8.0L V10 Engine: Removal & Installation Dodge Cab & Chassis R2500

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Removal & Installation (Single Tab)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-97381-S05698768482001050300000). Ensure disconnect fitting and fuel lines are clean. Note location of release tab and pull tab on disconnect fitting. see scheme 2
2. Press release tab. Using screwdriver, pry pull tab upward until pull tab separates from disconnect fitting. Remove disconnect fitting from fuel line. Inspect components for damage. If disconnect fitting is damaged, entire assembly must be replaced, as only pull tab can be replaced.
3. To install, ensure fuel line and disconnect fitting are clean. Lubricate fuel line and disconnect fitting with engine oil. Install disconnect fitting onto fuel line until disconnect fitting bottoms on fuel line.
4. Install NEW pull tab until pull tab locks into disconnect fitting. DO NOT reuse old pull tab. Pull on fuel line and disconnect fitting to ensure components are properly locked together. Reconnect negative battery cable. Start engine and check for leaks.

Removal & Installation (Dual Tab)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-97381-S05698768482001050300000). Ensure disconnect fitting and fuel lines are clean. Note location of tabs on disconnect fitting. see scheme 2
2. Squeeze both tabs against disconnect fitting. Pull disconnect fitting from fuel line. Tabs will remain on fuel line. Inspect components for damage. If disconnect fitting is damaged, replace entire assembly, as only tabs can be replaced.
3. To install, ensure fuel line and disconnect fitting are clean. Lubricate fuel line and disconnect fitting with engine oil. Install disconnect fitting onto fuel line until click sound is heard.
4. Pull on fuel line and disconnect fitting to ensure components are properly locked together. Reconnect negative battery cable. Start engine and check for leaks.

Removal & Installation (Plastic Retainer Ring)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-97381-S05698768482001050300000). Ensure disconnect fitting and fuel lines are clean. Note location of plastic retainer ring on disconnect fitting. see scheme 2
2. Firmly push disconnect fitting toward fuel line while pushing plastic retainer ring evenly into disconnect fitting. With plastic retainer ring fully depressed, pull disconnect fitting from fuel line. Inspect components for damage. If disconnect fitting is damaged, replace entire assembly.
3. To install, ensure fuel line and disconnect fitting are clean. Lubricate fuel line and disconnect fitting with engine oil. Install disconnect fitting onto fuel line until click sound is heard.
4. Pull on fuel line and disconnect fitting to ensure components are properly locked together. Reconnect negative battery cable. Start engine and check for leaks.

Removal & Installation (Fuel Line-To-Fuel Rail)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-97381-S05698768482001050300000) . Remove air cleaner housing if not previously removed. Ensure disconnect fitting and fuel line at rear corner of fuel rail are clean.
2. Install Fuel Line Release Fitting (7660) onto fuel line at fuel rail. Fuel line release fitting is used to release locking fingers on disconnect fitting. Pull fuel line from fuel rail. Locking fingers will remain in disconnect fitting on fuel rail.
3. Inspect disconnect fitting, locking fingers and fuel line fitting on fuel rail for damage. If any components are damaged, replace as necessary.
4. To install, ensure fuel line, fuel line fitting and disconnect fitting are clean. Lubricate components with engine oil. Install fuel line onto fuel rail.
5. Pull on fuel line and disconnect fitting to ensure components are properly locked together. Reconnect negative battery cable. Start engine and check for leaks.

Removal

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-97381-S05698768482001050300000) . Remove battery. Drain cooling system and engine oil. Remove upper crossmember and top core support.
2. On A/T models, ensure area around disconnect fitting on oil cooler lines on transmission oil cooler are clean. Disconnect oil cooler lines from transmission oil cooler by disengaging retainer on quick disconnect fitting on oil cooler line and pull oil cooler line from transmission oil cooler. Remove transmission oil cooler.
3. On all models, note direction of serpentine belt routing for installation reference. Route serpentine belt in proper direction to prevent water pump from rotating in wrong direction and causing engine overheating. Remove serpentine belt.
4. On A/C-equipped models, discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect and plugs hoses and openings at condenser. Remove condenser. Remove A/C compressor with hoses attached, and secure aside.
5. On all models, remove windshield washer fluid reservoir. Remove radiator and fan shroud. Remove generator with wires attached, and secure aside.
6. Remove upper intake manifold. See «INTAKE MANIFOLD»(ref-97381-S38885203512001050300000) . Remove ignition coils with spark plug wires.
7. Disconnect necessary coolant hoses, electrical connections and vacuum hoses. Disconnect hoses at power steering pump, if equipped. On M/T models, remove shift lever.
8. Disconnect necessary fuel lines using proper procedure. See «FUEL LINE QUICK-CONNECT FITTINGS»(ref-97381-S41285798802001050300000) . Raise and support vehicle. Disconnect exhaust pipe at exhaust manifolds. Remove starter. Support engine with engine hoist.
9. Manufacturer recommends removing transmission from vehicle for engine removal. Remove transmission. On A/T models, remove transmission oil cooler line brackets from oil pan.
10. On all models, remove engine mount through-bolts. Remove engine.

Installation

1. To install, reverse removal procedure. If installing front engine mounts onto cylinder block, install NEW bolts. Always use NEW bolts when installing transmission mount support bracket for rear mount on transmission case. Transmission mount support bracket is located between transmission case and rear mount.
2. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) .
3. On A/T models, before installing oil cooler lines on transmission and transmission oil cooler, ensure all fittings are clean. Install oil cooler line into quick disconnect fitting. Push oil cooler line inward until a click is heard. Pull on oil cooler line to ensure oil cooler line is locked into place. Fill transmission with Mopar ATF Plus Type 7176 fluid.
4. On all models, use proper procedure when installing fuel lines. See «FUEL LINE QUICK-CONNECT FITTINGS»(ref-97381-S41285798802001050300000) . Evacuate and recharge A/C system, if equipped.
5. Ensure serpentine belt is properly routed. For proper serpentine belt routing, see illustration in appropriate article in ENGINE COOLING.
6. Adjust all fluid levels. If oil filter was removed, prime oil pump by squirting engine oil into oil filter mounting stud on front cover until engine oil flows out of front cover. Fill oil filter with oil, and install.

1. Disconnect negative battery cable. Drain cooling system. Note direction of serpentine belt routing for installation reference. Route serpentine belt in proper direction to prevent water pump from rotating in wrong direction and causing engine overheating. Remove serpentine belt.
2. Remove generator brace and generator. On A/C-equipped models, remove A/C compressor with hoses attached, and secure aside. On all models, remove air cleaner cover and air filter from air cleaner housing. Remove air cleaner housing and gasket from throttle body.
3. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-97381-S05698768482001050300000). Disconnect fuel line from fuel rail using proper procedure. See «FUEL LINE QUICK-CONNECT FITTINGS»(ref-97381-S41285798802001050300000).
4. Disconnect necessary control cables, electrical connections, vacuum hoses and accelerator linkage. Remove ignition coils with spark plug wires. Remove heater coolant hoses, positive crankcase ventilation and evaporation control systems components for access to intake manifold.
5. Remove throttle body and gasket from upper intake manifold. Remove upper intake manifold bolts in proper sequence. (Scheme 2) Remove upper intake manifold and gasket.
6. Remove lower intake manifold bolts in sequence. (Scheme 3) Remove lower intake manifold.
7. Remove gaskets for lower intake manifold from cylinder heads. Remove seals for lower intake manifold from each end of cylinder block. DO NOT lose locator dowels used in cylinder heads and cylinder block for alignment of gaskets and seals for lower intake manifold. (Scheme 4)
8. If removing fuel rail with fuel injectors from lower intake manifold, remove fuel rail bolts from lower intake manifold.
9. Gently rock and pull upward on left fuel rail until fuel injectors just start to clear lower intake manifold. Gently rock and pull upward on right fuel rail until fuel injectors just start to clear lower intake manifold. Repeat procedure until all fuel injectors are clear of lower intake manifold. Remove fuel rail (with fuel injectors) from lower intake manifold.
10. If removing fuel injector from fuel rail, remove retaining clip holding fuel injector on fuel rail. Remove fuel injector from fuel rail.

Scheme 2

Scheme 3

Scheme 4

1. If installing fuel injector onto fuel rail, install NEW "O" ring onto fuel injector, if necessary. Install fuel injector onto fuel rail. Install retaining clip.
2. If installing fuel rail with fuel injectors, apply clean engine oil onto "O" ring on fuel injector. Ensure all fuel injectors are positioned with electrical connector facing toward passenger side of vehicle.
3. Install fuel rail (with fuel injectors) into lower intake manifold. DO NOT damage "O" rings on fuel injectors. Ensure fuel injectors are fully seated into lower intake manifold. Install and tighten fuel rail bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000).
4. Ensure gaskets surfaces on cylinder head and cylinder block are clean. Install NEW gaskets for lower intake manifold onto cylinder heads. Ensure locator dowels on gaskets align with holes in cylinder head. (Scheme 4)
5. Remove Blue peel-off paper from seal. Install seal on rear of cylinder block. (Scheme 4) Remove Brown peel-off paper from seal. Install seal onto front of cylinder block. (Scheme 4) Ensure slots in end of each seal engage with notches in gaskets for lower intake manifold and locator dowel hole aligns with locator dowel on cylinder block. Ensure seals are pushed firmly against cylinder block.
6. Apply sealant at each pocket area at corner of seal where it fits against gasket on cylinder head. (Scheme 4) DO NOT overfill pocket area with sealant.
7. Install lower intake manifold. Ensuring gaskets and seals remain in place. Install all bolts for lower intake manifold finger tight. Tighten lower intake manifold bolts to specification in sequence. (Scheme 3) See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000).
8. Using NEW gasket, install upper intake manifold. Install all bolts for upper intake manifold finger tight. Tighten upper intake manifold bolts to specification in sequence. (Scheme 2)
9. Using NEW gasket, install throttle body. Tighten throttle body nuts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000). To install remaining components, reverse removal procedure. Use proper procedure when installing fuel line on fuel rail. See «FUEL LINE QUICK-CONNECT FITTINGS»(ref-97381-S41285798802001050300000).
10. Use NEW gasket when installing air cleaner housing on throttle body. Tighten all bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000).
11. Ensure serpentine belt is properly routed. For proper serpentine belt routing, see illustration in appropriate article in ENGINE COOLING. Fill cooling system.

1. Disconnect negative battery cable. Raise and support vehicle. Disconnect exhaust pipe from exhaust manifold. Remove heat shields for access to exhaust manifold.
2. For passenger side exhaust manifold, disconnect oil dipstick tube bracket from exhaust manifold. For all exhaust manifolds, note location of studs for exhaust manifolds. Remove bolts, exhaust manifold and gasket.

To install, reverse removal procedure using NEW gaskets. When installing heat shields, ensure tabs on heat shield hook over slots in gaskets for exhaust manifold. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Remove upper and lower intake manifolds. See «INTAKE MANIFOLD»(ref-97381-S38885203512001050300000) . Remove exhaust manifold. See «EXHAUST MANIFOLD»(ref-97381-S39997278982001050300000) .
2. Remove rocker arms and push rods. See «ROCKER ARM & VALVE LIFTERS»(ref-97381-S23664062502001050300000) . Remove spark plugs. Remove cylinder head bolts, cylinder head and gasket.

1. To install, reverse removal procedure using NEW gaskets. Tighten cylinder head bolts to specification in sequence. (Scheme 5) See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000).
2. Use proper procedure when installing rocker arms and push rods. See «ROCKER ARM & VALVE LIFTERS»(ref-97381-S23664062502001050300000). Ensure proper procedure is used when installing intake manifolds. See «INTAKE MANIFOLD»(ref-97381-S38885203512001050300000).

Scheme 5

1. Disconnect negative battery cable. Remove cooling fan shroud from radiator. Note direction of serpentine belt routing for installation reference. Route serpentine belt in proper direction to prevent water pump from rotating wrong direction and causing engine overheating. Remove serpentine belt.
2. Remove cooling fan and fan clutch assembly from water pump by rotating nut on fan clutch assembly counterclockwise (viewed from front of engine) while holding water pump pulley. Store cooling fan in vertical position.
3. Remove vibration damper bolt. Using puller, pull vibration damper from crankshaft. Pull front seal from timing chain cover. DO NOT damage sealing surface on crankshaft and timing chain cover.

1. Install new front seal on Seal Installer (6806). Place seal installer and front seal on crankshaft. Thread Vibration Damper Installer (C3688) into crankshaft and push front seal into timing chain cover. Remove vibration damper puller/installer and seal installer.
2. To install remaining components, reverse removal procedure. Use vibration damper installer to press vibration damper onto crankshaft. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) .
3. Ensure serpentine belt is properly routed. For proper serpentine belt routing, see DRIVE BELT ROUTING in SPECIFICATIONS article in ENGINE COOLING.

1. Disconnect negative battery cable. Remove water pump. See «WATER PUMP»(ref-97381-S38993441722001050300000) . Remove A/C compressor with hoses attached, and secure aside. Remove generator, air injection pump and brackets.
2. Remove vibration damper bolt. Using puller, pull vibration damper from crankshaft.
3. Remove oil filter from timing chain cover. Loosen all oil pan-to-cylinder block bolts. Remove oil pan-to-timing chain cover bolts. Remove timing chain cover bolts.
4. Remove timing chain cover and gasket. DO NOT damage oil pan gasket. Remove crankshaft front seal from timing chain cover, if necessary.

1. Ensure sealing surfaces on cylinder block and timing chain cover are clean. Using NEW gasket, install timing chain cover onto cylinder block. Apply sealant at timing chain cover gasket-to-oil pan gasket joint area. Install timing chain cover bolts and oil pan-to-timing chain cover bolts finger tight.
2. Tighten timing chain cover bolts, oil pan-to-timing chain cover, and then oil pan-to-cylinder block bolts, to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) .
3. If installing NEW crankshaft front seal, install front seal on Seal Installer (6806). Place seal installer and front seal onto crankshaft. Thread Vibration Damper Installer (C3688) into crankshaft and push front seal into the timing chain cover. Remove vibration damper puller/installer and seal installer.
4. Use vibration damper installer to press vibration damper onto crankshaft. To install remaining components, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) .
5. Squirt engine oil into oil filter mounting stud on front cover until engine oil flows out of front cover to prime oil pump. Fill oil filter with oil and install.
6. Ensure serpentine belt is properly routed. For proper serpentine belt routing, see appropriate illustration in appropriate article in ENGINE COOLING. Fill cooling system.

1. Remove timing chain cover. See «TIMING CHAIN COVER»(ref-97381-S19749473912001050300000). Check timing chain stretch to determine if timing chain replacement is required.
2. Position measuring scale near link on timing chain at top of camshaft sprocket so movement can be measured. Place torque wrench on camshaft sprocket bolt. Apply 30 ft. lbs. (41 N.m) torque with cylinder heads installed or 15 ft. lbs. (20 N.m) torque with cylinder heads removed on camshaft sprocket bolt in direction of engine rotation. Note reading on measuring scale.
3. Apply equal torque in opposite direction and note amount of timing chain movement on measuring scale. Replace timing chain if movement exceeds 1/8" (3.17 mm).
4. Ensure camshaft end play is within specification. See «CAMSHAFT»(ref-97381-S01448563952001050300000) table under ENGINE SPECIFICATIONS. Replace camshaft thrust plate on front of camshaft if camshaft end play is not within specification.
5. To remove timing chain, rotate crankshaft so timing marks are aligned. (Scheme 6) Remove camshaft sprocket bolt. Remove camshaft sprocket with timing chain. If necessary to remove crankshaft sprocket, use Puller (6444) and Jaws (6820) to remove crankshaft sprocket.

1. If installing crankshaft sprocket on crankshaft, use Adapter (MD990799), Crankshaft Sprocket Installer (C3718) and Vibration Damper Installer (C3688) to press crankshaft sprocket onto crankshaft. Ensure crankshaft sprocket is installed with timing mark facing outward and fully seated on crankshaft.
2. Rotate crankshaft so timing mark on crankshaft sprocket is facing upward and aligned with centerline on camshaft. Install timing chain onto camshaft sprocket.
3. Align timing mark on camshaft sprocket with timing mark on crankshaft sprocket. Install camshaft sprocket and timing chain. Use straightedge to ensure timing marks are aligned on camshaft sprocket and crankshaft sprocket. (Scheme 6)
4. Install and tighten camshaft sprocket bolt to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000).
5. Ensure camshaft end play is within specification. See «CAMSHAFT»(ref-97381-S01448563952001050300000) table under ENGINE SPECIFICATIONS. Replace camshaft thrust plate on front of camshaft if camshaft end play is not within specification.
6. To install remaining components, reverse removal procedure. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) table. Ensure proper procedure is used when installing timing chain cover. See «TIMING CHAIN COVER»(ref-97381-S19749473912001050300000).

Scheme 6

1. Disconnect negative battery cable. It may be necessary to remove upper intake manifold for removal of rocker arm on passenger side. See «INTAKE MANIFOLD»(ref-97381-S38885203512001050300000).
2. On all applications, mark spark plug wire location for installation reference. Disconnect spark plug wires at spark plugs.
3. Note location of stud bolts in each valve cover for installation reference. Remove valve cover and gasket. Valve cover gasket may be reused if not damaged.
4. Remove rocker arm bolt. Remove rocker arm pedestals, rocker arms and retainer. (Scheme 7) Mark component location for installation reference.
5. Remove push rods. Mark component location for installation reference.
6. If removing valve lifters, remove lower intake manifold. See «INTAKE MANIFOLD»(ref-97381-S38885203512001050300000).
7. Remove bolts, yoke retainer and aligning yoke. (Scheme 7) Using twisting motion, remove valve lifter from cylinder block.

Scheme 7

1. If installing valve lifter, lubricate valve lifter with clean engine oil. Install valve lifter into original location on cylinder block. Position valve lifter with oil bleed hole, if equipped, toward front of cylinder block.
2. Install aligning yoke and yoke retainer. Install and tighten yoke retainer bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) .
3. Install push rods, rocker arms and rocker arm pedestals into original location. Install and tighten rocker arm bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) . DO NOT rotate or crank engine during or immediately after rocker arm installation.
4. Install lower and upper intake manifold. Ensure proper procedure is followed when installing intake manifolds. See «INTAKE MANIFOLD»(ref-97381-S38885203512001050300000) .
5. Note location of numbered tab on valve cover gasket. Numbered tab is located between mounting bolt holes on inner edge of valve cover gasket.
6. Install valve cover gaskets with number on numbered tab facing upward, toward valve cover. Driver's-side valve cover gasket should be installed with numbered tab area toward front of engine. Passenger's- side valve cover gasket should be installed with numbered tab area toward rear of engine.
7. Install valve cover and bolts. Ensure stud bolts are installed in original location. Tighten valve cover bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) .
8. To install remaining components, reverse removal procedure. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) . Allow engine to idle for a few minutes until valve lifters become quiet. DO NOT operate engine at speeds greater than idle speed until valve lifters have filled and become quiet, or valve mechanism may be damaged.

1. Remove rocker arms and valve lifters. See «ROCKER ARM & VALVE LIFTERS»(ref-97381-S23664062502001050300000) . NOTE: Valve lifters located in 4 corners may be lifted upward away from camshaft and retained in this position for camshaft removal and installation. These valve lifters may require cylinder head and gasket to be removed if valve lifter is being removed from cylinder block. Manufacturer states these valve lifters may be removed by cutting cylinder head gasket for access to valve lifter. If necessary to remove cylinder head and gasket, see «CYLINDER HEAD»(ref-97381-S02820970172001050300000) .
2. Remove timing chain. See «TIMING CHAIN»(ref-97381-S26318775972001050300000) . Ensure camshaft end play is within specification. See «CAMSHAFT»(ref-97381-S01448563952001050300000) table under ENGINE SPECIFICATIONS. Replace camshaft thrust plate on front of camshaft if camshaft end play is not within specification.
3. Remove bolts and camshaft thrust plate. Install long bolt in front of camshaft. Remove camshaft. DO NOT damage camshaft or camshaft bearings. Inspect camshaft bearings. See «CAMSHAFT BEARINGS»(ref-97381-S28025222412001050300000) .

1. Lubricate camshaft lobes and journals. Install long bolt into front of camshaft. Install camshaft. DO NOT damage camshaft or camshaft bearings.
2. Install camshaft thrust plate. Install and tighten camshaft thrust plate bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) .
3. To install remaining components, reverse removal procedure. Ensure proper procedure is used when installing rocker arm and push rods. See «ROCKER ARM & VALVE LIFTERS»(ref-97381-S23664062502001050300000) .
4. Ensure oil pump is primed after installing timing chain cover by squirting engine oil into oil filter mounting stud on front cover until engine oil flows out of front cover. Fill oil filter with engine oil before installing to provide proper engine lubrication.

1. Inspect camshaft bearing for damage. Replace camshaft bearing if damaged or if I.D. is not within specification. See «CAMSHAFT»(ref-97381-S01448563952001050300000) table under ENGINE SPECIFICATIONS.
2. Use Camshaft Bearing Remover/Installer (C-3132-A) for camshaft bearing replacement. Ensure oil holes in camshaft bearing and cylinder block are aligned. Apply sealant and install NEW core plug in rear of cylinder block at rear camshaft bearing area.

1. Manufacturer lists oil seal removal procedure with crankshaft rear oil seal retainer removed from cylinder block. Remove transmission and flywheel/flexplate.
2. Remove oil pan. See «OIL PAN»(ref-97381-S05812520002001050300000) . Remove bolts, crankshaft rear oil seal retainer and gasket. Remove oil seal from crankshaft rear oil seal retainer.

1. Install new oil seal into crankshaft rear oil seal retainer. Using Pilot (6687), install crankshaft rear oil seal retainer onto cylinder block.
2. Install and tighten crankshaft rear oil seal retainer bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) .
3. Using dial indicator, ensure surface of oil seal is even within .030-.050" (.762-1.27 mm) relative to rear surface on crankshaft. If oil seal is high in certain areas, tap high side of oil seal into crankshaft rear oil seal retainer.
4. Install oil pan using proper procedure. See «OIL PAN»(ref-97381-S05812520002001050300000) . To install remaining components, reverse removal procedure. Apply thread sealant onto threads of NEW flywheel/flexplate bolts before installing. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) .

1. Disconnect negative battery cable. Drain cooling system. Remove windshield washer fluid reservoir from fan shroud. Remove fan shroud from radiator, and position back on engine.
2. Remove upper radiator hose from radiator. Remove cooling fan and fan clutch assembly from water pump by rotating nut on fan clutch assembly counterclockwise (viewed from front of engine) while holding water pump pulley.
3. Remove cooling fan and fan clutch assembly with fan shroud as an assembly. Store cooling fan in a vertical position.
4. Note direction of serpentine belt routing for installation reference. Route serpentine belt in proper direction to prevent water pump from rotating in wrong direction and causing engine overheating. Remove serpentine belt.
5. Remove bolts and water pump pulley from water pump. Disconnect coolant hoses at water pump. Remove water pump bolts.
6. Loosen coolant by-pass hose clamp at water pump. Pull water pump from coolant by-pass hose. Remove water pump and "O" ring from timing chain cover. DO NOT pry water pump from timing chain cover, or sealing surfaces may be damaged.

1. If installing new water pump, apply thread sealant onto heater hose fitting, and install onto water pump so heater hose fitting is within proper area. (Scheme 8) Tighten heater hose fitting to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000).
2. To install remaining components, reverse removal procedure using NEW "O" ring. Apply petroleum jelly onto "O" ring, and install onto water pump before installing water pump.
3. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000). Rotate water pump to ensure impeller onto water pump does not contact timing chain cover.
4. Ensure serpentine belt is properly routed. For proper serpentine belt routing, see illustration in appropriate article in ENGINE COOLING.
5. Tighten water pump pulley bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000). Fill cooling system.

Scheme 8

1. Disconnect negative battery cable. Raise and support vehicle. Drain engine oil. Remove engine-to-transmission strut for access to oil pan.
2. On 2WD models, engine may have to be raised slightly for servicing of oil pan. On all models, note location of oil pan stud bolts and remaining bolts for installation reference. Remove bolts, oil pan and gasket.

1. Fabricate 4 guide dowels by cutting bolt head off of 1 1/2 x 5/16" bolts. Install guide dowels in all 4 corners of cylinder block.
2. Apply silicone sealant onto cylinder block-to-timing chain cover and at cylinder block-to-crankshaft rear oil seal retainer joining areas. Using NEW gasket, install oil pan onto cylinder block.
3. Install bolts in oil pan. Remove guide dowels. Install remaining oil pan bolts. Tighten oil pan bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) . To install remaining components, reverse removal procedure. Fill crankcase with engine oil.

Removal & Disassembly

1. Remove timing chain cover. See «TIMING CHAIN COVER»(ref-97381-S19749473912001050300000) under REMOVAL & INSTALLATION. Remove pressure relief valve plug and gasket. (Scheme 9)
2. Remove pressure relief valve spring and pressure relief valve. (Scheme 9) Remove oil pump cover, inner rotor and outer rotor from rear of timing chain cover.

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Lubricate rotors with petroleum jelly before installing into timing chain cover. Ensure inner rotor is installed in timing chain cover so chamfered side of rotor is facing upward (toward oil pump cover).
2. Use NEW gasket when installing pressure relief valve plug. Tighten oil pump cover bolts and pressure relief valve plug to specification. See «TORQUE SPECIFICATIONS»(ref-97381-S23573157422001050300000) . Ensure inner rotor moves freely after installing oil pump cover. CAUTION: Ensure oil pump is primed by squirting engine oil into oil filter mounting stud on front cover until engine oil flows out of front cover. Fill oil filter with engine oil before installing to provide proper engine lubrication.
3. To install, reverse removal procedure. Ensure proper procedure is followed when installing timing chain cover. See «TIMING CHAIN COVER»(ref-97381-S19749473912001050300000) under REMOVAL & INSTALLATION.

Scheme 9