2002 DODGE RAM seats

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)

valve guides. Identify valves to ensure installation in
original location.
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.
INSPECTION
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. 14). 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. 15).
(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.
INSTALLATION
(1) Clean valves thoroughly. Discard burned,
warped and cracked valves.
(2) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(3) Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve.
(4) Coat valve stems with lubrication oil and insert
them in cylinder head.
(5) If valves or seats are reground, check valve
stem height. If valve is too long, replace cylinder
head.
(6) Install new seals on all valve guides. Install
valve springs and valve retainers.(7) Compress valve springs with Valve Spring
Compressor Tool MD-998772A and adapter 6716A,
install locks and release tool. If valves and/or seats
are ground, measure the installed height of springs.
Make sure the measurement is taken from bottom of
spring seat in cylinder head to the bottom surface of
spring retainer. If spacers are installed, measure
from the top of spacer. If height is greater than 42.86
mm (1-11/16 inches), install a 1.587 mm (1/16 inch)
spacer in head counterbore. This should bring spring
height back to normal 41.27 to 42.86 mm (1-5/8 to
1-11/16 inch).
(8) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
ROCKER ARM / ADJUSTER
ASSEMBLY
REMOVAL
(1) Remove cylinder head cover and gasket (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - REMOVAL).
(2) Remove the rocker arm bolts and pivots (Fig.
16). Place them on a bench in the same order as
removed.
(3) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
(1) Rotate the crankshaft until the ªV8º mark lines
up with the TDC mark on the timing chain case
cover. This mark is located 147É ATDC from the No.1
firing position.
Fig. 14 Positioning Valve with Tool C-3973
1 - VALVE
2 - SPACER TOOL
Fig. 15 Measuring Valve Guide Wear
1 - VALVE
2 - SPECIAL TOOL C-3339
9 - 26 ENGINE 5.9LBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

ENGINE 8.0L
TABLE OF CONTENTS
page page
ENGINE 8.0L
DESCRIPTION.........................58
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........58
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - PERFORMANCE...........59
DIAGNOSIS AND TESTINGÐ ENGINE
DIAGNOSIS - MECHANICAL.............61
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - LUBRICATION.............63
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE.............64
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE......64
STANDARD PROCEDURE
STANDARD PROCEDUREÐCYLINDER
BORE HONING.......................65
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........66
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.........66
STANDARD PROCEDUREÐHYDROSTATIC
LOCK...............................66
REMOVAL.............................67
INSTALLATION.........................68
SPECIFICATIONS
8.OL ENGINE........................68
TORQUE............................71
SPECIAL TOOLS
8.0L ENGINE.........................72
AIR CLEANER ELEMENT
REMOVAL - 8.0L........................75
INSTALLATION - 8.0L....................75
CYLINDER HEAD
DESCRIPTION.........................76
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE.....................76
REMOVAL.............................76
CLEANING............................77
INSPECTION..........................77
INSTALLATION.........................77
CYLINDER HEAD COVER(S)
DESCRIPTION.........................78
REMOVAL.............................78
CLEANING............................79
INSPECTION..........................79
INSTALLATION.........................79INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................80
STANDARD PROCEDURE
VALVE SERVICE......................80
REMOVAL
REMOVALÐVALVE STEM SEALS.........82
REMOVALÐVALVES AND VALVE SPRINGS . 82
CLEANING............................83
INSPECTION..........................83
INSTALLATION
INSTALLATIONÐVALVE STEM SEAL......83
INSTALLATIONÐVALVES AND VALVE
SPRINGS............................84
ROCKER ARM / ADJUSTER ASSY
REMOVAL.............................84
INSTALLATION.........................84
ENGINE BLOCK
CLEANING............................85
INSPECTION..........................85
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS.......85
REMOVALÐCAMSHAFT................85
INSTALLATION
INSTALLATIONÐCAMSHAFT BEARINGS . . . 86
INSTALLATIONÐCAMSHAFT............86
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING................87
CRANKSHAFT
REMOVAL.............................87
INSTALLATION.........................88
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDUREÐFITTING
CRANKSHAFT MAIN BEARINGS..........88
REMOVAL.............................88
INSTALLATION.........................88
CRANKSHAFT OIL SEAL - FRONT
REMOVAL
REMOVALÐFRONT OIL SEAL - FRONT
COVER INSTALLED....................89
REMOVALÐFRONT OIL SEAL - FRONT
COVER REMOVED....................89
INSTALLATION
INSTALLATIONÐFRONT OIL SEAL ± FRONT
COVER INSTALLED....................89
INSTALLATIONÐFRONT OIL SEAL - FRONT
COVER REMOVED....................90
9 - 56 ENGINE 8.0LBR/BE

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
BR/BEENGINE 8.0L 9 - 61
ENGINE 8.0L (Continued)

INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves (Fig. 14) are arranged in-line and
inclined 18É. The rocker pivot support and the valve
guides are cast integral with the heads.
STANDARD PROCEDURE
VALVE SERVICE
VALVE GUIDES
Measure valve stem guide clearance as follows:
(1) Install Black Valve Guide Sleeve Tool C-6819
over valve stem for theINTAKEvalve and install
valve (Fig. 15). The special sleeve places the valve at
the correct height for checking with a dial indicator.
(2) Install Silver Valve Guide Sleeve Tool C-6818
over valve stem for theEXHAUSTvalve and install
valve. The special sleeve places the valve at the cor-
rect height for checking with a dial indicator.
(3) Attach Dial Indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 16).
(4) Move valve to and from the indicator. The total
dial indicator reading should not exceed 0.432 mm
(0.017 inch). Ream the guides for valves with over-
size stems if dial indicator reading is excessive or if
the stems are scuffed or scored.
Service valves with oversize stems are available as
shown belowREAMER SIZE 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.) (0.316 - 0.329 in.)
(5) 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
inch). Use a 2 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).
Fig. 14 Intake and Exhaust ValvesÐ8.0L Engine
1 - MARGIN
2 - VALVE SPRING RETAINER LOCK GROOVE
3 - STEM
4-FACE
Fig. 15 Positioning Valve Spacer Tool (Typical)
1 - VALVE
2 - SPACER TOOL
Fig. 16 Measuring Valve Guide Wear
1 - VALVE
2 - SPECIAL TOOL C-3339
9 - 80 ENGINE 8.0LBR/BE

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)

allowable tensions. Discard the springs that do not
meet specifications.
REMOVAL
REMOVALÐVALVE STEM SEALS
NOTE: This procedure is done with the cylinder
head installed.
(1) Disconnect the negative cable from the battery.
(2) Set engine basic timing to Top Dead Center
(TDC) and remove air cleaner.
(3) Remove cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL) and spark plugs (Refer to 8
- ELECTRICAL/IGNITION CONTROL/SPARK
PLUG - REMOVAL).
(4) Using suitable socket and flex handle at crank-
shaft retaining bolt, turn engine so that the piston of
the cylinder to be worked on, is at TDC on the com-
pression stroke.
(5) Remove rocker arms (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARM / ADJUSTER
ASSY - REMOVAL).
(6) With air hose attached to an adapter installed
in the spark plug hole, apply 620-689 kPa (90-100
psi) air pressure.
(7) Using Valve Spring Compressor Tool
MD-998772A with adapter 6716A (Fig. 20), compress
valve spring and remove retainer valve locks and
valve spring.
(8) Remove the valve stem seal.
REMOVALÐVALVES AND VALVE SPRINGS
(1) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).(2) Special studs must be used to adapt the Valve
Spring Compressor Tool to the V-10 cylinder head
(Fig. 21). Install the metric end into the Special Tool
MD998772A and the 5/16 end into the cylinder head.
(3) Compress valve springs using Valve Spring
Compressor Tool MD-998772A with Adapter 6716A
and Screw 6765 (Fig. 22). Tap the retainer using a
brass drift and ball peen hammer to loosen locks
away from retainer.
Fig. 19 Testing Valve Spring for Compressed
1 - TORQUE WRENCH
2 - VALVE SPRING TESTER
Fig. 20 Valve Spring Compressor MD-998772A with
Adaptor 6716-A and Screw 6765
1 - SPECIAL TOOL MD 998772A
2 - SPECIAL TOOL 6765
3 - SPECIAL TOOL 6716A
4 - AIR HOSE
Fig. 21 Special Studs 6715 for V-10 Engine
1 - SPECIAL TOOL 6715
9 - 82 ENGINE 8.0LBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

(4) Remove valve retaining locks, valve spring
retainers and valve springs. Check for abnormal
wear, replace as required.
(5) Remove the valve stem seals.
(6) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original location.
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.
INSPECTION
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. 23). 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. 24).
(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.
INSTALLATION
INSTALLATIONÐVALVE STEM SEAL
(1) Install new seal onto valve stem.
(2) Position valve spring onto valve stem.
(3) Position Valve Spring Compressor with Adapter
Studs onto cylinder head
(4) Compress valve spring and install retainer
valve locks.
(5) Remove air hose and adapter from spark plug
hole.
(6) Remove Valve Spring Compressor and Adapter
Studs.
(7) Install rocker arms (Refer to 9 - ENGINE/CYL-
INDER HEAD/ROCKER ARM / ADJUSTER ASSY -
INSTALLATION).
(8) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.For the
left side the number tab is at the front of
Fig. 22 Valve Spring Compressor MD-998772A with
Adaptor 6716-A and Screw 6765
1 - SPECIAL TOOL MD 998772A
2 - SPECIAL TOOL 6765
3 - SPECIAL TOOL 6716A
4 - AIR HOSE
Fig. 23 Positioning Valve with Tool C-3973
1 - VALVE
2 - SPACER TOOL
Fig. 24 Measuring Valve Guide Wear
1 - VALVE
2 - SPECIAL TOOL C-3339
BR/BEENGINE 8.0L 9 - 83
INTAKE/EXHAUST VALVES & SEATS (Continued)