1998 DODGE RAM 1500 Workshop Manual

windshield wipers wheel bolt torque refrigerant type adding oil bonnet keyless

Page 1433 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual INSTALLATION
(1) Throughly clean all gasket resdue from the
engine block.
(2) Use extream care and clean all gasket resdue
from the retainer.
(3) Position the gasket onto the retainer.
(4) Position th

INSTALLATION
(1) Throughly clean all gasket resdue from the
engine block.
(2) Use extream care and clean all gasket resdue
from the retainer.
(3) Position the gasket onto the retainer.
(4) Position the retainer onto the engine block.
(5) Install the retainer mounting bolts. Tighten the
bolts to 15 N´m (132 in. lbs.) using a crisscross pat-
tern, starting with the bolt on the lower right.
(6) Install a new rear seal(Refer to 9 - ENGINE/
ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR
- INSTALLATION).
(7) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(8) Install the drive plate / flywheel.
(9) Install the transmission.
(10) Check and verify engine oil level.
(11) Start engine and check for leaks.
FLEX PLATE
REMOVAL
(1) Remove the transmission.
(2) Remove the bolts and flexplate.
INSTALLATION
(1) Position the flexplate or flywheel onto the
crankshaft and install the bolts hand tight.
(2)For automatic transmissions:Tighten the
flexplate retaining bolts to 95 N´m (70 ft. lbs.).
(3)For manual transmissions:Tighten the fly-
wheel retaining bolts to 75 N´m (55 ft. lbs.).
(4) Install the transmission.
HYDRAULIC TAPPETS
DIAGNOSIS AND TESTING - HYDRAULIC
TAPPETS
Before disassembling any part of the engine to cor-
rect tappet noise, check the oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at
the pressure sending-unit. The pressure should be
between 207-552 kPa (30-70 psi) at 3,000 RPM.
Check the oil level after the engine reaches normal
operating temperature. Allow 5 minutes to stabilize
oil level, check dipstick. The oil level in the pan
should never be above the FULL mark or below the
ADD OIL mark on dipstick. Either of these two con-
ditions could be responsible for noisy tappets.
OIL LEVEL
HIGH
If oil level is above the FULL mark, it is possible
for the connecting rods to dip into the oil. With the
engine running, this condition could create foam in
the oil pan. Foam in oil pan would be fed to the
hydraulic tappets by the oil pump causing them to
lose length and allow valves to seat noisily.
LOW
Low oil level may allow oil pump to take in air. When
air is fed to the tappets, they lose length, which allows
valves to seat noisily. Any leaks on intake side of oil
pump through which air can be drawn will create the
same tappet action. Check the lubrication system from
the intake strainer to the pump cover, including the
relief valve retainer cap. When tappet noise is due to
aeration, it may be intermittent or constant, and usu-
ally more than one tappet will be noisy. When oil level
and leaks have been corrected, operate the engine at
fast idle. Run engine for a sufficient time to allow all of
the air inside the tappets to be bled out.
TAPPET NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate
engine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect
noisy tappet. The noisy tappet will cause the affected
spring and/or rocker arm to vibrate or feel rough in
operation.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
(3)
Valve tappet noise ranges from light noise to a
heavy click. A light noise is usually caused by excessive
leak-down around the unit plunger, or by the plunger
partially sticking in the tappet body cylinder. The tap-
pet should be replaced. A heavy click is caused by a tap-
pet check valve not seating, or by foreign particles
wedged between the plunger and the tappet body. This
will cause the plunger to stick in the down position.
This heavy click will be accompanied by excessive clear-
ance between the valve stem and rocker arm as valve
closes. In either case, tappet assembly should be
removed for inspection and cleaning.
(4) The valve train generates a noise very much
like a light tappet noise during normal operation.
Care must be taken to ensure that tappets are mak-
ing the noise. If more than one tappet seems to be
noisy, it's probably not the tappets.
9 - 210 ENGINE - 5.7LDR
CRANKSHAFT REAR OIL SEAL RETAINER (Continued)

Page 1434 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove the air cleaner(Refer to 9 - ENGINE/
AIR INTAKE SYSTEM - REMOVAL).
(3) Remove intake manifold(Refer to 9 - ENGINE/
MANIFOLDS/INTA

REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove the air cleaner(Refer to 9 - ENGINE/
AIR INTAKE SYSTEM - REMOVAL).
(3) Remove intake manifold(Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(4) Remove cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(5) Remove rocker arm assembly and push rod-
s(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARM / ADJUSTER ASSY - REMOVAL). Identify
push rods to ensure installation in original location.
(6) Remove the cylinder head(Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(7) Remove bolt from tappet guide holder.
(8) Remove tappet guide holder.
(9) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed and reused, identify
tappets to ensure installation in original location.
(10) Check camshaft lobes for abnormal wear.
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets in their original positions.
(3)
Install tappet guide holder. Install the tappet
guide holder bolt and tighten to 12 N´m (106 in. lbs.)
torque.
(4) Install cylinder head(Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(5) Install pushrods and rocker arm assembly(Re-
fer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARM / ADJUSTER ASSY - INSTALLATION).
(6) Install cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(7)
Install intake manifold(Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSTALLATION).
(8) Install the air cleaner(Refer to 9 - ENGINE/
AIR INTAKE SYSTEM - INSTALLATION).
(9) Connect the negative cable to the battery.
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) Road test vehicle and check for leaks.
PISTON & CONNECTING ROD
DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.The pistons are made of a high strength aluminum
alloy. Piston skirts are coated with a solid lubricant
(Molykote) to reduce friction and provide scuff resis-
tance. The piston top ring groove and land is anod-
ized. The connecting rods are made of forged
powdered metal, with a ªfractured capº design. A
pressed fit piston pin is used to attach the piston and
connecting rod.
STANDARD PROCEDUREÐPISTON FITTING
(1) To correctly select the proper size piston, a cyl-
inder bore gauge, capable of reading in 0.003 mm (
.0001 in.) INCREMENTS is required. If a bore gauge
is not available, do not use an inside micrometer.
(2) Measure the inside diameter of the cylinder
bore at a point 38.0 mm (1.5 inches) below top of
bore. Start perpendicular (across or at 90 degrees) to
the axis of the crankshaft at point A and then take
an additional bore reading 90 degrees to that at point
B (Fig. 11).
(3) The coated pistons will be serviced with the
piston pin and connecting rod pre-assembled. The
piston-rod assembly is specific for the left cylinder
bank ( odd numbered) and the right cylinder bank (
even numbered) and must not be interchanged.
(4) The coating material is applied to the piston
after the final piston machining process. Measuring
the outside diameter of a coated piston will not pro-
vide accurate results (Fig. 10). Therefore measuring
the inside diameter of the cylinder bore with a dial
Bore Gauge isMANDATORY. To correctly select the
proper size piston, a cylinder bore gauge capable of
reading in 0.003 mm (.0001 in.) increments is
required.
Fig. 10 MOLY COATED PISTON
1 - MOLY COATED
2 - MOLY COATED
DRENGINE - 5.7L 9 - 211
HYDRAULIC TAPPETS (Continued)

Page 1435 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (5) Piston installation into the cylinder bore
requires slightly more pressure than that required
for non-coated pistons. The bonded coating on the
piston will give the appearance of a line-to-line fi

(5) Piston installation into the cylinder bore
requires slightly more pressure than that required
for non-coated pistons. The bonded coating on the
piston will give the appearance of a line-to-line fit
with the cylinder bore.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the following components:
²Oil pan and gasket/windage tray (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - REMOVAL).
²Cylinder head covers (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL) and (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
²Timing chain cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- REMOVAL).
²Cylinder head(s) (Refer to 9 - ENGINE/CYLIN-
DER HEAD - REMOVAL) and (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(3) If necessary, remove top ridge of cylinder bores
with a reliable ridge reamer before removing pistons
from cylinder block.Be sure to keep tops of pis-
tons covered during this operation.Pistons and
connecting rods must be removed from top of cylinder
block. When removing piston and connecting rod
assemblies from the engine, rotate crankshaft so the
each connecting rod is centered in cylinder bore.CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods or caps, as damage to
connecting rods could occur
NOTE: Connecting rods and bearing caps are not
interchangeable and should be marked before
removing to ensure correct reassembly.
(4)
Mark connecting rod and bearing cap positions
using a permanent ink marker or scribe tool (Fig. 12).
CAUTION: Care must be taken not to damage the
fractured rod and cap joint face surfaces, as engine
damage may occur.
(5) Remove connecting rod cap. Install Special Tool
8507 Connecting Rod Guides into the connecting rod
being removed. Remove piston from cylinder bore.
Repeat this procedure for each piston being removed.
CAUTION: Care must be taken not to nick crank-
shaft journals, as engine damage may occur
(6) Immediately after piston and connecting rod
removal, install bearing cap on the mating connect-
ing rod to prevent damage to the fractured cap and
rod surfaces.
(7) Carefully remove piston rings from piston(s),
starting from the top ring down.
CLEANING
CAUTION: DO NOT use a wire wheel or other abra-
sive cleaning devise to clean the pistons or con-
necting rods. The pistons have a Moly coating, this
coating must not be damaged.
(1) Using a suitable cleaning solvent clean the pis-
tons in warm water and towel dry.
(2) Use a wood or plastic scraper to clean the ring
land grooves.
CAUTION: DO NOT remove the piston pin from the
piston and connecting rod assembly.
Fig. 11 BORE GAUGE - TYPICAL
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4-38MM
(1.5 in)
Fig. 12 IDENTIFY CONN ROD TO CYLINDER
9 - 212 ENGINE - 5.7LDR
PISTON & CONNECTING ROD (Continued)

Page 1436 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual INSPECTION
Check the connecting rod journal for excessive
wear, taper and scoring (Refer to 9 - ENGINE/EN-
GINE BLOCK/CONNECTING ROD BEARINGS -
STANDARD PROCEDURE).
Check the connecting rod for signs

INSPECTION
Check the connecting rod journal for excessive
wear, taper and scoring (Refer to 9 - ENGINE/EN-
GINE BLOCK/CONNECTING ROD BEARINGS -
STANDARD PROCEDURE).
Check the connecting rod for signs of twist or bend-
ing.
Check the piston for taper and elliptical shape
before it is fitted into the cylinder bore (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECT-
ING ROD - STANDARD PROCEDURE).
Check the piston for scoring, or scraping marks in
the piston skirts. Check the ring lands for cracks
and/or deterioration.
INSTALLATION
(1) Before installing piston and connecting rod
assemblies into the bore, install the piston rings(Re-
fer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS
- STANDARD PROCEDURE).
(2) Immerse the piston head and rings in clean
engine oil. Position a ring compressor over the piston
and rings. Tighten ring compressor.Ensure posi-
tion of rings do not change during this opera-
tion.
(3) Position bearing onto connecting rod. Lubricate
bearing surface with clean engine oil.
(4) Install Special Tool 8507 Connecting Rod
Guides into connecting rod bolt threads.
(5) The pistons are marked on the piston pin bore
surface with an raised ªFº or arrow on top of piston
indicating installation position. This mark must be
pointing toward the front of engine on both cylinder
banks.
(6) Wipe cylinder bore clean and lubricate with
engine oil.
(7) Rotate crankshaft until connecting rod journal
is on the center of cylinder bore. Insert rod and pis-
ton into cylinder bore and carefully position connect-
ing rod guides over crankshaft journal.
(8) Tap piston down in cylinder bore using a ham-
mer handle. While at the same time, guide connect-
ing rod into position on rod journal.
CAUTION: Connecting Rod Bolts are Torque to
Yield Bolts and Must Not Be Reused. Always
replace the Rod Bolts whenever they are loosened
or removed.
(9) Lubricate rod bolts and bearing surfaces with
engine oil. Install connecting rod cap and bearing.
Tighten bolts to 21 N´m (15 ft. lbs.) plus a 90É turn.
(10) Install the following components:
²Cylinder head(s). (Refer to 9 - ENGINE/CYLIN-
DER HEAD - INSTALLATION).²Cylinder head covers (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).
²Install the intake manifold.
²Oil pan and gasket/windage tray. (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(11) Fill crankcase with proper engine oil to cor-
rect level.
(12) Connect negative cable to battery.
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
Before reinstalling used rings or installing new
rings, the ring clearances must be checked.
(1) Wipe the cylinder bore clean.
(2) Insert the ring in the cylinder bore.
NOTE: The ring gap measurement must be made
with the ring positioned at least 12mm (0.50 inch.)
from bottom of cylinder bore.
(3) Using a piston, to ensure that the ring is
squared in the cylinder bore, slide the ring downward
into the cylinder.
(4) Using a feeler gauge check the ring end gap
(Fig. 13). Replace any rings not within specification.
PISTON RING SIDE CLEARANCE
NOTE: Make sure the piston ring grooves are clean
and free of nicks and burrs.
Fig. 13 Ring
1 - FEELER GAUGE
DRENGINE - 5.7L 9 - 213
PISTON & CONNECTING ROD (Continued)

Page 1437 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (5) Measure the ring side clearance as shown (Fig.
14)make sure the feeler gauge fits snugly between
the ring land and the ring. Replace any ring not
within specification.
(6) Rotate the ring around t

Page 1438 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (10) Install No. 2 intermediate piston ring using a
piston ring installer (Fig. 16).
(11) Install No. 1 upper piston ring using a piston
ring installer (Fig. 16).
(12) Position piston ring end gaps as

(10) Install No. 2 intermediate piston ring using a
piston ring installer (Fig. 16).
(11) Install No. 1 upper piston ring using a piston
ring installer (Fig. 16).
(12) Position piston ring end gaps as shown in
(Fig. 17). It is important that expander ring gap is at
least 45É from the side rail gaps, but not on the pis-
ton pin center or on the thrust direction.
VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).(4) Remove radiator upper hose.
(5) Remove upper fan shroud.
(6) Using Special Tools 6958 Spanner with Adapter
Pins 8346, loosen fan and viscous assembly from
water pump.
(7) Remove fan and viscous assembly.
(8) Remove crankshaft damper bolt.
(9) Remove damper using Special Tools 8513A
Insert and 8454 Three Jaw Puller.
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512±A, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Slide damper onto crankshaft slightly.
CAUTION: Special Tool 8512±A, is assembled in a
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.
(2) Assemble Special Tool 8512±A as follows, The
nut is threaded onto the shaft first. Then the roller
bearing is placed onto the threaded rod (The hard-
ened bearing surface of the bearingMUSTface the
nut). Then the hardened washer slides onto the
threaded rod (Fig. 18). Once assembled coat the
threaded rod's threads with MopartNickel Anti-
Seize or (Loctite No. 771).
Fig. 16 UPPER AND INTERMEDIATE RINGS
Fig. 17 PISTON RING END GAP POSITION
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 18 Proper Assembly Method for Special Tool
8512
1 - BEARING
2 - NUT
3 - THREADED ROD
4 - BEARING HARDENED SURFACE (FACING NUT)
5 - HARDENED WASHER
DRENGINE - 5.7L 9 - 215
PISTON RINGS (Continued)

Page 1439 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (3) Using Special Tool 8512±A, press damper onto
crankshaft.
(4) Install then tighten crankshaft damper bolt to
176 N´m (129 ft. lbs.).
(5) Install fan blade assembly (Refer to 7 - COOL-
ING/ENGINE/

(3) Using Special Tool 8512±A, press damper onto
crankshaft.
(4) Install then tighten crankshaft damper bolt to
176 N´m (129 ft. lbs.).
(5) Install fan blade assembly (Refer to 7 - COOL-
ING/ENGINE/FAN DRIVE VISCOUS CLUTCH -
INSTALLATION).
(6) Install radiator upper shroud and tighten fas-
teners to 11 N´m (95 in. lbs.).
(7) Install radiator upper hose.
(8) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(9) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(10) Connect negative cable to battery.
STRUCTURAL COVER
DESCRIPTION
The structural dust cover is made of die cast alu-
minum and joins the lower half of the transmission
bell housing to the engine.
OPERATION
The structural cover provides additional power-
train stiffness and reduces noise and vibration.
REMOVAL
(1) Raise vehicle on hoist.
CAUTION: On manual transmission vehicles, the
7/16 inch engine block to clutch housing bolts must
be loosened before removal of the structural dust
cover. Clutch housing distortion will occur if this
procedure is not followed.
(2) Remove the bolts retaining structural cover.
(3) Remove the structural cover.
INSTALLATION
AUTOMATIC TRANSMISSION
CAUTION: The structural cover must be installed as
described in the following steps. Failure to do so
will cause severe damage to the cover.
(1) Position the structural cover in the vehicle.
(2) Install all four bolts retaining the cover-to-en-
gine. DO NOT tighten the bolts at this time.
(3) Install the four cover-to-transmission bolts. Do
NOT tighten at this time.
CAUTION: The structural cover must be held tightly
against both the engine and the transmission bellhousing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) Torque the (4)structural dust cover bolts that
go into the transmission to 6-11 N´m (50-100 in.lbs.).
(5) Torque the (4) structural dust cover bolts that
go into the engine block to 6-11 N´m (50-100 in.lbs.).
(6) Starting with the two rear cover-to-engine
bolts, tighten bolts (1) (Fig. 19) to 54 N´m (40 ft. lbs.),
then tighten bolts (2) (Fig. 19) and (3) to 54 N´m ( 40
ft. lbs.) in the sequence shown.
(7) Install the exhaust pipe on left hand exhaust
manifold.
(8) Tighten exhaust manifold-to-exhaust pipe
retaining bolts to 20±26 N´m (15±20 ft. lbs.).
MANUAL TRANSMISSION
CAUTION: The 7/16 inch engine block to clutch
housing bolts must be loosened before removal/in-
stallation of the structural dust cover. Clutch hous-
ing distortion will occur if this procedure is not
followed.
(1) Position the structural cover in the vehicle.
CAUTION: The structural cover must be installed as
described in the following steps. Failure to do so
will cause severe damage to the cover, and engine
noise.
(2) Install all bolts retaining the cover-to-engine.
DO NOT tighten the bolts at this time (Fig. 20).
(3) Install the cover-to-transmission bolts. Do NOT
tighten at this time.
Fig. 19 Structural Cover
1 - BOLT
2 - BOLT
3 - BOLT
9 - 216 ENGINE - 5.7LDR
VIBRATION DAMPER (Continued)

Page 1440 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual CAUTION: The structural cover must be held tightly
against the corner formed by the engine and the
transmission clutch housing during tightening
sequence. Failure to do so may cause damage to
the cove

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