Dodge Ram Truck 1500-2500-3500. Manual — part 1417

BORE SPECIFICATIONS

BORE DIAMETER

Min.

102.000 mm (4.0157 in.)

Max.

102.116 mm (4.0203 in.)

OUT OF ROUNDNESS

Max.

0.038 mm (0.0015 in.)

TAPER

Max.

0.076 mm (.003 in.)

Inspect the cylinder bores for damage or excessive wear.

Measure the cylinder bores. If the cylinder bores exceed the limit, (Refer to 9 - ENGINE/ENGINE BLOCK - STAN-
DARD PROCEDURE).

Inspect the camshaft bores for scoring or excessive wear.

Measure the camshaft bores (Refer to 9 - ENGINE - SPECIFICATIONS).

If a bore exceeds the limit, (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) - STAN-
DARD PROCEDURE).

Inspect the tappet bores for scoring or excessive wear.

Measure tappet bore from bottom of block. Minimum tappet bore diameter 16.000 mm (0.0630 in.). Maximum tappet
bore 16.055 mm. (0.632 in.).

If out of limits, replace the cylinder block.

CAMSHAFT & BEARINGS (IN BLOCK)

REMOVAL

CAMSHAFT 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 bushing. Inspect the rest of the camshaft bores for damage or exces-
sive wear.If the bores without a bushing are worn beyond the limit, the engine must be removed for machin-
ing and installation of service 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.

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3. Mark the cylinder block so you can align the oil hole in the cylinder block with the oil hole in the bushing.

CAMSHAFT

1. Disconnect both battery negative cables.

2. Recover A/C refrigerant (if A/C equipped) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STAN-

DARD PROCEDURE).

3. Raise vehicle on hoist.

4. Drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCEDURE).

5. Lower vehicle.

6. Remove radiator upper hose.

7. Remove viscous fan/drive/shroud assembly (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: Disconnect transmission oil cooler lines from front of radiator 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 indicator ring (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION

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 Barring 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. 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 lift-
ing them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.

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25. Raise the tappets as follows, using the wooden

dowel rodsprovided 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 cyl-
inders will have to be cut for cowl panel
clearance. Press firmly to ensure that it is
seated in the tappet.

b. Raise the dowel rod to bring the tappet to the

top of its travel, and wrap a rubber band
around the dowel rods to prevent the tappets
from dropping into the crankcase.

c. Repeat

this

procedure

for

the

remaining

cylinders.

26. Verify that the camshaft timing marks are aligned

with the crankshaft mark.

27. Remove the bolts from the thrust plate.

28. Remove engine mount through bolts.

29. Install engine support fixture special tool # 8534,

and steel bracket/wing nut special tool #
8534A.

30. Raise engine enough to allow camshaft removal.

31. Remove the camshaft, gear and thrust plate.

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INSPECTION

Camshaft

CAMSHAFT DIMENSIONS

CAMSHAFT DIMENSIONS

Journal diameter (No.1 and No.7)

Min.

54.028 mm. (2.127 in.)

Max.

54.048 mm. (2.128 in.)

Journal diameter (No.2 through No.6)

Min.

53.962 mm. (2.1245 in.)

Max.

54.013 mm. (2.1265 in.)

Diameter of peak of lobe

Intake

Min.

47.175 mm (1.857 in.)

Max

47.855 mm.

Exhaust

Min.

45.632 mm. (1.797 in.)

Max.

46.312 mm. (1.823 in.)

1. Inspect the valve lobes (1) and bearing journals (2)

for cracks, pitting, scoring, or generally excessive
wear. Replace any camshaft that exceeds the
allowable limits.

2. Measure the bearing journals and lobes.

CAUTION: If Camshaft lobes are worn, requiring
camshaft replacement, it is necessary to replace
the tappets also. (Refer to 9 - ENGINE/ENGINE
BLOCK/SOLID LIFTERS - REMOVAL).

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