2002 DODGE RAM Service Repair Manual

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Page 1129 of 2255

DODGE RAM 2002 Service Repair Manual (3) Remove power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(4) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(5) Loosen oil pan bolts and remove t

(3) Remove power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(4) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(5) Loosen oil pan bolts and remove the front bolt
at each side.
(6) Remove the cover bolts.
(7) Remove chain case cover and gasket using
extreme caution to avoid damaging oil pan gasket.
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
(2) The water pump mounting surface must be
cleaned.
(3) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of MopartSilicone Rubber Adhe-
sive Sealant, or equivalent, at the joint between tim-
ing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.
NOTE: Special Tool 6635 must be used to align the
front cover and seal with the crankshaft.
(4) Position the special tool 6635 onto the crank-
shaft (Fig. 72).(5) Tighten chain case cover bolts to 41 N´m (30
ft.lbs.) torque. Tighten oil pan bolts to 24 N´m (215
in. lbs.) torque.
(6) Remove special tool 6635.
(7) Inspect the seal flange on the vibration
damper.
(8) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(9) Install water pump and housing assembly
using new gaskets (Refer to 7 - COOLING/ENGINE/
WATER PUMP - INSTALLATION).
(10) Install power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(11) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(12) Install the cooling system fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(13) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(14) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(15) Connect the negative cable to the battery.
(16) Start engine check for leaks.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove Timing Chain Cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(3) Re-install the vibration damper bolt finger
tight. Using a suitable socket and breaker bar, rotate
the crankshaft to align timing marks as shown in
(Fig. 73).
(4) Remove camshaft sprocket attaching bolt and
remove timing chain with crankshaft and camshaft
sprockets.
INSPECTIONÐMEASURING TIMING CHAIN
STRETCH
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam-
shaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
N´m (30 ft. lbs.) torque with cylinder head installed
or 20 N´m (15 ft. lbs.) torque with cylinder head
removed. With a torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
Fig. 72 Position Special Tool 6635 onto Crankshaft
1 - SPECIAL TOOL 6635
2 - OIL SEAL
3 - TIMING CHAIN COVER
9 - 54 ENGINE 5.9LBR/BE
TIMING BELT / CHAIN COVER(S) (Continued)

Page 1130 of 2255

DODGE RAM 2002 Service Repair Manual move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N´m (30 ft

Page 1131 of 2255

DODGE RAM 2002 Service Repair Manual ENGINE 8.0L
TABLE OF CONTENTS
page page
ENGINE 8.0L
DESCRIPTION.........................58
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........58
DIAGNOSIS AND TEST

ENGINE 8.0L
TABLE OF CONTENTS
page page
ENGINE 8.0L
DESCRIPTION.........................58
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........58
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - PERFORMANCE...........59
DIAGNOSIS AND TESTINGÐ ENGINE
DIAGNOSIS - MECHANICAL.............61
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - LUBRICATION.............63
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE.............64
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE......64
STANDARD PROCEDURE
STANDARD PROCEDUREÐCYLINDER
BORE HONING.......................65
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........66
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.........66
STANDARD PROCEDUREÐHYDROSTATIC
LOCK...............................66
REMOVAL.............................67
INSTALLATION.........................68
SPECIFICATIONS
8.OL ENGINE........................68
TORQUE............................71
SPECIAL TOOLS
8.0L ENGINE.........................72
AIR CLEANER ELEMENT
REMOVAL - 8.0L........................75
INSTALLATION - 8.0L....................75
CYLINDER HEAD
DESCRIPTION.........................76
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE.....................76
REMOVAL.............................76
CLEANING............................77
INSPECTION..........................77
INSTALLATION.........................77
CYLINDER HEAD COVER(S)
DESCRIPTION.........................78
REMOVAL.............................78
CLEANING............................79
INSPECTION..........................79
INSTALLATION.........................79INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................80
STANDARD PROCEDURE
VALVE SERVICE......................80
REMOVAL
REMOVALÐVALVE STEM SEALS.........82
REMOVALÐVALVES AND VALVE SPRINGS . 82
CLEANING............................83
INSPECTION..........................83
INSTALLATION
INSTALLATIONÐVALVE STEM SEAL......83
INSTALLATIONÐVALVES AND VALVE
SPRINGS............................84
ROCKER ARM / ADJUSTER ASSY
REMOVAL.............................84
INSTALLATION.........................84
ENGINE BLOCK
CLEANING............................85
INSPECTION..........................85
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS.......85
REMOVALÐCAMSHAFT................85
INSTALLATION
INSTALLATIONÐCAMSHAFT BEARINGS . . . 86
INSTALLATIONÐCAMSHAFT............86
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING................87
CRANKSHAFT
REMOVAL.............................87
INSTALLATION.........................88
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDUREÐFITTING
CRANKSHAFT MAIN BEARINGS..........88
REMOVAL.............................88
INSTALLATION.........................88
CRANKSHAFT OIL SEAL - FRONT
REMOVAL
REMOVALÐFRONT OIL SEAL - FRONT
COVER INSTALLED....................89
REMOVALÐFRONT OIL SEAL - FRONT
COVER REMOVED....................89
INSTALLATION
INSTALLATIONÐFRONT OIL SEAL ± FRONT
COVER INSTALLED....................89
INSTALLATIONÐFRONT OIL SEAL - FRONT
COVER REMOVED....................90
9 - 56 ENGINE 8.0LBR/BE

Page 1132 of 2255

DODGE RAM 2002 Service Repair Manual CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................90
INSTALLATION.........................90
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL.............................90
INSTALLATION.........

CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................90
INSTALLATION.........................90
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL.............................90
INSTALLATION.........................90
HYDRAULIC LIFTERS
DIAGNOSIS AND TESTINGÐHYDRAULIC
TAPPETS............................91
REMOVAL.............................92
CLEANING............................92
INSTALLATION.........................92
PISTON & CONNECTING ROD
DESCRIPTION.........................93
STANDARD PROCEDUREÐPISTON FITTING . 93
REMOVAL.............................94
CLEANING............................94
INSPECTION..........................94
INSTALLATION.........................94
PISTON RINGS
STANDARD PROCEDUREÐFITTING PISTON
RINGS..............................95
VIBRATION DAMPER
REMOVAL.............................96
INSTALLATION.........................97
FRONT MOUNT
REMOVAL.............................97
INSTALLATION.........................98
REAR MOUNT
REMOVAL.............................98
INSTALLATION.........................98
LUBRICATION
DESCRIPTION.........................98
OPERATION...........................98
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE OIL
LEAKS..............................99
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE.........................101OIL
STANDARD PROCEDURE - ENGINE OIL....101
OIL FILTER
REMOVAL............................102
INSTALLATION........................102
OIL PAN
REMOVAL............................102
CLEANING...........................103
INSPECTION.........................103
INSTALLATION........................103
OIL PUMP
REMOVAL............................104
CLEANING...........................104
INSPECTION.........................104
INSTALLATION........................106
INTAKE MANIFOLD
DESCRIPTION........................106
DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE.................106
REMOVAL............................107
CLEANING...........................107
INSPECTION.........................108
INSTALLATION........................108
EXHAUST MANIFOLD
DESCRIPTION........................109
OPERATION..........................109
REMOVAL............................109
CLEANING...........................109
INSPECTION.........................109
INSTALLATION........................109
TIMING BELT / CHAIN COVER(S)
REMOVAL............................110
INSTALLATION........................110
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL............................111
INSPECTIONÐMEASURING TIMING CHAIN
STRETCH...........................111
INSTALLATION........................111
BR/BEENGINE 8.0L 9 - 57

Page 1133 of 2255

DODGE RAM 2002 Service Repair Manual ENGINE 8.0L
DESCRIPTION
The 8.0 Liter (488 CID) ten-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.

ENGINE 8.0L
DESCRIPTION
The 8.0 Liter (488 CID) ten-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
Engine lubrication system consists of a gerotor
type oil pump mounted in the timing chain cover and
driven by the crankshaft. The V-10 uses a full flow
oil filter.
The cylinders are numbered from front to rear; 1,
3, 5, 7, 9 on the left bank and 2, 4, 6, 8, 10 on the
right bank. The firing order is 1-10-9-4-3-6-5-8-7-2
(Fig. 1) .
The engine serial number is located on the lower
left front of the cylinder block in front of the engine
mount (Fig. 2) . When component part replacement is
necessary, use the engine type and serial number for
reference.
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 IdentificationÐ(Serial Number)
1 - ENGINE SERIAL NO.
2 - ENGINE MOUNT LOCATION
9 - 58 ENGINE 8.0LBR/BE

Page 1134 of 2255

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 1135 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.

Page 1136 of 2255

DODGE RAM 2002 Service Repair Manual CONDITION POSSIBLE CAUSES CORRECTION
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary
(Refer to 8 -

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