Dodge Ram Truck 1500-2500-3500. Manual — part 1371

MANIFOLD - INTAKE

DESCRIPTION

The intake manifold is made of a composite material and features long runners which maximizes low end torque.
The intake manifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent
leaks.

DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKAGE

An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may
not be functioning.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE
WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR
LOOSE CLOTHING.

1. Start the engine.

2. Spray a small stream of water at the suspected leak area.

3. If a change in RPM is observed the area of the suspected leak has been found.

4. Repair as required.

REMOVAL

1. Disconnect negative cable from battery.

2. Remove resonator assembly and air inlet hose.

3. Disconnect electrical connectors for the following components:

•

Manifold Absolute Pressure (MAP) Sensor

•

Intake Air Temperature (IAT) Sensor

•

Throttle Position (TPS) Sensor

•

Coolant Temperature (CTS) Sensor

4. Disconnect brake booster hose and positive crankcase ventilation (PCV) hose.

5. Remove generator and set aside.

NOTE: It is not necessary to remove lines or remove freon from A/C compressor.

6. Remove air conditioning compressor and set aside..

7. Bleed fuel system (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE).

8. Remove intake manifold retaining fasteners in a crisscross pattern starting from the outside bolts and ending at

the middle bolts.

9. Remove intake manifold and IAFM as an assembly.

CLEANING

NOTE: There is NO approved repair procedure for the intake manifold. If severe damage is found during
inspection, the intake manifold must be replaced.

Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air
dry.

INSPECTION

1. Inspect the intake sealing surface for cracks, nicks and distortion.

2. Inspect the intake manifold vacuum hose fittings for looseness or blockage.

3. Inspect the manifold to throttle body mating surface for cracks, nicks and distortion.

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ENGINE - 5.7L - SERVICE INFORMATION

DR/DH

INSTALLATION

1. Install intake manifold seals.

2. Position intake manifold and IAFM.

3. Install intake manifold retaining bolts, and tighten in sequence from the middle bolts towards the outside in a

crisscross pattern. Torque fasteners to 12 N·m (105 in. lbs.).

4. Connect electrical connectors for the following components:

•

Manifold Absolute Pressure (MAP) Sensor

•

Intake Air Temperature (IAT) Sensor

•

Throttle Position (TPS) Sensor

•

Coolant Temperature (CTS) Sensor

•

Idle Air Control (IAC) Motor

5. Install generator.

6. Install A/C compressor.

7. Connect Brake booster hose and Positive crankcase ventilation (PCV) hose.

8. Install resonator assembly and air inlet hose.

9. Connect negative cable to battery.

MANIFOLD - EXHAUST

DESCRIPTION

The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust
manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is
used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat
shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is
backed off slightly to allow for the thermal expansion of the exhaust manifold.

OPERATION

The exhaust manifolds collect the engine exhaust exiting the combustion chambers, then channels the exhaust
gases to the exhaust pipes attached to the manifolds.

DR/DH

ENGINE - 5.7L - SERVICE INFORMATION

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REMOVAL

EXHAUST MANIFOLD

1. Disconnect negative battery cable.

2. Raise vehicle.

3. Remove exhaust pipe to manifold bolts.

4. Lower vehicle.

5. Install engine support fixture special tool #8534.

6. Raise engine enough to remove manifolds.

CAUTION: Do not damage engine harness while
raising the engine.

7. Remove heat shield.

8. Remove manifold bolts using sequence provided.

9. Remove manifold and gasket.

CLEANING

Clean mating surfaces on cylinder head and manifold.
Wash with solvent and blow dry with compressed air.

INSPECTION

Inspect manifold for cracks.

Inspect mating surfaces of manifold for flatness with a straight edge. Gasket surfaces must be flat within 0.2 mm per
300 mm (0.008 inch per foot).

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ENGINE - 5.7L - SERVICE INFORMATION

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INSTALLATION

EXHAUST MANIFOLD

1. Install manifold gasket and manifold.

2. Install manifold bolts and tighten using sequence

provided to 25 N·m (18 ft. lbs.).

3. Install heat shield and tighten nuts to 15 N·m (11 ft.

lbs.).

4. Lower engine.

CAUTION: Do not damage engine harness while
lowering the engine.

5. Remove engine support fixture from engine.

6. Raise vehicle.

7. Tighten right and left side engine mount through

bolts.

8. Install exhaust flange to pipe bolts.

9. Lower vehicle.

10. Connect negative battery cable.

DR/DH

ENGINE - 5.7L - SERVICE INFORMATION

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