1998 DODGE RAM 1500 light

(8) Torque the (3) bolts that attach the front axle
to the left engine bracket to 101 N´m (75 ft. lbs.).
(9) Install the engine oil filter, if removed.
(10) Install the front crossmember(Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT CROSS-
MEMBER - INSTALLATION).
(11) Install the skid plate.
(12) Lower the vehicle.
(13) Reconnect the negative battery cable.
REAR MOUNT
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Using a suitable jack, support transmission.
(3) Remove the nuts from the transmission mount
(Fig. 26).
(4) Remove the two bolts that attach the transmis-
sion mount to the engine bracket.
(5) Raise the transmission enough to remove the
mount from the crossmember.
(6) Remove the mount.
INSTALLATION
NOTE: Threadlocking compound must be applied to
the bolts before installation.(1) Install the two bolts that attach the transmis-
sion mount to the transmission bracket.
(2) Torque the bolts to 61N´m (45 ft.lbs.) torque.
(3) Lower the transmission so the transmission
mount rests on the crossmember, and the studs of
the transmission mount are aligned in the slots in
the crossmember.
(4) Install the nuts onto the transmission mount
studs through the crossmember access slot.
(5) Torque the nuts to 54N´m (40 ft. lbs.).
LUBRICATION
DESCRIPTION
The lubrication system (Fig. 27) is a full flow fil-
tration pressure feed type.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE
(1) Remove oil pressure sending unit and install
gauge assembly C-3292.
(2) Run engine until thermostat opens.
(3) Oil Pressure:
²Curb Idle±25 kPa (4 psi) minimum
²3000 rpm±170 - 758 kPa (25 - 110 psi)
(4) If oil pressure is 0 at idle, shut off engine.
Check for a clogged oil pick-up screen or a pressure
relief valve stuck open.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.If the oil leak source is not pos-
itively identified at this time, proceed with the air
leak detection test method.
Fig. 26 TRANSMISSION MOUNT
1 - MOUNT
2 - CROSSMEMBER
3 - NUT
4 - BOLT
9 - 220 ENGINE - 5.7LDR
FRONT MOUNT (Continued)

Air Leak Detection Test Method
(1) Remove the PCV valve from the IAFM. Cap or
plug the PCV valve grommet.
(2) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kPa (3 PSI) of test pressure.
(3) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provide the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.(4) If the leakage occurs at the rear oil seal area,
refer to the section, Inspection for Rear Seal Area
Leak.
(5) If no leaks are detected, turn off the air supply
and remove the air hose and all plugs and caps.
Install the PCV valve.
(6) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
Fig. 27 Engine Oil Lubrication System
DRENGINE - 5.7L 9 - 221
LUBRICATION (Continued)

If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, distributor seal,
camshaft bore cup plugs oil galley pipe plugs, oil
filter runoff, and main bearing cap to cylinder
block mating surfaces.
(4) If no leaks are detected, pressurize the crank-
case as outlined in the, Inspection (Engine oil Leaks
in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied. MOPARtprovides engine oils that conform to
this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only engine oils with multi-
ple viscosities such as 5W-30 in the 5.7L engines.
These are specified with a dual SAE viscosity grade
which indicates the cold-to-hot temperature viscosity
range. Select an engine oil that is best suited to your
particular temperature range and variation.
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 28).
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the left
hand of the engine on the 5.7L engines.
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
pressure loss or oil foaming can result.
Inspect engine oil level approximately every 800
kilometers (500 miles). Unless the engine has exhib-
ited loss of oil pressure, run the engine for about ten
Fig. 28 API SYMBOL
9 - 222 ENGINE - 5.7LDR
LUBRICATION (Continued)

minutes before checking oil level. Checking engine oil
level on a cold engine is not accurate.
To ensure proper lubrication of an engine, the
engine oil must be maintained at an acceptable level.
The acceptable levels are indicated between the ADD
and SAFE marks on the engine oil dipstick.
(1) Position vehicle on level surface.
(2) With engine OFF, allow approximately five
minutes for oil to settle to bottom of crankcase,
remove engine oil dipstick.
(3) Wipe dipstick clean.
(4) Install dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the ADD mark on
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in Maintenance Schedules(Refer to LUBRI-
CATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION).
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug if
damaged.
(6) Install drain plug in crankcase. Torque to 34
N´m ( 25 ft. lbs.).
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this sec-
tion.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing used
engine oil after it has been drained from a vehicle
engine. Refer to the WARNING at beginning of this
section.
OIL FILTER
REMOVAL
All engines are equipped with a high quality full-
flow, disposable type oil filter. DaimlerChrysler Cor-
poration recommends a Mopartor equivalent oil
filter be used.
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
(3) Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss.
(4) When filter separates from cylinder block oil
filter boss, tip gasket end upward to minimize oil
spill. Remove filter from vehicle.
NOTE: Make sure filter gasket was removed with fil-
ter.
(5) With a wiping cloth, clean the gasket sealing
surface of oil and grime.
INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, (Fig. 29) hand
tighten filter one half turn, or 180É,do not over
tighten.
(3) Add oil, verify crankcase oil level and start
engine. Inspect for oil leaks.
Fig. 29 Oil Filter Sealing Surface - Typical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
DRENGINE - 5.7L 9 - 223
OIL (Continued)

REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove resonator assembly and air inlet hose.
(3) Disconnect electrical connectors for the follow-
ing components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
(4) Disconnect brake booster hose and positive
crankcase ventilation (PCV) hose.
(5) Remove generator and set aside.
NOTE: It is not necessary to remove lines or
remove freon from A/C compressor.
(6) Remove air conditioning compressor and set
aside..
(7) Bleed fuel system (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY - STANDARD PROCE-
DURE).
(8) Remove intake manifold retaining fasteners in
a crisscross pattern starting from the outside bolts
and ending at the middle bolts.
(9) Remove intake manifold and IAFM as an
assembly.
CLEANING
NOTE: There is NO approved repair procedure for
the intake manifold. If severe damage is found dur-
ing inspection, the intake manifold must be
replaced.
Before installing the intake manifold thoroughly
clean the mating surfaces. Use a suitable cleaning
solvent, then air dry.
INSPECTION
(1) Inspect the intake sealing surface for cracks,
nicks and distortion.
(2) Inspect the intake manifold vacuum hose fit-
tings for looseness or blockage.
(3) Inspect the manifold to throttle body mating
surface for cracks, nicks and distortion.
INSTALLATION
(1) Install intake manifold seals.
(2) Position intake manifold and IAFM.
(3) Install intake manifold retaining bolts, and
tighten in sequence from the middle bolts towards
the outside in a crisscross pattern. Torque fasteners
to 12 N´m (105 in. lbs.).
(4) Connect electrical connectors for the following
components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
(5) Install generator.
(6) Install A/C compressor.
(7) Connect Brake booster hose and Positive crank-
case ventilation (PCV) hose.
(8) Install resonator assembly and air inlet hose.
(9) Connect negative cable to battery.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds are log style with a pat-
ented flow enhancing design to maximize perfor-
mance. The exhaust manifolds are made of high
silicon molybdenum cast iron. A perforated core
graphite exhaust manifold gasket is used to improve
sealing to the cylinder head. The exhaust manifolds
are covered by a three layer laminated heat shield
for thermal protection and noise reduction. The heat
shields are fastened with a torque prevailing nut
that is backed off slightly to allow for the thermal
expansion of the exhaust manifold.
OPERATION
The exhaust manifolds collect the engine exhaust
exiting the combustion chambers, then channels the
exhaust gases to the exhaust pipes attached to the
manifolds.
REMOVAL
EXHAUST MANIFOLD
(1) Disconnect negative battery cable.
(2) Raise vehicle.
(3) Remove exhaust pipe to manifold bolts.
(4) Lower vehicle.
(5) Install engine support fixture special tool
#8534.
(6) Raise engine enough to remove manifolds.
CAUTION: Do not damage engine harness while
raising the engine.
(7) Remove heat shield.
(8) Remove manifold bolts.
(9) Remove manifold and gasket.
CLEANING
Clean mating surfaces on cylinder head and mani-
fold. Wash with solvent and blow dry with com-
pressed air.
9 - 226 ENGINE - 5.7LDR
INTAKE MANIFOLD (Continued)

INSPECTIONÐPUSHRODS
Inspect the push rod ball and socket for signs of
scoring. Check for cracks where the ball and the
socket are pressed into the tube (Fig. 16).
Roll the push rod on a flat work surface with the
socket end hanging off the edge (Fig. 17). Replace
any push rod that appears to be bent.
INSTALLATION
WARNING: THE OUTSIDE EDGE OF THE HEAD
GASKET IS VERY SHARP. WHEN HANDLING THE
NEW HEAD GASKET, USE CARE NOT TO INJURE
YOURSELF.
(1) Install a new gasket with the part number side
up, and locate the gasket over the dowel sleeves.
(2) Using an engine lifting crane, lower the cylin-
der head onto the engine.
(3) Lightly lubricate head bolts with engine oil and
install. Using the sequence shown in (Fig. 18),
tighten bolts in the following steps:
(a) Torque bolts to 70 N´m (52 ft. lbs.)(b) Back off 360 degrees in sequence
(c) Torque bolts to 105 N´m (77 ft. lbs.)
(d) Re-check all bolts to 105 N´m (77 ft. lbs.)
(e) Tighten all bolts an additional
1¤4turn (90É)
(4) Install push rods into their original locations
(Fig. 19).Verify that they are seated in the tap-
pets.
(5) Lubricate valve stem tips and install the cross-
heads in their original locations.
(6) Lubricate the rocker arms and pedestals and
install them in their original locations (Fig. 20).
Install the bolts and torque them to 36 N´m (27 ft.
lbs.).
(7) Verify that the valve lash settings are main-
tained (Refer to 9 - ENGINE/CYLINDER HEAD/IN-
TAKE/EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
(8) Inspect rocker housing gasket for cuts and
proper installation into groove. Replace if damaged.
Fig. 16 Inspecting Push Rod for Cracks
Fig. 17 Inspecting Push Rod for Flatness
Fig. 18 Cylinder Head Bolt Torque Sequence
Fig. 19 Push Rod Installation
DRENGINE 5.9L DIESEL 9 - 253
CYLINDER HEAD (Continued)

(6) Use a drill, a fine grit Flex-hone and a mixture
of equal parts of mineral spirits and SAE 30W engine
oil to de-glaze the bores.
(7) The crosshatch angle is a function of drill
speed and how fast the hone is moved vertically (Fig.
47).
(8) Vertical strokes MUST be smooth continuous
passes along the full length of the bore (Fig. 47).
(9) Inspect the bore after 10 strokes.
(10) Use a strong solution of hot water and laun-
dry detergent to clean the bores. Clean the cylinder
bores immediately after de-glazing.
(11) Rinse the bores until the detergent is removed
and blow the block dry with compressed air.
(12) Check the bore cleanliness by wiping with a
white, lint free, lightly oiled cloth. If grit residue is
still present, repeat the cleaning process until all res-
idue is removed. Wash the bores and the complete
block assembly with solvent and dry with compressed
air. Place a clean shop towel around the top main
bearing saddle to deflect water and residue from pis-
ton cooling nozzels. Remove directed piston cooling
nozzles if installed.
(13) Be sure to remove the tape covering the lube
holes, rod journals, and piston cooling nozzles after
the cleaning process is complete.
STANDARD PROCEDUREÐCYLINDER BORE
REPAIR
Cylinder bore(s) can be repaired by one of two
methods:
²Method 1:ÐOver boring and using oversize pis-
tons and rings.
²Method 2:ÐBoring and installing a repair sleeve
to return the bore to standard dimensions.
METHOD 1ÐOVERSIZE BORE
Cylinder bore(s) can be repaired by one of two
methods:Oversize pistons and rings are available in two
sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393
inch).
Any combination of standard, 0.50 mm (0.0197
inch) or 1.00 mm (0.0393 inch) overbore may be used
in the same engine.
If more than 1.00 mm (0.0393 inch) overbore is
needed, a repair sleeve can be installed (refer to
Method 2ÐRepair Sleeve).
Cylinder block bores may be bored twice before use
of a repair sleeve is required. The first bore is 0.50
mm (0.0197 inch) oversize. The second bore is 1.00
mm (0.0393 inch) oversize.
After boring to size, use a honing stone to chamfer
the edge of the bore.
CYLINDER BORE DIMENSION CHART
DESCRIPTION MEASUREMENT
BORING DIAMETER
DIMENSION1st. REBORE - 102.469
mm (4.0342 in.)
2nd. REBORE - 102.969
mm (4.0539 in.)
HONING DIAMETER
DIMENSIONSSTANDARD - 102.020  
0.020 mm (4.0165  
0.0008 in.)
1st. REBORE - 102.520
  0.020 mm (4.0362  
0.0008 in.)
2nd. REBORE - 103.020
  0.020 mm 4.0559  
0.0008 in.)
CHAMFER
DIMENSIONSApprox. 1.25 mm (0.049
in.) by 30É
A correctly honed surface will have a crosshatch
appearance with the lines at 15É to 25É angles with
the top of the cylinder block (Fig. 48). For the rough
hone, use 80 grit honing stones. To finish hone, use
280 grit honing stones.
A maximum of 1.2 micrometer (48 microinch) sur-
face finish must be obtained.
Fig. 47 De-Glazing Drill Speed and Vertical Speed
Fig. 48 Crosshatch Pattern of Repaired Sleeve(s)
DRENGINE 5.9L DIESEL 9 - 265
ENGINE BLOCK (Continued)

After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry
detergent and hot water.
After rinsing, blow the block dry.
Check the bore cleanliness by wiping with a white,
lint-free, lightly- oiled cloth. There should be no grit
residue present.
If the block is not to be used right away, coat it
with a rust- preventing compound.
METHOD 2ÐREPAIR SLEEVE
If more than a 1.00 mm (0.03937 inch) diameter
oversize bore is required, the block must be bored
and a repair sleeve installed.
Bore the block cylinder bore to 104.500-104.515
mm (4.1142-4.1148 inch) - (Fig. 49).
Repair sleeves can be replaced by using a boring
bar to bore out the old sleeve. DO NOT cut the cyl-
inder bore beyond the oversize limit.
REPAIR SLEEVE BLOCK REBORE
DIMENSIONS CHART
BORE DIAMETER STEP DIMENSION
104.500 + 0.015 mm
(4.1142 + 0.0006 in.)6.35 mm (0.25 in.)
After machining the block for the new repair
sleeve, thoroughly clean the bore of all metal chips,
debris and oil residue before installing the sleeve.
Cool the repair sleeve(s) to a temperature of -12ÉC
(10ÉF) or below for a minimum of one hour. Be ready
to install the sleeve immediately after removing it
from the freezer.
Apply a coat of Loctite 620, or equivalent to the
bore that is to be sleeved.Wear protective gloves to push the cold sleeve into
the bore as far as possible.
Using a sleeve driver, drive the sleeve downward
until it contacts the step at the bottom of the bore
(Fig. 50).
A sleeve driver can be constructed as follows (Fig.
51).SLEEVE DRIVER CONSTRUCTION
SPECIFICATION CHART
ITEM MEASUREMENT
A 127 mm (5 in.)
B 38 mm (1.5 in.)
C 6.35 mm (0.25 in.)
D 25.4 mm (1 in.)
E 101 mm (3.976 in.)
F 107.343 mm (4.226 in.)
Set up a boring bar and machine the sleeve to
101.956 mm (4.014 inch).
Fig. 49 Block Bore for Repair Sleeve Dimensions
1 - BORE DIAMETER
2 - STEP DIMENSION
Fig. 50 Sleeve Installation
1 - SLEEVE DRIVER
2 - SLEEVE
3 - CONTACT
Fig. 51 Sleeve Driver Construction
1 - DRIVE
2 - HANDLE
9 - 266 ENGINE 5.9L DIESELDR
ENGINE BLOCK (Continued)