2002 DODGE RAM check engine

(11) Install the cylinder head cover and reusable
gasket (Fig. 85) (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION).
(12) Install gear housing cover (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- INSTALLATION).
(13) Install the crankshaft damper (Fig. 83) (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(14) Install the fan support/hub assembly (Fig. 82)
and tighten bolts to 24 N´m (18 ft. lbs.) torque.
(15) Install the crankcase breather housing (Refer
to 9 - ENGINE - INSTALLATION).
(16) Install the charge air cooler (with a/c con-
denser and auxiliary transmission oil cooler, if
equipped) and tighten the mounting bolts to 2 N´m
(17 in. lbs.) torque.
(17) Connect charge air cooler inlet and outlet
pipes. Tighten clamps to 10 N´m (100 in. lbs.) torque.
(18) Install the radiator upper support panel.
(19) Close radiator petcock and lower the radiator
into the engine compartment. Tighten the mounting
bolts to 11 N´m (95 in. lbs.) torque.
(20) Raise vehicle on hoist.
(21) Connect radiator lower hose and install
clamp.
(22) Connect transmission auxiliary oil cooler lines
(if equipped).
(23) Lower vehicle.
(24) Install the fan shroud and tighten the mount-
ing screws to 6 N´m (50 in. lbs.) torque.
(25) Install the viscous fan/drive assembly (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(26) Install the coolant recovery and windshield
washer fluid reservoirs to the fan shroud.
(27) Connect the coolant recovery hose to the radi-
ator filler neck.
(28) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(29) Install the front bumper assembly (Refer to 13
- FRAMES & BUMPERS/BUMPERS/FRONT
BUMPER - INSTALLATION).
(30) Add engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(31) Charge A/C system with refrigerant (if A/C
equipped) (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(32) Connect the battery negative cables.
(33) Start engine and check for engine oil and cool-
ant leaks.CONNECTING ROD BEARINGS
STANDARD PROCEDUREÐCONNECTING ROD
BEARING AND CRANKSHAFT JOURNAL
CLEARANCE
Measure the connecting rod bore with the bearings
installed and the bolts tightened to 100 N´m (73 ft.
lbs.) torque.
Record the smaller diameter.
Measure the diameter of the rod journal at the
location shown (Fig. 99). Calculate the average diam-
eter for each side of the journal.
The clearance is the difference between the con-
necting rod bore (smallest diameter) and the average
diameter for each side of the crankshaft journal.
Fig. 99 Connecting Rod Journal Diameter Limits
CONNECTING ROD JOURNAL DIAMETER
LIMITS CHART
DESCRIPTION MEASUREMENT
CRANKSHAFT ROD JOURNAL
DIAMETERMINIMUM 68.962 mm
(2.715 in.)
MAXIMUM 69.013 mm
(2.717 in.)
OUT-OF-ROUND MAXIMUM 0.050 mm (0.002 in.)
TAPER MAXIMUM 0.013 mm
(0.0005 in.)
BEARING CLEARANCE MAXIMUM 0.089 mm
(0.0035 in.)
9 - 158 ENGINE 5.9L DIESELBR/BE
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

(4) With the cover supported by wood blocks,
install the seal into the rear of the cover using crank-
shaft seal installer Special Tool 8281 and driver han-
dle C-4171 (Fig. 106). Strike the driver handle until
the installation tool bottoms out on the inside of the
cover.
(5) Install the plastic seal pilot (provided with seal
kit) into the crankshaft seal.(6) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover
sealing surface.
(7) Install the cover to the gear housing, aligning
the seal pilot with the nose of the crankshaft (Fig.
107).
(8) Install the cover bolts and tighten to 24 N´m
(18 ft. lbs.) torque. Remove pilot tool.
(9) Install the crankshaft damper (Fig. 104) and
torque the bolts to 125 N´m (92 ft. lbs.). Use the
engine barring tool to keep the engine from rotating
during tightening operation.
(10) Install the fan support/hub assembly (Fig.
103) and torque bolts to 24 N´m (18 ft. lbs.).
(11) Install cooling fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(12) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect battery negative cables.
(15) Start engine and check for oil leaks.
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the transmission and transfer case (if
equipped).
(3) Remove the clutch cover and disc (if manual
transmission equipped) (Refer to 6 - CLUTCH/
CLUTCH DISC - REMOVAL).
(4) Remove the flywheel or converter drive plate.
(5) Drill holes 180É apart into the seal. Be careful
not to contact the drill against the crankshaft.
Fig. 105 Removing Seal from Cover
1 - PUNCH
Fig. 106 Installing Seal Into Cover With Tool 8281
1 - SEAL INSTALLER 8281
2 - DRIVER HANDLE C4171
3 - SEAL
Fig. 107 Installing Front Cover with Seal Pilot
1 - SEAL PILOT
BR/BEENGINE 5.9L DIESEL 9 - 161
CRANKSHAFT OIL SEAL - FRONT (Continued)

(6) Install #10 sheet metal screws in the drilled
holes and remove the rear seal with a slide hammer
(Fig. 108).
INSTALLATION
CAUTION: The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks. The crankshaft and seal sur-
faces must be completely dry when the seal is
installed. Use a soap and water solution on outside
diameter of seal to ease assembly.
(1) Clean the crankshaft journal with a suitable
solvent and dry with a clean shop towel or com-
pressed air. Wipe the inside bore of the crankshaft
seal retainer with a clean shop towel.
(2) Inspect the crankshaft journal for gouges,
nicks, or other imperfections. If the seal groove in the
crankshaft is excessively deep, install the new seal
1/8º deeper into the retainer bore, or obtain a crank-
shaft wear sleeve that is available in the aftermar-
ket.
(3) Install the seal pilot, provided in the replace-
ment kit, onto the crankshaft.
(4) Using the provided alignment/installation tool,
start the seal over the pilot and into the retainer by
hand.
(5) Using a ball peen hammer, strike the tool at
the 12, 3, 6, and 9 o'clock positions until the align-
ment tool bottoms out on the retainer (Fig. 109).
(6) Remove the seal pilot.
(7) Install the flywheel or converter drive plate.
Tighten the bolts to 137 N´m (101 ft. lbs.) torque.(8) Install the clutch cover and disc (if equipped)
(Refer to 6 - CLUTCH/CLUTCH DISC - INSTALLA-
TION).
(9) Install the transmission and transfer case (if
equipped).
(10) Lower vehicle.
(11) Connect battery negative cables.
(12) Check engine oil level and adjust, if necessary.
(13) Start engine and check for oil leaks.
CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove the oil pan drain plug and drain the
engine oil. Re-install plug and torque to 60 N´m (44
ft. lbs.) torque.
(4) Remove transmission and transfer case (if
equipped) from vehicle.
(5) Remove flywheel or torque converter drive
plate.
(6) Disconnect starter cables from starter motor.
(7) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
(8) Disconnect cables from starter motor.
(9) Remove the eight flywheel housing to block
bolts and remove housing and starter motor as an
assembly.
Fig. 108 Crankshaft Rear Seal Removal
1 - NO. 10 SCREW
2 - REAR SEAL
3 - CRANKSHAFT
4 - SLIDE HAMMER
Fig. 109 Seal Installation Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
9 - 162 ENGINE 5.9L DIESELBR/BE
CRANKSHAFT OIL SEAL - REAR (Continued)

(8) Install the oil pan, suction tube and gaskets
(Refer to 9 - ENGINE/LUBRICATION/OIL PAN -
INSTALLATION).
(9) Install the flywheel housing and bolts. Tighten
the bolts to 60 N´m (44 ft. lbs.) torque.
(10) Install the starter motor (Refer to 8 - ELEC-
TRICAL/STARTING/STARTER MOTOR - INSTAL-
LATION).
(11) Install the flywheel or converter drive plate.
Tighten bolts to 137 N´m (101 ft. lbs.)
(12) Install the transmission and transfer case (if
equipped).
(13) Lower vehicle.(14) Fill the crankcase with new engine oil.
(15) Connect the battery negative cables.
(16) Start engine and check for oil leaks.
SOLID LIFTERS/TAPPETS
REMOVAL
NOTE: This procedure requires use of Miller Tool
8502 Tappet Replacement Kit, or Cummins Tool Kit
#3822513.
(1) Remove camshaft (Refer to 9 - ENGINE/EN-
GINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(2) Insert the trough (provided with tool kit) the
full length of the camshaft bore (Fig. 115). Make sure
the cap end goes in first and the open side faces up
(towards tappets).
(3)Remove only one tappet at a time.Remove
rubber band from one cylinder pair and attach tappet
dowel not being removed to the next cylinder pair
(Fig. 116).
(4) Raise dowel rod (disengage from tappet) and
allow tappet to fall into trough (Fig. 117).
(5) Carefully remove trough(do not rotate)and
tappet. If the tappet is not being replaced, mark it so
it can be installed in its original location.
(6) Re-install trough and repeat procedure on
remaining tappets.
CLEANING
Clean tappet with a suitable solvent. Rinse in hot
water and blow dry with a clean shop rag or com-
pressed air.
Fig. 113 Installing Seal Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
Fig. 114 Trimming Excess Gasket Material
1 - GASKET
Fig. 115 Inserting the Trough
1 - TROUGH
9 - 164 ENGINE 5.9L DIESELBR/BE
CRANKSHAFT REAR OIL SEAL RETAINER (Continued)

(5) Before removing the piston(s) from the bore(s):
(a) Remove any carbon ridge formations or
deposits at the top of the bore with a dull scraper
or soft wire brush.
(b) If cylinder bore wear ridges are found, use a
ridge reamer to cut the ridge from the bore. DO
NOT remove more metal than necessary to remove
the ridge.
NOTE: If cylinders have ridges, the cylinders are
oversize and will more than likely need boring.
(6) Using a hammer and steel stamp, identify the
front of the piston by stamping the cylinder number
in each piston to be removed at the top of the piston
toward the front of the engine. DO NOT stamp in the
outside 5 mm (.197 in.) of the piston diameter.
(7) Mark the connecting rod and cap with the cor-
responding cylinder numbers.
(8) Remove the connecting rod bolts and rod caps.
Use care so the cylinder bores and connecting rods
are not damaged.
(9) Use a hammer handle or similar object to push
the piston and connecting rod through the cylinder
bore.
(10) Store the piston/rod assemblies in a rack.
(11) If a piston must be replaced, replace with the
same part number (grading) that was removed.
CLEANING
CAUTION: DO NOT use bead blast to clean the pis-
tons. DO NOT clean the pistons and rods in an acid
tank.
Clean the pistons and pins in a suitable solvent,
rinse in hot water and blow dry with compressed air.
Soaking the pistons over night will loosen most of the
carbon build up. De-carbon the ring grooves with a
broken piston ring and again clean the pistons in sol-vent. Rinse in hot water and blow dry with com-
pressed air.
INSPECTION
INSPECTION
Inspect the pistons for damage and excessive wear.
Check top of the piston, ring grooves, skirt and pin
bore. Measure the piston skirt diameter (Fig. 128). If
the piston is out of limits, replace the piston.
The upper groove only needs to be inspected for
damage. Use a new piston ring to measure the clear-
ance in the intermediate ring groove (Fig. 129). If the
clearance of the intermediate ring exceeds 0.095 mm
(0.0038 inch), replace the piston.
Use a new oil ring to measure the clearance in the
oil groove (Fig. 129). If the clearance exceeds 0.085
mm (0.0034 inch), replace the piston.
Measure the pin bore (Fig. 130). The maximum
diameter is 40.012 mm (1.5753 inch). If the bore is
over limits, replace the piston.
Inspect the piston pin for nicks, gouges and exces-
sive wear. Measure the pin diameter (Fig. 131). The
minimum diameter is 39.990 mm (1.5744 inch). If the
diameter is out of limits, replace the pin.
Connecting Rods
CLEANING
Clean the connecting rods in a suitable solvent,
rinse in hot water and blow dry with compressed air.
INSPECTION
Inspect the connecting rod for damage and wear.
The I-Beam section of the connecting rod cannot have
dents or other damage. Damage to this part can
cause stress risers which will progress to breakage.
Fig. 127 Piston Grading Measurement
Fig. 128 Piston Skirt Diameter
PISTON SKIRT DIAMETER (MIN.)
101.864 mm (4.0104 in. )
BR/BEENGINE 5.9L DIESEL 9 - 169
PISTON & CONNECTING ROD (Continued)

bolt holes toward the camshaft. Use care when you
install the piston and connecting rod so the cylinder
bore is not damaged.
(7) Push the piston into the bore until the top of
the piston is approximately 50 mm (2 inch) below the
top of the block. Carefully pull the connecting rod
onto the crankshaft journal.
(8) Use clean engine oil to lubricate the threads
and under the heads of the connecting rod bolts.
(9) The number stamped on the rod cap at the
parting line must match and be installed towards the
oil cooler side of the engine (Fig. 135).
(10) Install the rod cap and bolts to the connecting
rod. Tighten the connecting rod and bolt evenly in 3
steps.
²Tighten the bolts to 35 N´m (26 ft. lbs.) torque.
²Tighten the bolts to 70 N´m (51 ft. lbs.) torque.
²Tighten the bolts to 100 N´m (73 ft. lbs.) torque.
(11) The crankshaft must rotate freely. Check for
freedom of rotation as the caps are installed. If the
crankshaft does not rotate freely, check the installa-
tion of the rod bearing and the bearing size.
(12) Measure the side clearance between the con-
necting rod and the crankshaft (Fig. 136). DO NOT
measure the clearance between the cap and crank-
shaft.(13) Install the suction tube and oil pan (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(14) Install the cylinder head onto the engine
(Refer to 9 - ENGINE/CYLINDER HEAD - INSTAL-
LATION).
(15) Install a new filter and fill the crankcase with
new engine oil.
(16) Connect the battery negative cables and start
engine.
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Determine the piston diameter and obtain the
appropriate ring set. The piston rings can be identi-
fied as shown in (Fig. 137).
(2) Position each ring in the cylinder and use a
piston to square it with the bore at a depth of 89.0
mm (3.5 inch) - (Fig. 138).
(3) Use a feeler gauge to measure the piston ring
gap.
Fig. 134 Piston/Rod Assembly at BDC
Fig. 135 Correct Rod Cap Installation
Fig. 136 Side Clearance between Connecting
Rod/Crankshaft
1 - FEELER GAUGE
Fig. 137 Piston Ring Identification
BR/BEENGINE 5.9L DIESEL 9 - 171
PISTON & CONNECTING ROD (Continued)

DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE
(1) Remove the engine oil pressure sensor and
install Oil Pressure Line and Gauge Tool C-3292 with
a suitable adapter.
(2) Start engine and warm to operating tempera-
ture.
(3) Record engine oil pressure and compare with
engine oil pressure chart.
CAUTION: If engine oil pressure is zero at idle, DO
NOT RUN THE ENGINE.
Engine Oil Pressure (MIN)
At Idle 103.4 kPa (15 psi)
At 2000 rpm 310.2 kPa (45 psi)
If minimum engine oil pressure is below these
ranges, (Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
(4) Remove oil pressure gauge and install the oil
pressure sensor. Tighten the sensor to 16 N´m (144
in. lbs.) torque.
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL LEVEL
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
To ensure proper lubrication of an engine, the
engine oil must be maintained at an acceptable level.
The acceptable oil level is in the SAFE RANGE on
the engine oil dipstick (Fig. 150).
Unless the engine has exhibited loss of oil pres-
sure, run the engine for about five minutes before
checking oil level. Checking engine oil level of a cold
engine is not accurate.
(1) Position vehicle on level surface.(2) With engine OFF, allow approximately ten min-
utes for oil to settle to bottom of crankcase, remove
engine oil dipstick.
(3) Wipe dipstick clean.
(4) Replace dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the SAFE RANGE
area on the dipstick.
(7) Replace dipstick
STANDARD PROCEDURE - ENGINE OIL
SERVICE
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
NOTE: Change engine oil and filter at intervals
specified in the owner's manual.
(1) Operate the engine until the water tempera-
ture reaches 60ÉC (140ÉF). Shut the engine off.
(2) Use a container that can hold at least 14 liters
(15 quarts) to hold the used oil. Remove the oil drain
plug and drain the used engine oil into the container.
1 - ROCKER ARM
2 - ROCKER SHAFT
3 - PEDESTAL
4 - FROM MAIN OIL RIFLE
5 - TO VALVE TRAIN
6 - MAIN OIL RIFLE
7 - FROM MAIN OIL RIFLE
8 - TO CAMSHAFT9 - TO PISTON COOLING NOZZLE
10 - FROM OIL COOLER
11 - CRANKSHAFT MAIN JOURNAL
12 - ROD JOURNAL
13 - TO ROD BEARING
14 - MAIN OIL RIFLE
Fig. 150 Oil Level Indicator (Dipstick)
1 - ADD OIL MARK
2 - O-RING
3 - SAFE RANGE
9 - 178 ENGINE 5.9L DIESELBR/BE
LUBRICATION (Continued)

(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)