engine DODGE RAM 2002 Service Repair Manual

(7) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover
sealing surface.
(8) Install the gear housing cover (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- INSTALLATION).
(9) Install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(10) Install the fan support/hub assembly and
torque bolts to 24 N´m (18 ft. lbs.).
(11) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(12) Install the cooling fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
(13) Connect battery negative cables.
(14) Start engine and check for oil leaks.
INTAKE MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the charge air cooler outlet tube from
the air inlet housing (Fig. 166).
(3) Remove the engine oil dipstick tube mounting
bolt (Fig. 166). Position dipstick tube to the side.
(4) Disconnect the air grid heater power cables at
the cable mounting studs (Fig. 167).
(5) Remove the four (4) air inlet housing mounting
bolts (Fig. 167) and remove the housing from top of
the heater elements.
(6) Remove the intake air grid heater from the
manifold (Fig. 168).
(7) Remove the high pressure fuel lines.(Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- REMOVAL).
(8) Remove the remaining intake manifold cover-
to-cylinder head bolts.
(9) Remove the intake manifold cover and gasket.
Keep the gasket material and any other material out
of the air intake.
(10) Clean the intake manifold cover and cylinder
head sealing surface.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) Using a new gasket, install the intake manifold
cover.
(2) Install the cover-to-cylinder head bolts that do
not hold down the high pressure fuel line support
brackets. Tighten the bolts to 24 N´m (18 ft. lbs.)
torque.
(3) Install the high pressure fuel lines (Refer to 14
- FUEL SYSTEM/FUEL DELIVERY/FUEL LINES -
INSTALLATION).
(4) Install the high pressure fuel line support
bracket-to-intake manifold cover bolts and tighten to
24 N´m (18 ft. lbs.) torque.
(5) Using two (2) new gaskets, install the intake
air grid heater and air inlet housing (Fig. 167). Posi-
tion the ground cable and install and tighten the
bolts to 24 N´m (18 ft. lbs.) torque.
(6) Install and tighten the air intake heater power
supply nuts to 14 N´m (120 in. lbs.) torque.
(7) Install the engine oil dipstick tube and mount-
ing bolt (Fig. 166).
Fig. 166 Charge Air Cooler Air Tube
1 - FRONT WIRING CLIP
2 - GROUND CABLE
3 - TUBE BOLT
4 - ENGINE OIL DIPSTICK TUBE
5 - CLAMPS
6 - AIR TUBE (INT. MAN.-TO-INTERCOOLER)
7 - RUBBER HOSE
8 - AIR INTAKE HOUSING
9 - CABLE BRACKET HOUSING
9 - 184 ENGINE 5.9L DIESELBR/BE
OIL PUMP (Continued)

(8) Position the charge air cooler outlet tube onto
the air inlet housing (Fig. 166). Tighten the clamps
to 8 N´m (72 in. lbs.) torque.(9) Perform the fuel system air bleed procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(10) Connect the battery negative cables.
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Disconnect the exhaust pipe from the turbo-
charger elbow (Fig. 169) .
(4) Lower vehicle.
(5) Disconnect the turbocharger air inlet hose (Fig.
170) .
(6) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger (Fig. 171) .
(7) Disconnect the charge air cooler inlet pipe from
the turbocharger (Fig. 171) .
(8) Remove the turbocharger and gasket from the
exhaust manifold.
(9) Remove the cab heater return pipe nut from
the exhaust manifold stud. Position the tube out of
the way.
(10) Remove the exhaust manifold-to-cylinder head
bolts and spacers (Fig. 172) .
(11) Remove the exhaust manifold and gaskets
(Fig. 172) .
CLEANING
Clean the cylinder head and exhaust manifold seal-
ing surfaces with a suitable scraper. Use a Scotch-
BriteŸ pad or equivalent.
Fig. 167 Air Inlet Housing
1 - GROUND STRAP
2 - AIR INTAKE HOUSING
3 - HEATER POWER CABLE MOUNTING STUDS
4 - FUEL LINE BRACKET BOLT
5 - HOUSING BOLTS (4)
Fig. 168 Intake Air Grid Heater
1 - AIR HEATER ELEMENTS
2 - LOWER GASKET
3 - BLOCK
4 - UPPER GASKET
Fig. 169 Exhaust Pipe
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
BR/BEENGINE 5.9L DIESEL 9 - 185
INTAKE MANIFOLD (Continued)

INSPECTION
Inspect the exhaust manifold for cracks. Measure
the exhaust manifold for flatness. Place a ruler over
all of the exhaust ports and insert a feeler gauge
between the port flange and the ruler.
INSTALLATION
(1) Using new gaskets, install the exhaust mani-
fold and gaskets. Install the bolts and spacers and
tighten the bolts in the sequence shown in (Fig. 172)
to 43 N´m (32 ft. lbs.) torque.
(2) Install the cab heater return hose to the man-
ifold bolt stud. Tighten the nut to 24 N´m (18 ft. lbs.)
torque.
(3) Install the turbocharger. Apply anti-seize to the
studs and then tighten the turbocharger mounting
nuts to 32 N´m (24 ft. lbs.) torque.
(4) Install the oil drain tube and oil supply line to
the turbocharger. Tighten the drain tube bolts to 24
N´m (18 ft. lbs.) torque.
(5)Pre-lube the turbocharger.Pour 50 to 60 cc
(2 to 3 oz.) clean engine oil in the oil supply line fit-
ting. Rotate the turbocharger impeller by hand to
distrubute the oil thoroughly.
(6) Install and tighten the oil supply line fitting
nut to 20 N´m (133 in. lbs.) torque.
Fig. 170 Turbocharger Air Inlet Hose
1 - AIR FILTER HOUSING COVER
2 - TURBOCHARGER
3 - AIR INLET TUBE
4 - HOSE CLAMP
5 - HINGE TABS
6 - FILTER MINDER
7 - CLIPS (4)
8 - TUBE ALIGNMENT NOTCHES
Fig. 171 Oil Supply Line and Charge Air Cooler Inlet
Duct
1 - EXHAUST PIPE
2 - TURBOCHARGER
3 - AIR INLET TUBE
4 - INTERCOOLER INLET DUCT
5 - WASTE GATE ACTUATOR
Fig. 172 Exhaust Manifold and Gaskets
9 - 186 ENGINE 5.9L DIESELBR/BE
EXHAUST MANIFOLD (Continued)

(7) Position the charge air cooler inlet pipe to the
turbocharger. With the clamp in position, tighten the
clamp nut to 8 N´m (72 in. lbs.) torque.
(8) Position the air inlet hose to the turbocharger
(Fig. 170). Tighten the clamp to 8 N´m (72 in. lbs.)
torque.
(9) Raise vehicle on hoist.
(10) Connect the exhaust pipe to the turbocharger
(Fig. 169) and tighten the bolts to 34 N´m (25 ft. lbs.)
torque.
(11) Lower the vehicle.
(12) Connect the battery negative cables.
(13) Start the engine to check for leaks.
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION
(1) Remove the cylinder head cover.
(2) Remove fuel injector from cylinder number 1.
(3) Remove the crankcase breather from the gear
housing cover.
(4) Using Special Tool 7471B rotate the engine
until the timing mark on the fuel pump gear is
aligned with the TDC mark on the gear housing
cover.
(5) Using a 8 in.x 1/4 in. dowel rod inserted into
cylinder number 1, rock the crankshaft back and
forth to verify piston number 1 is at TDC.
(6) With piston number 1 at TDC the timing mark
on the fuel pump gear should be aligned with the
TDC mark on the gear housing cover. If marks do not
line up, remove the gear housing cover.
(7) With cylinder number still at TDC, inspect the
keyway on the crankshaft gear for proper alignment
(12 o'clock position).
(8) If the keyway is not at 12 o'clock position
replace the crankshaft gear assembly.
(9) If the keyway is at 12 o'clock position, verify
timing mark alignment between the camshaft gear,
crankshaft gear and the fuel pump gear, if not
aligned inspect keyway on camshaft gear.
(10) Inspect keyway on camshaft gear for proper
alignment with the key in the camshaft, if alignment
is off replace the camshaft/gear assembly.
(11) If timing marks alignment is off and no dam-
age is found at either the crankshaft or camshaft
gear keyways, realign timing marks as necessary.
GEAR HOUSING
REMOVAL
(1) Disconnect the 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 hose from
radiator 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 (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(10) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(11) Remove the cooling fan support/hub from the
front of the engine (Fig. 173).
(12) Raise the vehicle on hoist.
(13) Remove the crankshaft damper (Fig. 174)
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(14) Lower the vehicle.
(15) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing (Fig.
175), taking care not to mar the gasket surfaces.
(16) Remove the fuel injection pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(17) Disconnect the camshaft position sensor con-
nector.
Fig. 173 Fan Support/Hub Assembly - Removal/
Installation
1 - FAN SUPPORT/HUB
2 - FAN PULLEY
BR/BEENGINE 5.9L DIESEL 9 - 187
EXHAUST MANIFOLD (Continued)

(18) Remove the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(19) Remove the six front oil pan fasteners.
(20) Remove the gear housing fasteners.
NOTE: Use care when removing the gear housing,
to avoid damage to the oil pan gasket, as the gas-
ket will be reused if it is not damaged.
(21) Slide a feeler gauge between the gear housing
and oil pan gasket, to break the gasket seal.
(22) Remove the gear housing and gasket (Fig.
176).
(23) Clean the gasket material from the cylinder
block and gear housing.
INSTALLATION
(1) Inspect the oil pan gasket, if the gasket can be
reused, coat both sides with a film of MopartSilicone
Rubber Adhesive Sealant.
(2) If the gasket is torn, it can be repaired. Cut the
old gasket off even with the front of the cylinder
block.
(3) Using the old gasket as a pattern, cut the front
section of a new gasket to the same size.
(4) Clean the sealing surfaces and coat the new
gasket on both sides with a film of MopartSilicone
Rubber Adhesive Sealant.
(5) Mark and trim 1.59mm (1/16 in.) off of the bot-
tom of the new gear housing gasket. Only trim the
part of the gasket that meets the oil pan.
NOTE: When properly trimmed, the gear housing
gasket should be even with the oil pan gasket when
installed.
(6) Install the new gear housing gasket on the
alignment dowels
NOTE: (M8ý1.25ý50) guide pins can be used to
assist in aligning the gasket and gear housing. Be
sure to remove the guide pins after alignment.
(7) Carefully install the gear housing, making sure
both gaskets stay in place (Fig. 176).
Fig. 174 Crankshaft Damper - Removal/Installation
1 - DAMPER
2 - BOLT
Fig. 175 Gear Housing and Cover
1 - GEAR HOUSING
2 - GEAR HOUSING COVER
Fig. 176 Gear Housing and Gasket
1 - DOWEL
2 - GASKET
3 - BOLT
4 - GEAR HOUSING
9 - 188 ENGINE 5.9L DIESELBR/BE
GEAR HOUSING (Continued)

(8) Install and tighten the gear housing bolts to 24
N´m (18 ft. lbs.) torque.
(9) Install and tighten the oil pan bolts to 24 N´m
(18 ft. lbs.) torque.
(10) Install the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - INSTALLATION). Align the crankshaft,
camshaft, and injection pump gear marks as shown
in (Fig. 177).
(11) If a new housing is installed, the camshaft
position sensor must be transferred to the new hous-
ing.
(12) Connect the camshaft position sensor connec-
tor.
(13) Install the injection pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(14) Obtain a seal pilot/installation tool from a
crankshaft front seal service kit and install the pilot
into the crankshaft front oil seal.
(15) Apply a bead of MopartSilicone Rubber
Adhesive Sealant or equivalent to the gear housing
cover. Be sure to surround all through holes.
(16) Using the seal pilot to align the cover (Fig.
178), install the cover to the housing and install the
bolts. Tighten the bolts to 24 N´m (18 ft. lbs.) torque.
(17) Remove the seal pilot.
(18) Raise the vehicle.
(19) Install the crankshaft damper (Fig. 174)
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(20) Lower vehicle.(21) Install the fan support/hub assembly (Fig.
173) and tighten bolts to 24 N´m (18 ft. lbs.) torque.
(22) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(23) Install the cooling fan and shroud together
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(24) Install the windshield washer reservoir to the
fan shroud and connect the washer pump supply
hose and electrical connection.
(25) Install the coolant recovery bottle to the fan
shroud and connect the hose to the radiator filler
neck.
(26) Install the radiator upper hose and clamps.
(27) Add engine oil.
(28) Add coolant (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(29) Connect the battery cables.
(30) Start engine and inspect for leaks.
GEAR HOUSING COVER
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 hose from
radiator 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.
Fig. 177 Camshaft/Crankshaft Gear Alignment
Fig. 178 Installing Cover with Seal Pilot
1 - SEAL PILOT
BR/BEENGINE 5.9L DIESEL 9 - 189
GEAR HOUSING (Continued)

(8) Remove viscous fan/drive assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(9) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(10) Remove the cooling fan support/hub from the
front of the engine (Fig. 179).
(11) Raise the vehicle on hoist.
(12) Remove the crankshaft damper (Fig. 180)
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(13) Lower the vehicle.
(14) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the gasket surfaces.
INSTALLATION
(1) Obtain a seal pilot/installation tool from a
crankshaft front seal service kit and install the pilot
into the seal.
(2) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover.
Be sure to surround all through holes.
(3) Using the seal pilot to align the cover (Fig.
182), install the cover to the housing and install the
bolts. Tighten the bolts to 24 N´m (18 ft. lbs.) torque.
(4) Remove the seal pilot.
(5) Raise the vehicle.
(6) Install the crankshaft damper (Fig. 180) (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(7) Lower vehicle.
Fig. 179 Fan Support/Hub AssemblyÐRemoval/
Installation
1 - FAN SUPPORT/HUB
2 - FAN PULLEY
Fig. 180 Crankshaft DamperÐRemoval/Installation
1 - DAMPER
2 - BOLT
Fig. 181 Gear Housing and Cover
1 - GEAR HOUSING
2 - GEAR HOUSING COVER
Fig. 182 Installing Cover with Seal Pilot
1 - SEAL PILOT
9 - 190 ENGINE 5.9L DIESELBR/BE
GEAR HOUSING COVER (Continued)

(8) Install the fan support/hub assy. (Fig. 179) and
tighten bolts to 24 N´m (18 ft. lbs.) torque.
(9) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(10) Install the cooling fan and shroud together
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(11) Install the windshield washer reservoir to the
fan shroud and connect the washer pump supply
hose and electrical connection.(12) Install the coolant recovery bottle to the fan
shroud and connect the hose to the radiator filler
neck.
(13) Install the radiator upper hose and clamps.
(14) Add coolant (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(15) Connect the battery cables.
(16) Start engine and inspect for leaks.
BR/BEENGINE 5.9L DIESEL 9 - 191
GEAR HOUSING COVER (Continued)

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION
DESCRIPTION - 5.9/8.0L.................2
DESCRIPTIONÐ5.9L DIESEL.............3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - GAS ENGINE . . . 4
DIAGNOSIS AND TESTING - DIESEL
ENGINE..............................4
SPECIFICATIONS
TORQUE.............................5
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................5
INSPECTION...........................6
INSTALLATION..........................6
CATALYTIC CONVERTER - 5.9L HD/8.0L
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................6
INSPECTION...........................6
INSTALLATION..........................7
EXHAUST PIPE - 3.9L/5.2L/5.9L
REMOVAL.............................7
INSPECTION...........................7
INSTALLATION..........................7
EXHAUST PIPE - 5.9L HD/8.0L
REMOVAL.............................7
INSPECTION...........................8
INSTALLATION..........................8
EXHAUST PIPE - 5.9L DIESEL
REMOVAL.............................9
INSPECTION...........................9
INSTALLATION..........................9
HEAT SHIELDS
DESCRIPTION.........................10
REMOVAL.............................10
INSTALLATION.........................10
MUFFLER - 3.9L/5.2L/5.9L/8.0L
REMOVAL.............................10INSTALLATION.........................10
MUFFLER - 5.9L DIESEL
REMOVAL.............................11
INSTALLATION.........................11
TAILPIPE - 3.9L/5.2L/5.9L
REMOVAL.............................11
INSPECTION..........................11
INSTALLATION.........................11
TAILPIPE - 5.9L HD/8.0L
REMOVAL.............................12
INSPECTION..........................12
INSTALLATION.........................12
TAILPIPE - 5.9L DIESEL
REMOVAL.............................12
INSPECTION..........................12
INSTALLATION.........................13
RESONATOR
REMOVAL.............................13
INSTALLATION.........................13
TURBOCHARGER SYSTEM
DIAGNOSIS AND TESTING -
TURBOCHARGER BOOST PRESSURE.....13
TURBOCHARGER
DESCRIPTION.........................14
OPERATION...........................14
REMOVAL.............................15
CLEANING............................16
INSPECTION..........................16
INSTALLATION.........................17
CHARGE AIR COOLER AND PLUMBING
DESCRIPTION.........................18
OPERATION...........................18
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS..............18
REMOVAL.............................18
CLEANING............................19
INSPECTION..........................19
INSTALLATION.........................20
BR/BEEXHAUST SYSTEM 11 - 1

EXHAUST SYSTEM
DESCRIPTION
DESCRIPTION - 5.9/8.0L
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.The federal gasoline engine exhaust system (Fig. 1)
consists of engine exhaust manifolds, exhaust pipes,
catalytic converter(s), extension pipe (if needed),
exhaust heat shields, muffler and exhaust tailpipe.
The California emission vehicles exhaust system
also contains the above components as well as mini
catalytic converters added to the exhaust pipe (Fig.
2).
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. Minimum
clearance between any exhaust component and the
body or frame is 25.4 mm (1.0 in.). If the system con-
tacts any body panel, it may amplify objectionable
noises from the engine or body.
Fig. 1 Exhaust System Gasoline EnginesÐFederal Emissions (Typical)
1 - CATALYTIC CONVERTER
2 - TAILPIPE
3 - MUFFLER4 - CATALYTIC CONVERTERS
5 - AIR INDUCTION LINES
6 - EXHAUST PIPE
11 - 2 EXHAUST SYSTEMBR/BE