2003 DODGE RAM Heating

CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS
NOTE: Measure the diameter of each bore. If the
camshaft bore for the first or rear cam bushing is
worn beyond the limit, install a new service bush-
ing. Inspect the rest of the camshaft bores for dam-
age or excessive wear.If the bores without a
bushing are worn beyond the limit, the engine must
be removed for machining and installation of ser-
vice bushings. If badly worn, replace the cylinder
block.
(1) Remove the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(2) Remove the bushing from the No.1 bore and
No.7 using a universal cam bushing tool.
(3) Mark the cylinder block so you can align the oil
hole in the cylinder block with the oil hole in the
bushing.
REMOVAL - CAMSHAFT
(1) Disconnect both battery negative cables.
(2) Recover A/C refrigerant (if A/C equipped) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE).
(3) Raise vehicle on hoist.
(4) Drain engine coolant into container suitable for
re-use (Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(5) Lower vehicle.
(6) Remove radiator upper hose.
(7) Remove viscous fan/drive assembly and fan
shroud (Refer to 7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL).
(8) Disconnect the coolant recovery bottle hose
from the radiator filler neck.
(9) Disconnect lower radiator hose from radiator
outlet.
(10)Automatic Transmission models:Discon-
nect transmission oil cooler lines from front of radia-
tor using Special Tool 6931 (unless equipped with
finger-release disconnect).
(11) Remove radiator mounting screws and lift
radiator out of engine compartment.
(12) Remove upper radiator support panel.
(13) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(14) Disconnect charge air cooler piping from the
cooler inlet and outlet.(15) Remove the two charge air cooler mounting
bolts.
(16) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(17) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(18) Remove accessory drive belt tensioner.
(19) Remove the fan support/hub assembly.
(20) Remove crankshaft damper and speed indica-
tor ring (Refer to 9 - ENGINE/ENGINE BLOCK/VI-
BRATION DAMPER - REMOVAL).
(21) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the sealing surfaces. Remove dust
seal with cover.
(22) Using Special Tool 7471±B Crankshaft Bar-
ring Tool, rotate the crankshaft to align the timing
marks on the crankshaft and the camshaft gears.
(23) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(24) Remove the rocker arms, cross heads, and
push rods (Fig. 55). Mark each component so they
can be installed in their original positions.
NOTE: The #5 cylinder intake and the #6 cylinder
intake and exhaust pushrods are removed by lifting
them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
(25) Raise the tappets as follows, using the wooden
dowel rods (Fig. 57)provided with the Miller Tool Kit
8502.
(a) Insert the slotted end of the dowel rod into
the tappet.The dowel rods for the rear two
cylinders will have to be cut for cowl panel
clearance.Press firmly to ensure that it is seated
in the tappet.
Fig. 55 Push Rod Removal/Installation
DRENGINE 5.9L DIESEL 9 - 317

(14) Install the fan support/hub assembly and
tighten bolts to 33 N´m (24 ft. lbs.) torque.
(15) Install the power steering pump.
(16) Install accessory drive belt tensioner. Torque
bolt to 43 Nm (43 ft. lbs.).
(17) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(18) Install the charge air cooler (with a/c con-
denser and auxiliary transmission oil cooler, if
equipped) and tighten the mounting bolts to 2 N´m
(17 in. lbs.) torque.
(19) Connect charge air cooler inlet and outlet
pipes. Tighten clamps to 11 N´m (95 in. lbs.) torque.
(20) Install the radiator upper support panel.
(21) Close radiator petcock and lower the radiator
into the engine compartment. Tighten the mounting
bolts to 11 N´m (95 in. lbs.) torque.
(22) Raise vehicle on hoist.
(23)
Connect radiator lower hose and install clamp.
(24) Connect transmission auxiliary oil cooler lines
(if equipped).
(25) Lower vehicle.
(26) Install the fan shroud and tighten the mount-
ing screws to 6 N´m (50 in. lbs.) torque.
(27) Install the electronically controlled viscous
fan/drive assembly. Connect harness connector.(Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(28) Install the coolant recovery and windshield
washer fluid reservoirs to the fan shroud.
(29) Connect the coolant recovery hose to the radi-
ator filler neck.
(30) Add engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(31) Charge A/C system with refrigerant (if A/C
equipped) (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(32) Connect the battery negative cables.
(33) Start engine and check for engine oil and cool-
ant leaks.
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING ROD
BEARING AND CRANKSHAFT JOURNAL
CLEARANCE
(1) Measure the connecting rod bore with bearings
removedand the bolts tightened to 100 N´m (73 ft.
lbs.) torque..
(2) Measure the connecting rod bore with the bear-
ingsinstalledand the bolts tightened to 100 N´m
(73 ft. lbs.) torque.
Measure within 20É arc from each side of the part-
ing line. Also measure 90É from parting line.Record the smallest and largest diameter.
Measure the diameter of the rod journal at the
location shown (Fig. 65). Calculate the average diam-
eter for each side of the journal.
Determine minimum bearing clearance by calculating
the differance between the smallest connecting rod bore
diameter with the bearing installed and the average
diameter for each side of the crankshaft journal.
Determine the maximum bearing clearance by calcu-
lating the difference between the largest connecting rod
bore diameter and the average diameter with the bear-
ing installed for each side of the crankshaft journal.
DESCRIPTION MEASUREMENT
CONNECTING ROD
BORE, BEARINGS
REMOVEDMIN. 72.99 mm (2.874
in.)
MAX. 73.01 mm (2.875
in.)
CONNECTING ROD
BORE, BEARINGS
INSTALLEDMIN. 69.05 mm (2.719
in.)
MAX. 69.10 mm (2.720
in.)
If the crankshaft is within limits, replace the bear-
ing. If the crankshaft is out of limits, grind the
crankshaft to the next smaller size and use oversize
rod bearings.
Fig. 65 Connecting Rod Journal Diameter Limits
CONNECTING ROD JOURNAL DIAMETER
LIMITS CHART
DESCRIPTION MEASUREMENT
CRANKSHAFT ROD JOURNAL
DIAMETERMin. 68.96 mm (2.715 in.)
Max. 69.01 mm (2.717 in.)
BEARING CLEARANCE Min. 0.04 mm (.002 in.)
Max. 0.12 mm (0.005 in.)
DRENGINE 5.9L DIESEL 9 - 321
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

(3) Discharge the air conditioning system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(4) Remove the upper crossmember.
(5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
(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.
9 - 362 ENGINE 8.0LDR
ENGINE 8.0L (Continued)

(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.
(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.SPECIFICATIONS
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
DRENGINE 8.0L 9 - 363
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)

(2) Insert MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, into the four corner joints
an excessive amount of sealant is not required to
ensure a leak proof seal. However, an excessive
amount of sealant may reduce the effectiveness of
the flange gasket. The sealant should be approxi-
mately 5 mm (0.2 in.) in diameter. (Fig. 70).
(3) Position the cross-over gaskets and press firmly
onto the block (Fig. 70).BE SURE THE BLOCK IS
OIL FREE..
(4) The lower intake manifold MUST be installed
within 3 minutes of sealant application. Carefully
lower intake manifold into position on the cylinder
block and heads. After intake manifold is in place,
inspect to make sure seals and gaskets are in place.
Finger start all the lower intake bolts.
(5) Tighten the lower intake manifold bolts in
sequence to 54 N´m (40 ft. lbs.) torque (Fig. 69).
Recheck all bolts are tightened to 54 N´m (40 ft. lbs.)
torque.
(6) Using a new gasket, position the upper intake
manifold onto the lower intake manifold.
(7) Finger start all bolts, alternate one side to the
other.
(8) Tighten upper intake manifold bolts in
sequence to 22 N´m (16 ft. lbs.) torque (Fig. 68).
(9) Using a new gasket, install the throttle body
onto the upper intake manifold. Tighten the bolts to
23 N´m (200 in. lbs.) torque.
(10) Install closed crankcase ventilation and evap-
oration control systems.
(11) Connect the heater hoses and bypass hose.
(12) Connect the vacuum lines.
(13) Install the coil assemblies and the ignition
wires.
(14) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.(15) Install the fuel lines (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(16) Using a new gasket, install the air cleaner
housing. Tighten the nuts to 11 N´m (96 in. lbs.)
torque. Install the air cleaner filter and cover.
(17) Install the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION). Position the com-
pressor brace and install the bolts. Tighten the brace
bolts to 41 N´m (30 ft. lbs.) torque.
(18) Install the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - INSTALLATION).
Position the generator brace and install the bolts.
Tighten the brace bolts to 41 N´m (30 ft. lbs.) torque.
(19) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(20) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(21) Connect the negative cable to the battery.
(22) Start engine check for leaks.
EXHAUST MANIFOLD
DESCRIPTION
Engine exhaust manifolds (Fig. 72) are made of
high molybdenum ductile cast iron. A special ribbed
design helps control permanent dimensional changes
during heat cycles.
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.
Fig. 71 Intake Manifold Flange
1 - LOCATOR DOWELS
2 - INTAKE MANIFOLD GASKETS
3 - LOCATOR DOWELS
Fig. 72 Exhaust ManifoldÐ8.0L Engine
1 - EXHAUST MANIFOLD
DRENGINE 8.0L 9 - 403
INTAKE MANIFOLD (Continued)

(5) Using Special Tool C-3688 Crankshaft Pulley/
Damper Installer Install pulley/vibration damper
(Fig. 75)
(6) Prime oil pump by squirting oil in the oil filter
mounting hole and filling the J-trap of the front tim-
ing cover. When oil is running out, install oil filter
that has been filled with oil.(7) Install water pump and housing assembly
using new o-ring (Refer to 7 - COOLING/ENGINE/
WATER PUMP - INSTALLATION).
(8) Install generator, air pump, and bracket assem-
bly.
(9) Install A/C compressor (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION).
(10) (10) Install the radiator fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(11) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(12) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(13) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect the negative cable to the battery.
(15) Road test vehicle and check for leaks.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Remove timing chain cover and gasket using
extreme caution to avoid damaging oil pan gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
(2) Aline camshaft and crankshaft centerline.
Remove camshaft sprocket attaching bolt and remove
timing chain and camshaft sprockets.
(3) Use puller 6444 and jaws 6820 to remove
crankshaft sprocket (Fig. 76).
INSPECTIONÐMEASURING TIMING CHAIN
STRETCH
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam-
shaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
N´m (30 ft. lbs.) torque with cylinder head installed
or 20 N´m (15 ft. lbs.) torque with cylinder head
removed. With a torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N´m (30 ft. lbs.) torque in the
reverse direction. With the cylinder heads removed,
apply 20 N´m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 77).
Fig. 74 PulleyÐDamper Removal
1-3JAWPULLER
Fig. 75 Installing Crankshaft
1 - SPECIAL TOOL C-3688
DRENGINE 8.0L 9 - 405
TIMING BELT / CHAIN COVER(S) (Continued)

SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Adjusting StrapÐBolt 23 Ð 200
Air Heater Power SupplyÐ
Nuts14 Ð 124
Air Inlet HousingÐBolts 24 18 Ð
Cab Heater Supply/Return
LineÐNuts24 18 Ð
Exhaust ClampÐNuts 48 35 Ð
Exhaust Manifold to Cylinder
HeadÐBolts
(Diesel Engine) 43 32 Ð
Exhaust Manifold to Cylinder
HeadÐBolts
(5.9L) 31 23 Ð
Exhaust Manifold to Cylinder
HeadÐBolts
(8.0L) 22 Ð 195
Exhaust Pipe to ManifoldÐ
Bolts31 23 Ð
Generator MountingÐBolts 41 30 Ð
Charge Air Cooler
MountingÐBolts2Ð17
Charge Air Cooler DuctÐ
Nuts11 Ð 9 5
Heat ShieldÐNuts and Bolts 11 Ð 95
Turbocharger flange studs 24 18 Ð
Turbocharger MountingÐ
Nuts43 32 Ð
Turbocharger Oil Drain
TubeÐBolts24 18 Ð
Turbocharger Oil Supply
LineÐFitting24 18 Ð
Turbocharger V-Band
ClampÐNut9Ð75
Turbocharger Oil Supply
fitting (at Turbocharger)36 27 Ð
Turbocharger Oil Supply
fitting (at lube filter head)24 18 Ð
Turbocharger Drain Hose
Clamps8Ð71
SPECIAL TOOLS
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the converter.
The stainless steel catalytic converter body is
designed to last the life of the vehicle. Excessive heat
can result in bulging or other distortion, but exces-
sive heat will not be the fault of the converter. If
unburned fuel enters the converter, overheating may
occur. If a converter is heat-damaged, correct the
cause of the damage at the same time the converter
is replaced. Also, inspect all other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid con-
taminating the catalyst core.
50 State emission vehicles incorporate two mini
catalytic converters located after the exhaust mani-
folds and before the inline catalytic converter.
OPERATION
The catalytic converter captures and burns any
unburned fuel mixture exiting the combustion cham-
bers during the exhaust stroke of the engine. This
process aids in reducing emissions output.
TURBOCHARGER TESTER 9022
11 - 4 EXHAUST SYSTEMDR
EXHAUST SYSTEM (Continued)