Camshaft Core Hole Plug: Removal & Installation RAM Cab & Chassis 3500 HD

INSTALLATION

1. Position the structural dust cover in the vehicle
2. Install all four bolts retaining the structural dust cover to the engine (3) hand tight.
3. Install the four cover to transmission bolts (1, 2 & 4) hand tight. CAUTION: The structural dust cover must be held tightly against both the engine and the transmission bell housing during the tightening sequence. Failure to do so may cause severe damage to the cover.
4. Tighten the structural dust cover-to-transmission bolts (1, 2 & 4) to 9 N.m (80 in. lbs.).
5. Tighten the structural dust cover-to-engine block bolts (3) to 9 N.m (80 in. lbs.).
6. Retighten the structural dust cover-to-transmission bolts to 54 N.m (40 ft. lbs.).
7. Retighten the structural dust cover-to-engine block bolts to 54 N.m (40 ft. lbs.).
8. Lower the transmission onto the crossmember and remove the jack.
9. Install the transmission mount to crossmember retaining nuts (1) and tighten to 54 N.m (40 ft. lbs.).
10. Position the steering rack to the frame, install the bolts (1) and tighten bolts/nuts to 258 N.m (190 ft. lbs.).
11. Lower the vehicle.

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1. Remove engine. Refer to «REMOVAL, 5.7L»(ref-476518-S31587140382012060400000) .
2. Remove the vibration damper (1) using Crankshaft Insert (special tool #8513A, Insert, Crankshaft) (2) and Puller (special tool #1023, Puller) (3). Refer to «DAMPER, VIBRATION, REMOVAL, 5.7L»(ref-476518-S28515775952012060400000) .
3. Remove the rear oil seal retainer. Refer to «RETAINER, CRANKSHAFT REAR OIL SEAL, REMOVAL, 5.7L»(ref-476518-S41941816542012060400000) .
4. Remove the oil pan. Refer to «PAN, OIL, REMOVAL, 5.7L»(ref-476518-S31283396772012060400000) .
5. Remove the oil pump pickup (1).
6. Remove the windage tray/oil pan gasket.
7. Remove the timing chain cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL, 5.7L»(ref-476518-S40596628682012060400000) .
8. Remove the oil pump (1). Refer to «PUMP, ENGINE OIL, REMOVAL, 5.7L»(ref-476518-S35319916502012060400000) .
9. Remove the timing chain (5) and sprockets (1, 3). Refer to «CHAIN AND SPROCKETS, TIMING, REMOVAL, 5.7L»(ref-476518-S35672805822012060400000) .
10. Identify rod bearing caps before removal. Remove rod bearing caps with bearings.
11. Identify main bearing caps (1) before removal.
12. Remove main bearing cap bolts.
13. Remove main bearing caps (1) and bearings one at a time.
14. Remove the thrust washers.
15. Remove the crankshaft out of the block.

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1. Select the proper main bearings. Refer to «Engine/Engine Block/BEARING(S), Crankshaft - Standard Procedure»(ref-476518-S15269676472012060400000) .
2. Install main bearings in block (1).
3. Install main bearing shells (2) in the bearing caps (1).
4. Lubricate the main bearing shells with clean engine oil.
5. Position the crankshaft (1) into the cylinder block.
6. Lubricate and install the thrust bearings (1). NOTE: The main cap crossbolts are torqued after final torque of the main cap bolts. Always use a new washer/seal on crossbolts.
7. Clean and oil all cap bolts. Install all main bearing caps (1) making sure the arrow (2) faces forward.
8. Tighten main bearing cap bolts to 13 N.m (10 ft. lbs.) in the sequence shown in illustration.
9. Tighten main bearing cap bolts to 27 N.m (20 ft. lbs.) in the sequence shown in illustration.
10. Rotate main cap bolts an additional 90° in the sequence shown in illustration.
11. Install the crossbolts with new seal washer. Starting with crossbolt A
12. Tighten crossbolt to 28 N.m (21 ft. lbs.).
13. Repeat crossbolt tightening procedure.
14. Measure crankshaft end play. Refer to «Engine/Engine Block/BEARING(S), Crankshaft - Standard Procedure»(ref-476518-S15269676472012060400000) .
15. Position the connecting rods onto the crankshaft and install the rod bearing caps. Refer to «ROD, PISTON AND CONNECTING, INSTALLATION, 5.7L»(ref-476518-S35143731322012060400000) .
16. Install timing chain (5) and sprockets (1, 3). Refer to «CHAIN AND SPROCKETS, TIMING, INSTALLATION, 5.7L»(ref-476518-S39750828302012060400000) .
17. Install the timing chain tensioner (4) and guide (2).
18. Install the oil pump (1). Refer to «PUMP, ENGINE OIL, INSTALLATION, 5.7L»(ref-476518-S39247865552012060400000) .
19. Install the timing chain case cover (1). Refer to «COVER(S), ENGINE TIMING, INSTALLATION, 5.7L»(ref-476518-S35543616332012060400000) .
20. Install the rear main seal and retainer. Refer to «RETAINER, CRANKSHAFT REAR OIL SEAL, INSTALLATION, 5.7L»(ref-476518-S19198211132012060400000) .
21. Install the windage tray/oil pan gasket.
22. Inspect oil pick up tube O-rings, replace as necessary.
23. Install the oil pick up tube (1) and tighten fasteners (2) to 28 Nm (248 in. lbs.).
24. Install the oil pan. Refer to «PAN, OIL, INSTALLATION, 5.7L»(ref-476518-S08996329102012060400000) .
25. Install the vibration damper. Refer to «DAMPER, VIBRATION, INSTALLATION, 5.7L»(ref-476518-S32295323722012060400000) .
26. Install the engine. Refer to «INSTALLATION, 5.7L»(ref-476518-S29366604722012060400000) .

REMOVAL

1. Disconnect negative cable from battery.
2. Remove accessory drive belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-476513-S39681365202012060400000) .
3. Drain cooling system. Refer to «STANDARD PROCEDURE»(ref-476513-S07101829012012060400000) .
4. Remove radiator upper hose.
5. Remove fan shroud. Refer to «FAN, COOLING, ELECTRIC, REMOVAL»(ref-476513-S10790828242012060400000) or «FAN, COOLING, VISCOUS, REMOVAL»(ref-476513-S05053996382012060400000) .
6. Remove crankshaft damper bolt.
7. Remove damper (1) using Crankshaft Insert (special tool #8513A, Insert, Crankshaft) (2) and Three Jaw Puller (special tool #1023, Puller) (3).

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1. Position the damper onto crankshaft.
2. Assemble the damper installer (special tool #8512A, Installer, Damper) (2), and the pressing cup (1) from A/C hub installer (special tool #6871, Installer, A/C Hub).
3. Using the damper installer (special tool #8512A, Installer, Damper) (2), and the pressing cup (1) from the A/C hub installer (special tool #6871, Installer, A/C Hub), press the damper onto crankshaft.
4. Install the crankshaft damper bolt.
5. Position the (special tool #10386, Holder, Vibration Damper) (2), onto the vibration damper (3).
6. Tighten the bolt to 176 N.m (130 ft. lbs.).
7. Install the cooling fan.
8. Install the radiator upper shroud and tighten the fasteners to 11 N.m (95 in. lbs.).
9. Install the radiator upper hose.
10. Install the accessory drive belt (1). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-476513-S03685655272012060400000) .
11. Refill the cooling system. Refer to «STANDARD PROCEDURE»(ref-476513-S07101829012012060400000) .
12. Connect the negative cable to battery.

Scheme 107

1. Remove the transmission. Refer to appropriate Transmission and Transfer Case articles.
2. Using the sequence shown in illustration, remove the flexplate retaining bolts.
3. Remove the flexplate.

1. Position the flexplate onto the crankshaft and install the retaining bolts hand tight.
2. Using the sequence shown in illustration, tighten the flexplate retaining bolts to 95 N.m (70 ft. lbs.).
3. Install the transmission. Refer to appropriate Transmission and Transfer Case articles.