2002 DODGE RAM service

(2) Install the push rods in the same order as
removed.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker arm bolts
to 28 N´m (21 ft. lbs.) torque.
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(4) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
ENGINE BLOCK
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leakage.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper. Refer to Honing Cylinder Bores in
the Service Procedures portion of this Section.
Inspect the oil line plug, the oil line plug is located
in the vertical passage at the rear of the block
between the oil-to-filter and oil-from-filter passages
(Fig. 17) . Improper installation or missing plug could
cause erratic, low, or no oil pressure.
The oil plug must come out the bottom. Use flat
dowel, down the oil pressure sending unit hole from
the top, to remove oil plug.
(1) Remove oil pressure sending unit from back of
block.
(2) Insert a 3.175 mm (1/8 in.) finish wire, or
equivalent, into passage.
(3) Plug should be 190.0 to 195.2 mm (7-1/2 to
7-11/16 in.) from machined surface of block (Fig. 17) .If plug is too high, use a suitable flat dowel to posi-
tion properly.
(4) If plug is too low, remove oil pan and No. 4
main bearing cap. Use suitable flat dowel to position
properly. Coat outside diameter of plug with Mopart
Stud and Bearing Mount Adhesive. Plug should be
54.0 to 57.7 mm (2-1/8 to 2-5/16 in.) from bottom of
the block.
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS
NOTE: This procedure requires that the engine is
removed from the vehicle.
(1) With engine completely disassembled, drive out
rear cam bearing core plug.
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
Fig. 16 Rocker Arms
1 - ROCKER ARMS
2 - CYLINDER HEAD
Fig. 17 Oil Line Plug
1 - RIGHT OIL GALLERY
2 - CYLINDER BLOCK
3 - OIL FROM FILTER TO SYSTEM
4 - OIL TO FILTER
5 - FROM OIL PUMP
6 - CRANKSHAFT
7 - PLUG
BR/BEENGINE 5.9L 9 - 27
ROCKER ARM / ADJUSTER ASSEMBLY (Continued)

INSTALLATION
Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight-
ened. All bearing capbolts removed during service
procedures are to be cleaned and oiled before instal-
lation.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 27).
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Tool C-3059.(3) Install the bearing caps. Clean and oil the
bolts. Tighten the capbolts to 115 N´m (85 ft. lbs.)
torque.
(4) Install the oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(5) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(6) Start engine check for leaks.
CRANKSHAFT OIL SEAL -
FRONT
DESCRIPTION
The crankshaft front seal is a one piece viton seal
with a steel housing. The front seal is located in the
engine front cover.
OPERATION
The crankshaft seals prevent oil from leaking from
around the crankshaft, either from the rear of the
engine or from the engine front cover.
REMOVAL
The oil seal can be replaced without removing the
timing chain cover, provided that the cover is not
misaligned.
(1) Disconnect the negative cable from the battery.
(2) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(3) If front seal is suspected of leaking, check front
oil seal alignment to crankshaft. The seal installa-
tion/alignment Tool 6635, should fit with minimum
interference. If tool does not fit, the cover must be
removed and installed properly.
(4) Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal bore of cover.
INSTALLATION
(1) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 28). Seat
the oil seal in the groove of the tool.
(2) Position the seal and tool onto the crankshaft
(Fig. 29).
(3) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 30).
(4) Remove the vibration damper bolt and seal
installation tool.
(5) Inspect the seal flange on the vibration
damper.
(6) Install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
Fig. 26 Main Bearing
Fig. 27 Upper Main Bearing Removal and
Installation with Tool C-3059
1 - SPECIAL TOOL C-3059
2 - BEARING
3 - SPECIAL TOOL C-3059
4 - BEARING
9 - 32 ENGINE 5.9LBR/BE
CRANKSHAFT MAIN BEARINGS (Continued)

(7) Connect the negative cable to the battery.
CRANKSHAFT OIL SEAL -
REAR
DESCRIPTION
The crankshaft rear seal is a two piece viton seal.
One part of the two piece rear seal is located in a slot
in the cylinder block oppsite the crankshaft mainbearing cap, the second part of the two piece seal is
located in the main bearing cap itself.
OPERATION
The crankshaft seals prevent oil from leaking from
around the crankshaft, either from the rear of the
engine or from the engine front cover.
REMOVAL
The service seal is a two piece, Viton seal. The
upper seal half can be installed with crankshaft
removed from engine or with crankshaft installed.
When a new upper seal is installed, install a new
lower seal. The lower seal half can be installed only
with the rear main bearing cap removed.
UPPER SEAL ÐCRANKSHAFT REMOVED
(1) Remove the crankshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CRANKSHAFT - REMOVAL). Dis-
card the old upper seal.
UPPER SEALÐCRANKSHAFT INSTALLED
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL).
(3) Remove the rear main bearing cap. Remove
and discard the old lower oil seal.
(4) Carefully remove and discard the old upper oil
seal.
Fig. 28 Placing Oil Seal on Installation Tool 6635
1 - CRANKSHAFT FRONT OIL SEAL
2 - INSTALL THIS END INTO SPECIAL TOOL 6635
Fig. 29 Position Tool and Seal onto Crankshaft
1 - SPECIAL TOOL 6635
2 - OIL SEAL
3 - TIMING CHAIN COVER
Fig. 30 Installing Oil Seal
1 - SPECIAL TOOL 6635
2 - TIMING CHAIN COVER
BR/BEENGINE 5.9L 9 - 33
CRANKSHAFT OIL SEAL - FRONT (Continued)

LOWER SEAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL).
(3) Remove the rear main bearing cap and discard
the old lower seal.
INSTALLATION
The service seal is a two piece, Viton seal. The
upper seal half can be installed with crankshaft
removed from engine or with crankshaft installed.
When a new upper seal is installed, install a new
lower seal. The lower seal half can be installed only
with the rear main bearing cap removed.
UPPER SEAL ÐCRANKSHAFT REMOVED
(1) Clean the cylinder block rear cap mating sur-
face. Be sure the seal groove is free of debris. Check
for burrs at the oil hole on the cylinder block mating
surface to rear cap.
(2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with
the white paint facing toward the rear of the engine.
(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine
oil.
(6) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(7) Apply 5 mm (0.20 in.) drop of MopartGasket
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 31). DO NOT over-apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application.
(8) To align the bearing cap, use cap slot, align-
ment dowel, and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than two times for proper engagement.
(9) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 N´m (85 ft. lbs.) torque.
(10) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(11) Apply MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, at bearing cap-to-block
joint to provide cap to block and oil pan sealing (Fig.
32). Apply enough sealant so that a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
(12) Install new front crankshaft oil seal (Refer to
9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION).(13) Immediately install the oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
UPPER SEALÐCRANKSHAFT INSTALLED
(1) Clean the cylinder block mating surfaces before
oil seal installation. Check for burrs at the oil hole on
the cylinder block mating surface to rear cap.
(2) Lightly oil the new upper seal lips with engine
oil. To allow ease of installation of the seal, loosen at
least the two main bearing caps forward of the rear
bearing cap.
Fig. 31 Sealant Application to Bearing Cap
1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS
2 - MOPARTGASKET MAKER (OR EQUIVALENT)
3 - CAP ALIGNMENT SLOT
4 - REAR MAIN BEARING CAP
Fig. 32 Apply Sealant to Bearing Cap-to-Block Joint
1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE
TIP
2 - SEALANT APPLIED
3 - CYLINDER BLOCK
4 - REAR MAIN BEARING CAP
9 - 34 ENGINE 5.9LBR/BE
CRANKSHAFT OIL SEAL - REAR (Continued)

tappets, which pass oil through hollow push rods to a
hole in the corresponding rocker arm. Oil from the
rocker arm lubricates the valve train components.The oil then passes down through the push rod guide
holes and the oil drain-back passages in the cylinder
head, past the valve tappet area, and then returns to
the oil pan (Fig. 49).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE OIL
LEAKS
Begin with a through visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil-soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
be sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light source.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.
Fig. 47 Engine Rear Support Cushion Assemblies
Fig. 48 Positive Displacement Oil PumpÐTypical
1 - INNER ROTOR AND SHAFT
2 - BODY
3 - DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 - COTTER PIN
5 - RETAINER CAP
6 - SPRING
7 - RELIEF VALVE
8 - LARGE CHAMFERED EDGE
9 - BOLT
10 - COVER
11 - OUTER ROTOR
BR/BEENGINE 5.9L 9 - 43
LUBRICATION (Continued)

(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24km (15 miles), and
repeat previous step.
(5) If the oil leak source is not positively identified
at this time, proceed with the air leak detection test
method as follows:
(6) Disconnect the breather cap to air cleaner hose
at the breather cap end. Cap or plug breather cap
nipple.
(7) Remove the PCV valve from the cylinder head
cover. Cap or plug the PCV valve grommet.
(8) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(9) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provide the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
(10) If the leakage occurs at the rear oil seal area,
refer to the section, Inspection for Rear Seal Area
Leak.
(11) If no leaks are detected, turn off the air sup-
ply and remove the air hose and all plugs and caps.
Install the PCV valve and breather cap hose. Proceed
to next step.
(12) Clean the oil off the suspect oil leak area
using a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE
(1) Remove oil pressure sending unit.
(2) Install Oil Pressure Line and Gauge Tool
C-3292. Start engine and record pressure. (Refer to 9
- ENGINE - SPECIFICATIONS).
OIL
STANDARD PROCEDURE - ENGINE OIL
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the right
front of the engine, left of the generator (Fig. 50).
CRANKCASE OIL LEVEL INSPECTION
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 levels are indicated between the ADD
and SAFE marks on the engine oil dipstick.
(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) Install 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 ADD mark on
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. This infor-
mation can be found in the owner's manual.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist vehicle.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
Fig. 50 Oil Level Indicator Location
1 - CYLINDER HEAD COVER
2 - ENGINE OIL FILL CAP
3 - DIPSTICK
4 - ENGINE OIL FILTER
5 - FILTER BOSS
BR/BEENGINE 5.9L 9 - 45
LUBRICATION (Continued)

ENGINE 8.0L
TABLE OF CONTENTS
page page
ENGINE 8.0L
DESCRIPTION.........................58
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........58
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - PERFORMANCE...........59
DIAGNOSIS AND TESTINGÐ ENGINE
DIAGNOSIS - MECHANICAL.............61
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - LUBRICATION.............63
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE.............64
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE......64
STANDARD PROCEDURE
STANDARD PROCEDUREÐCYLINDER
BORE HONING.......................65
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........66
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.........66
STANDARD PROCEDUREÐHYDROSTATIC
LOCK...............................66
REMOVAL.............................67
INSTALLATION.........................68
SPECIFICATIONS
8.OL ENGINE........................68
TORQUE............................71
SPECIAL TOOLS
8.0L ENGINE.........................72
AIR CLEANER ELEMENT
REMOVAL - 8.0L........................75
INSTALLATION - 8.0L....................75
CYLINDER HEAD
DESCRIPTION.........................76
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE.....................76
REMOVAL.............................76
CLEANING............................77
INSPECTION..........................77
INSTALLATION.........................77
CYLINDER HEAD COVER(S)
DESCRIPTION.........................78
REMOVAL.............................78
CLEANING............................79
INSPECTION..........................79
INSTALLATION.........................79INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................80
STANDARD PROCEDURE
VALVE SERVICE......................80
REMOVAL
REMOVALÐVALVE STEM SEALS.........82
REMOVALÐVALVES AND VALVE SPRINGS . 82
CLEANING............................83
INSPECTION..........................83
INSTALLATION
INSTALLATIONÐVALVE STEM SEAL......83
INSTALLATIONÐVALVES AND VALVE
SPRINGS............................84
ROCKER ARM / ADJUSTER ASSY
REMOVAL.............................84
INSTALLATION.........................84
ENGINE BLOCK
CLEANING............................85
INSPECTION..........................85
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS.......85
REMOVALÐCAMSHAFT................85
INSTALLATION
INSTALLATIONÐCAMSHAFT BEARINGS . . . 86
INSTALLATIONÐCAMSHAFT............86
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING................87
CRANKSHAFT
REMOVAL.............................87
INSTALLATION.........................88
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDUREÐFITTING
CRANKSHAFT MAIN BEARINGS..........88
REMOVAL.............................88
INSTALLATION.........................88
CRANKSHAFT OIL SEAL - FRONT
REMOVAL
REMOVALÐFRONT OIL SEAL - FRONT
COVER INSTALLED....................89
REMOVALÐFRONT OIL SEAL - FRONT
COVER REMOVED....................89
INSTALLATION
INSTALLATIONÐFRONT OIL SEAL ± FRONT
COVER INSTALLED....................89
INSTALLATIONÐFRONT OIL SEAL - FRONT
COVER REMOVED....................90
9 - 56 ENGINE 8.0LBR/BE

ENGINE 8.0L
DESCRIPTION
The 8.0 Liter (488 CID) ten-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
Engine lubrication system consists of a gerotor
type oil pump mounted in the timing chain cover and
driven by the crankshaft. The V-10 uses a full flow
oil filter.
The cylinders are numbered from front to rear; 1,
3, 5, 7, 9 on the left bank and 2, 4, 6, 8, 10 on the
right bank. The firing order is 1-10-9-4-3-6-5-8-7-2
(Fig. 1) .
The engine serial number is located on the lower
left front of the cylinder block in front of the engine
mount (Fig. 2) . When component part replacement is
necessary, use the engine type and serial number for
reference.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING - Preformance) or (Refer to 9 - ENGINE - DIAG-
NOSIS AND TESTING - Mechanical). Refer to 14 -
FUEL SYSTEM for fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING)
²Cylinder Combustion Pressure Leakage Test
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
²Cylinder Head Gasket Failure Diagnosis (Refer
to 9 - ENGINE/CYLINDER HEAD - DIAGNOSIS
AND TESTING)
²Intake Manifold Leakage Diagnosis (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING)
²Lash Adjuster (Tappet) Noise Diagnosis (Refer to
9 - ENGINE/ENGINE BLOCK/HYDRAULIC LIFT-
ERS (CAM IN BLOCK) - DIAGNOSIS AND TEST-
ING)
²Engine Oil Leak Inspection (Refer to 9 -
ENGINE/LUBRICATION - DIAGNOSIS AND TEST-
ING)
Fig. 1 Firing Order
Fig. 2 Engine IdentificationÐ(Serial Number)
1 - ENGINE SERIAL NO.
2 - ENGINE MOUNT LOCATION
9 - 58 ENGINE 8.0LBR/BE