2002 DODGE RAM engine oil

(9) Disconnect turbocharger oil supply line at the
turbocharger end. Cap off open ports to prevent
intrusion of dirt or foreign material.
(10) Remove exhaust manifold-to-cylinder head
bolts and spacers. Remove exhaust manifold and tur-
bocharger from the vehicle as an assembly.
(11) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove generator upper bracket.
(13) Disconnect radiator upper hose from the ther-
mostat housing.
(14) Disconnect the coolant temperature sensor
connector.
(15) Remove the engine harness to cylinder head
attaching bolt at front of head.
(16) Remove the engine harness ground fastener
at front of head below the thermostat housing.(17) Remove the throttle linkage cover (Fig. 15).
(18) Remove the six (6) accelerator pedal position
sensor assembly-to-cylinder head bracket bolts (Fig.
16) and secure the entire assembly out of the way.
Disconnect the APPS connector (Fig. 17).It is not
necessary to disconnect the cables from the
throttle control assembly.
(19) Remove the intake air grid heater wires from
the grid heater.
(20) Remove engine oil level indicator tube attach-
ing bolt from the air inlet housing.
Fig. 13 Cylinder Head and Gasket
1 - THERMOSTAT BORE
2 - INTAKE RUNNER
3 - CYLINDER HEAD
4 - CYLINDER HEAD GASKET
5 - CYLINDER BLOCK
Fig. 14 Exhaust Pipe-to-Turbocharger Elbow
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
Fig. 15 Throttle Linkage Cover
1 - CABLE/LEVER/LINKAGE COVER
2 - PUSH UP LOWER TAB
3 - SCREWS/CLIPS (2)
4 - TAB PUSH HERE
BR/BEENGINE 5.9L DIESEL 9 - 131
CYLINDER HEAD (Continued)

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)

(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)

original locations (Fig. 53). Tighten bolts to 36 N´m
(27 ft. lbs.) torque.
(4)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
(5) Install cylinder head cover and reusable gasket
(Fig. 52) (Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(6) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(7) Connect battery negative cables.
ROCKER ARM / ADJUSTER
ASSY
DESCRIPTION
The 24±valve overhead system incorporates rocker
arms that are designed to allow fuel injector service
without removing the rocker arms and pedestals. The
unique intake and exhaust rocker arms have their
own rocker shafts and are lubricated by passages
intersecting the cylinder block main oil rifle. Cross-
heads are used (Fig. 58), which allow each rocker
arm to operate two valves.
The solid push rods are hardened at the rocker
arm and tappet contact areas for superior strength
and durability.
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove cylinder head cover (Fig. 59) (Refer to
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Remove the rocker arm/pedestal fasteners (Fig.
60) and remove rocker arm and pedestal from cylin-
der head. Mark the arms and pedestals so they can
be installed in their original position.
CAUTION: When removing the rocker arms, the
sockets (Fig. 61) may come loose and fall into the
engine. Make sure they stay with the arm upon
removal/installation.
Fig. 56 Spring Compressor Mounting BaseÐPart of
Tool 8319±A
1 - COMPRESSOR MOUNTING BASE
Fig. 57 Compressing Valve Springs with Tool
8319±A
1 - SPECIAL TOOL 8319
Fig. 58 Overhead System Components
1 - EXHAUST ROCKER ARM
2 - INTAKE ROCKER ARM
3 - ROCKER SHAFT
4 - SOCKET
5 - ADJUSTING SCREW LOCK NUT
6 - PUSH ROD
7 - PEDESTAL
8 - CROSSHEAD
BR/BEENGINE 5.9L DIESEL 9 - 145
INTAKE/EXHAUST VALVES & SEATS (Continued)

(4) Lift the push rod(s) up and out of the engine
(Fig. 62). Mark them so they can be installed in their
original position.
NOTE: The #5 cyl. exhaust and #6 cyl. intake and
exhaust push rods must be raised through the pro-
vided cowl panel access holes.
(5) Lift the crosshead(s) off of the valve stems.
Mark them so they can be installed in their original
position.
CLEANING
Clean all components in a suitable solvent. If nec-
essary, use a wire brush or wheel to remove stubborn
deposits. Rinse in hot water and blow dry with com-
pressed air. Inspect oil passages in rocker arms and
pedestals. Apply compressed air to lubrication orifices
to purge contaminants.
INSPECTION
Rocker Arms
(1) Remove rocker shaft and inspect for cracks and
excessive wear in the bore or shaft. Remove socketand inspect ball insert and socket for signs of wear.
Replace retainer if necessary.
Measure the rocker arm bore and shaft (Fig. 63)
(Fig. 64).
Push Rods
Inspect the push rod ball and socket for signs of
scoring. Check for cracks where the ball and the
socket are pressed into the tube (Fig. 65).
Fig. 59 Cylinder Head CoverÐRemoval/Installation
1 - BOLT (5)
2 - GASKET
3 - ªTOP FRONTº
4 - ISOLATOR (5)
Fig. 60 Rocker Arms and PedestalsÐRemoval/
Installation
1 - ROCKER ARM
2 - PEDESTAL
Fig. 61 Rocker Arm Assembly Identification
1 - NUT
2 - ADJUSTING SCREW
3 - ROCKER SHAFT
4 - RETAINER
5 - SOCKET
9 - 146 ENGINE 5.9L DIESELBR/BE
ROCKER ARM / ADJUSTER ASSY (Continued)

INSTALLATION
(1) If previously removed, install the push rods in
their original location (Fig. 62).Verify that they
are seated in the tappets.
(2) Lubricate the valve tips and install the cross-
heads in their original locations.
(3) Lubricate the crossheads and push rod sockets
and install the rocker arms and pedestals (Fig. 60) in
their original locations. Tighten bolts to 36 N´m (27
ft. lbs.) torque.
(4)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
(5) Install cylinder head cover and reusable gasket
(Fig. 59) (Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(6) Connect battery negative cables.
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER BLOCK
REFACING
(1) The combustion deck can be refaced twice. The
first reface should be 0.25 mm (0.0098 inch). If addi-
tional refacing is required, an additional 0.25 mm
(0.0098 inch) can be removed. Total allowed refacing
is 0.50 mm (0.0197 inch) - (Fig. 68).
(2) The upper right corner of the rear face of the
block must be stamped with a X when the block is
refaced to 0.25 mm (0.0098 inch). A second X must be
stamped beside the first when the block is refaced to
0.50 mm (0.0197 inch) - (Fig. 69).
(3) Consult the parts catalog for the proper head
gaskets which must be used with refaced blocks to
ensure proper piston-to-valve clearance.
STANDARD PROCEDURE - CYLINDER BORE -
DE-GLAZE
(1) New piston rings may not seat in glazed cylin-
der bores.
(2) De-glazing gives the bore the correct surface
finish required to seat the rings. The size of the bore
is not changed by proper de-glazing.
(3) Cover the lube holes in the top of the block
with waterproof tape.
(4) A correctly honed surface will have a cross-
hatch appearance with the lines at 15É to 25É angles
(Fig. 70). For the rough hone, use 80 grit honing
stones. To finish hone, use 280 grit honing stones.
(5) Use a drill, a fine grit Flex-hone and a mixture
of equal parts of mineral spirits and SAE 30W engine
oil to de-glaze the bores.(6) The crosshatch angle is a function of drill
speed and how fast the hone is moved vertically (Fig.
71).
(7) Vertical strokes MUST be smooth continuous
passes along the full length of the bore (Fig. 71).
(8) Inspect the bore after 10 strokes.
(9) Use a strong solution of hot water and laundry
detergent to clean the bores. Clean the cylinder bores
immediately after de-glazing.
Fig. 68 Refacing Dimensions of the Cylinder Block
CYLINDER BLOCK REFACING DIMENSIONS
DIMENSION(A(
1st Reface 0.25mm (0.0098 in.)
2nd Reface 0.25mm (0.0098 in.)
Dim (A) Total 0.50 mm (0.0197 in.)
DIMENSION(B(
Dim.9B9(STD.)323.00 mm   0.10
mm(12.7165 in.  
0.0039 in.)
1st Reface322.75 mm   0.10
mm(12.7067 in.  
0.0039 in.)
2nd Reface322.50 mm   0.10
mm(12.6968 in.  
0.0039 in.)
Fig. 69 Stamp Block after Reface
9 - 148 ENGINE 5.9L DIESELBR/BE
ROCKER ARM / ADJUSTER ASSY (Continued)

(10) Rinse the bores until the detergent is removed
and blow the block dry with compressed air.
(11) Check the bore cleanliness by wiping with a
white, lint free, lightly oiled cloth. If grit residue is
still present, repeat the cleaning process until all res-
idue is removed. Wash the bores and the complete
block assembly with solvent and dry with compressed
air.
(12) Be sure to remove the tape covering the lube
holes after the cleaning process is complete.
STANDARD PROCEDUREÐCYLINDER BORE
REPAIR
Cylinder bore(s) can be repaired by one of two
methods:
²Method 1:ÐOver boring and using oversize pis-
tons and rings.
²Method 2:ÐBoring and installing a repair sleeve
to return the bore to standard dimensions.
METHOD 1ÐOVERSIZE BORE
Cylinder bore(s) can be repaired by one of two
methods:
Oversize pistons and rings are available in two
sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393
inch).Any combination of standard, 0.50 mm (0.0197
inch) or 1.00 mm (0.0393 inch) overbore may be used
in the same engine.
If more than 1.00 mm (0.0393 inch) overbore is
needed, a repair sleeve can be installed (refer to
Method 2ÐRepair Sleeve).
Cylinder block bores may be bored twice before use
of a repair sleeve is required (Fig. 72). The first bore
is 0.50 mm (0.0197 inch) oversize. The second bore is
1.00 mm (0.0393 inch) oversize.
After boring to size, use a honing stone to chamfer
the edge of the bore (Fig. 72).
CYLINDER BORE DIMENSION CHART
DESCRIPTION MEASUREMENT
BORING DIAMETER
DIMENSION1st. REBORE - 102.469
mm (4.0342 in.)
2nd. REBORE - 102.969
mm (4.0539 in.)
HONING DIAMETER
DIMENSIONSSTANDARD - 102.020  
0.020 mm (4.0165  
0.0008 in.)
1st. REBORE - 102.520
  0.020 mm (4.0362  
0.0008 in.)
2nd. REBORE - 103.020
  0.020 mm 4.0559  
0.0008 in.)
CHAMFER
DIMENSIONSApprox. 1.25 mm (0.049
in.) by 15É
A correctly honed surface will have a crosshatch
appearance with the lines at 15É to 25É angles with
the top of the cylinder block (Fig. 73). For the rough
hone, use 80 grit honing stones. To finish hone, use
280 grit honing stones.
Fig. 70 Cylinder Bore Crosshatch Pattern
Fig. 71 De-Glazing Drill Speed and Vertical SpeedFig. 72 Cylinder Bore Dimensions
1 - CHAMFER
BR/BEENGINE 5.9L DIESEL 9 - 149
ENGINE BLOCK (Continued)

A maximum of 1.2 micrometer (48 microinch) sur-
face finish must be obtained.
After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry
detergent and hot water.
After rinsing, blow the block dry.
Check the bore cleanliness by wiping with a white,
lint-free, lightly- oiled cloth. There should be no grit
residue present.
If the block is not to be used right away, coat it
with a rust- preventing compound.
METHOD 2ÐREPAIR SLEEVE
If more than a 1.00 mm (0.03937 inch) diameter
oversize bore is required, the block must be bored
and a repair sleeve installed.
Bore the block cylinder bore to 104.500-104.515
mm (4.1142-4.1148 inch) - (Fig. 74).
Repair sleeves can be replaced by using a boring
bar to bore out the old sleeve. DO NOT cut the cyl-
inder bore beyond the oversize limit.
REPAIR SLEEVE BLOCK REBORE
DIMENSIONS CHART
BORE DIAMETER STEP DIAMETER
104.500 + 0.015 mm
(4.1142 + 0.0006 in.)6.35 mm (0.25 in.)
After machining the block for the new repair
sleeve, thoroughly clean the bore of all metal chips,
debris and oil residue before installing the sleeve.
Cool the repair sleeve(s) to a temperature of -12ÉC
(10ÉF) or below for a minimum of one hour. Be ready
to install the sleeve immediately after removing it
from the freezer.
Apply a coat of Loctite 620, or equivalent to the
bore that is to be sleeved.
Wear protective gloves to push the cold sleeve into
the bore as far as possible.
Using a sleeve driver, drive the sleeve downward
until it contacts the step at the bottom of the bore
(Fig. 75).
A sleeve driver can be constructed as follows (Fig. 76).
SLEEVE DRIVER CONSTRUCTION
SPECIFICATION CHART
ITEM MEASUREMENT
A 127 mm (5 in.)
B 38 mm (1.5 in.)
C 6.35 mm (0.25 in.)
D 25.4 mm (1 in.)
E 101 mm (3.976 in.)
F 107.343 mm (4.226 in.)
Set up a boring bar and machine the sleeve to
101.956 mm (4.014 inch) - (Fig. 77).
Fig. 73 Crosshatch Pattern of Repaired Sleeve(s)
Fig. 74 Block Bore for Repair Sleeve Dimensions
1 - BORE DIAMETER
2 - STEP DIMENSION
Fig. 75 Sleeve Installation
1 - SLEEVE DRIVER
2 - SLEEVE
3 - CONTACT
9 - 150 ENGINE 5.9L DIESELBR/BE
ENGINE BLOCK (Continued)