2002 DODGE RAM oil pressure

(3) Always check the condition of the used oil. This
can give you an indication of engine problems that
might exist.
²Thin, black oil indicates fuel dilution.
²Milky discoloration indicates coolant dilution.
(4) Clean the area around the oil filter head.
Remove the filter (Refer to 9 - ENGINE/LUBRICA-
TION/OIL FILTER - REMOVAL).
(5) Install new oil filter (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION).
(6) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and seal-
ing surface on the oil pan and drain plug.
(7) Install the drain plug. Tighten the plug to 50
N´m (37 ft. lbs.) torque.
(8) Use only High-Quality Multi-Viscosity lubricat-
ing oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(9) Fill the engine with the correct grade of new oil
(Refer to LUBRICATION & MAINTENANCE/FLUID
CAPACITIES - SPECIFICATIONS).
(10) Start the engine and operate it at idle for sev-
eral minutes. Check for leaks at the filter and drain
plug.
(11) Stop engine. Wait several minutes to allow the
oil to drain back to the pan and check the level
again.
USED ENGINE OIL DISPOSAL Care should be
exercised when disposing of used engine oil after
it has been drained from a vehicle's engine.
OIL COOLER & LINES
CLEANING AND INSPECTION
Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. If the element leaks, replace the
element.
OIL FILTER
REMOVAL
(1) Clean the area around the oil filter head.
Remove the filter using a 90-95 mm filter wrench.
(2) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter
head. Make sure it is removed.
INSTALLATION
(1) Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine.
(2) Apply a light film of lubricating oil to the seal-
ing surface before installing the filter.
CAUTION: Mechanical over-tightening may distort
the threads or damage the filter element seal.
(3) Install the filter until it contacts the sealing
surface of the oil filter adapter. Tighten filter an
additional ó turn.
OIL PAN
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove transmission and transfer case (if
equipped).
(4) Remove flywheel.
(5) Disconnect starter cables from starter motor.
(6) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
(7) Drain the engine oil (Refer to 9 - ENGINE/LU-
BRICATION/OIL - STANDARD PROCEDURE).
(8) Install the oil pan drain plug with a new seal-
ing washer and tighten to 60 N´m (44 ft. lbs.) torque.
(9) Remove oil pan bolts, break the pan to block
seal, and lower pan slightly and remove oil suction
tube fasteners.
(10) Remove oil pan and suction tube (Fig. 151).
CLEANING
Remove all gasket material from the oil pan and
cylinder block sealing surfaces. Extra effort may be
required around T-joint areas. Clean oil pan and
flush suction tube with a suitable solvent.
INSPECTION
Inspect the oil pan, suction tube, and tube braces
for cracks and damage. Replace any defective compo-
nent. Inspect the oil drain plug and drain hole
threads. Inspect the oil pan sealing surface for
straightness. Repair any minor imperfections with a
ball-peen hammer. Do not attempt to repair an oil
pan by welding.
BR/BEENGINE 5.9L DIESEL 9 - 179
OIL (Continued)

INSTALLATION
(1) Fill the T-joint between the pan rail/gear hous-
ing and pan rail/rear seal retainer with sealant. Use
MopartSilicone Rubber Adhesive Sealant or equiva-
lent.
(2) Apply a film of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the oil pan gasket.
Apply sealant only to the side that faces the oil pan.
(3) Place suction tube in oil pan and guide them
into place (Fig. 151). Using a new tube to oil pump
gasket, install and tighten the suction tube bolts by
hand. Starting with the oil pump inlet bolts, tighten
the bolts to 24 N´m (18 ft. lbs.) torque. Tighten the
remaining tube brace bolts to 24 N´m (18 ft. lbs.)
torque.
(4) Starting in the center and working outward,
tighten the oil pan bolts to 24 N´m (18 ft. lbs.)
torque.
(5) Install the flywheel housing assembly with the
starter motor attached and tighten bolts to 60 N´m
(44 ft. lbs.) torque.
(6) Connect starter motor cables.
(7) Install transmission and transfer case (if
equipped).
(8) Lower vehicle.
(9) Install battery negative cables.
(10) Fill the crankcase with new engine oil.
(11) Start engine and check for leaks. Stop engine,
check oil level, and adjust, if necessary.
OIL PRESSURE RELIEF VALVE
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the threaded plug, spring and plunger
(Fig. 152). Insert a finger or a seal pick to lift the
plunger from the bore.
NOTE: If the plunger is stuck in the bore, it will be
necessary to remove the filter head.
CLEANING
(1) Clean the regulator spring and plunger with a
suitable solvent and blow dry with compressed air. If
the plunger bore requires cleaning, it is necessary to
remove the oil filter head to avoid getting debris into
the engine.
INSPECTION
Inspect the plunger and plunger bore for cracks
and excessive wear. Polished surfaces are acceptable.
Verify that the plunger moves freely in the bore.
Check the spring for height and load limitations
(Fig. 153) . Replace the spring if out of limits shown
in the figure.
INSTALLATION
(1) Install the plunger, spring, and plug as shown
in (Fig. 152). Tighten the plug to 80 N´m (60 ft. lbs.)
torque.
(2) Connect the battery negative cables.
(3) Start the engine and verify that it has oil pres-
sure.
Fig. 151 Oil Pan, Suction Tube and Gasket
1 - GASKET
2 - SUCTION TUBE
3 - OIL PAN
Fig. 152 Oil Pressure Regulator
1 - OIL FILTER
2 - PLUG
3 - GASKET
4 - SPRING
5 - VALVE
9 - 180 ENGINE 5.9L DIESELBR/BE
OIL PAN (Continued)

OIL PRESSURE SENSOR/
SWITCH
REMOVAL
(1) Disconnect the battery negative cables.
(2) Disconnect the oil pressure sensor connector
(Fig. 154).
(3) Using a suitable socket, remove the oil pres-
sure sensor from the block (counter-clockwise).
INSTALLATION
(1) If the sensor is not being replaced, inspect the
o-ring (Fig. 155) and replace if necessary.
(2) Install the oil pressure sensor and tighten to 16
N´m (144 in. lbs.) torque.(3) Connect the battery negative cables.
(4) Start engine and check for oil leaks at the sen-
sor.
OIL PUMP
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove fan/drive assembly (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(3) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove the fan support/hub assembly.
(5) Remove crankshaft damper (Fig. 156) (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(6) Remove the gear housing cover (Fig. 157)
(Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUS-
ING COVER - REMOVAL).
(7) Remove the four mounting bolts and pull the
pump from the bore in the cylinder block (Fig. 158).
CLEANING
Clean all parts in solvent and dry with compressed
air. Clean the old sealer residue from the back of the
gear housing cover and front of the gear housing.
INSPECTION
Disassemble and inspect the oil pump as fol-
lows:
(1) Visually inspect the lube pump gears for chips,
cracks or excessive wear.
Fig. 155 Oil Pressure Sensor and
1 - ENGINE OIL PRESSURE SENSOR
2 - O-RING
Fig. 153 Oil Pressure Regulator Spring Check
Fig. 154 Oil Pressure Sensor Location
1 - ENGINE OIL PRESSURE SENSOR
2 - ELECTRIAL CONNECTOR
3 - ECM
BR/BEENGINE 5.9L DIESEL 9 - 181
OIL PRESSURE RELIEF VALVE (Continued)

(7) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover
sealing surface.
(8) Install the gear housing cover (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- INSTALLATION).
(9) Install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(10) Install the fan support/hub assembly and
torque bolts to 24 N´m (18 ft. lbs.).
(11) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(12) Install the cooling fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
(13) Connect battery negative cables.
(14) Start engine and check for oil leaks.
INTAKE MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the charge air cooler outlet tube from
the air inlet housing (Fig. 166).
(3) Remove the engine oil dipstick tube mounting
bolt (Fig. 166). Position dipstick tube to the side.
(4) Disconnect the air grid heater power cables at
the cable mounting studs (Fig. 167).
(5) Remove the four (4) air inlet housing mounting
bolts (Fig. 167) and remove the housing from top of
the heater elements.
(6) Remove the intake air grid heater from the
manifold (Fig. 168).
(7) Remove the high pressure fuel lines.(Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- REMOVAL).
(8) Remove the remaining intake manifold cover-
to-cylinder head bolts.
(9) Remove the intake manifold cover and gasket.
Keep the gasket material and any other material out
of the air intake.
(10) Clean the intake manifold cover and cylinder
head sealing surface.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) Using a new gasket, install the intake manifold
cover.
(2) Install the cover-to-cylinder head bolts that do
not hold down the high pressure fuel line support
brackets. Tighten the bolts to 24 N´m (18 ft. lbs.)
torque.
(3) Install the high pressure fuel lines (Refer to 14
- FUEL SYSTEM/FUEL DELIVERY/FUEL LINES -
INSTALLATION).
(4) Install the high pressure fuel line support
bracket-to-intake manifold cover bolts and tighten to
24 N´m (18 ft. lbs.) torque.
(5) Using two (2) new gaskets, install the intake
air grid heater and air inlet housing (Fig. 167). Posi-
tion the ground cable and install and tighten the
bolts to 24 N´m (18 ft. lbs.) torque.
(6) Install and tighten the air intake heater power
supply nuts to 14 N´m (120 in. lbs.) torque.
(7) Install the engine oil dipstick tube and mount-
ing bolt (Fig. 166).
Fig. 166 Charge Air Cooler Air Tube
1 - FRONT WIRING CLIP
2 - GROUND CABLE
3 - TUBE BOLT
4 - ENGINE OIL DIPSTICK TUBE
5 - CLAMPS
6 - AIR TUBE (INT. MAN.-TO-INTERCOOLER)
7 - RUBBER HOSE
8 - AIR INTAKE HOUSING
9 - CABLE BRACKET HOUSING
9 - 184 ENGINE 5.9L DIESELBR/BE
OIL PUMP (Continued)

(4) Discharge the A/C system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE) and remove the A/C condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - REMOVAL) (Fig.
31) (if A/C equipped).
(5) Remove the transmission auxiliary cooler (Fig.
31) (Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - REMOVAL).
(6) Remove the boost tubes from the charge air
cooler (Fig. 32).
(7) Remove the charge air cooler bolts. Pivot the
charge air cooler forward and up to remove.
CLEANING
CAUTION: Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air cooler
will result.
NOTE: If internal debris cannot be removed from
the cooler, the charge air cooler MUST be replaced.
(1) If the engine experiences a turbocharger failure
or any other situation where oil or debris get into the
charge air cooler, the charge air cooler must be
cleaned internally.
(2) Position the charge air cooler so the inlet and
outlet tubes are vertical.
(3) Flush the cooler internally with solvent in the
direction opposite of normal air flow.(4) Shake the cooler and lightly tap on the end
tanks with a rubber mallet to dislodge trapped
debris.
(5) Continue flushing until all debris or oil are
removed.
(6) Rinse the cooler with hot soapy water to
remove any remaining solvent.
(7) Rinse thoroughly with clean water and blow
dry with compressed air.
INSPECTION
Visually inspect the charge air cooler for cracks,
holes, or damage. Inspect the tubes, fins, and welds
for tears, breaks, or other damage. Replace the
charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge
Air Cooler Tester Kit #3824556. This kit is available
through CumminstService Products. Instructions
are provided with the kit.
Fig. 31 Condenser and Transmission Auxiliary
Cooler
1 - A/C CONDENSOR
2 - TRANSMISSION COOLER
3 - INTERCOOLER
Fig. 32 Air Intake System Tubes
1 - CLAMP
2 - INTERCOOLER INLET DUCT
3 - CLAMP
4 - VALVE COVER
5 - AIR INLET HOUSING
6 - CLAMP
7 - INTERCOOLER OUTLET DUCT
8 - CLAMP
9 - INTERCOOLER
BR/BEEXHAUST SYSTEM 11 - 19
CHARGE AIR COOLER AND PLUMBING (Continued)

(2) The fuel filter/regulator is pressed into a rub-
ber grommet. Remove by twisting and pulling
straight up (Fig. 6).
CAUTION: Do not pull filter/regulator more than
three inches from fuel pump module. Damage to
coiled fuel tube (line) may result.
(3) Gently cut old fuel tube (line) clamp (Fig. 7)
taking care not to damage plastic fuel tube. Remove
and discard old fuel tube clamp.
(4) Remove plastic fuel tube from filter/regulator
by gently pulling downward. Remove filter/regulator
from fuel pump module.
Fig. 4 Filter/Regulator LocationÐWith 26 or 34
Gallon Fuel Tank
1 - FUEL FILTER/PRESSURE REGULATOR
2 - FUEL SUPPLY FITTING
3 - REAR FUEL TANK CHECK VALVE
4 - ELECTRICAL CONNECTOR
5 - FUEL PUMP MODULE
6 - FRONT FUEL TANK CHECK VALVE
7 - LOCKNUT
Fig. 5 Filter/Regulator LocationÐWith 35 Gallon
Fuel Tank
1 - FUEL FILTER/PRESSURE REGULATOR
2 - FUEL SUPPLY FITTING
3 - ELECTRICAL CONNECTOR
4 - LOCKNUT
5 - FUEL PUMP MODULE
6 - AUXILIARY CAPPED FITTING
Fig. 6 Filter/Regulator Removal and InstallationÐ
TYPICAL
1 - RUBBER GROMMET
2 - FUEL FILTER/FUEL PRESSURE REGULATOR
Fig. 7 Fuel Tube and ClampÐTYPICAL
1 - FUEL FILTER/FUEL PRESSURE REGULATOR
2 - TUBE CLAMP
3 - FUEL TUBE
14 - 6 FUEL DELIVERY - GASOLINEBR/BE
FUEL FILTER/PRESSURE REGULATOR (Continued)

WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND
FUEL SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: To prevent possible damage to the vehi-
cle electrical system and LCS adapter, the test
leads must be connected into relay cavities exactly
as shown in following steps.
Depending upon vehicle model, year or engine con-
figuration, three different types of relays may be
used: Type-1, type-2 and type±3.
(14) If equipped withtype±1 relay(Fig. 13),
attach test leads from LCS adapter into PDC relay
cavities number 30 and 87. For location of these cav-
ities, refer to numbers stamped to bottom of relay
(Fig. 13).
(15) If equipped withtype±2 relay(Fig. 14),
attach test leads from LCS adapter into PDC relay
cavities number 30 and 87. For location of these cav-
ities, refer to numbers stamped to bottom of relay
(Fig. 14).
(16) If equipped withtype±3 relay(Fig. 15),
attach test leads from LCS adapter into PDC relay
cavities number 3 and 5. For location of these cavi-
ties, refer to numbers stamped to bottom of relay
(Fig. 15).
(17) When LCS adapter test leads are attached
into relay cavities, fuel pumpwill be activated.
Determine fuel pump amperage on DRB screen.
Amperage should be below 10.0 amps. If amperage is
below 10.0 amps, and specifications for the Fuel
Pump Pressure, Fuel Pump Capacity and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ule is OK.
(18) If amperage is more than 10.0 amps, replace
fuel pump module assembly. The electric fuel pump
is not serviced separately.
(19) Disconnect test leads from relay cavities
immediately after testing.
Fig. 13 FUEL PUMP RELAY - TYPE 1
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 14 FUEL PUMP RELAY - TYPE 2
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
BR/BEFUEL DELIVERY - GASOLINE 14 - 11
FUEL PUMP (Continued)

FUEL PUMP MODULE
DESCRIPTION
The fuel pump module on all gas powered engines
is installed in the top of the fuel tank (Fig. 16) or
(Fig. 17). The fuel pump module (Fig. 16), (Fig. 17)or
(Fig. 18)contains the following:
²A combination fuel filter/fuel pressure regulator
²Electric fuel pump
²Fuel pump reservoir
²A separate in-tank fuel filter (at bottom of mod-
ule)
²Check valve (certain modules)
²Fuel gauge sending unit (fuel level sensor)
²Fuel supply line connection at filter/regulator
²A threaded locknut retaining pump module to
fuel tank
²A gasket between tank flange and module
²Auxiliary non-pressurized fuel supply fitting (not
all engines)
The fuel gauge sending unit (fuel level sensor), and
pick-up filter (at bottom of module) may be serviced
separately. If the electrical fuel pump requires ser-
vice, the entire fuel pump module must be replaced.
The fuel filter/fuel pressure regulator may be ser-
viced separately. Refer to Fuel Filter/Fuel Pressure
Regulator Removal/Installation for additional infor-
mation.
Fig. 15 FUEL PUMP RELAY - TYPE 3
TERMINAL LEGEND
NUMBER IDENTIFICATION
1 COIL BATTERY
2 COIL GROUND
3 COMMON FEED
4 NORMALLY CLOSED
5 NORMALLY OPEN
Fig. 16 Fuel Pump Module - Gas Powered With 26
or 34 Gallon Tank±Typical
1 - FUEL FILTER/PRESSURE REGULATOR
2 - FUEL SUPPLY FITTING
3 - REAR FUEL TANK CHECK VALVE
4 - ELECTRICAL CONNECTOR
5 - FUEL PUMP MODULE
6 - FRONT FUEL TANK CHECK VALVE
7 - LOCKNUT
Fig. 17 Fuel Pump Module - Gas Powered with 35
Gal. Tank
1 - FUEL FILTER/PRESSURE REGULATOR
2 - FUEL SUPPLY FITTING
3 - ELECTRICAL CONNECTOR
4 - LOCKNUT
5 - FUEL PUMP MODULE
6 - AUXILIARY CAPPED FITTING
14 - 12 FUEL DELIVERY - GASOLINEBR/BE
FUEL PUMP (Continued)