1998 DODGE RAM 1500 Intake manifold gasket

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either per-
formance (e.g., engine idles rough and stalls) or
mechanical (e.g., a strange noise).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING) - PERFORMANCE and (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)ÐMECHANICAL for
possible causes and corrections of malfunctions.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
DIAGNOSIS AND TESTING) and (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION - DIAGNOSIS
AND TESTING) for the fuel system diagnosis.Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following diagnosis:
²Cylinder Compression Pressure Test (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING).
²Cylinder Combustion Pressure Leakage Test
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING).
²Engine Cylinder Head Gasket Failure Diagnosis
(Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNO-
SIS AND TESTING).
²Intake Manifold Leakage Diagnosis (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING).
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary.
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to the terminals.
3. Faulty starter. 3. (Refer to 8 - ELECTRICAL/
STARTING - DIAGNOSIS AND
TESTING).
4. Faulty coil or control unit. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL
- REMOVAL).
5. Incorrect spark plug gap. 5. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING).
6. Dirt or water in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump, relay or wiring. 7. Repair or replace as necessary.
DRENGINE - 5.7L 9 - 183
ENGINE - 5.7L (Continued)

CONDITION POSSIBLE CAUSE CORRECTION
ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low. 1. (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/IDLE AIR
CONTROL MOTOR - REMOVAL).
2. Idle mixture too lean or too rich. 2. Refer to Powertrain Diagnosis
Information.
3. Vacuum leak. 3. Inspect intake manifold and
vacuum hoses, repair or replace as
necessary.
4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL
- REMOVAL).
5. Incorrect engine timing. 5. (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD PROCEDURE).
1. ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped spark
plugs.1. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING).
2. Dirt or water in fuel system. 2. Clean system and replace fuel
filter.
3. Faulty fuel pump. 3. (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL PUMP -
DIAGNOSIS AND TESTING).
4. Blown cylinder head gasket. 4. Replace cylinder head gasket.
5. Low compression. 5. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING).
6. Burned, warped or pitted valves. 6. Replace as necessary.
7. Plugged or restricted exhaust
system.7. Inspect and replace as necessary.
8. Faulty coil. 8. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL
- REMOVAL).
1. ENGINE MISSES ON
ACCELERATION1. Spark plugs dirty or incorrectly
gapped.1. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING).
2. Dirt in fuel system. 2. Clean fuel system.
3. Burned, warped or pitted valves. 3. Replcae as necessary.
4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL
- REMOVAL).
1. ENGINE MISSES AT HIGH SPEED 1. Spark plugs dirty or incorrectly
gapped.1. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING).
2. Faulty coil. 2. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL
- REMOVAL).
3. Dirt or water in fuel system. 3. Clean system and replace fuel
filter.
9 - 184 ENGINE - 5.7LDR
ENGINE - 5.7L (Continued)

(6) Remove the viscous fan/drive (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(7) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(8) Remove the upper crossmember and top core
support.
NOTE: It is not necessary to drain A/C system for
engine removal.
(9) Remove the A/C compressor with the lines
attached. Secure compressor out of the way.
(10) Remove generator assembly (Refer to 8 -
ELECTRICAL/CHARGING/GENERATOR -
REMOVAL).
(11) Remove the intake manifold and IAFM as an
assembly(Refer to 9 - ENGINE/MANIFOLDS/IN-
TAKE MANIFOLD - REMOVAL).
(12) Disconnect the heater hoses.
NOTE: It is not necessary to disconnect P/S hoses
from pump, for P/S pump removal.
(13) Remove the power steering pump and set
aside.
(14) Disconnect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(15) Raise and support the vehicle on a hoist and
drain the engine oil.
(16) Remove engine front mount thru-bolt nuts.
(17) Remove right side axle retaining bolts.
(18) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(19) Disconnect exhaust pipe at manifolds.
(20) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
(21) Remove the structural dust cover and trans-
mission inspection cover,(Refer to 9 - ENGINE/EN-
GINE BLOCK/STRUCTURAL COVER - REMOVAL).
(22) Remove drive plate to converter bolts (Auto-
matic transmission equipped vehicles).
(23) Remove transmission bell housing to engine
block bolts.
(24) Lower the vehicle.
(25) Install engine lift fixture, special tool # 8984.
(26) Separate engine from transmission, remove
engine from vehicle, and install engine assembly on a
repair stand.
INSTALLATION
(1) Install engine lift fixture Special tool # 8984.
(2) Position the engine in the engine compartment.
(3) Lower engine into compartment and align
engine with transmission:²Manual Transmission: Align clutch disc assem-
bly (if disturbed). Install transmission input shaft
into clutch disc while mating engine and transmis-
sion surfaces. Install two transmission to engine
block mounting bolts finger tight.
²Automatic Transmission: Mate engine and trans-
mission and install two transmission to engine block
mounting bolts finger tight.
(4) Position the thru-bolt into the support cushion
brackets.
(5) Lower engine assembly until engine mount
through bolts rest in mount perches.
(6) Install remaining transmission to engine block
mounting bolts and tighten.
(7) Tighten engine mount through bolts.
(8) Install drive plate to torque converter bolts.
(Automatic transmission models)
(9) Install the structural dust cover and transmis-
sion dust cover,(Refer to 9 - ENGINE/ENGINE
BLOCK/STRUCTURAL COVER - INSTALLATION).
(10) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(11) Install exhaust pipe to manifold.
(12) Lower the vehicle.
(13) Remove engine lift fixture, special tool # 8984.
(14) Connect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(15) Reinstall the power steering pump.
(16) Connect the heater hoses.
(17) Install the intake manifold.
(18) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(19) Install the generator and wire connections
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION).
(20) Install a/c compressor and lines (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION).
(21) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(22) Install upper radiator support crossmember.
(23) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(24) Connect the radiator lower hose.
(25) Connect the transmission oil cooler lines to
the radiator.
(26) Install the fan shroud.
(27) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(28) Connect the radiator upper hose.
(29) Install the washer bottle.
(30) Connect the transmission cooler lines.
DRENGINE - 5.7L 9 - 191
ENGINE - 5.7L (Continued)

þ Loss of engine power
þ Engine misfiring
þ Poor fuel economy
²Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
þ Engine overheating
þ Loss of coolant
þ Excessive steam (white smoke) emitting from
exhaust
þ Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test in this
section. An engine cylinder head gasket leaking
between adjacent cylinders will result in approxi-
mately a 50±70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system.
(3) Remove the air cleaner resonator and duct
work.
(4) Remove the generator.
(5) Remove closed crankcase ventilation system.
(6) Disconnect the evaporation control system.
(7) Perform the Fuel System Pressure Release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect heater hoses.
(9) Remove cylinder head covers and gaskets.
(10) Remove intake manifold and throttle body as
an assembly.
(11) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(12) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
(1) Inspect the cylinder head for out-of-flatness,
using a straightedge and a feeler gauge. If tolerances
exceed 0.0508 mm (0.002 in.) replace the cylinder
head.
(2) Inspect the valve seats for damage. Service the
valve seats as necessary.
(3) Inspect the valve guides for wear, cracks or
looseness. If either condition exist, replace the cylin-
der head.
(4) Inspect pushrods. Replace worn or bent push-
rods.
INSTALLATION
(1) Clean all surfaces of cylinder block and cylin-
der heads.
(2) Clean cylinder block front and rear gasket sur-
faces using a suitable solvent.
CAUTION: The head gaskets are not interchange-
able between left and right sides. They are marked
ªLº and ªRº to indicate left and right sides.
(3) Position new cylinder head gaskets onto the
cylinder block.
9 - 200 ENGINE - 5.7LDR
CYLINDER HEAD (Continued)

CAUTION: The head gaskets are marked ªTOPº to
indicate which side goes up.
(4) Position cylinder heads onto head gaskets and
cylinder block.
(5) Tighten the cylinder head bolts in three steps
(Fig. 4):
²Step 1Ð Snug tighten M12 cylinder head bolts,
in sequence, to 34 N´m (25 ft. lbs.) and M8 bolts to
20 N´m (15 ft. lbs.) torque.
²Step 2Ð Tighten M12 cylinder head bolts, in
sequence, to 54 N´m (40 ft. lbs.) and verify M8 bolts
to 20 N´m (15 ft. lbs.) torque..
²Step 3Ð Turn M12 cylinder head bolts, in
sequence, 90 degrees and tighten M8 bolts to 34 N´m
(25 ft. lbs.) torque.
(6) Install push rods and rocker arm assemblies in
their original position.
(7) Install the intake manifold and throttle body
assembly.
(8) If required, adjust spark plugs to specifications.
Install the plugs.
(9) Connect the heater hoses.
(10) Install the fuel supply line.
(11) Install the generator and drive belt.
(12) Install cylinder head covers(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(13) Connect the evaporation control system.
(14) Install the air cleaner.
(15) Fill cooling system.
(16) Connect the negative cable to the battery.
(17) Start engine check for leaks.CYLINDER HEAD COVER(S)
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect coil on plug connectors.
CAUTION: The ground straps must be installed in
the same location as removed. The covers are
machined to accept the ground straps in those
locations only.
(3) Remove cylinder head cover retaining bolts,
and ground straps.
(4) Remove cylinder head cover.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
INSTALLATION
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the
engine cylinder head cover. Prolonged contact with
other objects may wear a hole in the cylinder head
cover.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2)
Install cylinder head cover and hand start all fas-
teners. Verify that all double ended studs are in the cor-
rect location and install left and right ground straps.
CAUTION: The ground straps must be installed in
the same location as removed. The covers are
machined to accept the ground straps in those
locations only.
NOTE: The right hand ground strap is located on
the front inboard stud. The left hand ground strap
is located on the rear inboard stud.
(3) Tighten cylinder head cover bolts and double
ended studs to 8 N´m (70 in. lbs). Begin torque
sequence in the middle of head cover and torque
bolts moving outward in a crisscross pattern from top
to bottom.
(4) Install ignition coil on plug, and torque fasten-
ers to 12 N´m (105 in. lbs)
(5) Connect, ignition coil electrical connectors.
(6) Install PCV hose.
(7) Connect battery negative cable.
Fig. 4 CYLINDER HEAD TIGHTENING SEQUENCE
DRENGINE - 5.7L 9 - 201
CYLINDER HEAD (Continued)

(15) Remove timing chain(Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(16) Remove camshaft tensioner/thrust plate
assembly.
NOTE: Identify tappets to ensure installation in orig-
inal location.
(17) Remove the retainer assembly and tappets.
(18) Install a long bolt into front of camshaft to aid
in removal of the camshaft. Remove camshaft, being
careful not to damage cam bearings with the cam
lobes.
INSPECTION
(1) The cam bearings are not serviceable. Do not
attempt to replace cam bearings for any reason.
INSTALLATION
INSTALLATION - CAMSHAFT CORE HOLE PLUG
CAUTION: The new core hole plug must be installed
to the proper depth or camshaft damage could
develope. The plug must be installed squarely in
the bore.
(1) Install a new core hole plug at the rear of cam-
shaft, using special tool # 9048. Clean plug and apply
mopartlock and seal adhesive to the edge of the
plug, before installing. The plug must be installed to
a depth of+/-0.25mm from the end of the machined
bevel, that is the end of the bevel that is closest to
the cam bearing.
INSTALLATION - CAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft
(2) Install camshaft Tensioner plate assembly.
Tighten bolts to 28 N´m (250 in. lbs.) torque.
(3) Install timing chain and sprockets(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION) .
(4) Measure camshaft end play(Refer to 9 -
ENGINE - SPECIFICATIONS). If not within limits
install a new thrust plate.
(5) Install the oil pump(Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(6) Install the oil pick up tube.
(7) 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.(8) Install the tappets and retainer assembly(Refer
to 9 - ENGINE/ENGINE BLOCK/HYDRAULIC LIFT-
ERS (CAM IN BLOCK) - INSTALLATION).
(9) Install both left and right cylinder heads(Refer
to 9 - ENGINE/CYLINDER HEAD - INSTALLA-
TION) .
(10) Install pushrods
(11) Install rocker arms(Refer to 9 - ENGINE/CYL-
INDER HEAD/ROCKER ARM / ADJUSTER ASSY -
INSTALLATION).
(12) Install timing case cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(13) Install the oil pan(Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(14) Install cylinder head covers(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(15) Install intake manifold(Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSTALLA-
TION).
(16) Install the A/C compressor, and set aside
(17) Install the generator.
(18) Install the accessory drive belt.
(19) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
(20) Install the air cleaner assembly.
(21) Install the battery negative cable.
(22) Refill coolant.
(23) Refill engine oil.
(24) Start engine and check for leaks.
CRANKSHAFT
REMOVAL
(1) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(2) Remove the oil pan(Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(3) Remove the oil pump pickup.
(4) Remove the windage tray/oil pan gasket.
(5) Remove the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(6) Remove the oil pump(Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - REMOVAL).
(7) Remove the timing drive(Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(8) Identify rod bearing caps before removal.
Remove rod bearing caps with bearings.
(9) Identify main bearing caps before removal.
Remove main bearing caps and bearings one at a
time.
9 - 206 ENGINE - 5.7LDR
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

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)

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