1998 DODGE RAM 1500 Engine timing

OIL PAN
REMOVAL
(1) Disconnect the negative battery cable.
(2) Install engine support fixture special tool #
8534.Do not raise engine at this time.
(3) Loosen both left and right side engine mount
through bolts. Do not remove bolts.
(4) Remove the structural dust cover, if equipped.
(5) Drain engine oil.
(6) Remove the front crossmember(Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT CROSS-
MEMBER - REMOVAL).
CAUTION: Only raise the engine enough to provide
clearance for oil pan removal. Check for proper
clearance at fan shroud to fan and cowl to intake
manifold.
(7) Raise engine using special tool # 8534 to pro-
vide clearance to remove oil pan.
NOTE: Do not pry on oil pan or oil pan gasket. Gas-
ket is integral to engine windage tray and does not
come out with oil pan.
(8) Remove the oil pan mounting bolts and oil pan.
NOTE: The double ended oil pan studs must be
installed in the same location that they were
removed from.
(9) Unbolt oil pump pickup tube and remove tube.
(10) Inspect the integral windage tray and gasket
and replace as needed.
INSTALLATION
(1) Clean the oil pan gasket mating surface of the
block and oil pan.
(2) Inspect the integral windage tray and gasket
and replace as needed.
(3) Reinstall the oil pump pickup tube with new
o-ring. Tighten tube to pump fasteners to 28 N´m
(250 in. lbs.).
NOTE: The double ended oil pan studs must be
installed in the same location that they were
removed from.
(4) Position the oil pan and install the mounting
bolts and studs.. Tighten the mounting bolts to 12
N´m (105 in.lbs.).
(5) Lower the engine into mounts using special
tool # 8534.
(6) Install both the left and right side engine
mount through bolts. Tighten the nuts to 68 N´m (50
ft. lbs.).(7) Remove special tool # 8534.
(8) Install structural dust cover, if equipped.
(9) Install the front crossmember(Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT CROSS-
MEMBER - INSTALLATION).
(10) Fill engine oil.
(11) Reconnect the negative battery cable.
(12) Start engine and check for leaks.
OIL PUMP
REMOVAL
(1) Remove the oil pan and pick-up tube(Refer to 9
- ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(2) Remove the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(3) Remove the four bolts, and the oil pump.
CLEANING
(1) Wash all parts in a suitable solvent.
INSPECTION
CAUTION: Oil pump pressure relief valve and
spring should not be removed from the oil pump. If
these components are disassembled and or
removed from the pump the entire oil pump assem-
bly must be replaced.
(1) Remove the pump cover.
(2) Clean all parts thoroughly. Mating surface of
the oil pump housing should be smooth. If the pump
cover is scratched or grooved the oil pump assembly
should be replaced.
(3) Slide outer rotor into the body of the oil pump.
Press the outer rotor to one side of the oil pump body
and measure clearance between the outer rotor and
the body (Fig. 30). If the measurement is 0.235mm
(0.009 in.) or more the oil pump assembly must be
replaced.
(4) Install the inner rotor in the into the oil pump
body. Measure the clearance between the inner and
outer rotors (Fig. 31). If the clearance between the
rotors is .150 mm (0.006 in.) or more the oil pump
assembly must be replaced.
(5) Place a straight edge across the body of the oil
pump (between the bolt holes), if a feeler gauge of
.095 mm (0.0038 in.) or greater can be inserted
between the straightedge and the rotors, the pump
must be replaced (Fig. 32).
(6) Reinstall the pump cover. Torque fasteners to
15 N´m (132 in. lbs.).
9 - 224 ENGINE - 5.7LDR

NOTE: The 5.7 Oil pump is released as an assem-
bly. There are no DaimlerChrysler part numbers for
Sub-Assembly components. In the event the oil
pump is not functioning or out of specification it
must be replaced as an assembly.
INSTALLATION
(1) Position the oil pump onto the crankshaft and
install the 4 oil pump retaining bolts.(2) Tighten the oil pump retaining bolts to 28 N´m
(250 in. lbs.).
(3) Install the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install the pick-up tube and oil pan(Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
INTAKE MANIFOLD
DESCRIPTION
The intake manifold is made of a composite mate-
rial and features long runners which maximizes low
end torque. The intake manifold uses single plane
sealing which consist of eight individual press in
place port gaskets to prevent leaks.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPM is observed the area of the
suspected leak has been found.
(4) Repair as required.
Fig. 30 Measuring Outer Rotor Clearance
1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 31 Measuring Clearance Between Rotors -
Typical
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
Fig. 32 Measuring Clearance Over Rotors - Typical
1 - STRAIGHT EDGE
2 - FEELER GAUGE
DRENGINE - 5.7L 9 - 225
OIL PUMP (Continued)

INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straight edge. Gasket surfaces must be flat
within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
EXHAUST MANIFOLD
(1) Install manifold gasket and manifold.
(2) Install manifold bolts and tighten to 25 N´m
(18 ft. lbs.).
(3) Install heat shield and tighten nuts to 15 N´m
(11 ft. lbs.).
(4) Lower engine.
CAUTION: Do not damage engine harness while
lowering the engine.
(5) Remove engine support fixture from engine.
(6) Raise vehicle.
(7) Tighten right and left side engine mount
through bolts.
(8) Install exhaust flange to pipe bolts.
(9) Lower vehicle.
(10) Connect negative battery cable.
TIMING/CHAIN COVER
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove air cleaner assembly.
(3) Drain cooling system.
(4) Remove accessory drive belt.
(5) Remove fan and fan drive assembly (Refer to 7
- COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL).
(6) Remove coolant bottle and washer bottle.
(7) Remove fan shroud.
NOTE: It is not necessary to disconnect A/C lines or
discharge freon.
(8) Remove A/C compressor and set aside.
(9) Remove the generator.
(10) Remove upper radiator hose.
(11) Disconnect both heater hoses at timing cover.
(12) Disconnect lower radiator hose at engine.
(13) Remove accessory drive belt tensioner and
both idler pulleys.
(14) Remove crankshaft damper(Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).NOTE: Do not remove the hoses from the power
steering pump.
(15) Remove power steering pump and set aside.
(16) Remove the dipstick support bolt.
(17) Drain the engine oil.
(18) Remove the oil pan and pick up tube(Refer to
9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
NOTE: It is not necessary to remove water pump for
timing cover removal.
(19) Remove timing cover bolts and remove cover.
INSTALLATION
(1) Clean timing chain cover and block surface.
NOTE: Always install a new gasket on timing cover.
(2) Install cover and new gasket. Tighten fasteners
to 28 N´m (250 in. lbs.).
NOTE: The large lifting stud is torqued to 55 N´m
(40 ft. lbs.).
(3) Install the oil pan and pick up tube(Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(4) Install the A/C compressor.
(5) Install the generator.
(6) Install power steering pump.
(7) Install the dipstick support bolt.
(8) Install the thermostat housing.
(9) Install crankshaft damper(Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(10) Install accessory drive belt tensioner assembly
and both idler pulleys.
(11) Install radiator lower hose.
(12) Install both heater hoses.
(13) Install radiator fan shroud.
(14) Install the fan and fan drive assembly
(15) Install the accessory drive belt.
(16) Install the coolant bottle and washer bottle.
(17) Install the upper radiator hose.
(18) Install the air cleaner assembly.
(19) Fill cooling system.
(20) Refill engine oil.
(21) Connect the battery negative cable.
DRENGINE - 5.7L 9 - 227
EXHAUST MANIFOLD (Continued)

TIMING/CHAIN AND
SPROCKETS
REMOVAL
(1) Disconnect battery negative cable.
(2) Drain cooling system.
(3) Remove Timing Chain Cover.
CAUTION: The camshaft pin and the slot in the cam
sprocket must be clocked at 12:00. The crankshaft
keyway must be clocked at 2:00. The crankshaft
sprocket must be installed so that the dots and or
paint marking is at 6:00.
(4) Re-install the vibration damper bolt finger
tight. Using a suitable socket and breaker bar, rotate
the crankshaft to align timing chain sprockets and
keyways as shown (Fig. 33).
(5) Retract tensioner shoe until hole in shoe lines
up with hole in bracket. Slide a suitable pin into the
holes.
(6) Remove camshaft sprocket attaching bolt and
remove timing chain with crankshaft and camshaft
sprockets.
(7) If tensioner assembly is to be replaced, remove
the tensioner to block bolts and remove tensioner
assembly.
INSTALLATION
(1) If tensioner assembly is being replaced, install
tensioner and mounting bolts. Torque bolts to 28 N´m
(250 in. lbs.).
(2) Retract tensioner if required.
CAUTION: The camshaft pin and the slot in the cam
sprocket must be clocked at 12:00. The crankshaft
keyway must be clocked at 2:00. The crankshaft
sprocket must be installed so that the dots and or
paint marking is at 6:00.
(3) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores (Fig. 34).
CAUTION: The timing chain must be installed with
the single plated link aligned with the dot and or
paint marking on the camshaft sprocket. The crank-
shaft sprocket is aligned with the dot and or paint
marking on the sprocket between two plated timing
chain links.
(4) Place timing chain around both sprockets (Fig.
34).
(5) Lift sprockets and chain (keep sprockets tight
against the chain in position as shown).
(6) Slide both sprockets evenly over their respec-
tive shafts and check alignment of timing marks.
Fig. 33 5.7L TIMING MARK ALIGNMENT
1 - Chain Tensioner
2 - Camshaft Sprocket
3 - Crankshaft Sprocket
Fig. 34 5.7L TIMING MARK ALIGNMENT
1 - Chain Tensioner
2 - Camshaft Sprocket
3 - Crankshaft Sprocket
9 - 228 ENGINE - 5.7LDR

(7) Install the camshaft bolt. Tighten the bolt to
122 N´m (90 ft. lbs.) torque.
(8)Remove tensioner pin.Again, verify align-
ment of timing marks.
(9) Install the oil pump(Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(10) Install the oil pan and pick up(Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(11) Install the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(12) Fill cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(13) Connect battery negative cable.
(14) Start engine and check for oil and coolant
leaks.TIMING CHAIN/TENSIONER
DESCRIPTION
The timing chain tensioner is a stamped steel con-
stant tension mechanical design. It is mounted to the
front of the engine, behind the timing chain drive.
OPERATION
The timing chain tension is maintained by routing
the timing chain through the tensioner assembly. A
nylon covered spring steel arm presses on the timing
chain maintaining the correct chain tension.
DRENGINE - 5.7L 9 - 229
TIMING/CHAIN AND SPROCKETS (Continued)

CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................275
INSTALLATION........................275
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................276
INSTALLATION........................276
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................277
INSTALLATION........................277
SOLID LIFTERS/TAPPETS
REMOVAL............................279
CLEANING...........................279
INSPECTION.........................279
INSTALLATION........................280
PISTON & CONNECTING ROD
DESCRIPTION........................281
STANDARD PROCEDURE - HEAD GASKET
SELECTION.........................281
REMOVAL............................281
CLEANINGÐPISTON AND CONNECTING
ROD ..............................282
INSPECTION
INSPECTION - PISTONS...............282
INSPECTIONÐCONNECTING ROD.......283
INSTALLATION........................283
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................284
VIBRATION DAMPER
REMOVAL............................285
INSPECTION.........................285
INSTALLATION........................286
FRONT MOUNT
REMOVAL............................286
INSTALLATION........................287
REAR MOUNT
REMOVAL............................288
INSTALLATION........................288
LUBRICATION
DESCRIPTION........................289
OPERATION..........................289
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE.........................289
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
LEVEL.............................292STANDARD PROCEDURE - ENGINE OIL
SERVICE...........................292
OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION...........293
OIL FILTER
REMOVAL............................293
INSTALLATION........................293
OIL PAN
REMOVAL............................293
CLEANING...........................293
INSPECTION.........................293
INSTALLATION........................293
OIL PRESSURE RELIEF VALVE
REMOVAL............................294
CLEANING...........................294
INSPECTION.........................294
INSTALLATION........................294
OIL PRESSURE SWITCH
REMOVAL............................294
INSTALLATION........................294
OIL PUMP
REMOVAL............................294
CLEANING...........................295
INSPECTION.........................295
INSTALLATION........................296
INTAKE MANIFOLD
REMOVAL............................297
CLEANING...........................297
INSPECTION.........................297
INSTALLATION........................298
EXHAUST MANIFOLD
REMOVAL............................298
CLEANING...........................298
INSPECTION.........................298
INSTALLATION........................298
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION.......................299
GEAR HOUSING
REMOVAL............................299
INSTALLATION........................300
GEAR HOUSING COVER
REMOVAL............................301
INSTALLATION........................301
DRENGINE 5.9L DIESEL 9 - 231

(15) Remove the two charge air cooler mounting
bolts.
(16) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(17) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(18) Remove accessory drive belt tensioner.
(19) Remove the fan support/hub assembly.
(20) Remove crankshaft damper and speed indica-
tor ring (Refer to 9 - ENGINE/ENGINE BLOCK/VI-
BRATION DAMPER - REMOVAL).
(21) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the sealing surfaces. Remove dust
seal with cover.
(22) Using Special Tool 7471±B Crankshaft Bar-
ring Tool, rotate the crankshaft to align the timing
marks on the crankshaft and the camshaft gears.
(23) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(24) Remove the rocker arms, cross heads, and
push rods (Fig. 55). Mark each component so they
can be installed in their original positions.
NOTE: The #5 cylinder intake and the #6 cylinder
intake and exhaust pushrods are removed by lifting
them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
(25) Raise the tappets as follows, using the wooden
dowel rods (Fig. 57)provided with the Miller Tool Kit
8502.
(a) Insert the slotted end of the dowel rod into
the tappet.The dowel rods for the rear two
cylinders will have to be cut for cowl panel
clearance.Press firmly to ensure that it is seated
in the tappet.(b) Raise the dowel rod to bring the tappet to
the top of its travel, and wrap a rubber band
around the dowel rods (Fig. 57) to prevent the tap-
pets from dropping into the crankcase.
(c) Repeat this procedure for the remaining cyl-
inders.
(26) Verify that the camshaft timing marks are
aligned with the crankshaft mark (Fig. 56).
(27) Remove the bolts from the thrust plate.
(28) Remove engine mount through bolts.
(29) Install engine support fixture special tool #
8534,and steel bracket/wing nut special tool #
8534A.
(30) Raise engine enough to allow camshaft
removal.
(31) Remove the camshaft, gear and thrust plate.
Fig. 55 Push Rod Removal/Installation
Fig. 56 Timing Mark Alignment
Fig. 57 Use Wooden Dowel Rods to Secure Tappets
in Place - Typical
DRENGINE 5.9L DIESEL 9 - 269
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

(3) Inspect the camshaft bushing oil holes for
alignment with cylinder block (Fig. 60).
Camshaft Gear
Inspect the camshaft gear for cracks (gear and hub),
and chipped/broken/fretted teeth. If replacement is nec-
essary, camshaft and gear are replaced as an assembly.
(Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT &
BEARINGS (IN BLOCK) - REMOVAL).
Thrust Plate
Inspect the camshaft thrust plate for excessive
wear in the camshaft contact area. Measure thrust
plate thickness using the CAMSHAFT THRUST
PLATE THICKNESS CHART. Replace any thrust
plate that falls outside of these specifications:
CAMSHAFT THRUST PLATE THICKNESS CHART
MIN. 9.34 mm (0.368 in.)
MAX. 9.60 mm (0.378 in.)
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS
(1) Apply a coating of Loctitet640 Adhesive to the
backside of the new bushing. Avoid getting adhesive
in the oil hole.
(2) Use a universal cam bushing installation tool
and install the front bushing so that it is even with
the front face of the cylinder block. The oil hole must
be aligned. A 3.2 mm (0.128 inch) diameter rod must
be able to pass through the hole. (Fig. 61).
(3) Install the rear camshaft bushing is flush with
the rear face of the block. The oil hole must be
aligned. A 3.2 mm (0.128 inch) diameter rod must be
able to pass through the hole.
(4) Measure the installed bushings at the front
and rear bores. The minimum inside diameter is
54.083 mm (2.1293 inch), and the maximum inside
diameter is is 54.147 mm. (2.1318 in.).
INSTALLATION - CAMSHAFT
(1) Lubricate the camshaft bushing and bores with
fresh engine oil or suitable equivalent.
(2) Liberally coat the camshaft lobes, journals, and
thrust washer with fresh engine oil or suitable equiv-
alent.
CAUTION: When installing the camshaft, DO NOT
push it in farther than it will go with the thrust
washer in place.
(3) Install the camshaft and thrust plate. Align the
timing marks as shown (Fig. 62).
(4) Install the thrust plate bolts and tighten to 24
N´m (18 ft. lbs.) torque.
(5) Measure camshaft back lash and end clearance.
BACKLASH Ð 0.075Ð0.250 mm
(0.003Ð0.010 inch)
CLEARANCE Ð 0.025Ð0.500 mm
(0.001Ð0.020 inch)
Fig. 60 Inspecting Oil Hole Alignment
1 - CAMSHAFT BUSHING
Fig. 61 Oil Hole Alignment
1 - CAMSHAFT BUSHING
Fig. 62 Timing Mark Alignment
DRENGINE 5.9L DIESEL 9 - 271
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)