1993 DODGE TRUCK Service Repair Manual

9
- 60 5.2L
ENGINE

(8) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam­ shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
against the chain in position as described). (10) Slide both sprockets evenly over their respec­
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 5).
TIMING

MARKS
J9209-129

Fig.
5
Alignment
of Timing Marks (11) Install the camshaft bolt. Tighten the bolt to
68 Nnn (50 ft. lbs.) torque. (12) 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.
CLEANING Be sure mating surfaces of chain case cover and
cylinder block are clean and free from burrs.
INSTALLATION (1) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar Silicone Rubber Adhe­ sive Sealant, or equivalent, at the joint between tim­
ing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.
(2) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 6). Seat
the oil seal in the groove of the tool.
(3) Position the seal and tool onto the crankshaft
(Fig. 7). (4) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft (Fig. 8).
(5) Tighten chain case cover bolts to 41 Nnn (30 ft.
lbs.) torque. Tighten oil pan bolts to 24 Nnn (215 in.
lbs.) torque.
(6) Remove the vibration damper bolt and seal in­
stallation tool. (7) Install vibration damper.
(8) Install fuel lines (refer to Group 14, Fuel Sys­

tem).
CRANKSHAFT
k

FRONT
OIL
SEAL
INSTALL
THIS

END
INTO

SPECIAL
TOOL
6635
J9309-44

Fig.
6
Placing
Oil
Seal
on
Installation
Tool
6635
SPECIAL
TOOL
\ | OIL
SEAL

TIMING
CHAIN

COVER
J9309-45*-
Fig.
7 Position Tool and
Seal
onto Crankshaft
(9) Install water pump and housing assembly us­
ing new gaskets (refer to Group 7, Cooling System).
Tighten bolts to 41 Nnn (30 ft. lbs.) torque.
(10) Install power steering pump (refer to Group

19,
Steering).
(11) Install the serpentine belt (refer to Group 7,
Cooling System).
(12) Install the cooling system fan. Tighten the
bolts to 23 Nnn (17 ft. lbs.) torque. (13) Position the fan shroud and install the bolts.
Tighten the bolts to 11 Nnn (95 in. lbs.) torque.
(14) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure).
(15) Connect the negative cable to the battery.

•
J9309-46
Fig. 8 Installing Oil Seal
FRONT CRANKSHAFT OIL SEAL REPLACEMENT The oil seal can be replaced without removing the
timing chain cover provided the cover is not mis­ aligned. (1) Disconnect the negative cable from the battery.
(2) Remove vibration damper.
(3) If front seal is suspected of leaking, check front
oil seal alignment to crankshaft. The seal installa­
tion/alignment tool 6635, should fit with minimum interference. If tool does not fit, the cover must be re­
moved and installed properly. (4) 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 cover. (5) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 6). Seat
the oil seal in the groove of the tool. (6) Position the seal and tool onto the crankshaft
(Fig. 7). (7) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft (Fig. 8). (8) Remove the vibration damper bolt and seal in­
stallation tool. (9) Install the vibration damper. (10) Connect the negative cable to the battery.
CAMSHAFT This procedure requires that the engine is removed
from the vehicle. The camshaft has an integral oil pump and distrib­
utor drive gear (Fig. 9).
5.2L
ENGINE
9 - 61
J9309-71

Fig.
9 Camshaft and Sprocket Assembly REMOVAL

(1)
Remove intake manifold.
(2) Remove cylinder head covers. (3) Remove timing case cover and timing chain.

(4)
Remove rocker arms.
(5) Remove push rods and tappets. Identify each
part so it can be installed in its original location.

(6)
Remove distributor and lift out the oil pump
and distributor drive shaft.
(7) Remove camshaft thrust plate, note location of
oil tab (Fig. 10).
Fig. 10 Timing Chain Oil Tab Installation
(8) Install a long bolt into front of camshaft to fa­
cilitate removal of the camshaft. Remove camshaft,
being careful not to damage cam bearings with the cam lobes.

REMOVAL-BEARING
(1)
With engine completely disassembled, drive out
rear cam bearing core hole plug. (2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer

9 - 62 5.2L
ENGINE
Fig,
11 Camshaft
Bearings
Removal
and
installation

with
Tool C-3132-A
Tool C-3132-A) at back of each bearing shell. Drive out bearing shells (Fig. 11).

INSTALL A
TION-
BEARING
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
the new camshaft bearing shell over proper adapter. (2) Position rear bearing in the tool. Install horse­
shoe lock and by reversing removal procedure, care­
fully drive bearing shell into place. (3) Install remaining bearings in the same man­
ner. 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.

INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2 inches) of its final position in cylinder block.
Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1
pint of Mopar Crankcase Conditioner, or equiv­ alent. 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 Gear Installer Tool C-3509
with tongue back of distributor drive gear (Fig. 12).
Fig.
12 Camshaft
Holding
Tool C-3509 (Installed

Position)
• — —— — — •

Fig.
13
Alignment
of Timing Marks
(10) Install the camshaft bolt/cup washer. Tighten
bolt to 68 N«m (50 ft. lbs.) torque. (11) Measure camshaft end play. Refer to Specifi­
cations for proper clearance. If not within limits in­ stall a new thrust plate.
(12) 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.

DISTRIBUTOR
REMOVAL
Refer to Group 8D, Ignition Systems for the proper
procedure.

REMOVAL-DRIVE SHAFT BUSHING
(1) Insert Distributor Drive Shaft Bushing Puller
Tool C-3052 into old bushing and thread down until a tight fit is obtained (Fig. 14). (3) Hold tool in position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block Tool should remain installed until the camshaft and crankshaft sprockets and timing chain have been installed.

(4)
Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower right hole in thrust plate. Tighten bolts to 24 N*m (210 in. lbs.) torque.
Top edge of tab should be flat against thrust plate in
order to catch oil for chain lubrication.
(5) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and crankshaft bores.
(6) Place timing chain around both sprockets. (7) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in camshaft sprocket.
(8) Lift sprockets and chain (keep sprockets tight
against the chain in position as described). (9) Slide both sprockets evenly over their respec­
tive shafts and use a straightedge to check alignment of timing marks (Fig. 13).

•
5.2L
ENGINE
I - 63

Fig.
14 Distributor Driveshaft
Bushing
Removal
(2) Hold puller screw and tighten puller nut until
bushing is removed.
INSTALLA TION-DRIVE
SHAFT BUSHING
(1) Slide new bushing over burnishing end of Dis­
tributor Drive Shaft Bushing Driver/Burnisher Tool
C-3053.
Insert the tool and bushing into the bore. (2) Drive bushing and tool into position, using a
hammer (Fig. 15).
Fig. 15 Distributor Driveshaft Bushing Installation (3) As the burnisher is pulled through the bushing,
the bushing is expanded tight in the block and bur­ nished to correct size (Fig. 16). DO NOT ream this
bushing.

Fig.
16
Burnishing
Distributor Driveshaft
Bushing

DISTRIBUTOR TIMING Before installing the distributor and oil pump drive
shaft, time engine as follows:
(1) Rotate crankshaft until No.l cylinder is at top
dead center on the firing stroke. (2) When in this position, the timing mark on vi­
bration damper should be under "0" on the timing in­ dicator.
(3) Coat shaft and drive gear with engine oil. In­
stall the shaft so that after the gear spirals into
place, it will index with the oil pump shaft. The slot in top of drive gear should be aligned towards left
front intake manifold attaching bolt hole (Fig. 17).

Fig.
17 Position or Installed Distributor Drive Gear
INSTALLATION Refer to Group 8D, Ignition Systems for the proper
procedure.

OIL
PAN REMOVAL (1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick. (3) Raise vehicle.
(4) Drain engine oil. (5) Remove exhaust pipe.
(6) Remove left engine to transmission strut.
(7) Remove oil pan and one-piece gasket.
CLEANING Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove. DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the en­

gine.
Clean oil pan in solvent and wipe dry with a clean
cloth.
Clean oil screen and pipe thoroughly in clean sol­
vent. Inspect condition of screen.
INSPECTION Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor­
tion. Straighten flange, if necessary.
INSTALLATION (1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
inch bolts. Cut the head off the bolts and cut a slot

9
- 64 5.2L
ENGINE

• into the top of the dowel. This will allow easier in­
stallation and removal with a screwdriver (Fig. 1).
VI2' x 5/16"
BOLT
DOWEL SLOT

J9209-106

Fig. 1 Fabrication of Alignment Dowels
(2) Install the dowels in the cylinder block (Fig. 2). (3) Apply small amount of Mopar Silicone Rubber

DOWEL DOWEL

J9309-79

Fig. 2 Position of Dowels in Cylinder Block
Adhesive Sealant, or equivalent in the corner of the cap and the cylinder block. (4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24
N*m (215 in. lbs.) torque.
(7) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 N«m (215 in. lbs.)
torque. (8) Install the drain plug. Tighten drain plug to 34
N«m (25 ft. lbs.) torque.
(9) Install the engine to transmission strut.
(10) Install exhaust pipe.
(11) Lower vehicle. (11) Install dipstick.
(12) Connect the negative cable to the battery.
(13) Fill crankcase with oil to proper level.

OIL
PUMP
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from rear main bearing

cap.

DISASSEMBLE
(1) Remove the relief valve as follows: (a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole into the relief valve retainer cap and in­ sert a self-threading sheet metal screw.
(b) Clamp screw into a vise and while supporting
oil pump, remove cap by tapping pump body using a soft hammer. Discard retainer cap and remove
spring and relief valve (Fig. 3).

OIL PUMP
ASSEMBLY

SPRING
RELIEF
VALVE

'
RETAINER CAP COTTER
PIN

RH174

Fig.
3 Oil
Pressure
Relief
Valve

(2) Remove oil pump cover (Fig. 4).
(3) Remove pump outer rotor and inner rotor with
shaft (Fig. 4). (4) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
INNER ROTOR DISTRIBUTOR DRIVESHAFT
AND SHAFT
mm
(REFERENCE)
COTTER
PIN

LARGE
CHAMFERED
EDGE

Fig.
4 Oil
Pump
SPRING

RETAINER

CAP

RY10B

5.2L
ENGINE S - 65

INSPECTION

Mating surface of the oil pump cover should be
smooth. Replace pump assembly if cover is scratched
or grooved.
Lay a straightedge across the pump cover surface
(Fig. 5). If a 0.038 mm (0.0015 inch) feeler gauge can
be inserted between cover and straightedge, pump assembly should be replaced.

Fig.
5
Checking
Oil Pump
Cover
Flatness
Measure thickness and diameter of OUTER rotor.
If outer rotor thickness measures 20.9 mm (0.825 inch) or less or if the diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 6).

Fig.
6
Measuring
Outer Rotor
Thickness

If inner rotor measures 20.9 mm (0.825 inch) or

less,
replace inner rotor and shaft assembly (Fig. 7).
Slide outer rotor into pump body. Press rotor to the
side with your fingers and measure clearance be­
tween rotor and pump body (Fig. 8). If clearance is 0.356 mm (0.014 inch) or more, replace oil pump as­
sembly.
Install inner rotor and shaft into pump body. If
clearance between inner and outer rotors is 0.203
mm (0.008 inch) or more, replace shaft and both ro­
tors (Fig. 9).
Place a straightedge across the face of the pump,
between bolt holes. If a feeler gauge of 0.102 mm
Fig.
7
Measuring
Inner
Rotor
Thickness

Fig.
8
Measuring
Outer Rotor Clearance in
Housing

OUTER
ROTOR
INNER
ROTOR

RH179
Fig.
9
Measuring
Clearance Between
Rotors

(0.004 inch) or more can be inserted between rotors
and the straightedge, replace pump assembly (Fig.

10).
Inspect oil pressure relief valve plunger for scoring
and free operation in its bore. Small marks may be
removed with 400-grit wet or dry sandpaper.
The relief valve spring has a free length of approx­
imately 49.5 mm (1.95 inches). The spring should
test between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 inches). Replace spring that fails
to meet these specifications (Fig. 11).

i - 68 5.2L
ENGINE

RH180
Fig.
10
Measuring
Clearance Over Rotors If oil pressure was low and pump is within specifi­
cations, inspect for worn engine bearings or other
reasons for oil pressure loss. NBV y%L
RETAINER CAP
COTTER KEY CHAMFER RN98
Fig.
11 Proper Installation of Retainer Cap
ASSEMBLE
(1) Install pump rotors and shaft, using new parts
as required. (2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N»m (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin. (4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling ro­
tor cavity with engine oil.
INSTALLATION (1) Install oil pump. During installation slowly ro­
tate pump body to ensure driveshaft-to-pump rotor shaft engagement. (2) Hold the oil pump base flush against mating
surface on No.4 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
Nnn (30 ft. lbs.) torque.
(3) Install the oil pan.
PISTON
/
CONNECTING ROD
ASSEMBLY

The pistons are elliptically turned so that the di­
ameter at the pin boss is less than its diameter
across the thrust face. This allows for expansion un­
der normal operating conditions. Under operating
temperatures, expansion forces the pin bosses away from each other, causing the piston to assume a more
nearly round shape. All pistons are machined to the same weight, re­
gardless of size, to maintain piston balance. The piston pin rotates in the piston only and is re­
tained by the press interference fit of the piston pin
in the connecting rod.
REMOVAL (1) Remove the engine from the vehicle.
(2) Remove the cylinder head.
(3) Remove the oil pan.
(4) Remove top ridge of cylinder bores with a reli­
able ridge reamer before removing pistons from cyl­
inder block. Re 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 from the engine, ro­
tate crankshaft so that the connecting rod is centered in cylinder bore and at BDC. Be careful not to nick
crankshaft journals.
(7) After removal, install bearing cap on the mat­
ing rod.
INSPECTION Check the crankshaft connecting rod journal for ex­
cessive wear, taper and scoring. Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.
Check the pistons for taper and elliptical shape be­
fore they are fitted into the cylinder bore (Fig. 12).
FITTING PISTONS* Piston and cylinder wall must be clean and dry.
Specified clearance between the piston and the cylin­
der wall is 0.013-0.038 mm (0.0005-0.0015 inch).
Piston diameter should be measured at the top of
skirt, 90° to piston pin axis. Cylinder bores should be
measured halfway down the cylinder bore and trans­
verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21°C (70°F).
FITTING RINGS (1) Measurement of end gaps:
(a) Measure piston ring gap 2 inches from bot­
tom of cylinder bore. An inverted piston can be

•
5.2L
ENGINE
I - 67
DIAMETER
(D)

SHOULD
BE

0.0000-0.0152
mm

(0.0000-0.0006
in.)
LARGER
THAN
(C).
98.704-98.831
mm
•
(3.886-3.891
in.)-
FEELER
GAUGE

62.230
mm (2.45 in.)
1
26.543
mm

(1.045
in.)

±c

ELLIPTICAL
SHAPE
OF
THE
PISTON

SKIRT
SHOULD
BE
0.254-0.304
mm

(0.010-0.012
in.)
LESS AT
DIAMETER
(A)
THAN
ACROSS
THE
THRUST
FACES
AT
DIAMETER
(B).

J9309-9
Fig.
12
Piston
Measurements
used to push the rings down to ensure positioning
rings squarely in the cylinder bore before measur­ ing.
(b) Insert feeler gauge in the gap. The top com­
pression ring gap should be between 0.254-0.508 mm (0.010-0.020 inch). The second compression
ring gap should be between 0.508-0.762 mm (0.020-0.030 inch). The oil ring gap should be 0.254-1.270
mm (0.010-0.050 inch).
(c) Rings with insufficient end gap may be prop­
erly filled to the correct dimension. Rings with ex­ cess gaps should not be used.
(2) Install rings and confirm ring side clearance: (a) Install oil rings being careful not to nick or
scratch the piston.
(b) Install the compression rings using Installa­
tion Tool C-4184. The top compression may be in­ stalled with either side up. The second compression
ring must be installed with the identification mark
face up (toward top of piston) and the chamfer should face down. An identification mark on the
ring is a drill point, a stamped letter "O", an oval
depression or the word TOP.
(c) Measure side clearance between piston ring
and ring land (Fig. 13). Clearance should be 0.038-
0.076 mm (0.0015-0.0030 inch) for the compression

rings.
The steel rail oil ring should be free in
groove, but should not exceed 0.203 mm (0.0080
inch) side clearance.
(d) Pistons with insufficient or excessive side
clearance should be replaced. (3) Arrange ring gaps 90° apart as shown in Fig.
RING

GROOVE

J9209-136

Fig.
13
Measuring
Piston
Ring
Side
Clearance
OIL
RING

SPACER
GAP
TOP
COMPRESSION
RING
GAP
SECOND
COMPRESSION
RING
GAP

OIL
RING
RAIL
GAP (TOP) OIL
RING
RAIL

GAP
(BOTTOM)
J9309-80
14. Fig.
14 Proper
Ring
Installation

CONNECTING
ROD
BEARINGS
Fit all rods on a bank until completed. DO NOT al­
ternate from one bank to another, because connect­ ing rods and pistons are not interchangeable from
one bank to another.
The bearing caps are not interchangeable and
should be marked at removal to ensure correct as­
sembly.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing shell, make certain that the V-groove in the shell is
in line with the V-groove in the cap. This provides
lubrication of the cylinder wall in the opposite bank.
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 0.025 mm (0.001 inch). Bearings are available in 0.025 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under­
size.
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.