5.7l Engine - Overhaul Dodge Pickup R1500

DESCRIPTION

The 5.7L engine (Scheme 336)(345 CID) eight-cylinder engine is a 90° V-Type lightweight, deep skirt cast iron block, aluminum heads, single cam, overhead valve engine with hydraulic roller tappets. The heads incorporate splayed valves with a hemispherical style combustion chamber and dual spark plugs. The cylinders are numbered from front to rear; 1, 3, 5, 7 on the left bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2.

Scheme 336

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION

Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance.

These malfunctions may be classified as either performance (e.g., engine idles rough and stalls) or mechanical (e.g., a strange noise).

(Refer to PERFORMANCE and (Refer to MECHANICAL for possible causes and corrections of malfunctions. (Refer to FUEL DELIVERY - GAS ) and (Refer to FUEL INJECTION - GAS ) for the fuel system diagnosis.

Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the following diagnosis

1. Cylinder Compression Pressure Test (Refer to «DIAGNOSIS AND TESTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul__diagnosis-and-testing-cylinder-compression) ).
2. Cylinder Combustion Pressure Leakage Test (Refer to «DIAGNOSIS AND TESTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul__diagnosis-and-testing-cylinder-combustion-pressure) ).
3. Engine Cylinder Head Gasket Failure Diagnosis (Refer to «DIAGNOSIS AND TESTING-CYLINDER HEAD GASKET FAILURE»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul__diagnosis-and-testing-cylinder-head-gasket-failure) ).
4. Intake Manifold Leakage Diagnosis (Refer to «DIAGNOSIS AND TESTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul__diagnosis-and-testing-intake-manifold) ).

DIAGNOSIS AND TESTING-ENGINE DIAGNOSIS - PERFORMANCE

PERFORMANCE TROUBLE SYMPTOM CHART

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL

MECHANICAL TROUBLE SYMPTOM CHART

DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE

The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.

Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.

1. Clean the spark plug recesses with compressed air.
2. Remove the spark plugs.
3. Disable the fuel system (Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine__standard-procedure-fuel-system-pressure) ).
4. Remove the ASD relay (Refer to «AUTOMATIC SHUT DOWN RELAY»(/dodge/pickup-r1500/1997-2012/remont/ignition-system/#ignition-control) ).
5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Pressure variation should not exceed 25% between cylinders.

DIAGNOSIS AND TESTING- CYLINDER COMBUSTION PRESSURE LEAKAGE

The combustion pressure leakage test provides an accurate means for determining engine condition.

Combustion pressure leakage testing will detect

1. Exhaust and intake valve leaks (improper seating).
2. Leaks between adjacent cylinders or into water jacket.
3. Any causes for combustion/compression pressure loss.

1. Check the coolant level and fill as required. DO NOT install the radiator cap.
2. Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.
3. Remove the spark plugs.
4. Remove the oil filler cap.
5. Remove the air cleaner hose.
6. Calibrate the tester according to the manufacturer's instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379 kPa (200 psi) maximum and 552 kPa (80 psi) recommended.
7. Perform the test procedures on each cylinder according to the tester manufacturer's instructions. Set piston of cylinder to be tested at TDC compression, While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the radiator coolant.

All gauge pressure indications should be equal, with no more than 25% leakage.

FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the cylinder.

Refer to CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART .

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION

LUBRICATION TROUBLE SYMPTOM CHART

ENGINE MECHANICAL DIAGNOSIS CHART

ENGINE MECHANICAL DIAGNOSIS CHART

STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS

Damaged or worn threads can be repaired. Essentially, this repair consists of

1. Drilling out worn or damaged threads.
2. Tapping the hole with a special Heli-Coil Tap, or equivalent.
3. Installing an insert into the tapped hole to bring the hole back to its original thread size.

STANDARD PROCEDURE-HYDROSTATIC LOCK

When an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps below.

1. Perform the Fuel Pressure Release Procedure (Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine__standard-procedure-fuel-system-pressure) ).
2. Disconnect the negative cable(s) from the battery.
3. Inspect air cleaner, induction system, and intake manifold to ensure system is dry and clear of foreign material.
4. Place a shop towel around the spark plugs to catch any fluid that may possibly be under pressure in the cylinder head. Remove the spark plugs.
5. With all spark plugs removed, rotate the crankshaft using a breaker bar and socket.
6. Identify the fluid in the cylinders (coolant, fuel, oil, etc.).
7. Be sure all fluid has been removed from the cylinders.
8. Repair engine or components as necessary to prevent this problem from occurring again.
9. Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
10. Install new spark plugs. Tighten the spark plugs to 41 N.m (30 ft. lbs.) torque.
11. Drain engine oil. Remove and discard the oil filter.
12. Install the drain plug. Tighten the plug to 34 N.m (25 ft. lbs.) torque.
13. Install a new oil filter.
14. Fill engine crankcase with the specified amount and grade of oil. (Refer to owner's manual ).
15. Connect the negative cable(s) to the battery.
16. Start the engine and check for any leaks.

REMOVAL

1. Perform the Fuel System Pressure Release procedure (Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine__standard-procedure-fuel-system-pressure) ).
2. Disconnect the battery negative cable.
3. Remove the air cleaner resonator and duct work as an assembly.
4. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas) ).
5. Remove the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
6. Remove the viscous fan/drive (Refer to «FAN DRIVE VISCOUS CLUTCH-GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
7. Remove radiator (Refer to «RADIATOR-3.7L/4.7L/5.7L»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
8. Remove the upper crossmember and top core support. NOTE: It is not necessary to drain A/C system for engine removal.
9. Remove the A/C compressor with the lines attached. Secure compressor out of the way.
10. Remove generator assembly (Refer to «GENERATORS & REGULATORS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) ).
11. Remove the intake manifold and IAFM as an assembly (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
12. Disconnect the heater hoses. NOTE: It is not necessary to disconnect P/S hoses from pump, for P/S pump removal.
13. Remove the power steering pump and set aside.
14. Disconnect the fuel supply line (Refer to «QUICK CONNECT FITTING»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine) ).
15. Raise and support the vehicle on a hoist and drain the engine oil.
16. Remove engine front mount thru-bolt nuts.
17. Remove right side axle retaining bolts.
18. Disconnect the transmission oil cooler lines from their retainers at the oil pan bolts.
19. Disconnect exhaust pipe at manifolds.
20. Disconnect the starter wires. Remove starter motor (Refer to «STARTERS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) ).
21. Remove the structural dust cover and transmission inspection cover, (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
22. Remove drive plate to converter bolts (Automatic transmission equipped vehicles).
23. Remove transmission bell housing to engine block bolts.
24. Lower the vehicle.
25. Install engine lift fixture, special tool # 8984.
26. Separate engine from transmission, remove engine from vehicle, and install engine assembly on a repair stand.

INSTALLATION

1. Install engine lift fixture Special tool # 8984.
2. Position the engine in the engine compartment.
3. Lower engine into compartment and align engine with transmission: Manual Transmission: Align clutch disc assembly (if disturbed). Install transmission input shaft into clutch disc while mating engine and transmission surfaces. Install two transmission to engine block mounting bolts finger tight. Automatic Transmission: Mate engine and transmission and install two transmission to engine block mounting bolts finger tight.
4. Position the thru-bolt into the support cushion brackets.
5. Lower engine assembly until engine mount through bolts rest in mount perches.
6. Install remaining transmission to engine block mounting bolts and tighten.
7. Tighten engine mount through bolts.
8. Install drive plate to torque converter bolts. (Automatic transmission models)
9. Install the structural dust cover and transmission dust cover, (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
10. Install the starter and connect the starter wires (Refer to «STARTERS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) ).
11. Install exhaust pipe to manifold.
12. Lower the vehicle.
13. Remove engine lift fixture, special tool # 8984.
14. Connect the fuel supply line (Refer to «QUICK CONNECT FITTING»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine) ).
15. Reinstall the power steering pump.
16. Connect the heater hoses.
17. Install the intake manifold.
18. Using a new gasket, install throttle body (Refer to «THROTTLE BODY»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-gas-engine) ).
19. Install the generator and wire connections (Refer to «GENERATORS & REGULATORS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) ).
20. Install a/c compressor and lines (Refer to «A/C COMPRESSOR»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing__ac-compressor) ).
21. Install the accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
22. Install upper radiator support crossmember.
23. Install radiator (Refer to «RADIATOR-3.7L/4.7L/5.7L»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
24. Connect the radiator lower hose.
25. Connect the transmission oil cooler lines to the radiator.
26. Install the fan shroud.
27. Install the fan (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
28. Connect the radiator upper hose.
29. Install the washer bottle.
30. Connect the transmission cooler lines.
31. Install the air cleaner resonator and duct work.
32. Add engine oil to crankcase (Refer to owner's manual ).
33. Fill cooling system (Refer to «REFILLING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).
34. Connect battery negative cable.
35. Start engine and inspect for leaks.
36. Road test vehicle.

GENERAL DESCRIPTION

ENGINE GENERAL DESCRIPTION

CYLINDER BLOCK

CYLINDER BLOCK SPECIFICATION

PISTONS

PISTONS SPECIFICATION

PISTON PINS

PISTON PINS SPECIFICATION

PISTON RINGS

PISTON RINGS SPECIFICATION

CONNECTING RODS

CONNECTING RODS SPECIFICATION

CRANKSHAFT

CRANKSHAFT SPECIFICATION

CAMSHAFT

CAMSHAFT SPECIFICATION

VALVE TIMING

VALVE TIMING SPECIFICATION

CYLINDER HEAD

CYLINDER HEAD SPECIFICATION

HYDRAULIC TAPPETS

HYDRAULIC TAPPETS SPECIFICATION

VALVES

VALVES SPECIFICATION

VALVE SPRING

VALVE SPRING SPECIFICATION

OIL PUMP

OIL PUMP SPECIFICATION

OIL PRESSURE

OIL PRESSURE SPECIFICATION

TORQUE CHART 5.7L ENGINE

TORQUE SPECIFICATION CHART 5.7L ENGINE

Scheme 337

Scheme 338

Scheme 339

Scheme 340

Scheme 341

Scheme 342

Scheme 343

Scheme 344

Scheme 345

Scheme 346

Scheme 347

Scheme 348

Scheme 349

Scheme 350

Scheme 351

Scheme 352

Scheme 353

Scheme 354

Scheme 355

Scheme 356

Scheme 357

Scheme 358

Filter Element Only

Housing removal is not necessary for element (filter) replacement.

Scheme 359

1. Loosen clamp (Scheme 359) and disconnect air duct at air cleaner cover.
2. Pry over 4 spring clips (Scheme 359) from housing cover (spring clips retain cover to housing).
3. Release housing cover from locating tabs on housing (Scheme 359) and remove cover.
4. Remove air cleaner element (filter) from housing.
5. Clean inside of housing before replacing element.

Scheme 360

1. Loosen clamp (Scheme 359) and disconnect air duct at air cleaner cover.
2. Lift entire housing assembly from 4 locating pins (Scheme 360)

1. Install filter element into housing.
2. Position housing cover into housing locating tabs (Scheme 359)
3. Pry up 4 spring clips (Scheme 359) 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.

OPERATION-CYLINDER HEAD

The cylinder head closes the combustion chamber allowing the pistons to compress the air fuel mixture to the correct ratio for ignition. The valves located in the cylinder head open and close to either allow clean air into the combustion chamber or to allow the exhaust gases out, depending on the stroke of the engine.

DIAGNOSIS AND TESTING-CYLINDER HEAD GASKET FAILURE

A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket.

1. Possible indications of the cylinder head gasket leaking between adjacent cylinders are: Loss of engine power Engine misfiring Poor fuel economy
2. Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are: Engine overheating Loss of coolant Excessive steam (white smoke) emitting from exhaust Coolant foaming

CYLINDER-TO-CYLINDER LEAKAGE TEST

To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in Cylinder Compression Pressure Test in this section. An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50-70% reduction in compression pressure.

CYLINDER-TO-WATER JACKET LEAKAGE TEST

VISUAL TEST METHOD

With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens.

If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.

COOLING SYSTEM TESTER METHOD

Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester's pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.

CHEMICAL TEST METHOD

Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent. Perform test following the procedures supplied with the tool kit.

1. Disconnect the battery negative cable.
2. Drain cooling system.
3. Remove the air cleaner resonator and duct work.
4. Remove the generator.
5. Remove closed crankcase ventilation system.
6. Disconnect the evaporation control system.
7. Perform the Fuel System Pressure Release procedure (Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine__standard-procedure-fuel-system-pressure) ). Disconnect the fuel supply line (Refer to «QUICK CONNECT FITTING»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine) ).
8. Disconnect heater hoses.
9. Remove cylinder head covers and gaskets.
10. Remove intake manifold and throttle body as an assembly.
11. Remove rocker arm assemblies and push rods. Identify to ensure installation in original locations.
12. Remove the head bolts from each cylinder head and remove cylinder heads. Discard the cylinder head gasket.

CLEANING

Clean all surfaces of cylinder block and cylinder heads.

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

INSPECTION

1. Inspect the cylinder head for out-of-flatness, using a straightedge and a feeler gauge. If tolerances exceed 0.0508 mm (0.002 in.) replace the cylinder head.
2. Inspect the valve seats for damage. Service the valve seats as necessary.
3. Inspect the valve guides for wear, cracks or looseness. If either condition exist, replace the cylinder head.
4. Inspect pushrods. Replace worn or bent push-rods.

Scheme 361

1. Clean all surfaces of cylinder block and cylinder heads.
2. Clean cylinder block front and rear gasket surfaces using a suitable solvent. CAUTION: The head gaskets are not interchangeable between left and right sides. They are marked "L" and "R" to indicate left and right sides.
3. Position new cylinder head gaskets onto the cylinder block. CAUTION: The head gaskets are marked "TOP" to indicate which side goes up.
4. Position cylinder heads onto head gaskets and cylinder block.
5. Tighten the cylinder head bolts in three steps (Scheme 361): Step 1 - Snug tighten M12 cylinder head bolts, in sequence, to 34 N.m (25 ft. lbs.) and M8 bolts to 20 N.m (15 ft. lbs.) torque. Step 2 - Tighten M12 cylinder head bolts, in sequence, to 54 N.m (40 ft. lbs.) and verify M8 bolts to 20 N.m (15 ft. lbs.) torque. Step 3 - Turn M12 cylinder head bolts, in sequence, 90 degrees and tighten M8 bolts to 34 N.m (25 ft. lbs.) torque.
6. Install push rods and rocker arm assemblies in their original position.
7. Install the intake manifold and throttle body assembly.
8. If required, adjust spark plugs to specifications. Install the plugs.
9. Connect the heater hoses.
10. Install the fuel supply line.
11. Install the generator and drive belt.
12. Install cylinder head covers (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
13. Connect the evaporation control system.
14. Install the air cleaner.
15. Fill cooling system.
16. Connect the negative cable to the battery.
17. Start engine check for leaks.

1. Disconnect battery negative cable.
2. Disconnect coil on plug connectors. CAUTION: The ground straps must be installed in the same location as removed. The covers are machined to accept the ground straps in those locations only.
3. Remove cylinder head cover retaining bolts and ground straps.
4. Remove cylinder head cover.

Note. The gasket may be used again, provided no cuts, tears, or deformation has occurred.

1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary.
2. Install cylinder head cover and hand start all fasteners. Verify that all double ended studs are in the correct location and install left and right ground straps. CAUTION: The ground straps must be installed in the same location as removed. The covers are machined to accept the ground straps in those locations only. NOTE: The right hand ground strap is located on the front inboard stud. The left hand ground strap is located on the rear inboard stud.
3. Tighten cylinder head cover bolts and double ended studs to 8 N.m (70 in. lbs). Begin torque sequence in the middle of head cover and torque bolts moving outward in a crisscross pattern from top to bottom.
4. Install ignition coil on plug, and torque fasteners to 12 N.m (105 in. lbs)
5. Connect, ignition coil electrical connectors.
6. Install PCV hose.
7. Connect battery negative cable.

DESCRIPTION - VALVE GUIDES

The valve guides are made of powered metal and are pressed into the cylinder head. The guides are not replaceable or serviceable, and valve guide reaming is not recommended. If the guides are worn beyond acceptable limits, replace the cylinder heads.

Both the intake and exhaust valves are made of steel. The intake valve is 50.93 mm (2.00 inches) in diameter and the exhaust valve is 39.53 mm (1.55 inches) in diameter. All valves use three bead lock keepers to retain the springs and promote valve rotation.

STANDARD PROCEDURE - REFACING

Note. Valve seats that are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced.

Note. When refacing valves and valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained.

Scheme 362

1. Using a suitable dial indicator measure the center of the valve seat Total run out must not exceed 0.051 mm (0.002 in).
2. Apply a small amount of Prussian blue to the valve seat, insert the valve into the cylinder head, while applying light pressure on the valve rotate the valve. Remove the valve and examine the valve face. If the blue is transferred below the top edge of the valve face, lower the valve seat using a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, raise the valve seat using a 65 degree stone.
3. When the seat is properly positioned the width of the intake seat must be 1.018 - 1.62 mm (0.0464 -0.0637 in.) and the exhaust seat must be 1.48 - 1.92 mm (0.058 - 0.075 in.).
4. Check the valve spring installed height after refacing the valve and seat. The installed height for both intake and exhaust valve springs must not exceed 46.0 mm (1.81 in.). VALVE FACE AND VALVE SEAT ANGLE CHART VALVE FACE AND VALVE SEAT ANGLE SPECIFICATION CHART DESCRIPTION SPECIFICATION SEAT WIDTH INTAKE EXHAUST 1.018-1.62 mm (0.0464 - 0.0637 in.) 1.48 - 1.92 mm (0.058 - 0.075 in.) FACE ANGLE (INT. AND EXT.) 45° - 451/2° SEAT ANGLE (INT. AND EXT.) 441/2°-45°
5. The valve seat must maintain an angle of 44.5 - 45.0 degrees angle.
6. The valve face must maintain a face angle of 45.0 - 45.5 degrees angle (Scheme 362)

1. Remove the cylinder head (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
2. Compress valve springs using Valve Spring Compressor Tool special tool # C-3422and adapter 8464.
3. Remove valve retaining locks, valve spring retainers, 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.

1. Clean valves thoroughly. Discard burned, warped and cracked valves.
2. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
3. Measure valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve.
4. Coat valve stems with lubrication oil and insert them in cylinder head.
5. If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head.
6. Install new seals on all valve guides. Install valve springs and valve retainers.
7. Compress valve springs with Valve Spring Compressor Tool special tool # C- 3422and adapter 8464, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer.
8. Install cylinder head. (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).

1. Remove cylinder head cover. (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) )
2. Loosen the rocker shafts using the following sequence: Center, center-left, center-right, left, right,. CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with an "I".
3. Remove the rocker shafts. Note location for reassembly. CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side.
4. Remove the pushrods. Note pushrod location for reassembly.

1. Install the push rods in the same order as removed. CAUTION: Verify that pushrod is installed into rocker arm and lifter correctly while installing rocker shaft assembly. Recheck after rocker shaft has been torqued to specification. CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with the letter "I".
2. Install rocker shaft assemblies in the same order as removed. CAUTION: Ensure that hold downs and rocker arms are not overlapped when torquing bolts.
3. Tighten the rocker shaft bolts to 22 N.m (195 in. lbs.) torque,using the following sequence: Center, center-right, center-left, right, left. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes).
4. Install cylinder head cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).

The valve guide seals are made of rubber and incorporate an integral steel valve spring seat. The integral garter spring maintains consistent lubrication control to the valve stems.

Scheme 363

1. Disconnect negative battery cable.
2. Remove air cleaner assembly.
3. Remove air intake resonator.
4. Remove spark plug cables.
5. Remove ignition coil connectors (Scheme 363)
6. Remove ignition coils.
7. Remove one spark plug.
8. Remove valve cover. CAUTION: The piston must be at TDC, and both valves closed on the cylinder to be serviced. NOTE: If removing intake valve spring, install special tool# 9070, pushrod retaining plate, to retain the intake pushrods.
9. Remove exhaust/intake rocker arm shafts.
10. Install spring compressor, special tool# 9065. NOTE: All valve springs and seals are removed in the same manner.
11. Charge cylinder with air. NOTE: Tap the top of the valve spring retainer to loosen the spring retainers locks.
12. Compress valve spring and remove valve retainer locks.
13. Release spring compressor and remove valve spring. NOTE: The valve springs are interchangeable between intake and exhaust.
14. Remove valve seal.

1. Install valve seal.
2. Install valve spring.
3. Using special tool# 9065, compress valve spring and install valve spring retainer and locks.
4. Release air charge in cylinder.
5. Remove spring compressor tool # 9065. CAUTION: Verify that the pushrods are fully seated into lifter and rocker arm. Recheck after rocker arm shaft has been torqued to specification.
6. Install rocker arm shaft and pushrods (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
7. Tighten the rocker shaft bolts to 22 N.m (195 in. lbs.) torque,using the following sequence: Center, center-right, center-left, right, left.
8. Remove special tool# 9070, pushrod retaining plate, if used.
9. Install cylinder head cover.
10. Tighten cylinder head cover bolts and double ended studs (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
11. Install spark plugs.
12. Install ignition coil on plug, and torque fasteners to 12 N.m (105 in. lbs)
13. Install ignition coil connectors.
14. Install spark plug cables.
15. Install air intake resonator.
16. Install air cleaner assembly.
17. Connect negative battery cable.

Thoroughly clean the oil pan and engine block gasket surfaces.

Use compressed air to clean out

1. The galley at the oil filter adaptor hole.
2. The front and rear oil galley holes.
3. The feed holes for the crankshaft main bearings.

Once the block has been completely cleaned, apply Loctite PST pipe sealant with Teflon 592 to the threads of the front and rear oil galley plugs. Tighten the 1/4 inch NPT plugs to 20 N.m (177 in. lbs.) torque. Tighten the 3/8 inch NPT plugs to 27 N.m (240 in. lbs.) torque.

Scheme 364

1. It is mandatory to use a dial bore gauge to measure each cylinder bore diameter. To correctly select the proper size piston, a cylinder bore gauge, capable of reading in 0.003 mm (.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer (Scheme 364)
2. Measure the inside diameter of the cylinder bore at three levels below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft and then take two additional reading.
3. Measure the cylinder bore diameter crosswise to the cylinder block near the top of the bore. Repeat the measurement near the middle of the bore, then repeat the measurement near the bottom of the bore.
4. Determine taper by subtracting the smaller diameter from the larger diameter.
5. Rotate measuring device 90° and repeat steps above.
6. Determine out-of-roundness by comparing the difference between each measurement.
7. If cylinder bore taper does not exceed 0.025 mm (0.001 inch) and out-of-roundness does not exceed 0.025 mm (0.001 inch), the cylinder bore can be honed. If the cylinder bore taper or out- of-round condition exceeds these maximum limits, the cylinder block must be replaced. A slight amount of taper always exists in the cylinder bore after the engine has been in use for a period of time.

REMOVAL - CAMSHAFT CORE HOLE PLUG

1. Remove the rear cam bearing core plug.

REMOVAL - CAMSHAFT

1. Remove the battery negative cable.
2. Remove the air cleaner assembly.
3. Drain coolant.
4. Remove the accessory drive belt.
5. Remove the generator.
6. Remove the A/C compressor, and set aside
7. Remove the radiator (Refer to «RADIATOR-3.7L/4.7L/5.7L»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
8. Remove intake manifold (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
9. Remove cylinder head covers (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
10. Remove both left and right cylinder heads (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
11. Remove the oil pan (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
12. Remove timing case cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
13. Remove the oil pick up tube.
14. Remove the oil pump (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
15. Remove timing chain (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
16. Remove camshaft tensioner/thrust plate assembly. NOTE: Identify tappets to ensure installation in original location.
17. Remove the retainer assembly and tappets.
18. 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.

1. The cam bearings are not serviceable. Do not attempt to replace cam bearings for any reason.

INSTALLATION - CAMSHAFT CORE HOLE PLUG

1. Install a new core hole plug at the rear of camshaft, using special tool # 9048. Clean plug and apply mopar® lock and seal adhesive to the edge of the plug, before installing. The plug must be installed to a depth of + / - 0.25mm from the end of the machined bevel, that is the end of the bevel that is closest to the cam bearing.

INSTALLATION - CAMSHAFT

1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft
2. Install camshaft Tensioner plate assembly. Tighten bolts to 28 N.m (250 in. lbs.) torque.
3. Install timing chain and sprockets (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
4. Measure camshaft end play (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ). If not within limits install a new thrust plate.
5. Install the oil pump (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
6. Install the oil pick up tube.
7. 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.
8. Install the tappets and retainer assembly (Refer to «HYDRAULIC TAPPETS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
9. Install both left and right cylinder heads (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
10. Install pushrods
11. Install rocker arms (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
12. Install timing case cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
13. Install the oil pan (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
14. Install cylinder head covers (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
15. Install intake manifold (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
16. Install the A/C compressor, and set aside
17. Install the generator.
18. Install the accessory drive belt.
19. Install the radiator (Refer to «RADIATOR-3.7L/4.7L/5.7L»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
20. Install the air cleaner assembly.
21. Install the battery negative cable.
22. Refill coolant.
23. Refill engine oil.
24. Start engine and check for leaks.

1. Remove the vibration damper (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
2. Remove the oil pan (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
3. Remove the oil pump pickup.
4. Remove the windage tray/oil pan gasket.
5. Remove the timing chain cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
6. Remove the oil pump (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
7. Remove the timing drive (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
8. Identify rod bearing caps before removal. Remove rod bearing caps with bearings.
9. Identify main bearing caps before removal. Remove main bearing caps and bearings one at a time.
10. Remove the thrust washers.
11. Remove the rear oil seal retainer (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
12. Remove the crankshaft out of the block.
13. Remove and discard the crankshaft rear oil seal.
14. Remove and discard the front crankshaft oil seal.

Scheme 365

1. Select the proper main bearings (Refer to «STANDARD PROCEDURE - CRANKSHAFT MAIN BEARING - FITTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
2. Install main bearings in block and caps, and lubricate bearings.
3. Position the crankshaft into the cylinder block.
4. Install the thrust washers. NOTE: The main cap crossbolts are torqued after final torque of the main cap bolts. Always use a new washer/seal on crossbolts.
5. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten in two steps using the following sequence (Scheme 365) Step 1-27 N.m ( 20ft. lbs.) torque. Step 2 - Turn main cap bolts an additional 90°.
6. Install the crossbolts with new washer/gasket. Starting with crossbolt A (Scheme 365) torque each cross-bolt to 28 N.m ( 21ft. lbs.)torque.
7. Repeat crossbolt torque procedure.
8. Measure crankshaft end play (Refer to «STANDARD PROCEDURE - CRANKSHAFT MAIN BEARING - FITTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
9. Position the connecting rods onto the crankshaft and install the rod bearing caps (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
10. Install timing drive (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
11. Install oil pump (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
12. Install the timing chain cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
13. Install the rear main seal and retainer (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
14. Install the windage tray/oil pan gasket.
15. Install the oil pick up tube.
16. Install the oil pan (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
17. Install the vibration damper (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
18. Install the engine (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul__installation) ).

MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)

Crankshaft removed from the cylinder block.

Clean the oil off the main bearing journal.

Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal.

The maximum allowable taper is 0.008mm (0.0004 inch.) and maximum out of round is 0.005mm (0.0002 inch). Compare the measured diameter with the journal diameter specification (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance.

CRANKSHAFT MAIN BEARING SELECTION

The main bearings are "select fit" to achieve proper oil clearances. For main bearing selection, the crankshaft counterweight has grade identification marks stamped into it. These marks are read from left to right, corresponding with journal number 1, 2, 3, 4 and 5.

Note. Service main bearings are coded. These codes identify what size (grade) the bearing is.

MAIN BEARING SELECTION CHART - 5.7L

MAIN BEARING SELECTION SPECIFICATION CHART - 5.7L

Wipe the inserts clean and inspect for abnormal wear patterns and for metal or other foreign material imbedded in the lining. Normal main bearing insert wear patterns are illustrated (Scheme 366)

Scheme 366

Note. If any of the crankshaft journals are scored, the crankshaft must be repaired or replaced.

Inspect the back of the inserts for fractures, scrapings or irregular wear patterns.

Inspect the upper insert locking tabs for damage.

Replace all damaged or worn bearing inserts.

1. Disconnect negative cable from battery.
2. Remove accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) )
3. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas) ).
4. Remove upper radiator hose.
5. Remove radiator shroud attaching fasteners.
6. Remove radiator cooling fan and shroud (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
7. Remove crankshaft damper bolt.
8. Remove damper using Special Tools 8513A Insert and 8454 Three Jaw Puller.
9. Using Special Tool 9071, remove crankshaft front seal.

1. Using Special Tool 8348 and 8512A, install crankshaft front seal. CAUTION: To prevent severe damage to the Crankshaft or Damper, thoroughly clean the damper bore and the crankshaft nose before installing Damper.
2. Install vibration damper (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
3. Install radiator cooling fan and shroud (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
4. Install upper radiator hose.
5. Install accessory drive belt refer (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
6. Refill cooling system (Refer to «REFILLING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).
7. Connect negative cable to battery.

DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS

Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.

If the leakage occurs at the crankshaft rear oil seal area

1. Disconnect the battery.
2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak: Circular spray pattern generally indicates seal leakage or crankshaft damage. Where leakage tends to run straight down, possible causes are a porous block, camshaft bore cup plugs, oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. See appropriate section for proper repair procedures of these items.
4. If no leaks are detected, pressurized the crank-case as outlined in «AIR LEAK DETECTION TEST METHOD»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul__air-leak-detection-test-method) CAUTION: Do not exceed 20.6 kPa (3 psi).
5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks or scratches. The crankshaft seal flange is specially machined to complement the function of the rear oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. (Refer to «DIAGNOSIS AND TESTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ), under the Oil Leak row, for components inspections on possible causes and corrections.
7. After the oil leak root cause and appropriate corrective action have been identified, (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).

Note. This procedure can be performed in vehicle.

1. If being preformed in vehicle, remove the transmission.
2. Remove the flexplate (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ). NOTE: The crankshaft oil seal CAN NOT be reused after removal. NOTE: The crankshaft rear oil seal remover Special Tool 8506 must be installed deeply into the seal. Continue to tighten the removal tool into the seal until the tool can not be turned farther. Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine.
3. Using Special Tool 8506, remove the crankshaft rear oil seal.

1. Position the plastic seal guide onto the crankshaft rear face. Then position the crankshaft rear oil seal onto the guide.
2. Using Special Tools 8349 Crankshaft Rear Oil Seal Installer and C-4171 Driver Handle, with a hammer, tap the seal into place. Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore.
3. Install the flexplate.
4. Install the transmission.

1. Disconnect negative cable from battery.
2. Remove the transmission.
3. Remove the drive plate / flywheel.
4. Remove the oil pan (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
5. Remove the rear oil seal retainer mounting bolts.
6. Carefully remove the retainer from the engine block.

1. Throughly clean all gasket resdue from the engine block.
2. Use extream care and clean all gasket resdue from the retainer.
3. Position the gasket onto the retainer.
4. Position the retainer onto the engine block.
5. Install the retainer mounting bolts. Tighten the bolts to 15 N.m (132 in. lbs.) using a crisscross pattern, starting with the bolt on the lower right.
6. Install a new rear seal (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
7. Install the oil pan (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
8. Install the drive plate / flywheel.
9. Install the transmission.
10. Check and verify engine oil level.
11. Start engine and check for leaks.

1. Remove the transmission.
2. Remove the bolts and flexplate.

1. Position the flexplate or flywheel onto the crankshaft and install the bolts hand tight.
2. For automatic transmissions: Tighten the flexplate retaining bolts to 95 N.m (70 ft. lbs.).
3. For manual transmissions: Tighten the flywheel retaining bolts to 75 N.m (55 ft. lbs.).
4. Install the transmission.

DIAGNOSIS AND TESTING - HYDRAULIC TAPPETS

Before disassembling any part of the engine to correct 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 between 207-552 kPa (30-70 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 two conditions could be responsible for noisy tappets.

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 hydraulic 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 intake 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 intermittent or constant, and usually more than one tappet 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 engine 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. NOTE: Worn valve guides or cocked springs are sometimes 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 appreciably 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 excessive leak-down around the unit plunger, or by the plunger partially, sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is caused by a tappet check valve not seating, or by foreign particles 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 inspection and cleaning.
4. 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. If more than one tappet seems to be noisy, it's probably not the tappets.

1. Disconnect the negative cable from the battery.
2. Remove the air cleaner (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
3. Remove intake manifold (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
4. Remove cylinder head cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
5. Remove rocker arm assembly and push rods (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ). Identify push rods to ensure installation in original location.
6. Remove the cylinder head (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
7. Remove bolt from tappet guide holder.
8. Remove tappet guide holder.
9. Pull tappet out of bore with a twisting motion. If all tappets are to be removed and reused, identify tappets to ensure installation in original location.
10. Check camshaft lobes for abnormal wear.

1. Lubricate tappets.
2. Install tappets in their original positions.
3. Install tappet guide holder. Install the tappet guide holder bolt and tighten to 12 N.m (106 in. lbs.) torque.
4. Install cylinder head (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
5. Install pushrods and rocker arm assembly (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
6. Install cylinder head cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
7. Install intake manifold (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
8. Install the air cleaner (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
9. Connect the negative cable to the battery. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet.
10. Road test vehicle and check for leaks.

The pistons are made of a high strength aluminum alloy. Piston skirts are coated with a solid lubricant (Molykote) to reduce friction and provide scuff resistance. The piston top ring groove and land is anodized. The connecting rods are made of forged powdered metal, with a "fractured cap" design. A pressed fit piston pin is used to attach the piston and connecting rod.

Scheme 367

Scheme 368

1. To correctly select the proper size piston, a cylinder bore gauge, capable of reading in 0.003 mm (.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer.
2. Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B (Scheme 367)
3. The coated pistons will be serviced with the piston pin and connecting rod pre-assembled. The piston-rod assembly is specific for the left cylinder bank ( odd numbered) and the right cylinder bank (even numbered) and must not be interchanged.
4. The coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston will not provide accurate results (Scheme 368) Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY. To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (.0001 in.) increments is required.
5. Piston installation into the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.

Scheme 369

1. Disconnect negative cable from battery.
2. Remove the following components: Oil pan and gasket/windage tray (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ). Cylinder head covers (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ) and (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ). Timing chain cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ). Cylinder head(s) (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ) and (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool (Scheme 369) CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
5. Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur
6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
7. Carefully remove piston rings from piston(s), starting from the top ring down.

1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry.
2. Use a wood or plastic scraper to clean the ring land grooves. CAUTION: DO NOT remove the piston pin from the piston and connecting rod assembly.

Check the connecting rod journal for excessive wear, taper and scoring (Refer to CRANKSHAFT ).

Check the connecting rod for signs of twist or bending.

Check the piston for taper and elliptical shape before it is fitted into the cylinder bore (Refer to STANDARD PROCEDURE-PISTON FITTING ).

Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration.

1. Before installing piston and connecting rod assemblies into the bore, install the piston rings (Refer to «STANDARD PROCEDURE - PISTON RING FITTING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul__standard-procedure-piston-ring-fitting) ).
2. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation.
3. Position bearing onto connecting rod. Lubricate bearing surface with clean engine oil.
4. Install Special Tool 8507 Connecting Rod Guides into connecting rod bolt threads.
5. The pistons are marked on the piston pin bore surface with an raised "F" or arrow on top of piston indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks.
6. Wipe cylinder bore clean and lubricate with engine oil.
7. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal.
8. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal. CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed.
9. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 21 N.m (15 ft. lbs.) plus a 90° turn.
10. Install the following components: Cylinder head(s). (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ). Cylinder head covers (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ). Install the intake manifold. Oil pan and gasket/windage tray. (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
11. Fill crankcase with proper engine oil to correct level.
12. Connect negative cable to battery.

STANDARD PROCEDURE - PISTON RING FITTING

Before reinstalling used rings or installing new rings, the ring clearances must be checked.

Scheme 370

Scheme 371

Scheme 372

Scheme 373

Scheme 374

1. Wipe the cylinder bore clean.
2. Insert the ring in the cylinder bore. NOTE: The ring gap measurement must be made with the ring positioned at least 12mm (0.50 inch.) from bottom of cylinder bore.
3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder.
4. Using a feeler gauge check the ring end gap (Scheme 370) Replace any rings not within specification. PISTON RING SIDE CLEARANCE NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs.
5. Measure the ring side clearance as shown (Scheme 371)make sure the feeler gauge fits snugly between the ring land and the ring. Replace any ring not within specification.
6. Rotate the ring around the piston, the ring must rotate in the groove with out binding. PISTON RING SPECIFICATION CHART PISTON RING SPECIFICATION CHART Ring Position Groove Clearance Maximum Clearance Upper Ring 0.6715-0.7105 mm (0.0264-- 0.0279 in.) 0.11 mm (0.004 in.) Intermediate Ring 0.5455-0.6245 mm(0.0214-0.0245 in.) 0.10 mm(0.004 in.) Ring Position Ring Gap Wear Limit Upper Ring 0.23-0.38 mm (0.0090-0.0149 in.) 0.43 mm(0.017 in.) Intermediate Ring 0.35-0.60 mm(0.0137-0.0236 in.) 0.74 mm(0.029 in.) Oil Control Ring (Steel Rail) 0.015-0.66 mm (0.0059-- 0.0259 in.) 1.55 mm(0.061 in.)
7. The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston. NOTE: Piston rings are installed in the following order: Oil ring expander. Lower oil ring side rail. Upper oil ring side rail. No. 2 Intermediate piston ring. No. 1 Upper piston ring.
8. Install the oil ring expander.
9. Install upper side rail (Scheme 372) by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail.
10. Install No. 2 intermediate piston ring using a piston ring installer (Scheme 373)
11. Install No. 1 upper piston ring using a piston ring installer (Scheme 373)
12. Position piston ring end gaps as shown in (Scheme 374) It is important that expander ring gap is at least 45° from the side rail gaps, but not on the piston pin center or on the thrust direction.

1. Disconnect negative cable from battery.
2. Remove accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
3. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__draining-cooling-system-all-gas) ).
4. Remove radiator upper hose.
5. Remove upper fan shroud.
6. Using Special Tools 6958 Spanner with Adapter Pins 8346, loosen fan and viscous assembly from water pump.
7. Remove fan and viscous assembly.
8. Remove crankshaft damper bolt.
9. Remove damper using Special Tools 8513A Insert and 8454 Three Jaw Puller.

Scheme 375

1. Slide damper onto crankshaft slightly. CAUTION: Special Tool 8512-A, is assembled in a specific sequence. Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft.
2. Assemble Special Tool 8512-A as follows, The nut is threaded onto the shaft first. Then the roller bearing is placed onto the threaded rod (The hardened bearing surface of the bearing MUST face the nut). Then the hardened washer slides onto the threaded rod (Scheme 375) Once assembled coat the threaded rod's threads with Mopar® Nickel Anti-Seize or (Loctite No. 771).
3. Using Special Tool 8512-A, press damper onto crankshaft.
4. Install then tighten crankshaft damper bolt to 176 N.m (129 ft. lbs.).
5. Install fan blade assembly (Refer to «FAN DRIVE VISCOUS CLUTCH-GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
6. Install radiator upper shroud and tighten fasteners to 11 N.m (95 in. lbs.).
7. Install radiator upper hose.
8. Install accessory drive belt ( «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
9. Refill cooling system (Refer to «REFILLING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).
10. Connect negative cable to battery.

The structural dust cover is made of die cast aluminum and joins the lower half of the transmission bell housing to the engine.

OPERATION

The structural cover provides additional powertrain stiffness and reduces noise and vibration.

1. Raise vehicle on hoist. CAUTION: On manual transmission vehicles, the 7/16 inch engine block to clutch housing bolts must be loosened before removal of the structural dust cover. Clutch housing distortion will occur if this procedure is not followed.
2. Remove the bolts retaining structural cover.
3. Remove the structural cover.

AUTOMATIC TRANSMISSION

Scheme 376

1. Position the structural cover in the vehicle.
2. Install all four bolts retaining the cover-to-engine. DO NOT tighten the bolts at this time.
3. Install the four cover-to-transmission bolts. Do NOT tighten at this time. CAUTION: The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence. Failure to do so may cause damage to the cover.
4. Torque the (4)structural dust cover bolts that go into the transmission to 6-11 N.m (50-100 in.lbs.).
5. Torque the (4) structural dust cover bolts that go into the engine block to 6-11 N.m (50-100 in.lbs.).
6. Starting with the two rear cover-to-engine bolts, tighten bolts (1) (Scheme 376) to 54 N.m (40 ft. lbs.), then tighten bolts (2) (Scheme 376) and (3) to 54 N.m ( 40 ft. lbs.) in the sequence shown.
7. Install the exhaust pipe on left hand exhaust manifold.
8. Tighten exhaust manifold-to-exhaust pipe retaining bolts to 20-26 N.m (15-20 ft. lbs.).

MANUAL TRANSMISSION

Scheme 377

1. Position the structural cover in the vehicle. CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will cause severe damage to the cover, and engine noise.
2. Install all bolts retaining the cover-to-engine. DO NOT tighten the bolts at this time (Scheme 377)
3. Install the cover-to-transmission bolts. Do NOT tighten at this time. CAUTION: The structural cover must be held tightly against the corner formed by the engine and the transmission clutch housing during tightening sequence. Failure to do so may cause damage to the cover and engine noise.
4. Torque the (2)structural dust cover bolts that go into the clutch housing to 6-11 N.m (50-100 in.lbs.).
5. Torque the (4) structural dust cover bolts that go into the engine block to 6-11 N.m (50-100 in.lbs.).
6. Torque the structural cover bolt that is closest to the rear face of block on the passenger side of block to 54 N.m (40 ft. lbs.).
7. Torque the structural cover bolt that is closest to the front face of block on the drivers side to 54 N.m (40 ft. lbs.).
8. Torque the remaining (2) structural cover bolts that go into the block in an "X" pattern to 54 N.m (40 ft. lbs.).
9. Torque the structural cover bolts that go into the clutch housing to 54 N.m (40 ft. lbs.).
10. Torque the 7/16 inch engine block to clutch housing bolts to 68 N.m (50 ft. lbs.).

Scheme 378

Scheme 379

1. Disconnect negative battery cable.
2. Raise vehicle.
3. Remove engine mount through bolts.
4. Raise engine using engine support fixture special tool # 8534.
5. Remove engine mount to insulator bolts (Scheme 378), (Scheme 379)
6. Remove insulator from engine.

Scheme 380

1. Disconnect the negative cable from the battery.
2. Raise the vehicle.
3. Remove the skid plate.
4. Remove the front crossmember (Refer to «FRONT CROSSMEMBER»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#frames-bumpers) ).
5. Remove the engine oil filter.
6. Support the engine using engine support fixture, special tool # 8534.
7. Support the front axle with a suitable jack.
8. Remove the (4) bolts that attach the engine mounts to the front axle (Scheme 380)
9. Remove the (3) bolts that attach the front axle to the left engine bracket.
10. Lower the front axle.
11. Remove the (6) through bolts
12. Raise the engine far enough to be able to remove the left and right engine mounts.
13. Remove the engine mounts.

Scheme 381

1. Install insulator on the engine (Scheme 381) NOTE: For mount to engine block and left engine bracket to front axle bolts, apply Mopar® Lock and Seal Adhesive, Medium Strength Threadlocker.
2. Install upper and lower mount mounting bolts. Tighten bolts to 61 N.m (45 ft. lbs.).
3. Lower the engine using engine support fixture special tool # 8534.
4. Install mount through bolts.
5. Tighten through bolts on both sides to 61 N.m (45 ft. lbs.).
6. Lower vehicle.
7. Connect negative battery cable.

4WD

Note. For mount to engine block and left engine bracket to front axle bolts, apply Mopar® Lock and Seal Adhesive, Medium Strength Threadlocker.

Scheme 382

1. Install the right and left side engine mounts to the front axle. Torque nuts to 94 N.m (70 ft. lbs.).
2. Raise the front axle into the frame and install the left and right side through bolts. Torque nuts to 94 N.m (70 ft. lbs.).
3. Insert the two upper through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts.
4. Lower the engine using engine support fixture special tool # 8534, until the left and right side engine brackets rest on the through bolts, and the lower engine bracket through holes align with the engine mounts, and the left engine bracket holes align with the front axle slots (Scheme 382)
5. Loose assemble the (3) bolts that attach the front axle to the left engine bracket.
6. Loose assemble the lower through bolts.
7. Torque the nuts for the (4) through bolts to 101 N.m (75 ft. lbs.).
8. Torque the (3) bolts that attach the front axle to the left engine bracket to 101 N.m (75 ft. lbs.)
9. Install the engine oil filter, if removed.
10. Install the front crossmember (Refer to «FRONT CROSSMEMBER»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#frames-bumpers) ).
11. Install the skid plate.
12. Lower the vehicle.
13. Reconnect the negative battery cable.

1. Raise the vehicle on a hoist.
2. Using a suitable jack, support transmission.
3. Remove the nuts from the transmission mount (Scheme 383)
4. Remove the two bolts that attach the transmission mount to the engine bracket.
5. Raise the transmission enough to remove the mount from the crossmember.
6. Remove the mount.

Note. Threadlocking compound must be applied to the bolts before installation.

Scheme 383

1. Install the two bolts that attach the transmission mount to the transmission bracket.
2. Torque the bolts to 61N.m (45 ft.lbs.) torque.
3. Lower the transmission so the transmission mount rests on the crossmember, and the studs of the transmission mount are aligned in the slots in the crossmember.
4. Install the nuts onto the transmission mount studs through the crossmember access slot.
5. Torque the nuts to 54N.m (40 ft. lbs.).

The lubrication system (Scheme 384) is a full flow filtration pressure feed type.

Scheme 384

DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE

1. Remove oil pressure sending unit and install gauge assembly C-3292.
2. Run engine until thermostat opens.
3. Oil Pressure: Curb Idle-25 kPa (4 psi) minimum 3000 rpm-170 - 758 kPa (25 - 110 psi)
4. If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck open.

DIAGNOSIS AND TESTING - ENGINE OIL LEAK

Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed

1. Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak.
2. Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light.
3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair per service manual instructions.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspection. If the oil leak source is not positively identified at this time, proceed with the air leak detection test method.

Air Leak Detection Test Method

1. Remove the PCV valve from the IAFM. Cap or plug the PCV valve grommet.
2. Attach an air hose with pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.
3. Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual procedures.
4. If the leakage occurs at the rear oil seal area, refer to the section, «INSPECTION FOR REAR SEAL AREA LEAK»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul__inspection-for-rear-seal-area-leaks) .
5. If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve.
6. Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.

INSPECTION FOR REAR SEAL AREA LEAKS

Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.

If the leakage occurs at the crankshaft rear oil seal area

1. Disconnect the battery.
2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak: Circular spray pattern generally indicates seal leakage or crankshaft damage. Where leakage tends to run straight down, possible causes are a porous block, distributor seal, camshaft bore cup plugs oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces.
4. If no leaks are detected, pressurize the crank-case as outlined in «AIR LEAK DETECTION TEST METHOD»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul__air-leak-detection-test-method) CAUTION: Do not exceed 20.6 kPa (3 psi).
5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled.

STANDARD PROCEDURE - ENGINE OIL SERVICE

The engine oil level indicator is located at the left hand of the engine on the 5.7L engines.

CRANKCASE OIL LEVEL INSPECTION

Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about ten minutes before checking oil level. Checking engine oil level on a cold engine is not accurate.

To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick.

1. Position vehicle on level surface.
2. With engine OFF, allow approximately five minutes for oil to settle to bottom of crankcase, remove engine oil dipstick.
3. Wipe dipstic clean.
4. Install dipstick and verify it is seated in the tube.
5. Remove dipstick, with handle held above the tip, take oil level reading.
6. Add oil only if level is below the ADD mark on dipstick.

ENGINE OIL CHANGE

Change engine oil at mileage and time intervals described in Maintenance Schedules (Refer to owner's manual ).

Run engine until achieving normal operating temperature.

1. Position the vehicle on a level surface and turn engine off.
2. Hoist and support vehicle on safety stands.
3. Remove oil fill cap.
4. Place a suitable drain pan under crankcase drain.
5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged.
6. Install drain plug in crankcase. Torque to 34 N.m ( 25 ft. lbs.).
7. Lower vehicle and fill crankcase with specified type and amount of engine oil described in this section.
8. Install oil fill cap.
9. Start engine and inspect for leaks.
10. Stop engine and inspect oil level.

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING at beginning of this section.

All engines are equipped with a high quality full-flow, disposable type oil filter. DaimlerChrysler Corporation recommends a Mopar® or equivalent oil filter be used.

1. Position a drain pan under the oil filter.
2. Using a suitable oil filter wrench loosen filter.
3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss.
4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter.
5. With a wiping cloth, clean the gasket sealing surface of oil and grime.

Scheme 385

1. Lightly lubricate oil filter gasket with engine oil.
2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Scheme 385) hand tighten filter one half turn, or 180°,do not over tighten.
3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks.

1. Disconnect the negative battery cable.
2. Install engine support fixture special tool # 8534. Do not raise engine at this time.
3. Loosen both left and right side engine mount through bolts. Do not remove bolts.
4. Remove the structural dust cover, if equipped.
5. Drain engine oil.
6. Remove the front crossmember (Refer to «FRONT CROSSMEMBER»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#frames-bumpers) ). CAUTION: Only raise the engine enough to provide clearance for oil pan removal. Check for proper clearance at fan shroud to fan and cowl to intake manifold.
7. Raise engine using special tool # 8534 to provide clearance to remove oil pan. NOTE: Do not pry on oil pan or oil pan gasket. Gasket is integral to engine windage tray and does not come out with oil pan.
8. Remove the oil pan mounting bolts and oil pan. NOTE: The double ended oil pan studs must be installed in the same location that they were removed from.
9. Unbolt oil pump pickup tube and remove tube.
10. Inspect the integral windage tray and gasket and replace as needed.

1. Clean the oil pan gasket mating surface of the block and oil pan.
2. Inspect the integral windage tray and gasket and replace as needed.
3. Reinstall the oil pump pickup tube with new o-ring. Tighten tube to pump fasteners to 28 N.m (250 in. lbs.). NOTE: The double ended oil pan studs must be installed in the same location that they were removed from.
4. Position the oil pan and install the mounting bolts and studs. Tighten the mounting bolts to 12 N.m (105 in.lbs.).
5. Lower the engine into mounts using special tool # 8534.
6. Install both the left and right side engine mount through bolts. Tighten the nuts to 68 N.m (50 ft. lbs.).
7. Remove special tool # 8534.
8. Install structural dust cover, if equipped.
9. Install the front crossmember (Refer to «FRONT CROSSMEMBER»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#frames-bumpers) ).
10. Fill engine oil.
11. Reconnect the negative battery cable.
12. Start engine and check for leaks.

1. Remove the oil pan and pick-up tube (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
2. Remove the timing chain cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
3. Remove the four bolts, and the oil pump.

1. Wash all parts in a suitable solvent.

Scheme 386

Scheme 387

Scheme 388

1. Remove the pump cover.
2. Clean all parts thoroughly. Mating surface of the oil pump housing should be smooth. If the pump cover is scratched or grooved the oil pump assembly should be replaced.
3. Slide outer rotor into the body of the oil pump. Press the outer rotor to one side of the oil pump body and measure clearance between the outer rotor and the body (Scheme 386) If the measurement is 0.235mm (0.009 in.) or more the oil pump assembly must be replaced.
4. Install the inner rotor in the into the oil pump body. Measure the clearance between the inner and outer rotors (Scheme 387) If the clearance between the rotors is.150 mm (0.006 in.) or more the oil pump assembly must be replaced.
5. Place a straight edge across the body of the oil pump (between the bolt holes), if a feeler gauge of.095 mm (0.0038 in.) or greater can be inserted between the straightedge and the rotors, the pump must be replaced (Scheme 388)
6. Reinstall the pump cover. Torque fasteners to 15 N.m (132 in. lbs.).

Note. The 5.7 Oil pump is released as an assembly. There are no DaimierChrysler part numbers for Sub-Assembly components. In the event the oil pump is not functioning or out of specification it must be replaced as an assembly.

1. Position the oil pump onto the crankshaft and install the 4 oil pump retaining bolts.
2. Tighten the oil pump retaining bolts to 28 N.m (250 in. lbs.).
3. Install the timing chain cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
4. Install the pick-up tube and oil pan (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).

The intake manifold is made of a composite material and features long runners which maximizes low end torque. The intake manifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent leaks.

DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKAGE

An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.

1. Start the engine.
2. Spray a small stream of water at the suspected leak area.
3. If a change in RPM is observed the area of the suspected leak has been found.
4. Repair as required.

1. Disconnect negative cable from battery.
2. Remove resonator assembly and air inlet hose.
3. Disconnect electrical connectors for the following components: Manifold Absolute Pressure (MAP) Sensor Intake Air Temperature (IAT) Sensor Throttle Position (TPS) Sensor Coolant Temperature (CTS) Sensor
4. Disconnect brake booster hose and positive crankcase ventilation (PCV) hose.
5. Remove generator and set aside. NOTE: It is not necessary to remove lines or remove freon from A/C compressor.
6. Remove air conditioning compressor and set aside.
7. Bleed fuel system (Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine__standard-procedure-fuel-system-pressure) ).
8. Remove intake manifold retaining fasteners in a crisscross pattern starting from the outside bolts and ending at the middle bolts.
9. Remove intake manifold and IAFM as an assembly.

Note. There is NO approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced.

Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry.

1. Inspect the intake sealing surface for cracks, nicks and distortion.
2. Inspect the intake manifold vacuum hose fittings for looseness or blockage.
3. Inspect the manifold to throttle body mating surface for cracks, nicks and distortion.

1. Install intake manifold seals.
2. Position intake manifold and IAFM.
3. Install intake manifold retaining bolts, and tighten in sequence from the middle bolts towards the outside in a crisscross pattern. Torque fasteners to 12 N.m (105 in. lbs.).
4. Connect electrical connectors for the following components: Manifold Absolute Pressure (MAP) Sensor Intake Air Temperature (IAT) Sensor Throttle Position (TPS) Sensor Coolant Temperature (CTS) Sensor Idle Air Control (IAC) Motor
5. Install generator.
6. Install A/C compressor.
7. Connect Brake booster hose and Positive crankcase ventilation (PCV) hose.
8. Install resonator assembly and air inlet hose.
9. Connect negative cable to battery.

The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold.

The exhaust manifolds collect the engine exhaust exiting the combustion chambers, then channels the exhaust gases to the exhaust pipes attached to the manifolds.

EXHAUST MANIFOLD

1. Disconnect negative battery cable.
2. Raise vehicle.
3. Remove exhaust pipe to manifold bolts.
4. Lower vehicle.
5. Install engine support fixture special tool #8534.
6. Raise engine enough to remove manifolds. CAUTION: Do not damage engine harness while raising the engine.
7. Remove heat shield.
8. Remove manifold bolts.
9. Remove manifold and gasket.

Clean mating surfaces on cylinder head and manifold. Wash with solvent and blow dry with compressed air.

Inspect manifold for cracks.

Inspect mating surfaces of manifold for flatness with a straight edge. Gasket surfaces must be flat within 0.2 mm per 300 mm (0.008 inch per foot).

1. Install manifold gasket and manifold.
2. Install manifold bolts and tighten to 25 N.m (18 ft. lbs.).
3. Install heat shield and tighten nuts to 15 N.m (11 ft. lbs.).
4. Lower engine. CAUTION: Do not damage engine harness while lowering the engine.
5. Remove engine support fixture from engine.
6. Raise vehicle.
7. Tighten right and left side engine mount through bolts.
8. Install exhaust flange to pipe bolts.
9. Lower vehicle.
10. Connect negative battery cable.

1. Disconnect the battery negative cable.
2. Remove air cleaner assembly.
3. Drain cooling system.
4. Remove accessory drive belt.
5. Remove fan and fan drive assembly (Refer to «FAN DRIVE VISCOUS CLUTCH-GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
6. Remove coolant bottle and washer bottle.
7. Remove fan shroud. NOTE: It is not necessary to disconnect A/C lines or discharge freon.
8. Remove A/C compressor and set aside.
9. Remove the generator.
10. Remove upper radiator hose.
11. Disconnect both heater hoses at timing cover.
12. Disconnect lower radiator hose at engine.
13. Remove accessory drive belt tensioner and both idler pulleys.
14. Remove crankshaft damper (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ). NOTE: Do not remove the hoses from the power steering pump.
15. Remove power steering pump and set aside.
16. Remove the dipstick support bolt.
17. Drain the engine oil.
18. Remove the oil pan and pick up tube (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ). NOTE: It is not necessary to remove water pump for timing cover removal.
19. Remove timing cover bolts and remove cover.

1. Clean timing chain cover and block surface. NOTE: Always install a new gasket on timing cover.
2. Install cover and new gasket. Tighten fasteners to 28 N.m (250 in. lbs.). NOTE: The large lifting stud is torqued to 55 N.m (40 ft. lbs.).
3. Install the oil pan and, pick up tube (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
4. Install the A/C compressor.
5. Install the generator.
6. Install power steering pump.
7. Install the dipstick support bolt.
8. Install the thermostat housing.
9. Install crankshaft damper (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
10. Install accessory drive belt tensioner assembly and both idler pulleys.
11. Install radiator lower hose.
12. Install both heater hoses.
13. Install radiator fan shroud.
14. Install the fan and fan drive assembly
15. Install the accessory drive belt.
16. Install the coolant bottle and washer bottle.
17. Install the upper radiator hose.
18. Install the air cleaner assembly.
19. Fill cooling system.
20. Refill engine oil.
21. Connect the battery negative cable.

Scheme 389

1. Disconnect battery negative cable.
2. Drain cooling system.
3. Remove Timing Chain Cover. CAUTION: The camshaft pin and the slot in the cam sprocket must be clocked at 12:00. The crankshaft keyway must be clocked at 2:00. The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00.
4. Re-install the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align timing chain sprockets and keyways as shown (Scheme 389)
5. Retract tensioner shoe until hole in shoe lines up with hole in bracket. Slide a suitable pin into the holes.
6. Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets.
7. If tensioner assembly is to be replaced, remove the tensioner to block bolts and remove tensioner assembly.

Scheme 390

1. If tensioner assembly is being replaced, install tensioner and mounting bolts. Torque bolts to 28 N.m (250 in. lbs.).
2. Retract tensioner if required. CAUTION: The camshaft pin and the slot in the cam sprocket must be clocked at 12:00. The crankshaft keyway must be clocked at 2:00. The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00.
3. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores (Scheme 390) CAUTION: The timing chain must be installed with the single plated link aligned with the dot and or paint marking on the camshaft sprocket. The crankshaft sprocket is aligned with the dot and or paint marking on the sprocket between two plated timing chain links.
4. Place timing chain around both sprockets (Scheme 390)
5. Lift sprockets and chain (keep sprockets tight against the chain in position as shown).
6. Slide both sprockets evenly over their respective shafts and check alignment of timing marks.
7. Install the camshaft bolt. Tighten the bolt to 122 N.m (90 ft. lbs.) torque.
8. Remove tensioner pin. Again, verify alignment of timing marks.
9. Install the oil pump (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
10. Install the oil pan and pick up (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
11. Install the timing chain cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#57l-engine-overhaul) ).
12. Fill cooling system (Refer to «REFILLING COOLING SYSTEM - ALL GAS ENGINES»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__refilling-cooling-system-all-gas) ).
13. Connect battery negative cable.
14. Start engine and check for oil and coolant leaks.

The timing chain tensioner is a stamped steel constant tension mechanical design. It is mounted to the front of the engine, behind the timing chain drive.

The timing chain tension is maintained by routing the timing chain through the tensioner assembly. A nylon covered spring steel arm presses on the timing chain maintaining the correct chain tension.

See also:
• FUEL DELIVERY - GAS
• FUEL INJECTION - GAS
• STARTERS
• SPARK PLUG
• STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE
• EVAPORATIVE EMISSIONS
• DRAINING COOLING SYSTEM - ALL GAS ENGINES
• ACCESSORY DRIVE
• FAN DRIVE VISCOUS CLUTCH-GAS ENGINES
• GENERATORS & REGULATORS
• A/C COMPRESSOR
• REFILLING COOLING SYSTEM - ALL GAS ENGINES
• FRONT CROSSMEMBER
• PERFORMANCE
• MECHANICAL
• DIAGNOSIS AND TESTING
• DIAGNOSIS AND TESTING
• DIAGNOSIS AND TESTING-CYLINDER HEAD GASKET FAILURE
• DIAGNOSIS AND TESTING
• DIAGNOSIS AND TESTING
• STANDARD PROCEDURE - REFACING
• CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
• STANDARD PROCEDURE - ENGINE OIL SERVICE
• DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE
• INSTALLATION
• AIR LEAK DETECTION TEST METHOD
• CRANKSHAFT
• STANDARD PROCEDURE - PISTON RING FITTING
• INSPECTION FOR REAR SEAL AREA LEAK