2002 DODGE RAM length

ing stones. A true and complete surface must be
obtained.
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 in.) total indicator reading.
(3) Inspect the valve seat with Prussian blue, to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center ofvalve face, contact is satisfactory. If the blue is trans-
ferred to the top edge of valve face, lower valve seat
with a 15É stone. If the blue is transferred to bottom
edge of valve face raise valve seat with a 60É stone.
(4) When seat is properly positioned the width of
intake seats should be 1.016-1.524 mm (0.040-0.060
in.). The width of the exhaust seats should be 1.524-
2.032 mm (0.060-0.080 in.).
VALVE SPRINGS
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested. As an example the compression length of
the spring to be tested is 1-5/16 in.. Turn table of
Universal Valve Spring Tester Tool until surface is in
line with the 1-5/16 in. mark on the threaded stud.
Be sure the zero mark is to the front (Fig. 13). Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by 2. This will give the
spring load at test length. Fractional measurements
are indicated on the table for finer adjustments.
Refer to specifications to obtain specified height and
allowable tensions. Discard the springs that do not
meet specifications.
REMOVAL
(1) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(2) Compress valve springs using Valve Spring
Compressor Tool MD- 998772A and adapter 6716A.
(3) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
Fig. 11 Intake and Exhaust Valves
1 - MARGIN
2 - VALVE SPRING RETAINER LOCK GROOVE
3 - STEM
4-FACE
Fig. 12 Refacing Valve Seats
1-STONE
2 - PILOT
3 - VALVE SEAT
4 - SHROUD
Fig. 13 Testing Valve Spring for Compressed
Length
1 - TORQUE WRENCH
2 - VALVE SPRING TESTER
BR/BEENGINE 5.9L 9 - 25
INTAKE/EXHAUST VALVES & SEATS (Continued)

CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may
occur.
(4) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(5) Install the distributor (Refer to 8 - ELECTRI-
CAL/IGNITION CONTROL/DISTRIBUTOR -
INSTALLATION).
HYDRAULIC LIFTERS
DIAGNOSIS AND TESTINGÐHYDRAULIC
TAPPETS
Before disassembling any part of the engine to cor-
rect tappet noise, check the oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at
the pressure sending-unit. The pressure should be
between 207-552 kPa (30-80 psi) at 3,000 RPM.
Check the oil level after the engine reaches normal
operating temperature. Allow 5 minutes to stabilize
oil level, check dipstick. The oil level in the pan
should never be above the FULL mark or below the
ADD OIL mark on dipstick. Either of these two con-
ditions could be responsible for noisy tappets.
OIL LEVEL
HIGH
If oil level is above the FULL mark, it is possible
for the connecting rods to dip into the oil. With the
engine running, this condition could create foam in
the oil pan. Foam in oil pan would be fed to the
hydraulic tappets by the oil pump causing them to
lose length and allow valves to seat noisily.
LOW
Low oil level may allow oil pump to take in air.
When air is fed to the tappets, they lose length,
which allows valves to seat noisily. Any leaks on
intake side of oil pump through which air can be
drawn will create the same tappet action. Check the
lubrication system from the intake strainer to the
pump cover, including the relief valve retainer cap.
When tappet noise is due to aeration, it may be
intermittent or constant, and usually more than one
tappet will be noisy. When oil level and leaks have
been corrected, operate the engine at fast idle. Run
engine for a sufficient time to allow all of the air
inside the tappets to be bled out.
TAPPET NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate
engine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect
noisy tappet. The noisy tappet will cause the affected
spring and/or rocker arm to vibrate or feel rough in
operation.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
(3)
Valve tappet noise ranges from light noise to a
heavy click. A light noise is usually caused by exces-
sive leak-down around the unit plunger, or by the
plunger partially sticking in the tappet body cylinder.
The tappet should be replaced. A heavy click is caused
by a tappet check valve not seating, or by foreign par-
ticles wedged between the plunger and the tappet
body. This will cause the plunger to stick in the down
position. This heavy click will be accompanied by
excessive clearance between the valve stem and rocker
arm as valve closes. In either case, tappet assembly
should be removed for inspection and cleaning.
(4) The valve train generates a noise very much
like a light tappet noise during normal operation.
Care must be taken to ensure that tappets are mak-
Fig. 34 Distributor Driveshaft Bushing Installation
1 - SPECIAL TOOL C-3053
2 - BUSHING
Fig. 35 Burnishing Distributor Driveshaft Bushing
1 - SPECIAL TOOL C-3053
2 - BUSHING
9 - 36 ENGINE 5.9LBR/BE
DISTRIBUTOR BUSHING (Continued)

INSTALLATION
(1) With engine raised SLIGHTLY, position the
engine support bracket/cushion and heat shields to
the block. Install new bolts and tighten to 81 N´m (60
ft. lbs.) torque.
(2) Install the through-bolt into the engine support
bracket/cushion.
(3) Lower engine with support/lifting fixture while
guiding the engine bracket/cushion and through-bolt
into support cushion brackets (Fig. 46) .
(4) Install through-bolt nuts and tighten the nuts
to 102 N´m (75 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Remove lifting fixture.
REAR MOUNT
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Position a transmission jack in place.
(3) Remove support cushion stud nuts (Fig. 47).
(4) Raise rear of transmission and engine
SLIGHTLY.
(5) Remove the bolts holding the support cushion
to the transmission support bracket. Remove the sup-
port cushion.
(6) If necessary, remove the bolts holding the
transmission support bracket to the transmission.
INSTALLATION
(1) If removed, position the transmission support
bracket to the transmission. Install new attaching
bolts and tighten to 88 N´m (65 ft. lbs.) torque.
(2) Position support cushion to transmission sup-
port bracket. Install stud nuts and tighten to 41 N´m
(30 ft. lbs.) torque.
(3) Using the transmission jack, lower the trans-
mission and support cushion onto the crossmember
(Fig. 47) .
(4) Install the support cushion bolts and tighten to
41 N´m (30 ft. lbs.) torque.
(5) Remove the transmission jack.
(6) Lower the vehicle.
LUBRICATION
DESCRIPTION
A gear-type positive displacement pump (Fig. 48) is
mounted at the underside of the rear main bearing
cap. The pump uses a pick-up tube and screen
assembly to gather engine oil from the oil pan.
OPERATION
The pump draws oil through the screen and inlet
tube from the sump at the rear of the oil pan. The oil
is driven between the drive and idler gears and
pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
the inlet side of the full flow oil filter. After passing
through the filter element, the oil passes from the
center outlet of the filter through an oil gallery that
channels the oil up to the main gallery, which
extends the entire length on the right side of the
block. The oil then goes down to the No. 1 main bear-
ing, back up to the left side of the block, and into the
oil gallery on the left side of the engine.
Galleries extend downward from the main oil gal-
lery to the upper shell of each main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Each connecting rod bearing has half a hole in it, oil
passes through the hole when the rods rotate and the
hole lines up, oil is then thrown off as the rod
rotates. This oil throwoff lubricates the camshaft
lobes, distributor drive gear, cylinder walls, and pis-
ton pins.
The hydraulic valve tappets receive oil directly
from the main oil gallery. The camshaft bearings
receive oil from the main bearing galleries. The front
camshaft bearing journal passes oil through the cam-
shaft sprocket to the timing chain. Oil drains back to
the oil pan under the No. 1 main bearing cap.
The oil supply for the rocker arms and bridged
pivot assemblies is provided by the hydraulic valve
Fig. 46 Positioning Engine Front Mounts
1 - ENGINE SUPPORT BRACKET/CUSHION
2 - SUPPORT CUSHION BRACKET
9 - 42 ENGINE 5.9LBR/BE
FRONT MOUNT (Continued)

Inspect oil pressure relief valve plunger for scoring
and free operation in its bore. Small marks may be
removed with 400-grit wet or dry sandpaper.
The relief valve spring has a free length of approx-
imately 49.5 mm (1.95 inches). The spring should
test between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 inches). Replace spring that fails
to meet these specifications (Fig. 63).
If oil pressure was low and pump is within specifi-
cations, inspect for worn engine bearings or other
reasons for oil pressure loss.
ASSEMBLY
(1) Install pump rotors and shaft, using new parts
as required.
Fig. 59 Measuring Inner Rotor Thickness
Fig. 60 Measuring Outer Rotor Clearance in
Housing
1 - PUMP BODY
2 - OUTER ROTOR
3 - FEELER GAUGE
Fig. 61 Measuring Clearance Between Rotors
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
Fig. 62 Measuring Clearance Over Rotors
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 63 Proper Installation of Retainer Cap
1 - RETAINER CAP
2 - CHAMFER
3 - COTTER KEY
BR/BEENGINE 5.9L 9 - 49
OIL PUMP (Continued)

(2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N´m (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling
rotor cavity with engine oil.
INSTALLATION
(1) Install oil pump. During installation slowly
rotate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
(2) Hold the oil pump base flush against mating
surface on No.5 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
N´m (30 ft. lbs.) torque.
(3) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
INTAKE MANIFOLD
DESCRIPTION
The aluminum intake manifold (Fig. 64) is a single
plane design with equal length runners and uses a
separate plenum, therefore the manifold does have a
plenum gasket. It also uses separate flange gaskets
and front and rear cross-over gaskets. Extreme care
must be used when sealing the gaskets to ensure
that excess sealant does not enter the intake runners
causing a restriction. Whenever the intake manifold
is removed inspect the plenum pan for evidence of
excess oil buildup, this condition indicates that the
plenum pan gasket is leaking.
OPERATION
The intake manifold, meters and delivers air to the
combustion chambers allowing the fuel delivered by
the fuel injectors to ignite, thus producing power.
DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.(3) If a change in RPMs occur, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL).
(4) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner.
(7) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel lines (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect the accelerator linkage (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL) and if so equipped,
the speed control and transmission kickdown cables.
(9) Remove the return spring.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the heat indicator sending unit
wire.
Fig. 64 Intake Manifold and Throttle BodyÐV-8 Gas
Engines Typical
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
9 - 50 ENGINE 5.9LBR/BE
OIL PUMP (Continued)

DESCRIPTION SPECIFICATION
(2.0745 ± 2.0755 in.)
No. 3 52.30 ± 52.32 mm
(2.059 ± 2.060 in.)
No. 4 51.89 ± 51.92 mm
(2.043 ± 2.044 in.)
No. 5 51.49 ± 51.51 mm
(2.027 ± 2.028 in.)
No. 6 48.69 ± 48.72 mm
(1.917 ± 1.918 in.)
Bearing to Journal
Clearance
No. 1,3,4,5,6 0.0254 ± 0.0762 mm
(0.001 ± 0.003 in.)
No. 2 0.0381 ± 0.0889 mm
(0.0005 ± 0.0035 in.)
Service Limit 0.127 mm (0.005 in.)
End Play 0.127 ± 0.381 mm
(0.005 ± 0.015 in.)
CONNECTING RODS
Piston Pin bore Diameter 24.940 ± 24.978 mm
(0.9819 ± 0.9834 in.)
Side Clearance 0.25 ± 0.46 mm
(0.010 ± 0.018 in.)
Total Weight (Less
Bearing)744 gms. (26.24 oz.)
CRANKSHAFT
Rod Journal Diameter 53.950 ± 53.975 mm
(2.124 ± 2.125 in.)
Out of Round (Max.) 0.0254 mm (0.001 in.)
Taper (Max.) 0.0254 mm (0.001 in.)
Bearing Clearance 0.005 ± 0.074 mm
(0.0002 ± 0.0029 in.)
Service Limit 0.0762 mm (0.003 in.)
Main Bearing Journal
Diameter76.187 ± 76.213 mm
(2.8995 ± 3.0005 in.)
Out of Round (Max.) 0.0254 mm (0.001 in.)DESCRIPTION SPECIFICATION
Taper (Max.) 0.0254 mm (0.001 in.)
Bearing Clearance 0.0051 ± 0.058 mm
(0.0002 ± 0.0023 in.)
Service Limit 0.071 mm (0.0028 in.)
End Play 0.076 ± 0.305 mm
(0.003 ± 0.012 in.)
Service LimitÐEnd Play 0.381 mm (0.015 in.)
CYLINDER BLOCK
Cylinder Bore Diameter 101.60 ± 101.65 mm
(4.0003 ± 4.0008 in.)
Out of Round (Max.) 0.0762 mm (0.003 in.)
Taper (Max.) 0.127 mm (0.005 in.)
Lifter Bore Diameter 22.982 ± 23.010 mm
(0.9048 ± 0.9059 in.)
CYLINDER HEAD AND VALVES
Valve Seat Angle 44.5É
Runout (Max.) 0.0762 mm (0.003 in.)
Width (Finish) ± Intake 1.016 ± 1.524 mm
(0.040 ± 0.060 in.)
Valve Face Angle 45É
Valve Head Diameter
Intake 48.640 ± 48.900 mm
(1.915 ± 1.925 in.)
Exhaust 41.123 ± 41.377 mm
(1.619 ± 1.629 in.)
Overall Length
Intake 145.19 ± 145.82 mm
(5.716 ± 5.741 in.)
Exhaust 145.54 ± 146.18 mm
(5.730 ± 5.755 in.)
Lift (@ zero lash)
Intake 9.91 mm (0.390 in.)
Exhaust 10.34 mm (0.407 in.)
Stem Diameter 7.900 ± 7.920 mm
(0.311 ± 0.312 in.)
BR/BEENGINE 8.0L 9 - 69
ENGINE 8.0L (Continued)

DESCRIPTION SPECIFICATION
Guide Bore 9.500 ± 9.525 mm
(0.374 ± 0.375 on.)
Stem to Guide Clearance 0.025 ± 0.076 mm
(0.001 ± 0..003 in.)
Service Limit 0.4318 (0.017 in.)
Valve Spring Free Length 49.962 mm (1.967 in.)
Spring Tension
Valve Closed 378 N @ 41.66 mm
(85 lbs. @ 1.64 in.)
Valve Open 890 N @ 30.89 mm
(200 lbs. @ 1.212 in.)
Number of Coils 6.8
Installed Height 41.66 mm (1.64 in.)
Wire Diameter 4.50 mm (0.177 in.)
HYDRAULIC TAPPETS
Body Diameter 22.949 ± 22.962 mm
(0.9035 ± 0.9040 in.)
Clearance (to bore) 0.0203 ± 0.0610 mm
(0.0008 ± 0.0024 in.)
Dry Lash 1.524 ± 5.334 mm
(0.060 ± 0.210 in.)
Push Rod Length 195.52 ± 196.02 mm
(7.698 ± 7.717 in.)
OIL PRESSURE
Curb Idle (Min.*) 83 kPa (12 psi)
@ 3000 rpm 345 ± 414 kPa (50 ± 60
psi)
* If oil pressure is zero at curb idle, DO NOT RUN
ENGINE.
OIL PUMP
Clearance over Rotors
(Max.)0.1906 mm (0.0075 in.)
Cover Out of Flat (Max.) 0.051 mm (0.002 in.)
Inner Rotor Thickness
(Min.)14.925 ± 14.950 mm
(0.5876 ± 0.5886 in.)DESCRIPTION SPECIFICATION
Outer Rotor
Clearance (Max.) 0.1626 mm (0.006 in.)
Diameter (Min.) 82.461 mm (3.246 in.)
Thickness (Min.) 14.925 mm (0.5876 in.)
Tip Clearance between
Rotors
(Max.) 0.584 mm (0.0230 in.)
PISTONS
Clearance at Top of Skirt 0.013 ± 0.038 mm
(0.0005 ± 0.0015 in.)
Piston Length 82.5 mm (3.25 in.)
Piston Ring Groove
Depth
#1&2 91.30 ± 91.55 mm
(3.594 ± 3.604 in.)
#3 92.90 ± 93.15 mm
(3.657 ± 3.667 in.)
Weight 463 ± 473 grams (16.33
± 16.68 oz.)
Piston to Bore Clearance 0.013 ± 0.038 mm
(0.0005 ± 0.0015 in.)
Service Limit 0.0762 mm (0.003 in.)
PISTON PINS
Clearance in Piston 0.010 ± 0.020 mm
(0.0004 ± 0.0008 in.)
Diameter 24.996 ± 25.001 mm
(0.9841 ± 0.9843 in.)
End Play NONE
Length 67.8 ± 68.3 mm
(2.67 ± 2.69 in.)
PISTON RINGS
Ring Gap
Compression Rings 0.254 ± 0.508 mm
(0.010 ± 0.020 in.)
Oil Control (Steel Rails) 0.381 ± 1.397 mm
(0.015 ± 0.055 in.)
9 - 70 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)

REFACING VALVES AND VALVE SEATS
The intake and exhaust valves have a 45É face
angle and a 45É to 44 1/2É seat angle (Fig. 17).
VALVE FACE AND SEAT ANGLES CHART
ITEM DESCRIPTION SPECIFICATION
ASEAT WIDTH 1.016 - 1.524
mm
INTAKE (0.040 - 0.060
in.)
SEAT WIDTH 1.016 - 1.524
mm
EXHAUST (0.040 - 0.060
in.)
BFACE ANGLE
(INT. and EXT.) 45É
CSEAT ANGLE
(INT. and EXT.) 44óÉ
DCONTACT
SURFACE Ð
VALVES
Inspect the remaining margin after the valves are
refaced (Fig. 18). Valves with less than 1.190 mm
(0.047 inch) margin should be discarded.
VALVE SEATS
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-ing stones. A true and complete surface must be
obtained.
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.038
mm (0.0015 inch) total indicator reading.
(3) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to the top edge of valve face, lower valve seat
with a 15É stone. If the blue is transferred to bottom
edge of valve face raise valve seat with a 60É stone.
(4) When seat is properly positioned the width of
valve seats should be 1.016-1.524 mm (0.040-0.060
inch).
VALVE SPRING INSPECTION
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested. As an example the compression length of
the spring to be tested is 1-5/16 inch. Turn table of
Universal Valve Spring Tester Tool until surface is in
line with the 1-5/16 inch mark on the threaded stud.
Be sure the zero mark is to the front (Fig. 19). Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by 2. This will give the
spring load at test length. Fractional measurements
are indicated on the table for finer adjustments.
Refer to specifications to obtain specified height and
Fig. 17 Valve Face and Seat Angles
1 - CONTACT POINT
Fig. 18 Intake and Exhaust Valves
1 - MARGIN
2 - VALVE SPRING RETAINER LOCK GROOVE
3 - STEM
4-FACE
BR/BEENGINE 8.0L 9 - 81
INTAKE/EXHAUST VALVES & SEATS (Continued)