2002 DODGE RAM Service Repair Manual

service keyless entry dashboard wiper size coolant wiring diagram

Page 1185 of 2255

DODGE RAM 2002 Service Repair Manual (2) Install the dipstick bracket on to the exhaust
manifold (right side only).
(3) Position washers and exhaust heat shields onto
the manifold stud bolts (Fig. 76). Be sure the tabs on
the heat shield

(2) Install the dipstick bracket on to the exhaust
manifold (right side only).
(3) Position washers and exhaust heat shields onto
the manifold stud bolts (Fig. 76). Be sure the tabs on
the heat shields are hooked over the top of the
exhaust gasket. Install the nuts and tighten to 20
N´m (175 in. lbs.) torque.
(4) Raise and support the vehicle.
(5) Assemble exhaust pipe to manifold.
(6) Lower the vehicle.
(7) Connect the negative cable to the battery.
(8) Start engine check for leaks.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).
(4) Remove fan and fan shroud (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(5) Unbolt A/C compressor and set on top of
engine.
(6) Remove generator, air pump, and bracket
assembly.
(7) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(8) Remove damper bolt and washer.
(9) Using Special Tool 1026 3-Jaw Puller remove
pulley/damper from the crankshaft. (Fig. 77)
(10) Loosen oil pan bolts and remove the front oil
pan bolts that mount the pan to the timing chain
cover.
(11) Remove the cover bolts.
(12) Remove timing chain cover and gasket using
extreme caution to avoid damaging oil pan gasket.
(13) Inspect surface of cover. Remove any burrs or
high spots.
INSTALLATION
(1) Be sure mating surfaces of timing chain cover
and cylinder block are clean and free from burrs.
(2) Lubricate the pump rotors using petroleum
jelly or lubriplate (Refer to 9 - ENGINE/LUBRICA-
TION/OIL PUMP - INSTALLATION).
(3) Using a new cover gasket, carefully install tim-
ing chain 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.(4) Tighten timing chain cover bolts to 47 N´m (35
ft. lbs.) torque. Tighten oil pan bolts to 24 N´m (215
in. lbs.) torque.
(5) Using Special Tool C-3688 Crankshaft Pulley/
Damper Installer Install pulley/vibration damper
(Fig. 78)
Fig. 77 PulleyÐDamper Removal
1-3JAWPULLER
Fig. 78 Installing Crankshaft
1 - SPECIAL TOOL C-3688
9 - 110 ENGINE 8.0LBR/BE
EXHAUST MANIFOLD (Continued)

Page 1186 of 2255

DODGE RAM 2002 Service Repair Manual (6) Prime oil pump by squirting oil in the oil filter
mounting hole and filling the J-trap of the front tim-
ing cover. When oil is running out, install oil filter
that has been filled with oil.
(7) I

(6) Prime oil pump by squirting oil in the oil filter
mounting hole and filling the J-trap of the front tim-
ing cover. When oil is running out, install oil filter
that has been filled with oil.
(7) Install water pump and housing assembly
using new o-ring (Refer to 7 - COOLING/ENGINE/
WATER PUMP - INSTALLATION).
(8) Install generator, air pump, and bracket assem-
bly.
(9) Install A/C compressor (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION).
(10) (10) Install the radiator fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(11) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(12) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(13) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect the negative cable to the battery.
(15) Road test vehicle and check for leaks.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Remove timing chain cover and gasket using
extreme caution to avoid damaging oil pan gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
(2) Aline camshaft and crankshaft centerline.
Remove camshaft sprocket attaching bolt and remove
timing chain and camshaft sprockets.
(3) Use puller 6444 and jaws 6820 to remove
crankshaft sprocket (Fig. 79).
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
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. lbs.) torque in thereverse direction. With the cylinder heads removed,
apply 20 N´m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 80).
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
INSTALLATION
(1) Line up key in crankshaft with keyway in
sprocket, press on crankshaft timing sprocket, use
tools C-3688, C-3718 and MB-990799, seat sprocket
against crankshaft shoulder (Fig. 81).
Fig. 79 Crankshaft Sprocket Removal.
1 - SPECIAL TOOL 6444
2 - SPECIAL TOOL 6820
Fig. 80 Measuring Timing Chain Stretch
1 - TORQUE WRENCH
2 - 3.175 MM
(0.125 IN.)
BR/BEENGINE 8.0L 9 - 111
TIMING BELT / CHAIN COVER(S) (Continued)

Page 1187 of 2255

DODGE RAM 2002 Service Repair Manual (2) Turn crankshaft to line up the timing mark
with the crankshaft and camshaft centerline.
(3) Put chain on camshaft sprocket.
(4) Align timing marks and install chain and cam-
shaft sprocket onto cr

Page 1188 of 2255

DODGE RAM 2002 Service Repair Manual ENGINE 5.9L DIESEL
TABLE OF CONTENTS
page page
ENGINE 5.9L DIESEL
DESCRIPTION........................115
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - MECHANICAL............116
DIAGN

ENGINE 5.9L DIESEL
TABLE OF CONTENTS
page page
ENGINE 5.9L DIESEL
DESCRIPTION........................115
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - MECHANICAL............116
DIAGNOSIS AND TESTINGÐSMOKE
DIAGNOSIS CHARTS..................118
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS........122
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS........122
STANDARD PROCEDUREÐHYDROSTATIC
LOCK..............................122
REMOVAL
REMOVALÐENGINE..................123
REMOVALÐCRANKCASE BREATHER
VAPOR CANISTER...................125
INSTALLATION
INSTALLATIONÐENGINE..............125
INSTALLATIONÐCRANKCASE BREATHER
VAPOR CANISTER...................126
SPECIFICATIONS
5.9L DIESEL........................127
TORQUE...........................127
SPECIAL TOOLS
5.9L DIESEL ENGINE.................128
ENGINE DATA PLATE
DESCRIPTION........................129
AIR CLEANER ELEMENT
REMOVAL............................129
INSTALLATION........................130
CYLINDER HEAD
DESCRIPTION........................130
REMOVAL............................130
CLEANING
CLEANINGÐCYLINDER HEAD..........134
CLEANINGÐCROSSHEADS............134
CLEANINGÐPUSHRODS..............134
INSPECTION
INSPECTIONÐCYLINDER HEAD.........134
INSPECTIONÐCROSSHEADS..........135
INSPECTIONÐPUSHRODS.............135
INSTALLATION........................136
CYLINDER HEAD COVER(S)
REMOVAL............................137
CLEANING...........................137
INSPECTION.........................138
INSTALLATION........................138INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................138
STANDARD PROCEDURE
STANDARD PROCEDURE -
VALVES,GUIDES AND SPRINGS.........138
STANDARD PROCEDUREÐVALVE LASH
ADJUSTMENT AND VERIFICATION.......141
REMOVAL............................143
INSTALLATION........................143
ROCKER ARM / ADJUSTER ASSY
DESCRIPTION........................145
REMOVAL............................145
CLEANING...........................146
INSPECTION.........................146
INSTALLATION........................148
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
BLOCK REFACING...................148
STANDARD PROCEDURE - CYLINDER
BORE - DE-GLAZE...................148
STANDARD PROCEDUREÐCYLINDER
BORE REPAIR.......................149
STANDARD PROCEDUREÐCAM BORE
REPAIR ............................151
INSPECTION.........................151
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS......152
REMOVALÐCAMSHAFT...............152
INSPECTION.........................155
INSTALLATION
INSTALLATIONÐCAMSHAFT BEARINGS . . 157
INSTALLATIONÐCAMSHAFT............157
CONNECTING ROD BEARINGS
STANDARD PROCEDUREÐCONNECTING
ROD BEARING AND CRANKSHAFT
JOURNAL CLEARANCE................158
CRANKSHAFT
DESCRIPTION........................159
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDUREÐMAIN BEARING
CLEARANCE........................159
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................160
INSTALLATION........................160
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................161
INSTALLATION........................162
BR/BEENGINE 5.9L DIESEL 9 - 113

Page 1189 of 2255

DODGE RAM 2002 Service Repair Manual CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................162
INSTALLATION........................163
SOLID LIFTERS/TAPPETS
REMOVAL............................164
CLEANING..................

CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................162
INSTALLATION........................163
SOLID LIFTERS/TAPPETS
REMOVAL............................164
CLEANING...........................164
INSPECTION.........................165
INSTALLATION........................165
PISTON & CONNECTING ROD
DESCRIPTION........................165
STANDARD PROCEDUREÐPISTON
GRADING..........................166
REMOVAL............................168
CLEANING...........................169
INSPECTION
INSPECTION........................169
Connecting Rods.....................169
INSTALLATION........................170
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................171
VIBRATION DAMPER
REMOVAL............................172
INSPECTION.........................172
INSTALLATION........................173
FRONT MOUNT
REMOVAL............................173
INSTALLATION........................174
REAR MOUNT
REMOVAL............................174
INSTALLATION........................174
LUBRICATION
DESCRIPTION........................174
OPERATION..........................174
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE.........................178
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
LEVEL.............................178
STANDARD PROCEDURE - ENGINE OIL
SERVICE...........................178OIL COOLER & LINES
CLEANING AND INSPECTION............179
OIL FILTER
REMOVAL............................179
INSTALLATION........................179
OIL PAN
REMOVAL............................179
CLEANING...........................179
INSPECTION.........................179
INSTALLATION........................180
OIL PRESSURE RELIEF VALVE
REMOVAL............................180
CLEANING...........................180
INSPECTION.........................180
INSTALLATION........................180
OIL PRESSURE SENSOR/SWITCH
REMOVAL............................181
INSTALLATION........................181
OIL PUMP
REMOVAL............................181
CLEANING...........................181
INSPECTION.........................181
INSTALLATION........................182
INTAKE MANIFOLD
REMOVAL............................184
CLEANING...........................184
INSPECTION.........................184
INSTALLATION........................184
EXHAUST MANIFOLD
REMOVAL............................185
CLEANING...........................185
INSPECTION.........................186
INSTALLATION........................186
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION.......................187
GEAR HOUSING
REMOVAL............................187
INSTALLATION........................188
GEAR HOUSING COVER
REMOVAL............................189
INSTALLATION........................190
9 - 114 ENGINE 5.9L DIESELBR/BE

Page 1190 of 2255

DODGE RAM 2002 Service Repair Manual ENGINE 5.9L DIESEL
DESCRIPTION
The cylinder block is constructed of cast iron. The
casting is a skirted design which incorporates longi-
tudal ribs for superior strength and noise reduction.
The block

Page 1191 of 2255

DODGE RAM 2002 Service Repair Manual The cylinders are numbered front front to rear
(Fig. 1);1to6.Thefiring order is 1±5±3±6±2±4.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES C

Page 1192 of 2255

DODGE RAM 2002 Service Repair Manual CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL
PRESSURE TOO HIGH1. Pressure switch/gauge not
operating properly.1. Verify pressure switch is functioning
correctly. If not, replace switch/gauge.

CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL
PRESSURE TOO HIGH1. Pressure switch/gauge not
operating properly.1. Verify pressure switch is functioning
correctly. If not, replace switch/gauge.
2. Engine running to cold. 2. Refer to Coolant Temperature Below
Normal (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
3. Oil viscosity too thick. 3. Make sure the correct oil is being used.
(Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
4. Oil pressure relief valve stuck
closed or binding4. Check and replace valve.
LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as
required.
2. Crankcase being overfilled. 2. Verify that the correct dipstick is being
used.
3. Incorrect oil specification or
viscosity.3. (a) Make sure the correct oil is being
used (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(b) Look for reduced viscosity from dilution
with fuel.
(c) Review/reduce oil change intervals.
4. Oil cooler leak 4. Check and replace the oil cooler.
5. High blow-by forcing oil out the
breather.5. Check the breather tube area for signs of
oil loss. Perform the required repairs.
6. Turbocharger leaking oil to the air
intake.6. Inspect the air ducts for evidence of oil
transfer. Repair as required.
7. Piston rings not sealing (oil being
consumed by the engine).7. Perform blow-by check. Repair as
required.
COMPRESSION KNOCKS 1. Air in the fuel system. 1. Bleed the fuel system (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
2. Poor quality fuel or water/gasoline
contaminated fuel.2. Verify by operating from a temporary
tank with good fuel. Clean and flush the
fuel tank. Replace fuel/water separator filter.
3. Engine overloaded. 3. Verify the engine load rating is not being
exceeded.
4. Incorrect injection pump timing. 4. Check injection pump for proper
installation.
5. Improperly operating injectors. 5. Check and replace inoperative injectors.
EXCESSIVE VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts.
2. Damaged fan or improperly
operating accessories.2. Check and replace the vibrating
components.
3. Improperly operating vibration
damper3. Inspect/replace vibration damper.
BR/BEENGINE 5.9L DIESEL 9 - 117
ENGINE 5.9L DIESEL (Continued)

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