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Description: Diagnosis RAM Cab & Chassis 3500 HD

Mechanical 6 illustrations ~867 words

INSPECTION

Check the connecting rod journal for excessive wear, taper and scoring. Refer to Engine/Engine Block/ROD, Piston and Connecting - Standard Procedure .

Check the connecting rod for signs of twist or bending.

Check the piston for taper and elliptical shape before it is fitted into the cylinder bore. Refer to Engine/Engine Block/ROD, Piston and Connecting - Standard Procedure .

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

Scheme 122

Scheme 122: INSTALLATION
Scheme 122: INSTALLATION

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

Note. Make sure the piston ring grooves are clean and free of nicks and burrs.

Scheme 123

Scheme 123
Scheme 123

Scheme 124

Scheme 124
Scheme 124

Scheme 125

Scheme 125
Scheme 125
  1. Check piston ring clearance. Refer to «Engine/Engine Block/RING(S), Piston - Standard Procedure»(ref-476518-S22873981852012060400000) .
  2. Before installing piston and connecting rod assemblies into the bore, install the piston rings. Refer to «Engine/Engine Block/RING(S), Piston - Standard Procedure»(ref-476518-S22873981852012060400000) .
  3. Immerse the piston head and rings in clean engine oil and position a ring compressor over the piston and rings and tighten the ring compressor. Ensure the position of rings do not change during this operation.
  4. Position the rod bearing (1) onto the connecting rod and lubricate bearing surface with clean engine oil.
  5. Install Connecting Rod Guides (special tool #8507, Guides, Connecting Rod) (1) into the connecting rod bolt threads.
  6. The pistons are marked on the piston pin bore surface with an raised "F" or arrow on top of piston indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks.
  7. Wipe cylinder bore clean and lubricate with clean engine oil.
  8. Rotate the crankshaft until the connecting rod journal is centered with the cylinder bore.
  9. Insert the piston and rod assembly into the cylinder bore and carefully position the connecting rod over the crankshaft journal.
  10. Tap the piston down into the cylinder bore using a hammer handle while guiding the connecting rod into position on the rod journal.
  11. Remove the Connecting Rod Guides (special tool #8507, Guides, Connecting Rod).
  12. Wipe the connecting rod cap (1) clean and lubricate with clean engine oil and install the bearing (3). NOTE: The connecting rods and bearing caps are not interchangeable, line up the previously marked bearing caps and connecting rods to ensure assembly to their original location.
  13. Lubricate the bearing surfaces with clean engine oil and position the rod cap in place. CAUTION: When installing the connecting rods, make sure the wide side of the connecting rod faces the crankshaft and the narrow sides face each other. CAUTION: Always replace the connecting rod bolts whenever they are loosened or removed.
  14. Lubricate the new rod cap bolts with clean engine oil, install and tighten to 21 N.m (15 ft. lbs.) plus 90°.
  15. Install the timing chain cover. Refer to «COVER(S), ENGINE TIMING, INSTALLATION, 5.7L»(ref-476518-S35543616332012060400000) .
  16. Install the new oil pan gasket/windage tray and oil pan. Refer to «PAN, OIL, INSTALLATION, 5.7L»(ref-476518-S08996329102012060400000) .
  17. Install the engine oil dipstick tube and dipstick.
  18. Lower the vehicle.
  19. Using the Engine Lift Fixture (special tool #8984B, Fixture, Engine Lifting) (1), Engine Lift Adapter (special tool #8984-UPD, Adapter, Engine Lift) (2) and the Engine Support Fixture (special tool #8534B, Fixture, Driveline Support) (3) lower the engine into position and remove.
  20. Raise and support the vehicle.
  21. Position the steering gear (2), install mounting bolts (1) and tighten to 95 N.m (70 ft. lbs.).
  22. Install the engine mount nuts (1, 2) and tighten to 95 N.m (70 ft. lbs.).
  23. Lower the vehicle.
  24. Install the cylinder head(s). Refer to «CYLINDER HEAD, INSTALLATION, 5.7L»(ref-476518-S06920310142012060400000) .
  25. Position the air cleaner housing (2), install the air cleaner housing retaining bolt (3) and securely tighten.
  26. Connect the makeup air hose (1).
  27. Connect the intake air temperature sensor (4) electrical connector.
  28. Connect the air duct to the throttle body and tighten clamp to 3 N.m (30 in. lbs.).
  29. Fill the engine with oil. Refer to «Engine/Lubrication/OIL - Standard Procedure»(ref-476518-S39577089102012060400000) .
  30. Install the engine covers (1).
  31. Connect the negative battery cable (3).

Scheme 126

Scheme 126
Scheme 126
  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 upper radiator hose.
  5. Remove radiator shroud attaching fasteners.
  6. Remove radiator cooling fan and shroud. Refer to «FAN, COOLING, ELECTRIC, REMOVAL»(ref-476513-S10790828242012060400000) or «FAN, COOLING, VISCOUS, REMOVAL»(ref-476513-S05053996382012060400000) .
  7. Remove crankshaft damper bolt.
  8. Remove damper using Crankshaft Insert (special tool #8513A, Insert, Crankshaft) (2) and Three Jaw Puller (special tool #1023, Puller) (1). Refer to «DAMPER, VIBRATION, REMOVAL, 5.7L»(ref-476518-S28515775952012060400000) .
  9. Using Seal Remover (special tool #9071, Remover, Seal) (1), remove crankshaft front seal (2).

Scheme 127

Scheme 127: INSTALLATION
Scheme 127: INSTALLATION
CAUTIONThe front crankshaft seal must be installed dry. Do not apply lubricant to the sealing lip or the outer edge.
  1. Using Crankshaft Front Oil Seal Installer (special tool #9072, Installer, Seal) (2) and Damper Installer (special tool #8512A, Installer, Damper) (1), install crankshaft front seal. CAUTION: To prevent severe damage to the crankshaft or damper, thoroughly clean the damper bore and the crankshaft nose before installing damper.
  2. Install vibration damper. Refer to «DAMPER, VIBRATION, INSTALLATION, 5.7L»(ref-476518-S32295323722012060400000) .
  3. Install radiator cooling fan and shroud. Refer to «FAN, COOLING, ELECTRIC, INSTALLATION»(ref-476513-S24058317952012060400000) or «FAN, COOLING, VISCOUS, INSTALLATION»(ref-476513-S23043532902012060400000) .
  4. Install upper radiator hose.
  5. Install accessory drive belt refer. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-476513-S03685655272012060400000) .
  6. Refill cooling system. Refer to «STANDARD PROCEDURE»(ref-476513-S07101829012012060400000) .
  7. Connect negative cable to battery.

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