2002 DODGE RAM height

ELECTRICAL/RESTRAINTS/CLOCKSPRING -
REMOVAL) and (Refer to 19 - STEERING/COLUMN
- REMOVAL).
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE AIRBAG SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
WARNING: THE DRIVER AIRBAG TRIM COVER
MUST NEVER BE PAINTED. REPLACEMENT TRIM
COVERS ARE SERVICED IN THE ORIGINAL COL-
ORS. PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TRIM COVER RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
(1) Assemble the driver airbag trim cover onto the
airbag housing. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/DRIVER AIRBAG - ASSEMBLY).
(2) When installing the driver airbag, reconnect
the clockspring driver airbag pigtail wire harness
connector to the airbag inflator connector receptacle
by pressing straight in on the connector (Fig. 10). You
can be certain that the connector is fully engaged by
listening carefully for a distinct, audible click as the
connector snaps into place.
(3) Reconnect the clockspring horn switch pigtail
wire harness connector to the horn switch feed pig-
tail wire connector, which is located on the back of
the driver airbag.
(4) Carefully position the driver airbag in the
steering wheel. Be certain that the clockspring pig-
tail wires in the steering wheel hub area are not
pinched between the driver airbag and the steering
wheel.(5) From the underside of the steering wheel,
install and tighten the two screws that secure the
driver airbag to the steering wheel armature.
Tighten the screws to 10.2 N´m (90 in. lbs.).
(6) Do not reconnect the battery negative cable at
this time. The airbag system verification test proce-
dure should be performed following service of any
airbag system component. (Refer to 8 - ELECTRI-
CAL/RESTRAINTS - STANDARD PROCEDURE -
VERIFICATION TEST).
FRONT SEAT BELT &
RETRACTOR
REMOVAL
REMOVAL - STANDARD CAB
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Move the front seats to their most forward
position for easiest access to the front shoulder belt
lower seat belt anchor plate, the retractor, and the
B-pillar.
(2) Remove the screw that secures the lower seat
belt anchor plate to the floor panel near the base of
the B-pillar.
(3) Unsnap and lift the front shoulder belt turning
loop cover to access the screw that secures the turn-
ing loop to the height adjuster (Fig. 15).
(4) Remove the screw that secures the shoulder
belt turning loop to the height adjuster.
(5) Remove the shoulder belt turning loop from the
height adjuster.
(6) Remove the trim from the B-pillar. (Refer to 23
- BODY/INTERIOR/B-PILLAR TRIM - REMOVAL).
(7) Disengage the front seat shoulder belt turning
loop and lower seat belt anchor plate from the B-pil-
lar trim.
8O - 18 RESTRAINTSBR/BE
DRIVER AIRBAG (Continued)

(8) Remove the screw that secures the retractor to
the B-pillar.
(9) Remove the front shoulder belt and retractor
from the B-pillar.
REMOVAL - CLUB/QUAD CAB
The front seat shoulder belt and retractor are inte-
gral to the driver and passenger front seat backs on
club cab and quad cab models.
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Remove the trim cover from the front seat back
frame. (Refer to 23 - BODY/SEATS/SEAT BACK
COVER - REMOVAL).
(2) Remove the screws that secure the retractor
cover to the seat back frame.
(3) Remove the retractor cover from the seat back
frame.
(4) Remove the two screws that secure the seat
belt retractor to the seat back frame (Fig. 16).(5) Remove the front shoulder belt and retractor
from the seat back frame.
INSTALLATION
INSTALLATION - STANDARD CAB
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Position the retractor onto the B-pillar (Fig.
15).
(2) Install and tighten the screw that secures the
retractor to the B-pillar. Tighten the screw to 40 N´m
(29 ft. lbs.).
(3) Engage the front seat shoulder belt turning
loop and lower seat belt anchor plate with the B-pil-
lar trim.
(4) Reinstall the trim onto the B-pillar. (Refer to
23 - BODY/INTERIOR/B-PILLAR TRIM - INSTAL-
LATION).
(5) Position the shoulder belt turning loop onto the
height adjuster.
Fig. 15 Front Shoulder Belt - Standard Cab
1 - TURNING LOOP COVER
2 - SHOULDER BELT ASSEMBLY
Fig. 16 Seat Belt Retractor
1 - RETRACTOR SCREWS
2 - SEAT BACK FRAME
BR/BERESTRAINTS 8O - 19
FRONT SEAT BELT & RETRACTOR (Continued)

(6) Install and tighten the screw that secures the
shoulder belt turning loop to the height adjuster.
Tighten the screw to 30 N´m (22 ft. lbs.).
(7) Fold and snap the cover over the front shoulder
belt turning loop to conceal the screw that secures
the turning loop to the height adjuster.
(8) Install and tighten the screw that secures the
lower seat belt anchor plate to the floor panel near
the base of the B-pillar. Tighten the screw to 40 N´m
(29 ft. lbs.).
INSTALLATION - CLUB/QUAD CAB
The front seat shoulder belt and retractor are inte-
gral to the driver and passenger front seat backs on
club cab and quad cab models.
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Position the front shoulder belt and retractor
onto the seat back frame.
(2) Install and tighten the two screws that secure
the seat belt retractor to the seat back frame (Fig.
16). Tighten the screws to 16 N´m (12 ft. lbs.).
(3) Position the retractor cover onto the seat back
frame.
(4) Install and tighten the screws that secure the
retractor cover to the seat back frame. Tighten the
screws to 2 N´m (17 in. lbs.).
(5) Reinstall the trim cover onto the front seat
back frame. (Refer to 23 - BODY/SEATS/SEAT BACK
COVER - INSTALLATION).
FRONT SEAT BELT BUCKLE
REMOVAL
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELTTHAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Move the front seat to its most forward position
for easiest access to the front seat belt buckle
anchors.
(2) Tilt both front seat backs forward far enough to
access the seat belt buckle anchor screws.
(3) On the driver's side only, disconnect the body
wire harness connector for the seat belt switch from
the seat belt switch pigtail wire connector on the seat
belt buckle.
(4) Remove the screw that secures the seat belt
buckle to the anchor on the seat cushion frame.
(5) Remove the front seat belt buckle from the seat
cushion frame.
INSTALLATION
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Position the front seat belt buckle onto the seat
cushion frame.
(2) On the driver's side only, reconnect the body
wire harness connector for the seat belt switch to the
seat belt switch pigtail wire connector on the seat
belt buckle.
(3) Install and tighten the screw that secures the
seat belt buckle to the anchor on the seat cushion
frame. Tighten the screw to 40 N´m (29 ft. lbs.).
8O - 20 RESTRAINTSBR/BE
FRONT SEAT BELT & RETRACTOR (Continued)

between the seat belt switch and the instrument
cluster as required.
(4) Check for continuity between the seat belt
switch sense circuit cavities in the body wire harness
connector for the seat belt switch and the instrument
panel wire harness connector (Connector C2) for the
instrument cluster. There should be continuity. If
OK, proceed to the diagnosis for the instrument clus-
ter. (Refer to 8 - ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND TESTING). If not OK,
repair the open seat belt switch sense circuit between
the seat belt switch and the instrument cluster as
required.
SEAT BELT TURNING LOOP
ADJUSTER
REMOVAL
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Remove the knob from the lever of the seat belt
turning loop adjuster. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/TURNING LOOP HEIGHT ADJUSTER
KNOB - REMOVAL).
(2) Remove the screw that secures the shoulder
belt turning loop to the height adjuster.
(3) Remove the trim from the B-pillar. (Refer to 23
- BODY/INTERIOR/B-PILLAR TRIM - REMOVAL).
(4) Remove the screw that secures the upper end
of the height adjuster to the B-pillar.(5) Pull the upper end of the height adjuster away
from the B-pillar far enough to disengage the hooks
on the lower end of the adjuster from the slots in the
pillar.
(6) Remove the adjuster from the B-pillar.
INSTALLATION
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Position the height adjuster to the B-pillar
with the hook formations oriented toward the lower
end of the adjuster.
(2) Engage the hooks on the lower end of the
adjuster into the slots in the B-pillar.
(3) Tilt the upper end of the height adjuster up
into position against the B-pillar.
(4) Install and tighten the screw that secures the
upper end of the height adjuster to the B-pillar.
Tighten the screw to 41 N´m (30 ft. lbs.).
(5) Reinstall the trim onto the B-pillar. (Refer to
23 - BODY/INTERIOR/B-PILLAR TRIM - INSTAL-
LATION).
(6) Install and tighten the anchor screw that
secures the seat belt turning loop to the adjuster.
Tighten the screw to 30 N´m (22 ft. lbs.).
(7) Reinstall the knob onto the lever of the seat
belt turning loop adjuster. (Refer to 8 - ELECTRI-
CAL/RESTRAINTS/TURNING LOOP HEIGHT
ADJUSTER KNOB - INSTALLATION).
BR/BERESTRAINTS 8O - 29
SEAT BELT SWITCH (Continued)

TURNING LOOP HGT
ADJUSTER KNOB
REMOVAL
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Unsnap and lift the seat belt turning loop cover
to expose the anchor screw that secures the turning
loop to the height adjuster.
(2) Using the head of the turning loop anchor
screw as a fulcrum, carefully pry the knob from the
height adjuster lever with a suitable trim tool (Fig.
25).
INSTALLATION
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE ORRETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Fold and snap the seat belt turning loop cover
back into place over the anchor screw that secures
the turning loop to the adjuster.
(2) Position the height adjuster knob to the seat
belt turning loop height adjuster lever.
(3) Using hand pressure, push the knob firmly and
evenly onto the lever until it is fully engaged.
Fig. 25 Turning Loop Height Adjuster Knob
Removal - Typical
1 - KNOB
2 - ADJUSTER LEVER
3 - SEAT BELT TURNING LOOP
4 - TRIM TOOL (SNAP-ON A179A)
8O - 30 RESTRAINTSBR/BE

DESCRIPTION SPECIFICATION
Out of Round (Max.) 0.0254 mm (0.001 in.)
Taper (Max.) 0.0254 mm (0.001 in.)
Lifter Bore
Diameter 22.99 ± 23.01 mm
(0.9051 ± 0.9059 in.)
Distributor Drive Bushing
Press Fit
Bushing to Bore
Interference0.0127 ± 0.3556 mm
(0.0005 ± 0.0140 in.)
Shaft to Bushing
Clearance0.0178 ± 0.0686 mm
(0.0007 ± 0.0027 in.)
CYLINDER HEAD AND VALVES
Valve Seat
Angle 44.25É ± 44.75É
Runout (Max.) 0.0762 mm (0.003 in.)
Width (Finish)
Intake 1.016 ± 1.524 mm
(0.040 ± 0.060 in.)
Exhaust 1.524 ± 2.032 mm
(0.060 ± 0.080 in.)
Valves
Face Angle 43.25É ± 43.75É
Head Diameter
Intake 47.752 mm (1.88 in.)
Exhaust 41.072 (1.617 in.)
Length (Overall)
Intake 126.21 ± 126.85 mm
(4.969 ± 4.994 in.)
Exhaust 126.44 ± 127.30 mm
(4.978 ± 5.012 in.)
Lift (@ zero lash)
Intake 10.414 mm (0.410 in.)
Exhaust 10.592 mm (0.417 in.)
Stem Diameter
Intake 9.449 ± 9.474 mm
(0.372 ± 0.373 in.)DESCRIPTION SPECIFICATION
Exhaust 9.423 ± 9.449 mm
(0.371 ± 0.372 in.)
Guide Bore 9.500 ± 9.525 mm
(0.374 ± 0.375 on.)
Stem to Guide Clearance
Intake 0.0254 ± 0.0762 mm
(0.001 ± 0..003 in.)
Exhaust 0.0508 ± 0.1016 mm
(0.002 ± 0.004 in.)
Service Limit 0.4318 (0.017 in.)
Valve Springs
Free Length 49.962 mm (1.967 in.)
Spring Tension
Valve closed 378 N @ 41.66 mm
(85 lbs. @ 1.64 in.)
Valve open 890 N @ 30.89 mm
(200 lbs. @ 1.212 in.)
Number of Coils 6.8
Installed Height 41.66 mm (1.64 in.)
Wire Diameter 4.50 mm (0.177 in.)
HYDRAULIC TAPPETS
Body Diameter 22.949 ± 22.962 mm
(0.9035 ± 0.9040 in.)
Clearance (to bore) 0.0279 ± 0.0610 mm
(0.0011 ± 0.0024 in.)
Dry Lash 1.524 ± 5.334 mm
(0.060 ± 0.210 in.)
Push Rod Length 175.64 ± 176.15 mm
(6.915 ± 6.935 in.)
OIL PRESSURE
Curb Idle (Min.*) 41.4 kPa (6 psi)
@ 3000 rpm 207 ± 552 kPa (30 ± 80
psi)
Oil Pressure Bypass
Valve Setting 62 ± 103 kPa (9 ± 15 psi)
BR/BEENGINE 5.9L 9 - 15
ENGINE 5.9L (Continued)

CYLINDER HEAD COVER(S)
REMOVAL
NOTE: A steel backed silicon gasket is used with
the cylinder head cover (Fig. 7). This gasket can be
used again.
(1) Disconnect the negative cable from the battery.
(2) Disconnect the spark plug wires form the spark
plugs and set aside.
(3) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
(4) Remove cylinder head cover and gasket.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
INSTALLATION
(1) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas-
ket. Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(3) Install closed crankcase ventilation system and
evaporation control system.
(4) Connect the spark plug wires to the spark
plugs.
(5) Connect the negative cable to the battery.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
Both the intake and exhaust valves are made of
steel. The intake valve is 48.768 mm (1.92 inches) in
diameter and the exhaust valve is 41.148 mm (1.62
inches) in diameter and has a 2.032 mm (0.080 inch)
wafer interia welded to the tip for durability. These
valves are not splayed.
STANDARD PROCEDUREÐVALVES, GUIDES
AND SPRINGS
VALVE CLEANING
Clean valves thoroughly. Discard burned, warped,
or cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
VALVE GUIDES
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 in.), replace the valve.
Measure valve stem guide clearance as follows:
(1) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 8). The special
sleeve places the valve at the correct height for
checking with a dial indicator.
(2) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angles to valve stem being
measured (Fig. 9).
(3) Move valve to and from the indicator. The total
dial indicator reading should not exceed 0.432 mm
(0.017 in.). Ream the guides for valves with oversize
stems if dial indicator reading is excessive or if the
stems are scuffed or scored.
Fig. 7 Cylinder Head Cover Gasket
1 - CYLINDER HEAD COVER GASKET
Fig. 8 Positioning Valve with Tool C-3973
1 - VALVE
2 - SPACER TOOL
BR/BEENGINE 5.9L 9 - 23

ing stones. A true and complete surface must be
obtained.
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 in.) total indicator reading.
(3) Inspect the valve seat with Prussian blue, to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center ofvalve face, contact is satisfactory. If the blue is trans-
ferred to the top edge of valve face, lower valve seat
with a 15É stone. If the blue is transferred to bottom
edge of valve face raise valve seat with a 60É stone.
(4) When seat is properly positioned the width of
intake seats should be 1.016-1.524 mm (0.040-0.060
in.). The width of the exhaust seats should be 1.524-
2.032 mm (0.060-0.080 in.).
VALVE SPRINGS
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested. As an example the compression length of
the spring to be tested is 1-5/16 in.. Turn table of
Universal Valve Spring Tester Tool until surface is in
line with the 1-5/16 in. mark on the threaded stud.
Be sure the zero mark is to the front (Fig. 13). Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by 2. This will give the
spring load at test length. Fractional measurements
are indicated on the table for finer adjustments.
Refer to specifications to obtain specified height and
allowable tensions. Discard the springs that do not
meet specifications.
REMOVAL
(1) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(2) Compress valve springs using Valve Spring
Compressor Tool MD- 998772A and adapter 6716A.
(3) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
Fig. 11 Intake and Exhaust Valves
1 - MARGIN
2 - VALVE SPRING RETAINER LOCK GROOVE
3 - STEM
4-FACE
Fig. 12 Refacing Valve Seats
1-STONE
2 - PILOT
3 - VALVE SEAT
4 - SHROUD
Fig. 13 Testing Valve Spring for Compressed
Length
1 - TORQUE WRENCH
2 - VALVE SPRING TESTER
BR/BEENGINE 5.9L 9 - 25
INTAKE/EXHAUST VALVES & SEATS (Continued)