Long Block Replacement

Complete removal and replacement of the 8.3L V10 long block assembly, including disconnection of all engine systems, removal from vehicle, transfer of external components, and reinstallation with new gaskets and fluids.

Warnings

Tools required

Parts

• Long block assembly (8.3L V10) × 1 — Use OEM specification
• Engine oil filter × 1 — Mopar MO-090
• Intake manifold gasket set × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Thermostat housing gasket × 1 — Use OEM specification
• Water pump gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Front and rear crankshaft seals × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Spark plugs × 10 — Champion RC12YC or equivalent
• Coolant (Zerex G-05 HOAT 50/50) × 1 — 19 quarts total
• Engine oil (0W-40 full synthetic) × 1 — 11 quarts total
• Anti-seize compound × 1 — Copper-based high-temp
• RTV silicone sealant × 1 — Mopar or equivalent

Fluids

• 0W-40 full synthetic — 11 qt
• Zerex G-05 HOAT 50/50 — 19 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Disconnect negative battery cable, then positive battery cable. Remove battery from vehicle for clearance.
3. Remove engine cover panels and air intake system completely.
4. Drain engine oil completely into appropriate container. Remove oil filter.
5. Drain coolant from radiator petcock and engine block drain plugs into appropriate container.
6. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls, then crank for 5 seconds.
7. Have AC system professionally evacuated and recovered by certified technician.
8. Raise vehicle on lift or securely support on jack stands at all four corners at proper lift points.
9. Remove both front wheels for access to frame and subframe components.
10. Place transmission jack under transmission for support during engine removal.

Procedure

1. 1

   Disconnect Hood and Cowl Components
   Mark hood hinge positions with paint pen or marker for proper reinstallation alignment. With assistant supporting hood, remove hood hinge bolts (4 bolts total, 2 per side) and lift hood away from vehicle. Remove cowl panel by removing plastic clips and fasteners along leading edge. Disconnect windshield washer hoses from nozzles. Set hood and cowl aside in protected area.
2. 2

   Remove Radiator and Cooling System Components
   Disconnect upper and lower radiator hoses from engine using hose clamp pliers. Disconnect coolant overflow hose. Disconnect transmission cooler lines from radiator using line wrench. Cap lines to prevent fluid loss. Remove radiator mounting bolts (2 bolts at top) and lift radiator assembly straight up and out of vehicle. Remove electric cooling fans with radiator as assembly. Disconnect heater hoses at firewall connections.
3. 3

   Disconnect AC and Power Steering Systems
   With AC system already evacuated, disconnect AC compressor lines at compressor using line disconnect tools. Cap all openings immediately to prevent moisture contamination. Disconnect power steering pressure and return hoses at pump. Cap pump ports and hose ends. Remove power steering reservoir from mounting location.
4. 4

   Disconnect Fuel System
   Locate fuel supply and return lines at fuel rail connections. Use appropriate fuel line disconnect tools to separate quick-connect fittings. Have shop towels ready to catch residual fuel. Cap fuel lines and fuel rail ports to prevent contamination. Disconnect fuel rail electrical connector and injector harness connections.
5. 5

   Remove Serpentine Belt and Accessories
   Using serpentine belt tool or breaker bar on tensioner pulley, rotate tensioner clockwise and slip belt off pulleys. Remove belt from engine bay. Remove AC compressor mounting bolts (4 bolts) and secure compressor to frame with wire - do not allow to hang by hoses. Remove power steering pump mounting bolts (3 bolts) and secure pump aside. Remove alternator electrical connections (B+ terminal and field connector), then remove alternator mounting bolts (verify count per service manual) and remove alternator.
6. 6

   Disconnect Engine Electrical Systems
   Disconnect main engine harness connector at PCM/bulkhead connection. Disconnect throttle body electrical connector. Disconnect all ignition coil connectors (10 coils total). Disconnect camshaft position sensor connector (1 sensor). Disconnect crankshaft position sensor connector. Disconnect oil pressure sensor and coolant temperature sensor connectors. Disconnect knock sensors (2 sensors). Disconnect MAP sensor and IAT sensor connectors. Disconnect alternator field connector if not already removed. Remove engine harness ground straps from engine block to frame (locate 2 primary ground points on passenger side of block).
7. 7

   Disconnect Throttle Body and Vacuum Systems
   Disconnect throttle body linkage at throttle lever. If equipped with cruise control, disconnect cruise control cable. Disconnect vacuum brake booster line from intake manifold. Disconnect PCV hose from valve cover. Disconnect EVAP purge solenoid vacuum line and electrical connector. Disconnect any remaining vacuum lines, marking each for reinstallation reference.
8. 8

   Disconnect Exhaust System
   From underneath vehicle, spray exhaust flange bolts with penetrating oil and allow to soak. Remove exhaust manifold-to-header pipe flange nuts at both banks (3 nuts per side, 6 total). Separate exhaust pipes from manifolds using pry bar if necessary. Support exhaust system forward section with wire or exhaust hangers to prevent strain on remaining connections.
9. 9

   Separate Transmission from Engine
   Ensure transmission jack is properly supporting transmission weight. This vehicle uses a manual transmission with a clutch — there is no torque converter or flexplate to unbolt. Disconnect the clutch hydraulic line/slave cylinder as required. Remove starter motor by disconnecting electrical connections (B+ cable and solenoid trigger wire) and removing starter mounting bolts (2 bolts). Remove transmission bellhousing-to-engine block bolts - verify all bolts are removed including upper bellhousing bolts accessible from engine bay (typical count is 6-8 bolts depending on transmission type). Carefully slide transmission back approximately 2 inches on jack to separate input shaft from pilot bearing while keeping transmission level. Note: Remove clutch slave cylinder/hydraulic line access as needed. Note: this is a manual transmission — there is no torque converter. Support the transmission and prepare to separate it from the engine (clutch and flywheel remain with engine unless being serviced).
10. 10

    Attach Engine Hoist and Remove Motor Mounts
    Thread lifting chains or straps through engine lift brackets on cylinder heads. The Viper V10 has factory lift points cast into heads near front and rear. Attach chains to engine leveler on hoist. Take up slack in hoist chain until slight tension is on engine - do not lift yet. Remove engine mount-to-frame bracket bolts on both sides (2 bolts per side, 4 total). Remove engine mount-through-bolts connecting mounts to engine block (1 bolt per side, 2 total). Verify all electrical, fuel, coolant, vacuum, and mechanical connections are disconnected.
11. 11

    Remove Engine from Vehicle
    With assistant guiding, slowly raise engine using hoist while monitoring clearance around engine bay. Use engine leveler to adjust angle - engine will need to tilt slightly nose-up to clear firewall and subframe. As engine rises, continue checking for any missed connections or interference points. Lift engine high enough to clear radiator support and front body structure. Once clear of engine bay, swing hoist forward and lower engine onto engine stand or secure work surface. Remove lifting chains.
12. 12

    Transfer External Components to New Long Block
    Working on old engine, systematically remove and transfer all external components to new long block: Remove intake manifold (multiple bolts in specific pattern), exhaust manifolds using penetrating oil on studs, valve covers, thermostat housing, water pump, timing cover if accessible, oil pan if needed for pickup tube clearance, oil filter adapter, all sensors (coolant temp, oil pressure, cam position sensor, crank position, knock sensors), motor mounts, flexplate/flywheel, rear main seal housing, fuel rail and injectors as assembly, throttle body, alternator brackets, AC compressor brackets, power steering pump brackets, and any wiring harness brackets or grounds. Inspect all components for wear and replace as needed. Install new gaskets on all mating surfaces. Apply anti-seize to exhaust manifold studs before installation. Torque all fasteners to specification.
13. 13

    Install New Long Block into Vehicle
    Attach lifting chains to new engine using same lift points. Raise engine with hoist to appropriate height and carefully guide into engine bay. Use engine leveler to adjust angle for clearance. Lower engine slowly while aligning motor mount brackets with frame mounts. With assistant guiding from below and sides, continue lowering until engine mounts align. Install engine mount-through-bolts finger tight, then mount-to-frame bolts. Once all mount hardware is installed, torque mounting bolts to specification. Remove lifting chains from engine.
14. 14

    Reconnect Transmission to Engine
    With transmission supported on jack, carefully slide transmission forward toward engine, aligning the input shaft with the clutch disc splines and pilot bearing. Align transmission with engine block dowel pins. Install all transmission-to-engine bellhousing bolts and torque to specification in star pattern.ft to access torque converter bolt holes through inspection cover opening. Install all torque converter-to-flexplate bolts and torque to specification. Install starter motor with new mounting bolts if original threads are damaged, connect electrical terminals (B+ cable and solenoid trigger), and torque starter bolts. Install transmission inspection cover. Note: clutch-pressure-plate-bolts
15. 15

    Reconnect Exhaust System
    From underneath vehicle, align exhaust pipes with exhaust manifold flanges. Install new exhaust manifold gaskets if not already done during component transfer. Install exhaust flange nuts at both banks and torque to specification. Ensure exhaust system has proper clearance from frame, transmission, and driveshaft throughout range of motion.
16. 16

    Reinstall Accessories and Serpentine Belt
    Install alternator to mounting bracket and torque bolts to specification. Connect alternator electrical connections (B+ terminal and field connector). Install power steering pump to bracket and torque mounting bolts to specification. Install AC compressor to bracket and torque mounting bolts to specification. Route serpentine belt around all pulleys following belt routing diagram on fan shroud or underhood label. Using belt tool on tensioner, rotate tensioner clockwise and slip belt onto final pulley. Release tensioner and verify belt is properly seated in all pulley grooves.
17. 17

    Reconnect All Electrical Connections
    Working systematically, reconnect all electrical connections in reverse order of removal: Main engine harness connector at bulkhead/PCM, throttle body connector, all 10 ignition coil connectors, camshaft position sensor connector, crankshaft position sensor, oil pressure sensor, coolant temperature sensor, both knock sensors, MAP sensor, IAT sensor, fuel injector harness, EVAP purge solenoid, and any additional sensors. Install engine harness ground straps to block and frame. Verify all connectors are fully seated and locked.
18. 18

    Reconnect Fuel System
    Remove caps from fuel lines and fuel rail ports. Connect fuel supply and return lines to fuel rail using quick-connect fittings - push firmly until audible click is heard and verify connection by pulling on line. Connect fuel injector electrical harness if not done in previous step.
19. 19

    Reconnect AC and Power Steering Systems
    Remove caps from AC compressor ports and line fittings. Install AC lines to compressor and torque fittings to specification using line wrenches. Connect power steering pressure and return hoses to pump. Install power steering fluid reservoir to mounting location. Secure all lines with proper routing clips and brackets.
20. 20

    Install Radiator and Cooling System
    Install radiator with cooling fans as assembly, guiding into position and aligning lower mount pins with frame receptacles. Install upper radiator mounting bolts and torque to specification. Connect transmission cooler lines to radiator. Connect upper and lower radiator hoses to engine using new hose clamps. Connect coolant overflow hose. Connect heater hoses at firewall. Verify all hose clamps are tight.
21. 21

    Reconnect Throttle Body and Vacuum Systems
    Connect throttle body linkage to throttle lever and adjust for smooth operation with no binding. Connect cruise control cable if equipped. Reconnect vacuum brake booster line to intake manifold. Connect PCV hose to valve cover. Connect EVAP purge solenoid vacuum line and electrical connector. Reconnect all remaining vacuum lines per earlier reference marks or photos.
22. 22

    Install Cowl and Hood
    Position cowl panel and install plastic clips and fasteners along leading edge. Connect windshield washer hoses to nozzles. With assistant supporting hood, align hood with marked hinge positions and install hood hinge bolts finger tight (4 bolts total). Check hood alignment with fenders and adjust as needed, then torque hinge bolts to specification.
23. 23

    Fill All Fluids
    Install new oil filter and hand-tighten plus 3/4 turn. Install oil drain plug with new crush washer and torque to specification. Fill engine with 11 quarts of 0W-40 full synthetic oil through oil fill cap. Fill coolant system: Start by filling radiator completely with Zerex G-05 HOAT 50/50 coolant. Fill coolant overflow reservoir to COLD mark. Fill power steering reservoir with the manufacturer-specified power steering fluid (verify ATF+4 vs. dedicated PS fluid per service manual) to proper level. Check transmission fluid level per manufacturer procedure (if accessible while cold). Do not start engine yet - proceed to final verification steps.
24. 24

    Final Systems Check and Initial Start
    Reinstall front wheels and torque lug nuts to specification. Lower vehicle to ground. Reinstall battery, connecting positive cable first, then negative. Perform final visual inspection of entire engine bay, verifying all connections are secure and no tools or parts are left in engine bay. Turn ignition to ON position (do not start) and observe for fuel leaks at rail and lines. Check for any warning lights on instrument cluster. Prime fuel system by cycling ignition ON for 5 seconds, OFF for 10 seconds, repeat 3 times. Start engine and immediately check for leaks (oil, coolant, fuel, power steering). Allow engine to idle and warm to operating temperature. Monitor temperature gauge closely. Bleed cooling system by opening bleed screw on thermostat housing and adding coolant until steady stream flows. As engine warms, check coolant level and add as needed - system will require full 19 quarts. Check for proper oil pressure on gauge. Listen for unusual noises.
25. 25

    AC System Recharge and Final Checks
    Have AC system professionally recharged with R-134a refrigerant to proper capacity by certified technician. After recharge, test AC operation. Check power steering fluid level and top off as needed. Check for any fluid leaks underneath vehicle with engine at operating temperature. Perform final torque verification on all critical fasteners accessible from engine bay (motor mounts, transmission bell housing accessible bolts). Reset PCM by disconnecting battery for 30 seconds if check engine light is present due to lost fuel trims or incomplete monitors. Test drive vehicle to verify proper operation under load and at highway speeds.

Reassembly

1. All installation follows removal in reverse order with new gaskets throughout.
2. Transfer all external components from old long block to new long block with new gaskets and seals at every mating surface.
3. Torque all fasteners to specification using torque wrench and angle gauge where TTY (torque-to-yield) procedure is specified.
4. Apply anti-seize compound to exhaust manifold studs and spark plug threads before installation.
5. Use proper RTV silicone sealant on oil pan corners and timing cover-to-block joints per factory service manual specifications.
6. Ensure all electrical connectors are fully seated and locked - verify by gentle pull test.
7. Double-check routing of all hoses, lines, and wiring harnesses to avoid contact with hot exhaust components or moving parts.
8. Bleed cooling system completely using thermostat housing bleed screw - air pockets will cause overheating.

Verification

• Start engine and verify oil pressure gauge shows normal pressure (40+ psi at idle when warm).
• Verify no leaks at all fluid connection points (oil, coolant, fuel, power steering, AC, transmission).
• Verify coolant temperature reaches normal operating range (190-210°F) and remains stable.
• Check that all 10 cylinders are firing - rough idle indicates misfire or electrical connection issue.
• Verify all accessories function properly (alternator charging, AC cooling, power steering assist).
• Test drive vehicle through full RPM range and verify smooth operation with no unusual noises or vibrations.
• Verify no check engine light or warning lights on instrument cluster after drive cycle.
• Recheck all fluid levels after test drive with engine at operating temperature - top off as needed.
• Inspect underneath vehicle for any new leaks after test drive.
• Verify transmission shifts properly through all gears under load.

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