2003 DODGE RAM engine

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil. (Refer to 9 - ENGINE/
LUBRICATION/OIL - STANDARD
PROCEDURE)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. (Refer to 9 -
ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) for
engine oil pressure test/specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic tappets/
lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats or
valve faces9. Grind valves and seats
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level.
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. (Refer to 9 -
ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) engine
oil pressure test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
(Refer to 9 - ENGINE/LUBRICATION/
OIL - STANDARD PROCEDURE) for
correct procedure/engine oil
specifications
4. Excessive connecting rod bearing
clearance4. Measure bearings for correct
clearance with plasti-gage. Repair as
necessary
5. Connecting rod journal out of
round5. Replace crankshaft or grind
journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level.
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. (Refer to 9 -
ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING)
3. Thin or diluted oil 3. Change oil to correct viscosity.
9 - 184 ENGINE - 5.7LDR
ENGINE - 5.7L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
4. Excessive main bearing clearance 4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing for
excessive wear on flanges
6. Crankshaft main journal out of
round or worn6. Grind journals or replace crankshaft
7. Loose flywheel or torque converter 7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace oil pump assembly.
5. Thin or diluted oil 5. Change oil to correct viscosity.
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean and
reinstall
8. Oil pickup tube loose, broken, bent
or clogged8. Inspect oil pickup tube and pump,
and clean or replace if necessary
9. Oil pump cover warped or cracked 9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated gaskets 1. Replace gasket
2. Loose fastener, broken or porous
metal part2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking3. Replace seal
4. Leaking oil gallery plug or cup plug 4. Remove and reseal threaded plug.
Replace cup style plug
EXCESSIVE OIL CONSUMPTION OR
SPARK PLUGS OIL FOULED1. CCV System malfunction 1. (Refer to 25 - EMISSIONS
CONTROL/EVAPORATIVE
EMISSIONS - DESCRIPTION) for
correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
DRENGINE - 5.7L 9 - 185
ENGINE - 5.7L (Continued)

STANDARD PROCEDURE
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) Disconnect the battery negative cable.
(2) Remove the air cleaner resonator and duct
work as an assembly.
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Remove the viscous fan/drive (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(6) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(7) Remove the upper crossmember and top core
support.
NOTE: It is not necessary to drain A/C system for
engine removal.
(8) Remove the A/C compressor with the lines
attached. Secure compressor out of the way.
(9) Remove generator assembly (Refer to 8 -
ELECTRICAL/CHARGING/GENERATOR - REMOV-
AL).
(10) Perform the Fuel System Pressure Release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).
(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) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(18) Disconnect exhaust pipe at manifolds.
(19) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
9 - 186 ENGINE - 5.7LDR
ENGINE - 5.7L (Continued)

(20) Remove the structural dust cover and trans-
mission inspection cover,(Refer to 9 - ENGINE/EN-
GINE BLOCK/STRUCTURAL COVER - REMOVAL).
(21) Remove drive plate to converter bolts (Auto-
matic transmission equipped vehicles).
(22) Remove transmission bell housing to engine
block bolts.
(23) Lower the vehicle.
(24) Install engine lift fixture, special tool # 8984.
(25) 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.
(31) Install the air cleaner resonator and duct
work..
(32) Add engine oil to crankcase (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES - SPEC-
IFICATIONS).
(33) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(34) Connect battery negative cable.
(35) Start engine and inspect for leaks.
(36) Road test vehicle.
DRENGINE - 5.7L 9 - 187
ENGINE - 5.7L (Continued)

SPECIFICATIONS
5.7L ENGINE
DESCRIPTION SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type 90É V-8 OHV
Bore and Stroke 99.5 x 90.9 mm
(3.91 x 3.58 in.)
Displacement 5.7L (345 c.i.)
Compression Ratio 9.6:1
Firing Order 1±8±4±3±6±5±7±2
Lubrication Pressure Feed ± Full
Flow
Filtration
Cooling System Liquid Cooled ± Forced
Circulation
Cylinder Block Cast Iron
Cylinder Head Aluminum
Crankshaft Nodular Iron
Camshaft Hollow assembled
camshaft
Pistons Aluminum Alloy w/strut
Connecting Rods Powdered metal
CAMSHAFT
Bearing Journal Diameter
No. 1 58.2 mm
(2.29 in.)
No. 2 57.8 mm
(2.27 in.)
No. 3 57.4 mm
(2.26 in.)
No. 4 57.0 mm
(2.24 in.)
No. 5 43.633 mm
(1.72 in.)
DESCRIPTION SPECIFICATION
Bearing to Journal
Clearance Standard
No. 1 0.040 ± 0.080 mm
(.0015 ± .003 in.)
No. 2 0.050 ± 0.090 mm
(0.0019 ± .0035 in.)
No. 3 0.040 ± 0.080 mm
(.0015 ± .003 in.)
No. 4 0.050 ± 0.090 mm
(0.0019 ± .0035 in.)
No. 5 0.040 ± 0.080 mm
(.0015 ± .003 in.)
Camshaft End Play 0.080 - 0.290 mm
(0.0031 - 0.0114 in.)
CONNECTING RODS
Piston Pin bore Diameter 23.955 ± 23.975 mm
(0.9431 ± 0.9438 in.)
Side Clearance 0.10 - 0.35mm
( 0.003 - 0.0137 in.)
CRANKSHAFT
Rod Journal
Diameter 53.992 ± 54.008 mm
(2.125 ± 2.126 in.)
Out of Round (Max.) 0.005 mm (0.0002 in.)
Taper (Max.) 0.003 mm ( 0.0001 in.)
Bearing Clearance 0.020 ± 0.060 mm
(0.0007 ± 0.0023 in.)
Main Bearing Journal
Diameter 64.988 ± 65.012 mm
(2.5585 ± 2.5595 in.)
Out of Round (Max.) 0.005 mm (0.0002 in.)
Taper (Max.) 0.003 mm (0.0001 in.)
Bearing Clearance
0.023 ± 0.051mm
(0.0009 ± 0.002 in.)
Crankshaft End Play 0.052 ± 0.282 mm
(0.002 ± 0.011 in.)
Service Limit 0.282 mm ( 0.011 in.)
9 - 188 ENGINE - 5.7LDR
ENGINE - 5.7L (Continued)

DESCRIPTION SPECIFICATION
CYLINDER BLOCK
Cylinder Bore
Diameter 99.50 ± mm
(3.917 ± in.)
Out of Round (Max.) 0.00762 ± mm
.0003 ( in.)
Taper (Max.) 0.0127 ± mm
0005 ( in.)
Lifter Bore
Diameter 21.45 ± 21.425 mm
(0.8444 ± 0.8435 in.)
CYLINDER HEAD AND VALVES
Valve Seat
Angle 44.50É ± 45.00É
Runout (Max.) 0.05 mm (0.0019 in.)
Width (Finish)
Intake 1.018 ± 1.62 mm
(0.0464 ± 0.0637 in.)
Exhaust 1.48 ± 1.92 mm
(0.0582 ± 0.0755 in.)
Valves
Face Angle 45.0É ± 45.5É
Head Diameter
Intake 50.67 mm ± 50.93 mm
(1.99 in.) ± (2.00 in.)
Exhaust 39.27mm ± 39.53mm
(1.54 in.) ± (1.55 in.)
Length (Overall)
Intake 123.38 ± 123.76 mm
(4.857 in. ± 4.872 in.)
Exhaust 120.475 ± 120.855 mm
(4.743 in. ± 4.758 in.)
Valve Lift (@ zero lash)
Intake 12 mm (0.472 in.)
Exhaust 11.7 mm (0.460 in.)
Stem Diameter
Intake 7.935 - 7.953 mm
(0.312 - 0.313 in.)DESCRIPTION SPECIFICATION
Exhaust 7.905 - 7.925 mm
(0.311 - 0.312 in.)
Guide Bore 7.975 - 8.000 mm
(0.313 - 0.314 on.)
Stem to Guide Clearance
Intake 0.022 - 0.065 mm
(0.0008 - 0.0025 in.)
Exhaust 0.050 - 0.095 mm
(0.0019 - 0.0037 in.)
Valve Springs
Spring Tension
Valve closed 422 N @ 46.0 mm
(95 lbs. @ 1.81 in.)
Valve open @ 33.5 mm
Number of Coils 7.4
Installed Height 46.0 mm (1.81 in.)
Wire Diameter 5.39 x 4.52mm
(0.212 ± 0.177in.)
HYDRAULIC TAPPETS
Body Diameter 21.387 - 21.405 mm
(0.8420 - 0.8427 in.)
Clearance (to bore) 0.020 - 0.063 mm
(0.0007 - 0.0024 in.)
Dry Lash 3.0 mm (at the valve)
(0.1181 in.)
OIL PRESSURE
Curb Idle (Min.*) 25 kPa ( 4 psi)
@ 3000 rpm 170-758 kPa ( 25-110
psi)
* If oil pressure is zero at curb idle, DO NOT RUN
ENGINE.
OIL PUMP
Clearance over Rotors
(Max.).095 mm ( 0.0038 in.)
Outer Rotor to pump
body
DRENGINE - 5.7L 9 - 189
ENGINE - 5.7L (Continued)

DESCRIPTION SPECIFICATION
Clearance (Max.) 0.235 mm ( 0.009 in.)
Tip Clearance between
Rotors (Max.) .150 mm (0.006 in.)
PISTONS
Clearance at Top of Skirt
measured at 45.0 mm
(1.77 in.) below deck0.0215 - 0.0485 mm
(0.0008 - 0.0019 in.)
Land Clearance (Diam.)
Groove #1 0.6715 - 0.7105 mm
(0.0264 - 0.0279 in.)
Groove #2 .5455 - .6245
(0.0214 - 0.0245 in.)
Piston Length 54.70 ± 55.30mm
(2.153 ± 2.177 in.)
Piston Ring Groove
Width
Groove #1 1.51 - 1.54 mm
(0.0594 - 0.0606 in.)
Groove #2 1.51 - 1.53 mm
(0.0594 - 0.0602 in.)
Groove #3 3.030 - 3.055 mm
(0.1192 - 0.1202 in.)
Weight 413 grams
(14.56 oz.)
PISTON PINS
Clearance in Piston 0.009 - 0.018 mm
(0.00035 - 0.00070 in.)
Diameter 24.0 - 24.003 mm
(0.9448 - 0.9449 in.)
Length 69.75 - 70.25 mm
(2.74 - 2.76 in.)
PISTON RINGS
Ring Gap
Compression Ring (Top) 0.23 - 0.38 mm
(0.0090 - 0.0149 in.)DESCRIPTION SPECIFICATION
Compression Ring (2nd) 0.35 - 0.60 mm
(0.0137 - 0.0236 in.)
Oil Control (Steel Rails) 0.15 - 0.66 mm
(0.0059 - 0.0259 in.)
Ring Side Clearance
Compression Rings
Top 0.02 - 0.068 mm
(0.0007 - 0.0026 in.)
2nd 0.02 - 0.058 mm
(0.0007 - 0.0022 in.)
Ring Width
Compression rings 1.472 - 1.490 mm
(0.05795 - 0.0586 in.)
Oil Ring (Steel Rails) &
Max.0.447 - 0.473 mm
(0.0175 - 0.0186 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) 27É
Opens (BTDC) 233É
Intake Valve
Closes (ATDC) 253É
Opens (BTDC) 7É
Valve Overlap 34É
9 - 190 ENGINE - 5.7LDR
ENGINE - 5.7L (Continued)

TORQUE
TORQUE CHART 5.7L ENGINE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Block Pipe Plugs
(1/4 NPT)20 Ð 177
(3/8 NPT) 27 Ð 240
Camshaft SprocketÐBolt 122 90 Ð
Camshaft Tensioner
PlateÐBolts28 Ð 250
Timing Chain Case CoverÐ
Bolts28 Ð 250
Lifting Stud 55 40 Ð
Connecting Rod CapÐBolts 21
plus
90É
Turn15
plus
90É
TurnÐ
Main Bearing CapÐBolts
M-1227
plus
90É
TurnÐÐ
Crossbolts
M-828 Ð Ð
Cylinder HeadÐBolts
M-12 Bolts
Step 1 34 25 Ð
Step 2 54 40 Ð
Step 3 Turn
90ÉTurn
90ÉÐ
M-8 Bolts Ð
Step 1 20 15 Ð
Step 2 34 25 Ð
Cylinder Head CoverÐBolts 8 Ð 70
Exhaust Manifold to Cylinder
Head25 Ð 220
FlywheelÐBolts 95 70 Ð
Front InsulatorÐThrough
bolt/nut95 70 Ð
Front Insulator to Support
Bracket
ÐStud Nut (4WD) 41 30 Ð
ÐThrough Bolt/Nut (4WD) 102 75 Ð
Front Insulator to BlockÐ
Bolts (2WD)95 70 Ð
GeneratorÐMounting Bolt 55 40 Ð
Intake ManifoldÐBolts Refer to Procedure
DESCRIPTION N´m Ft. In.
Oil PanÐBolts 12 Ð 105
Oil Dipstick Tube 12 Ð 105
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐAttaching Bolts 28 Ð 250
Oil Pump Pickup Tube ± Bolt
and Nut28 Ð 250
Rear Seal Retainer Attaching
Bolts15 Ð 132
Rear Insulator to BracketÐ 68 50 Ð
Through-Bolt (2WD)
Rear Insulator to
Crossmember41 30 Ð
Support BracketÐNut (2WD)
Rear Insulator to
CrossmemberÐ68 50 Ð
Nuts (4WD)
Rear Insulator to
TransmissionÐ68 50 Ð
Bolts (4WD)
Rear Insulator BracketÐBolts 68 50 Ð
(4WD Automatic)
Rear Support Bracket to 41 30 Ð
Crossmember FlangeÐNuts
Rear Support Plate to
Transfer41 30 Ð
CaseÐBolts
Rocker ArmÐBolts 22 Ð 195
Spark Plugs Ð Ð Ð
Thermostat HousingÐBolts 28 Ð 250
Throttle BodyÐBolts 12 Ð 105
Transfer Case to Insulator 204 105 Ð
Mounting PlateÐNuts
Transmission Support
BracketÐ68 50 Ð
Bolts (2WD)
Vibration DamperÐBolt 176 129 Ð
Water Pump to Timing Chain 28 Ð 250
Case CoverÐBolts
DRENGINE - 5.7L 9 - 191
ENGINE - 5.7L (Continued)