DodgeRegular Cab Pick-up20025.9L Diesel/dodge/regular-cab-pick-up/2002/5-9l-diesel/
BR platform

2002 Dodge Regular Cab Pick-up — 5.9L Diesel

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2002 Regular Cab Pick-up 5.9L Diesel. Covers both the standard and High Output 5.9L Diesel.

Engine 5.9L Diesel

The 2002 Dodge Regular Cab Pick-up 5.9L Diesel. It takes 5.0 qt of 10W-30 engine oil.

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity5.0 qtOEM · verified
Engine oil type10W-30 APIOEM · verified
Lug nut torque135 ft-lbsOEM · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 65 - LATE · 650 - LATE CCA battery, OE oil filter 04781452BF. Note the factory fuel filter is now discontinued — plan on a superseded or quality aftermarket equivalent, which the part pages below list where known. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 65 - LATE · 650 - LATE CCAOEM · verified
Tire sizeLT265-70R17EOEM · verified
Wheel / rim8 inOEM · verified

OE service part numbers OEM · verified

Engine oil filter04781452BF alt 05281090AB
Engine air filter68441763AA
Fuel filter04798825AD discontinued · alt 04897498AA
Spark plugSPZFR6F11G alt 68303921AA
BatteryBB65F121AA
Front wiper blades55077100AE
Serpentine belt05135746AA alt 53032307AC
Thermostat53021051AB alt 52028185AC

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 5.0 qt of 10W-30 API engine oil, GL-5 · 80W-90 in the differential, DOT 3 brake fluid. Torque lug nuts to 135 ft-lbs, the oil drain plug to 37.0 ft-lbs. The firing order is 1-10-9-4-3-6-5-8-7-2. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Brake FluidDOT 3
Differential Gear OilGL-5 · 80W-90
Differential Gear Oil Capacity7.2 Pints,
Differential Gear OilGL-5 · 80W-90
Differential Gear Oil Capacity10 Pints,
Engine CoolantHOAT · MS9769
Engine CoolantHOAT · MS9769
Engine Oil10W-30 · API

Engine torques

Connecting Rod (Large End) Bearings48 ft-lbs
Engine Flywheel Bolts100 ft-lbs
Engine Flywheel Bolts55 ft-lbs
Exhaust Manifold to Cylinder Head Bolts25 ft-lbs
Engine Oil Pan Drain Plug25.0 ft-lbs
Engine Oil Pan Drain Plug44.0 ft-lbs
Engine Oil Pan Drain Plug44.0 ft-lbs
Engine Oil Pan Drain Plug37.0 ft-lbs

Chassis torques

Leaf Spring to Axle (U-bolts)6010
Leaf Spring to Chassis Bracket6010
Leaf Spring to Rear Shackle6010
Leaf Spring Rear Shackle to Chassis Bracket6010
Lug Nuts135 ft-lbs
Transfer Case Fill Plug30.0-40.0 ft-lbs
Transfer Case Drain Plug30.0-40.0 ft-lbs
Front Wheel Hub180 ft-lbs

Ignition

Cylinder Firing Order1-8-4-3-6-5-7-2
Cylinder Firing Order1-10-9-4-3-6-5-8-7-2
Curb Idle Speed (No Load)700 rpm
Curb Idle Speed Variance (No Load)200 rpm
Spark Plug ManufacturerChampion
Spark Plug TypeRC12LC4
Spark Plug Gap0.040 in
Spark Plug Torque30.0 ft-lbs

Battery & A/C

RefrigerantR134a
Refrigerant Capacity1.50 lbs
Oil GroupPAG
Oil TypeSP-10
Oil Capacity6.00 oz
Standard BCI Group Number65 - LATE
Standard BCI Cranking Performance650 - LATE cca
Optional BCI Group Number27

Service checks

Pressure Test15 psi
Radiator Cap Pressure Relief14-18 psi
Fuel Pump Pressure Minimum54.0 psi
Regulated Fuel System Pressure (With Vacuum)44.0-54.0 psi
Injector Primary Resistance13-16 @ 68 degreesF ohms
Engine Compression100 Minimum psi
Engine Oil Pressure30-80 psi
Engine Oil Pressure RPM3000 rpm

Brakes

Torque Caliper to Bracket24 ft-lbs
Torque to Knuckle130 ft-lbs
Torque Caliper to Bracket24 ft-lbs
Torque to Knuckle100 ft-lbs
Torque Caliper to Bracket24 ft-lbs
Torque to Knuckle60-130 ft-lbs / 60-210 ft-lbs
Rotor Max Parallel Variation0.001 in
Rotor Runout Limit0.005 in

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages
126 ft. lbs., Step 2: 51 ft. lbs., Step 3: 7326 ft. lbs
Cylinder Head — tightening sequence 6 stages

Prep Do not reuse old bolts. Coat new bolts with the specified engine oil.

152.0 ft. lbs.52 ft. lbs
2loosen all bolts 360 degrees360 degrees
377.0 ft. lbs.77 ft. lbs
477.0 ft. lbs.77 ft. lbs
590 degrees90 degrees
690 degrees90 degrees
Intake Manifold to Engine Bolts — tightening sequence 1 stages
16 ft. lbs. ( 1 ft. lbs. at a time.), step 2: bolts 5-12: 6 ft. lbs., step 3: all to 6 ft. lbs., step 4: all to 12 ft. lbs., step 5: all to 126 ft. lbs
Main Bearings — tightening sequence 1 stages
145 ft. lbs., Step 2: 85 ft. lbs., Step 3: 12945 ft. lbs
Oil Pump to Cylinder BLock Bolts/Studs — tightening sequence 1 stages
17 ft. lbs., Step 2: 187 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 6,000 mi; spark plugs every 60,000 mi; coolant every 6,000 mi. The big-interval services (every 6,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 6,000 miDriveshaft U-Joint (lubricate) · Engine Coolant System (leak inspection) · Engine Oil (drain & refill) · Engine Oil Filter (replace) · Transmission Assembly (inspect)
Every 7,500 miBrake Hydraulic System (inspect fluid level) · Brake Line (inspect) · Brake Linings (adjust) · CV Joint Boot (inspect) · Crankcase Breather Bottle (drain) · Differential (inspect fluid level)
Every 15,000 miAccessory Drive Belt (inspect) · Fuel Filter (replace) · Water Pump (inspect)
Every 22,500 miAccessory Drive Belt (inspect) · Suspension Ball Joint (inspect)
Every 24,000 miEngine Air Filter Element (replace) · Engine Breather Filter (clean)
Every 30,000 miCrankshaft Vibration Damper (inspect) · Radiator Fan Clutch (inspect)
Every 45,000 miTransfer Case Assembly (inspect fluid level)
At 60,000 miAccessory Drive Belt (inspect)
Every 60,000 miDistributor Cap (inspect) · Distributor Rotor (inspect) · PCV Valve (replace) · Spark Plug Wires (replace)

Owner how-tos

Condensed service procedures for routine maintenance. Procedures that require dealer diagnostic equipment are identified and summarized only.

Common procedures

Key fob — remote (RKE) programming programming new fob buttons Dealer tool OEM · verified
Tool requiredDRBIII scan tool (dealer / locksmith)
WhyTransmitter codes are written into the receiver in the passenger door module
Anti-theft (SKIS) — module initialization after immobilizer module replacement Dealer tool OEM · verified
When neededAfter Sentry Key Immobilizer Module (SKIM) replacement
Tool requiredDRBIII scan tool
Also requiredThe vehicle's four-digit PIN code

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P2002
Diesel particulate filter efficiency below threshold — Bank 1
P0401
Exhaust gas recirculation (EGR) flow insufficient
P20EE
SCR NOx catalyst efficiency below threshold — Bank 1
P0087
Fuel rail / system pressure too low
P0299
Turbocharger / supercharger underboost condition

VIN tools

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VIN
Decode a VIN to confirm the transmission and build data for a specific Regular Cab Pick-up. OEM
Build data
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Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2002 Regular Cab Pick-up 5.9L Diesel take?

5.0 qt of 10W-30 API, per the factory manual.