2002 DODGE RAM service

(8) Install and tighten the gear housing bolts to 24
N´m (18 ft. lbs.) torque.
(9) Install and tighten the oil pan bolts to 24 N´m
(18 ft. lbs.) torque.
(10) Install the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - INSTALLATION). Align the crankshaft,
camshaft, and injection pump gear marks as shown
in (Fig. 177).
(11) If a new housing is installed, the camshaft
position sensor must be transferred to the new hous-
ing.
(12) Connect the camshaft position sensor connec-
tor.
(13) Install the injection pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(14) Obtain a seal pilot/installation tool from a
crankshaft front seal service kit and install the pilot
into the crankshaft front oil seal.
(15) Apply a bead of MopartSilicone Rubber
Adhesive Sealant or equivalent to the gear housing
cover. Be sure to surround all through holes.
(16) Using the seal pilot to align the cover (Fig.
178), install the cover to the housing and install the
bolts. Tighten the bolts to 24 N´m (18 ft. lbs.) torque.
(17) Remove the seal pilot.
(18) Raise the vehicle.
(19) Install the crankshaft damper (Fig. 174)
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(20) Lower vehicle.(21) Install the fan support/hub assembly (Fig.
173) and tighten bolts to 24 N´m (18 ft. lbs.) torque.
(22) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(23) Install the cooling fan and shroud together
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(24) Install the windshield washer reservoir to the
fan shroud and connect the washer pump supply
hose and electrical connection.
(25) Install the coolant recovery bottle to the fan
shroud and connect the hose to the radiator filler
neck.
(26) Install the radiator upper hose and clamps.
(27) Add engine oil.
(28) Add coolant (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(29) Connect the battery cables.
(30) Start engine and inspect for leaks.
GEAR HOUSING COVER
REMOVAL
(1) Disconnect both 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.
Fig. 177 Camshaft/Crankshaft Gear Alignment
Fig. 178 Installing Cover with Seal Pilot
1 - SEAL PILOT
BR/BEENGINE 5.9L DIESEL 9 - 189
GEAR HOUSING (Continued)

(8) Remove viscous fan/drive assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(9) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(10) Remove the cooling fan support/hub from the
front of the engine (Fig. 179).
(11) Raise the vehicle on hoist.
(12) Remove the crankshaft damper (Fig. 180)
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(13) Lower the vehicle.
(14) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the gasket surfaces.
INSTALLATION
(1) Obtain a seal pilot/installation tool from a
crankshaft front seal service kit and install the pilot
into the seal.
(2) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover.
Be sure to surround all through holes.
(3) Using the seal pilot to align the cover (Fig.
182), install the cover to the housing and install the
bolts. Tighten the bolts to 24 N´m (18 ft. lbs.) torque.
(4) Remove the seal pilot.
(5) Raise the vehicle.
(6) Install the crankshaft damper (Fig. 180) (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(7) Lower vehicle.
Fig. 179 Fan Support/Hub AssemblyÐRemoval/
Installation
1 - FAN SUPPORT/HUB
2 - FAN PULLEY
Fig. 180 Crankshaft DamperÐRemoval/Installation
1 - DAMPER
2 - BOLT
Fig. 181 Gear Housing and Cover
1 - GEAR HOUSING
2 - GEAR HOUSING COVER
Fig. 182 Installing Cover with Seal Pilot
1 - SEAL PILOT
9 - 190 ENGINE 5.9L DIESELBR/BE
GEAR HOUSING COVER (Continued)

CAUTION: The turbocharger is only serviced as an
assembly. Do not attempt to repair the turbocharger
as turbocharger and/or engine damage can result.
CLEANING
Clean the turbocharger and exhaust manifold
mounting surfaces with a suitable scraper.
INSPECTION
Visually inspect the turbocharger and exhaust
manifold gasket surfaces. Replace stripped or eroded
mounting studs.
(1) Visually inspect the turbocharger for cracks.
The following cracks are NOT acceptable:
²Cracks in the turbine and compressor housing
that go completely through.
²Cracks in the mounting flange that are longer
than 15 mm (0.6 in.).
²Cracks in the mounting flange that intersect
bolt through-holes.
²Two (2) Cracks in the mounting flange that are
closer than 6.4 mm (0.25 in.) together.
(2) Visually inspect the impeller and compressor
wheel fins for nicks, cracks, or chips. Note: Some
impellers may have a factory placed paint mark
which, after normal operation, appears to be a crack.
Remove this mark with a suitable solvent to verify
that it is not a crack.
(3) Visually inspect the turbocharger compressor
housing for an impeller rubbing condition (Fig. 26).
Replace the turbocharger if the condition exists.
(4) Measure the turbocharger axial end play:
(a) Install a dial indicator as shown in (Fig. 27).
Zero the indicator at one end of travel.
Fig. 23 Exhaust Pipe Removal/Installation
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
Fig. 24 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. 25 Oil Supply Line and Charge Air Cooler Inlet
Duct
1 - EXHAUST PIPE
2 - TURBOCHARGER
3 - AIR INLET TUBE
4 - COOLER INLET DUCT
11 - 16 EXHAUST SYSTEMBR/BE
TURBOCHARGER (Continued)

(4) Discharge the A/C system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE) and remove the A/C condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - REMOVAL) (Fig.
31) (if A/C equipped).
(5) Remove the transmission auxiliary cooler (Fig.
31) (Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - REMOVAL).
(6) Remove the boost tubes from the charge air
cooler (Fig. 32).
(7) Remove the charge air cooler bolts. Pivot the
charge air cooler forward and up to remove.
CLEANING
CAUTION: Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air cooler
will result.
NOTE: If internal debris cannot be removed from
the cooler, the charge air cooler MUST be replaced.
(1) If the engine experiences a turbocharger failure
or any other situation where oil or debris get into the
charge air cooler, the charge air cooler must be
cleaned internally.
(2) Position the charge air cooler so the inlet and
outlet tubes are vertical.
(3) Flush the cooler internally with solvent in the
direction opposite of normal air flow.(4) Shake the cooler and lightly tap on the end
tanks with a rubber mallet to dislodge trapped
debris.
(5) Continue flushing until all debris or oil are
removed.
(6) Rinse the cooler with hot soapy water to
remove any remaining solvent.
(7) Rinse thoroughly with clean water and blow
dry with compressed air.
INSPECTION
Visually inspect the charge air cooler for cracks,
holes, or damage. Inspect the tubes, fins, and welds
for tears, breaks, or other damage. Replace the
charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge
Air Cooler Tester Kit #3824556. This kit is available
through CumminstService Products. Instructions
are provided with the kit.
Fig. 31 Condenser and Transmission Auxiliary
Cooler
1 - A/C CONDENSOR
2 - TRANSMISSION COOLER
3 - INTERCOOLER
Fig. 32 Air Intake System Tubes
1 - CLAMP
2 - INTERCOOLER INLET DUCT
3 - CLAMP
4 - VALVE COVER
5 - AIR INLET HOUSING
6 - CLAMP
7 - INTERCOOLER OUTLET DUCT
8 - CLAMP
9 - INTERCOOLER
BR/BEEXHAUST SYSTEM 11 - 19
CHARGE AIR COOLER AND PLUMBING (Continued)

FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
DESCRIPTION..........................1
SPECIFICATIONS - TORQUE...............1
FRONT AIR DAM
REMOVAL.............................2
INSTALLATION..........................2
FRONT FASCIA
REMOVAL.............................2
INSTALLATION..........................2
ADJUSTMENTS
ADJUSTMENT.........................2
FRONT LOWER FASCIA
REMOVAL.............................3
INSTALLATION..........................3
FRONT FASCIA - SPORT
REMOVAL.............................3
INSTALLATION..........................3
FRONT BUMPER
REMOVAL.............................4
INSTALLATION..........................4
FRONT BUMPER - SPORT
REMOVAL.............................5INSTALLATION..........................5
REAR BUMPER
REMOVAL.............................6
INSTALLATION..........................6
FRAME
DESCRIPTION
DESCRIPTION........................6
FRAME SERVICE......................7
SPECIFICATIONS
FRAME DIMENSION....................8
CAB CHASSIS ADAPTER BRACKET
REMOVAL.............................10
INSTALLATION.........................10
FRONT TOW HOOK
REMOVAL.............................10
INSTALLATION.........................10
TRAILER HITCH
REMOVAL.............................11
INSTALLATION.........................11
TRANSFER CASE SKID PLATE
REMOVAL.............................11
INSTALLATION.........................11
BUMPERS
DESCRIPTION
Bumpers are used at the front and rear of the
vehicle. Bumpers may be chrome or painted.Bumpers are designed to protect the exterior sheet-
metal in low impact situations. The bumpers are
attached to the frame and provide mounting points
for some optional accessories such as fog lights and
tow hooks.
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Cab chassis adapter nut 108 80 Ð
Front bumper bracket to frame nut 68 50 Ð
Front bumper outer brace bolt 68 50 Ð
Rear bumper to brace nut 40 30 Ð
Rear bumper brace to bracket nut 101 75 Ð
Rear bumper bracket to frame nut 101 75 Ð
Skid plate crossmember to frame bolt 54 40 Ð
Skid plate to crossmember bolt 40 30 Ð
Skid plate to transmission crossmember bolt 54 40 Ð
Spare tire winch bolt 27 20 Ð
Trailer hitch nut 108 80 Ð
BR/BEFRAME & BUMPERS 13 - 1

FRAME SERVICE
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT. BEFORE PROCEEDING WITH FRAME
REPAIR INVOLVING GRINDING OR WELDING, VER-
IFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING
OR IN CONTACT WITH REPAIR AREA, PERSONAL
INJURY CAN RESULT. DO NOT ALLOW OPEN
FLAME TO CONTACT PLASTIC BODY PANELS.
FIRE OR EXPLOSION CAN RESULT. WHEN
WELDED FRAME COMPONENTS ARE REPLACED,
100% PENETRATION WELD MUST BE ACHIEVED
DURING INSTALLATION. IF NOT, DANGEROUS
OPERATING CONDITIONS CAN RESULT. STAND
CLEAR OF CABLES OR CHAINS ON PULLING
EQUIPMENT DURING FRAME STRAIGHTENING
OPERATIONS, PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT SUPPORTED ON SAFETY STANDS,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Do not drill holes in top
or bottom frame rail flanges, frame rail failure can
result. Do Not use softer than Grade 5 bolts to
replace production fasteners, loosening or failure
can result. When using heat to straighten frame
components do not exceed 566ÉC (1050ÉF), metal
fatigue can result. Welding the joints around riveted
cross members and frame side rails can weaken
frame.
FRAME STRAIGHTENING
When necessary, a conventional frame that is bent
or twisted can be straightened by application of heat.
The temperature must not exceed 566ÉC (1050ÉF).
The metal will have a dull red glow at the desired
temperature. Excessive heat will decrease the
strength of the metal and result in a weakened
frame.
Welding the joints around riveted cross members
and frame side rails is not recommended.
A straightening repair process should be limited to
frame members that are not severely damaged. The
replacement bolts, nuts and rivets that are used to
join the frame members should conform to the same
specifications as the original bolts, nuts and rivets.
FRAME REPAIRS
DRILLING HOLES
Do not drill holes in frame side rail top and bottom
flanges, metal fatigue can result causing frame fail-
ure. Holes drilled in the side of the frame rail must
be at least 38 mm (1.5 in.) from the top and bottom
flanges.
Additional drill holes should be located away from
existing holes.
WELDING
Use MIG, TIG or arc welding equipment to repair
welded frame components.
Frame components that have been damaged should
be inspected for cracks before returning the vehicle
to use. If cracks are found in accessible frame com-
ponents perform the following procedures.
(1) Drill a hole at each end of the crack with a 3
mm (O.125 in.) diameter drill bit.
(2) Using a suitable die grinder with 3 inch cut off
wheel, V-groove the crack to allow 100% weld pene-
tration.
(3) Weld the crack.
(4) If necessary when a side rail is repaired, grind
the weld smooth and install a reinforcement channel
(Fig. 9) over the repaired area.
NOTE: If a reinforcement channel is required, the
top and bottom flanges should be 0.250 inches nar-
rower than the side rail flanges. Weld only in the
areas indicated (Fig. 9).
Fig. 9 Frame Reinforcement
1 - .250 IN FROM EDGE
2 - TOP FLANGE
3 - BOTTOM FLANGE
4 - FRAME RAIL
5 - FRAME REPAIR REINFORCEMENT
BR/BEFRAME & BUMPERS 13 - 7
FRAME (Continued)

FUEL DELIVERY - GASOLINE
DESCRIPTION - FUEL DELIVERY SYSTEM
The fuel delivery system consists of:
²the fuel pump module containing the electric
fuel pump, fuel filter/fuel pressure regulator, rollover
valve (certain modules), fuel gauge sending unit (fuel
level sensor) and a separate fuel filter located at bot-
tom of pump module
²fuel tubes/lines/hoses
²quick-connect fittings
²fuel injector rail
²fuel injectors
²fuel tank
²fuel tank filler/vent tube assembly
²fuel tank filler tube cap
²accelerator pedal
²throttle cable
OPERATION - FUEL DELIVERY SYSTEM
Fuel is returned through the fuel pump module
and back into the fuel tank through the fuel filter/
fuel pressure regulator. A separate fuel return line
from the engine to the tank is not used with any gas-
oline powered engine.
The fuel tank assembly consists of: the fuel tank,
fuel pump module assembly, fuel pump module lock-
nut/gasket and fuel tank check valve(s) (refer to 25,
Emission Control System for Fuel Tank Check Valve
information).
A fuel filler/vent tube assembly using a pressure/
vacuum, 1/4 turn fuel filler cap is used. The fuel
filler tube contains a flap door located below the fuel
fill cap.
Also to be considered part of the fuel system is the
evaporation control system. This is designed to
reduce the emission of fuel vapors into the atmo-
sphere. The description and function of the Evapora-
tive Control System is found in 25, Emission Control
Systems.
Both fuel filters (at bottom of fuel pump module
and within fuel pressure regulator) are designed for
extended service. They do not require normal sched-
uled maintenance. Filters should only be replaced if
a diagnostic procedure indicates to do so.
DIAGNOSIS AND TESTING - FUEL PRESSURE
LEAK DOWN TEST
Use this test in conjunction with the Fuel Pump
Pressure Test and Fuel Pump Capacity Test.
Check Valve Operation:The electric fuel pump
outlet contains a one-way check valve to prevent fuel
flow back into the tank and to maintain fuel supply
line pressure (engine warm) when pump is not oper-
ational. It is also used to keep the fuel supply linefull of gasoline when pump is not operational. After
the vehicle has cooled down, fuel pressure may drop
to 0 psi (cold fluid contracts), but liquid gasoline will
remain in fuel supply line between the check valve
and fuel injectors.Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition.When the elec-
tric fuel pump is activated, fuel pressure should
immediately(1±2 seconds) rise to specification.
Abnormally long periods of cranking to restart a
hotengine that has been shut down for a short
period of time may be caused by:
²Fuel pressure bleeding past a fuel injector(s).
²Fuel pressure bleeding past the check valve in
the fuel pump module.
(1) Disconnect the fuel inlet line at fuel rail. Refer
to Fuel Tubes/Lines/Hoses and Clamps for proce-
dures. On some engines, air cleaner housing removal
may be necessary before fuel line disconnection.
(2) Obtain correct Fuel Line Pressure Test Adapter
Tool Hose. Tool number 6539 is used for 5/16º fuel
lines and tool number 6631 is used for 3/8º fuel lines.
(3) Connect correct Fuel Line Pressure Test
Adapter Tool Hose between disconnected fuel line
and fuel rail (Fig. 1).
Fig. 1 CONNECTING ADAPTER TOOLÐTYPICAL
1 - VEHICLE FUEL LINE
2 - TEST PORT ªTº
3 - SPECIAL TOOL 6923, 6631, 6541 OR 6539
4 - FUEL PRESSURE TEST GAUGE
5 - FUEL LINE CONNECTION AT RAIL
6 - FUEL RAIL
14 - 2 FUEL DELIVERY - GASOLINEBR/BE

(4) Connect the 0-414 kPa (0-60 psi) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropriate Adaptor Tool.The DRBtIII Scan
Tool along with the PEP module, the 500 psi
pressure transducer, and the transducer-to-test
port adapter may also be used in place of the
fuel pressure gauge.
The fittings on both tools must be in good
condition and free from any small leaks before
performing the proceeding test.
(5) Start engine and bring to normal operating
temperature.
(6) Observe test gauge. Normal operating pressure
should be 339 kPa +/±34 kPa (49.2 psi +/±5 psi).
(7) Shut engine off.
(8) Pressure should not fall below30 psi for five
minutes.
(9) If pressure falls below 30 psi, it must be deter-
mined if a fuel injector, the check valve within the
fuel pump module, or a fuel tube/line is leaking.
(10) Again, start engine and bring to normal oper-
ating temperature.
(11) Shut engine off.
(12)Testing for fuel injector or fuel rail leak-
age:Clamp off the rubber hose portion of Adaptor
Tool between the fuel rail and the test port ªTº on
Adapter Tool. If pressure now holds at or above 30
psi, a fuel injector or the fuel rail is leaking.
(13)Testing for fuel pump check valve, filter/
regulator check valve or fuel tube/line leakage:
Clamp off the rubber hose portion of Adaptor Tool
between the vehicle fuel line and test port ªTº on
Adapter Tool. If pressure now holds at or above 30
psi, a leak may be found at a fuel tube/line. If no
leaks are found at fuel tubes or lines, one of the
check valves in either the electric fuel pump or filter/
regulator may be leaking.
Note: A quick loss of pressure usually indicates a
defective check valve in the filter/regulator. A slow
loss of pressure usually indicates a defective check
valve in the electric fuel pump.
The electric fuel pump is not serviced separately.
Replace the fuel pump module assembly. The filter/
regulator may be replaced separately on certain
applications. Refer to Fuel Filter/Fuel Pressure Reg-
ulator Removal/Installation for additional informa-
tion.
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fill cap.(2) Remove fuel pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(3) Start and run engine until it stalls.
(4) Attempt restarting engine until it will no
longer run.
(5) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unplug connector from any fuel injector.
(7) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.
(8) Connect other end of jumper wire to positive
side of battery.
(9) Connect one end of a second jumper wire to
remaining injector terminal.
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentarily touch other end of jumper wire
to negative terminal of battery for no more than a
few seconds.
(11) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(12) Disconnect quick-connect fitting at fuel rail.
Refer to Quick-Connect Fittings.
(13) Return fuel pump relay to PDC.
(14) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRBtscan tool must be
used to erase a DTC.
SPECIFICATIONS
SPECIFICATIONS - FUEL SYSTEM PRESSURE -
GAS ENGINES
All Gasoline Powered Engines:339 kPa   34
kPa (49.2 psi   5 psi)
BR/BEFUEL DELIVERY - GASOLINE 14 - 3
FUEL DELIVERY - GASOLINE (Continued)