Chrysler RAM TRUCK 2500 1994 Service Manual page 839

9 - 118 8.0L ENGINE
(6) Add Teflon sealer to threads of flex plate or fly­
wheel bolts to crankshaft. Install the flywheel and
clutch or the torque converter and drive plate assem­
blies.
(7) Install the transmission.
CYLINDER BLOCK
Remove the engine assembly from the vehicle.
DISASSEMBLE
(1) Remove the cylinder head.
(2) Remove the oil pan.
(3) Remove the piston/connecting rod assemblies.
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
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
• The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
• The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
• The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely co­
ordinated with the fitting of pistons and rings so
specified clearances may be maintained.
Refer to Standard Service Procedures i n the begin­
ning of this Group for the proper honing of cylinder
bores.
ENGINE CORE OIL / CAMSHAFT PLUGS
Engine core plugs have been pressed into the oil
galleries behind the camshaft thrust plate. This will
reduce internal leakage and help maintain higher oil
pressure at idle.
HEiOWAL
(1) Using a blunt tool such as a drift or a screw­
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 18).
(2) With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig.
18).
CYLINDER
^ BLOCK
r
/
i
DRIFT
S E C O N D
REMOVE PLUG
WITH PLIERS
FIRST
STRIKE HERE
WITH HAMMER
9209-41
Fig. 18 Core Hole Plug Removal
CLEANING
Thoroughly clean inside of cup plug hole i n cylinder
block or head. Be sure to remove old sealer.
Make certain the new plug is cleaned of all oil or
grease.
INSTALLATION
(1) Coat edges of plug and core hole with Mopar
Gasket Maker, or equivalent.
CAUTION: DO NOT drive cup plug into the casting
a s restricted coolant flow c a n result and c a u s e s e ­
rious engine problems.
(2) Using proper drive plug, drive plug into hole.
The sharp edge of the plug should be at least 0.50
mm (0.020 inch) inside the lead-in chamfer.
I t is not necessary to wait for curing of the sealant.
The cooling system can be filled and the vehicle
placed i n service immediately.
ASSEMBLE
(1) Install the piston/connecting rod assembly.
(2) Install the oil pan.
(3) Install the cylinder head.
(4) Install the engine into the vehicle.