DODGE RAM 2002 Service Repair Manual

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)

(1) Install any of the original connecting rod and
piston assemblies into the No.1 cylinder. DO NOT
install the piston rings.
(2) Install the upper bearing shell in the connect-
ing rod with the tang of the bearing in the slot of the
connecting rod. The connecting rod bearing shell
must be installed in the original connecting rod and
cap. Use clean lubricating oil to coat the inside diam-
eter of the connecting rod bearing shell.
(3) Install the bearing shell in the connecting rod
cap with the tang of the bearing in the slot to the
cap. Use clean lubricating oil to coat the inside diam-
eter of the bearing shell.
(4) The four digit number stamped on the connect-
ing rod and cap at the parting line must match andbe installed on the oil cooler side of the engine.
Install the connecting rod cap and cap screws.
Tighten the cap screws to 35 N´m (26 ft. lbs.) torque.
(5) Use a fine grit stone to remove any burrs from
the cylinder block head deck. Zero the dial indicator
to the cylinder block head deck.
(6) Move the dial indicator directly over the piston
pin to eliminate any side-to-side movement.
(7) Rotate the crankshaft to top dead center
(TDC). Rotate the crankshaft clockwise and counter-
clockwise to find the highest dial indicator reading.
Record the reading.
(8) Remove the piston and connecting rod assem-
bly from the No.1 cylinder and install the assembly
into the No.2 cylinder. Repeat the procedure for every
cylinder using the same piston and connecting rod
assembly.
(9) Determine the grade of the piston being used
by referring to the Piston Protrusion Chart below.
Four digits on top of the piston can be cross refer-
enced to a DaimlerChrysler part number for replace-
ment (Fig. 126). If the number on the piston cannot
be seen, measure from the top of the piston to the top
of the piston pin to see what grade piston is used
(Fig. 127).
NOTE: NEVER INTERMIX PISTONS FROM ONE
ENGINE APPLICATION TO ANOTHER ENGINE
APPLICATION. SEVER DRIVEABILITY CONCERNS
MAY RESULT.
Fig. 125 Connecting Rod
Fig. 126 Piston Grading Number Location
BR/BEENGINE 5.9L DIESEL 9 - 167
PISTON & CONNECTING ROD (Continued)

PISTON PROTRUSION CHART
IF MEASURING PISTON IS AND USE
GRADING #:
PROTRUSION IS GRADE:
245 HP 235 HP
6050 61530.609-0.711 mm
A
(0.024-0.028 in.)
6050 61530.508-0.609mm
B
(0.020-0.024 in.)
6050 61530.406-0.508 mm
C
(0.016-0.020 in.)
6051 61540.711-0.813 mm
A
(0.028-0.032 in.)
6051 61540.609-0.711 mm
B
(0.024-0.028 in.)
6051 61540.508-0.609 mm
C
(0.020-0.024 in.)
6052 61550.813-0.914 mm
A
(0.032-0.036 in.)
6052 61550.711-0.813 mm
B
(0.028-0.032 in.)
6052 61550.609-0.711 mm
C
(0.024-0.028 in.)
NOTE: Use the table below when piston grading
numbers are missing or not legible.
ALTERNATIVE GRADE IDENTIFICATION METHOD
DIMENSION(A(REF. NUMBER GRADE
235 HP 245 HP
51.554-51.607 mm
6153 6050 A
(2.029-2.031 in.)
51.654-51.707 mm
6154 6051 B
(2.033-2.035 in.)
51.754-51.807 mm
6155 6052 C
(2.037-2.039 in.)
REMOVAL
(1) Disconnect the battery cables.
(2) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(3) Remove the oil pan and suction tube (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - REMOVAL).(4) Using Miller Tool 7471-B crankshaft barring
tool, rotate the crankshaft so all of the pistons are
below TDC.
9 - 168 ENGINE 5.9L DIESELBR/BE
PISTON & CONNECTING ROD (Continued)

(5) Before removing the piston(s) from the bore(s):
(a) Remove any carbon ridge formations or
deposits at the top of the bore with a dull scraper
or soft wire brush.
(b) If cylinder bore wear ridges are found, use a
ridge reamer to cut the ridge from the bore. DO
NOT remove more metal than necessary to remove
the ridge.
NOTE: If cylinders have ridges, the cylinders are
oversize and will more than likely need boring.
(6) Using a hammer and steel stamp, identify the
front of the piston by stamping the cylinder number
in each piston to be removed at the top of the piston
toward the front of the engine. DO NOT stamp in the
outside 5 mm (.197 in.) of the piston diameter.
(7) Mark the connecting rod and cap with the cor-
responding cylinder numbers.
(8) Remove the connecting rod bolts and rod caps.
Use care so the cylinder bores and connecting rods
are not damaged.
(9) Use a hammer handle or similar object to push
the piston and connecting rod through the cylinder
bore.
(10) Store the piston/rod assemblies in a rack.
(11) If a piston must be replaced, replace with the
same part number (grading) that was removed.
CLEANING
CAUTION: DO NOT use bead blast to clean the pis-
tons. DO NOT clean the pistons and rods in an acid
tank.
Clean the pistons and pins in a suitable solvent,
rinse in hot water and blow dry with compressed air.
Soaking the pistons over night will loosen most of the
carbon build up. De-carbon the ring grooves with a
broken piston ring and again clean the pistons in sol-vent. Rinse in hot water and blow dry with com-
pressed air.
INSPECTION
INSPECTION
Inspect the pistons for damage and excessive wear.
Check top of the piston, ring grooves, skirt and pin
bore. Measure the piston skirt diameter (Fig. 128). If
the piston is out of limits, replace the piston.
The upper groove only needs to be inspected for
damage. Use a new piston ring to measure the clear-
ance in the intermediate ring groove (Fig. 129). If the
clearance of the intermediate ring exceeds 0.095 mm
(0.0038 inch), replace the piston.
Use a new oil ring to measure the clearance in the
oil groove (Fig. 129). If the clearance exceeds 0.085
mm (0.0034 inch), replace the piston.
Measure the pin bore (Fig. 130). The maximum
diameter is 40.012 mm (1.5753 inch). If the bore is
over limits, replace the piston.
Inspect the piston pin for nicks, gouges and exces-
sive wear. Measure the pin diameter (Fig. 131). The
minimum diameter is 39.990 mm (1.5744 inch). If the
diameter is out of limits, replace the pin.
Connecting Rods
CLEANING
Clean the connecting rods in a suitable solvent,
rinse in hot water and blow dry with compressed air.
INSPECTION
Inspect the connecting rod for damage and wear.
The I-Beam section of the connecting rod cannot have
dents or other damage. Damage to this part can
cause stress risers which will progress to breakage.
Fig. 127 Piston Grading Measurement
Fig. 128 Piston Skirt Diameter
PISTON SKIRT DIAMETER (MIN.)
101.864 mm (4.0104 in. )
BR/BEENGINE 5.9L DIESEL 9 - 169
PISTON & CONNECTING ROD (Continued)

Measure the connecting rod pin bore (Fig. 132).
The maximum diameter is 40.042 mm (1.5764 inch).
If out of limits, replace the connecting rod.
INSTALLATION
(1) Lubricate the cylinder bores with clean engine
oil.
(2) Generously lubricate the rings and piston
skirts with clean engine oil.
(3) Compress the rings using a piston ring com-
pressor tool (Fig. 133). If using a strap-type ring com-
pressor, make sure the inside end of the strap does
not hook on a ring gap and break the ring.
(4) Bar the crankshaft so the rod journal for the
piston to be installed is at BDC (Bottom Dead Cen-
ter) - (Fig. 134).
(5) Be sure the mark you made on the piston and
the numbers on the rod and cap are oriented as illus-
trated.
(6) Position the piston and rod assembly into the
cylinder bore with the mark you made on the piston
towards the front of the cylinder block. In this posi-
tion the numbers on the connecting rod should be
facing the oil cooler side of the engine, and the rod
Fig. 129 Intermediate and Oil Ring Clearances
1 - FEELER GAUGE
2 - RING
3 - PISTON
Fig. 130 Piston Pin Bore
1 - PISTON
2 - PIN BORE
Fig. 131 Piston Pin Diameter
1 - PISTON PIN
Fig. 132 Connecting Rod Pin Bore
1 - CONNECTING ROD
Fig. 133 Piston Ring Compressor Tool
1 - PISTON RING COMPRESSOR TOOL
9 - 170 ENGINE 5.9L DIESELBR/BE
PISTON & CONNECTING ROD (Continued)

bolt holes toward the camshaft. Use care when you
install the piston and connecting rod so the cylinder
bore is not damaged.
(7) Push the piston into the bore until the top of
the piston is approximately 50 mm (2 inch) below the
top of the block. Carefully pull the connecting rod
onto the crankshaft journal.
(8) Use clean engine oil to lubricate the threads
and under the heads of the connecting rod bolts.
(9) The number stamped on the rod cap at the
parting line must match and be installed towards the
oil cooler side of the engine (Fig. 135).
(10) Install the rod cap and bolts to the connecting
rod. Tighten the connecting rod and bolt evenly in 3
steps.
²Tighten the bolts to 35 N´m (26 ft. lbs.) torque.
²Tighten the bolts to 70 N´m (51 ft. lbs.) torque.
²Tighten the bolts to 100 N´m (73 ft. lbs.) torque.
(11) The crankshaft must rotate freely. Check for
freedom of rotation as the caps are installed. If the
crankshaft does not rotate freely, check the installa-
tion of the rod bearing and the bearing size.
(12) Measure the side clearance between the con-
necting rod and the crankshaft (Fig. 136). DO NOT
measure the clearance between the cap and crank-
shaft.(13) Install the suction tube and oil pan (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(14) Install the cylinder head onto the engine
(Refer to 9 - ENGINE/CYLINDER HEAD - INSTAL-
LATION).
(15) Install a new filter and fill the crankcase with
new engine oil.
(16) Connect the battery negative cables and start
engine.
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Determine the piston diameter and obtain the
appropriate ring set. The piston rings can be identi-
fied as shown in (Fig. 137).
(2) Position each ring in the cylinder and use a
piston to square it with the bore at a depth of 89.0
mm (3.5 inch) - (Fig. 138).
(3) Use a feeler gauge to measure the piston ring
gap.
Fig. 134 Piston/Rod Assembly at BDC
Fig. 135 Correct Rod Cap Installation
Fig. 136 Side Clearance between Connecting
Rod/Crankshaft
1 - FEELER GAUGE
Fig. 137 Piston Ring Identification
BR/BEENGINE 5.9L DIESEL 9 - 171
PISTON & CONNECTING ROD (Continued)

PISTON RING GAP CHART
TOP RING 0.35 - 0.45 mm (0.014 - 0.0177
in.)
INTERMEDIATE
RING0.85-1.15 mm (0.0334 -
0.0452 in.)
OIL CONTROL
RING0.250-0.550
mm(0.0100 -
0.0215 in.)
(4) The top surface of all of the rings are identified
with the word TOP or the supplier's MARK. Assem-
ble the rings with the word TOP or the supplier's
MARK up.
(5) Position the oil ring expander in the oil control
ring groove (bottom groove).
(6) Install the oil control ring with the end gap
OPPOSITE the ends on the expander (Fig. 139).
(7) Install the intermediate piston ring in the sec-
ond groove.
(8) Install the top piston ring in the top groove
(Fig. 140).
(9) Position the rings as shown in (Fig. 141).
VIBRATION DAMPER
REMOVAL
(1) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove the four (4) damper to crankshaft bolts
and remove damper (Fig. 142).
INSPECTION
(1) Inspect the damper hub for cracks and replace
if any are found.(2) Inspect the index lines on the damper hub and
the inertia member (Fig. 143). If the lines are more
Fig. 138 Position of Ring in Cylinder Bore
1 - PISTON
2 - CYLINDER BORE
3 - DEPTH
Fig. 139 Oil Control Ring/Expander Location in
Groove
1 - OIL CONTROL RING
2 - EXPANDER
3 - PISTON
Fig. 140 Piston Ring Installation Tool
1 - PISTON RING INSTALLATION TOOL
Fig. 141 Piston Ring Orientation
1 - TOP RING
2 - INTERMEDIATE RING
3 - OIL CONTROL RING
9 - 172 ENGINE 5.9L DIESELBR/BE
PISTON RINGS (Continued)

than 1.59 mm (1/16 in.) out of alignment, replace the
damper.
(3) Inspect the rubber member for deterioration or
missing segments (Fig. 144).
INSTALLATION
(1) Install the crankshaft damper and bolts (Fig.
142). Tighten bolts to 125 N´m (92 ft. lbs.) torque.
(2) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
FRONT MOUNT
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the viscous fan/drive assembly (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(3) Raise vehicle on hoist.
(4) Support engine with a screw jack and wood
block.
(5) Loosen the thru-bolt and nut (Fig. 145).
(6) Passenger side mount: Remove the two (2)
transmission oil cooler bracket to engine mount bolts.
(7) Lift the engine SLIGHTLY and remove the four
(4) mount to block bolts.
(8) Remove the mount from the vehicle.
Fig. 142 Crankshaft Damper Removal/Installation
1 - DAMPER
2 - BOLT
Fig. 143 Inspect Index Lines for Alignment
1 - INDEX LINES
2 - HUB
3 - INERTIA MEMBER
Fig. 144 Inspect Damper Rubber Member
Fig. 145 Front Engine MountÐTypical
1 - MOUNT
2 - BOLT (4)
BR/BEENGINE 5.9L DIESEL 9 - 173
VIBRATION DAMPER (Continued)

INSTALLATION
(1) With engine raised SLIGHTLY, position the
engine mount to the block. Install the bolts and
tighten to 149 N´m (110 ft. lbs.) torque.
(2) Install the thru-bolt into the engine mount.
(3) Lower the engine while guiding the mount and
thru-bolt into the frame mounted support cushion
brackets (Fig. 146).
(4) Install the thru-bolt nut and tighten the nut to
88 N´m (65 ft. lbs.) torque.
(5) Passenger side: Install the two (2) transmission
oil cooler bracket to mount bolts. Tighten the bolts to
47 N´m (35 ft. lbs.) torque.
(6) Remove lifting fixture.
(7) Lower the vehicle.
(8) Install the viscous fan/drive assembly (Refer to
7 - COOLING/ENGINE/RADIATOR FAN - INSTAL-
LATION).
(9) Connect the battery negative cables.
REAR MOUNT
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Position a transmission jack in place.
(3) Remove support cushion stud nuts (Fig. 147).
(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 102 N´m (75 ft. lbs.) torque.
(2) Position support cushion to transmission sup-
port bracket. Install stud nuts and tighten to 47 N´m
(35 ft. lbs.) torque.
(3) Using the transmission jack, lower the trans-
mission and support cushion onto the crossmember
(Fig. 50) .
(4) Install the support cushion bolts and tighten to
47 N´m (35 ft. lbs.) torque.
(5) Remove the transmission jack.
(6) Lower the vehicle.
LUBRICATION
DESCRIPTION
NOTE: Refer to (Fig. 148) and (Fig. 149) for circuit
illustrations.
A gear driven gerotor type oil pump is mounted
behind the front gear cover in the lower right portion
on the engine.
OPERATION
A gerotor style oil pump draws oil from the crank-
case through the suction tube and delivers it through
the block where it enters the oil cooler cover and
pressure regulator valve. When oil pressure exceeds
449 kPa (65 PSI), the valve opens exposing the dump
port, which routes excess oil back to the oil sump.
At the same time, oil is directed to a cast in pas-
sage in the oil cooler cover, leading to the oil cooler
element. As the oil travels through the element
plates, it is cooled by engine coolant traveling past
the outside of the plates. It is then routed to the oil
filter head and through a full flow oil filter. If a
plugged filter is encountered, the filter by-pass valve
opens, allowing unfiltered oil to lubricate the engine.
This condition can be avoided by frequent oil and fil-
ter changes, per the maintenance schedules found in
the owners manual. The by-pass valve is calibrated
to open when it sees a pressure drop of more than
344 kPa (50 psi) across the oil filter.
The oil filter head then divides the oil between the
engine and the turbocharger. The turbocharger
receives filtered, cooled and pressurized oil through a
supply line from the filter head. The oil lubricates
the turbocharger and returns to the pan by way of a
drain tube connecting the bottom of the turbocharger
to a pressed in tube in the cylinder block.
Oil is then carried across the block to an angle
drilling which intersects the main oil rifle. The main
Fig. 146 Positioning Engine Front Mounts
1 - ENGINE SUPPORT BRACKET/CUSHION
2 - SUPPORT CUSHION BRACKET
9 - 174 ENGINE 5.9L DIESELBR/BE
FRONT MOUNT (Continued)

oil rifle runs the length of the block and delivers oil
to the crankshaft main journals and valve train. Oil
travels to the crankshaft through a series of transfer
drillings (one for each main bearing) and lubricates a
groove in the main bearing upper shell. From there
another drilling feeds the camshaft main journals.
The piston cooling nozzles are also supplied by the
main bearing upper shell. Crankshaft internal cross-
drillings supply oil to the connecting rod journals.Another series of transfer drillings intersecting the
main oil rifle supply the valve train components. Oil
travels up the drilling, through a hole in the head
gasket, and through a drilling in the cylinder head
(one per cylinder), where it enters the rocker arm
pedestal and is divided between the intake and
exhaust rocker arm. Oil travels up and around the
rocker arm mounting bolt, and lubricates the rocker
shaft by cross drillings that intersect the mounting
bolt hole. Grooves at both ends of the rocker shaft
supply oil through the rocker arm where the oil trav-
els to the push rod and socket balls (Fig. 148) and
(Fig. 149).
Fig. 147 Engine Rear Support Cushion Assembly
BR/BEENGINE 5.9L DIESEL 9 - 175
LUBRICATION (Continued)