULL mark, it is possible
for the connecting rods to dip into the oil. With the
engine running this condition could create foam in
the oil pan. Foam in oil pan would be fed to the hy­
draulic tappets by the oil pump causing them to lose
length and allow valves to seat noisily.
LOW Low oil level may allow oil pump to take in air.
When air is fed to the tappets, they lose length
which allows valves to seat noisily. Any leaks on in­
take side of oil pump through which air can be drawn will create the same tappet action. Check the
lubrication system from the intake strainer to the
pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be in­ termittent or constant, and usually more than 1 tap­
pet will be noisy. When oil level and leaks have been
corrected, operate the engine at fast idle. Run engine
for a sufficient time to allow all of the air inside the
tappets to be bled out.

TAPPET
NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate en­
gine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect
noisy tappet. The noisy tappet will cause the affected
spring and/or rocker arm to vibrate or feel rough in
operation.
Worn valve guides or cocked springs are some­
times mistaken for noisy tappets. If such is the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not appre­
ciably reduced, it can be assumed the noise is in
the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear.
(3) Valve tappet noise ranges from light noise to a
heavy click. A light noise is usually caused by exces­ sive leak-down around the unit plunger or by the
plunger partially sticking in the tappet body cylin­ der. The tappet should be replaced. A heavy click is caused by a tappet check valve not seating or by for­
eign particles becoming wedged between the plunger and the tappet body. This will cause the plunger to
stick in the down position. This heavy click will be accompanied by excessive clearance between the
valve stem and rocker arm as valve closes. In either

case,
tappet assembly should be removed for inspec­
tion and cleaning.
The valve train generates a noise very much like a
light tappet noise during normal operation. Care
must be taken to ensure that tappets are making the
noise. In general, if more than one tappet seems to
be noisy, its probably not the tappets.

REMOVAL
(1) Remove the air cleaner.
(2) Remove cylinder head cover.
(3) Remove rocker assembly and push rods. Iden­
tify push rods to ensure installation in original loca­
tion.
(4) Remove intake manifold.
(5) Remove yoke retainer and aligning yokes.
(6) Slide Hydraulic Tappet Remover/Installer Tool
C-4129-A through opening in cylinder head and seat
tool firmly in the head of tappet.
(7) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed, identify tappets to
ensure installation in original location.
(8) If the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to
next oversize. Replace with oversize tappet.

CAUTION:
Th© plunger and
tappet
bodies are not
interchangeable. The plunger and valve must al­

ways
be
fitted
to the
original
body. It is advisable to

work
on one
tappet
at a
time
to avoid
mixing
of parts. Mixed
parts
are not
compatible.
DO NOT
dis­

assemble
a
tappet
on a
dirty
work
bench,

DISASSEMBLE
(1) Pry out plunger retainer spring clip (Fig. 17).
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, check valve, check valve spring, check valve
retainer and plunger spring (Fig. 17). Check valve could be flat or ball.

ASSEMBLE

(1) Clean all tappet parts in a solvent that will re­
move all varnish and carbon.
(2) Replace tappets that are unfit for further ser­
vice with new assemblies.
(3) If plunger shows signs of scoring or wear, in­
stall a new tappet assembly. If valve is pitted, or
valve seat on end of plunger is prevented from seat­
ing, install a new tappet assembly. (4) Assemble tappets (Fig. 17).
PLUNGER
CHECK

BALL
PLUNGER
RETAINER
SPRING CLIP
ROLLER
TAPPET BODY RETAINER I PLUNGER
CHECK VALVE
SPRING PLUNGER
CAP
J9109-220
Fig.
17 Hydraulic
Tappet
Assembly

INSTALLATION
(1) Lubricate tappets.
(2) Install tappets and push rods in their original
positions. Ensure that the oil feed hole in the side of
the tappet body faces up (away from the crankshaft). (3) Install aligning yokes with ARROW toward
camshaft. (4) Install yoke retainer. Tighten the bolts to 23
N»m (200 in. lbs.) torque. Install intake manifold. (5) Install push rods in original positions.
(6) Install rocker arm.
(7) Install cylinder head cover.
(8) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To
prevent
damage to valve mechanism,
engine must not be run above
fast
idle
until
all hy­
draulic
tappets
have
filled
with
oil and have become
quiet.
VALVE
TIMING

(1) Turn crankshaft until the No.6 exhaust valve
is closing and No.6 intake valve is opening. (2) Insert a 6.350 mm (1/4 inch) spacer between
rocker arm pad and stem tip of No.l intake valve. Allow spring load to bleed tappet down giving in ef­
fect a solid tappet. (3) Install a dial indicator so plunger contacts
valve spring retainer as nearly perpendicular as pos­
sible.
Zero the indicator. (4) Rotate the crankshaft clockwise (normal run­
ning direction) until the valve has lifted 0.254 mm (0.010 inch). The timing of the crankshaft should
now read from 10° before top dead center to 2° after
top dead center. Remove spacer.

CAUTION:
DO NOT
turn
crankshaft any
further

clockwise as valve spring
might
bottom
and
result
in serious
damage.

(5) If reading is not within specified limits: (a) Check sprocket index marks.
(b) Inspect timing chain for wear.
(c) Check accuracy of DC mark on timing indica­
tor.

VIBRATION DAMPER
REMOVAL (1) Disconnect the negative cable from the battery.
(2) Remove fan shroud retainer bolts and set
shroud back over engine.
(3) Remove the cooling system fan.
(4) Remove the serpentine belt (refer to Group 7,
Cooling System).
(5) Remove the vibration damper pulley. (6) Remove vibration damper bolt and washer from
end of crankshaft. (7) Install bar and screw from Puller Tool Set
C-3688. Install 2 bolts with washers through the
puller tool and into the vibration damper (Fig. 1).
(8) Pull vibration damper off of the crankshaft.
J9209-81

Fig.
1
Vibration
Damper
Assembly

•
5.2L
ENGINE
9 - 59
INSTALLATION

(1) Position the vibration damper onto the crank­
shaft. (2) Place installing tool, part of Puller Tool Set
C-3688 in position and press the vibration damper
onto the crankshaft (Fig. 2).

Fig.
2 Installing
Vibration
Damper

(3) Install the crankshaft bolt and washer. Tighten
the bolt to 183 N*m (135 ft. lbs.) torque.
(4) Install the crankshaft pulley. Tighten the pul­
ley bolts to 23 Nin (200 in. lbs.) torque.
(5) Install the serpentine belt (refer to Group 7,
Cooling System).
(6) Install the cooling system fan. Tighten the
bolts to 23 N*m (17 ft. lbs.) torque.
(7) Position the fan shroud and install the bolts.
Tighten the retainer bolts to 11 N»m (95 in. lbs.)
torque.
(8) Connect the negative cable to the battery.

TIMING
CHAIN
COVER
REMOVAL (1) Disconnect the negative cable from the battery.
(2) Drain cooling system (refer to Group 7, Cooling
System).
(3) Remove the serpentine belt (refer to Group 7,
Cooling System).
(4) Remove water pump (refer to Group 7, Cooling
System).
(5) Remove power steering pump (refer to Group

19,
Steering). (6) Remove vibration damper.
(7) Remove fuel lines (refer to Group 14, Fuel Sys­

tem).
(8) Loosen oil pan bolts and remove the front bolt
at each side.
(9) Remove the cover bolts.
(10) Remove chain case cover and gasket using ex­
treme caution to avoid damaging oil pan gasket.
(11) Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal surface of cover (Fig. 3).
Fig.
3
Removal
of Front Crankshaft Oil
Seal

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 di­
rection 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 re­
moved. 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 Nnn (30 ft. lbs.) torque in the re­
verse direction. With the cylinder heads removed, ap­
ply 20 N»m (15 ft. lbs.) torque in the reverse direction. Note the amount of chain movement (Fig.

4).

Fig.
4
Measuring
Timing
Chain
Wear and Stretch
(4) Install a new timing chain, if its movement ex­
ceeds 3.175 mm (1/8 inch). (5) If chain is not satisfactory, remove camshaft
sprocket attaching bolt and remove timing chain
with crankshaft and camshaft sprockets.
(6) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(7) Place timing chain around both sprockets.

9
- 60 5.2L
ENGINE

(8) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam­ shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
against the chain in position as described). (10) Slide both sprockets evenly over their respec­
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 5).
TIMING

MARKS
J9209-129

Fig.
5
Alignment
of Timing Marks (11) Install the camshaft bolt. Tighten the bolt to
68 Nnn (50 ft. lbs.) torque. (12) 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.
CLEANING Be sure mating surfaces of chain case cover and
cylinder block are clean and free from burrs.
INSTALLATION (1) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar Silicone 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.
(2) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 6). Seat
the oil seal in the groove of the tool.
(3) Position the seal and tool onto the crankshaft
(Fig. 7). (4) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft (Fig. 8).
(5) Tighten chain case cover bolts to 41 Nnn (30 ft.
lbs.) torque. Tighten oil pan bolts to 24 Nnn (215 in.
lbs.) torque.
(6) Remove the vibration damper bolt and seal in­
stallation tool. (7) Install vibration damper.
(8) Install fuel lines (refer to Group 14, Fuel Sys­

tem).
CRANKSHAFT
k

FRONT
OIL
SEAL
INSTALL
THIS

END
INTO

SPECIAL
TOOL
6635
J9309-44

Fig.
6
Placing
Oil
Seal
on
Installation
Tool
6635
SPECIAL
TOOL
\ | OIL
SEAL

TIMING
CHAIN

COVER
J9309-45*-
Fig.
7 Position Tool and
Seal
onto Crankshaft
(9) Install water pump and housing assembly us­
ing new gaskets (refer to Group 7, Cooling System).
Tighten bolts to 41 Nnn (30 ft. lbs.) torque.
(10) Install power steering pump (refer to Group

19,
Steering).
(11) Install the serpentine belt (refer to Group 7,
Cooling System).
(12) Install the cooling system fan. Tighten the
bolts to 23 Nnn (17 ft. lbs.) torque. (13) Position the fan shroud and install the bolts.
Tighten the bolts to 11 Nnn (95 in. lbs.) torque.
(14) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure).
(15) Connect the negative cable to the battery.

•
J9309-46
Fig. 8 Installing Oil Seal
FRONT CRANKSHAFT OIL SEAL REPLACEMENT The oil seal can be replaced without removing the
timing chain cover provided the cover is not mis­ aligned. (1) Disconnect the negative cable from the battery.
(2) Remove vibration damper.
(3) If front seal is suspected of leaking, check front
oil seal alignment to crankshaft. The seal installa­
tion/alignment tool 6635, should fit with minimum interference. If tool does not fit, the cover must be re­
moved and installed properly. (4) Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal surface of cover. (5) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 6). Seat
the oil seal in the groove of the tool. (6) Position the seal and tool onto the crankshaft
(Fig. 7). (7) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft (Fig. 8). (8) Remove the vibration damper bolt and seal in­
stallation tool. (9) Install the vibration damper. (10) Connect the negative cable to the battery.
CAMSHAFT This procedure requires that the engine is removed
from the vehicle. The camshaft has an integral oil pump and distrib­
utor drive gear (Fig. 9).
5.2L
ENGINE
9 - 61
J9309-71

Fig.
9 Camshaft and Sprocket Assembly REMOVAL

(1)
Remove intake manifold.
(2) Remove cylinder head covers. (3) Remove timing case cover and timing chain.

(4)
Remove rocker arms.
(5) Remove push rods and tappets. Identify each
part so it can be installed in its original location.

(6)
Remove distributor and lift out the oil pump
and distributor drive shaft.
(7) Remove camshaft thrust plate, note location of
oil tab (Fig. 10).
Fig. 10 Timing Chain Oil Tab Installation
(8) Install a long bolt into front of camshaft to fa­
cilitate removal of the camshaft. Remove camshaft,
being careful not to damage cam bearings with the cam lobes.

REMOVAL-BEARING
(1)
With engine completely disassembled, drive out
rear cam bearing core hole plug. (2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer

9 - 62 5.2L
ENGINE
Fig,
11 Camshaft
Bearings
Removal
and
installation

with
Tool C-3132-A
Tool C-3132-A) at back of each bearing shell. Drive out bearing shells (Fig. 11).

INSTALL A
TION-
BEARING
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
the new camshaft bearing shell over proper adapter. (2) Position rear bearing in the tool. Install horse­
shoe lock and by reversing removal procedure, care­
fully drive bearing shell into place. (3) Install remaining bearings in the same man­
ner. 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.

INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2 inches) of its final position in cylinder block.
Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1
pint of Mopar Crankcase Conditioner, or equiv­ alent. 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 Gear Installer Tool C-3509
with tongue back of distributor drive gear (Fig. 12).
Fig.
12 Camshaft
Holding
Tool C-3509 (Installed

Position)
• — —— — — •

Fig.
13
Alignment
of Timing Marks
(10) Install the camshaft bolt/cup washer. Tighten
bolt to 68 N«m (50 ft. lbs.) torque. (11) Measure camshaft end play. Refer to Specifi­
cations for proper clearance. If not within limits in­ stall a new thrust plate.
(12) 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.

DISTRIBUTOR
REMOVAL
Refer to Group 8D, Ignition Systems for the proper
procedure.

REMOVAL-DRIVE SHAFT BUSHING
(1) Insert Distributor Drive Shaft Bushing Puller
Tool C-3052 into old bushing and thread down until a tight fit is obtained (Fig. 14). (3) Hold tool in position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block Tool should remain installed until the camshaft and crankshaft sprockets and timing chain have been installed.

(4)
Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower right hole in thrust plate. Tighten bolts to 24 N*m (210 in. lbs.) torque.
Top edge of tab should be flat against thrust plate in
order to catch oil for chain lubrication.
(5) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and crankshaft bores.
(6) Place timing chain around both sprockets. (7) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in camshaft sprocket.
(8) Lift sprockets and chain (keep sprockets tight
against the chain in position as described). (9) Slide both sprockets evenly over their respec­
tive shafts and use a straightedge to check alignment of timing marks (Fig. 13).

•
5.2L
ENGINE
I - 63

Fig.
14 Distributor Driveshaft
Bushing
Removal
(2) Hold puller screw and tighten puller nut until
bushing is removed.
INSTALLA TION-DRIVE
SHAFT BUSHING
(1) Slide new bushing over burnishing end of Dis­
tributor Drive Shaft Bushing Driver/Burnisher Tool
C-3053.
Insert the tool and bushing into the bore. (2) Drive bushing and tool into position, using a
hammer (Fig. 15).
Fig. 15 Distributor Driveshaft Bushing Installation (3) As the burnisher is pulled through the bushing,
the bushing is expanded tight in the block and bur­ nished to correct size (Fig. 16). DO NOT ream this
bushing.

Fig.
16
Burnishing
Distributor Driveshaft
Bushing

DISTRIBUTOR TIMING Before installing the distributor and oil pump drive
shaft, time engine as follows:
(1) Rotate crankshaft until No.l cylinder is at top
dead center on the firing stroke. (2) When in this position, the timing mark on vi­
bration damper should be under "0" on the timing in­ dicator.
(3) Coat shaft and drive gear with engine oil. In­
stall the shaft so that after the gear spirals into
place, it will index with the oil pump shaft. The slot in top of drive gear should be aligned towards left
front intake manifold attaching bolt hole (Fig. 17).

Fig.
17 Position or Installed Distributor Drive Gear
INSTALLATION Refer to Group 8D, Ignition Systems for the proper
procedure.

OIL
PAN REMOVAL (1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick. (3) Raise vehicle.
(4) Drain engine oil. (5) Remove exhaust pipe.
(6) Remove left engine to transmission strut.
(7) Remove oil pan and one-piece gasket.
CLEANING Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove. DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the en­

gine.
Clean oil pan in solvent and wipe dry with a clean
cloth.
Clean oil screen and pipe thoroughly in clean sol­
vent. Inspect condition of screen.
INSPECTION Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor­
tion. Straighten flange, if necessary.
INSTALLATION (1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
inch bolts. Cut the head off the bolts and cut a slot

9
- 64 5.2L
ENGINE

• into the top of the dowel. This will allow easier in­
stallation and removal with a screwdriver (Fig. 1).
VI2' x 5/16"
BOLT
DOWEL SLOT

J9209-106

Fig. 1 Fabrication of Alignment Dowels
(2) Install the dowels in the cylinder block (Fig. 2). (3) Apply small amount of Mopar Silicone Rubber

DOWEL DOWEL

J9309-79

Fig. 2 Position of Dowels in Cylinder Block
Adhesive Sealant, or equivalent in the corner of the cap and the cylinder block. (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.
(6) Install the oil pan bolts. Tighten the bolts to 24
N*m (215 in. lbs.) torque.
(7) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 N«m (215 in. lbs.)
torque. (8) Install the drain plug. Tighten drain plug to 34
N«m (25 ft. lbs.) torque.
(9) Install the engine to transmission strut.
(10) Install exhaust pipe.
(11) Lower vehicle. (11) Install dipstick.
(12) Connect the negative cable to the battery.
(13) Fill crankcase with oil to proper level.

OIL
PUMP
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from rear main bearing

cap.

DISASSEMBLE
(1) Remove the relief valve as follows: (a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole into the relief valve retainer cap and in­ sert a self-threading sheet metal screw.
(b) Clamp screw into a vise and while supporting
oil pump, remove cap by tapping pump body using a soft hammer. Discard retainer cap and remove
spring and relief valve (Fig. 3).

OIL PUMP
ASSEMBLY

SPRING
RELIEF
VALVE

'
RETAINER CAP COTTER
PIN

RH174

Fig.
3 Oil
Pressure
Relief
Valve

(2) Remove oil pump cover (Fig. 4).
(3) Remove pump outer rotor and inner rotor with
shaft (Fig. 4). (4) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
INNER ROTOR DISTRIBUTOR DRIVESHAFT
AND SHAFT
mm
(REFERENCE)
COTTER
PIN

LARGE
CHAMFERED
EDGE

Fig.
4 Oil
Pump
SPRING

RETAINER

CAP

RY10B

5.2L
ENGINE S - 65

INSPECTION

Mating surface of the oil pump cover should be
smooth. Replace pump assembly if cover is scratched
or grooved.
Lay a straightedge across the pump cover surface
(Fig. 5). If a 0.038 mm (0.0015 inch) feeler gauge can
be inserted between cover and straightedge, pump assembly should be replaced.

Fig.
5
Checking
Oil Pump
Cover
Flatness
Measure thickness and diameter of OUTER rotor.
If outer rotor thickness measures 20.9 mm (0.825 inch) or less or if the diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 6).

Fig.
6
Measuring
Outer Rotor
Thickness

If inner rotor measures 20.9 mm (0.825 inch) or

less,
replace inner rotor and shaft assembly (Fig. 7).
Slide outer rotor into pump body. Press rotor to the
side with your fingers and measure clearance be­
tween rotor and pump body (Fig. 8). If clearance is 0.356 mm (0.014 inch) or more, replace oil pump as­
sembly.
Install inner rotor and shaft into pump body. If
clearance between inner and outer rotors is 0.203
mm (0.008 inch) or more, replace shaft and both ro­
tors (Fig. 9).
Place a straightedge across the face of the pump,
between bolt holes. If a feeler gauge of 0.102 mm
Fig.
7
Measuring
Inner
Rotor
Thickness

Fig.
8
Measuring
Outer Rotor Clearance in
Housing

OUTER
ROTOR
INNER
ROTOR

RH179
Fig.
9
Measuring
Clearance Between
Rotors

(0.004 inch) or more can be inserted between rotors
and the straightedge, replace pump assembly (Fig.

10).
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 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 inches). Replace spring that fails
to meet these specifications (Fig. 11).