2002 DODGE RAM battery

(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)

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)

Overall variation end to end or side to side is 0.075
mm (0.003 inch).
If the surface exceeds the limit, .
Inspect the cylinder bores for damage or excessive
wear.
Measure the cylinder bores (Fig. 80). If the cylin-
der bores exceeds the limit, (Refer to 9 - ENGINE/
ENGINE BLOCK - STANDARD PROCEDURE).
Inspect the camshaft bores for scoring or excessive
wear.
Measure the camshaft bores (Refer to 9 - ENGINE
- SPECIFICATIONS). Limit for the No.1 bore applies
to the ID of the bushing.
If a bore exceeds the limit, (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - STANDARD PROCEDURE).
Inspect the tappet bores for scoring or excessive
wear 16.000 mm min - 16.055 mm max ( .63 in. min
- .6321 in. max ) (Fig. 81). If out of limits, replace the
cylinder block.
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS
NOTE: Measure the diameter of each bore. (The
limit for the bushing in the No.1 bore is the same as
for the other bores without bushings). The limit of
the inside diameter is 54.089 min. - 54.164 max. mm
(2.1295 min. - 2.1325 max. inch). If the camshaft
bore for the first cam bushing is worn beyond the
limit, install a new service bushing. Inspect the rest
of the camshaft bores for damage or excessive
wear.If the bores without a bushing are worn
beyond the limit, the engine must be removed for
machining and installation of service bushings. If
badly worn, replace the cylinder block.
(1) Remove the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(2) Remove the bushing from the No.1 bore, using
a universal cam bushing tool.
(3) Mark the cylinder block so you can align the oil
hole in the cylinder block with the oil hole in the
bushing.
REMOVALÐCAMSHAFT
(1) Disconnect both battery negative cables.
(2) Recover A/C refrigerant (if A/C equipped) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE).
(3) Raise vehicle on hoist.
(4) Drain engine coolant into container suitable for
re-use (Refer to 7 - COOLING - STANDARD PROCE-
DURE).
Fig. 79 Combustion Deck Face Measurement
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 80 Cylinder Bore Diameter
Fig. 81 Tappet Bore Diameter
9 - 152 ENGINE 5.9L DIESELBR/BE
ENGINE BLOCK (Continued)

(11) Install the cylinder head cover and reusable
gasket (Fig. 85) (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION).
(12) Install gear housing cover (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- INSTALLATION).
(13) Install the crankshaft damper (Fig. 83) (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(14) Install the fan support/hub assembly (Fig. 82)
and tighten bolts to 24 N´m (18 ft. lbs.) torque.
(15) Install the crankcase breather housing (Refer
to 9 - ENGINE - INSTALLATION).
(16) Install the charge air cooler (with a/c con-
denser and auxiliary transmission oil cooler, if
equipped) and tighten the mounting bolts to 2 N´m
(17 in. lbs.) torque.
(17) Connect charge air cooler inlet and outlet
pipes. Tighten clamps to 10 N´m (100 in. lbs.) torque.
(18) Install the radiator upper support panel.
(19) Close radiator petcock and lower the radiator
into the engine compartment. Tighten the mounting
bolts to 11 N´m (95 in. lbs.) torque.
(20) Raise vehicle on hoist.
(21) Connect radiator lower hose and install
clamp.
(22) Connect transmission auxiliary oil cooler lines
(if equipped).
(23) Lower vehicle.
(24) Install the fan shroud and tighten the mount-
ing screws to 6 N´m (50 in. lbs.) torque.
(25) Install the viscous fan/drive assembly (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(26) Install the coolant recovery and windshield
washer fluid reservoirs to the fan shroud.
(27) Connect the coolant recovery hose to the radi-
ator filler neck.
(28) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(29) Install the front bumper assembly (Refer to 13
- FRAMES & BUMPERS/BUMPERS/FRONT
BUMPER - INSTALLATION).
(30) Add engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(31) Charge A/C system with refrigerant (if A/C
equipped) (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(32) Connect the battery negative cables.
(33) Start engine and check for engine oil and cool-
ant leaks.CONNECTING ROD BEARINGS
STANDARD PROCEDUREÐCONNECTING ROD
BEARING AND CRANKSHAFT JOURNAL
CLEARANCE
Measure the connecting rod bore with the bearings
installed and the bolts tightened to 100 N´m (73 ft.
lbs.) torque.
Record the smaller diameter.
Measure the diameter of the rod journal at the
location shown (Fig. 99). Calculate the average diam-
eter for each side of the journal.
The clearance is the difference between the con-
necting rod bore (smallest diameter) and the average
diameter for each side of the crankshaft journal.
Fig. 99 Connecting Rod Journal Diameter Limits
CONNECTING ROD JOURNAL DIAMETER
LIMITS CHART
DESCRIPTION MEASUREMENT
CRANKSHAFT ROD JOURNAL
DIAMETERMINIMUM 68.962 mm
(2.715 in.)
MAXIMUM 69.013 mm
(2.717 in.)
OUT-OF-ROUND MAXIMUM 0.050 mm (0.002 in.)
TAPER MAXIMUM 0.013 mm
(0.0005 in.)
BEARING CLEARANCE MAXIMUM 0.089 mm
(0.0035 in.)
9 - 158 ENGINE 5.9L DIESELBR/BE
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

CRANKSHAFT MAIN JOURNAL DIAMETER
CHART
ITEM SPECIFICATION
MINIMUM DIAMETER 82.962 mm (3.2662 in.)
MAXIMUM DIAMETER 83.013 mm (3.2682 in.)
Calculate the main bearing journal to bearing
clearance. the clearance specifications are 0.119 mm
(0.00475 inch). If the crankshaft journal is within
limits, replace the main bearings. If not within spec-
ifications, grind the crankshaft to next size and use
oversize bearings.
CRANKSHAFT OIL SEAL -
FRONT
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 from radia-
tor 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.
(8) Remove the fan shroud-to-radiator mounting
bolts.
(9) Remove viscous fan/drive assembly.The fan
drive nut has left handed threads.(Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(10) Remove cooling fan shroud and fan assembly
from the vehicle.
(11) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove the cooling fan support/hub from the
front of the engine (Fig. 103).
(13) Raise the vehicle on hoist.
(14) Remove the crankshaft damper (Fig. 104).
(15) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the gasket surfaces.
(16) Support the cover on a flat work surface with
wooden blocks (Fig. 105), and using a suitable punch
and hammer, drive the old seal out of the cover from
the outside of the cover (Fig. 105).
INSTALLATION
(1) Clean cover and housing gasket mating sur-
faces. Use a suitable scraper and be careful not todamage the gear housing surface, since it is alumi-
num. Remove any old sealer from the oil seal bore.
Thoroughly clean the front seal area of the crank-
shaft. The seal lip and the sealing surface on the
crankshaft must be free from all oil residue to pre-
vent seal leaks.
(2) Inspect the gear housing and cover for cracks
and replace if necessary. Carefully straighten any
bends or imperfections in the gear cover with a ball-
peen hammer on a flat surface. Inspect the crank-
shaft front journal for any grooves or nicks that
would affect the integrity of the new seal.
(3) Apply a bead of MopartStud & Bearing Mount
to the outside diameter of the seal. Do not lubricate
the inside diameter of the new seal.
Fig. 103 Fan Support Hub AssemblyÐRemoval/
Installation
1 - FAN SUPPORT/HUB
2 - FAN PULLEY
Fig. 104 Crankshaft DamperÐRemoval/Installation
1 - DAMPER
2 - BOLT
9 - 160 ENGINE 5.9L DIESELBR/BE
CRANKSHAFT MAIN BEARINGS (Continued)

(4) With the cover supported by wood blocks,
install the seal into the rear of the cover using crank-
shaft seal installer Special Tool 8281 and driver han-
dle C-4171 (Fig. 106). Strike the driver handle until
the installation tool bottoms out on the inside of the
cover.
(5) Install the plastic seal pilot (provided with seal
kit) into the crankshaft seal.(6) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover
sealing surface.
(7) Install the cover to the gear housing, aligning
the seal pilot with the nose of the crankshaft (Fig.
107).
(8) Install the cover bolts and tighten to 24 N´m
(18 ft. lbs.) torque. Remove pilot tool.
(9) Install the crankshaft damper (Fig. 104) and
torque the bolts to 125 N´m (92 ft. lbs.). Use the
engine barring tool to keep the engine from rotating
during tightening operation.
(10) Install the fan support/hub assembly (Fig.
103) and torque bolts to 24 N´m (18 ft. lbs.).
(11) Install cooling fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(12) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect battery negative cables.
(15) Start engine and check for oil leaks.
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the transmission and transfer case (if
equipped).
(3) Remove the clutch cover and disc (if manual
transmission equipped) (Refer to 6 - CLUTCH/
CLUTCH DISC - REMOVAL).
(4) Remove the flywheel or converter drive plate.
(5) Drill holes 180É apart into the seal. Be careful
not to contact the drill against the crankshaft.
Fig. 105 Removing Seal from Cover
1 - PUNCH
Fig. 106 Installing Seal Into Cover With Tool 8281
1 - SEAL INSTALLER 8281
2 - DRIVER HANDLE C4171
3 - SEAL
Fig. 107 Installing Front Cover with Seal Pilot
1 - SEAL PILOT
BR/BEENGINE 5.9L DIESEL 9 - 161
CRANKSHAFT OIL SEAL - FRONT (Continued)