Dodge Ram Truck 1500-2500-3500. Manual — part 1429
EXHAUST SYSTEM
DESCRIPTION
GAS ENGINES
CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system
floor pan exhaust heat shields. Light overspray near the edges is permitted. Application of coating will
result in excessive floor pan temperatures and objectionable fumes.
Exhaust System - 3.7L Engine - Typical
Exhaust System 4.7L Engine - Typical
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EXHAUST SYSTEM
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The federal gasoline engine exhaust system consists of engine exhaust manifolds, exhaust pipes, catalytic convert-
er(s), extension pipe (if needed), exhaust heat shields, muffler and exhaust tailpipe , ,
The California emission vehicles exhaust system also contains the above components as well as mini catalytic con-
verters added to the exhaust pipe.
The exhaust system must be properly aligned to prevent stress, leakage and body contact. Minimum clearance
between any exhaust component and the body or frame is 25.4 mm (1.0 in.). If the system contacts any body panel,
it may amplify objectionable noises from the engine or body.
5.9L DIESEL
CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system
floor pan exhaust heat shields. Light overspray near the edges is permitted. Application of coating will
result in excessive floor pan temperatures and objectionable fumes.
The diesel engine exhaust system consists of an engine exhaust manifold, turbocharger, exhaust pipe, resonator,
extension pipe, catalytic converter, muffler and exhaust tailpipe.
The exhaust system must be properly aligned to prevent stress, leakage and body contact. The exhaust compo-
nents should be kept a minimum of 25.4 mm (1.0 in.) away from the body and frame. If the system contacts any
body panel, it may amplify objectionable noises from the engine or body.
Exhaust System 5.7L Engine - Typical
DR/DH
EXHAUST SYSTEM
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DIAGNOSIS AND TESTING
GAS ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSE
CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
1. Leaks at pipe joints.
1. Tighten clamps/bolts at leaking
joints.
2. Rusted or blown out muffler.
2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.
3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.
4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.
5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.
6. Tighten exhaust manifold to
cylinder head bolts.
7. Catalytic converter rusted or
blown out.
7. Replace catalytic converter assy.
8. Restriction in exhaust system.
8. Remove restriction, if possible.
Replace restricted part if necessary.
CAUTION:
When servicing and replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing
the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
DIESEL ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSE
CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
1. Leaks at pipe joints.
1. Tighten clamps/bolts at leaking
joints.
2. Rusted or blown out muffler.
2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.
3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.
4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.
5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.
6. Tighten exhaust manifold to
cylinder head bolts. Replace gasket
if necessary.
7. Turbocharger mounting flange
cracked.
7. Remove turbocharger and
inspect. (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER -
REMOVAL).
8. Restriction in exhaust system.
8. Remove restriction, if possible.
Replace restricted part if necessary.
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EXHAUST SYSTEM
DR/DH
SPECIFICATIONS
TORQUE
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Bolt-Adjusting Strap
23
-
200
Nuts-Air Heater Power Supply
14
-
124
Bolts-Air Inlet Housing
24
18
-
Nuts-Cab Heater Supply/Return Line
24
18
-
Nuts-Exhaust Clamp
54.3
40
-
Bolts-Exhaust Manifold to Cylinder Head-(Diesel Engine)
43
32
-
Bolts-Exhaust Manifold to Cylinder Head-(5.9L)
31
23
-
Bolts-Exhaust Manifold to Cylinder Head-(8.3L)
22
-
195
Bolts-Exhaust Pipe to Manifold
31
23
-
Bolts-Generator Mounting
41
30
-
Bolts-Charge Air Cooler Mounting
10
-
90
Nuts-Charge Air Cooler Duct
11
-
95
Bolt-Generator to Block-Diesel
24
18
-
Nuts and Bolts-Heat Shield
11
-
95
Nuts-Heat Shield-Diesel
24
18
-
Electronically Controlled Wastegate Command Valve
34
25
-
Turbocharger flange studs
24
18
-
Nuts-Turbocharger Mounting
43
32
-
Bolts-Turbocharger Oil Drain Tube
24
18
-
Fitting-Turbocharger Oil Supply Line
24
18
-
Nut-Turbocharger V-Band Clamp
5.6
-
70
Turbocharger Oil Supply fitting (at Turbocharger)
36
27
-
Turbocharger Oil Supply fitting (at lube filter head)
24
18
-
DR/DH
EXHAUST SYSTEM
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