2002 DODGE RAM remove seats

valve stem diameter to obtain valve stem-to-guide
clearance. Measure valve margin (rim thickness)
(Fig. 43). Measure the valve spring free length and
maximum inclination (Fig. 44). Test valve spring
force with tool C-647 (Fig. 45).
INSTALLATION
(1) Install new valve seals. The yellow springs are
for the intake valves and the green seals are for the
exhaust valves.
(2) Install the valves in their original postion. The
exhaust valves are identified by a dimple on the
valve head (Fig. 46).
(3) Install the valve springs and retainer.
(4) Install the valve spring compressor tool 8319±A
as shown in (Fig. 37) and (Fig. 38).
(5) Compress the valve springs and install the
valve retaining locks (Fig. 39).
(6) Remove the compressor and repeat the proce-
dure on the remaining cylinders.
(7) Install the injector clamp and hold down bolts
and tighten to 10 N´m (89 in. lbs.) torque.
Fig. 40 Visually Inspect Valves for Abnormal Wear
Fig. 41 Measure Valve Stem Diameter
VALVE STEM DIAMETER
6.990 mm (0.2752 in.) MIN
7.010 mm (0.2760 in.) MAX
Fig. 42 Measure Valve Guide Bore
Fig. 43 Measure Valve Margin (Rim Thickness)
VALVE MARGIN (RIM THICKNESS)
0.72 mm (0.031 in.) MIN.
Fig. 44 Measure Valve Spring Free Length and Max.
Inclination
VALVE SPRING FREE LENGTH
47.75 mm (1.88 in.)
MAX INCLINATION
1.5 mm (.059 in.)
9 - 140 ENGINE 5.9L DIESELBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

(8) Install the cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
STANDARD PROCEDUREÐVALVE LASH
ADJUSTMENT AND VERIFICATION
NOTE: To obtain accurate readings, valve lash mea-
surements AND adjustments should only be per-
formed when the engine coolant temperature is less
than 60É C (140É F).
The 24±valve overhead system is a ªlow-mainte-
nanceº design. Routine adjustments are no longer
necessary, however, measurement should still take
place when trouble-shooting performance problems,or upon completion of a repair that includes removal
and installation of the valve train components.
(1) Disconnect battery negative cables.
(2) Remove cylinder head cover (Fig. 47) (Refer to
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Remove the crankcase breather and vapor can-
ister (Fig. 48).
(4) Using the crankshaft barring tool #7471±B,
rotate the engine and align the pump gear mark with
the top dead center (TDC) mark on the gear housing
cover (Fig. 49).
(5) With the engine in this position (pump gear
mark at 12 o'clock), valve lash can be measured at
the following rocker arms:INTAKE 1±2±4 /
EXHAUST 1±3±5. Measure the valve lash by insert-
ing a feeler gauge between the rocker arm socket and
crosshead (Fig. 50). Refer to VALVE LASH LIMIT
CHART for the correct specifications. If the measure-
ment fallswithinthe limits, adjustment/resettingis
notnecessary. If measurement finds the lashout-
sideof the limits, adjustment/resettingisrequired.
Fig. 45 Testing Valve Spring with Tool C-647
1 - SPECIAL TOOL C-647
VALVE SPRING FORCE 35.33 mm @ 339.8 N (1.39 IN. @76.4
lbs.)
Fig. 46 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
Fig. 47 Cylinder Head Cover and Gasket
1 - BOLT (5)
2 - GASKET
3 - ªTOP FRONTº
4 - ISOLATOR (5)
BR/BEENGINE 5.9L DIESEL 9 - 141
INTAKE/EXHAUST VALVES & SEATS (Continued)

(9) Install the cylinder head cover (Fig. 47) (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - INSTALLATION).
(10) Install the fuel pump gear access cover.
(11) Connect the battery negative cables.
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the cylinder head cover (Fig. 52) (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - REMOVAL).
(3) Remove the rocker arms and crossheads (Fig.
53) from the cylinder(s) to be serviced. Mark each
component so they can be installed in their original
position.
(4) Remove the crankcase breather vapor canister
and breather housing (Fig. 55).
(5) Using the crankshaft barring tool #7471±B
(Fig. 51), rotate the engine to line up the mark on
the pump gear with the TDC mark on the cover.At
this engine position, cylinders #1 and #6 can be
serviced.
(6) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) With the fuel injection pump gear mark aligned
at TDC, add a paint mark anywhere on the gear
housing cover next to the crankshaft damper. Place
another mark on the vibration damper in alignment
with the mark you just made on the cover.
(8) Divide the crankshaft damper into three
equally sized segments as follows:
(a) Using a tape measure, measure the circum-
ference of the crankshaft damper and divide the
measurement by three (3).
(b) Measure that distance in a counter-clockwise
direction from the first balancer mark and place
another mark on the balancer.
(c) From the second damper mark, again mea-
sure in a counter-clockwise direction and place a
mark on the damper at the same distance you
measured when placing the second damper mark.
The damper should now be marked in three
equally spaced locations and the fuel pump gear
mark should still be aligned with the TDC mark on
the cover.
(9) Compress the valve springs at cyls. #1 and #6
as follows:
(a) Remove the injector clamp (Fig. 54) from the
cylinder(s) to be serviced.Do not remove the
bolt shown in (Fig. 54).
(b) Install the valve spring compressor mounting
base as shown in (Fig. 56). Reinstall the injector
clamp bolt finger tight.
(c) Install the top plate, washer, and nut. Using
a suitable wrench tighten the nut (clock-wise) (Fig.57) to compress the valve springs and remove the
collets.
(d) Rotate the compressor nut counter-clockwise
to relieve tension on springs. Remove spring com-
pressor.
(e) Remove and replace retainers, springs, and
seals as necessary.
(f)Do not rotate the engine until the
springs and retainers are re-installed.
(g) Install seals, springs and retainers. Install
spring compressor, compress valve springs and
install the collets.
(h) Release the spring tension and remove the
compressor. Verify that the collets are seated by
tapping on the valve stem with a plastic hammer.
(10) Using the crankshaft barring tool, rotate the
engine until the next crankshaft damper paint mark
aligns with the mark you placed on the cover.In this
position, cylinders #2 and #5 can be serviced.
(11) Repeat the valve spring compressing proce-
dure previously performed and service the retainers,
springs, and seals as necessary.
(12) Using the crankshaft barring tool, rotate the
engine until the next crankshaft damper paint mark
aligns with the mark you placed on the cover.In this
position, cylinders #3 and #4 can be serviced.
(13) Repeat the spring compressing procedure pre-
viously performed and service the retainers, springs,
and seals as necessary.
INSTALLATION
(1) Install all injector clamps into their original
location (Fig. 54). Tighten the hold down bolt to 10
N´m (89 in. lbs.) torque.
(2) Lubricate the valve tips and install the cross-
heads in their original locations.
Fig. 51 Rotating Engine with Barring Tool
1 - REAR FLANGE
2 - BARRING TOOL
BR/BEENGINE 5.9L DIESEL 9 - 143
INTAKE/EXHAUST VALVES & SEATS (Continued)

(3) Lubricate the crossheads and push rod sockets
and install the rocker arms and pedestals in their
Fig. 52 Cylinder Head Cover Removal/Installation
1 - BOLT (5)
2 - GASKET
3 - ªTOP FRONTº
4 - ISOLATOR (5)
Fig. 53 Rocker Arm and Crosshead Removal/
Installation
1 - ROCKER ARM
2 - PEDESTAL
Fig. 54 Injector Clamp Removal/Installation
1 - DO NOT REMOVE
2 - INJECTOR CLAMP
Fig. 55 Crankcase Breather Vapor Canister
1 - ENGINE FRONT COVER STUD
2 - STRAP
3 - VAPOR CANISTER
4 - NUT
5 - CAP
6 - CRANKCASE BREATHER
7 - CLAMP
8 - HOSE
9 - 144 ENGINE 5.9L DIESELBR/BE
INTAKE/EXHAUST VALVES & SEATS (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)

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)

Thrust Plate
Inspect the camshaft thrust plate for excessive
wear in the camshaft contact area. Measure thrust
plate thickness using the CAMSHAFT THRUST
PLATE THICKNESS CHART . Replace any thrust
plate that falls outside of these specifications:
CAMSHAFT THRUST PLATE THICKNESS CHART
9.34 mm (0.368 in.) MIN.
9.58 mm (0.377 in.) MAX.
INSTALLATION
INSTALLATIONÐCAMSHAFT BEARINGS
(1) Apply a coating of Loctitet640 Adhesive to the
backside of the new bushing. Avoid getting adhesive
in the oil hole.
(2) Use a universal cam bushing installation tool
and install the bushing so that it is even with the
front face of the cylinder block. The oil hole must be
aligned. A 3.2 mm (0.128 inch) diameter rod must be
able to pass through the hole (Fig. 97).
(3) Measure the installed bushing. The limit of the
inside diameter is 54.133 mm (2.1312 inch).
INSTALLATIONÐCAMSHAFT
(1) Lubricate the camshaft bushing and bores with
fresh engine oil or suitable equivalent.
(2) Liberally coat the camshaft lobes, journals, and
thrust washer with fresh engine oil or suitable equiv-
alent.
CAUTION: When installing the camshaft (Fig. 91),
DO NOT push it in farther than it will go with the
thrust washer in place. Pushing it too far can dis-
lodge the plug in the rear of the camshaft bore and
cause an oil leak.(3) Install the camshaft (Fig. 91) and thrust plate.
Align the timing marks as shown in (Fig. 89).
(4) Install the thrust plate bolts and tighten to 24
N´m (18 ft. lbs.) torque.
(5) Measure camshaft back lash and end clearance
(Fig. 98).
(6) Remove the wooden dowel rods and rubber
bands from the tappets.
(7) Lubricate the push rods with engine oil and
install in their original location (Fig. 87).Verify that
they are seated in the tappets.
(8) Lubricate the valve tips with engine oil and
install the crossheads in their original locations.
(9) Lubricate the crossheads and push rod sockets
with engine oil and install the rocker arms and ped-
estals in their original locations (Fig. 86). Tighten
bolts to 36 N´m (27 ft. lbs.) torque.
(10)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
Fig. 96 Inspect Camshaft Gear for Cracks and
Fretting
Fig. 97 Oil Hole Alignment
1 - CAMSHAFT BUSHING
Fig. 98 Camshaft Backlash and End Clearance
BACKLASH Ð 0.080Ð0.330 mm
(0.003Ð0.013 inch)
CLEARANCE Ð 0.152Ð0.254 mm
(0.006Ð0.010 inch)
BR/BEENGINE 5.9L DIESEL 9 - 157
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

INSTALLATION
(1) Install pitman shaft bearing into housing with
a bearing driver and handle.
(2) Coat the oil seal and washer withspecial
greasesupplied with the new seal.
(3) Install the oil seal with a driver and handle.
(4) Install backup washer.
(5) Install the retainer ring with snap ring pliers.
(6) Coat the dust seal withspecial greasesup-
plied with the new seal.
(7) Install dust seal with a driver and handle.
(8) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover.
(9) Install preload adjuster nut.Do not tighten
nut until after Over-Center Rotation Torque
adjustment has been made.
(10) Install gasket to side cover and bend tabs
around edges of side cover (Fig. 11).
(11) Install pitman shaft assembly and side cover
to housing.
(12) Install side cover bolts and tighten to 60 N´m
(44 ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment, (Refer to 19 - STEERING/GEAR - ADJUST-
MENTS).
PITMAN SHAFT SEAL
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Remove preload adjuster nut (Fig. 19).
(3) Rotate the stub shaft with a 12 point socket
from stop to stop and count the number of turns.
(4) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
(5) Remove side cover bolts and remove side cover,
gasket and pitman shaft as an assembly (Fig. 19).
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(6) Remove pitman shaft from the side cover.
(7) Remove dust seal from the housing with a seal
pick (Fig. 20).
CAUTION: Use care not to score the housing bore
when prying out seals and washer.
(8) Remove retaining ring with snap ring pliers.
(9) Remove washer from the housing.
(10) Remove oil seal from the housing with a seal
pick.
(11) Remove pitman shaft bearing from housing
with a bearing driver and handle (Fig. 21).
Fig. 19 Side Cover and Pitman Shaft
1 - SIDE COVER BOLTS
2 - PRELOAD ADJUSTER NUT
3 - SIDE COVER
4 - GASKET SEAL
5 - PITMAN SHAFT GEAR
6 - HOUSING ASSEMBLY
Fig. 20 Pitman Shaft Seals & Bearing
1 - BEARING
2 - WASHER
3 - DUST SEAL
4 - RETAINER
5 - OIL SEAL
BR/BEGEAR 19 - 25
PITMAN SHAFT (Continued)