8.0L V10 Engine: Removal & Installation Dodge Pickup R2500

REMOVAL

1. Remove the battery.
2. Drain cooling system.
3. Discharge the air conditioning system, if equipped.
4. Remove the upper crossmember.
5. Remove the transmission oil cooler.
6. Remove the serpentine belt.
7. Remove the A/C compressor with the lines attached. Set aside.
8. If equipped, remove the condenser.
9. Remove the washer fluid reservoir bottle.
10. Disconnect the top radiator hose.
11. Remove the fan.
12. Remove the fan shroud.
13. Disconnect the lower radiator hose.
14. Disconnect the transmission cooler lines.
15. Remove radiator.
16. Remove the generator with the wire connections.
17. Remove the air cleaner.
18. Disconnect the throttle linkage.
19. Remove throttle body.
20. Remove the upper intake manifold. See «INTAKE MANIFOLD»(ref-174645-S34232090772005040700000) .
21. Remove the coil assemblies with the ignition cables.
22. Disconnect the heater hoses.
23. Disconnect the power steering hoses, if equipped.
24. Perform the fuel system pressure release procedure. Disconnect the fuel line.
25. On manual transmission vehicles, remove the shift lever.
26. Raise and support the vehicle on a hoist.
27. Remove the drain plug and drain the engine oil.
28. Loosen front engine mount through-bolt nuts.
29. Remove the transmission cooler line brackets from oil pan.
30. Disconnect exhaust pipe at manifold.
31. Disconnect the starter wires. Remove starter motor.
32. Remove transmission.
33. Lower vehicle. CAUTION: DO NOT lift the engine by the intake manifold.
34. Install an engine lifting fixture.
35. Remove engine from vehicle and install engine assembly on a repair stand.

INSTALLATION

1. Remove engine from the repair stand and position in the engine compartment. Position the thru bolt into the support cushion brackets.
2. Install an engine support fixture.
3. Raise and support the vehicle on a hoist.
4. Install Transmission.
5. Install the starter and connect the starter wires.
6. Install exhaust pipe to manifold.
7. Install the transmission cooler line brackets from oil pan.
8. Tighten the Front mount through-bolts and nuts to 102 N.m (75 ft. lbs.).
9. Install the drain plug and tighten to 34 N.m (25 ft. lbs.) torque.
10. Prime oil pump by squirting oil in the oil filter mounting hole and filling the J-trap of the front timing cover. When oil is running out, install oil filter that has been filled with oil.
11. Lower the vehicle.
12. Remove engine lifting fixture.
13. On Manual Transmission vehicles, install the shift lever.
14. Connect the fuel lines.
15. Connect the heater hoses.
16. Install the upper intake manifold. See «INTAKE MANIFOLD»(ref-174645-S34232090772005040700000) .
17. Install the coil assemblies with the ignition cables.
18. Using a new gasket, install throttle body.
19. Connect the throttle linkage.
20. Install the air cleaner box.
21. Install the generator and wire connections.
22. Install the upper crossmember.
23. Install radiator.
24. Connect the lower radiator hose.
25. Install the transmission oil cooler.
26. Connect the transmission cooler lines.
27. Connect the power steering hoses, if equipped.
28. Install the fan shroud.
29. Install the fan.
30. Connect the top radiator hose.
31. Install the washer fluid reservoir bottle.
32. If equipped, install the condenser.
33. Install the A/C compressor with the lines attached.
34. Install the serpentine belt
35. Evacuate and charge the air conditioning system, if equipped.
36. Add coolant to the cooling system.
37. Install the battery.
38. Warm engine and adjust as required.
39. Road test vehicle.

For air cleaner element required maintenance schedules (listed in time or mileage intervals), refer to lubrication and maintenance schedule.

A small amount of engine oil wetting the inside of the air cleaner housing is normal. When servicing, wipe out oil from air cleaner housing.

Scheme 58

Scheme 59

1. Loosen clamp and remove air inlet tube at front of air cleaner housing cover. (Scheme 58)and (Scheme 59).
2. The air cleaner housing and air cleaner element cover are equipped with spring clips to seal cover to housing. (Scheme 59) Unlatch clips from air cleaner cover and remove cover from air cleaner housing.
3. Remove air cleaner element from air cleaner cover.
4. Before installing a new air cleaner element, clean inside of air cleaner housing.
5. If housing removal is necessary, disconnect crankcase vent hose and remove 4 housing-to-throttle body nuts.

For air cleaner element required maintenance schedules (listed in time or mileage intervals), refer to lubrication and maintenance schedule.

Scheme 60

1. After installing housing, tighten 4 nuts to 11 N.m (96 in. lbs.) and connect crankcase vent hose.
2. Position air cleaner element (filter) into air cleaner cover. Latch spring clips to seal cover to housing.
3. Install air inlet tube at air cleaner housing inlet.
4. Install and tighten clamp at air inlet tube. (Scheme 60)

Die-cast magnesium cylinder head covers reduce noise and provide a good sealing surface. (Scheme 61) A steel backed silicon gasket is used with the cylinder head cover. (Scheme 62)

Scheme 61

Scheme 62

1. Disconnect the negative cable from the battery.
2. Disconnect closed ventilation system and evaporation control system from cylinder head cover. Identify each system for installation.
3. Remove the upper intake manifold to remove the right side head cover. See «INTAKE MANIFOLD»(ref-174645-S34232090772005040700000).
4. Remove cylinder head cover bolts and stud bolts. Remove the covers and gaskets. (Scheme 62) The gasket may be used again.

1. Check the gasket for use in head cover installation. If damaged, use a new gasket.
2. Install the gasket onto the head rail. For the left side the number tab is at the front of engine with the number up. For the right side the number tab is at the rear of engine with the number up. CAUTION: The cylinder head cover fasteners have a special plating. DO NOT use alternative fasteners.
3. Position the cylinder head cover onto the gasket. Install the stud bolts and hex head bolts in the proper positions. (Scheme 61) Tighten the stud bolts and the bolts to 16 N.m (144 in. lbs.) torque.
4. If removed, install the upper intake manifold. See «INTAKE MANIFOLD»(ref-174645-S34232090772005040700000).
5. Install closed crankcase ventilation system and evaporation control system onto the proper head cover. DO NOT switch the systems.
6. Connect the negative cable to the battery.
7. Start engine and check for leaks.

REMOVAL-VALVE STEM SEALS

Note. This procedure is done with the cylinder head installed.

Scheme 63

1. Disconnect the negative cable from the battery.
2. Set engine basic timing to Top Dead Center (TDC) and remove air cleaner.
3. Remove cylinder head covers. See «CYLINDER HEAD COVER(S)»(ref-174645-S16181463262005040700000). Remove spark plugs.
4. Using suitable socket and flex handle at crankshaft retaining bolt, turn engine so that the piston of the cylinder to be worked on, is at TDC on the compression stroke.
5. Remove rocker arms. «ROCKER ARM/ADJUSTER ASSY»(ref-174645-S34877954842005040700000).
6. With air hose attached to an adapter installed in the spark plug hole, apply 620-689 kPa (90-100 psi) air pressure.
7. Using Valve Spring Compressor Tool MD-998772A with adapter 6716A compress valve spring and remove retainer valve locks and valve spring. (Scheme 63)
8. Remove the valve stem seal.

Scheme 64

Scheme 65

1. Remove the cylinder head. See «CYLINDER HEAD»(ref-174645-S11019270062005040700000).
2. Special studs must be used to adapt the Valve Spring Compressor Tool to the V-10 cylinder head. (Scheme 64) Install the metric end into the Special Tool MD998772A and the 5/16 end into the cylinder head.
3. Compress valve springs using Valve Spring Compressor Tool MD-998772A with Adapter 6716A and Screw 6765. (Scheme 65) Tap the retainer using a brass drift and ball peen hammer to loosen locks away from retainer.
4. Remove valve retaining locks, valve spring retainers and valve springs. Check for abnormal wear, replace as required.
5. Remove the valve stem seals.
6. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location.

INSTALLATION-VALVES AND VALVE SPRINGS

1. Clean valves thoroughly. Discard burned, warped and cracked valves.
2. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
3. Measure valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve.
4. Make sure there are no burrs on valve stems.
5. Coat valve stems with lubrication oil. Insert valves into valve guides in cylinder head.
6. Install new seals on all valve guides (BLACK on intake and BROWN on exhaust) . Install valve springs and valve retainers.
7. Compress valve springs with Valve Spring Compressor Tool MD-998772A and adapter 6716A, install locks and release tool. Tap the retainer with a brass or heavy plastic hammer to ensure locks have been seated.
8. If valves and/or seats were ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer. If height is greater than 42.86 mm (1-11/16 inches), install a 1.587 mm (1/16 inch) spacer in head counterbore. Ensure this brings spring height back to normal, 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
9. Install the cylinder head. See «CYLINDER HEAD»(ref-174645-S11019270062005040700000) .

Scheme 66

1. Disconnect spark plug wires by pulling the boot straight out in line with plug.
2. Remove cylinder head cover and gasket. See «CYLINDER HEAD COVER(S)»(ref-174645-S16181463262005040700000).
3. Remove the rocker arm bolts and the rocker arm assembly. (Scheme 66) Place rocker arm assemblies on a bench in the same order as removed.
4. Remove the push rods and place them on a bench in the same order as removed.

1. Install the push rods in the same order as removed.
2. Install rocker arm assemblies in the same order as removed. Tighten the rocker arm bolts to 28 N.m (21 ft. lbs.) torque.
3. Install cylinder head cover and gasket. See «CYLINDER HEAD COVER(S)»(ref-174645-S16181463262005040700000) .
4. Connect spark plug wires.

REMOVAL-CAMSHAFT BEARINGS

This procedure requires that the engine is removed from the vehicle.

1. With engine completely disassembled, drive out rear cam bearing core hole plug. NOTE: It is not advisable to attempt to replace camshaft bearings unless special removal and installation tools are available, such as recommended tool 8544 Camshaft Bushing Remover Installer.
2. Using recommended tool 8544 Camshaft Bushing Remover Installer, Drive out bearing shells.

Scheme 67

1. Remove rocker arms and push rods. «ROCKER ARM/ADJUSTER ASSY»(ref-174645-S34877954842005040700000). Identify each part so it can be installed in its original location. NOTE: The 4 corner tappets can not be removed without removing the cylinder heads and gaskets. However, they can be lifted and retained for camshaft removal.
2. Remove the Bolts retaining the yoke retaining spider. Remove the yoke retaining spider, tappet aligning yokes and tappets.
3. Remove upper and lower intake manifolds «INTAKE MANIFOLD»(ref-174645-S34232090772005040700000).
4. Remove timing chain cover. See «TIMING BELT/CHAIN COVER(S)»(ref-174645-S17335984332005040700000). Remove timing chain and sprockets. See «TIMING BELT/CHAIN AND SPROCKETS»(ref-174645-S38660575952005040700000).
5. Remove camshaft thrust plate. (Scheme 67)
6. Install a long bolt into front of camshaft to aid in removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes.

INSTALLATION-CAMSHAFT BEARINGS

1. Install new camshaft bearings using recommended Tool 8544 Camshaft Bushing Remover Installer, by sliding the new camshaft bearing shell over proper adapter.
2. Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing. If the camshaft bearing shell oil holes are not in exact alignment, remove and install them correctly. Install a new core hole plug at the rear of camshaft. Be sure this plug does not leak.

Scheme 68

Scheme 69

1. Lubricate camshaft lobes and camshaft bearing journals. Using a long bolt, insert the camshaft into the cylinder block. NOTE: Whenever an engine has been rebuilt, a new camshaft and/or new tappets installed, add 1 pint of Mopar® Crankcase Conditioner, or equivalent. The oil mixture should be left in engine for a minimum of 805 km (500 miles). Drain at the next normal oil change.
2. Install camshaft thrust plate. Tighten the Torx bolts to 22 N.m (16 ft. lbs.) torque.
3. Check camshaft end play. The end play should be 0.051-0.152 mm (0.002-0.006 inch) with a new thrust plate and up to 0.254 mm (0.010 inch) with a used thrust plate. If not within these limits install a new thrust plate.
4. Line up key with keyway in sprocket, then using Special Tools C-3688, C-3718 and MB990799 install crankshaft timing sprocket. Make sure the sprocket seats against the crankshaft shoulder. (Scheme 68)
5. Install timing chain and sprocket. See «TIMING BELT/CHAIN AND SPROCKETS»(ref-174645-S38660575952005040700000).
6. Install the timing chain cover. See «TIMING BELT/CHAIN COVER(S)»(ref-174645-S17335984332005040700000).
7. Install the crankshaft pulley/damper. See «VIBRATION DAMPER»(ref-174645-S31829702572005040700000).
8. Prime oil pump by squirting oil in the oil filter mounting hole and filling the J-trap of the front timing cover. When oil is running out, install oil filter that has been filled with oil.
9. Each tappet reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the tappets must be replaced.
10. Install tappets and push rods in their original location.
11. Position the tappet aligning yokes and yoke retaining spider.
12. Install the retaining spider mounting bolts. Tighten bolts to 22 N.m (16 ft. lbs.).
13. Install the rocker arms. «ROCKER ARM/ADJUSTER ASSY»(ref-174645-S34877954842005040700000).
14. The cylinder head cover gasket can be used again. Install the gasket onto the head rail. For the left side the number tab is at the front of engine with the number up. For the right side the number tab is at the rear of engine with the number up. CAUTION: The cylinder head cover fasteners have a special plating. DO NOT use alternative fasteners.
15. Install cylinder head cover. (Scheme 69) See «CYLINDER HEAD COVER(S)»(ref-174645-S16181463262005040700000).
16. Install the intake manifolds. See «INTAKE MANIFOLD»(ref-174645-S34232090772005040700000).
17. Start engine and check for leaks.

When a crankshaft is replaced, all main and connecting rod bearings should be replaced with new bearings. Therefore, selective fitting of the bearings is not required when a crankshaft and bearings are replaced.

Scheme 70

1. Remove the oil pan and oil pickup tube. See «OIL PAN»(ref-174645-S32839009792005040700000).
2. Remove the timing chain cover and gasket. Remove and discard the front crankshaft oil seal and cover gasket.
3. Remove transmission.
4. Remove the rear seal retainer. See «CRANKSHAFT OIL SEAL - REAR»(ref-174645-S37215329782005040700000).
5. Identify main bearing caps before removal. (Scheme 70) Remove bearing caps and lower bearings one at a time.
6. Remove the connecting rod bearing caps.
7. Lift the crankshaft straight out of the block.
8. Remove the upper main bearings from the block.

When a crankshaft is replaced, all main and connecting rod bearings should be replaced with new bearings. Therefore, selective fitting of the bearings is not required when a crankshaft and bearings are replaced.

Note. Lubricate crankshaft main bearings with clean engine oil.

1. Position upper main bearings into block.
2. Position the crankshaft into the cylinder block.
3. Lubricate the main journals with clean engine oil. Install upper main bearings, caps and bolts. Follow the 2 step tightening sequence, starting with main bearing cap 1.
4. Lubricate the connecting rod bearings and journals with clean engine oil. Carefully install connecting rods to the crankshaft.
5. Using Special Tool 8359 Seal Installer install new oil into oil seal retainer.
6. Using Special Tool 6687 Guide, install the rear seal retainer with a new gasket.
7. Install the timing chain cover with a new gasket and oil seal.
8. Prime oil pump by squirt oil in the oil filter mounting hole and filling the J-trap of the front timing cover. When oil is running out, install oil filter that has been filled with oil.
9. Apply a rearward axial load of 667 N (150 lbs-f) on crankshaft centerline, driving No. 3 main cap and thrust bearing against No. 3 bulkhead. Repeat procedure, driving crankshaft forward to align rear flange of thrust bearings in a common plane. Front face of No. 1 main cap must not extend forward in front of face of No. 1 bulkhead.
10. Install the oil pickup tube. Tighten the bolts to 16 N.m (144 in. lbs.) torque.
11. Install the oil pan.

Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened. All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation.

When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side.

1. Start bearing in place, and insert Crankshaft Main Bearing Remover/Installer Tool C-3059 into oil hole of crankshaft. see scheme 67
2. Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Tool C-3059.
3. Lubricate the main journals with clean engine oil. Install main bearing caps and bolts. Follow the 2 step tightening sequence, starting with No. 1 main bearing cap.
4. Apply a rearward axial load of 667 N (150 lbs-f) on crankshaft centerline, driving No. 3 main cap and thrust bearing against No. 3 bulkhead. Repeat procedure, driving crankshaft forward to align rear flange of thrust bearings in a common plane. Front face of No. 1 main cap must not extend forward in front of face of No. 1 bulkhead.
5. Install the oil pump pick-up tube and oil pan. See «OIL PAN»(ref-174645-S32839009792005040700000).

Scheme 71

1. Disconnect the negative cable from the battery.
2. Remove vibration damper from the crankshaft. See «VIBRATION DAMPER»(ref-174645-S31829702572005040700000).
3. Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal surface of the cover. (Scheme 71)

REMOVAL-FRONT OIL SEAL - FRONT COVER REMOVED

1. Remove engine front cover. See «TIMING BELT/CHAIN COVER(S)»(ref-174645-S17335984332005040700000) .
2. Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal surface of the cover.

Scheme 72

1. Position the crankshaft front oil seal onto seal installer special tool 6806 and C-3688. (Scheme 72) Install seal.
2. Install vibration damper. See «VIBRATION DAMPER»(ref-174645-S31829702572005040700000).
3. Install serpentine belt.
4. Install cooling fan and shroud.
5. Connect negative cable to the battery.
6. Start engine and check for leaks.

Scheme 73

Scheme 74

1. Position the crankshaft front oil seal onto seal installer special tool 6806.
2. Use tool 6761 to support timing chain cover when installing oil seal with tool 6806, and install seal. (Scheme 73)and (Scheme 74).
3. Install engine front cover. See «TIMING BELT/CHAIN COVER(S)»(ref-174645-S17335984332005040700000).

Note. This procedure does not require the removal of the seal retainer from the engine block.

1. Remove the transmission.
2. Carefully, remove the rear seal from the retainer. Discard the oil seal.

1. Wash all parts in a suitable solvent and inspect carefully for damage or wear.
2. Position Special Tool 6687 Seal Guide, onto the crankshaft.
3. Position the oil seal onto the Seal guide, then using Special Tool 8359 Seal Installer and C-4171 Driver Handle, Install the oil seal.
4. The seal face surface must be countersunk into the retainer .762-1.27 mm (0.030-0.050 in.).
5. Install the transmission.
6. Check and verify engine oil is at correct level.
7. Start engine and check for leaks.

1. Disconnect negative cable from battery.
2. Remove the transmission.
3. Remove the drive plate/flywheel.
4. Remove the oil pan. See «OIL PAN»(ref-174645-S32839009792005040700000) .
5. Remove the rear oil seal retainer mounting bolts.
6. Carefully remove the retainer from the engine block.

1. Thoroughly clean all gasket residue from the engine block.
2. Use extreme care and clean all gasket residue from the retainer.
3. Apply a small amount of Mopar® Silicone Rubber Adhesive Sealant to the retainer gasket. Position the gasket onto the retainer.
4. Position Special Tool 6687 Seal Guide onto the crankshaft.
5. Position the retainer and seal over the guide and onto the engine block.
6. Install the retainer mounting bolts. Tighten the bolts to 22 N.m (16 ft. lbs.).
7. Install the oil pan. See «OIL PAN»(ref-174645-S32839009792005040700000) .
8. Install drive plate/flywheel.
9. Install the transmission.
10. Check and verify engine oil level.
11. Start engine and check for leaks.

1. Lubricate tappets.
2. Install tappets in their original positions. Ensure that the oil bleed hole (if so equipped) faces forward.
3. Install tappet aligning yokes. Position the yoke retainer spider over the tappet aligning yokes. see scheme 73 Install the yoke retaining spider bolts and tighten to 22 N.m (16 ft. lbs.).
4. Install the push rods in their original location.
5. Install the rocker arms. «ROCKER ARM/ADJUSTER ASSY»(ref-174645-S34877954842005040700000).
6. Install lower and upper intake manifold. See «INTAKE MANIFOLD»(ref-174645-S34232090772005040700000).
7. The cylinder head cover gasket can be used again. Install the gasket onto the head rail. For the left side the number tab is at the front of engine with the number up. For the right side the number tab is at the rear of engine with the number up.
8. Install cylinder head cover. See «CYLINDER HEAD COVER(S)»(ref-174645-S16181463262005040700000).
9. Install the air cleaner. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet.
10. Connect the negative cable to the battery.
11. Road test vehicle and check for leaks.

1. Remove the engine from the vehicle. See «REMOVAL»(ref-174645-S11610527582005040700000) .
2. Remove cylinder head. See «CYLINDER HEAD»(ref-174645-S11019270062005040700000) .
3. Remove the oil pan and oil pump pick-up tube. See «OIL PAN»(ref-174645-S32839009792005040700000) .
4. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation.
5. Be sure the connecting rod and connecting rod cap are identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts.
6. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies, rotate crankshaft center the connecting rod in the cylinder bore and at BDC. Be careful not to nick crankshaft journals. DO NOT try to remove black coating on skirt. This is the dry film lubricant.
7. After removal, install bearing cap on the mating rod.

1. If removed, position the transmission support bracket to the transmission. Install new attaching bolts and tighten to 102 N.m (75 ft. lbs.) torque.
2. Position support cushion to transmission support bracket. Install stud nuts and tighten to 47 N.m (35 ft. lbs.) torque.
3. Using the transmission jack, lower the transmission and support cushion onto the crossmember. see scheme 86
4. Install the support cushion bolts and tighten to 47 N.m (35 ft. lbs.) torque.
5. Remove the transmission jack.
6. Lower the vehicle.

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

Scheme 75

1. Position a drain pan under the oil filter.
2. Using a suitable oil filter wrench loosen filter.
3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. (Scheme 75)
4. When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from vehicle.
5. With a wiping cloth, clean the gasket sealing surface of oil and grime. see scheme 88
6. Install new filter. See «OIL FILTER»(ref-174645-S31526363682005040700000).

Scheme 76

1. Lightly lubricate oil filter gasket with engine oil or chassis grease.
2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one full turn, DO NOT over tighten. (Scheme 76)
3. Add oil. See «OIL»(ref-174645-S11479089212005040700000).

Scheme 77

1. Disconnect the negative cable from the battery.
2. Raise vehicle.
3. Drain engine oil.
4. Remove left engine to transmission strut.
5. Remove oil pan mounting bolts, pan and one-piece gasket. The engine may have to be raised slightly on 2WD vehicles.
6. Remove the oil pick-up tube assembly. (Scheme 77) Discard the gasket.

1. Using a new gasket position the engine exhaust manifold onto the cylinder head. Install bolts and stud bolts in the proper position. see scheme 112 Tighten the bolts to 22 N.m (16 ft. lbs.).
2. Install the dipstick bracket on to the exhaust manifold (right side only).
3. Position washers and exhaust heat shields onto the manifold stud bolts. see scheme 112 Be sure the tabs on the heat shields are hooked over the top of the exhaust gasket. Install the nuts and tighten to 20 N.m (175 in. lbs.).
4. Raise and support the vehicle.
5. Assemble exhaust pipe to manifold.
6. Lower the vehicle.
7. Connect the negative cable to the battery.
8. Start engine check for leaks.

Scheme 78

1. Disconnect the negative cable from the battery.
2. Drain cooling system.
3. Remove the serpentine belt.
4. Remove fan and fan shroud.
5. Unbolt A/C compressor and set on top of engine.
6. Remove generator, air pump, and bracket assembly.
7. Remove water pump.
8. Remove damper bolt and washer.
9. Using Special Tool 1026 3-Jaw Puller remove pulley/damper from the crankshaft. (Scheme 78)
10. Loosen oil pan bolts and remove the front oil pan bolts that mount the pan to the timing chain cover.
11. Remove the cover bolts.
12. Remove timing chain cover and gasket using extreme caution to avoid damaging oil pan gasket.
13. Inspect surface of cover. Remove any burrs or high spots.

Scheme 79

1. Be sure mating surfaces of timing chain cover and cylinder block are clean and free from burrs.
2. Lubricate the pump rotors using petroleum jelly or Lubriplate. See «OIL PUMP»(ref-174645-S12204336602005040700000).
3. Using a new cover gasket, carefully install timing chain cover to avoid damaging oil pan gasket. Use a small amount of Mopar® Silicone Rubber Adhesive Sealant, or equivalent, at the joint between timing chain cover gasket and the oil pan gasket. Finger tighten the timing chain cover bolts at this time.
4. Tighten timing chain cover bolts to 47 N.m (35 ft. lbs.). Tighten oil pan bolts to 24 N.m (215 in. lbs.).
5. Using Special Tool C-3688 Crankshaft Pulley/Damper Installer, install pulley/vibration damper. (Scheme 79)
6. Prime oil pump by squirting oil in the oil filter mounting hole and filling the J-trap of the front timing cover. when oil is running out, install oil filter that has been filled with oil.
7. Install water pump and housing assembly using new O-ring.
8. Install generator, air pump, and bracket assembly.
9. Install A/C compressor.
10. Install the radiator fan.
11. Position the fan shroud and install the bolts. Tighten the bolts to 11 N.m (95 in. lbs.).
12. Install the serpentine belt.
13. Fill cooling system.
14. Connect the negative cable to the battery.
15. Road test vehicle and check for leaks.

Scheme 80

1. Remove timing chain cover and gasket using extreme caution to avoid damaging oil pan gasket. See «TIMING BELT/CHAIN COVER(S)»(ref-174645-S17335984332005040700000).
2. Aline camshaft and crankshaft centerline. Remove camshaft sprocket attaching bolt and remove timing chain and camshaft sprockets.
3. Use puller 6444 and jaws 6820 to remove crankshaft sprocket. (Scheme 80)

Scheme 81

1. Place a scale next to the timing chain so that any movement of the chain may be measured.
2. Place a torque wrench and socket over camshaft sprocket attaching bolt. Apply torque in the direction of crankshaft rotation to take up slack; 41 N.m (30 ft. lbs.) torque with cylinder head installed or 20 N.m (15 ft. lbs.) torque with cylinder head removed. With a torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to move. It may be necessary to block the crankshaft to prevent rotation.
3. Hold a scale with dimensional reading even with the edge of a chain link. With cylinder heads installed, apply 14 N.m (30 ft. lbs.) torque in the reverse direction. With the cylinder heads removed, apply 20 N.m (15 ft. lbs.) torque in the reverse direction. Note the amount of chain movement. (Scheme 81)
4. Install a new timing chain, if its movement exceeds 3.175 mm (1/8 inch).

Scheme 82

Scheme 83

1. Line up key in crankshaft with keyway in sprocket, press on crankshaft timing sprocket, use tools C-3688, C-3718 and MB-990799, seat sprocket against crankshaft shoulder. (Scheme 82)
2. Turn crankshaft to line up the timing mark with the crankshaft and camshaft centerline.
3. Put chain on camshaft sprocket.
4. Align timing marks and install chain and camshaft sprocket onto crankshaft sprocket. Check to see that timing marks are on the centerline of the crankshaft and camshaft centerline. (Scheme 83)
5. Install the camshaft bolt. Tighten the bolt to 61 N.m (45 ft. lbs.).
6. Check camshaft end play. The end play should be 0.051-0.152 mm (0.002-0.006 inch) with a new thrust plate and up to 0.254 mm (0.010 inch) with a used thrust plate. If not within these limits install a new thrust plate.
7. Install timing chain cover. See «TIMING BELT/CHAIN COVER(S)»(ref-174645-S17335984332005040700000).