2002 DODGE RAM air condition

stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Install drain plug in crankcase.
(7) Change oil filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL).
(8) Lower vehicle and fill crankcase with specified
type (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION) and amount of
engine oil (Refer to LUBRICATION & MAINTE-
NANCE - SPECIFICATIONS).
(9) Install oil fill cap.
(10) Start engine and inspect for leaks.
(11) Stop engine and inspect oil level.
OIL FILTER
REMOVAL
All engines are equipped with a high quality full-
flow, disposable type oil filter. DaimlerChrysler Cor-
poration recommends a Mopartor equivalent oil
filter be used.
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
(3) Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss (Fig. 51).
(4) When filter separates from adapter nipple, tip
gasket end upward to minimize oil spill. Remove fil-
ter from vehicle.
(5) With a wiping cloth, clean the gasket sealing
surface (Fig. 52) of oil and grime.
(6) Install new filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - INSTALLATION).
INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, (Fig. 52) hand
tighten filter one full turn, do not over tighten.(3) Add oil (Refer to 9 - ENGINE/LUBRICATION/
OIL - STANDARD PROCEDURE).
OIL PAN
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
(5) Remove exhaust pipe.
(6) Remove left engine to transmission strut.
(7) Loosen the right side engine support bracket
cushion thru-bolt nut and raise the engine slightly.
Remove oil pan by sliding backward and out.
(8) Remove the one-piece gasket.
CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove.DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the
engine.
Clean oil pan in solvent and wipe dry with a clean
cloth.
Clean oil screen and pipe thoroughly in clean sol-
vent. Inspect condition of screen.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor-
tion. Straighten flange, if necessary.
INSTALLATION
(1) Clean the block and pan gasket surfaces.
Fig. 51 Oil Filter RemovalÐTypical
1 - ENGINE OIL FILTER
2 - OIL FILTER WRENCH
Fig. 52 Oil Filter Sealing SurfaceÐTypical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
9 - 46 ENGINE 5.9LBR/BE
OIL (Continued)

(2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N´m (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling
rotor cavity with engine oil.
INSTALLATION
(1) Install oil pump. During installation slowly
rotate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
(2) Hold the oil pump base flush against mating
surface on No.5 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
N´m (30 ft. lbs.) torque.
(3) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
INTAKE MANIFOLD
DESCRIPTION
The aluminum intake manifold (Fig. 64) is a single
plane design with equal length runners and uses a
separate plenum, therefore the manifold does have a
plenum gasket. It also uses separate flange gaskets
and front and rear cross-over gaskets. Extreme care
must be used when sealing the gaskets to ensure
that excess sealant does not enter the intake runners
causing a restriction. Whenever the intake manifold
is removed inspect the plenum pan for evidence of
excess oil buildup, this condition indicates that the
plenum pan gasket is leaking.
OPERATION
The intake manifold, meters and delivers air to the
combustion chambers allowing the fuel delivered by
the fuel injectors to ignite, thus producing power.
DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.(3) If a change in RPMs occur, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL).
(4) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner.
(7) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel lines (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect the accelerator linkage (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL) and if so equipped,
the speed control and transmission kickdown cables.
(9) Remove the return spring.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the heat indicator sending unit
wire.
Fig. 64 Intake Manifold and Throttle BodyÐV-8 Gas
Engines Typical
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
9 - 50 ENGINE 5.9LBR/BE
OIL PUMP (Continued)

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 Battery. (Refer to
8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD
PROCEDURE). Check charging
system. (Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND
TESTING).
2. Corroded or loose battery
connections2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. (Refer to
8 - ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Seized accessory drive
component4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace seized
component.
5. Engine internal mechanical
failure or hydro-static lock5. Refer to (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
ENGINE CRANKS BUT WILL NOT
START1. No spark 1. Check for spark. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- DESCRIPTION)
2. No fuel 2. Perform fuel pressure test, and if
necessary, inspect fuel injector(s)
and driver circuits. (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/
FUEL PUMP - DIAGNOSIS AND
TESTING).
3. Low or no engine compression 3. Perform cylinder compression
pressure test. (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING).
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/
DISTRIBUTOR - REMOVAL).
3. Worn or incorrect gapped spark
plugs3. Clean plugs and set gap. (Refer
to 8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG -
CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
BR/BEENGINE 8.0L 9 - 59
ENGINE 8.0L (Continued)

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. Burned, warped, or pitted valves 9. Install/Reface valves as
necessary
10. Plugged or restricted exhaust
system10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted
cables
12. Faulty ignition coil 12. Test and replace, as necessary
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/
THROTTLE BODY - REMOVAL).
2. Engine idle speed too low 2. Check Idle Air Control circuit.
(Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/IDLE AIR CONTROL
MOTOR - DESCRIPTION)
3. Worn or incorrectly gapped spark
plugs3. Replace or clean and re-gap
spark plugs (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
SPARK PLUG - CLEANING)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or
crossed5. Check for correct firing order or
replace spark plug cables. (Refer to
8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG CABLE -
DIAGNOSIS AND TESTING)
6. Faulty coil 6. Test and replace, if necessary
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket
and vacuum hoses (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD - DIAGNOSIS AND
TESTING).
ENGINE MISSES ON
ACCELERATION1. Worn or incorrectly gapped spark
plugs1. Replace spark plugs or clean and
set gap. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING)
2. Spark plug cables defective or
crossed2. Replace or rewire secondary
ignition cables. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
SPARK PLUG CABLE - REMOVAL)
9 - 60 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
4. Excessive connecting rod
bearing clearanceMeasure bearings for correct
clearance with plasti-gage. Repair
as necessary
5. Connecting rod journal out of
round5. Replace crankshaft or grind
journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level.
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING)
3. Thin or diluted oil 3. Change oil to correct viscosity.
4. Excessive main bearing
clearance4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
6. Crankshaft main journal out of
round or worn6. Grind journals or replace
crankshaft
7. Loose flywheel or torque
converter7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if
necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace oil pump assembly.
5. Thin or diluted oil 5. Change oil to correct viscosity.
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pump suction tube loose,
broken, bent or clogged8. Inspect suction tube and clean or
replace if necessary
9. Oil pump cover warped or
cracked9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated
gaskets1. Replace gasket
2. Loose fastener, broken or porous
metal part2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking3. Replace seal
4. Leaking oil gallery plug or cup
plug4. Remove and reseal threaded
plug. Replace cup style plug
9 - 62 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE OIL CONSUMPTION
OR SPARK PLUGS OIL FOULED1. CCV System malfunction 1. (Refer to 25 - EMISSIONS
CONTROL/EVAPORATIVE
EMISSIONS - DESCRIPTION) for
correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - LUBRICATION
CONDITION POSSIBLE CAUSES CORRECTION
OIL LEAKS 1. Gaskets and O-Rings. 1.
(a) Misaligned or damaged. (a) Replace as necessary.
(b) Loose fasteners, broken or
porous metal parts.(b) Tighten fasteners, Repair or
replace metal parts.
2. Crankshaft rear seal 2. Replace as necessary.
3. Crankshaft seal flange.
Scratched, nicked or grooved.3. Polish or replace crankshaft.
4. Oil pan flange cracked. 4. Replace oil pan.
5. Timing chain cover seal,
damaged or misaligned.5. Replace seal.
6. Scratched or damaged vibration
damper hub.6. Polish or replace damper.
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.
2. Faulty oil pressure sending unit. 2. Replace sending unit.
3. Low oil pressure. 3. Check pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter.
5. Worn oil pump. 5. Replace as necessary.
6. Thin or diluted oil. 6. Change oil and filter.
7. Excessive bearing clearance. 7. Replace as necessary.
8. Oil pump relief valve stuck. 8. Clean or replace relief valve.
9. Oil pump suction tube loose or
damaged.9. Replace as necessary.
BR/BEENGINE 8.0L 9 - 63
ENGINE 8.0L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
OIL PUMPING AT RINGS; SPARK
PLUGS FOULING1. Worn or damaged rings. 1. Hone cylinder bores and replace
rings.
2. Carbon in oil ring slots. 2. Replace rings.
3. Incorrect ring size installed. 3. Replace rings.
4. Worn valve guides. 4. Ream guides and replace valves.
5. Leaking intake gasket. 5. Replace intake gaskets.
6. Leaking valve guide seals. 6. Replace valve guide seals.
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise, the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs (Refer to 8 - ELEC-
TRICAL/IGNITION CONTROL/SPARK PLUG -
REMOVAL).
(3) Secure the throttle in the wide-open position.
(4) Disconnect the ignition coil.
(5) Insert a compression pressure gauge and rotate
the engine with the engine starter motor for three
revolutions.
(6) Record the compression pressure on the third
revolution. Continue the test for the remaining cylin-
ders.
(Refer to 9 - ENGINE - SPECIFICATIONS) for the
correct engine compression pressures.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing)
²Leaks between adjacent cylinders or into water
jacket²Any causes for combustion/compression pressure
loss
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM HOT COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn OFF the
engine.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.
Perform the test procedure on each cylinder accord-
ing to the tester manufacturer's instructions. While
testing, listen for pressurized air escaping through
the throttle body, tailpipe or oil filler cap opening.
Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder CYLINDER COMBUSTION
PRESSURE LEAKAGE DIAGNOSIS CHART.
9 - 64 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODYIntake valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
TAILPIPEExhaust valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
RADIATORHead gasket leaking or cracked
cylinder head or blockRemove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERSHead gasket leaking or crack in
cylinder head or block between
adjacent cylindersRemove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLYStuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wallInspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
STANDARD PROCEDURE
STANDARD PROCEDUREÐCYLINDER BORE
HONING
Before honing, stuff plenty of clean shop towels
under the bores and over the crankshaft to keep
abrasive materials from entering the crankshaft
area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.
The hone marks should INTERSECT at 50É to 60É
for proper seating of rings (Fig. 3).
(4) A controlled hone motor speed between 200 and
300 RPM is necessary to obtain the proper cross-hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50É to 60É
angle. Faster up and down strokes increase the cross-
hatch angle.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
Fig. 3 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
BR/BEENGINE 8.0L 9 - 65
ENGINE 8.0L (Continued)