8.3l Engine - Overhaul - srt-10 Dodge Pickup R1500

DESCRIPTION

The engine is an 8.3 Liter (505 CID), 10-cylinder, 90° V-type, lightweight, single-cam, overhead valve engine (Scheme 533) This engine is designed for premium unleaded fuel.

The crankshaft is forged steel. The cylinder block and cylinder heads are aluminum. The firing order is 1-10-9-4-3-6-5-8-7-2. The cylinders are numbered from front to rear as follows

Scheme 533

1. on the left bank-1, 3, 5, 7, 9
2. on the right bank-2, 4, 6, 8, 10

Vehicle Identification Number

This number is located on the rear of the cylinder block just below the right cylinder head (Scheme 534)

Engine Serial Number

This number is located on the lower right front of the cylinder block near the oil pressure sensor (Scheme 534)

Scheme 534

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 mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls).

Refer to the ENGINE DIAGNOSIS - MECHANICAL CHART and the ENGINE DIAGNOSIS - PERFORMANCE CHART , for possible causes and corrections of malfunctions. Refer to POWERTRAIN DIAGNOSTIC PROCEDURES (PART 1) and POWERTRAIN DIAGNOSTIC PROCEDURES (PART 2) for fuel system diagnosis.

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

1. Cylinder Compression Pressure Test
2. Cylinder Combustion Pressure Leakage Test
3. Cylinder Head Gasket Failure Diagnosis
4. Intake Manifold Leakage Diagnosis
5. Hydraulic Tappet Noise Diagnosis
6. Engine Oil Leak Inspection

ENGINE DIAGNOSIS - PERFORMANCE

DIAGNOSTIC REFERANCE CHART

ENGINE DIAGNOSIS - MECHANICAL

DIAGNOSTIC REFERANCE CHART

DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST

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. Check engine oil level and add oil if necessary.
2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly.
3. Remove the Auto Shut Down (ASD) relay from the Power Distribution Center (PDC).
4. Disconnect ignition cables from spark plugs.
5. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference.
6. Be sure throttle blade is fully open during the compression check.
7. Insert compression gauge adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer (Special Tool CH7059) with cable adaptors to the DRBIII®. For Special Tool identification, (Refer to «SPECIAL TOOLS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
8. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure.
9. Repeat the previous step for all remaining cylinders.
10. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder.
11. If one or more cylinders have abnormally low compression pressures, repeat the compression test.
12. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present.

CYLINDER COMBUSTION PRESSURE LEAKAGE TEST

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 pressure cap.
2. Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.
3. Clean spark plug recesses with compressed air.
4. Remove the spark plugs.
5. Remove the oil fill cap.
6. Remove the air cleaner.
7. 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, with 552 kPa (80 psi) recommended.
8. Perform the test procedures on each cylinder according to the tester manufacturer's instructions. While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the coolant pressure bottle.

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

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

CYLINDER HEAD GASKET FAILURE DIAGNOSIS

A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent water jacket, or an external coolant leak may be present.

Possible indications of the cylinder head gasket leaking between adjacent cylinders are

1. Loss of engine power
2. Engine misfiring
3. Poor fuel economy

Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are

1. Engine overheating
2. Loss of coolant
3. Excessive steam (white smoke) emitting from exhaust
4. 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. Cylinders adjacent to each other will both have low compression.

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.

DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS

An intake manifold air leak is characterized by lower than normal manifold vacuum, rough idle, or engine misfire.

1. Start the engine.
2. Spray a small stream of water (Spray Bottle) at the suspected leak area.
3. If engine RPM'S change, the area of the suspected leak has been found.
4. Repair as required.

PRELIMINARY STEP TO CHECKING THE HYDRAULIC TAPPETS

Before disassembling any part of the engine to correct tappet noise, check engine oil level and oil pressure.

1. Check the engine oil level. Oil Level Check: stop engine after reaching normal operating temperature The oil level should never be above the FULL mark on dipstick, or below the ADD mark. Either of these two conditions could be responsible for noisy tappets. Allow 5 minutes to stabilize oil level, check dipstick.
2. Remove oil pressure sensor.
3. Install a reliable oil pressure gauge at oil pressure sensor location.

The oil pressure should be between 30 and 80 psi (206.8 to 551.6 kPa) at 2000 rpm.

OIL LEVEL TOO HIGH

If oil level is above the FULL mark on dipstick, it is possible for the connecting rods to dip into the oil while engine is running and create foam. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to become soft and allow valves to seat noisily.

OIL LEVEL TOO LOW

Low oil level may allow pump to take in air which when fed to the tappets, causes them to become soft and allows valves to seat noisily. Any leaks on intake side of 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, engine should be operated at fast idle to allow all of the air inside of the tappets to be bled out.

VALVE TRAIN NOISE DIAGNOSIS

To determine source of valve train noise, operate engine at idle with cylinder head covers removed and listen for source of the noise.

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.

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 which will necessitate replacing the tappet, or by the plunger partially sticking in the tappet body cylinder. A heavy click is caused either by a tappet check valve not seating, or by foreign particles becoming wedged between the plunger and the tappet body causing 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 and replaced.

DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION

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 as necessary.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspection.
5. If the oil leak source is not positively identified at this time, proceed with the air leak detection test method as follows: Disconnect the PCV hoses at the cylinder head covers and plug or cap the outlet on the covers. 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. 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 provides the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual procedures. If the leakage occurs at the crankshaft rear oil seal area, refer to the section, «INSPECTION FOR REAR SEAL AREA LEAK»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10__inspection-for-rear-seal-area-leaks) .
6. If no leaks are detected, turn off the air supply. Remove the air hose, all plugs, and caps. Connect the PCV hoses. Proceed to next step.
7. 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. NOTE: If oil leakage is observed at the dipstick tube to oil pan location; remove the tube, clean and reseal using Mopar® Stud & Bearing Mount (press fit tube applications only), and for O-ring style tubes, remove tube and replace the O-ring seal.

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 clutch housing inspection cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak. If a leak is present in this area, remove transmission for further inspection. Circular spray pattern generally indicates seal leakage or crankshaft damage. Where leakage tends to run straight down, possible causes are a porous block, oil gallery cup plug or rear crankshaft seal retainer gasket leak. See proper repair procedures for these items.
4. If no leaks are detected, pressurize the crank-case as previously described. 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.
7. After the oil leak root cause and appropriate corrective action have been identified, replace component(s) as necessary.

STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS

Using a blunt tool such as a drift and a hammer, strike the bottom edge of the cup plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug (Scheme 535)

Scheme 535

Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with Mopar® Stud and Bearing Mount. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 in.) inside the lead-in chamfer.

It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately.

STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS

There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in-place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket.

There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Engine RTV GEN II, Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties and can not be used in place of the other.

MOPAR® ENGINE RTV GEN II

Mopar® Engine RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® ATF RTV

Mopar® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® GASKET MAKER

Mopar® Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.

MOPAR® BED PLATE SEALANT

Mopar® Bed Plate Sealant is a unique (green-in-color) anaerobic type gasket material that is specially made to seal the area between the bedplate and cylinder block without disturbing the bearing clearance or alignment of these components. The material cures slowly in the absence of air when torqued between two metallic surfaces, and will rapidly cure when heat is applied.

MOPAR® GASKET SEALANT

Mopar® Gasket Sealant is a slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This material is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 4 oz/16 oz. can w/applicator.

FORM-IN-PLACE GASKET AND SEALER APPLICATION

Mopar® Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing material off the location.

Mopar® Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location.

Mopar® Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets.

STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.

Never use the following to clean gasket surfaces

1. Metal scraper
2. Abrasive pad or paper to clean cylinder block and head
3. High speed power tool with an abrasive pad or a wire brush (Scheme 536)

Note. Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Only use the following for cleaning gasket surfaces

1. Solvent or a commercially available gasket remover
2. Plastic or wood scraper (Scheme 536)
3. Drill motor with 3M Roloc™ Bristle Disc (white or yellow) (Scheme 536)

STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE

When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used.

1. Inspect air cleaner, induction system and intake manifold to ensure system is dry and clear of foreign material.
2. Remove negative battery cable.
3. Place a shop towel around the spark plugs when removing them from the engine. This will catch any fluid that may possibly be in the cylinder under pressure.
4. With all spark plugs removed, rotate engine crankshaft using a breaker bar and socket.
5. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other).
6. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting rods, pistons, valves, etc.)
7. Repair engine or components as necessary to prevent this problem from re-occurring. CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart.
8. Install new spark plugs.
9. Drain engine oil and remove oil filter.
10. Fill engine with specified amount of approved oil and install new oil filter.
11. Connect negative battery cable.
12. Start engine and check for any leaks.

REMOVAL - ENGINE ASSEMBLY

Note. For Special Tool Identification, (Refer to SPECIAL TOOLS ).

Scheme 536

Scheme 537

Scheme 538

Scheme 539

Scheme 540

Scheme 541

1. Perform 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 negative battery cable.
3. Disconnect throttle body air inlet duct, remove air cleaner cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10__removal) ).
4. Raise and support the vehicle.
5. Remove the lower engine shield.
6. 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) ).
7. Paint mark and remove the driveshaft (Refer to «PROPELLER SHAFT»(/dodge/pickup-r1500/1997-2012/remont/driveshaft-universal-joints/#drive-shaft) ).
8. Remove the transmission (Refer to «MANUAL TRANSMISSION - T56»(/dodge/pickup-r1500/1997-2012/remont/manual-trans/#overhaul-t56-manual-transmission) ).
9. Remove the starter (Refer to «STARTERS»(/dodge/pickup-r1500/1997-2012/remont/starter/#starting-system) ).
10. Disconnect the front exhaust pipe flange to exhaust manifold fasteners (Scheme 537)
11. Disconnect the hydraulic cooling fan lines and capture any spillage (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
12. Drain engine oil and remove the oil filter.
13. Separate the air conditioning hose from the fan shroud.
14. Disconnect the lower radiator hose.
15. Disconnect the power steering line support bracket at the lower left of the radiator.
16. Loosen both engine mount through bolts.
17. Separate the ground strap from the floor board, above the right exhaust flange (Scheme 538)
18. Lower the vehicle.
19. Discharge air conditioning system using a suitable refrigerant recovery machine (Refer to «REFRIGERANT SYSTEM RECOVERY»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing__refrigerant-system-recovery) ).
20. Remove the upper radiator hose.
21. Disconnect windshield washer hose at the splice.
22. Remove radiator core support.
23. Disconnect the cooling fan harness connector (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
24. Remove the radiator and radiator fan assembly (Refer to «RADIATOR - SRT-10»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) and «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
25. Remove the A/C condenser, cap and position the hoses aside.
26. Disconnect the heater hoses at the top front cover and at the lower coolant housing and position aside.
27. Disconnect the oil cooler hoses from the engine and position aside (Refer to «STANDARD PROCEDURE - OIL COOLER LINE QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
28. Remove accessory drive belt (Scheme 539)
29. Disconnect and remove generator (Scheme 539)
30. Remove power steering pump mounting bolts and set pump aside (Scheme 539) Capture any fluid spillage.
31. Disconnect A/C lines and electrical connector from A/C compressor. Plug holes in A/C compressor to prevent debris from entering A/C compressor. WARNING: Capture and properly store any fuel spillage when disconnecting the fuel line
32. Disconnect brake booster vacuum hose and fuel line to fuel rail (Scheme 540)
33. Disconnect the cruise control, accelerator cable and fuel vapor purge harness, then set aside (Scheme 541)
34. Disconnect the engine harness connectors on top of the intake manifold.
35. Disconnect the spark plug wires from the spark plugs and set the plug wires on top of the engine.
36. Disconnect the ground strap at the thermostat housing and pull the electrical harness underneath the intake manifold and set aside.
37. Install Special Tool 9363 - Engine Lifting Brackets (Scheme 543) and (Scheme 542) to the exhaust manifold heat shield studs where indicated
38. Insert engine lifting bar through the access holes in the engine lifting brackets and secure with the bar retaining pins (Scheme 543)
39. Remove engine with an engine hoist (Scheme 544)

Scheme 542

Scheme 543

Scheme 544

Scheme 545

Scheme 546

1. Attach engine hoist and lower the engine into engine compartment, aligning the left and right engine mounts
2. Remove engine hoist and engine lifting bar and brackets.
3. Install the exhaust manifold heat shield fasteners and tighten to 6 N.m (50 in.lbs.) (Scheme 545)
4. Connect the ground strap to the thermostat housing and route the electrical and purge harness underneath the throttle body and attach the connectors.
5. Connect the fuel vapor purge lines (Scheme 541)
6. Properly route and connect the spark plug wires.
7. Connect the engine electrical harnesses (3).
8. Connect the brake booster vacuum hose, fuel line, cruise control and accelerator cables (Scheme 540)
9. Install the A/C lines at the A/C compressor (Refer to «A/C COMPRESSOR»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing__ac-compressor) ).
10. Connect A/C clutch electrical connector.
11. Install the power steering pump (Scheme 539)
12. Install the generator (Scheme 539)
13. Install the accessory drive belt (Scheme 539)
14. Connect the heater hoses to the engine.
15. Install the radiator and cooling fan assembly.
16. Install the A/C condenser.
17. Connect the A/C lines to the condenser.
18. Connect the cooling fan electrical connector.
19. Connect the windshield washer hose at the splice.
20. Install the coolant recovery container.
21. Install the upper radiator hose.
22. Install the throttle body air inlet duct and the air cleaner element cover.
23. Raise and support the vehicle.
24. Install transmission.
25. Install transmission bolts (Scheme 546) and tighten bolts to: 7/16 Transmission bolts and washers - 68 N.m (50 ft. lbs.) Transmission to top of engine - 41 N.m (30 ft. lbs.) Transmission to oil pan - 30 N.m (22 ft. lbs.)
26. Install drive shaft.
27. Install the ground strap to the floor pan above the right exhaust manifold flange (Scheme 538)
28. Connect the front exhaust pipes to the exhaust manifolds and tighten the fasteners to 34 N.m (25 ft. lbs.).
29. Connect oil cooler lines and connect the oil pressure sensor and oil temperature sensor (Scheme 547)
30. Install the power steering line support bracket at the radiator.
31. Install lower radiator hose (Scheme 547)
32. Connect the cooling fan hydraulic lines (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
33. Connect the A/C line to the fan shroud.
34. Install under body shield.
35. Lower vehicle.
36. Fill engine crankcase with the proper oil to the correct level (refer to owner's manual).
37. Evacuate and recharge the air conditioning (Refer to «REFRIGERANT SYSTEM CHARGE»(/dodge/pickup-r1500/1997-2012/remont/manual-hvac-system/#hvac-plumbing__refrigerant-system-charge) ).
38. Fill the cooling system (Refer to «STANDARD PROCEDURE - REFILLING COOLING SYSTEM - SRT-10»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__standard-procedure-refilling-cooling-syste) ).
39. Fill power steering to proper level and purge the system (Refer to «PUMP»(/dodge/pickup-r1500/1997-2012/remont/manual-power-steering/#power-steering-system) ).
40. Connect the negative battery cable.
41. Start the engine and run until operating temperature is obtained.
42. Turn engine off and inspect for leaks.
43. Recheck all fluid levels, fill as required.

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

CYLINDER BLOCK

CYLINDER BLOCK SPECIFICATION

CRANKSHAFT

CRANKSHAFT SPECIFICATION

MAIN BEARING JOURNALS

MAIN BEARING JOURNALS SPECIFICATION

CONNECTING RODS

CONNECTING RODS SPECIFICATION

PISTONS

PISTONS SPECIFICATION

PISTON PINS

PISTON PINS SPECIFICATION

PISTON RING

PISTON RING SPECIFICATION

CAMSHAFT

CAMSHAFT SPECIFICATION

HYDRAULIC TAPPETS

HYDRAULIC TAPPETS SPECIFICATION

CYLINDER HEAD

CYLINDER HEAD SPECIFICATION

CYLINDER HEAD VALVE SEAT

CYLINDER HEAD VALVE SEAT SPECIFICATION

VALVES

VALVES SPECIFICATION

VALVE SPRING

VALVE SPRING SPECIFICATION

LUBRICATION

LUBRICATION SPECIFICATION

OIL PUMP

OIL PUMP SPECIFICATION

TORQUE

TORQUE SPECIFICATION

TORQUE SPECIFICATION

Scheme 547

Scheme 548

Scheme 549

Scheme 550

Scheme 551

Scheme 552

Scheme 553

Scheme 554

Scheme 555

Scheme 556

Scheme 557

Scheme 558

Scheme 559

Scheme 560

Scheme 561

Scheme 562

Scheme 563

Scheme 564

Scheme 565

Scheme 566

Scheme 567

Air deflectors mounted to the hood and front grill route the cool incoming air into the right inner fender where the inlet for the air cleaner housing resides. Air passes through a filter element inside the housing, through a air inlet duct, and into the throttle body.

Scheme 568

1. Unclip the air cleaner cover and release the top of the air cleaner housing assembly (Scheme 569)
2. Pull the air filter element up and out of the air cleaner housing assembly.

INSTALLATION

1. Install the air filter element into the housing assembly.
2. Position the alignment tabs of the housing cover into the lower housing assuring the position of the interlocking tabs (Scheme 569)
3. Clip and snap the air cleaner housing cover retainers

Scheme 569

1. Disconnect the air inlet duct and crankcase ventilation hose from the air cleaner housing.
2. Remove the air cleaner housing fastener on the front core support.
3. Lift up and remove the housing off of the guide pins and grommets.

1. Position the housing over the guide pins and push down to seat (Scheme 570)
2. Install and tighten the housing fasteners (Scheme 570)
3. Connect the throttle body air inlet duct and crank case ventilation hose to the air cleaner housing cover.

REMOVAL

Note. This procedure covers either the left or right engine mount.

Scheme 570

Scheme 571

1. Raise vehicle on hoist.
2. Support oil pan with suitable jack.
3. Loosen engine mount to block bolts (Scheme 571) or (Scheme 572)
4. Loosen engine mount to frame nut
5. Raise engine with jack. Remove engine mount to block bolts.
6. Remove engine mount (Scheme 571) or (Scheme 572)

Note. This procedure covers either the left or right engine mount.

1. With engine raised, position engine mount onto engine and install bolts. Tighten bolts to 41 N.m (30 ft. lbs.) (Scheme 571) or (Scheme 572)
2. Lower engine with jack while guiding engine mount studs into frame slots.
3. Install engine mount to frame nut. Tighten nut to 102 N.m (75 ft. lbs.) (Scheme 571) or (Scheme 572)
4. Remove jack.
5. Lower vehicle.

Note. Care must be taken to protect the intake manifold powder coating from scrapes and abrasions.

Scheme 572

Scheme 573

1. Perform the fuel system pressure release procedure, before attempting any repairs. (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 negative battery cable.
3. Disconnect throttle body air inlet duct, IAT sensor, CCV hose and remove air cleaner cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10__removal) ).
4. Disconnect throttle cable from throttle cam. Remove throttle cable from bracket and set aside (Scheme 573)
5. Disconnect brake booster vacuum hose from the intake manifold and set aside. WARNING: WRAP A SHOP TOWEL AROUND FUEL LINE TO CATCH ANY GASOLINE SPILLAGE.
6. Disconnect fuel line quick connect fitting from fuel rail (Refer to «QUICK CONNECT FITTING»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine) ) (Scheme 574)
7. Disconnect the following electrical connectors: Left cylinder head fuel injectors MAP sensor Engine Coolant Temperature (ECT) Sensor Idle Speed Control Sensor (ISC) Throttle Position Sensor (TPS) Right cylinder head fuel injectors
8. Carefully separate the fuel injector harness push pins from the intake manifold.
9. Disconnect the purge solenoid hose from beneath the throttle body (Scheme 575)
10. Disconnect CCV hoses from left and right cylinder head covers. CAUTION: Care must be taken when removing the number nine cylinder inside intake manifold bolt. Failure to do so may result in personal injury or possible damage.
11. Remove the intake manifold bolts and intake manifold (Scheme 576)
12. Cover the intake manifold openings with a suitable cover when servicing to prevent any debris from entering cylinder heads.

INSPECTION

1. Inspect manifold for cracks or other damage.
2. Inspect manifold sealing surfaces for damage.

Scheme 574

Scheme 575

Note. Care must be taken to protect the intake manifold powder coat from possible scrapes and abrasions.

Scheme 576

Scheme 577

Scheme 578

Scheme 579

1. Clean gasket surfaces and remove covering from intake manifold openings.
2. Carefully install the intake manifold gaskets and alignment pins (Scheme 577)
3. Set the intake manifold in position on the engine. Install intake manifold bolts and tighten initially to 1 N.m (10 in. lbs.). Tighten bolts starting at the center and working outward to 11 N.m (95 in. lbs.) (Scheme 578)
4. Connect CCV hoses to left and right cylinder head covers.
5. Connect fuel line to fuel rail (Scheme 574) Pull backward on the quick connect fitting to ensure complete insertion.
6. Connect the brake booster vacuum hose.
7. Connect the throttle cable housing to the bracket and then attach the cable to the throttle linkage (Scheme 579)
8. Attach the purge solenoid hose to the underside of the throttle body housing (Scheme 580)
9. Reconnect the following electrical connectors: Left cylinder head fuel injectors Engine Coolant Temperature (ECT) Sensor MAP sensor Idle Speed Control Throttle Position Sensor Right cylinder head fuel injectors
10. Install air cleaner cover assembly, connect throttle body air inlet hose, CCV hose and connect the Intake Air Temperature Sensor (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10__installation) ).
11. Connect negative battery cable.
12. With the DRB III® Scan Tool, use the ASD Fuel System Test to pressurize fuel system to check for leaks. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.

Note. Care must be taken to protect the cylinder head covers powder coating from scrapes and abrasions. This procedure covers either the left or right exhaust manifold.

Scheme 580

Scheme 581

1. Disconnect negative battery cable. NOTE: When servicing the right exhaust manifold it is necessary to remove the upper oil dip stick tube fastener and position the tube aside.
2. Raise vehicle on hoist.
3. Loosen and remove the fasteners from the exhaust pipe to exhaust manifold.
4. Separate exhaust pipe from the exhaust manifold.
5. Lower the vehicle.
6. Disconnect the spark plug wires from the spark plugs and set aside.
7. Remove manifold heat shield from exhaust manifold (Scheme 581), (Scheme 582) NOTE: Note the location of exhaust manifold studs and bolts for proper installation.
8. Remove studs and bolts attaching manifold to cylinder head and remove manifold (Scheme 581), (Scheme 582)

Inspect exhaust manifolds for damage or cracks. Check for distortion of the cylinder head mounting surfaces with a straightedge and feeler gauge (Scheme 583)

Note. Care must be taken to protect the cylinder head covers powder coating from scrapes and abrasions. This procedure covers either the left or right exhaust manifold.

Scheme 582

1. Install new gasket and install exhaust manifold Tighten attaching fasteners to 23 N.m (200 in. lbs.) (Scheme 581), (Scheme 582) NOTE: When installing right exhaust manifold, properly position the oil level indicator tube, install fastener and tighten to the cylinder head cover specification.
2. Install manifold heat shield and tighten attaching fasteners to 6 N.m (50 in. lbs.) (Scheme 581), (Scheme 582)
3. Install the spark plug wires.
4. Raise vehicle on hoist. STANDARD:. 101 mm (.004 inch) LIMIT:.203 mm (.008 inch)
5. Connect exhaust pipe to exhaust manifold. Tighten fasteners to 34 N.m (25 ft.lbs.).
6. Lower vehicle.
7. Connect negative battery cable.

REMOVAL - CYLINDER HEAD(S)

Note. Care must be taken to protect the intake manifold and cylinder head covers powder coating from scrapes and abrasions. This procedure covers either the left or right cylinder head.

The aluminum alloy cylinder head shown in (Scheme 584) is held in place by 12, 1/2 inch bolts and 8, 1/4 inch bolts.

Scheme 583

1. Release the fuel pressure (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 negative battery cable.
3. Disconnect the throttle body air inlet duct, I.A.T. sensor, CCV hose and remove the air cleaner cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
4. Drain the 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. Raise and support the vehicle.
6. Disconnect the front exhaust pipe to exhaust manifold connection.
7. Lower the vehicle.
8. Remove intake manifold (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
9. Disconnect the spark plug wires by pulling on the boot straight out in line with the spark plug. Dislodge spark plug retainers from the cylinder head cover studs and position the spark plug wires aside.
10. Disconnect the oil level indicator tube and set aside.
11. Disconnect CCV hoses from cylinder head covers.
12. Remove the cylinder head covers (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
13. Remove exhaust manifold heat shields.
14. Remove exhaust manifold(s) and gasket(s) (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ). NOTE: If rocker arms and push rods are to be reused, identify each component to ensure installation in original locations.
15. Remove the rocker arm and pedestal assemblies (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
16. Remove push rods (Scheme 584)
17. Remove the 12 head bolts and 8 cylinder head tappet gallery bolts from cylinder head(s) (Scheme 584)
18. Remove cylinder head(s) and gasket(s).

Scheme 584

1. Before cleaning, check for leaks, damage and cracks.
2. Clean cylinder head and oil passages.
3. Check cylinder head for flatness (Scheme 585)
4. Inspect all surfaces with a straightedge if there is any reason to suspect leakage. If out-of-flatness exceeds 0.019 mm (0.00075 in.) times the span length in inches in any direction, either replace head or lightly machine the head surface. As an example, if a 12.0 inch span is 1.0 mm (0.004 in.) out-of-flat, allowable is 12 x 0.019 mm (0.00075 in.) equals 0.22 mm (0.009 in.). This amount of out-of-flat is acceptable. *Maximum of 0.2 mm (0.008 in.) for grinding is permitted. CAUTION: This is a combined total dimension of stock removal from cylinder head surface.

INSTALLATION - CYLINDER HEAD(S)

Note. This procedure covers either the left or right cylinder head.

Scheme 585

Scheme 586

1. Clean all surfaces of engine block and cylinder heads (Refer to «STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10__standard-procedure-engine-gasket-surface) ). CAUTION: Remove all gasket material from cylinder head and block using a plastic scraper only. DO NOT use a metal scraper, as damage to sealing surface may occur. NOTE: A multi-layer steel head gasket is used.
2. Install new gasket(s) on the engine block. Assure all coolant passages and bolt holes align properly. (Scheme 586) CAUTION: Cylinder head bolts are coated, DO NOT oil.
3. Install cylinder head(s) over dowel pins. Install cylinder head bolts 1-12. Tighten cylinder head bolts 1-12 in the sequence shown in (Scheme 587) using a two step torque sequence: First to 47 N.m (35 ft. lbs.). Second to 122 N.m (90 ft. lbs.).
4. After cylinder head bolts 1-12 have been tightened to specifications, install and tighten cylinder head tappet gallery bolts A-H in sequence shown in (Scheme 587) to 11 N.m (95 in. lbs.).
5. Inspect the push rods. Replace worn or bent push rods as necessary.
6. Install push rods. Install rocker arms and pedestal assemblies into their original positions. Ensure push rods are seated properly under each rocker arm. Tighten rocker arm bolts to 35 N.m (26 ft. lbs.) (Scheme 584)
7. Install exhaust manifold(s) and gasket(s) (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
8. Install exhaust manifold heat shields.
9. Install cylinder head covers (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
10. Position and install the oil level indicator tube. Tighten fastener to 11N.m (95 in. lbs.).
11. Connect CCV hoses to cylinder head covers.
12. Install the spark plug wires and plug wire retainers.
13. Install intake manifold (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
14. Raise and support the vehicle.
15. Connect the exhaust system to the exhaust manifolds.
16. Drain the engine oil (Refer to «STANDARD PROCEDURE»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
17. Lower the vehicle.
18. Fill engine oil to the proper level.
19. Fill the cooling system (Refer to «STANDARD PROCEDURE - REFILLING COOLING SYSTEM - SRT-10»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__standard-procedure-refilling-cooling-syste) ).
20. Connect negative battery cable.
21. Install the air cleaner cover, throttle inlet duct, connect the I.A.T. sensor and CCV hose.
22. Start engine and inspect for leaks.

LEFT CYLINDER HEAD COVER

Note. Care must be taken to protect the cylinder head cover powder coating from scrapes and abrasions.

1. Disconnect CCV hose from cylinder head cover.
2. Disconnect left side spark plug wires by pulling on the boot straight out in line with plug. Dislodge spark plug wire retainers from cylinder head cover studs. Reposition spark plug wires aside.
3. Disconnect the power brake booster vacuum hose at the intake manifold and set aside. NOTE: For reassembly purposes, identify location of cylinder head cover attaching studs and bolts.
4. Remove cylinder head cover fasteners. Remove cylinder head cover from engine (Scheme 588)

RIGHT CYLINDER HEAD COVER

Note. Care must be taken to protect the cylinder head cover powder coating from scrapes and abrasions.

Scheme 587

1. Disconnect CCV hose from cylinder head cover.
2. Disconnect right side spark plug wires by pulling on the boot straight out in line with plug. Dislodge spark plug wire retainers from cylinder head cover studs. Reposition spark plug wires aside.
3. Remove the oil level indicator tube fastener and position tube aside. NOTE: For reassembly purposes, identify location of cylinder head cover attaching studs and bolts.
4. Remove cylinder head cover fasteners.
5. Remove cylinder head cover from engine (Scheme 588)

Note. Care must be taken to protect the cylinder head covers powder coating from scrapes and abrasions.

1. Inspect cylinder head cover gasket. Replace as necessary.
2. Place cylinder head cover onto cylinder head (Scheme 588) Install and tighten cylinder head cover fasteners to 11 N.m (95 in. lbs.) in sequence shown in (Scheme 589)
3. Connect spark plug wires. Position spark plug wire retainers onto cylinder head cover studs.
4. Connect CCV hose to cylinder head cover.
5. Connect the power brake booster vacuum hose to the intake manifold port.

Scheme 588

1. Inspect cylinder head cover gasket. Replace as necessary.
2. Place cylinder head cover onto cylinder head (Scheme 588)Install and tighten cylinder head cover fasteners to 11 N.m (95 in. lbs.) in sequence shown in (Scheme 589)
3. Position the oil level indicator tube into position. Tighten fastener to 11 N.m (95 in. lbs.).
4. Connect spark plug wires. Position spark plug wire retainers onto cylinder head cover studs.
5. Connect CCV hose to cylinder head cover.

Note. Before replacing parts, inspect all related valvetrain components for damage to prevent engine misfire.

1. Remove cylinder head cover(s) (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
2. Remove two rocker pedestal bolts per each cylinder (Scheme 584)
3. Remove rocker arm assemblies as a pair (Scheme 584)
4. If rocker arm assemblies are disassembled for cleaning or replacement, reassemble rocker arms in their original position.

Note. Before replacing parts, inspect all related valvetrain components for damage to prevent engine misfire.

1. Install rocker arm and pedestal assemblies into position. Ensure push rods are seated properly under each rocker arm. Tighten rocker arm bolts to 35 N.m (26 ft. lbs.) (Scheme 584) CAUTION: THE ROCKER ARM PEDESTAL BOLTS SHOULD BE TORQUED DOWN SLOWLY. ALLOW 20 MINUTES TAPPET BLEED DOWN TIME AFTER INSTALLATION OF THE ROCKER BOLTS BEFORE ENGINE OPERATION.
2. Install cylinder head cover(s) (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).

VALVE SPRING TESTING

The valve springs should be tested whenever removed for inspection, reconditioning, or replacement (Scheme 590)

Scheme 589

1. Obtain specifications for spring tension at specified spring length (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
2. Turn table of Special Tool C-647 until the surface is in line with the spring length specification mark on the threaded stud and the zero mark is on the front.
3. Place spring over stud on the table and lift compressing lever to set tone device.
4. Pull on torque wrench (beam or dial type) until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length.
5. Compare reading to the specification. Discard the springs that do not meet specifications.

Scheme 590

1. Disconnect negative battery cable.
2. Disconnect secondary ignition wires and remove spark plugs.
3. Remove cylinder head cover(s) (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
4. Rotate crankshaft until No. 1 piston is at TDC on compression stroke.
5. Remove rocker arms with pivots. The rocker arms should not be disturbed and remain on pivot block.
6. With air hose attached to spark plug adapter installed in No. 1 spark plug hole, apply 620.5 to 689 kPa (90 to 100 psi) air pressure. This is to hold valves into place while servicing components. CAUTION: Place a suitable shop towel around the valve spring being serviced to prevent the valve retaining locks from entering the engine once the valve spring is compressed.
7. Using valve spring compressor MD998772-A with insert 6716-A, compress valve spring and remove valve retaining locks (Scheme 591)
8. Release valve spring compressor.
9. Remove valve spring and retainer (Scheme 593)
10. Remove valve seal (Scheme 593) NOTE: Black valve seals are intake. Brown valve seals are exhaust (Scheme 593)
11. The intake and exhaust valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as guide. Push seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. CAUTION: Do not pinch seal between retainer and top of valve guide.
12. Follow the same procedure on the remaining 9 cylinders. Make sure piston is at TDC on the cylinder the valve spring is being removed.
13. Remove spark plug adapter tool.
14. Install rocker arm and pedestal assemblies. Ensure push rods are seated properly under each rocker arm. Tighten rocker arm bolts to 35 N.m (26 ft. lbs.).
15. Install cylinder head covers (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
16. Install spark plugs and connect secondary ignition wires.
17. Connect negative battery cable.

Note. Before replacing parts, inspect all related valvetrain components for damage to prevent engine misfire.

Scheme 591

1. With the cylinder head removed, compress valve springs using a valve spring compressor (Scheme 592)
2. Remove valve retaining locks (Scheme 593)
3. Slowly release valve spring compressor.
4. Remove valve spring retainer and valve spring (Scheme 593)
5. Before removing the valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify the valves to ensure installation in original location.
6. Remove valve seal (Scheme 593)
7. Repeat procedure for remaining valves.

Note. Before replacing parts, inspect all related valvetrain components for damage to prevent engine misfire.

Note. Black valve seals are intake. Brown valve seals are exhaust (Scheme 593)

Scheme 592

Scheme 593

1. Install valve seals (Scheme 593)
2. Coat the valve stems with clean engine oil and insert them in the cylinder head.
3. Install valve spring seats (Scheme 593)
4. Install valve springs and valve retainers (Scheme 593)
5. Compress valve springs with a valve spring compressor. Install retaining locks and release tool.
6. If valves and/or seats have been reground, measure valve tip height (A) (Scheme 594) Make sure measurements are taken from cylinder head surface to the top of valve stem. If valve tip height is greater than 52.96 mm (2.085 in.), grind the valve tip until within specifications.
7. If valves and/or seats have been reground, measure installed height of springs (B) (Scheme 594) Make sure measurements are taken from top of spring seat to the bottom surface of valve spring retainer. If height is greater than 44.45 mm (1.75 in.), install a 0.794 mm (1/32 in.) spacer in head counter-bore under the valve spring seat to bring spring height back to 43.69-44.45 mm (1.72-1.75 in.).

VALVE AND VALVE SEAT - REFACING

The valve face and valve seat angles are shown in (Scheme 595) (Refer to SPECIFICATIONS ) for valve face and seat angles.

Inspect the remaining margin after the valves are refaced. (Refer to SPECIFICATIONS ).

Scheme 594

VALVE SEATS

Scheme 595

1. When refacing 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.
2. Measure the concentricity of valve seat using a dial indicator. Total runout should not exceed 0.051 mm (0.002 in.) total indicator reading.
3. Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, lower valve seat with a 30 degree stone. If the blue is transferred to the bottom edge of valve face raise valve seat with a 75 degrees stone. NOTE: Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise cylinder head must be replaced.
4. When seat is properly positioned the width of both seats should be 1.02-1.52 mm (0.040-0.060 in.) (Scheme 595)

Valve

1. Clean valves thoroughly and discard any burned, bent, warped, and cracked valves.
2. Measure valve stems for wear (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).

Note. Valve stems are chrome plated and should not be polished (Scheme 597)

Scheme 596

Scheme 597

1. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
2. Measure valve stem guide clearance as follows: Install valve into cylinder head so it is 14 mm (0.551 in.) off the valve seat. A small piece of hose may be used to hold valve in place. Attach Special Tool C-3339, dial indicator to cylinder head and set it at right angle of valve stem being measured (Scheme 598) Move valve to and from the indicator. (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ) for valve guide specifications. If guides are out of specifications, ream to next oversize.
3. Ream the guides for valves with oversized stems if dial indicator reading is excessive or if the stems are scuffed or scored.
4. Service valves with oversize stems and over size seals are available in 0.15 mm (0.005 in.) and 0.40 mm (0.015 in.) oversize. NOTE: Oversize seals must be used with oversize valves.
5. Select the correct size reamer to accommodate the oversize valve stem. Refer to «VALVE GUIDE OVERSIZE CHART»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10__valve-guide-oversize-chart).
6. Slowly turn reamer by hand and clean guide thoroughly before installing new valve. Do not attempt to ream the valve guides from standard directly to 0.40 mm (0.015 in.). Use a step procedure of 0.15 mm (0.005 in.) to 0.40 mm (0.015 in.), so the valve guides may be reamed true in relation to the valve seat. After reaming guides, the seat runout should be measured and resurfaced if necessary. See «REFACING VALVES AND VALVE SEATS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10__valve-and-valve-seat-refacing). NOTE: Replace cylinder head if guide does not clean up with 0.40 mm (0.015 inch) oversize reamer, or if guide is loose in cylinder head.

VALVE GUIDE OVERSIZE CHART

VALVE GUIDE OVERSIZE SPECIFICATION CHART

Scheme 598

Scheme 599

Scheme 600

1. Disconnect negative battery cable.
2. Disconnect throttle body air inlet duct at the throttle body, CCV hose, disconnect the I.A.T. sensor and remove air cleaner housing cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10__removal) ).
3. Remove the oil indicator tube fastener at the right cylinder head cover (Scheme 599)
4. Raise and support the vehicle.
5. Remove the lower engine shield.
6. 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) ).
7. Drain engine oil and remove oil filter (Refer to «STANDARD PROCEDURE»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
8. Drain power steering.
9. Disconnect the cooling fan return hose at radiator fan.
10. Disconnect the radiator fan pressure hose to power steering rack.
11. Disconnect the power steering hose to power steering pump.
12. Separate the A/C hose from the radiator fan module.
13. Remove the lower radiator hoses.
14. Remove the front frame cross member (Refer to «FRONT CROSSMEMBER»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#frames-bumpers) ).
15. Remove the flywheel inspection cover. NOTE: Capture and properly dispose of any fuel spillage.
16. Disconnect oil cooler line at the timing cover using Special Tool 9005 (Refer to «STANDARD PROCEDURE - OIL COOLER LINE QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
17. Separate the oil cooler coolant hose from the timing cover.
18. Wiggle oil indicator tube free of oil pan.
19. Loosen engine mounts (Scheme 600) NOTE: Care must be taken not to damage the A/C compressor when placing the jack stand and raising the engine
20. Raise and support the engine with a jack stand at the A/C bracket (Scheme 600)
21. Remove the engine oil pan.
22. Lower the engine and remove the jack stand.
23. Remove the oil pump pick up tube (Scheme 601)
24. Remove accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
25. Remove A/C compressor mounting bolts. Reposition A/C compressor. Do not disconnect A/C lines (Scheme 602)
26. Disconnect the power steering line support bracket at the radiator.
27. Lower the vehicle.
28. Remove the upper radiator hose and coolant recovery container.
29. Remove the cooling fan module (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
30. Remove the upper idler pulley.
31. Remove power steering pump mounting bolts. Reposition power steering pump aside. Do not disconnect power steering lines.
32. Remove the generator (Refer to «GENERATORS & REGULATORS»(/dodge/pickup-r1500/1997-2012/remont/charging-system/#charging-system-generators-regulators) ).
33. Disconnec the heater hose at the timing cover.
34. Disconnect the ground wire at the thermostat housing. NOTE: Do Not remove the camshaft position sensor from the timing cover.
35. Disconnect the camshaft sensor wiring harness connector.
36. Disconnect engine coolant temperature (ECT) sensor connector.
37. Remove crankshaft pulley and damper (Refer to «CRANKSHAFT DAMPER»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
38. Remove the timing cover (Scheme 602)

Scheme 601

Scheme 602

Scheme 603

Scheme 604

1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. Crankshaft oil seal must be removed to insure correct oil pump engagement.
2. Install the timing chain cover gasket (Scheme 603)
3. Position the oil pump inner rotor mating flats in the same position as the crankshaft drive flats.
4. Install the timing chain cover onto crankshaft. Ensure the oil pump is engaged on the crankshaft correctly or severe damage may result (Refer to «OIL PUMP»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
5. Hand start bolts #1 and #2 (Scheme 604)
6. Loosely install A/C compressor mounting bracket (Scheme 602)
7. Hand start remaining timing chain cover bolts (Scheme 604)
8. Torque timing chain cover bolts in the sequence shown in (Scheme 604) to 23 N.m (200 in. lbs.).
9. Torque A/C compressor mounting bracket bolts to 23 N.m (200 in. lbs.).
10. Install crankshaft oil seal (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
11. Raise vehicle on hoist.
12. Install oil pump pick up tube using a new o-ring. Torque 1/4-20 bolt to 11 N.m (95 in. lbs.). Torque 5/16-18 nuts to 23 N.m (200 in. lbs.) (Scheme 605)
13. Support the engine with a jack stand (Scheme 600)
14. Install oil pan and drain plug (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
15. Remove the jackstand.
16. Tighten the engine mount to frame nuts to 102 N.m (75 ft.lbs.).
17. Connect the oil cooler coolant hose to the timing cover.
18. Connect the oil cooler line (Refer to «STANDARD PROCEDURE - OIL COOLER LINE QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
19. Install the lower radiator hose.
20. Install the flywheel inspection cover.
21. Install the front frame cross member (Refer to «FRONT CROSSMEMBER»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#frames-bumpers) ).
22. Lower vehicle.
23. Position the compressor and install A/C compressor mounting bolts. Torque bolts to 23 N.m (200 in. lbs.).
24. Connect heater hose at timing cover.
25. Install crankshaft damper and pulley (Refer to «CRANKSHAFT DAMPER»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
26. Install generator. Connect electrical connectors.
27. Install the idler pulley.
28. Connect the camshaft position sensor wiring harness connector.
29. Connect engine coolant temperature (ECT) sensor wiring harness connector.
30. Install power steering pump mounting bolts.
31. Install accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
32. Install the radiator fan assembly (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
33. Raise and support the vehicle.
34. Connect the hydraulic lines to the fan assembly and steering rack then connect the A/C hose to the fan shroud.
35. Install a New oil filter.
36. Lower the vehicle.
37. Install upper radiator hose and connect the ground wire at the thermostat housing.
38. Install air cleaner housing cover assembly, connect throttle body air inlet duct, IAT sensor and CCV hose.(Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10__installation) ).
39. Fill and purge air from the power steering system.
40. Fill engine crankcase with proper oil to correct level.
41. Fill and purge air from the cooling system (Refer to «STANDARD PROCEDURE - REFILLING COOLING SYSTEM SRT-10»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__standard-procedure-refilling-cooling-syste) ).
42. Connect negative battery cable.
43. Start the vehicle and inspect for leaks.
44. Install the lower engine shield.

TIMING CHAIN AND CAMSHAFT SPROCKET REMOVAL

1. Remove timing chain cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
2. Rotate crankshaft until timing marks are aligned (Scheme 610)
3. Remove the camshaft sprocket attaching bolts (Scheme 606)
4. Remove the timing chain with camshaft sprocket.

Scheme 605

Scheme 606

Scheme 607

1. Install Special Tool 8194 into end of crankshaft (Scheme 607) Lubricate the end of Special Tool 8194 with wheel bearing grease or equivalent. NOTE: Lubricate the threads of Special Tool 5048 using Mopar® Nickel Anti-seize Compound or equivalent, before beginning crankshaft sprocket removal.
2. Using Special Tools 9056 and 5048, remove crankshaft sprocket (Scheme 608)

CRANKSHAFT SPROCKET INSTALLATION

1. Position a new crankshaft sprocket on the crankshaft with timing mark facing out. Align crankshaft keyway with slot in crankshaft sprocket. NOTE: Lubricate the threads of Special Tool 9055 using Mopar® Nickel Anti-seize Compound or equivalent, before beginning crankshaft sprocket installation.
2. Install the crankshaft sprocket using Special Tool 9055 (Scheme 609)

Scheme 608

Scheme 609

1. Rotate the crankshaft sprocket so the timing mark is at the 12 O'clock position.
2. Place the timing chain around the camshaft sprocket and place the timing mark to the 6 O'clock position.
3. Place the timing chain around crankshaft sprocket and install the camshaft sprocket into position.
4. Using straight edge, check alignment of timing marks (Scheme 610)
5. Install the camshaft sprocket bolts. Tighten the bolts to 23 N.m (200 in. lbs.).
6. Rotate crankshaft 2 revolutions. Timing marks should line up. If timing marks do not line up, remove cam sprocket and realign.
7. Measure camshaft end play. (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ). If not within specifications, install new thrust plate.
8. Install timing chain cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).

The engine lubrication system is a full-flow filtration pressure feed type.

OPERATION

Engine oil stored in the oil pan is taken in and discharged by an internal gear type oil pump, which is driven by the crankshaft. A pressure relief valve is located in the timing chain case cover; it regulates oil pressure. The oil is pumped through an oil filter and feeds a main oil gallery. Also, oil is routed to an external oil cooler. The main oil gallery feeds oil under pressure to the main bearings, connecting rod bearings, and camshaft bearings. Passages in the cylinder block feed oil to the hydraulic lifters. The oil then flows through hollow pushrods, which feed the rocker arm pivots.

CHECKING ENGINE OIL PRESSURE

1. Remove oil pressure sensor (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
2. Install oil pressure gauge.
3. Warm engine at high idle until thermostat opens. CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM.
4. Oil pressure should be 68.9 kPa (10 psi) at idle or 310-517 kPa (45-75 psi) at 3000 RPM.

CHECKING ENGINE OIL LEVEL

The best time to check engine oil level is after the vehicle has sat overnight. If the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level (Scheme 611)

Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove the engine oil indicator. The indicator is calibrated for 1 quart within the SAFE zone.

ENGINE OIL AND FILTER CHANGE

Scheme 610

Change engine oil and filter at mileage and time intervals described in owner's manual.

1. Run engine until achieving normal operating temperature.
2. Position the vehicle on a level surface and turn engine off.
3. Open hood, remove oil fill cap.
4. Raise vehicle on hoist.
5. Remove underbody front shield
6. Place a suitable drain pan under oil pan drain plug.
7. Remove drain plug from oil pan and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged.
8. Install drain plug in crankcase.
9. Remove oil filter and replace with new.
10. Install under body shield.
11. Lower vehicle and fill crankcase with specified type and amount of engine oil (refer to owner's manual).
12. Install oil fill cap.
13. Start engine and inspect for leaks.
14. Stop engine and inspect oil level. Adjust oil level as necessary.

OIL SPECIFICATION

DaimlerChrysler Corporation recommends a fully synthetic API certified engine oil of the proper viscosity grade for refill. Viper engine factory fill is Mobil 1® 10W-30 Synthetic.

OIL FILTER SPECIFICATION

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

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine.

An engine oil cooler is used on all models. The cooler is a coolant-to-oil type and mounted on the right front inner fender (Scheme 614)

Engine oil travels from the oil pump and filter to the oil cooler via an oil supply line. The oil is cooled and returned to the engine via an oil return line. Engine oil is then pumped into the main oil gallery. Engine coolant flows into the cooler from the heater return hose and exits into the water pump inlet nipple.

Scheme 611

1. Remove dust cap by pulling it straight back off of quick connect fitting (Scheme 612)
2. Place disconnect tool (Special Tool 9005) onto oil cooler line with the fingers of the tool facing the quick connect fitting (Scheme 612)
3. Slide disconnect tool down the line and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting (Scheme 612)
4. Rotate the disconnect tool 60° to expand the retaining clip (Scheme 612)
5. While holding the disconnect tool against the quick connect fitting, pull back on the oil cooler line to remove (Scheme 612)

Scheme 612

1. Align oil cooler line with quick connect fitting while pushing straight into the fitting (Scheme 613)
2. Push in on oil cooler line until a "click" is heard or felt (Scheme 613)
3. Slide dust cap down the oil cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely (Scheme 613) Dust cap will only snap over quick connect fitting when the cooler line is properly installed. NOTE: If dust cap will not snap into place, repeat assembly step # 2.

Scheme 613

1. Disconnect throttle body air inlet hose, remove air cleaner housing assembly (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
2. 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) ).
3. Disconnect oil cooler coolant hoses (Scheme 614)
4. Using Special Tool 9005, disconnect oil supply and return lines at oil cooler (Refer to «STANDARD PROCEDURE - OIL COOLER LINE QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ) (Scheme 614)
5. Remove fasteners securing oil cooler to inner fender and remove oil cooler.

1. Position oil cooler to mounting position.
2. Install oil cooler fasteners. Tighten to 12 N.m (105 in. lbs.) (Scheme 614)
3. Connect oil supply and return lines to oil cooler (Scheme 614) and.
4. Connect oil cooler coolant hoses (Scheme 614)
5. Install air cleaner housing assembly, connect throttle body air inlet hose (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
6. Fill cooling system (Refer to «STANDARD PROCEDURE - REFILLING COOLING SYSTEM SRT-10»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__standard-procedure-refilling-cooling-syste) ).
7. Start the engine to circulate and fill the oil cooler. Shut off the engine and check the oil level. Add oil as needed.
8. Inspect the oil cooler connections for leaks.

Scheme 614

Scheme 615

1. Disconnect the negative battery cable.
2. Disconnect engine oil indicator tube fastener from the right cylinder head cover.
3. Raise vehicle on hoist.
4. Remove the lower engine shield.
5. Drain engine oil.
6. Remove the front crossmember (Refer to «FRONT CROSSMEMBER»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#frames-bumpers) )
7. Remove flywheel inspection cover.
8. Loosen engine mount through bolts.
9. Wiggle and separate the oil level indicator tube from the oil pan. NOTE: Careful positioning of the jack stand is necessary to prevent damage to other components
10. Raise and support the front of the engine with a jackstand located on the A/C bracket (Scheme 615)
11. Remove transmission to oil pan fasteners (Scheme 616)
12. Remove oil pan bolts and remove oil pan (Scheme 617) NOTE: Clean and inspect oil pan gasket. The pan gasket can be used again if in good condition.

Scheme 616

Scheme 617

1. Clean gasket surfaces. Inspect oil pan gasket. Replace as necessary.
2. Apply an 1/8 in. bead of Mopar Engine RTV at the two joints between the cylinder block to timing chain case cover and the two joints between the rear main seal retainer and engine block.
3. Position oil pan and gasket to engine block, seat the oil level indicator tube in the oil pan and hand start all fasteners (Scheme 618)
4. Run the transmission to oil pan bolts in finger tight (Scheme 616)
5. Torque 5/16-18 oil pan bolts to 23 N.m (200 in. lbs.). Torque 1/4-20 oil pan bolts to 11 N.m (95 in lbs.).
6. Torque transmission to oil pan bolts to 23 N.m (200 in. lbs.) (Scheme 616)
7. Lower the engine and remove the jack stand.
8. Tighten engine mount through bolts to 102 N.m (75 ft. lbs.).
9. Install flywheel inspection cover.
10. Install frame front cross member (Refer to «FRONT CROSSMEMBER»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#frames-bumpers) ).
11. Lower vehicle.
12. Install the oil level indicator tube fastener.
13. Fill the crankcase with the correct oil to proper level.
14. Start the engine and inspect for leaks.

Note. The oil pump is serviced with the timing chain cover (Scheme 619)

Scheme 618

1. Remove timing chain cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
2. Disassemble oil pump (Refer to «DISASSEMBLY»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
3. Inspect oil pump parts (Refer to «INSPECTION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).

DISASSEMBLY

1. Remove oil pump cover screws and lift off cover (Scheme 620)
2. Remove pump rotors.
3. Remove oil pressure relief valve and spring (Scheme 621)
4. Wash all parts in a suitable solvent and inspect carefully for damage or wear.

CLEANING

Clean all parts thoroughly. Mating surface of the chain case cover should be smooth. Replace pump cover if scratched or grooved.

Scheme 619

Scheme 620

Scheme 621

Scheme 622

Scheme 623

Scheme 624

Scheme 625

1. Lay a straightedge across the pump cover surface (Scheme 622) If a 0.076 mm (0.003 in.) feeler gauge can be inserted between cover and straight edge, cover should be replaced.
2. Measure thickness and diameter of rotors. If either rotor thickness measures 18.92 mm (0.744 in.) or less, or if the outer rotor diameter is 82.45 mm (3.246 in.) or less, replace rotor set (Scheme 623) and (Scheme 624)
3. Measure clearance between outer rotor and case (Scheme 625) If measurement is 0.19 mm (0.007 in.) or more, and outer rotor is within specification, replace chain case cover.
4. Measure clearance between the outer rotor and inner rotor (Scheme 626) If clearance between inner and outer rotors is 0.150 mm (0.006 in.) or more, replace rotor set.
5. Place a straightedge across the face of the chain case cover, in between the bolt holes. If a feeler gauge of 0.077 mm (0.003 in.) or more can be inserted between rotors and the straightedge, and the rotors are within specification, replace the case cover.
6. Inspect oil pressure relief valve for scoring and free operation in its bore. Small marks may be removed with 400 grit wet or dry sandpaper.
7. The relief valve spring has a free length of approximately 68.7 mm (2.70 in.) and should test between 22.5 and 27.5 pounds when compressed to 57 mm (2.24 in.). Replace spring that fails to meet specifications.
8. If oil pressure is low and pump is within specifications, inspect for worn engine bearings or other reasons for oil pressure loss.

ASSEMBLY

1. Assemble pump using new parts as required.
2. Install spring onto oil pressure relief valve.
3. Lubricate oil pressure relief valve and spring with clean engine oil.
4. Install oil pressure relief valve and spring.
5. Inspect relief valve plug o-ring. Replace as necessary. Torque plug to 34 N.m (25 ft. lbs.) (Scheme 621)
6. Install pump rotors with chamfer side to the inside of chain case cover.
7. Install oil pump cover and screws. Tighten cover screws to 23 N.m (200 in. lbs.) (Scheme 620)
8. Prime oil pump before installation by filling rotor cavity with engine oil.

1. Assemble oil pump (Refer to «ASSEMBLY»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
2. Prime oil pump before installation by filling rotor cavity with the correct engine oil.
3. Install timing chain cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
4. Install NEW oil filter.
5. Fill the crankcase with the correct engine oil to the proper level.

Scheme 626

1. Disconnect oil pressure sensor electrical connector.
2. Remove oil pressure sensor

1. Apply thread sealer to oil pressure sensor threads.
2. Install oil pressure sensor (Scheme 627)
3. Connect electrical connector.

1. Disconnect oil temperature sensor electrical connector.
2. Remove oil temperature sensor (Scheme 627)

1. Apply thread sealer to oil temperature sensor threads.
2. Install oil temperature sensor (Scheme 627)
3. Connect electrical connector.

The cylinder block is made of a sand-cast aluminum alloy. The cylinder block has interference-fit cast iron cylinder liners. The cylinder liners are thermally installed during block manufacturing; they are not serviceable items.

Six iron main bearing caps use four bolts per cap; two vertical and two horizontal. A crankshaft oil scraper is attached to the main bearing caps via extended main bearing cap bolts and nuts.

CYLINDER BORE HONING

Before honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area.

Scheme 627

1. Used carefully, the Cylinder Bore Sizing Hone C-823, equipped with 220 grit stones, is the best tool for this job. In addition to deglazing, it will reduce taper and out-of-round, as well as removing light scuffing, scoring and scratches. Usually, a few strokes will clean up a bore and maintain the required limits. CAUTION: DO NOT use rigid type hones to remove cylinder wall glaze.
2. Deglazing of the cylinder walls may be done if the cylinder bore is straight and round. Use a cylinder surfacing hone, Honing Tool C-3501, equipped with 280 grit stones (C-3501-3810). about 20-60 strokes, depending on the bore condition, will be sufficient to provide a satisfactory surface. Using honing oil C-3501-3880, or a light honing oil, available from major oil distributors. CAUTION: DO NOT use engine or transmission oil, mineral spirits, or kerosene.
3. Honing should be done by moving the hone up and down fast enough to get a crosshatch pattern. The hone marks should INTERSECT at 50° to 60° for proper seating of rings (Scheme 628)
4. A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper cross-hatch angle. The number of up and down strokes per minute can be regulated to get the desired 50° to 60° angle. Faster up and down strokes increase the cross-hatch angle.
5. After honing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash parts with a solution of hot water and detergent. Dry parts thoroughly. Use a clean, white, lintfree cloth to check that the bore is clean. Oil the bores after cleaning to prevent rusting.

1. When cleaning the cylinder block, remove the oil gallery plugs at the front and rear of the block.
2. Spray compressed air into all oil gallery passages to ensure they are clear of blockage.
3. Use a wooden or plastic scraper and Mopar® Brake Parts Cleaner or the equivalent to remove the old gasket.
4. Clean the oil passages in the crankshaft with a brush.

The cylinder walls should be checked for out-of-round and taper with Special Tool C-119 (Scheme 629) If the cylinder walls are badly scuffed or scored, the cylinder bore can be machined oversize. Oversize piston and rings are available.

Measure the cylinder bore at three levels in directions A and B (Scheme 629) Top measurement should be 12 mm (0.50 in.) down and bottom measurement should be 12 mm (0.50 in.) up from bottom of bore. (Refer to SPECIFICATIONS ) for cylinder bore and piston specifications.

Scheme 628

The roller type design hydraulic tappets are positioned in the cylinder block. Roller tappet alignment is maintained by machined flats on tappet body being fitted in pairs into ten aligning yokes (Scheme 630)

Scheme 629

1. Remove cylinder head(s) (Refer to «CYLINDER HEAD(S)»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ). NOTE: If tappets are to be reused, identify tappet location to ensure installation in original location.
2. Remove tappet aligning yoke bolt (Scheme 630)
3. Remove tappets from bores. CAUTION: Do not disassemble tappets.

Scheme 630

1. Lubricate tappets.
2. Install tappets in their original positions with oil holes facing up (Scheme 631) CAUTION: The "handle" on the tappet aligning yoke must be installed in the outboard position; i.e. toward the cylinders.
3. With roller tappets in proper position, install aligning yoke assemblies. Apply Mopar® Lock & Seal Adhesive (Medium Strength Threadlocker) to the screws and tighten to 11 N.m (95 in. lbs.) (Scheme 630)
4. Install cylinder heads (Refer to «CYLINDER HEAD(S)»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
5. Start and operate engine. Warm up to normal operating temperature. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet.

Scheme 631

1. Perform the fuel pressure relief procedure (Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE REL»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine__standard-procedure-fuel-system-pressure) ).
2. Disconnect the negative battery cable.
3. Raise and support the vehicle.
4. Remove the front engine shield.
5. Drain the cooling system
6. Drain the power steering fluid.
7. Remove the oil pan (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
8. Lower the vehicle.
9. Remove the radiator and radiator fan assembly (Refer to «RADIATOR - SRT-10»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) and «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
10. Remove intake manifold (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
11. Remove cylinder head covers (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
12. Remove timing chain cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
13. Remove rocker arm assemblies. NOTE: Identify each push rod to be replaced in its original location.
14. Remove push rods.
15. Remove cylinder heads (Refer to «CYLINDER HEAD(S)»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
16. Remove hydraulic tappets (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
17. Remove timing chain and camshaft sprocket (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
18. Remove camshaft thrust plate (Scheme 632)
19. Slowly remove camshaft being careful not to damage camshaft bearing surfaces with the cam lobes (Scheme 632)

1. Lubricate camshaft lobes and camshaft bearing journals.
2. Slowly install camshaft being careful not to damage camshaft bearing surfaces with the cam lobes (Scheme 632)
3. Install camshaft thrust plate with two screws as shown in (Scheme 632) Tighten to 24 N.m (210 in. lbs.).
4. Install timing chain and camshaft sprocket (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
5. Measure camshaft end play. End Play should measure 0.0127-0.381 mm (0.005-0.015 in.) 0.381 mm (0.015 in. Max.). If not within limits, install a new thrust plate.
6. When camshaft is replaced, all of the tappets must be replaced. Each hydraulic tappet must be installed with oil hole facing up (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
7. Install timing chain cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
8. Install cylinder heads (Refer to «CYLINDER HEAD(S)»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
9. Install push rods in their original location.
10. Install rocker arms (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
11. Install intake manifold (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
12. Install cylinder head covers (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
13. Install the radiator and fan assembly (Refer to «RADIATOR - SRT-10»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) and «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
14. Raise and support the vehicle.
15. Install the oil pan (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
16. Install the front engine shield.
17. Lower the vehicle.
18. Fill and purge air from the power steering (Refer to «PUMP»(/dodge/pickup-r1500/1997-2012/remont/manual-power-steering/#power-steering-system) ).
19. Fill and purge air from the cooling system (Refer to «STANDARD PROCEDURE - REFILLING COOLING SYSTEM - SRT-10»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#engine-cooling-system-diagnosis-servicing-specifications__standard-procedure-refilling-cooling-syste) ).
20. Fill engine crankcase with the proper oil to the correct level (Refer to «STANDARD PROCEDURE»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
21. Connect the negative battery cable.
22. Start the vehicle and inspect for leaks.

The pistons are made of cast aluminum with an added anodized coating on both sides of the skirt and the top piston ring groove for reduced wear and it's low friction properties. Three piston rings are used; two compression and one three-piece oil control ring. The piston pin (press-fit into the rods) joins the piston to a forged steel, fractured cap, designed connecting rod, with a custom twelve point nine millimeter threaded bolt. The piston and connecting rod is serviced as an assembly and is not interchangeable with previous model years.

PISTON FITTING

All pistons are machined to the same weight in grams, to maintain piston balance.

Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin axis at size location shown in (Scheme 633) Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in (Scheme 634) (Refer to SPECIFICATIONS ) for cylinder bore and piston specifications.

Note. Pistons and cylinder bores should be measured at normal room temperature, 70°F (21 °C).

Scheme 632

Scheme 633

Scheme 634

1. Using a feeler gauge, check connecting rod side clearance (Scheme 635) (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ) for connecting rod side clearance specifications.

Note. Pistons and connecting rods are to be removed as an assembly from top of cylinder block.

Scheme 635

Scheme 636

Scheme 637

1. Remove cylinder heads (Refer to «CYLINDER HEAD(S)»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
2. Remove oil pan (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
3. Remove the oil pump pick up tube and the crankshaft oil scraper (Scheme 636) and (Scheme 637) CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.
4. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if necessary using a permanent ink or paint marker (Scheme 638) CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage may occur. NOTE: Do not reuse connecting rod bolts.
5. Remove connecting rod bolts and cap. Push each piston and rod assembly out the block. NOTE: Be careful not to nick crankshaft journals.
6. After removal, install bearing cap on the mating rod.

CONNECTING ROD

1. Check the connecting rods for twist or bend.
2. Check the condition of the large end. Use an oil stone to remove any nicks and burrs.
3. Check the condition of the pin bore in the small end of the connecting rod. Use an oil stone to remove all nicks and burrs.

PISTON PIN

1. Inspect for free rotation of the piston pin in the piston.

PISTON

1. Inspect all piston surfaces for nicks and scuffs.
2. Inspect piston and ring grooves for wear.

Note. Pistons and connecting rods are serviced as an assembly. Left bank pistons are labeled "ODD". Right bank pistons are labeled "EVEN".

Scheme 638

Scheme 639

1. Install piston rings (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ). NOTE: Before installing pistons, and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in (Scheme 647)
2. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. Be sure position of rings does not change during this operation.
3. Rotate crankshaft so that the connecting rod journal is at the bottom of it's stroke and in the center of the cylinder bore.
4. The arrow on top of piston must be pointing toward front of engine (Scheme 639)
5. Install new connecting rod bearing in connecting rod and rod cap.
6. Install piston assembly from the top of the block (Scheme 640) Tap the piston down in cylinder bore, using a hammer handle. Guide the rod over the crankshaft journal.
7. Install rod cap. Install NEW connecting rod bolts. Bolt threads should be oiled with engine oil. Torque connecting rod bolts to 68 N.m (50 ft. lbs.).
8. Install the crankshaft oil scraper. Torque crankshaft oil scraper nuts to 23 N.m (200 in. lbs.) (Scheme 637)
9. Install oil pump pick up tube using a new o-ring. Torque 1/4-20 bolt to 11 N.m (95 in. lbs.). Torque 5/16-18 nuts to 23 N.m (200 in. lbs.) (Scheme 636)
10. Install oil pan (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
11. Install cylinder heads (Refer to «CYLINDER HEAD(S)»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).

Scheme 640

Scheme 641

1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 in.) from bottom of cylinder bore. Check gap with feeler gauge (Scheme 641) (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ) for piston ring specifications.
2. Check piston ring side clearance (Scheme 642) (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ) for piston ring specifications.

Scheme 642

1. Using a suitable ring expander, remove upper and intermediate piston rings (Scheme 643)
2. Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston.
3. Clean ring grooves of any carbon deposits.

The No. 1 and No. 2 piston rings have a different cross section. Install rings with manufacturers I.D. mark facing up, to the top of the piston (Scheme 644)

Scheme 643

Scheme 644

Scheme 645

Scheme 646

1. Install oil ring expander.
2. Install the lower oil ring side rail by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander. (Scheme 645)
3. Install upper oil ring side rail.
4. Install No. 2 piston ring and then No. 1 piston ring (Scheme 646)
5. Position piston ring end gaps as shown in (Scheme 647)
6. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control.

The bearing caps are not interchangeable and should be paint marked or scribed at removal to insure correct assembly.

The bearing shells must be installed so that the tangs are in the machined grooves in the rods and caps.

Limits of taper or out-of-round on any crankshaft journals should be held to 0.013 mm (0.0005 in.). Bearings are available in 0.025 mm (0.001 in.), 0.051 mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 mm (0.010 in.) and 0.305 mm (0.012 in.) undersize. Install the bearings in pairs. Do not use a new bearing half with an old bearing half. Do not file the rods or bearing caps.

CONNECTING ROD BEARING - FITTING

Fit all rods on one bank until complete. Do not alternate from one bank to another, because when the rods are assembled to pistons correctly, they are not interchangeable from one bank to another.

The bearing caps are not interchangeable and should be marked at removal to insure correct assembly.

The bearing shells must be installed so that the tangs are in the machined grooves in the rods and caps.

Limits of taper or out-of-round on any crankshaft journals should be held to 0.013 mm (0.0005 in.). Bearings are available in 0.025 mm (0.001 in.), 0.051 mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 mm (0.010 in.) and 0.305 mm (0.012 in.) undersize. Install the bearings in pairs. Do not use a new bearing half with an old bearing half. Do not file the rods or bearing caps.

1. (Refer to «STANDARD PROCEDURE»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ) - Measuring Connecting Rod Bearing Clearance to determine bearing clearance.
2. Before installing the connecting rod cap bolts, the bolt threads should be oiled with engine oil.
3. Install bolts finger tight, then alternately torque each bolt to assemble the cap properly.
4. Tighten the connecting rod bolts to 68 N.m (50 ft. lbs.).

MEASURING CONNECTING ROD BEARING CLEARANCE

Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage

Scheme 647

Scheme 648

1. Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke.
2. Remove oil film from surface to be checked. Plastigage is soluble in oil.
3. Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap approximately 6.35 mm (1/4 inch.) off center and away from the oil hole (Scheme 648) In addition, suspect areas can be checked by placing plastigage in the suspect area.
4. Before assembling the rod cap with Plastigage in place, the crankshaft must be rotated until the connecting rod being checked starts moving toward the top of the engine. Only then should the cap be assembled and torqued to specifications. Do not rotate the crankshaft while assembling the cap or the Plastigage may be smeared, giving inaccurate results.
5. Remove the bearing cap and compare the width of the flattened Plastigage (Scheme 649) with the metric scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ). Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale.
6. Plastigage is available in a variety of clearance ranges. The 0.025-0.076 mm (.001-.003 inch) is usually the most appropriate for checking engine bearing proper specifications.

Scheme 649

Scheme 650

1. Raise and support the vehicle.
2. Remove the engine front shield.
3. Disconnect the radiator fan hydraulic lines (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
4. Lower vehicle.
5. Disconnect the air inlet duct, IAT sensor, CCV hose at the throttle body, and remove the air cleaner housing cover.
6. Remove accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
7. Remove the radiator fan (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
8. Raise and support the vehicle.
9. Remove crankshaft pulley.
10. Remove crankshaft damper bolt.
11. Install crankshaft insert, Special Tool 8194 (Scheme 650) Lubricate the end of Special Tool 8194 with wheel bearing grease or equivalent. NOTE: Lubricate the threads of the puller using Mopar® Nickel Anti-seize Compound or equivalent, before beginning crankshaft damper removal.
12. Using a bolt-grip type universal puller, remove the crankshaft damper (Scheme 651)

Note. Lubricate the threads of Special Tool 9055 using Mopar® Nickel Anti-seize Compound or equivalent, before beginning crankshaft damper installation.

Scheme 651

1. Raise and support the vehicle.
2. Install crankshaft damper using Special Tool 9055 (Scheme 652)
3. Install and tighten damper bolt to 176 N.m (130 ft. lbs.).
4. Install the crankshaft pulley. Tighten crankshaft pulley bolts to 23 N.m (200 in. lbs.).
5. Install the front engine shield.
6. Lower the vehicle.
7. Install accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
8. Install the radiator fan (Refer to «FAN-RADIATOR»(/dodge/pickup-r1500/1997-2012/remont/cooling-fan/#engine-cooling-system-removal-installtion) ).
9. Install air cleaner cover connecting the CVV hose, IAT, and air duct to the throttle body housing.
10. Lower vehicle.

1. Disconnect the air inlet duct, IAT sensor, CCV hose at the throttle body, and remove the air cleaner housing cover.
2. Remove accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
3. Remove crankshaft damper (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
4. Use Special Tool C-4679-A to remove crankshaft oil seal (Scheme 653) Be careful not to damage the crankshaft seal surface of cover.

Scheme 652

Scheme 653

1. Install the new seal by using Special Tool MD 998306 (Scheme 654)
2. Place seal into opening with seal spring towards the inside of engine. Install seal until it bottoms out in timing chain cover.
3. Install crankshaft damper (Refer to «CRANKSHAFT DAMPER»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
4. Install accessory drive belt (Refer to «ACCESSORY DRIVE»(/dodge/pickup-r1500/1997-2012/remont/accessory-drive-belts/#accessory-drive-belt) ).
5. Install air cleaner cover connecting the CVV hose, IAT sensor, and air duct to the throttle body housing.

Scheme 654

1. Remove transmission (Refer to «MANUAL TRANSMISSION - T56»(/dodge/pickup-r1500/1997-2012/remont/manual-trans/#overhaul-t56-manual-transmission) ).
2. Remove clutch and flywheel. NOTE: The oil seal and retainer are serviced as an assembly.
3. Remove the seal retainer bolts from cylinder block and oil pan (Scheme 655)
4. Remove the oil seal and retainer assembly (Scheme 655)

Scheme 655

Scheme 656

1. Clean the engine block and retainer. Make sure surfaces are clean and free of oil.
2. Install Special Tool 9060 (seal guide) onto end of crankshaft (Scheme 656) Align hole in tool with dowel pin on crankshaft.
3. Carefully position retainer/oil seal to block. Tighten the retainer bolts to 11 N.m (95 in. lbs.) (Scheme 657)
4. Install flywheel and clutch.
5. Install transmission (Refer to «MANUAL TRANSMISSION - T56»(/dodge/pickup-r1500/1997-2012/remont/manual-trans/#overhaul-t56-manual-transmission) ).

The main bearing caps are not interchangeable and should be marked at removal to insure correct assembly. Upper and lower main bearing halves are NOT interchangeable. Lower main bearing halves of 1, 2, 4, 5 and 6 are interchangeable. Upper main bearing halves of 1, 2, 4, 5 and 6 are interchangeable.

Upper and lower No. 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine (Scheme 658) All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. Bearing shells are available in standard and the following undersizes: 0.025 mm (0.001 in.), 0.051 mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 mm (0.010 in.), 0.305 mm (0.012 in.) and 0.508 mm (0.020 in.). Never install an undersize bearing that will reduce clearance below specifications.

Scheme 657

PLASTIGAGE METHOD

Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage

1. Remove oil film from surface to be checked. Plastigage is soluble in oil.
2. The total clearance of the main bearings can only be determined by removing the weight of the crankshaft. This can be accomplished by either of two methods

PREFERRED METHOD

1. Shimming the bearings adjacent to the bearing to be checked in order to remove the clearance between upper bearing shell and the crankshaft. This can be accomplished by placing a minimum of 0.254 mm (.010 inch) shim (e. g. cardboard, matchbook cover, etc.) between the bearing shell and the bearing cap on the adjacent bearings and tighten bolts to 14-20 N.m (10-15 ft.lb.) When checking #1 main brg. shim #2 main brg. When checking #2 main brg. shim #1 & 3 main brg. When checking #3 main brg. shim #2 & 4 main brg. When checking #4 main brg. shim #3 & 5 main brg. When checking #5 main brg. shim #4 & #6 main brg. When checking #6 main brg. shim #5 main brg. NOTE: REMOVE ALL SHIMS BEFORE REASSEMBLING ENGINE

Scheme 658

Scheme 659

1. With the weight of the crankshaft being supported by a jack under the counterweight adjacent to the bearing being checked.
2. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6.35 mm (1/4 inch) off center and away from the oil holes (Scheme 659) (In addition, suspect areas can be checked by placing the Plastigage in the suspect area). Torque the bearing cap bolts of the bearing being checked to the proper specifications.
3. Remove the bearing cap and compare the width of the flattened Plastigage (Scheme 660) with the metric scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Refer to Engine Specifications. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale.
4. Plastigage is available in a variety of clearance ranges. The 0.025-0.076 mm (.001-.003 inch) is usually the most appropriate for checking engine bearing proper specifications.

MEASURING CRANKSHAFT END PLAY

1. Mount a dial indicator to front of engine, locating probe on nose of crankshaft (Scheme 661)
2. Move crankshaft all the way to the rear of its travel.
3. Zero the dial indicator.
4. Move crankshaft all the way to the front and read the dial indicator. (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ) for crankshaft end-play specifications.

Scheme 660

1. Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek using care not to damage any bearing surface. Do not loosen main bearing cap.
2. Use a feeler gauge between number 3 thrust bearing and machined crankshaft surface to determine end play. (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ) for crankshaft end-play specifications.

CRANKSHAFT JOURNAL MEASUREMENT

The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out-of-round on any crankshaft journals should be held to 0.013 mm (0.0005 in.). Journal grinding should not exceed 0.508 mm (0.020 in.) under the standard journal diameter. DO NOT grind thrust faces of No. 3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages.

Scheme 661

1. Measure the journal outside diameter as shown in (Scheme 662) (Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ) for crankshaft specifications.

Scheme 662

Scheme 663

1. Remove engine assembly from vehicle (Refer to «REMOVAL - ENGINE ASSEMBLY»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10__removal-engine-assembly) ).
2. Mount engine on a suitable repair stand.
3. Remove oil pan (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
4. Remove crankshaft rear oil seal retainer (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
5. Remove crankshaft pulley and damper (Refer to «CRANKSHAFT DAMPER»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
6. Remove timing chain cover (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
7. Remove timing chain and crankshaft sprocket-. (Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
8. Remove oil pump pick up tube (Scheme 663)
9. Remove crankshaft oil scraper (Scheme 664) CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.
10. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if necessary using a permanent ink or paint marker (Scheme 665) CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage many occur. NOTE: Do not reuse connecting rod bolts.
11. Remove connecting rod bolts and caps.
12. Main bearing caps are not interchangeable and should be marked before removal to ensure correct reassembly.
13. Remove the side main bearing cap bolts and main bearing cap bolts (Scheme 666)
14. Remove the main bearing caps.
15. When removing the crankshaft, it should be lifted straight out of the engine block. This will prevent any damage to the engine and crankshaft.

Scheme 664

Scheme 665

1. The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 in.). Journal grinding should not exceed 0.508 mm (0.020 inch) under the standard journal diameter. DO NOT grind thrust faces of No. 3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages. CAUTION: With the forged crankshafts it is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine.
2. Check and clean all oil holes for blockage and debris.

Scheme 666

Scheme 667

Scheme 668

Scheme 669

1. Install upper main bearing shells into engine block (Scheme 667)
2. Lubricate upper main bearing shells with clean engine oil.
3. Install the crankshaft.
4. Install lower main bearing shells into main bearing caps (Scheme 667)
5. Install each main bearing cap in proper sequence and direction (Scheme 668) Tighten all bolts finger tight.
6. Tighten the main cap bolts in the following tightening sequence: Step 1 Tighten main bearing cap bolts 1-12 in the sequence order shown in (Scheme 669) to 20 N.m (15 ft. lbs.). This will seat the bearing caps onto the engine block. Step 2 To ensure correct thrust bearing alignment the following procedure must be done: Move crankshaft all the way to the rear of its travel. Then, move crankshaft all the way to the front of its travel. Wedge an appropriate tool between the rear of the cylinder block and rear crankshaft counterweight. This will hold the crankshaft in it's most forward position. Step A1 -tighten the A1 bolts to 61 N.m (45 ft. lbs.) in the sequence order shown in (Scheme 669) Step A2 -tighten the A2 bolts to 115 N.m (85 ft. lbs.) in the sequence order shown in (Scheme 669) Step A3 -tighten the A3 Bolts to 54 N.m (40 ft. lbs.) in the sequence order shown in (Scheme 669)
7. Remove the holding tool.
8. Install new connecting rod bearings.
9. Install rod caps. Install NEW connecting rod bolts. Bolt threads should be oiled with engine oil. Torque connecting rod bolts to 68 N.m (50 ft. lbs.).
10. Install the crankshaft oil scraper and tighten nuts to 23 N.m (200 in. lbs.) (Scheme 664)
11. Install oil pump pick up tube using a new o-ring. Torque 1/4-20 bolt to 11 N.m (95 in. lbs.). Torque 5/16-18 nuts to 23 N.m (200 in. lbs.) (Scheme 670)
12. Install the crankshaft rear oil seal and retainer (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
13. Install lower crankshaft gear along with the timing chain (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
14. Install timing chain cover (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
15. Install oil pan (Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
16. Install crankshaft damper and pulley (Refer to «CRANKSHAFT DAMPER»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).
17. Install engine assembly (Refer to «INSTALLATION - ENGINE ASSEMBLY»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) ).

Scheme 670

1. Remove transmission (Refer to «MANUAL TRANSMISSION - T56»(/dodge/pickup-r1500/1997-2012/remont/manual-trans/#overhaul-t56-manual-transmission) ).
2. Remove clutch and flywheel.
3. Using Special Tools 8990 and C-3752 remove pilot bearing from crankshaft (Scheme 671)

Note. New pilot bearing has special grease packed into bearing. Do not wash grease from bearing. Install bearing with part number markings facing out (Scheme 672)

Scheme 671

Scheme 672

1. Install pilot bearing with Special Tools 9058 and C-4171 see scheme 141
2. Install flywheel and clutch.
3. Install transmission (Refer to «MANUAL TRANSMISSION - T56»(/dodge/pickup-r1500/1997-2012/remont/manual-trans/#overhaul-t56-manual-transmission) ).

See also:
• POWERTRAIN DIAGNOSTIC PROCEDURES (PART 1)
• POWERTRAIN DIAGNOSTIC PROCEDURES (PART 2)
• BATTERY SYSTEM
• GENERATORS & REGULATORS
• STARTERS
• STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE
• DRAINING COOLING SYSTEM - ALL GAS ENGINES
• PROPELLER SHAFT
• MANUAL TRANSMISSION - T56
• FAN-RADIATOR
• REFRIGERANT SYSTEM RECOVERY
• A/C COMPRESSOR
• REFRIGERANT SYSTEM CHARGE
• STANDARD PROCEDURE - REFILLING COOLING SYSTEM - SRT-10
• PUMP
• QUICK CONNECT FITTING
• FRONT CROSSMEMBER
• ACCESSORY DRIVE
• ENGINE DIAGNOSIS - MECHANICAL CHART
• ENGINE DIAGNOSIS - PERFORMANCE CHART
• STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE
• DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST
• DIAGNOSIS AND TESTING
• INSPECTION FOR REAR SEAL AREA LEAK
• REMOVAL
• INSTALLATION
• STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION
• VALVE GUIDE OVERSIZE CHART
• REFACING VALVES AND VALVE SEATS
• REMOVAL - ENGINE ASSEMBLY