change time DODGE RAM 2002 Service Owner's Manual

activates the washer pump/motor, which dispenses
washer fluid onto the windshield glass through the
washer nozzles.
When the ignition switch is in the Accessory or On
positions, battery current from a fuse in the Junction
Block (JB) is provided through a fused ignition
switch output (run-acc) circuit to the wiper motor
park switch, the wiper relay, and the multi-function
switch. The internal circuitry of the multi-function
switch provides a direct hard wired battery current
output to the low speed or high speed brushes of the
wiper motor when the Lo or Hi switch setting is
selected, which causes the wipers to cycle at the
selected speed. The intermittent wipe, and wipe-af-
ter-wash features of the wiper and washer system
are provided by the electronic intermittent wipe logic
circuit within the Central Timer Module (CTM). In
order to provide the intermittent wipe feature, the
CTM monitors the wiper switch state and the wiper
motor park switch state. In order to provide the
wipe-after-wash feature, the CTM monitors both the
washer switch state and the wiper motor park switch
state. When a Delay position is selected with the
multi-function switch control knob, the CTM logic cir-
cuit responds by calculating the correct delay inter-
val. The CTM then energizes the wiper relay by
pulling the relay control coil to ground. The ener-
gized wiper relay directs battery current through the
normally open contact of the relay back through the
internal circuitry of the multi-function switch to the
low speed brush of the wiper motor. The CTM moni-
tors the wiper motor operation through the wiper
park switch sense circuit, which allows the CTM to
determine the proper timing to begin the next wiper
blade sweep. The normal delay intervals are driver
adjustable from about one-half second to about eigh-
teen seconds.
The high-line and premium CTM also provides a
speed sensitive intermittent wipe feature. By moni-
toring vehicle speed messages received from the Pow-
ertrain Control Module (PCM) over the Chrysler
Collision Detection (CCD) data bus network, the
high-line or premium CTM is able to adjust the delay
intervals to compensate for vehicle speed. Above
about sixteen kilometers-per-hour (ten miles-per-
hour) the delay is driver adjustable from about one-
half second to about eighteen seconds. Below about
sixteen kilometers-per-hour (ten miles-per-hour) the
delay times are doubled by the CTM, from about one
second to about thirty-six seconds.
When the Off position of the multi-function switch
wiper control knob is selected, one of two events is
possible. The event that will occur depends upon the
position of the wiper blades on the windshield at the
moment that the Off position is selected. If the wiper
blades are in the down position on the windshieldwhen the Off position is selected, the park switch
that is integral to the wiper motor is closed to ground
and the wiper motor ceases to operate. If the wiper
blades are not in the down position on the windshield
at the moment the Off position is selected, the park
switch is closed to battery current through a fused
ignition switch output (run-acc) circuit. The park
switch sense circuit directs this battery current to
the low speed brush of the wiper motor through the
normally closed contact of the wiper relay and the
internal Off position circuitry of the multi-function
switch. This causes the wiper motor to continue run-
ning until the wiper blades are in the down position
on the windshield and the park switch is again
closed to ground.
When the Wash position of the multi-function
switch is selected, the Wash position circuitry within
the switch directs battery current to the washer
pump/motor. The CTM monitors the washer switch
state through a washer switch sense input. When the
washer switch is closed with the wiper system turned
Off, the CTM operates the wiper motor through the
wiper relay in the same manner as it does to provide
the Delay mode operation. After the state of the
washer switch changes to open, the CTM monitors
the wiper motor through the wiper park switch sense
circuit, which allows the CTM to monitor the number
of wiper blade sweeps.
Proper testing of the CTM, the PCM, or the CCD
data bus vehicle speed messages requires a DRBIIIt
scan tool. Refer to the appropriate diagnostic infor-
mation. Refer to the owner's manual in the vehicle
glove box for more information on the features and
operation of the wiper and washer system.
DIAGNOSIS AND TESTING - WIPER &
WASHER SYSTEM
WIPER SYSTEM
The diagnosis found here addresses an electrically
inoperative wiper system. If the wiper motor oper-
ates, but the wipers do not move on the windshield,
replace the faulty wiper module. If the wipers oper-
ate, but chatter, lift, or do not clear the glass, clean
and inspect the wiper system components as
required. (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS - INSPECTION) and (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS - CLEANING). Refer to
the appropriate wiring information. The wiring infor-
mation includes wiring diagrams, proper wire and
connector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
The following tests will help to diagnose the hard
wired components and circuits of the wiper system.
BR/BEWIPERS/WASHERS 8R - 3
WIPERS/WASHERS (Continued)

All Ram truck models have two 50 centimeter
(19.69 inch) wiper blades with non-replaceable rub-
ber elements (squeegees). These wiper blades also
include an anti-lift feature. The wiper blades cannot
be adjusted or repaired. If faulty, worn, or damaged
the entire wiper blade unit must be replaced.
OPERATION
The wiper blade is moved back and forth across the
glass by the wiper arms when the wipers are being
operated. The wiper blade superstructure is the flex-
ible frame that grips the wiper blade element and
evenly distributes the force of the spring-loaded
wiper arm along the length of the element. The com-
bination of the wiper arm force and the flexibility of
the superstructure makes the element conform to
and maintain proper contact with the glass, even as
the blade is moved over the varied curvature found
across the glass surface. The wiper element flexor
provides the claws of the blade superstructure with a
rigid, yet flexible component on the element which
can be gripped. The rubber element is designed to be
stiff enough to maintain an even cleaning edge as it
is drawn across the glass, but resilient enough to
conform to the glass surface and flip from one clean-
ing edge to the other each time the wiper blade
changes directions.
REMOVAL
NOTE: The driver side and passenger side wiper
blades are not interchangeable. The driver side
wiper blade has an extra bridge and eight pairs of
claws securing the wiper element. The passenger
side wiper blade has six pairs of claws securing the
wiper element. The notched retainer end of both
wiper elements should always be oriented towards
the end of the wiper blade that is nearest to the
wiper pivot.
(1) Turn the wiper control knob on the end of the
multi-function switch control stalk to the On posi-
tion. Cycle the wiper blades to a convenient working
location on the windshield by turning the ignition
switch to the On and Off positions.
(2) Lift the wiper arm to raise the wiper blade and
element off of the glass.
(3) To remove the wiper blade from the wiper arm,
push the pivot block latch release tab under the tip
of the arm and slide the blade away from the tip
towards the pivot end of the arm far enough to dis-
engage the pivot block from the hook (Fig. 7).
(4) Extract the hook formation on the tip of the
wiper arm from the opening in the wiper blade
superstructure ahead of the wiper blade pivot block/
latch unit.CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(5) Gently lower the wiper arm tip onto the glass.
INSTALLATION
NOTE: The driver side and passenger side wiper
blades are not interchangeable. The driver side
wiper blade has an extra bridge and eight pairs of
claws securing the wiper element. The passenger
side wiper blade has six pairs of claws securing the
wiper element. The notched retainer end of both
wiper elements should always be oriented towards
the end of the wiper blade that is nearest to the
wiper pivot.
(1) Lift the wiper arm off of the windshield glass.
(2) Position the wiper blade near the hook forma-
tion on the tip of the arm with the notched retainer
for the wiper element oriented towards the end of the
wiper arm that is nearest to the wiper pivot.
(3) Insert the hook formation on the tip of the
wiper arm through the opening in the wiper blade
superstructure ahead of the wiper blade pivot block/
latch unit far enough to engage the pivot block with
the hook (Fig. 7).
(4) Slide the wiper blade pivot block/latch up into
the hook formation on the tip of the wiper arm until
the latch release tab snaps into its locked position.
(5) Gently lower the wiper blade onto the glass.
WIPER MODULE
DESCRIPTION
The wiper module is secured with screws to the
cowl plenum panel and concealed within the cowl
plenum area beneath the cowl plenum cover/grille
panel. The ends of the wiper pivot shafts that pro-
trude through dedicated openings in the cowl plenum
Fig. 7 Wiper Blade Remove/Install - Typical
1 - RELEASE TAB
BR/BEWIPERS/WASHERS 8R - 13
WIPER BLADE (Continued)

(14) Apply MopartSilicone Rubber Adhesive Seal-
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 24).
Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
(15) Install new front crankshaft oil seal (Refer to
9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION).
(16) Immediately install the oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(17) If the transmission was removed, install the
transmission. Refer to 21 - TRANSMISSION/TRANS-
AXLE.
CRANKSHAFT MAIN
BEARINGS
DESCRIPTION
Main bearings (Fig. 25) are located in the cylinder
block. One half of the main bearing is located in the
crankshaft main bore the other half of the matching
bearing is located in the main bearing cap. there are
five main bearings. Number three main bearing is
flanged, this flange controls crankshaft thrust.
OPERATION
The main bearings encircle the crankshaft main
bearing journals, this aligns the crankshaft to the
centerline of the engine and allows the crankshaft to
turn without wobbling or shaking therefore eliminat-ing vibration. The main bearings are available in
standard and undersizes.
STANDARD PROCEDUREÐCRANKSHAFT MAIN
BEARING FITTING
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter-
changeable. Lower main bearing halves of No.2 and 4
are interchangeable.
Upper and lower No.3 bearing halves are flanged
to carry the crankshaft thrust loads. They are NOT
interchangeable with any other bearing halves in the
engine (Fig. 26). Bearing shells are available in stan-
dard and the following undersizes: Never install an
undersize bearing that will reduce clearance below
specifications.
Main Bearing Undersize Availability List
²0.25 mm (0.001 inch)
²0.051 mm (0.002 inch)
²0.076 mm (0.003 inch)
²0.254 mm (0.010 inch)
²0.305 mm (0.012 inch)
REMOVAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump from the rear main bear-
ing cap (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - REMOVAL).
(3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 27).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
Fig. 24 Apply Sealant to Bearing Cap to Block Joint
1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE
TIP
2 - SEALANT APPLIED
3 - CYLINDER BLOCK
4 - REAR MAIN BEARING CAP
Fig. 25 Main Bearing Orientation
BR/BEENGINE 5.9L 9 - 31
CRANKSHAFT (Continued)

(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing the
assemblies from the engine, rotate crankshaft so that
the connecting rod is centered in cylinder bore and at
BDC.Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mat-
ing rod.
CLEANING
Clean the piston and connecting rod assembly
using a suitable solvent.
INSPECTION
Check the connecting rod journal for excessive
wear, taper and scoring (Refer to 9 - ENGINE/EN-
GINE BLOCK/CONNECTING ROD BEARINGS -
STANDARD PROCEDURE).
Check the connecting rod for signs of twist or bend-
ing.
Check the piston for taper and elliptical shape
before it is fitted into the cylinder bore (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECT-
ING ROD - STANDARD PROCEDURE).
Check the piston for scoring, or scraping marks in
the piston skirts. Check the ring lands for cracks
and/or deterioration.
INSTALLATION
(1) Be sure that compression ring gaps are stag-
gered so that neither is in line with oil ring rail gap.
(2) Before installing the ring compressor, be sure
the oil ring expander ends are butted and the rail
gaps located properly (Fig. 38).(3) Immerse the piston head and rings in clean
engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench
(part of Tool C-385).Be sure position of rings
does not change during this operation.
(4) Install connecting rod bolt protectors on rod
bolts. The long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal.
(7) The notch, or groove, on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, con-
necting rod cap, and cylinder bore number are the
same. Install nuts on cleaned and oiled rod bolts and
tighten nuts to 61 N´m (45 ft. lbs.) torque.
(9) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(10) Install the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION).
(11) Install the engine into the vehicle (Refer to 9 -
ENGINE - INSTALLATION).
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Measurement of end gaps:
(a) Measure piston ring gap 2 in. from bottom of
cylinder bore. An inverted piston can be used to
push the rings down to ensure positioning rings
squarely in the cylinder bore before measuring.
(b) Insert feeler gauge in the gap. The top com-
pression ring gap should be between 0.254-0.508
mm (0.010-0.020 in.). The second compression ring
gap should be between 0.508-0.762 mm
(0.020-0.030 in.). The oil ring gap should be 0.254-
1.270 mm (0.010-0.050 in.).
(c) Rings with insufficient end gap may be prop-
erly filed to the correct dimension. Rings with
excess gaps should not be used.
(2) Install rings, and confirm ring side clearance:
(a) Install oil rings being careful not to nick or
scratch the piston. Install the oil control rings
according to instructions in the package. It is not
necessary to use a tool to install the upper and
Fig. 38 Proper Ring Installation
1 - OIL RING SPACER GAP
2 - SECOND COMPRESSION RING GAP OIL RING RAIL GAP
(TOP)
3 - OIL RING RAIL GAP (BOTTOM)
4 - TOP COMPRESSION RING GAP
BR/BEENGINE 5.9L 9 - 39
PISTON & CONNECTING ROD (Continued)

(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24km (15 miles), and
repeat previous step.
(5) If the oil leak source is not positively identified
at this time, proceed with the air leak detection test
method as follows:
(6) Disconnect the breather cap to air cleaner hose
at the breather cap end. Cap or plug breather cap
nipple.
(7) Remove the PCV valve from the cylinder head
cover. Cap or plug the PCV valve grommet.
(8) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(9) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provide the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
(10) If the leakage occurs at the rear oil seal area,
refer to the section, Inspection for Rear Seal Area
Leak.
(11) If no leaks are detected, turn off the air sup-
ply and remove the air hose and all plugs and caps.
Install the PCV valve and breather cap hose. Proceed
to next step.
(12) Clean the oil off the suspect oil leak area
using a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE
(1) Remove oil pressure sending unit.
(2) Install Oil Pressure Line and Gauge Tool
C-3292. Start engine and record pressure. (Refer to 9
- ENGINE - SPECIFICATIONS).
OIL
STANDARD PROCEDURE - ENGINE OIL
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the right
front of the engine, left of the generator (Fig. 50).
CRANKCASE OIL LEVEL INSPECTION
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 levels are indicated between the ADD
and SAFE marks on the engine oil dipstick.
(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) Install 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 ADD mark on
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. This infor-
mation can be found in the owner's manual.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist vehicle.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
Fig. 50 Oil Level Indicator Location
1 - CYLINDER HEAD COVER
2 - ENGINE OIL FILL CAP
3 - DIPSTICK
4 - ENGINE OIL FILTER
5 - FILTER BOSS
BR/BEENGINE 5.9L 9 - 45
LUBRICATION (Continued)

CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING ROD
BEARING FITTING
Fit all rods on a bank until completed. DO NOT
alternate from one bank to another, because connect-
ing rods and pistons are not interchangeable from
one bank to another.
The bearing caps are not interchangeable and
should be marked at removal to ensure correct
assembly.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing shell,
be certain that the V-groove in the shell is in line
with the V-groove in the cap. This provides lubrica-
tion of the cylinder wall in the opposite bank.
The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and
caps.
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 in.).
Bearings are available in 0.025 mm (0.001 in.), 0.051
mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 mm
(0.010 in.) and 0.305 mm (0.012 in.) undersize.Install the bearings in pairs. DO NOT use a new
bearing half with an old bearing half. DO NOT
file the rods or bearing caps.
CRANKSHAFT
REMOVAL
When a crankshaft is replaced, all main and con-
necting rod bearings should be replaced with new
bearings. Therefore, selective fitting of the bearings
is not required when a crankshaft and bearings are
replaced.
(1) Remove the oil pan and oil pickup tube (refer
to Oil Pan in this section for correct procedure).
(2) Remove the timing chain cover and gasket.
Remove and discard the front crankshaft oil seal and
cover gasket.
(3) Remove Transmission (refer to Group 21,
Transmission).
(4) Remove the rear seal retainer (refer to Crank-
shaft Rear Seal Retainer in this section for correct
procedure).
(5) Identify main bearing caps before removal (Fig.
30) . Remove bearing caps and lower bearings one at
a time.
(6) Remove the connecting rod bearing caps.
(7) Lift the crankshaft straight out of the block.
Fig. 29 Cylinder Head Cover
1 - CYLINDER HEAD COVER
2 - CYLINDER HEAD COVER GASKET
Fig. 30 Main Bearing Identification
1 - MAIN BEARING CAP
2 - UPPER MAIN BEARINGS
3 - CRANKSHAFT
4 - LOWER MAIN BEARINGS
BR/BEENGINE 8.0L 9 - 87
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

(8) Remove the upper main bearings from the
block.
INSTALLATION
When a crankshaft is replaced, all main and con-
necting rod bearings should be replaced with new
bearings. Therefore, selective fitting of the bearings
is not required when a crankshaft and bearings are
replaced.
NOTE: Lubricate crankshaft main bearings with
clean engine oil.
(1) Position upper main bearings into block.
(2) Position the crankshaft into the cylinder block.
(3) Lubricate the main journals with clean engine
oil. Install upper main bearings, caps and bolts. Fol-
low the 2 step tightening sequence, starting with
main bearing cap 1.
(4) Lubricate the connecting rod bearings and jour-
nals with clean engine oil. Carefully install connect-
ing rods to the crankshaft.
(5) Using Special Tool 8359 Seal Installer install
new oil into oil seal retainer.
(6) Using Special Tool 6687 Guide, install the rear
seal retainer with a new gasket.
(7) Install the timing chain cover with a new gas-
ket and oil seal.
(8) Prime oil pump by squirt 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) Apply a rearward axial load of 667 N (150
lbs-f) on crankshaft centerline, driving No.3 main cap
and thrust bearing against No.3 bulkhead. Repeat
procedure, driving crankshaft forward to align rear
flange of thrust bearings in a common plane. Front
face of No.1 main cap must not extend forward in
front of face of No.1 bulkhead.
(10) Install the oil pickup tube. Tighten the bolts
to 16 N´m (144 in. lbs.) torque.
(11) Install the oil pan.
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDUREÐFITTING
CRANKSHAFT MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter-
changeable. All lower main bearing halves are inter-
changeable. Upper main bearing halves of No. 2, 4,
and 5 are interchangeable. Upper main bearinghalves of No. 1 and 6 are interchangeable, this also
applies to the lower bearing halves.
The No.3 main bearing is flanged to carry the
crankshaft thrust loads. This bearing is NOT inter-
changeable with any other bearing halves in the
engine. Bearing shells are available in standard and
the following undersizes: 0.25 mm (0.001 inch), 0.051
mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm
(0.010 inch) and 0.305 mm (0.012 inch). Never install
an undersize bearing that will reduce clearance
below specifications.
REMOVAL
(1) Remove the oil pan and oil pump pick-up tube
(Refer to 9 - ENGINE/LUBRICATION/OIL PAN -
REMOVAL).
(2) Identify bearing caps before removal. Remove
bearing caps one at a time.
(3) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 31).
(4) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
INSTALLATION
Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight-
ened. All bearing capbolts removed during service
procedures are to be cleaned and oiled before instal-
lation.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
Fig. 31 Upper Main Bearing Removal and
Installation with Tool C-3059
1 - SPECIAL TOOL C-3059
2 - BEARING
3 - SPECIAL TOOL C-3059
4 - BEARING
9 - 88 ENGINE 8.0LBR/BE
CRANKSHAFT (Continued)

The acceptable levels are indicated between the ADD
and SAFE marks on the engine oil dipstick.
(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) Install 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 ADD mark on
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. This infor-
mation can be found in the owner's manual.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist vehicle.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Install drain plug in crankcase.
(7) Change oil filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL).
(8) Lower vehicle and fill crankcase with specified
type (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION) and amount of
engine oil (Refer to LUBRICATION & MAINTE-
NANCE - SPECIFICATIONS).
(9) Install oil fill cap.
(10) Start engine and inspect for leaks.
(11) Stop engine and inspect oil level.
OIL FILTER
REMOVAL
All engines are equipped with a high quality full-
flow, disposable type oil filter. DaimlerChrysler Cor-
poration recommends a Mopartor equivalent oil
filter be used.
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
(3) Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss (Fig. 54).(4) When filter separates from adapter nipple, tip
gasket end upward to minimize oil spill. Remove fil-
ter from vehicle.
(5) With a wiping cloth, clean the gasket sealing
surface (Fig. 52) of oil and grime.
(6) Install new filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - INSTALLATION).
INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, (Fig. 55) hand
tighten filter one full turn, do not over tighten.
(3) Add oil (Refer to 9 - ENGINE/LUBRICATION/
OIL - STANDARD PROCEDURE).
OIL PAN
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise vehicle.
Fig. 54 Oil Filter RemovalÐTypical
1 - ENGINE OIL FILTER
2 - OIL FILTER WRENCH
Fig. 55 Oil Filter Sealing SurfaceÐTypical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
9 - 102 ENGINE 8.0LBR/BE
OIL (Continued)

(8) Connect the engine harness connector and
ground cable to the PDC.
(9) Connect the vacuum pump supply hose.
(10) Connect the APPS connector (Fig. 5).
(11) Install the APPS assembly bracket to the cyl-
inder head bracket.
(12) Install the throttle linkage cover.
(13) Connect the power steering pressure and
return lines.
(14) Connect the passenger battery ground cable to
the engine block. Tighten the bolt to 77 N´m (57 ft.
lbs.) torque.
(15) Connect the engine block heater connector.
(16) Connect the a/c compressor electrical connec-
tors.
(17) Install the charge air cooler and a/c condenser
(if a/c equipped). Install and tighten the charge air
cooler mounting bolts to 2 N´m (17 in. lbs.) torque.
(18) Connect the charge air cooler piping. Torque
all clamps to 8 N´m (72 in. lbs.) torque.
(19) Connect the a/c refrigerant lines to the a/c
condenser (if equipped).
(20) Install the front bumper (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT
BUMPER - INSTALLATION).(21) Install the radiator upper support panel.
(22) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
(23) Connect the transmission quick-connect oil
cooler lines to the radiator. Push together until an
audible ªclickº is heard. Verify connection by pulling
apart.
(24) Raise vehicle.
(25) Connect a/c compressor suction/discharge hose
(if a/c equipped).
(26) Install the radiator lower hose and clamps.
(27) Install the starter motor (Refer to 8 - ELEC-
TRICAL/STARTING/STARTER MOTOR - INSTAL-
LATION).
(28) Install the transmission and transfer case (if
equipped).
(29) Connect the exhaust pipe to the turbocharger
elbow (Fig. 3). Torque the bolts to 34 N´m (25 ft. lbs.)
torque.
(30) Connect the transmission auxiliary oil cooler
lines (if equipped).
(31) Lower the vehicle
(32) Connect the heater core supply and return
hoses.
(33) Install the cooling fan and shroud at the same
time (Refer to 7 - COOLING/ENGINE/RADIATOR
FAN - INSTALLATION).
(34) Install the coolant recovery bottle to the fan
shroud (Fig. 2) and connect the hose to the radiator
filler neck.
(35) Install the windshield washer bottle to the fan
shroud and connect the pump supply hose and elec-
trical connections.
(36) Install the radiator upper hose and clamps.
(37) Change oil filter and install new engine oil.
(38) Fill cooling system with coolant (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(39) Connect battery negative cables.
(40) Perform the fuel line air bleed procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(41) Start engine and inspect for engine oil, cool-
ant, and fuel leaks.
INSTALLATIONÐCRANKCASE BREATHER
VAPOR CANISTER
(1) Position vapor canister with strap over stud on
engine front cover. Install retaining nut. Tighten nut
10 N´m ( 89 in. lbs.).
(2) If removed, position hose onto crankcase
breather, then position clamp.
(3) Position lower portion of hose into vapor canis-
ter, then install and tighten cap.
Fig. 9 Crankcase Breather Vapor Canister
1 - ENGINE FRONT COVER STUD
2 - STRAP
3 - VAPOR CANISTER
4 - NUT
5 - CAP
6 - CRANKCASE BREATHER
7 - CLAMP
8 - HOSE
9 - 126 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (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)