Crankshaft R&R

Complete removal and installation of the crankshaft on a 1992 Dodge Viper 8.0L V10, including engine removal, disassembly of rotating assembly, crankshaft extraction, and installation with new bearings.

Warnings

Tools required

Parts

• Main bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Rod bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Rear main seal housing gasket × 1 — Use OEM specification
• Front main seal housing gasket × 1 — Use OEM specification
• Oil pump pickup tube O-ring × 1 — Use OEM specification
• Main bearing cap bolts (TTY) × 10 — Use OEM specification
• Connecting rod bolts (TTY) × 20 — Use OEM specification
• Harmonic balancer bolt × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil 10W-30 × 11 — Use OEM specification
• Engine coolant (ethylene glycol 50/50) × 24 — Use OEM specification
• RTV silicone sealant (high-temp) × 1 — Use OEM specification

Fluids

• Engine oil 10W-30 conventional — 11 qt
• Engine coolant ethylene glycol 50/50 — 24 qt

Preparation

1. Position vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and isolate from battery post
3. Drain engine oil completely and remove oil filter
4. Drain cooling system completely from engine block and radiator
5. Relieve fuel system pressure by removing fuel pump relay and cranking engine until it stalls
6. Remove hood assembly after marking hinge positions for reinstallation alignment
7. Support vehicle on jack stands at all four corners with wheels removed for access

Procedure

1. 1

   Remove Engine from Vehicle
   Disconnect all electrical connectors from engine including alternator, starter, ignition coils, camshaft position sensors, crankshaft position sensor, and engine harness connectors. Label each connection for reinstallation. Disconnect throttle cables and cruise control cable from throttle body. Remove air intake system completely. Disconnect fuel supply and return lines at fuel rail using proper disconnect tools. Disconnect all coolant hoses including upper and lower radiator hoses, heater hoses, and bypass hoses. Disconnect exhaust system at manifold flanges. Remove transmission bellhousing-to-engine bolts and separate transmission from engine using transmission jack for support. Remove engine mount bolts at both left and right motor mounts. Attach engine hoist to verified factory lifting points or a properly bolted engine lift plate/bracket rated for the load. Verify all connections are disconnected. Carefully lift engine forward and upward out of engine bay. Transfer engine to heavy-duty engine stand and secure using bellhousing bolt holes.
   Torque spec

   Transmission-to-Engine Bolts68 Nm (50 lb-ft)
2. 2

   Remove External Engine Components
   With engine on stand, remove alternator and mounting bracket. Remove power steering pump and set aside without disconnecting hoses. Remove A/C compressor and secure to side without disconnecting refrigerant lines. Remove the ignition system components and spark plugs. Remove valve covers from both cylinder heads. Remove intake manifold assembly completely, noting any coolant passages that require draining. Remove exhaust manifolds from both cylinder heads. Remove water pump assembly. Remove oil filter adapter housing and oil pressure sending unit.
3. 3

   Remove Harmonic Balancer and Timing Cover
   Using an impact wrench or breaker bar, remove the harmonic balancer center bolt. Install harmonic balancer puller and remove balancer from crankshaft snout. Do not pry or hammer on balancer as this can damage crankshaft or balancer. Remove all timing cover bolts noting their different lengths and locations. There are both 8mm and 10mm bolts securing the timing cover. Carefully separate timing cover from engine block, using plastic scraper if necessary to break RTV seal. Remove front crankshaft seal from timing cover for replacement.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)

   Timing Cover Bolts - 8mm12 Nm (9 lb-ft)

   Timing Cover Bolts - 10mm45 Nm (33 lb-ft)
4. 4

   Remove Timing Chain and Camshaft Components
   Rotate crankshaft to Top Dead Center (TDC) for cylinder #1 and verify timing marks on the crankshaft and camshaft sprockets are properly aligned. Mark the timing chain orientation to both sprockets for reference. Remove the timing chain tensioner if equipped. Remove the single camshaft sprocket bolt(s) and remove the camshaft sprocket with the timing chain as an assembly. Note: the 8.0L V10 is a pushrod OHV engine with a single block-mounted camshaft. This provides clearance for crankshaft removal and prevents timing chain interference.
   Torque spec

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
5. 5

   Remove Oil Pan and Oil Pump
   Remove all oil pan bolts in reverse of tightening sequence. Carefully separate oil pan from engine block using plastic scraper to break RTV seal. Remove oil pump pickup tube mounting bolt and remove pickup tube from oil pump. Remove oil pump mounting bolts and remove oil pump assembly from front of engine block. Inspect oil pump drive gear engagement with crankshaft.
   Torque spec

   Oil Pan Bolt12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)

   Oil Pump Bolts37 Nm (27 lb-ft)
6. 6

   Remove Flywheel and Rear Main Seal Housing
   Lock flywheel using appropriate holding tool or large pry bar wedged against ring gear teeth and engine block. Remove all flywheel bolts in star pattern. Remove flywheel from crankshaft flange. Remove rear main seal housing bolts and carefully pry housing away from engine block. Note the RTV sealing pattern for reinstallation. Remove old rear main seal from housing for replacement.
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)

   Rear Main Seal Housing12 Nm (9 lb-ft)
7. 7

   Remove Connecting Rod Caps and Pistons
   Rotate crankshaft to position connecting rod at bottom dead center. Mark each connecting rod cap with cylinder number and orientation using permanent marker or number stamps before removal. Remove connecting rod cap bolts from cylinder #1. Remove rod cap and bearing insert, keeping them together with the cylinder number. Push piston and rod assembly upward into cylinder bore and secure with plastic connecting rod bolt protectors to prevent cylinder wall damage. Repeat this process for all 10 cylinders, keeping each rod cap, bolts, and bearing with its respective cylinder number. Do not allow connecting rods to strike crankshaft journals during removal.
   ⚠Connecting rod caps and bolts are matched sets and not interchangeable between cylinders. Keep all components organized by cylinder number.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
8. 8

   Remove Main Bearing Caps and Extract Crankshaft
   Mark each main bearing cap with its position number (front to rear) and orientation using permanent marker or number stamps. The caps are directional and not interchangeable. Remove main bearing cap bolts from all main caps in sequence from the outer caps toward the center. Remove each main cap carefully, keeping the lower bearing insert with its respective cap. Once all caps are removed, carefully lift crankshaft straight up and out of the engine block. This requires two people due to the 65-pound weight. Place crankshaft on a padded workbench or crankshaft stand. Remove upper main bearing inserts from engine block, keeping them organized with their respective position numbers. Note: Inspect thrust bearing surfaces on the thrust main bearing for wear (verify thrust position per factory manual).
   ⚠️Crankshaft weighs approximately 65 pounds. Use proper lifting technique and have an assistant to prevent injury.
   ⚠Main bearing caps are numbered and directional. Incorrect installation will cause immediate engine failure.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
9. 9

   Inspect and Measure Crankshaft
   Thoroughly clean all crankshaft journals with solvent and lint-free rags. Inspect all main and rod journals for scoring, discoloration, or damage. Using a micrometer, measure each main journal and rod journal in multiple locations to check for taper and out-of-round conditions. Main journal standard diameter is approximately 2.99 inches, rod journal standard diameter is approximately 2.24 inches. Measure crankshaft endplay using a dial indicator positioned against the crankshaft snout while prying the crankshaft fore and aft. Standard endplay specification is 0.0035-0.0095 inches. Inspect thrust bearing surfaces on center main bearing (position #3) for wear. If journals are worn beyond 0.001 inch taper or 0.0005 inch out-of-round, crankshaft must be reground and undersized bearings used. Inspect oil passages in crankshaft for blockage.
   ℹ️If crankshaft requires grinding, all journals must be ground to maintain proper balance. Consult machine shop for available undersize bearing options.
10. 10

    Prepare Engine Block and Install Main Bearings
    Thoroughly clean engine block main bearing saddles and all bearing cap mating surfaces with brake cleaner and lint-free rags. Remove all old RTV sealant residue. Inspect bearing saddles for damage or wear. Clean all oil passages in the block using compressed air and ensure no debris remains. Install new upper main bearing inserts into engine block saddles, ensuring the bearing tabs engage the notches in the saddles and the oil holes align with block oil passages. Do not lubricate bearings yet. Install new lower main bearing inserts into main bearing caps, ensuring proper tab engagement. Verify each bearing is properly seated.
11. 11

    Install Crankshaft and Check Bearing Clearances
    Cut sections of Plastigage to the width of each bearing journal. Place one strip of Plastigage on each main journal of the crankshaft. Carefully lower crankshaft into engine block bearing saddles, ensuring thrust bearing surfaces on center main (position #3) are properly aligned. Install main bearing caps in their correct positions and orientations according to the marks made during disassembly. Install NEW main bearing cap bolts (TTY bolts must not be reused). Hand-tighten all bolts, then torque to 75 Nm (55 lb-ft) in sequence from center cap outward. Do not rotate crankshaft. Remove each main cap carefully and measure the flattened Plastigage width using the scale on the package. Bearing clearance should be 0.0005-0.0021 inches for main bearings. If clearance is outside specification, verify correct bearing size and crankshaft journal condition. Remove Plastigage residue completely.
    ⚠Main bearing cap bolts are torque-to-yield and must be replaced with new bolts. Do not reuse old bolts.
    ⚠Do not rotate crankshaft with Plastigage installed as this will invalidate clearance measurement.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
12. 12

    Final Crankshaft Installation
    Remove all main caps again. Thoroughly remove all Plastigage residue from bearings and crankshaft journals. Lubricate all upper and lower main bearing surfaces with clean engine assembly lube or 10W-30 engine oil. Carefully lower crankshaft into block. Apply a small amount of assembly lube to thrust bearing surfaces on center main bearing. Install main bearing caps in correct positions and orientations. Install NEW main bearing cap bolts. Hand-tighten all bolts, then torque in sequence from center cap outward: first to 75 Nm (55 lb-ft), then rotate each bolt an additional 90 degrees using torque angle gauge. Verify crankshaft rotates freely by hand with smooth, consistent drag. Re-check crankshaft endplay with dial indicator; should be 0.0035-0.0095 inches. If endplay is excessive, thrust bearing or center main cap may be incorrectly installed.
    ⚠Main bearing cap bolts require torque-plus-angle tightening. Final torque is 75 Nm plus 90 degrees rotation.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
13. 13

    Install Connecting Rods and Pistons
    Install connecting rod bearing inserts into each rod and cap, ensuring tabs engage properly. Lubricate rod bearing surfaces with assembly lube. Rotate crankshaft to position rod journal at bottom dead center for cylinder #1. Remove rod bolt protectors. Lubricate piston rings with engine oil. Carefully guide piston and connecting rod assembly down into cylinder bore, ensuring ring compressor is used and rings enter bore squarely. Align connecting rod with crankshaft journal and carefully pull rod onto journal. Install lower bearing insert into rod cap. Install rod cap in correct orientation according to marks made during disassembly. Install NEW connecting rod bolts (TTY). Torque rod bolts to 45 Nm (33 lb-ft), then rotate each bolt an additional 90 degrees using torque angle gauge. Verify rod side clearance is 0.006-0.022 inches using feeler gauge. Repeat for all 10 cylinders, keeping all components matched to their original cylinder positions.
    ⚠Connecting rod bolts are torque-to-yield and must be replaced with new bolts. Do not reuse old bolts.
    ⚠Use plastic rod bolt protectors or rubber hose over rod bolts when inserting rods to prevent scratching cylinder walls or crankshaft journals.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
14. 14

    Install Rear Main Seal Housing
    Install new rear main seal into rear seal housing using appropriate seal driver tool, ensuring seal is seated evenly and flush with housing face. Seal lip should face toward engine (inward). Clean rear seal housing mounting surface on engine block thoroughly. Apply a thin 2mm bead of RTV silicone sealant to the engine block mating surface around the seal housing bolt holes, and at the corners where the seal housing meets the oil pan rail. Position rear seal housing onto engine block, ensuring seal does not roll or damage during installation. Install rear seal housing bolts and torque to 12 Nm (9 lb-ft) in a crisscross pattern. Allow RTV to cure for 30 minutes before installing flywheel.
    Torque spec

    Rear Main Seal Housing12 Nm (9 lb-ft)
15. 15

    Install Flywheel
    Clean crankshaft flange and flywheel mounting surface thoroughly. Position flywheel onto crankshaft flange, aligning dowel pin. Apply small amount of thread locker to flywheel bolt threads. Install flywheel bolts and hand-tighten. Lock flywheel from rotating using holding tool. Torque flywheel bolts to 95 Nm (70 lb-ft) in star pattern in three steps: 30 Nm, 60 Nm, then final 95 Nm. Verify flywheel is seated flush against crankshaft flange.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)
16. 16

    Install Oil Pump and Oil Pan
    Install new O-ring onto oil pump pickup tube. Install pickup tube into oil pump body and torque mounting bolt to 12 Nm (9 lb-ft). Prime oil pump by filling pump cavity with clean engine oil. Install oil pump onto engine block, engaging oil pump drive with crankshaft. Torque oil pump mounting bolts to 37 Nm (27 lb-ft). Clean oil pan and engine block mating surfaces thoroughly, removing all old RTV residue. Apply a 3mm bead of RTV silicone sealant to oil pan flange, circling all bolt holes. Position oil pan onto engine block within 10 minutes of applying RTV. Install oil pan bolts and torque to 12 Nm (9 lb-ft) in sequence from center outward. Allow RTV to cure for 2 hours before filling with oil.
    Torque spec

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pump Bolts37 Nm (27 lb-ft)

    Oil Pan Bolt12 Nm (9 lb-ft)
17. 17

    Install Timing Components and Front Seal
    Install oil slinger onto crankshaft snout if equipped. Install camshaft sprockets onto camshafts, aligning timing marks. Install timing chain onto both camshaft sprockets, ensuring chain direction and timing marks are properly oriented. Engage chain with crankshaft sprocket and verify all timing marks are aligned with crankshaft at TDC for cylinder #1. Install timing chain guides and torque guide bolts to 12 Nm (9 lb-ft). Install timing chain tensioner and torque bolt to 25 Nm (18 lb-ft). Rotate crankshaft two complete revolutions and re-verify timing mark alignment. Install new front crankshaft seal into timing cover using seal driver tool, ensuring seal is flush with cover face. Clean timing cover and engine block mating surfaces. Apply thin bead of RTV sealant to timing cover gasket surfaces. Position timing cover onto engine block, aligning over crankshaft snout and dowel pins. Install timing cover bolts: torque 8mm bolts to 12 Nm (9 lb-ft) and 10mm bolts to 45 Nm (33 lb-ft), in sequence from center outward.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

    Timing Cover Bolts - 8mm12 Nm (9 lb-ft)

    Timing Cover Bolts - 10mm45 Nm (33 lb-ft)
18. 18

    Install Harmonic Balancer
    Clean crankshaft snout and harmonic balancer bore thoroughly. Lightly lubricate crankshaft snout and seal contact surface with clean engine oil. Align harmonic balancer keyway with crankshaft key. Slide balancer onto crankshaft snout by hand as far as possible. Install harmonic balancer bolt with washer. Using impact wrench or torque wrench with holding tool to prevent crankshaft rotation, torque balancer bolt to the factory-specified value (verify from service manual). Verify harmonic balancer is fully seated against the crankshaft sprocket/shoulder.
    ⚠Never hammer harmonic balancer onto crankshaft. Use balancer bolt to draw balancer into position.
    Torque spec

    Harmonic Balancer Bolt180 Nm (133 lb-ft)
19. 19

    Reinstall External Engine Components
    Reinstall water pump assembly with new gasket. Reinstall exhaust manifolds with new gaskets on both cylinder heads. Reinstall intake manifold assembly with new gaskets, torquing bolts in proper sequence from center outward. Install spark plugs torqued to specification. Install ignition coils. Reinstall valve covers with new gaskets. Reinstall A/C compressor, power steering pump, and alternator with mounting brackets. Install new oil filter.
20. 20

    Reinstall Engine into Vehicle
    Carefully lower engine into engine bay using engine hoist, aligning engine with transmission bellhousing. Guide engine onto motor mount brackets while maneuvering bellhousing pilot into alignment with transmission input shaft. Install engine mount bolts at both left and right mounts and torque to specification. Mate engine to transmission and install bellhousing-to-engine bolts, torquing to 68 Nm (50 lb-ft). Reconnect exhaust system at manifold flanges. Reconnect all coolant hoses including upper and lower radiator hoses, heater hoses, and bypass hoses. Reconnect fuel supply and return lines at fuel rail. Reconnect throttle cables and cruise control cable. Reconnect all electrical connectors to engine including alternator, starter, ignition coils, sensors, and engine harness connectors according to labels made during removal. Reinstall air intake system. Reinstall hood assembly, aligning with marks made during removal.
    Torque spec

    Transmission-to-Engine Bolts68 Nm (50 lb-ft)
21. 21

    Fill Fluids and Initial Start
    Install oil drain plug with new crush washer and torque to 35 Nm (26 lb-ft). Fill engine with the factory-specified oil quantity and viscosity (verify capacity and grade from service manual). Refill cooling system with the factory-specified quantity of ethylene glycol 50/50 coolant mixture (verify capacity from service manual) through the radiator and overflow tank. Reconnect negative battery cable. Remove fuel pump relay to disable fuel system. Crank engine for 10-15 seconds to build oil pressure without starting. Reinstall fuel pump relay. Start engine and immediately verify oil pressure on gauge. Listen for abnormal noises. Allow engine to idle until cooling fan cycles, monitoring for leaks at oil pan, timing cover, rear main seal, and all gasket surfaces. Check coolant level and top off as needed after engine reaches operating temperature and air is purged from system. Shut down engine and re-check oil level after 5 minutes, adding oil as needed.
    ⚠️If oil pressure does not register within 10 seconds of starting, immediately shut down engine to prevent damage.
    ⚠Monitor closely for leaks during first run. Any significant oil leak requires immediate shutdown and repair.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Reassembly follows removal steps in reverse order
2. All torque-to-yield (TTY) fasteners including main bearing cap bolts, connecting rod bolts, and harmonic balancer bolt must be replaced with new parts
3. Use new gaskets and seals throughout including oil pan gasket, timing cover gasket, rear main seal, and front crankshaft seal
4. Apply RTV silicone sealant to oil pan and timing cover mating surfaces as specified
5. Verify all timing marks are properly aligned before final timing cover installation
6. Torque all fasteners to specification using proper sequence where applicable
7. Prime oil pump before installation by filling with clean engine oil
8. Allow RTV sealant to cure for specified time before filling fluids or starting engine

Verification

• Verify crankshaft rotates freely by hand with smooth, consistent resistance before final assembly
• Confirm crankshaft endplay is within specification (0.0035-0.0095 inches) using dial indicator
• Verify all main bearing and rod bearing clearances are within specification (0.0005-0.0021 inches for mains) using Plastigage
• Confirm all timing marks align properly after rotating crankshaft two complete revolutions
• Verify oil pressure registers immediately upon initial start (within 10 seconds)
• Check for any oil leaks at oil pan, timing cover, rear main seal, and oil filter after engine reaches operating temperature
• Listen for abnormal engine noises including knocking, ticking, or rattling that would indicate bearing or assembly issues
• Verify engine idles smoothly and cooling system maintains proper operating temperature
• Re-check oil level after initial run and top off as necessary
• Road test vehicle to verify normal operation under load and confirm no warning lights or abnormal conditions

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