DODGE RAM 2002 Service Repair Manual

Fig. 148 Lubrication System Circulation
1 - TO FILTER
2 - FROM FILTER
3 - TO MAIN OIL RIFLE
4 - CLOSED
5 - OPEN
6 - TO COOLER
7 - FROM PUMP8 - CLOSED
9 - OPEN
10 - TO OIL SUMP
11 - OIL DRAIN
12 - OIL SUPPLY
9 - 176 ENGINE 5.9L DIESELBR/BE
LUBRICATION (Continued)

Fig. 149 Lubrication System CirculationÐCont'd
BR/BEENGINE 5.9L DIESEL 9 - 177
LUBRICATION (Continued)

DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE
(1) Remove the engine oil pressure sensor and
install Oil Pressure Line and Gauge Tool C-3292 with
a suitable adapter.
(2) Start engine and warm to operating tempera-
ture.
(3) Record engine oil pressure and compare with
engine oil pressure chart.
CAUTION: If engine oil pressure is zero at idle, DO
NOT RUN THE ENGINE.
Engine Oil Pressure (MIN)
At Idle 103.4 kPa (15 psi)
At 2000 rpm 310.2 kPa (45 psi)
If minimum engine oil pressure is below these
ranges, (Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
(4) Remove oil pressure gauge and install the oil
pressure sensor. Tighten the sensor to 16 N´m (144
in. lbs.) torque.
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL LEVEL
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
To ensure proper lubrication of an engine, the
engine oil must be maintained at an acceptable level.
The acceptable oil level is in the SAFE RANGE on
the engine oil dipstick (Fig. 150).
Unless the engine has exhibited loss of oil pres-
sure, run the engine for about five minutes before
checking oil level. Checking engine oil level of a cold
engine is not accurate.
(1) Position vehicle on level surface.(2) With engine OFF, allow approximately ten min-
utes for oil to settle to bottom of crankcase, remove
engine oil dipstick.
(3) Wipe dipstick clean.
(4) Replace dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the SAFE RANGE
area on the dipstick.
(7) Replace dipstick
STANDARD PROCEDURE - ENGINE OIL
SERVICE
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
NOTE: Change engine oil and filter at intervals
specified in the owner's manual.
(1) Operate the engine until the water tempera-
ture reaches 60ÉC (140ÉF). Shut the engine off.
(2) Use a container that can hold at least 14 liters
(15 quarts) to hold the used oil. Remove the oil drain
plug and drain the used engine oil into the container.
1 - ROCKER ARM
2 - ROCKER SHAFT
3 - PEDESTAL
4 - FROM MAIN OIL RIFLE
5 - TO VALVE TRAIN
6 - MAIN OIL RIFLE
7 - FROM MAIN OIL RIFLE
8 - TO CAMSHAFT9 - TO PISTON COOLING NOZZLE
10 - FROM OIL COOLER
11 - CRANKSHAFT MAIN JOURNAL
12 - ROD JOURNAL
13 - TO ROD BEARING
14 - MAIN OIL RIFLE
Fig. 150 Oil Level Indicator (Dipstick)
1 - ADD OIL MARK
2 - O-RING
3 - SAFE RANGE
9 - 178 ENGINE 5.9L DIESELBR/BE
LUBRICATION (Continued)

(3) Always check the condition of the used oil. This
can give you an indication of engine problems that
might exist.
²Thin, black oil indicates fuel dilution.
²Milky discoloration indicates coolant dilution.
(4) Clean the area around the oil filter head.
Remove the filter (Refer to 9 - ENGINE/LUBRICA-
TION/OIL FILTER - REMOVAL).
(5) Install new oil filter (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION).
(6) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and seal-
ing surface on the oil pan and drain plug.
(7) Install the drain plug. Tighten the plug to 50
N´m (37 ft. lbs.) torque.
(8) Use only High-Quality Multi-Viscosity lubricat-
ing oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(9) Fill the engine with the correct grade of new oil
(Refer to LUBRICATION & MAINTENANCE/FLUID
CAPACITIES - SPECIFICATIONS).
(10) Start the engine and operate it at idle for sev-
eral minutes. Check for leaks at the filter and drain
plug.
(11) Stop engine. Wait several minutes to allow the
oil to drain back to the pan and check the level
again.
USED ENGINE OIL DISPOSAL Care should be
exercised when disposing of used engine oil after
it has been drained from a vehicle's engine.
OIL COOLER & LINES
CLEANING AND INSPECTION
Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. If the element leaks, replace the
element.
OIL FILTER
REMOVAL
(1) Clean the area around the oil filter head.
Remove the filter using a 90-95 mm filter wrench.
(2) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter
head. Make sure it is removed.
INSTALLATION
(1) Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine.
(2) Apply a light film of lubricating oil to the seal-
ing surface before installing the filter.
CAUTION: Mechanical over-tightening may distort
the threads or damage the filter element seal.
(3) Install the filter until it contacts the sealing
surface of the oil filter adapter. Tighten filter an
additional ó turn.
OIL PAN
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove transmission and transfer case (if
equipped).
(4) Remove flywheel.
(5) Disconnect starter cables from starter motor.
(6) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
(7) Drain the engine oil (Refer to 9 - ENGINE/LU-
BRICATION/OIL - STANDARD PROCEDURE).
(8) Install the oil pan drain plug with a new seal-
ing washer and tighten to 60 N´m (44 ft. lbs.) torque.
(9) Remove oil pan bolts, break the pan to block
seal, and lower pan slightly and remove oil suction
tube fasteners.
(10) Remove oil pan and suction tube (Fig. 151).
CLEANING
Remove all gasket material from the oil pan and
cylinder block sealing surfaces. Extra effort may be
required around T-joint areas. Clean oil pan and
flush suction tube with a suitable solvent.
INSPECTION
Inspect the oil pan, suction tube, and tube braces
for cracks and damage. Replace any defective compo-
nent. Inspect the oil drain plug and drain hole
threads. Inspect the oil pan sealing surface for
straightness. Repair any minor imperfections with a
ball-peen hammer. Do not attempt to repair an oil
pan by welding.
BR/BEENGINE 5.9L DIESEL 9 - 179
OIL (Continued)

INSTALLATION
(1) Fill the T-joint between the pan rail/gear hous-
ing and pan rail/rear seal retainer with sealant. Use
MopartSilicone Rubber Adhesive Sealant or equiva-
lent.
(2) Apply a film of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the oil pan gasket.
Apply sealant only to the side that faces the oil pan.
(3) Place suction tube in oil pan and guide them
into place (Fig. 151). Using a new tube to oil pump
gasket, install and tighten the suction tube bolts by
hand. Starting with the oil pump inlet bolts, tighten
the bolts to 24 N´m (18 ft. lbs.) torque. Tighten the
remaining tube brace bolts to 24 N´m (18 ft. lbs.)
torque.
(4) Starting in the center and working outward,
tighten the oil pan bolts to 24 N´m (18 ft. lbs.)
torque.
(5) Install the flywheel housing assembly with the
starter motor attached and tighten bolts to 60 N´m
(44 ft. lbs.) torque.
(6) Connect starter motor cables.
(7) Install transmission and transfer case (if
equipped).
(8) Lower vehicle.
(9) Install battery negative cables.
(10) Fill the crankcase with new engine oil.
(11) Start engine and check for leaks. Stop engine,
check oil level, and adjust, if necessary.
OIL PRESSURE RELIEF VALVE
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the threaded plug, spring and plunger
(Fig. 152). Insert a finger or a seal pick to lift the
plunger from the bore.
NOTE: If the plunger is stuck in the bore, it will be
necessary to remove the filter head.
CLEANING
(1) Clean the regulator spring and plunger with a
suitable solvent and blow dry with compressed air. If
the plunger bore requires cleaning, it is necessary to
remove the oil filter head to avoid getting debris into
the engine.
INSPECTION
Inspect the plunger and plunger bore for cracks
and excessive wear. Polished surfaces are acceptable.
Verify that the plunger moves freely in the bore.
Check the spring for height and load limitations
(Fig. 153) . Replace the spring if out of limits shown
in the figure.
INSTALLATION
(1) Install the plunger, spring, and plug as shown
in (Fig. 152). Tighten the plug to 80 N´m (60 ft. lbs.)
torque.
(2) Connect the battery negative cables.
(3) Start the engine and verify that it has oil pres-
sure.
Fig. 151 Oil Pan, Suction Tube and Gasket
1 - GASKET
2 - SUCTION TUBE
3 - OIL PAN
Fig. 152 Oil Pressure Regulator
1 - OIL FILTER
2 - PLUG
3 - GASKET
4 - SPRING
5 - VALVE
9 - 180 ENGINE 5.9L DIESELBR/BE
OIL PAN (Continued)

OIL PRESSURE SENSOR/
SWITCH
REMOVAL
(1) Disconnect the battery negative cables.
(2) Disconnect the oil pressure sensor connector
(Fig. 154).
(3) Using a suitable socket, remove the oil pres-
sure sensor from the block (counter-clockwise).
INSTALLATION
(1) If the sensor is not being replaced, inspect the
o-ring (Fig. 155) and replace if necessary.
(2) Install the oil pressure sensor and tighten to 16
N´m (144 in. lbs.) torque.(3) Connect the battery negative cables.
(4) Start engine and check for oil leaks at the sen-
sor.
OIL PUMP
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove fan/drive assembly (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(3) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove the fan support/hub assembly.
(5) Remove crankshaft damper (Fig. 156) (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(6) Remove the gear housing cover (Fig. 157)
(Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUS-
ING COVER - REMOVAL).
(7) Remove the four mounting bolts and pull the
pump from the bore in the cylinder block (Fig. 158).
CLEANING
Clean all parts in solvent and dry with compressed
air. Clean the old sealer residue from the back of the
gear housing cover and front of the gear housing.
INSPECTION
Disassemble and inspect the oil pump as fol-
lows:
(1) Visually inspect the lube pump gears for chips,
cracks or excessive wear.
Fig. 155 Oil Pressure Sensor and
1 - ENGINE OIL PRESSURE SENSOR
2 - O-RING
Fig. 153 Oil Pressure Regulator Spring Check
Fig. 154 Oil Pressure Sensor Location
1 - ENGINE OIL PRESSURE SENSOR
2 - ELECTRIAL CONNECTOR
3 - ECM
BR/BEENGINE 5.9L DIESEL 9 - 181
OIL PRESSURE RELIEF VALVE (Continued)

(2) Remove the back plate (Fig. 159).
(3) Mark TOP on the gerotor planetary using a felt
tip pen (Fig. 159).
(4) Remove the gerotor planetary (Fig. 159).
Inspect for excessive wear or damage. Inspect the
pump housing and gerotor drive for damaged and
excessive wear.
(5) Install the gerotor planetary in the original
position. The chamfer must be on the O.D. and down.
(6) Measure the tip clearance (Fig. 160). Maximum
clearance is 0.1778 mm (0.007 inch). If the oil pump
is out of limits, replace the pump.
(7) Measure the clearance of the gerotor drive/
gerotor planetary to port plate (Fig. 161). Maximum
clearance is 0.127 mm (0.005 inch). If the oil pump is
out of limits, replace the pump.(8) Measure the clearance of the gerotor planetary
to the body bore (Fig. 162). Maximum clearance is
0.381 mm (0.015 inch). If the oil pump is out of lim-
its, replace the pump.
(9) Measure the gears backlash (Fig. 163). The
limits of a used pump is 0.075- 0.85 mm (0.0296-
0.0335 inch). If the backlash is out of limits, replace
the oil pump.
(10) Install the back plate.
INSTALLATION
(1) Lubricate the pump with clean engine oil. Fill-
ing the pump with clean engine oil during installa-
tion will help to prime the pump at engine start up.
(2) Verify the idler gear pin is installed in the
locating bore in the cylinder block.
Fig. 156 Crankshaft Damper Removal/Installation
1 - DAMPER
2 - BOLT
Fig. 157 Gear Housing and Cover
1 - GEAR HOUSING
2 - GEAR HOUSING COVER
Fig. 158 Oil Pump Removal/Installation
1 - OIL PUMP
2 - BOLT (4)
Fig. 159 Gerotor Planetary and Gerotor
1 - OIL PUMP BACK PLATE
2 - GEROTOR
3 - GEROTOR PLANETARY
9 - 182 ENGINE 5.9L DIESELBR/BE
OIL PUMP (Continued)

(3) Install the pump (Fig. 158). Tighten the oil
pump mounting bolts in two steps, in the sequence
shown in (Fig. 164).
²Step 1ÐTighten to 5 N´m (44 in. lbs.) torque.
²Step 2ÐTighten to 24 N´m (18 ft. lbs.) torque.
(4) The back plate on the pump seats against the
bottom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump
will not touch the cylinder block.(5) Measure the idler gear to pump drive gear
backlash and the idler gear to crankshaft gear back-
lash (Fig. 165). The backlash should be 0.75- 0.85
mm (0.0296-0.0335 inch). If the backlash is out of
limits, replace the oil pump.
(6) If the adjoining gear moves when you measure
the backlash, the reading will be incorrect.
Fig. 160 Measuring Tip Clearance
1 - FEELER GAUGE
Fig. 161 Measuring Gerotor to Port Plate Clearance
1 - PORT PLATE
2 - GEROTOR
Fig. 162 Measuring Gerotor Planetary to Body Bore
Clearance
1 - BODY BORE
2 - GEROTOR PLANETARY
Fig. 163 Measure Gear Backlash
1 - OIL PUMP DRIVE GEAR
2 - IDLER GEAR
3 - BACKLASH
4 - BACKLASH
Fig. 164 Oil Pump Mounting Bolt Torque Sequence
Fig. 165 Idler Gear to Pump Drive Gear and
Crankshaft Gear Backlash
BR/BEENGINE 5.9L DIESEL 9 - 183
OIL PUMP (Continued)

(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)