2003 DODGE RAM app

MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtGASKET SEALANT
MopartGasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This mate-
rial is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will pre-
vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier than using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Perform the Fuel Pressure Release Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(7) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N´m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil. (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery.
(16) Start the engine and check for any leaks.
REMOVAL
(1) Remove the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
DRENGINE 8.0L 9 - 361
ENGINE 8.0L (Continued)

DESCRIPTION N´m Ft. In.
Heat ShieldÐNuts 20 Ð 175
Hydraulic Tappet Yoke
Retaining22 16 Ð
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 54 40 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
Bolts8.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
(2.061 ± 2.062 in.)
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.)
9 - 364 ENGINE 8.0LDR
ENGINE 8.0L (Continued)

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 mmDESCRIPTION SPECIFICATION
(3.657 ± 3.667 in.)
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 31É
9 - 366 ENGINE 8.0LDR
ENGINE 8.0L (Continued)

CRANKSHAFT 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.
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
DRENGINE 8.0L 9 - 367
ENGINE 8.0L (Continued)

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 negative cable from the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the heat shields (Fig. 7).
(4) Remove the intake manifold-to-generator
bracket support rod. Remove the generator (Refer to
8 - ELECTRICAL/CHARGING/GENERATOR -
REMOVAL).
(5) Remove closed crankcase ventilation system.
(6) Disconnect the evaporation control system.
(7) Remove the air cleaner.
(8) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
Fig. 6 Cylinder Head Assembly
1 - SPARK PLUG
2 - INTAKE VALVES
3 - SPARK PLUG
4 - INTAKE VALVES
5 - SPARK PLUG
6 - SPARK PLUG
7 - INTAKE VALVE
8 - SPARK PLUG
9 - EXHAUST VALVE
10 - EXHAUST VALVES
11 - EXHAUST VALVES
Fig. 7 Spark Plug Wire Heat Shields (Left Side
Shown)
1 - EXHAUST MANIFOLD
2 - HEAT SHIELD
DRENGINE 8.0L 9 - 371
CYLINDER HEAD (Continued)

REMOVAL
REMOVALÐVALVE STEM SEALS
NOTE: This procedure is done with the cylinder
head installed.
(1) Disconnect the negative cable from the battery.
(2) Set engine basic timing to Top Dead Center
(TDC) and remove air cleaner.
(3) Remove cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL) and spark plugs (Refer to 8
- ELECTRICAL/IGNITION CONTROL/SPARK
PLUG - REMOVAL).
(4) Using suitable socket and flex handle at crank-
shaft retaining bolt, turn engine so that the piston of
the cylinder to be worked on, is at TDC on the com-
pression stroke.
(5) Remove rocker arms (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARM / ADJUSTER
ASSY - REMOVAL).
(6) With air hose attached to an adapter installed
in the spark plug hole, apply 620-689 kPa (90-100
psi) air pressure.
(7) Using Valve Spring Compressor Tool
MD-998772A with adapter 6716A (Fig. 19), compress
valve spring and remove retainer valve locks and
valve spring.
(8) Remove the valve stem seal.
REMOVALÐVALVES AND VALVE SPRINGS
(1) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(2) Special studs must be used to adapt the Valve
Spring Compressor Tool to the V-10 cylinder head
(Fig. 20). Install the metric end into the Special Tool
MD998772A and the 5/16 end into the cylinder head.
Fig. 18 Testing Valve Spring for Compressed
1 - TORQUE WRENCH
2 - VALVE SPRING TESTER
Fig. 19 Valve Spring Compressor MD-998772A with
Adaptor 6716-A and Screw 6765
1 - SPECIAL TOOL MD 998772A
2 - SPECIAL TOOL 6765
3 - SPECIAL TOOL 6716A
4 - AIR HOSE
Fig. 20 Special Studs 6715 for V-10 Engine
1 - SPECIAL TOOL 6715
DRENGINE 8.0L 9 - 377
INTAKE/EXHAUST VALVES & SEATS (Continued)

(8) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.For the
left side the number tab is at the front of
engine with the number up. For the right side
the number tab is at the rear of engine with the
number up.
CAUTION: The cylinder head cover fasteners have a
special plating. DO NOT use alternative fasteners.
(9) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION) (Fig. 24).
(10) Install closed crankcase ventilation system.
(11) Connect the evaporation control system.
(12) Install air cleaner.
(13) Connect the negative cable to the battery.
(14) Road test vehicle and check for leaks.
INSTALLATIONÐVALVES AND VALVE SPRINGS
(1) Clean valves thoroughly. Discard burned,
warped and cracked valves.(2) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(3) Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve.
(4) Make sure there are no burrs on valve stems.
(5) Coat valve stems with lubrication oil. Insert
valves into valve guides in cylinder head.
(6) Install new seals on all valve guides(BLACK
on intake and BROWN on exhaust). Install valve
springs and valve retainers.
(7) Compress valve springs with Valve Spring
Compressor Tool MD-998772A and adapter 6716A,
install locks and release tool. Tap the retainer with a
brass or heavy plastic hammer to ensure locks have
been seated.
(8) If valves and/or seats were ground, measure
the installed height of springs. Make sure the mea-
surement is taken from bottom of spring seat in cyl-
inder head to the bottom surface of spring retainer. If
spacers are installed, measure from the top of spacer.
If height is greater than 42.86 mm (1-11/16 inches),
install a 1.587 mm (1/16 inch) spacer in head coun-
terbore. Ensure this brings spring height back to nor-
mal, 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
(9) Install the cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
ROCKER ARM / ADJUSTER
ASSY
REMOVAL
(1) Disconnect spark plug wires by pulling the boot
straight out in line with plug.
(2) Remove cylinder head cover and gasket (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - REMOVAL).
(3) Remove the rocker arm bolts and the rocker
arm assembly (Fig. 25). Place rocker arm assemblies
on a bench in the same order as removed.
(4) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
Fig. 24 Cylinder Head Covers
1 - CYLINDER HEAD COVER
2 - CYLINDER HEAD COVER GASKET
DRENGINE 8.0L 9 - 379
INTAKE/EXHAUST VALVES & SEATS (Continued)

(1) Install the push rods in the same order as
removed.
(2) Install rocker arm assemblies in the same
order as removed. Tighten the rocker arm bolts to 53
N´m (40 ft. lbs.) torque.
(3) Install cylinder head cover and gasket (Refer to
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(4) Connect spark plug wires.
ENGINE BLOCK
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool,
Special tool 6879 or equivalent. The cylinder block
should be bored and honed with new pistons and
rings fitted if:
²The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
²The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
²The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coor-
dinated with the fitting of pistons and rings so spec-
ified clearances may be maintained.
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS
This procedure requires that the engine is removed
from the vehicle.
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
NOTE: It is not advisable to attempt to replace cam-
shaft bearings unless special removal and installa-
tion tools are available, such as recommended tool
8544 Camshaft Bushing Remover Installer.
(2) Using recommended tool 8544 Camshaft Bush-
ing Remover Installer, Drive out bearing shells.
REMOVALÐCAMSHAFT
(1) Remove rocker arms and push rods (Refer to 9
- ENGINE/CYLINDER HEAD/ROCKER ARM /
ADJUSTER ASSY - REMOVAL). Identify each part
so it can be installed in its original location.
NOTE: The 4 corner tappets can not be removed
without removing the cylinder heads and gaskets.
However, they can be lifted and retained for cam-
shaft removal.
(2) Remove the Bolts retaining the yoke retaining
spider. Remove the yoke retaining spider, tappet
aligning yokes and tappets.
(3) Remove upper and lower intake manifolds
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - REMOVAL).
(4) Remove timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL) and timing chain and
sprockets (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT/CHAIN AND SPROCKETS -
REMOVAL).
Fig. 25 Rocker Arm - Typical
1 - ROCKER ARMS
2 - ROCKER ARM PEDESTALS
3 - RETAINER
9 - 380 ENGINE 8.0LDR
ROCKER ARM / ADJUSTER ASSY (Continued)