2002 DODGE RAM Service Repair Manual

set clock seat adjustment immobilizer heater mirror coolant reservoir

Page 1209 of 2255

DODGE RAM 2002 Service Repair Manual (32) Remove the fuel return line banjo bolt at the
rear of the cylinder head (Fig. 24). Be careful not to
drop the two (2) sealing washers.
(33) Reinstall the engine lift bracket at the rear of
cylind

(32) Remove the fuel return line banjo bolt at the
rear of the cylinder head (Fig. 24). Be careful not to
drop the two (2) sealing washers.
(33) Reinstall the engine lift bracket at the rear of
cylinder head.
(34) Remove twenty six (26) cylinder head-to-block
bolts.
(35) Attach an engine lift crane to engine lift
brackets and lift cylinder head off engine and out of
vehicle.
(36) Remove the head gasket and inspect for fail-
ure.
CLEANING
CLEANINGÐCYLINDER HEAD
CAUTION: Do not wire brush head surface while
fuel injectors are still installed. Fuel injector dam-
age can result.
Clean the carbon from the injector nozzle seat with
a nylon or brass brush.
Scrape the gasket residue from all gasket surfaces.
Wash the cylinder head in hot soapy water solution
(88ÉC or 140ÉF).
After rinsing, use compressed air to dry the cylin-
der head.
Polish the gasket surface with 400 grit paper. Use
an orbital sander or sanding block to maintain a flat
surface.
CLEANINGÐCROSSHEADS
Clean all crossheads in a suitable solvent. If neces-
sary, use a wire brush or wheel to remove stubborn
deposits. Rinse in hot water and blow dry with com-
pressed air.
CLEANINGÐPUSHRODS
Clean the pushrods in a suitable solvent. Rinse in
hot water and blow dry with compressed air. If nec-
essary, use a wire brush or wheel to remove stubborn
deposits.
INSPECTION
INSPECTIONÐCYLINDER HEAD
Inspect the cylinder head for cracks in the combus-
tion surface. Pressure test any cylinder head that is
visibly cracked. A cylinder head that is cracked
between the injector bore and valve seat can be pres-
sure tested and reused if OK; however, if the crack
extendsintothe valve seat, the valve seatmustbe
replaced.
Visually inspect the cylinder block and head com-
bustion surfaces for localized dips or imperfections.
Check the cylinder head and block combustion sur-
faces for overall out-of-flatness. If either the visual or
manual inspection exceeds the limits, then the head
or block must be surfaced.
Check the top surface for damage caused by the
cylinder head gasket leaking between cylinders.
Inspect the block and head surface for nicks, ero-
sion, etc.
Check the head distortion (Fig. 25). The distortion
of the combustion deck face is not to exceed 0.010
mm (0.0004 inch) in any 50.8 mm (2.00 inch) diame-
Fig. 23 Push Rod Removal
Fig. 24 Fuel Drain Fitting at Rear of Head
1 - LINE
2 - WASHERS
3 - BANJO BOLT
9 - 134 ENGINE 5.9L DIESELBR/BE
CYLINDER HEAD (Continued)

Page 1210 of 2255

DODGE RAM 2002 Service Repair Manual ter. Overall variation end to end or side to side 0.30
mm (0.012 inch).
DO NOT proceed with the in-chassis overhaul if
the cylinder head or block surface is damaged or not
flat (within specifications)

Page 1211 of 2255

DODGE RAM 2002 Service Repair Manual INSTALLATION
WARNING: THE OUTSIDE EDGE OF THE HEAD
GASKET IS VERY SHARP. WHEN HANDLING THE
NEW HEAD GASKET, USE CARE NOT TO INJURE
YOURSELF.
(1) Install a new gasket with the part number side
up, and

INSTALLATION
WARNING: THE OUTSIDE EDGE OF THE HEAD
GASKET IS VERY SHARP. WHEN HANDLING THE
NEW HEAD GASKET, USE CARE NOT TO INJURE
YOURSELF.
(1) Install a new gasket with the part number side
up, and locate the gasket over the dowel sleeves.
(2) Using an engine lifting crane, lower the cylin-
der head onto the engine.
(3) Lightly lubricate head bolts with engine oil and
install. Using the sequence shown in (Fig. 30),
tighten bolts in the following steps:
(a) Torque bolts to 80 N´m (59 ft. lbs.)
(b) Torque bolts to 105 N´m (77 ft. lbs.)
(c) Re-check all bolts to 105 N´m (77 ft. lbs.)
(d) Tighten all bolts an additional ò turn (90É)
(4) Connect fuel return line at rear of head (Fig.
24). Install both sealing washers and torque banjo
bolt to 24 N´m (18 ft. lbs.).
(5) Install push rods into their original locations
(Fig. 31).Verify that they are seated in the tap-
pets.
(6) Lubricate valve stem tips and install the cross-
heads in their original locations.
(7) Lubricate the rocker arms and pedestals and
install them in their original locations (Fig. 32).
Install the bolts and torque them to 36 N´m (27 ft.
lbs.).
(8) Verify that the valve lash settings are main-
tained (Refer to 9 - ENGINE/CYLINDER HEAD/IN-
TAKE/EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).(9) Install cylinder head cover (Fig. 33) (Refer to 9
- ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(10) Connect the IAT and MAP sensor connectors.
(11) Install the fuel filter canister assembly and
torque mounting bolts to 24 N´m (18 ft. lbs.).
(12) Connect the lift pump to fuel filter low pres-
sure line. Torque fittings to 24 N´m (18 ft. lbs.).
(13) Connect the Water-in-Fuel and Fuel Heater
Element connectors at the filter assembly.
(14) Remove the engine lift bracket at rear of cyl-
inder head.
(15)Install the high pressure fuel lines (Fig.
18) (Fig. 19) as follows:
(a) Lubricate the threads (both ends) of the high
pressure line nuts with diesel fuel or engine oil.
Fig. 30 Cylinder Head Bolt Torque Sequence
Fig. 31 Push Rod Installation
Fig. 32 Rocker Arms and Pedestal Installation
1 - ROCKER ARM
2 - PEDESTAL
9 - 136 ENGINE 5.9L DIESELBR/BE
CYLINDER HEAD (Continued)

Page 1212 of 2255

DODGE RAM 2002 Service Repair Manual (b) Install the rear line bundle (cyls. #3, 5, and
6), and tighten the threads at the head and pump
by hand.
(c) Torque the connections at the cylinder head
first. Torque connections to 38 N´m (28 ft

(b) Install the rear line bundle (cyls. #3, 5, and
6), and tighten the threads at the head and pump
by hand.
(c) Torque the connections at the cylinder head
first. Torque connections to 38 N´m (28 ft. lbs.).
(d) Torque the line connections at the injection
pump to 24 N´m (18 ft. lbs.).
(e) Install the front line bundle (cyls. #1, 2, and
4) following the same procedure used for the rear
line bundle.
(f) Torque the connections at the cylinder head
first. Torque connections to 38 N´m (28 ft. lbs.).
(g) Torque the line connections at the injection
pump to 24 N´m (18 ft. lbs.).
(h) Install the injection line support bracket to
intake cover/cylinder head bolts and torque to 24
N´m (18 ft. lbs.).
(16) Install the engine lift bracket at the rear of
cylinder head. Torque to 77 N´m (57 ft. lbs.).
(17) Install the fuel filter to injection pump low
pressure line. Inspect and replace sealing washers if
necessary. Torque banjo bolts to 24 N´m (18 ft. lbs.).
(18) Using new gaskets, install the intake grid
heater and air inlet housing. Torque bolts to 24 N´m
(18 ft. lbs.).(19) Connect the APPS connector (Fig. 17).
(20) Install the APPS assembly. to the cylinder
head bracket and torque bolts to 12 N´m (105 in.
lbs.).
(21) Install the throttle linkage cover (Fig. 15).
(22) Install the charge air cooler-to-air inlet hous-
ing duct assembly. Torque all clamps to 11 N´m (100
in. lbs.).
(23) Connect intake grid heater wires.
(24) Fasten engine harness to front of cylinder
head with bolt.
(25) Install engine harness ground wire and torque
bolt to 24 N´m (18 ft. lbs.).
(26) Connect engine coolant temperature sensor
connector.
(27) Connect radiator upper hose to thermostat
housing.
(28) Install generator upper bracket and torque
bolts to 41 N´m (31 ft. lbs.).
(29) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(30) Install exhaust manifold/turbocharger assem-
bly. and start all bolts/spacers by hand. Torque bolts
to 43 N´m (32 ft. lbs.).
(31) Connect turbocharger oil drain tube.
(32) Perform the turbocharger pre-lube procedure.
Refer to Group 11, Exhaust System and Turbo-
charger for the correct procedure.
(33) Connect the turbocharger oil supply line.
(34) Install air cleaner housing and duct.
(35) Raise vehicle on hoist.
(36) Install exhaust pipe to turbocharger elbow
(Fig. 14). Torque bolts to 34 N´m (25 ft. lbs.).
(37) Lower vehicle.
(38) Fill engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(39) Start engine and check for leaks.
CYLINDER HEAD COVER(S)
REMOVAL
(1) Disconnect both battery negative cables.
(2) Loosen the five (5) cylinder head cover bolts
(Fig. 34) . Remove the front three bolts and leave the
rear two bolts in the cover.
(3) Lift cover off of cylinder head.
CLEANING
Using a suitable solvent, Clean and dry gasket
mating surfaces on cylinder head and cover. Wipe
gasket dry and inspect for re-use.
Fig. 33 Cylinder Head Cover Installation
1 - BOLT (5)
2 - GASKET
3 - ªTOP FRONTº
4 - ISOLATOR (5)
BR/BEENGINE 5.9L DIESEL 9 - 137
CYLINDER HEAD (Continued)

Page 1213 of 2255

DODGE RAM 2002 Service Repair Manual INSPECTION
The cylinder head cover gasket and isolators
are reusable.However, should cracks be present in
the rubber/silicone construction, the defective compo-
nents should be replaced.
INSTALLATION

INSPECTION
The cylinder head cover gasket and isolators
are reusable.However, should cracks be present in
the rubber/silicone construction, the defective compo-
nents should be replaced.
INSTALLATION
(1) Install the gasket as shown in (Fig. 34). Make
sure the gasket is properly located around the cylin-
der head bolts, with the words ªtop frontº facing up
and towards front of engine.
(2) Place two bolts and isolators into the rear two
mounting holes and install the cover.
(3) Install the remaining bolts and isolators. Start-
ing with the center bolt, torque in a circular pattern
to 24 N´m (18 ft. lbs.).
(4) Connect both battery negative cables.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves are made of heat resistant steel, and
have chrome plated stems to prevent scuffing. Theintake and exhaust valves are both similar in head
diameter and overall length, but they have unique
face angles which makes them non-interchangeable.
The valves are distinguished by unique dimples on
the exhaust valve head (Fig. 35) .
The exhaust valve springs are made from high
strength, chrome silicon steel. The exhaust valve
springs are also exhaust brake compatible.
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVES,GUIDES
AND SPRINGS
REMOVAL
(1) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(2) Support cylinder head on stands, or install
head bolts upside down (through combustion surface
side) to protect injector tips from damage from work
bench.
(3) Remove the injector clamp (Fig. 36) from the
cylinder(s) to be serviced.Do not remove the bolt
shown in (Fig. 36).
(4) Install the valve spring compressor mounting
base (special tool 8319±A) as shown in (Fig. 37).
Reinstall the injector clamp bolt finger tight.
(5) Install the compressor top plate, washer, and
nut. Using a suitable wrench, tighten the nut (clock-
wise) to compress the valve springs (Fig. 38) and
remove the locks.
(6) Rotate the compressor nut counter-clockwise to
relieve tension on the springs. Remove the spring
compressor.
(7) Remove the retainers, springs, valve seals (if
necessary), and valves (Fig. 39). Arrange or number
Fig. 34 Cylinder Head Cover and Gasket
1 - BOLT (5)
2 - GASKET
3 - ªTOP FRONTº
4 - ISOLATOR (5)
Fig. 35 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
9 - 138 ENGINE 5.9L DIESELBR/BE
CYLINDER HEAD COVER(S) (Continued)

Page 1214 of 2255

DODGE RAM 2002 Service Repair Manual all components so they can be installed in their orig-
inal locations.
(8) Repeat the procedure on all cylinders to be ser-
viced.
CLEANING
Clean the valve stems with crocus cloth or a
Scotch-BriteŸ

Page 1215 of 2255

DODGE RAM 2002 Service Repair Manual valve stem diameter to obtain valve stem-to-guide
clearance. Measure valve margin (rim thickness)
(Fig. 43). Measure the valve spring free length and
maximum inclination (Fig. 44). Test valve spring
f

Page 1216 of 2255

DODGE RAM 2002 Service Repair Manual (8) Install the cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
STANDARD PROCEDUREÐVALVE LASH
ADJUSTMENT AND VERIFICATION
NOTE: To obtain accurate readings, valve lash mea-
suremen

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