2002 DODGE RAM roof

SPLICE
NUMBERLOCATION FIG.
S184 (Diesel) Engine Harnes, in T/O to Engine Control Module N/S
S202 Instrument Panel Harness, Near Overdrive Switch 31
S203 Instrument Panel Harness, Near Overdrive Switch 31
S204 instrument Panel Harness, In T/O to Cup Holder Lamp 31
S207 Instrument Panel Harness, Near Blower Motor 31
S209 Steering Wheel Harness, Near Remote Radio Switch N/S
S210 Steering Wheel Harness, Near Remote Radio Switch N/S
S300 Body Harness, Left Side Instrument Panel 36
S301 Body Harness, Left Side Instrument Panel 36
S302 Body Harness, Left Side Instrument Panel 36
S303 Body Harness, Left Side Instrument Panel 36
S304 Body Harness, Left Side Instrument Panel 36
S305 Body Harness, Right Side Instrument Panel N/S
S306 Body Harness, Left Side Instrument Panel 36
S307 Body Harness, Left Cowl 36
S308 Body Harness, Left Cowl 36
S310 At Left Body Ground N/S
S311 At Left Body Ground N/S
S313 Left Rear Frame Rail 28
S314 Left Rear Frame Rail N/S
S315 Left Rear Frame Rail N/S
S316 Left Rear Frame Rail 28
S317 Left Rear Frame Rail 28
S318 In T/O to Trailer Tow 28
S319 In T/O to Left Rear Lamps 28
S320 In T/O to Trailer Tow 28
S321 In T/O to Left Rear Lamps 28
S322 Overhead Console Harness, At Roof Lamps 26
S323 Overhead Console Harness, At Roof Lamps 26
S324 Overhead Console Harness, At Roof Lamps 26
S325 Overhead Console Harness, At Roof Lamps 26
S326 Overhead Console Harness, At Roof Lamps 26
S327 Power Seat Harness, Near Switch N/S
S328 Power Seat Harness, Near T/O to Body Wiring N/S
S329 Door Harness, Near Left Door Near Grommet N/S
S330 Door Harness, Near Right Door Near Grommet N/S
S331 Chassis Harness, Near T/O to Fuel Pump Module 28
S332 Body Harness, Left Side Instrument Panel 36
S333 Power Seat Harness, Near T/O to Passenger Seat Jumper N/S
S335 Power Seat harness, Near T/O to Body Wiring N/S
S336 Power Seat Harness, Under Passenger Seat N/S
BR/BE8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE
NUMBERLOCATION FIG.
S337 Power Seat Harness, Under Passenger Seat N/S
S340 Overhead Console Harness, At Roof Lamps 26
S401 Tail/Stop/Turn and Back-up Lamp Harness, Near T/O to Left
Back-up LampN/S
S402 Tail/Stop/Turn and Back-up Lamp Harness, Near T/O to Right
Back-up LampN/S
S404 Fender Lamp Harness, Near T/O to Tailgate Lamp N/S
S406 Fender Lamp Harness, Near T/O to Tailgate Lamp N/S
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONBR/BE
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

(13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear end seals.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 65). Dis-
card the gasket.
(19) If required, remove the plenum pan and gas-
ket. Discard gasket.
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) If removed, position new plenum gasket and
install plenum pan (Fig. 66).
(2) Tighten plenum pan mounting bolts as follows:²Step 1. Tighten bolts to 5.4 N´m (48 in. lbs.)
²Step 2. Tighten bolts to 9.5 N´m (84 in. lbs.)
²Step 3. Check all bolts are at 9.5 N´m (84 in.
lbs.)
(3) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 68). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(4) Apply MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, to the four corner joints.
An excessive amount of sealant is not required to
ensure a leak proof seal. However, an excessive
amount of sealant may reduce the effectiveness of
the flange gasket. The sealant should be approxi-
mately 5 mm (0.2 in) in diameter and 15 mm (0.6 in.)
long.
(5) Install the front and rear end seals (Fig. 67)
Make sure the molded dowel pins on the end seals
fully enter the corresponding holes in the cylinder
block.
(6) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. After intake
manifold is in place, inspect to make sure seals are
in place.
(7) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N´m
(200 in. lbs.) torque.
(8) Install the intake manifold bolts and tighten as
follows (Fig. 69):
Fig. 65 Throttle Body Assembly
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
Fig. 66 Plenum Pan Bolt Tightening Sequence
BR/BEENGINE 5.9L 9 - 51
INTAKE MANIFOLD (Continued)

INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) Install the intake manifold side gaskets. Be
sure that the locator dowels are positioned in the
head (Fig. 74).(2) Insert MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, into the four corner joints
an excessive amount of sealant is not required to
ensure a leak proof seal. However, an excessive
amount of sealant may reduce the effectiveness of
the flange gasket. The sealant should be approxi-
mately 5 mm (0.2 in.) in diameter. (Fig. 73).
(3) Position the cross-over gaskets and press firmly
onto the block (Fig. 73).BE SURE THE BLOCK IS
OIL FREE.
(4) The lower intake manifold MUST be installed
within 3 minutes of sealant application. Carefully
lower intake manifold into position on the cylinder
block and heads. After intake manifold is in place,
inspect to make sure seals and gaskets are in place.
Finger start all the lower intake bolts.
(5) Tighten the lower intake manifold bolts in
sequence to 54 N´m (40 ft. lbs.) torque (Fig. 72).
Recheck all bolts are tightened to 54 N´m (40 ft. lbs.)
torque.
(6) Using a new gasket, position the upper intake
manifold onto the lower intake manifold.
(7) Finger start all bolts, alternate one side to the
other.
(8) Tighten upper intake manifold bolts in
sequence to 22 N´m (16 ft. lbs.) torque (Fig. 71).
(9) Using a new gasket, install the throttle body
onto the upper intake manifold. Tighten the bolts to
23 N´m (200 in. lbs.) torque.
(10) Install closed crankcase ventilation and evap-
oration control systems.
(11) Connect the heater hoses and bypass hose.
(12) Connect the vacuum lines.
(13) Install the coil assemblies and the ignition
wires.
(14) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
Fig. 72 Lower Intake Manifold
Fig. 73 Lower Intake Manifold Gaskets
1 - INTAKE MANIFOLD GASKET
2 - SEALANT
3 - CROSS-OVER GASKETS
4 - SEALANT
5 - LOCATOR DOWELS
Fig. 74 Intake Manifold Flange
1 - LOCATOR DOWELS
2 - INTAKE MANIFOLD GASKETS
3 - LOCATOR DOWELS
9 - 108 ENGINE 8.0LBR/BE
INTAKE MANIFOLD (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)

ROOF PANEL Ð CLUB CAB
BR/BEBODY 23 - 31
BODY (Continued)

ROOF PANEL Ð QUAD CAB
23 - 32 BODYBR/BE
BODY (Continued)

ROOF PANEL - REG CAB
23 - 40 BODYBR/BE
BODY (Continued)