2002 DODGE RAM seats

C206 (HEATED SEATS) - (I/P SIDE)
CAV CIRCUIT
1 P137 20DG
2 P7 20LB/BK
3 P140 20VT/BK
4 P138 20VT/LG
5 P139 20WT
6 F235 16RD
7 P8 20LB/WT
C237 - (I/P SIDE)
CAV CIRCUIT
1 C5 16LG
2 Z2 22BK/LG
3-
4-
5-
6 C82 22YL/OR
7-
8 C7 12BK/TN
9-
10 -
11 C4 16TN
12 F15 22DB
13 -
14 C6 14LB
C237 - (RESISTOR BLOCK SIDE)
CAV CIRCUIT
1 C5 16LG
2 Z2 20BK/LG
3-
4-
5-
6 C82 20YL/OR
7-
8 C7 12BK/TN
9-
10 -
11 C4 16TN
12 F15 20DB
13 -
14 C6 14LB
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21

JOINT CONNECTOR NO.5-NATURAL 22 WAY
CAV CIRCUIT FUNCTION
1 M1 20PK FUSED B(+)
2 M1 22PK FUSED B(+)
3 M1 22PK FUSED B(+)
4 Z3 20BK/OR GROUND
5 Z3 18BK/OR GROUND
6 Z3 22BK/OR GROUND
7 Z3 18BK/OR GROUND
8 E2 22OR PANEL LAMPS FEED
9 E2 22OR PANEL LAMPS FEED
10 E2 22OR PANEL LAMPS FEED
11 - -
12 M1 22PK FUSED B(+)
13 M1 22PK FUSED B(+)
14 Z3 20BK/OR (HEATED SEATS) GROUND
15 Z3 20BK/OR (HEATED SEATS) GROUND
16 Z3 22BK/OR (EXCEPT BASE/MIDLINE) GROUND
17 Z3 22BK/OR (EXCEPT BASE/MIDLINE) GROUND
18 - -
19 - -
20 E2 22OR PANEL LAMPS FEED
21 E2 22OR PANEL LAMPS FEED
22 E2 22OR PANEL LAMPS FEED
JOINT CONNECTOR NO.6-NATURAL 22 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3- -
4 L50 16WT/TN BRAKE LAMP SWITCH OUTPUT
5 L50 16WT/TN BRAKE LAMP SWITCH OUTPUT
6 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
7 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
8 Z9 16BK/VT(EXCEPT BASE/LOWLINE) GROUND
9 Z9 20BK/VT(SLT+HIGHLINE) GROUND
10 X3 20BK/RD(EXCEPT BASE/MIDLINE) HORN RELAY CONTROL
10 M22 22WT(BASE/MIDLINE) DOME LAMPS SWITCH SENSE
11 X3 20BK/RD(EXCEPT BASE/MIDLINE) HORN RELAY CONTROL
11 M22 22WT(BASE/MIDLINE) DOME LAMPS SWITCH SENSE
12 M22 22WT(BASE/MIDLINE) DOME LAMPS SWITCH SENSE
12 X3 20BK/RD(EXCEPT BASE/MIDLINE) HORN RELAY CONTROL
13 V10 16BR WASHER SWITCH SENSE
14 V10 16BR WASHER SWITCH SENSE
15 V10 16BR WASHER SWITCH SENSE
16 - -
17 - -
18 Z9 16BK/VT GROUND
19 Z9 16BK/VT(XECEPT BASE/LOWLINE) GROUND
20 G26 22LB KEY-IN IGNITION SWITCH SENSE
21 G26 22LB KEY-IN IGNITION SWITCH SENSE
22 G26 22LB KEY-IN IGNITION SWITCH SENSE
8W - 80 - 52 8W-80 CONNECTOR PIN-OUTSBR/BE

JOINT CONNECTOR NO.7-NATURAL 22 WAY
CAV CIRCUIT FUNCTION
1 D1 18VT/BR CCD BUS (+)
2 D1 18VT/BR CCD BUS (+)
3 D1 20VT/BR CCD BUS (+)
4 D2 18WT/BK CCD BUS (-)
5 D2 18WT/BK CCD BUS (-)
6 D2 20WT/BK CCD BUS (-)
7 D2 20WT/BK CCD BUS (-)
8 D1 20VT/BR CCD BUS (+)
9 D1 20VT/BR CCD BUS (+)
10 D1 20VT/BR CCD BUS (+)
11 D1 20VT/BR CCD BUS (+)
12 D1 20VT/BR CCD BUS (+)
13 D1 20VT/BR CCD BUS (+)
14 D2 20WT/BK CCD BUS (-)
15 D2 20WT/BK CCD BUS (-)
16 D2 20WT/BK CCD BUS (-)
17 D2 20WT/BK (REMOTE RADIO) CCD BUS (-)
18 - -
19 - -
20 D1 20VT/BR (REMOTE RADIO) CCD BUS (+)
21 - -
22 - -
JOINT CONNECTOR NO.8-NATURAL 22 WAY
CAV CIRCUIT FUNCTION
1 M2 22YL COURTESY LAMPS DRIVER
2 M2 22YL COURTESY LAMPS DIRVER
3 M2 22YL COURTESY LAMPS DRIVER
4 F15 22DB FUSED IGNITION SWITCH OUTPUT(RUN)
5 F15 22DB FUSED IGNITION SWITCH OUTPUT(RUN)
6 F15 22DB FUSED IGNITION SWITCH OUTPUT(RUN)
7 F15 20DB(HEATED SEATS) FUSED IGNITION SWITCH OUTPUT(RUN)
8 G75 22TN(BASE/MIDLINE) DRIVER DOOR AJAR SWITCH SENSE
8 E2 22OR(HEATED SEATS) PANEL LAMPS FEED
9 E2 22OR(HEATED SEATS) PANEL LAMPS FEED
9 G75 22TN(BASE/MIDLINE) DRIVER DOOR AJAR SWITCH SENSE
10 Z6 18 BK/PK GROUND
11 Z6 18BK/PK GROUND
12 Z6 18BK/PK GROUND
13 E17 18YL/BK DAY BRIGHTNESS SENSE
14 E17 18YL/BK DAY BRIGHTNESS SENSE
15 E17 18YL/BK DAY BRIGHTNESS SENSE
16 F15 18DB FUSED IGNITION SWITCH OUTPUT(RUN)
17 F15 22DB FUSED IGNITION SWITCH OUTPUT(RUN)
18 E2 22OR(HEATED SEATS) PANEL LAMPS FEED
18 G75 22TN(BASE/MIDLINE) DRIVER DOOR AJAR SWITCH SENSE
19 E2 22OR(HEATED SEATS) PANEL LAMPS FEED
19 G75 22TN(BASE/MIDLINE) DRIVER DOOR AJAR SWITCH SENSE
20 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT(RUN-START)
21 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT(RUN-START)
22 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT(RUN-START)
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53

RIGHT TWEETER (PREMIUM)-2WAY
CAV CIRCUIT FUNCTION
1 X82 20LB/RD AMPLIFIED HIGH RIGHT FRONT SPEAKER (+)
2 X80 20LB/BK AMPLIFIED HIGH RIGHT FRONT SPEAKER (-)
RIGHT VISOR/VANITY LAMP - BLACK 2 WAY
CAV CIRCUIT FUNCTION
A M1 20PK FUSED B(+)
B Z4 20BK GROUND
SEAT BELT SWITCH (CLUB CAB)-2WAY
CAV CIRCUIT FUNCTION
1 Z2 20BK/LG GROUND
2 G10 22LG/RD (HEATED SEATS) SEAT BELT SWITCH SENSE
2 G10 20LG/RD (MANUAL NON-HEATED
SEATS)SEAT BELT SWITCH SENSE
SEAT BELT SWITCH (STANDARD CAB) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z2 20BK/LG GROUND
2 G10 20LG/RD SEAT BELT SWITCH SENSE
SEAT HEAT INTERFACE MODULE - 14 WAY
CAV CIRCUIT FUNCTION
1 P7 20LB/BK DRIVER HEATED SEAT SWITCH
2 P144 20BK/WT SEAT TEMPERATURE 5V SUPPLY
3 P130 16TN RIGHT SEAT HEATER B(+) DRIVER
4 F235 16RD B(+) TO HEATED SEAT MODULE
5 P131 16RD/DG LEFT SEAT HEATER B(+) DRIVER
6 F235 16RD B(+) TO HEATED SEAT MODULE
7 P142 22DB RIGHT SEAT TEMPERATURE SENSOR INPUT
8 P141 20TN/LB LEFT SEAT TEMPERATURE SENSOR INPUT
9 P8 20LB/WT PASSENGER HEATED SEAT SWITCH
10 P138 20VT/LG RIGHT SEAT LOW HEAT LED DRIVER
11 P140 20VT/BK RIGHT SEAT HIGH HEAT LED DRIVER
12 P137 20DG LEFT SEAT LOW HEAT LED DRIVER
13 Z2 18BK/LG GROUND
14 P139 20WT LEFT SEAT HIGH HEAT LED DRIVER
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79

ENGINE
TABLE OF CONTENTS
page page
ENGINE 5.9L.............................. 1
ENGINE 8.0L............................. 56ENGINE 5.9L DIESEL..................... 113
ENGINE 5.9L
TABLE OF CONTENTS
page page
ENGINE 5.9L
DESCRIPTION..........................3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............3
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTINGÐ ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - LUBRICATION..............8
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE..............9
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.......9
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........10
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.........11
STANDARD PROCEDUREÐHYDROSTATIC
LOCK...............................11
STANDARD PROCEDURE - CYLINDER
BORE HONING.......................11
REMOVAL.............................12
INSTALLATION.........................12
SPECIFICATIONS
5.9L ENGINE.........................13
TORQUE............................17
SPECIAL TOOLS
5.9L ENGINE.........................18
CYLINDER HEAD
DESCRIPTION
DESCRIPTIONÐCYLINDER HEAD........20
DESCRIPTION - CYLINDER HEAD COVER
GASKET............................20OPERATION
OPERATIONÐCYLINDER HEAD..........21
OPERATION - CYLINDER HEAD COVER
GASKET............................21
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE.....................21
REMOVAL.............................21
CLEANING............................22
INSPECTION..........................22
INSTALLATION.........................22
CYLINDER HEAD COVER(S)
REMOVAL.............................23
CLEANING............................23
INSPECTION..........................23
INSTALLATION.........................23
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................23
STANDARD PROCEDUREÐVALVES, GUIDES
AND SPRINGS.......................23
REMOVAL.............................25
CLEANING............................26
INSPECTION..........................26
INSTALLATION.........................26
ROCKER ARM / ADJUSTER ASSEMBLY
REMOVAL.............................26
INSTALLATION.........................26
ENGINE BLOCK
CLEANING............................27
INSPECTION..........................27
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS.......27
REMOVALÐCAMSHAFT................28
INSTALLATION
INSTALLATIONÐCAMSHAFT BEARINGS . . . 28
INSTALLATIONÐCAMSHAFT............29
BR/BEENGINE 9 - 1

CONDITION POSSIBLE CAUSES CORRECTION
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL)
DIAGNOSIS AND TESTINGÐ ENGINE
DIAGNOSIS - MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil. (Refer to 9 -
ENGINE/LUBRICATION/OIL -
STANDARD PROCEDURE)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) for
engine oil pressure test/
specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic
tappets/lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats
or valve faces9. Grind valves and seats
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level.
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) engine
oil pressure test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
(Refer to 9 - ENGINE/
LUBRICATION/OIL - STANDARD
PROCEDURE) for correct
procedure/engine oil specifications
9 - 6 ENGINE 5.9LBR/BE
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

VALVE GUIDES
Service valves with oversize stems are available.
Refer to REAMER SIZES CHART
REAMER SIZES CHART
REAMER O/S VALVE GUIDE SIZE
0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316 - 0.317 in.)
0.381 mm 8.331 - 8.357 mm
(0.015 in.) (0.328 - 0.329 in.)
(1) Slowly turn reamer by hand and clean guide
thoroughly before installing new valve.Ream the
valve guides from standard to 0.381 mm (0.015
in.). Use a two step procedure so the valve
guides are reamed true in relation to the valve
seat:
²Step 1ÐReam to 0.0763 mm (0.003 inch).
²Step 2ÐReam to 0.381 mm (0.015 inch).
REFACING VALVES AND VALVE SEATS
The intake and exhaust valves have a 43-1/4É to
43-3/4É face angle and a 44-1/4É to 44-3/4É seat angle
(Fig. 10).
VALVE FACE AND VALVE SEAT ANGLE CHART
ITEM DESCRIPTION SPECIFICATION
ASEAT WIDTH
INTAKE 1.016 - 1.524 mm
(0.040 - 0.060 in.)
EXHAUST 1.524 - 2.032 mm
(0.060 - 0.080 in.)
BFACE ANGLE
(INT. AND EXT.) 43òÉ - 43ôÉ
CSEAT ANGLE
(INT. AND EXT.) 44òÉ - 44ôÉ
DCONTACT
SURFACE Ð
VALVES
Inspect the remaining margin after the valves are
refaced (Fig. 11). Valves with less than 1.190 mm
(0.047 in.) margin should be discarded.
VALVE SEATS
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 12).
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
Fig. 9 Measuring Valve Guide Wear
1 - VALVE
2 - SPECIAL TOOL C-3339
Fig. 10 Valve Face and Seat Angles
1 - CONTACT POINT
9 - 24 ENGINE 5.9LBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)