roof DODGE RAM 2002 Service Owner's Manual

INSTALLATION
(1) If previously removed, install the push rods in
their original location (Fig. 62).Verify that they
are seated in the tappets.
(2) Lubricate the valve tips and install the cross-
heads in their original locations.
(3) Lubricate the crossheads and push rod sockets
and install the rocker arms and pedestals (Fig. 60) in
their original locations. Tighten bolts to 36 N´m (27
ft. lbs.) torque.
(4)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
(5) Install cylinder head cover and reusable gasket
(Fig. 59) (Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(6) Connect battery negative cables.
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER BLOCK
REFACING
(1) The combustion deck can be refaced twice. The
first reface should be 0.25 mm (0.0098 inch). If addi-
tional refacing is required, an additional 0.25 mm
(0.0098 inch) can be removed. Total allowed refacing
is 0.50 mm (0.0197 inch) - (Fig. 68).
(2) The upper right corner of the rear face of the
block must be stamped with a X when the block is
refaced to 0.25 mm (0.0098 inch). A second X must be
stamped beside the first when the block is refaced to
0.50 mm (0.0197 inch) - (Fig. 69).
(3) Consult the parts catalog for the proper head
gaskets which must be used with refaced blocks to
ensure proper piston-to-valve clearance.
STANDARD PROCEDURE - CYLINDER BORE -
DE-GLAZE
(1) New piston rings may not seat in glazed cylin-
der bores.
(2) De-glazing gives the bore the correct surface
finish required to seat the rings. The size of the bore
is not changed by proper de-glazing.
(3) Cover the lube holes in the top of the block
with waterproof tape.
(4) A correctly honed surface will have a cross-
hatch appearance with the lines at 15É to 25É angles
(Fig. 70). For the rough hone, use 80 grit honing
stones. To finish hone, use 280 grit honing stones.
(5) Use a drill, a fine grit Flex-hone and a mixture
of equal parts of mineral spirits and SAE 30W engine
oil to de-glaze the bores.(6) The crosshatch angle is a function of drill
speed and how fast the hone is moved vertically (Fig.
71).
(7) Vertical strokes MUST be smooth continuous
passes along the full length of the bore (Fig. 71).
(8) Inspect the bore after 10 strokes.
(9) Use a strong solution of hot water and laundry
detergent to clean the bores. Clean the cylinder bores
immediately after de-glazing.
Fig. 68 Refacing Dimensions of the Cylinder Block
CYLINDER BLOCK REFACING DIMENSIONS
DIMENSION(A(
1st Reface 0.25mm (0.0098 in.)
2nd Reface 0.25mm (0.0098 in.)
Dim (A) Total 0.50 mm (0.0197 in.)
DIMENSION(B(
Dim.9B9(STD.)323.00 mm   0.10
mm(12.7165 in.  
0.0039 in.)
1st Reface322.75 mm   0.10
mm(12.7067 in.  
0.0039 in.)
2nd Reface322.50 mm   0.10
mm(12.6968 in.  
0.0039 in.)
Fig. 69 Stamp Block after Reface
9 - 148 ENGINE 5.9L DIESELBR/BE
ROCKER ARM / ADJUSTER ASSY (Continued)

ROOF PANEL Ð CLUB CAB
BR/BEBODY 23 - 31
BODY (Continued)

ROOF PANEL Ð QUAD CAB
23 - 32 BODYBR/BE
BODY (Continued)

ROOF PANEL - REG CAB
23 - 40 BODYBR/BE
BODY (Continued)

STRUCTURAL ADHESIVE LOCATIONS
ROOF PANELS Ð REGULAR CAB
23 - 44 BODYBR/BE
BODY (Continued)

CAB REAR PANEL
ROOF PANEL
BR/BEBODY 23 - 53
BODY (Continued)

BODY GAP AND FLUSH MEASUREMENTS
REGULAR CAB
NOTE: All measurements are in MM.
REGULAR CAB
DESCRIPTION GAP FLUSH
A Grille to Fascia 19.0 +/- 3.0 N/A
B Hood to Grille 1.0 +/- 0.75 0.0 + 0.0/- 1.0
C1 Hood to Fender 6.0 +/- 1.0 1.5 +/- 1.0
C2 Hood to Fender 6.0 +/- 1.0 3.5 +/- 1.0
C3 Hood to Fender 6.0 +/-1.0 1.5 +/- 1.0
C4 Hood to Fender 6.0 +/- 1.0 1.5 +/- 1.0
D Door to Hood/Fender 5.0 +/- 1.0 0.0 +/- 1.0
E Door to Windshield Molding N/A 2.0 +/- 2.0
F Door to Roof 6.0 +/- 1.5 2.0 +/- 1.0
G Door to Quarter 5.0 +/- 1.0 0.0 +/- 1.0
H Fender/Door/Quarter Char Line U/D N/A 0.0 +/- 1.0
I Door to Sill 7.7 +/- 2.0 0.0 +/- 1.5
J Fender to Aperture 5.0 +/- 1.0 0.0 +/- 1.0
K Grille to Headlamp 6.0 +/- 3.0 N/A
L Grille to Fender 5.0 +/- 0.75 1.0 +/- 0.5
23 - 56 BODYBR/BE
BODY (Continued)

CLUB CAB
NOTE: All measurements are in MM.
CLUB CAB
DESCRIPTION GAP FLUSH
A Door to Windshield Molding N/A 2.0 +/- 2.0
B1 Door to Roof 5.0 +/- 1.5 0.0 +/- 1.0
B2 Door to Roof 5.0 +/- 1.5 1.4   1.0 CONS. W/IN 1.5
B3 Door to Roof 5.0 +/- 1.5 4.1   1.0 CONS. W/IN 1.5
C Quarter Glass to Quarter (top) 5.0 +/- 1.0 3.5 +/- 1.5
D Quarter Glass to Quarter (rear) 5.0 +/- 2.0 3.25 +/- 1.5
E Cab to Box (side view) 31.0 +/- 3.0 3.25 +/- 2.5
F Quarter Glass to Quarter (bottom) 5.0 +/- 1.5 N/A
G Quarter Glass to Quarter (front) in-line within +/- 1.0
H Door to Quarter 5.0 +/- 1.0 0.0 +/- 1.0
I Quarter Glass to Door N/A 2.0 +/- 1.5
J Door to Hood/Fender 5.0 +/- 1.0 0.0 +/- 1.0
K Grille to Headlamp 6.0 +/- 3.0 N/A
L Grille to Fender 5.0 +/- 0.75 1.0 +/- 0.5
BR/BEBODY 23 - 57
BODY (Continued)

QUAD CAB
NOTE: All measurements are in MM.
QUAD CAB
DESCRIPTION GAP FLUSH
A Door to Windshield Molding N/A 2.0 +/- 2.0
B Front Door to Roof 5.0 +/- 1.5 0.0 +/- 1.0
C Rear Door to Roof 5.0 +/- 1.0 0.0 +/- 1.0
D Rear Door Glass to Rear Door (top) 5.0 +/- 1.0 3.25 +/- 1.5
E Rear Door Glass to Rear Door (rear) 5.0 +/- 2.0 3.25 +/- 1.5
F Rear Door to Quarter 5.5 +/- 1.0 0.0 +/- 1.0
G Rear Door Glass to Rear Door (bottom) 5.0 +/- 1.5 N/A
H Front Door to Rear Door 5.0 +/- 1.0 0.0 +/- 1.0
I Rear Door Glass to Rear Door (front) in-line within +/- 1.0
Rear Door Glass to Front Door N/A 3.25 +/- 1.5
J Door to Hood/Fender 5.0 +/- 1.0 0.0 +/- 1.0
K Grille to Headlamp 6.0 +/- 3.0 N/A
L Grille to Fender 5.0 +/- 0.75 1.0 +/- 0.5
23 - 58 BODYBR/BE
BODY (Continued)

(4) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
LATCH STRIKER - LOWER
REMOVAL
(1) Using a grease pencil or equivalent, mark the
position of the lower striker on the sill.
(2) Remove the torx screws attaching the striker to
the sill (Fig. 11) .
(3) Separate striker from sill.
INSTALLATION
(1) Using the alignment marks, position striker on
sill.
(2) Install the torx screws attaching the striker to
the sill (Fig. 11) . Tighten screws to 28 N´m (21 ft.
lbs.) torque.
LATCH STRIKER - UPPER
REMOVAL
(1) Remove screws attaching striker trim cover to
roof.
(2) Remove bolts attaching striker to roof (Fig. 11).
(3) Separate upper striker from roof.
INSTALLATION
(1) Position upper striker on roof.
(2) Install bolts attaching striker to roof (Fig. 11) .
Tighten bolts to 23 N´m (17 ft. lbs.) torque.
(3) Install the screws attaching striker trim cover
to roof.
RELEASE CABLE
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Disengage release cable from inside release
handle (Fig. 12).
(3) Peel back waterdam
(4) Disengage release cable from shutface door
handle (Fig. 13).
(5) Separate release cable from cargo door.
INSTALLATION
(1) Position release cable in cargo door.
(2) Engage release cable to shutface door handle.
(3) Reposition waterdam
(4) Engage release cable to inside release handle.
(5) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
Fig. 11 Cargo Door Strikers
1 - UPPER STRIKER
2 - LOWER STRIKER
Fig. 12 Cargo Door Release Handle
1 - CARGO DOOR RELEASE CABLE
2 - CARGO DOOR RELEASE HANDLE
23 - 82 DOOR - CARGOBR/BE
LATCH - UPPER (Continued)