2002 DODGE RAM Service Repair Manual

steering wheel coolant glove box technical specifications towing service

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DODGE RAM 2002 Service Repair Manual contained within a small, rectangular, molded plastic
housing and is connected to all of the required inputs
and outputs by five integral male spade-type termi-
nals that extend from the bottom of the

contained within a small, rectangular, molded plastic
housing and is connected to all of the required inputs
and outputs by five integral male spade-type termi-
nals that extend from the bottom of the relay base.
Relays cannot be adjusted or repaired and, if faulty
or damaged, the unit must be replaced.
OPERATION
A micro-relay is an electromechanical switch that
uses a low current input from one source to control a
high current output to another device. The movable
common feed contact point is held against the fixed
normally closed contact point by spring pressure.
When the relay coil is energized, an electromagnetic
field is produced by the coil windings. This electro-
magnetic field draws the movable relay contact point
away from the fixed normally closed contact point,
and holds it against the fixed normally open contact
point. When the relay coil is de-energized, spring
pressure returns the movable contact point back
against the fixed normally closed contact point. A
resistor is connected in parallel with the relay coil in
the relay, and helps to dissipate voltage spikes and
electromagnetic interference that can be generated as
the electromagnetic field of the relay coil collapses.
DIAGNOSIS AND TESTING - MICRO-RELAY
(1) Remove the relay from its mounting location.
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 67.5 - 82.5 ohms. If OK, go to
Step 4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, reinstall the relay and use a DRBIIIt
scan tool to perform further testing. Refer to the
appropriate diagnostic information.
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
REMOVAL
(1) Remove the relay by grasping it firmly and
pulling it straight out from its receptacle.
INSTALLATION
(1) Align the micro-relay terminals with the termi-
nal cavities in the receptacle.(2) Push firmly and evenly on the top of the relay
until the terminals are fully seated in the terminal
cavities in the receptacle.
RELAY
DESCRIPTION
A relay is an electromechanical device that
switches fused battery current to a electrical compo-
nent when the ignition switch is turned to the Acces-
sory or Run positions, or when controlled by a
electronic module. The relays are located in the junc-
tion block or power distribution center (Fig. 17).
The relay is a International Standards Organiza-
tion (ISO) relay. Relays conforming to the ISO speci-
fications have common physical dimensions, current
capacities, terminal patterns, and terminal functions.
A relay cannot be repaired or adjusted and, if
faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor and three (two fixed and one movable) elec-
trical contacts. The movable (common feed) relay con-
tact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor is connected in
parallel with the electromagnetic coil in the relay,
and helps to dissipate voltage spikes that are pro-
duced when the coil is de-energized.
Fig. 17 TYPE 1 RELAY
8W - 97 - 14 8W-97 POWER DISTRIBUTIONBR/BE
MICRO-RELAY (Continued)

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DODGE RAM 2002 Service Repair Manual DIAGNOSIS AND TESTING - RELAY
The relays are located in the junction block or
power distribution center. For complete circuit dia-
grams, refer toWiring Diagrams.
(1) Remove the relay from its mountin

DIAGNOSIS AND TESTING - RELAY
The relays are located in the junction block or
power distribution center. For complete circuit dia-
grams, refer toWiring Diagrams.
(1) Remove the relay from its mounting location.
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 60.7 - 80.3 ohms. If OK, go to
Step 4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform the Relay Circuit Test that
follows. If not OK, replace the faulty relay.
DIAGNOSIS AND TESTING - RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) of
the junction block or power distribution center is con-
nected to battery voltage and should be hot at all
times. Check for battery voltage at the fused B(+) cir-
cuit cavity in the junction block receptacle for the
relay. If OK, go to Step 2. If not OK, repair the fused
B(+) circuit to the Power Distribution Center (PDC)
fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the fused B(+) fuse in the junction block that feedsthe accessory when the relay is energized by the igni-
tion switch. There should be continuity between the
junction block cavity for relay terminal 87 and the
fused B(+) fuse in the junction block at all times. If
OK, go to Step 4. If not OK, repair the open fused
B(+) circuit to the junction block fuse as required.
(4) The coil ground terminal (85) is connected to
the electromagnet in the relay. It receives battery
feed to energize the relay when the ignition switch is
in the Accessory or Run positions. Turn the ignition
switch to the On position. Check for battery voltage
at the fused ignition switch output (acc/run) circuit
cavity for relay terminal 85 in the junction block
receptacle for the relay. If OK, go to Step 5. If not
OK, repair the open fused ignition switch output
(acc/run) circuit to the ignition switch as required.
(5) The coil battery terminal (86) is connected to
the electromagnet in the relay. The junction block
cavity for this terminal should have continuity to
ground at all times. If not OK, repair the open
ground circuit to ground as required.
REMOVAL
(1) Remove the relay by grasping it firmly and
pulling it straight out from its receptacle.
INSTALLATION
(1) Position the relay to the proper receptacle.
(2) Align the relay terminals with the terminal
cavities in the receptacle.
(3) Push firmly and evenly on the top of the relay
until the terminals are fully seated in the terminal
cavities in the receptacle.
BR/BE8W-97 POWER DISTRIBUTION 8W - 97 - 15
RELAY (Continued)

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DODGE RAM 2002 Service Repair Manual ENGINE
TABLE OF CONTENTS
page page
ENGINE 5.9L.............................. 1
ENGINE 8.0L............................. 56ENGINE 5.9L DIESEL..................... 113
ENGINE 5.9L
TABLE OF CONTENTS
page

ENGINE
TABLE OF CONTENTS
page page
ENGINE 5.9L.............................. 1
ENGINE 8.0L............................. 56ENGINE 5.9L DIESEL..................... 113
ENGINE 5.9L
TABLE OF CONTENTS
page page
ENGINE 5.9L
DESCRIPTION..........................3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............3
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTINGÐ ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - LUBRICATION..............8
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE..............9
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.......9
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........10
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.........11
STANDARD PROCEDUREÐHYDROSTATIC
LOCK...............................11
STANDARD PROCEDURE - CYLINDER
BORE HONING.......................11
REMOVAL.............................12
INSTALLATION.........................12
SPECIFICATIONS
5.9L ENGINE.........................13
TORQUE............................17
SPECIAL TOOLS
5.9L ENGINE.........................18
CYLINDER HEAD
DESCRIPTION
DESCRIPTIONÐCYLINDER HEAD........20
DESCRIPTION - CYLINDER HEAD COVER
GASKET............................20OPERATION
OPERATIONÐCYLINDER HEAD..........21
OPERATION - CYLINDER HEAD COVER
GASKET............................21
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE.....................21
REMOVAL.............................21
CLEANING............................22
INSPECTION..........................22
INSTALLATION.........................22
CYLINDER HEAD COVER(S)
REMOVAL.............................23
CLEANING............................23
INSPECTION..........................23
INSTALLATION.........................23
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................23
STANDARD PROCEDUREÐVALVES, GUIDES
AND SPRINGS.......................23
REMOVAL.............................25
CLEANING............................26
INSPECTION..........................26
INSTALLATION.........................26
ROCKER ARM / ADJUSTER ASSEMBLY
REMOVAL.............................26
INSTALLATION.........................26
ENGINE BLOCK
CLEANING............................27
INSPECTION..........................27
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS.......27
REMOVALÐCAMSHAFT................28
INSTALLATION
INSTALLATIONÐCAMSHAFT BEARINGS . . . 28
INSTALLATIONÐCAMSHAFT............29
BR/BEENGINE 9 - 1

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DODGE RAM 2002 Service Repair Manual CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING................29
CRANKSHAFT
DESCRIPTION.........................29
OPERATION...........................29
REMOVAL..........

CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING................29
CRANKSHAFT
DESCRIPTION.........................29
OPERATION...........................29
REMOVAL.............................30
INSTALLATION.........................30
CRANKSHAFT MAIN BEARINGS
DESCRIPTION.........................31
OPERATION...........................31
STANDARD PROCEDUREÐCRANKSHAFT
MAIN BEARING FITTING................31
REMOVAL.............................31
INSTALLATION.........................32
CRANKSHAFT OIL SEAL - FRONT
DESCRIPTION.........................32
OPERATION...........................32
REMOVAL.............................32
INSTALLATION.........................32
CRANKSHAFT OIL SEAL - REAR
DESCRIPTION.........................33
OPERATION...........................33
REMOVAL.............................33
INSTALLATION.........................34
DISTRIBUTOR BUSHING
REMOVAL.............................35
INSTALLATION.........................35
HYDRAULIC LIFTERS
DIAGNOSIS AND TESTINGÐHYDRAULIC
TAPPETS............................36
REMOVAL.............................37
CLEANING............................37
INSTALLATION.........................37
PISTON & CONNECTING ROD
DESCRIPTION.........................38
STANDARD PROCEDURE - PISTON FITTING . 38
REMOVAL.............................38
CLEANING............................39
INSPECTION..........................39
INSTALLATION.........................39
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING.............................39
VIBRATION DAMPER
REMOVAL.............................40
INSTALLATION.........................40
FRONT MOUNT
REMOVAL.............................41
INSTALLATION.........................42
REAR MOUNT
REMOVAL.............................42INSTALLATION.........................42
LUBRICATION
DESCRIPTION.........................42
OPERATION...........................42
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE OIL
LEAKS..............................43
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE..........................45
OIL
STANDARD PROCEDURE - ENGINE OIL.....45
OIL FILTER
REMOVAL.............................46
INSTALLATION.........................46
OIL PAN
REMOVAL.............................46
CLEANING............................46
INSPECTION..........................46
INSTALLATION.........................46
OIL PUMP
REMOVAL.............................47
DISASSEMBLY.........................47
INSPECTION..........................47
ASSEMBLY............................49
INSTALLATION.........................50
INTAKE MANIFOLD
DESCRIPTION.........................50
OPERATION...........................50
DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE..................50
REMOVAL.............................50
CLEANING............................51
INSPECTION..........................51
INSTALLATION.........................51
EXHAUST MANIFOLD
DESCRIPTION.........................53
OPERATION...........................53
REMOVAL.............................53
CLEANING............................53
INSPECTION..........................53
INSTALLATION.........................53
TIMING BELT / CHAIN COVER(S)
REMOVAL.............................53
INSTALLATION.........................54
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL.............................54
INSPECTIONÐMEASURING TIMING CHAIN
STRETCH...........................54
INSTALLATION.........................55
9 - 2 ENGINE 5.9LBR/BE

Page 1078 of 2255

DODGE RAM 2002 Service Repair Manual ENGINE 5.9L
DESCRIPTION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fue

ENGINE 5.9L
DESCRIPTION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
The engine lubrication system consists of a rotor
type oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 1) .
The engine serial number is stamped into a
machined pad located on the left, front corner of the
cylinder block. When component part replacement is
necessary, use the engine type and serial number for
reference (Fig. 2) .
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING - Preformance) or (Refer to 9 - ENGINE - DIAG-
NOSIS AND TESTING - Mechanical). Refer to 14 -
FUEL SYSTEM for fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING)
²Cylinder Combustion Pressure Leakage Test
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
²Cylinder Head Gasket Failure Diagnosis (Refer
to 9 - ENGINE/CYLINDER HEAD - DIAGNOSIS
AND TESTING)
²Intake Manifold Leakage Diagnosis (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING)
²Lash Adjuster (Tappet) Noise Diagnosis (Refer to
9 - ENGINE/ENGINE BLOCK/HYDRAULIC LIFT-
ERS (CAM IN BLOCK) - DIAGNOSIS AND TEST-
ING)
²Engine Oil Leak Inspection (Refer to 9 -
ENGINE/LUBRICATION - DIAGNOSIS AND TEST-
ING)
Fig. 1 Firing Order
Fig. 2 Engine Identification Number
BR/BEENGINE 5.9L 9 - 3

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DODGE RAM 2002 Service Repair Manual DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - PERFORMANCE
PERFORMANCE DIAGNOSIS CHARTÐGASOLINE ENGINES
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace

Page 1080 of 2255

DODGE RAM 2002 Service Repair Manual CONDITION POSSIBLE CAUSES CORRECTION
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression (Refer
to 9 - ENGINE - DIAGNOSIS AND
TESTING).
9.

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