2002 DODGE RAM key

GENERATOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K20 18DG GENERATOR FIELD
2 T125 18DB GENERATOR SOURCE
GLOVE BOX LAMP AND SWITCH-2WAY
CAV CIRCUIT FUNCTION
1 M1 22PK FUSED B(+)
2 Z3 22BK/OR GROUND
HEADLAMP SWITCH C1 - BLACK 14 WAY
CAV CIRCUIT FUNCTION
1 L7 16BK/YL HEADLAMP SWITCH OUTPUT
2 F33 16PK/RD FUSED B(+)
3 G26 22LB KEY-IN IGNITION SWITCH SENSE
4 G75 22TN (BASE) DRIVER DOOR AJAR SWITCH SENSE
4 Z3 22BK/OR GROUND
5 Z3 18BK/OR GROUND
6 L2 18LG HEADLAMP SWITCH OUTPUT
7 L39 22LB FOG LAMP SWITCH OUTPUT
8 E17 18YL/BK DAY BRIGHTNESS SENSE
9 Z3 20BK/OR GROUND
10 M22 22WT DOME LAMP SWITCH SENSE
11 M3 22PK/DB CARGO LAMP DRIVER
12 M2 22YL COURTESY LAMPS DRIVER
13 M11 22PK/LB COURTESY LAMPS SWITCH OUTPUT
13 M22 22WT (BASE) DOME LAMP SWITCH SENSE
14 E1 18TN PANEL LAMPS DIMMER SWITCH SIGNAL
HEADLAMP SWITCH C2-2WAY
CAV CIRCUIT FUNCTION
1 Z3 20BK/OR GROUND
2 L35 22BR/YL FOG LAMP RELAY OUTPUT
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47

IGNITION COIL 6 PACK (8.0L) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 K19 18BK/GY IGNITION COIL NO. 1 DRIVER
2 A142 14DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
3 K32 18YL/GY IGNITION COIL NO. 4 DRIVER
4 K43 18DG/GY IGNITION COIL NO. 5 DRIVER
IGNITION SWITCH C1 - BLACK 7 WAY
CAV CIRCUIT FUNCTION
1 A41 14YL IGNITION SWITCH OUTPUT (START)
2 A21 12DB IGNITION SWITCH OUTPUT (RUN-START)
3- -
4 A2 14PK/BK FUSED B(+)
5 A22 14BK/OR IGNITION SWITCH OUTPUT (RUN)
6 A31 12BK/WT IGNITION SWITCH OUTPUT (RUN-ACC)
7 A1 10RD FUSED B(+)
IGNITION SWITCH C2 - GRAY 4 WAY
CAV CIRCUIT FUNCTION
1 Z3 22BK/OR GROUND
1 G75 22TN (IEM) DRIVER DOOR AJAR SWITCH SENSE
2 G26 22LB KEY-IN IGNITION SWITCH SENSE
3- -
4- -
INSTRUMENT CLUSTER C1 - 10 WAY
CAV CIRCUIT FUNCTION
1- -
2 G5 22DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 G11 22WT/LG PARK BRAKE SWITCH SENSE
4 Z2 20BK/LG GROUND
5 Z3 20BK/OR GROUND
6 F73 20YL FUSED B(+)
7- -
8 G85 22OR/BK (DIESEL) WAIT-TO-START WARNING INDICATOR DRIVER
9 D2 20WT/BK CCD BUS (-)
10 D1 20VT/BR CCD BUS (+)
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49

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

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)

move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N´m (30 ft. lbs.) torque in the
reverse direction. With the cylinder heads removed,
apply 20 N´m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 74).
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
INSTALLATION
(1) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(2) Place timing chain around both sprockets.
(3) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(4) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(5) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 75).
(6) Install the camshaft bolt. Tighten the bolt to 68
N´m (50 ft. lbs.) torque.
(7) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 mm (0.010 inch) with a
used thrust plate. If not within these limits install a
new thrust plate.
(8) Install the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
Fig. 73 Alignment of Timing Marks
1 - TIMING MARKS
Fig. 74 Measuring Timing Chain Stretch
1 - TORQUE WRENCH
2 - 3.175 MM
(0.125 IN.)
Fig. 75 Alignment of Timing Marks
1 - TIMING MARKS
BR/BEENGINE 5.9L 9 - 55
TIMING BELT/CHAIN AND SPROCKETS (Continued)

INSTALLATION
INSTALLATIONÐCAMSHAFT BEARINGS
(1) Install new camshaft bearings using recom-
mended Tool 8544 Camshaft Bushing Remover
Installer, by sliding the new camshaft bearing shell
over proper adapter.
(2) Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft.Be sure this plug does not leak.
INSTALLATIONÐCAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing
journals. Using a long bolt, insert the camshaft into
the cylinder block.
NOTE: Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1 pint of
MoparTCrankcase Conditioner, or equivalent. The
oil mixture should be left in engine for a minimum
of 805 km (500 miles). Drain at the next normal oil
change.
(2) Install camshaft thrust plate. Tighten the torx
bolts to 22 N´m (16 ft. lbs.) torque.
(3) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 mm (0.010 inch) with a
used thrust plate. If not within these limits install a
new thrust plate.
(4) Line up key with keyway in sprocket, then
using Special Tools C-3688, C-3718 and MB990799
install crankshaft timing sprocket. Make sure the
sprocket seats against the crankshaft shoulder (Fig.
28).
(5) Install timing chain and sprocket (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(6) Install the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install the crankshaft pulley/damper (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(8) Prime oil pump by squirting oil in the oil filter
mounting hole and filling the J-trap of the front tim-
ing cover. When oil is running out, install oil filter
that has been filled with oil.
(9) Each tappet reused must be installed in the
same position from which it was removed.When
camshaft is replaced, all of the tappets must be
replaced.(10) Install tappets and push rods in their original
location.
(11) Position the tappet aligning yokes and yoke
retaing spider.
(12) Install the retaining spider mounting bolts.
Tighten bolts to 22 N´m (16 ft. lbs.).
(13) Install the rocker arms (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARM / ADJUSTER
ASSY - INSTALLATION).
(14) 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
engine with the number up. For the right side
the number tab is at the rear of engine with the
number up.
CAUTION: The cylinder head cover fasteners have a
special plating. DO NOT use alternative fasteners.
(15) Install cylinder head cover (Fig. 29) (Refer to
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(16) Install the intake manifolds (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(17) Start engine and check for leaks.
Fig. 28 Crankshaft Sprocket Installation
1 - SPECIAL TOOL C-3688
2 - SPECIAL TOOL C-3718
3 - SPECIAL TOOL MD990799
9 - 86 ENGINE 8.0LBR/BE
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

(6) Prime oil pump by squirting oil in the oil filter
mounting hole and filling the J-trap of the front tim-
ing cover. When oil is running out, install oil filter
that has been filled with oil.
(7) Install water pump and housing assembly
using new o-ring (Refer to 7 - COOLING/ENGINE/
WATER PUMP - INSTALLATION).
(8) Install generator, air pump, and bracket assem-
bly.
(9) Install A/C compressor (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION).
(10) (10) Install the radiator fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(11) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(12) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(13) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect the negative cable to the battery.
(15) Road test vehicle and check for leaks.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Remove timing chain cover and gasket using
extreme caution to avoid damaging oil pan gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
(2) Aline camshaft and crankshaft centerline.
Remove camshaft sprocket attaching bolt and remove
timing chain and camshaft sprockets.
(3) Use puller 6444 and jaws 6820 to remove
crankshaft sprocket (Fig. 79).
INSPECTIONÐMEASURING TIMING CHAIN
STRETCH
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam-
shaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
N´m (30 ft. lbs.) torque with cylinder head installed
or 20 N´m (15 ft. lbs.) torque with cylinder head
removed. With a torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N´m (30 ft. lbs.) torque in thereverse direction. With the cylinder heads removed,
apply 20 N´m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 80).
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
INSTALLATION
(1) Line up key in crankshaft with keyway in
sprocket, press on crankshaft timing sprocket, use
tools C-3688, C-3718 and MB-990799, seat sprocket
against crankshaft shoulder (Fig. 81).
Fig. 79 Crankshaft Sprocket Removal.
1 - SPECIAL TOOL 6444
2 - SPECIAL TOOL 6820
Fig. 80 Measuring Timing Chain Stretch
1 - TORQUE WRENCH
2 - 3.175 MM
(0.125 IN.)
BR/BEENGINE 8.0L 9 - 111
TIMING BELT / CHAIN COVER(S) (Continued)

incorporates a centrally located high swirl combus-
tion bowl, and utilizes a ªkeystoneº style top com-
pression ring (Fig. 124) , and a ªTapered Faceºintermediate ring (Fig. 124) , for superior cylinder
wall scraping. Piston cooling nozzles cool the piston
and pin with engine oil supplied by the crankshaft
main journals.
The connecting rods (Fig. 125) are a split angle
design constructed of micro alloy. The rods have a
pressed in place wrist pin bushing which is lubri-
cated by the piston cooling nozzle oil spray.
STANDARD PROCEDUREÐPISTON GRADING
²When rebuilding an engine with the original cyl-
inder block, crankshaft and pistons, make sure the
pistons are installed in their original cylinder.
²If replacing the piston(s), make sure the replace-
ment piston(s) are the same grade as the one being
replaced.
²If a new cylinder block and/or crankshaft is
used, the piston grading procedureMUSTbe per-
formed to determine the proper piston grade for each
cylinder.
Fig. 120 Retrieve Tappet Installation Tool through
Cam Bore
Fig. 121 Insert Tool and Pull Tappet Into Place
Fig. 122 Rotate Trough One Half Turn (180É)
Fig. 123 Piston
Fig. 124 Piston Ring Identification
9 - 166 ENGINE 5.9L DIESELBR/BE
PISTON & CONNECTING ROD (Continued)