2002 DODGE RAM torque

(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)

(3) Install the pump (Fig. 158). Tighten the oil
pump mounting bolts in two steps, in the sequence
shown in (Fig. 164).
²Step 1ÐTighten to 5 N´m (44 in. lbs.) torque.
²Step 2ÐTighten to 24 N´m (18 ft. lbs.) torque.
(4) The back plate on the pump seats against the
bottom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump
will not touch the cylinder block.(5) Measure the idler gear to pump drive gear
backlash and the idler gear to crankshaft gear back-
lash (Fig. 165). The backlash should be 0.75- 0.85
mm (0.0296-0.0335 inch). If the backlash is out of
limits, replace the oil pump.
(6) If the adjoining gear moves when you measure
the backlash, the reading will be incorrect.
Fig. 160 Measuring Tip Clearance
1 - FEELER GAUGE
Fig. 161 Measuring Gerotor to Port Plate Clearance
1 - PORT PLATE
2 - GEROTOR
Fig. 162 Measuring Gerotor Planetary to Body Bore
Clearance
1 - BODY BORE
2 - GEROTOR PLANETARY
Fig. 163 Measure Gear Backlash
1 - OIL PUMP DRIVE GEAR
2 - IDLER GEAR
3 - BACKLASH
4 - BACKLASH
Fig. 164 Oil Pump Mounting Bolt Torque Sequence
Fig. 165 Idler Gear to Pump Drive Gear and
Crankshaft Gear Backlash
BR/BEENGINE 5.9L DIESEL 9 - 183
OIL PUMP (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)

(8) Position the charge air cooler outlet tube onto
the air inlet housing (Fig. 166). Tighten the clamps
to 8 N´m (72 in. lbs.) torque.(9) Perform the fuel system air bleed procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(10) Connect the battery negative cables.
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Disconnect the exhaust pipe from the turbo-
charger elbow (Fig. 169) .
(4) Lower vehicle.
(5) Disconnect the turbocharger air inlet hose (Fig.
170) .
(6) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger (Fig. 171) .
(7) Disconnect the charge air cooler inlet pipe from
the turbocharger (Fig. 171) .
(8) Remove the turbocharger and gasket from the
exhaust manifold.
(9) Remove the cab heater return pipe nut from
the exhaust manifold stud. Position the tube out of
the way.
(10) Remove the exhaust manifold-to-cylinder head
bolts and spacers (Fig. 172) .
(11) Remove the exhaust manifold and gaskets
(Fig. 172) .
CLEANING
Clean the cylinder head and exhaust manifold seal-
ing surfaces with a suitable scraper. Use a Scotch-
BriteŸ pad or equivalent.
Fig. 167 Air Inlet Housing
1 - GROUND STRAP
2 - AIR INTAKE HOUSING
3 - HEATER POWER CABLE MOUNTING STUDS
4 - FUEL LINE BRACKET BOLT
5 - HOUSING BOLTS (4)
Fig. 168 Intake Air Grid Heater
1 - AIR HEATER ELEMENTS
2 - LOWER GASKET
3 - BLOCK
4 - UPPER GASKET
Fig. 169 Exhaust Pipe
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
BR/BEENGINE 5.9L DIESEL 9 - 185
INTAKE MANIFOLD (Continued)

INSPECTION
Inspect the exhaust manifold for cracks. Measure
the exhaust manifold for flatness. Place a ruler over
all of the exhaust ports and insert a feeler gauge
between the port flange and the ruler.
INSTALLATION
(1) Using new gaskets, install the exhaust mani-
fold and gaskets. Install the bolts and spacers and
tighten the bolts in the sequence shown in (Fig. 172)
to 43 N´m (32 ft. lbs.) torque.
(2) Install the cab heater return hose to the man-
ifold bolt stud. Tighten the nut to 24 N´m (18 ft. lbs.)
torque.
(3) Install the turbocharger. Apply anti-seize to the
studs and then tighten the turbocharger mounting
nuts to 32 N´m (24 ft. lbs.) torque.
(4) Install the oil drain tube and oil supply line to
the turbocharger. Tighten the drain tube bolts to 24
N´m (18 ft. lbs.) torque.
(5)Pre-lube the turbocharger.Pour 50 to 60 cc
(2 to 3 oz.) clean engine oil in the oil supply line fit-
ting. Rotate the turbocharger impeller by hand to
distrubute the oil thoroughly.
(6) Install and tighten the oil supply line fitting
nut to 20 N´m (133 in. lbs.) torque.
Fig. 170 Turbocharger Air Inlet Hose
1 - AIR FILTER HOUSING COVER
2 - TURBOCHARGER
3 - AIR INLET TUBE
4 - HOSE CLAMP
5 - HINGE TABS
6 - FILTER MINDER
7 - CLIPS (4)
8 - TUBE ALIGNMENT NOTCHES
Fig. 171 Oil Supply Line and Charge Air Cooler Inlet
Duct
1 - EXHAUST PIPE
2 - TURBOCHARGER
3 - AIR INLET TUBE
4 - INTERCOOLER INLET DUCT
5 - WASTE GATE ACTUATOR
Fig. 172 Exhaust Manifold and Gaskets
9 - 186 ENGINE 5.9L DIESELBR/BE
EXHAUST MANIFOLD (Continued)

(7) Position the charge air cooler inlet pipe to the
turbocharger. With the clamp in position, tighten the
clamp nut to 8 N´m (72 in. lbs.) torque.
(8) Position the air inlet hose to the turbocharger
(Fig. 170). Tighten the clamp to 8 N´m (72 in. lbs.)
torque.
(9) Raise vehicle on hoist.
(10) Connect the exhaust pipe to the turbocharger
(Fig. 169) and tighten the bolts to 34 N´m (25 ft. lbs.)
torque.
(11) Lower the vehicle.
(12) Connect the battery negative cables.
(13) Start the engine to check for leaks.
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION
(1) Remove the cylinder head cover.
(2) Remove fuel injector from cylinder number 1.
(3) Remove the crankcase breather from the gear
housing cover.
(4) Using Special Tool 7471B rotate the engine
until the timing mark on the fuel pump gear is
aligned with the TDC mark on the gear housing
cover.
(5) Using a 8 in.x 1/4 in. dowel rod inserted into
cylinder number 1, rock the crankshaft back and
forth to verify piston number 1 is at TDC.
(6) With piston number 1 at TDC the timing mark
on the fuel pump gear should be aligned with the
TDC mark on the gear housing cover. If marks do not
line up, remove the gear housing cover.
(7) With cylinder number still at TDC, inspect the
keyway on the crankshaft gear for proper alignment
(12 o'clock position).
(8) If the keyway is not at 12 o'clock position
replace the crankshaft gear assembly.
(9) If the keyway is at 12 o'clock position, verify
timing mark alignment between the camshaft gear,
crankshaft gear and the fuel pump gear, if not
aligned inspect keyway on camshaft gear.
(10) Inspect keyway on camshaft gear for proper
alignment with the key in the camshaft, if alignment
is off replace the camshaft/gear assembly.
(11) If timing marks alignment is off and no dam-
age is found at either the crankshaft or camshaft
gear keyways, realign timing marks as necessary.
GEAR HOUSING
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.(3) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle hose from
radiator filler neck and lift bottle off of fan shroud.
(7) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(8) Remove the fan shroud-to-radiator mounting
bolts.
(9) Remove viscous fan/drive assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(10) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(11) Remove the cooling fan support/hub from the
front of the engine (Fig. 173).
(12) Raise the vehicle on hoist.
(13) Remove the crankshaft damper (Fig. 174)
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(14) Lower the vehicle.
(15) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing (Fig.
175), taking care not to mar the gasket surfaces.
(16) Remove the fuel injection pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(17) Disconnect the camshaft position sensor con-
nector.
Fig. 173 Fan Support/Hub Assembly - Removal/
Installation
1 - FAN SUPPORT/HUB
2 - FAN PULLEY
BR/BEENGINE 5.9L DIESEL 9 - 187
EXHAUST MANIFOLD (Continued)