Page 1329 of 2889

(6) Remove the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).
(7) Remove the A/C compressor with the lines
attached (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
REMOVAL). Set aside.
(8) If equipped, remove the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - REMOVAL).
(9) Remove the washer fluid reservoir bottle (Refer
to 8 - ELECTRICAL/WIPERS/WASHERS -
REMOVAL AND INSTALLATION).
(10) Disconnect the top radiator hose.
(11) Remove the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - REMOVAL).
(12) Remove the fan shroud.
(13) Disconnect the lower radiator hose.
(14) Disconnect the transmission cooler lines.
(15) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(16) Remove the generator with the wire connec-
tions (Refer to 8 - ELECTRICAL/CHARGING/GEN-
ERATOR - REMOVAL).
(17) Remove the air cleaner.
(18) Disconnect the throttle linkage.
(19) Remove throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(20) Remove the upper intake manifold (Refer to 9
- ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(21) Remove the coil assemblies with the ignition
cables.
(22) Disconnect the heater hoses.
(23) Disconnect the power steering hoses, if
equipped.
(24) Perform the Fuel System Pressure release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE). Disconnect
the fuel line (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(25) On Manual Transmission vehicles, remove the
shift lever.
(26) Raise and support the vehicle on a hoist.
(27) Remove the drain plug and drain the engine
oil.
(28) Loosen front engine mount thru-bolt nuts.
(29) Remove the transmission cooler line brackets
from oil pan.
(30) Disconnect exhaust pipe at manifold.
(31) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
(32) Remove transmission.(33) Lower vehicle.
CAUTION: DO NOT lift the engine by the intake
manifold.
(34) Install an engine lifting fixture.
(35) Remove engine from vehicle and install
engine assembly on a repair stand.
INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment. Position the thru-
bolt into the support cushion brackets.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4) Install Transmission.
(5) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(6) Install exhaust pipe to manifold.
(7) Install the transmission cooler line brackets
from oil pan.
(8) Tighten the Front mount thru-bolts and nuts to
102N´m (75 ft. lbs.).
(9) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(10) Prime oil pump by squirting oil in the oil fil-
ter mounting hole and filling the J-trap of the front
timing cover. When oil is running out, install oil filter
that has been filled with oil.
(11) Lower the vehicle.
(12) Remove engine lifting fixture.
(13) On Manual Transmission vehicles, install the
shift lever.
(14) Connect the fuel lines (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(15) Connect the heater hoses.
(16) Install the upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(17) Install the coil assemblies with the ignition
cables.
(18) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(19) Connect the throttle linkage.
(20) Install the air cleaner box.
(21) Install the generator and wire connections
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION).
(22) Install the upper crossmember.
(23) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(24) Connect the lower radiator hose.
9 - 182 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)
Page 1330 of 2889

(25) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
(26) Connect the transmission cooler lines.
(27) Connect the power steering hoses, if equipped.
(28) Install the fan shroud.
(29) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(30) Connect the top radiator hose.
(31) Install the washer fluid reservoir bottle (Refer
to 8 - ELECTRICAL/WIPERS/WASHERS - INSTAL-
LATION).
(32) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - INSTALLATION).
(33) Install the A/C compressor with the lines
attached (Refer to 24 - HEATING & AIR CONDI-TIONING/PLUMBING/A/C COMPRESSOR -
INSTALLATION).
(34) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(35) Evacuate (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE) and charge the air conditioning system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(36) Add coolant to the cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(37) Install the battery.
(38) Warm engine and adjust as required.
(39) Road test vehicle.
BR/BEENGINE 8.0L 9 - 183
ENGINE 8.0L (Continued)
Page 1331 of 2889

SPECIFICATIONS
8.OL ENGINE
DESCRIPTION SPECIFICATION
CAMSHAFT
Bearing Diameter
No. 1 53.16 ± 53.19 mm
(2.093 ± 2.094 in.)
No. 2 52.76 ± 52.78 mm
(2.077 ± 2.078 in.)
No. 3 52.35 ± 52.37 mm
No. 4 51.94 ± 51.97 mm
(2.045 ± 2.046 in.)
No. 5 51.54 ± 51.56 mm
(2.029 ± 2.030 in.)
No. 6 48.74 ± 48.77 mm
(1.919 ± 1.920 in.)
Bearing Journal Diameter
No. 1 53.11 ± 53.14 mm
(2.091 ± 2.092 in.)
No. 2 52.69 ± 52.72 mm
(2.0745 ± 2.0755 in.)
No. 3 52.30 ± 52.32 mm
(2.059 ± 2.060 in.)
No. 4 51.89 ± 51.92 mm
(2.043 ± 2.044 in.)
No. 5 51.49 ± 51.51 mm
(2.027 ± 2.028 in.)
No. 6 48.69 ± 48.72 mm
(1.917 ± 1.918 in.)
Bearing to Journal
Clearance
No. 1,3,4,5,6 0.0254 ± 0.0762 mm
(0.001 ± 0.003 in.)
No. 2 0.0381 ± 0.0889 mm
(0.0005 ± 0.0035 in.)
Service Limit 0.127 mm (0.005 in.)
End Play 0.127 ± 0.381 mm
(0.005 ± 0.015 in.)
DESCRIPTION SPECIFICATION
CONNECTING RODS
Piston Pin bore Diameter 24.940 ± 24.978 mm
(0.9819 ± 0.9834 in.)
Side Clearance 0.25 ± 0.46 mm
(0.010 ± 0.018 in.)
Total Weight (Less
Bearing)744 gms. (26.24 oz.)
CRANKSHAFT
Rod Journal Diameter 53.950 ± 53.975 mm
(2.124 ± 2.125 in.)
Out of Round (Max.) 0.0254 mm (0.001 in.)
Taper (Max.) 0.0254 mm (0.001 in.)
Bearing Clearance 0.005 ± 0.074 mm
(0.0002 ± 0.0029 in.)
Service Limit 0.0762 mm (0.003 in.)
Main Bearing Journal
Diameter76.187 ± 76.213 mm
(2.8995 ± 3.0005 in.)
Out of Round (Max.) 0.0254 mm (0.001 in.)
Taper (Max.) 0.0254 mm (0.001 in.)
Bearing Clearance 0.0051 ± 0.058 mm
(0.0002 ± 0.0023 in.)
Service Limit 0.071 mm (0.0028 in.)
End Play 0.076 ± 0.305 mm
(0.003 ± 0.012 in.)
Service LimitÐEnd Play 0.381 mm (0.015 in.)
CYLINDER BLOCK
Cylinder Bore Diameter 101.60 ± 101.65 mm
(4.0003 ± 4.0008 in.)
Out of Round (Max.) 0.0762 mm (0.003 in.)
Taper (Max.) 0.127 mm (0.005 in.)
Lifter Bore Diameter 22.982 ± 23.010 mm
(0.9048 ± 0.9059 in.)
9 - 184 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)
Page 1332 of 2889

DESCRIPTION SPECIFICATION
CYLINDER HEAD AND VALVES
Valve Seat Angle 44.5É
Runout (Max.) 0.0762 mm (0.003 in.)
Width (Finish) ± Intake 1.016 ± 1.524 mm
(0.040 ± 0.060 in.)
Valve Face Angle 45É
Valve Head Diameter
Intake 48.640 ± 48.900 mm
(1.915 ± 1.925 in.)
Exhaust 41.123 ± 41.377 mm
(1.619 ± 1.629 in.)
Overall Length
Intake 145.19 ± 145.82 mm
(5.716 ± 5.741 in.)
Exhaust 145.54 ± 146.18 mm
(5.730 ± 5.755 in.)
Lift (@ zero lash)
Intake 9.91 mm (0.390 in.)
Exhaust 10.34 mm (0.407 in.)
Stem Diameter 7.900 ± 7.920 mm
(0.311 ± 0.312 in.)
Guide Bore 9.500 ± 9.525 mm
(0.374 ± 0.375 on.)
Stem to Guide Clearance 0.025 ± 0.076 mm
(0.001 ± 0..003 in.)
Service Limit 0.4318 (0.017 in.)
Valve Spring Free Length 49.962 mm (1.967 in.)
Spring Tension
Valve Closed 378 N @ 41.66 mm
(85 lbs. @ 1.64 in.)
Valve Open 890 N @ 30.89 mm
(200 lbs. @ 1.212 in.)
Number of Coils 6.8
Installed Height 41.66 mm (1.64 in.)
Wire Diameter 4.50 mm (0.177 in.)DESCRIPTION SPECIFICATION
HYDRAULIC TAPPETS
Body Diameter 22.949 ± 22.962 mm
(0.9035 ± 0.9040 in.)
Clearance (to bore) 0.0203 ± 0.0610 mm
(0.0008 ± 0.0024 in.)
Dry Lash 1.524 ± 5.334 mm
(0.060 ± 0.210 in.)
Push Rod Length 195.52 ± 196.02 mm
(7.698 ± 7.717 in.)
OIL PRESSURE
Curb Idle (Min.*) 83 kPa (12 psi)
@ 3000 rpm 345 ± 414 kPa (50 ± 60
psi)
* If oil pressure is zero at curb idle, DO NOT RUN
ENGINE.
OIL PUMP
Clearance over Rotors
(Max.)0.1906 mm (0.0075 in.)
Cover Out of Flat (Max.) 0.051 mm (0.002 in.)
Inner Rotor Thickness
(Min.)14.925 ± 14.950 mm
(0.5876 ± 0.5886 in.)
Outer Rotor
Clearance (Max.) 0.1626 mm (0.006 in.)
Diameter (Min.) 82.461 mm (3.246 in.)
Thickness (Min.) 14.925 mm (0.5876 in.)
Tip Clearance between
Rotors
(Max.) 0.584 mm (0.0230 in.)
PISTONS
Clearance at Top of Skirt 0.013 ± 0.038 mm
(0.0005 ± 0.0015 in.)
Piston Length 82.5 mm (3.25 in.)
Piston Ring Groove
Depth
#1&2 91.30 ± 91.55 mm
(3.594 ± 3.604 in.)
#3 92.90 ± 93.15 mm
(3.657 ± 3.667 in.)
BR/BEENGINE 8.0L 9 - 185
ENGINE 8.0L (Continued)
Page 1333 of 2889

DESCRIPTION SPECIFICATION
Weight 463 ± 473 grams (16.33
± 16.68 oz.)
Piston to Bore Clearance 0.013 ± 0.038 mm
(0.0005 ± 0.0015 in.)
Service Limit 0.0762 mm (0.003 in.)
PISTON PINS
Clearance in Piston 0.010 ± 0.020 mm
(0.0004 ± 0.0008 in.)
Diameter 24.996 ± 25.001 mm
(0.9841 ± 0.9843 in.)
End Play NONE
Length 67.8 ± 68.3 mm
(2.67 ± 2.69 in.)
PISTON RINGS
Ring Gap
Compression Rings 0.254 ± 0.508 mm
(0.010 ± 0.020 in.)
Oil Control (Steel Rails) 0.381 ± 1.397 mm
(0.015 ± 0.055 in.)
Ring Side Clearance
Compression Rings 0.074 ± 0.097 mm
(0.0029 ± 0.0038 in.)
Oil Ring (Steel Rails) 2.591 ± 2.743 mm
(0.102 ± 0.108 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) 25É
Opens (BBDC) 60É
Duration 265É
Intake Valve
Closes (ATDC) 61É
Opens (BBDC) 6É
Duration 246É
Valve Overlap 31ÉCRANKSHAFT JOURNAL MARKING
LOCATION
MEASURE-
MENTITEM IDENTIFI-
CATIONLOCATION
OF
IDENTIFI-
CATION
0.0254 mm
(0.001 in.)
U/SCrankshaft
JournalsRorM
M-2-3 ect.
(indicating
No. 2 and
3 main
bearing
journal)
and/or
R-1-4 ect.
(indicating
No. 1 and
4
connecting
rod
journal)Milled flat
on No. 8
crankshaft
counter-
weight.
0.508 mm
(0.020 in.)
O/SCylinder
BoresA Following
engine
serial
number.
0.2032 mm
(0.008 in.)
O/SHydraulic
TappetsLDiamond-
shaped
stamp top
pad - front
of engine
and flat
ground on
outside
surface of
each O/S
tappet
bore.
0.127 mm
(0.005 in.)Valve
StemsX Milled pad
adjacent to
two tapped
holes 3/89
on each
end of
cylinder
head.
9 - 186 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)
Page 1334 of 2889

TORQUE
TORQUE CHART 8.0L ENGINE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft SprocketÐBolt 75 55 Ð
Camshaft Thrust PlateÐ
Bolts22 16 Ð
Coil Pack BracketÐBolts 21 Ð 190
Connecting Rod CapÐBolts 61 45 Ð
Main BearingÐBolts
Step 1 27 20 Ð
Step 2 115 85 Ð
Crankshaft Pulley/DamperÐ
Bolt312 230 Ð
Crankshaft Rear Seal
RetainerÐ22 16 Ð
Bolts
Cylinder HeadÐBolts
Step 1 58 43 Ð
Step 2 143 105 Ð
Cylinder Head CoverÐBolts 16 Ð 144
Drive Plate to CrankshaftÐ
Bolts75 55 Ð
Drive Plate to Torque
ConverterÐ47 35 Ð
Bolts
EGR TubeÐNut 34 25 Ð
EGR ValveÐBolts 20 Ð 174
Engine Support Bracket/
InsulatorÐ68 50 Ð
Through Bolt
Engine Support Bracket/
Insulator to47 35 Ð
BlockÐBolts
Exhaust Manifold to Cylinder
HeadÐ22 16 Ð
Bolt
Generator MountingÐBolt 41 30 Ð
Generator to Intake Manifold
Bracket41 30 Ð
ÐBolts
Heat ShieldÐNuts 20 Ð 175
Hydraulic Tappet Yoke
Retaining22 16 Ð
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
SpiderÐBolts
Intake Manifold (Lower)Ð
Bolts54 40 Ð
Intake Manifold (Upper)Ð
Bolts22 16 Ð
Oil Filter 9 Ð 80 +
45É
Oil Filter Connector 46 34 Ð
Oil Pan
Ð1/4 - 20 Bolts 11 Ð 96
Ð5/16 - 18 Bolts 16 Ð 144
ÐStud Bolts 16 Ð 144
ÐDrain Plug 34 25 Ð
Oil Pan Pick Up TubeÐBolts 16 Ð 144
Oil Pump AttachingÐBolts 41 30 Ð
Oil Pump CoverÐBolts 14 Ð 125
Oil Pump Pressure
ReliefÐPlug20 15 Ð
Rocker ArmÐBolts 28 21 Ð
Spark Plugs 41 30 Ð
Starter MountingÐBolts 68 50 Ð
Timing Chain CoverÐBolts 47 35 Ð
Thermostat HousingÐBolts 25 Ð 220
Throttle BodyÐNuts 11 Ð 96
Transfer Case to Insulator
Mounting204 150 Ð
PlateÐNuts
Transmission Support
BracketÐ102 75 Ð
Bolts
Transmission Support
CushionÐ47 35 Ð
Bolts
Transmission Support
Cushion47 35 Ð
StudÐNuts
Water Pump to Chain Case
CoverÐ41 30 Ð
Bolts
BR/BEENGINE 8.0L 9 - 187
ENGINE 8.0L (Continued)
Page 1335 of 2889
SPECIAL TOOLS
8.0L ENGINE
Valve Compressor Adapting Stud Tool 6715
Valve Spring Compressor Adapter Tool 6716A
Valve Spring Compressor Tool MD-998772A
Valve Spring Compressor Screw Tool 6756
Black Valve Guide Sleeve Tool C6819
Silver Valve Guide Sleeve Tool C6818
Dial Indicator Tool C3339
Crankshaft Pulley/Damper Installer Tool C3688
Crankshaft Sprocket Puller Tool 6444
Crankshaft Sprocket Puller Jaws Tool 6820
9 - 188 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)
Page 1336 of 2889
Crankshaft Sprocket Installer Tool 3718
Crankshaft Sprocket Installer Tool MD990799
Front Oil Seal Installer Tool 6806
Front Oil Seal Installer Tool 6761
Camshaft Bearing Installer Tool C3132A
Compression Ring Installer Tool C4184
Piston Ring Compressor Tool C385
Seal Installer Tool 6687
Crankshaft Main Bearing Remover/Installer Tool
C3059
Puller 1026
BR/BEENGINE 8.0L 9 - 189
ENGINE 8.0L (Continued)