5.7 Hemi – CAMSHAFT – INSTALLATION
CAMSHAFT CORE HOLE PLUG
1. Clean core hole in block.
NOTE: Do not apply adhesive to the new core hole plug. A new plug will have adhesive pre-applied.
2. Install a new core hole plug at the rear of camshaft, using suitable flat faced tool. The plug must be fully seated
on the cylinder block shoulder.
CAMSHAFT
CAUTION: 5.7L engines equipped with MDS uses a unique camshaft for use with the Multi Displacement System. When installing a new camshaft, the replacement camshaft must be compatible with the Multi Displacement System.
1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft.
2. Install camshaft Tensioner plate assembly. lighten bolts to 28 N·m (250 in. Ibs.).
3. Install timing chain and sprockets (Refer to 9 – ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS – INSTALLATION).
4. Measure camshaft end play (Refer to 9 – ENGINE – SPECIFICATIONS). If not within limits install a new
thrust plate.
5. Install the oil pump (Refer to 9 – ENGINE/LUBRICATION/OIL PUMP – INSTALLATION).
6. Install the oil pick up tube.
7. Each tappet (2) reused must be installed in the same position from which it was removed. When camshaft is
replaced, an of the tappets must be replaced.
8. Install tappets (2) and retaining yoke assembly (1) (Refer to 9 • ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS (CAM IN BLOCK) – INSTALLATION).
9. Install both left and right cylinder heads (4) (Refer to 9 – ENGINE/CYLINDER HEAD – INSTALLATION).
10. Install push rods.
11. Install rocker arms (Refer to 9 – ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY –
INSTALLATION).
12. Install timing case cover (Refer to 9 – ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) – INSTALLATION).
13. Install the oil pan (Refer to 9 – ENGINE/LUBRICATION/OIL PAN – INSTALLATION).
14. Install cylinder head covers (Refer to 9 – ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) –
INSTALLATION).
15. Install intake manifold (Refer to 9 – ENGINE/MAN- IFOLDS/INTAKE MANIFOLD – INSTALLATION).
16. Install the A/C compressor (2).
17. Install the generator (2).
18. Install the accessory drive belt (Refer to 7 – COOLING/ACCESSORY DRIVE/DRIVE BELTS – INSTALLATION).
19. Install the radiator (Refer to 7 – COOLING/ENGINE/RADIATOR – INSTALLATION).
20. Install the air cleaner assembly.
21. Install the battery negative cable.
22. Refill coolant (Refer to 7 – COOLING – STANDARD PROCEDURE).
23. Refill engine oil.
24. Start engine and check for leaks.
5.7 Hemi – CAMSHAFT – REMOVAL
REMOVAL
CAMSHAFT CORE HOLE PLUG
CAUTION: Do not damage the rear surface of the camshaft or the core plug sealing surface, when removing the core plug.
1. Remove the rear cam bearing core plug.
CAMSHAFT
1. Remove the battery negative cable.
2. Remove the air cleaner assembly.
3. Drain coolant (Refer to 7 – COOLING – STANDARD PROCEDURE).
4. Remove the accessory drive belt (Refer to 7 – COOLING/ACCESSORY DRIVE/DRIVE BELTS – REMOVAL).
5. Remove the generator.
6. Remove the A/C compressor, and set aside.
7. Remove the radiator (Refer to 7 – COOLING/ENGINE/RADIATOR – REMOVAL).
8. Remove intake manifold (Refer to 9 – ENGINE/MANIFOLDS/INTAKE MANIFOLD – REMOVAL).
9. Remove cylinder head covers (Refer to 9 – ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) – REMOVAL).
10. Remove both left and right cylinder heads (4) (Refer to 9 – ENGINE/CYLINDER HEAD – REMOVAL).
11. Remove the oil pan (Refer to 9 – ENGINE/LUBRICATION/OIL PAN – REMOVAL).
12. Remove timing case cover (1) (Refer to 9 – ENGINENALVE TIMINGITIMING BELT / CHAIN COVER(S) –
REMOVAL).
13. Remove the oil pick up tube.
14. Remove the oil pump (Refer to 9 – ENGINE/LUBRICATION/OIL PUMP – REMOVAL).
15. Remove timing chain (2) (Refer to 9 – ENGINE/VALVE TIMINGITIMING BELT/CHAIN AND SPROCKETS – REMOVAL).
16. Remove camshaft tensioner/thrust plate assembly.
17. Remove the tappets (2) and retainer (1) assembly.
18. Install a long bolt into front of camshaft to aid in removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes.
5.7 Hemi – ENGINE BLOCK – INSPECTION
1. It is mandatory to use a dial bore gauge to measure each cylinder bore diameter. To correctly select the proper size piston, a cylinder bore gauge, INCREMENTS capable is of required. reading in If 0.003 a bore mm gauge (.0001 is in.) not available, do not use an inside micrometer.
2. three Measure levels the below inside top diameter of bore. of the Start cylinder perpendicular bore at (across or at 90 degrees) to the axis of the crankshaft and then take two additional reading.
3. Measure the cylinder bore diameter crosswise to the cylinder block near the top of the bore. Repeat the measurement near the middle of the bore, then repeat the measurement near the bottom of the bore.
4. Determine taper by subtracting the smaller diameter from the larger diameter.
5. Rotate measuring device 90° and repeat steps above.
6. Determine out-ot-roundness by comparing the difference between each measurement.
7. If cylinder bore taper does not exceed 0.025 mm (0.001 inch) and out-of-roundness does not exceed 0.015 mm
(0.0006 inch), the cylinder bore can be honed. It the cylinder bore taper or out- of-round condition exceeds these
maximum limits, the cylinder block must be replaced. A slight amount of taper always exists in the cylinder bore
after the engine has been in use for a period of time.
5.7 Hemi – ENGINE BLOCK – CLEANING
Thoroughly clean the oil pan and engine block gasket surfaces.
Use compressed air to clean out:
• The galley at the oil filter adaptor hole.
• The front and rear oil galley holes.
• The feed holes for the crankshaft main bearings.
Once the block has been completely cleaned, apply Loctite PST pipe sealant with Teflon 592 to the threads of the
front and rear oil galley plugs. Tighten the 1/4 inch NPT plugs to 20 N·m (177 in. Ibs.) torque. Tighten the 3/8 inch
NPT plugs to 27 N·m (240 in. Ibs.) torque.
5.7 Hemi – SPRINGS – VALVE – INSTALLATION
1. Install valve seal.
2. Install valve spring.
3. Using special tool# 9065 (1 ,3,), compress valve spring and install valve spring retainer and locks.
4. Release air charge in cylinder (1).
5. Remove spring compressor tool # 9065 (3).
CAUTION: Verify that the pushrods are fully seated into lifter and rocker arm. Recheck after rocker arm shaft has been torqued to specification.
6. Install rocker arm shaft and pushrods (Refer to 9 – ENGINE/CYLINDER HEAD/ROCKER ARM/ ADJUSTER ASSY – INSTALLATION).
7. Tighten the rocker shaft bolts to 22 N·m (195 in. Ibs.) torque. using the rocker shaft torque sequence.
8. Remove special tool# 9070, pushrod retaining plate (1). if used.
9. Install cylinder head cover (1).
10. Tighten cylinder head cover bolts and double ended studs (Refer to 9 – ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) – INSTALLATION) .
11. Install spark plugs.
12. Install ignition coil on plug (2), and torque fasteners (3) to 7 N·m (62 in. Ibs)
13. Install ignition coil connectors (4).
14. Install air intake resonator.
15. Install air cleaner assembly.
16. Connect negative battery cable.
5.7 Hemi – SPRINGS – VALVE – REMOVAL
1. Disconnect negative battery cable.
2. Remove air cleaner assembly.
3. Remove air intake resonator.
4. Remove ignition coil connector (1).
5. Remove ignition coils (2).
6. Remove one spark plug.
7. Remove cylinder head cover (1) using the sequence shown (Refer to 9 – ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) – REMOVAL).
CAUTION: The piston must be at TDC, and both valves closed on the cylinder to be serviced.
NOTE: If removing intake valve spring, install push rod retaining plate 9070, (1), to retain the intake push rods (2).
8. Remove exhaust/intake rocker arm shafts using the sequence shown.
9. Install rocker arm shaft 9065 (1).
10. Install spring compressor 9065 (1,3,) and exhaust adapter arm (1) if needed.
NOTE: All valve springs and seals are removed In the same manner.
11. Insert air hose (1) into spark plug hole and charge cylinder with air.
NOTE: Tap the top of the valve spring retainer to loosen the spring retainers locks.
12. Compress valve spring with valve spring compressor 9065 (3) and remove valve retainer locks.
13. Release spring compressor (3) and remove valve spring.
NOTE: The valve springs are interchangeable between intake and exhaust.
14. Remove valve seal.
5.7 Hemi – SEALS – VALVE GUIDE – DESCRIPTION
The valve guide seals are made of rubber and incorporate an integral steel valve spring seat. The integral garter
spring maintains consistent lubrication control to the valve stems.
5.7 Hemi – ROCKER ARM – INSTALLATION
CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side.
1. Install the push rods in the same order as removed.
2. Install the push rod retainer (1) 9070.
CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust, failure to install in the correct location could result in engine damage. The intake rocker arms are marked with the letter “I”.
3. Install rocker shaft assemblies in the same order as removed.
4. Tighten the rocker shaft bolts to 22 N·m (195 in. Ibs.) as shown.
CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes).
5. Remove push rod retainer (1) 9070.
6. Install cylinder head cover (Refer to 9 – ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) –
INSTALLATION).
5.7 Hemi – ROCKER ARM – REMOVAL
1. Remove cylinder head cover. (Refer to 9 – ENGINE/CYLINDER HEAD/CYLI NDER HEAD COVER(S) – REMOVAL).
2. Install push rod retainer (1) 9070.
3. Loosen the rocker shafts using the sequence provided.
CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with an “I”.
4. Remove the rocker shafts. Note location for reassembly.
CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side.
5. Remove the push rods. Note push rod location for reassembly.
5.7 Hemi – VALVES & SEATS – INTAKE/EXHAUST – INSTALLATION
1. Clean valves (4,5) 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. Coat valve stems with clean engine oil and insert them in cylinder head.
5. If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head.
6. Install new valve seals (3). valve springs (6) retainers (2).
7. Compress valve springs with Valve Spring Compressor C· 3422 (1) and adapter 8464
8. Install valve keepers (1) and release tool.
NOTE: If valves and/or seats are ground, measure the installed height (8) of springs.
9. Make sure· the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer (8).
10. Install cylinder head (Refer to 9 – ENGINE/CYLINDER HEAD – INSTALLATION).
