Dodge Ram Truck 1500-2500-3500. Manual — part 1385

MANIFOLD-EXHAUST

REMOVAL

NOTE: Care must be taken to protect the cylinder
head covers powder coating from scrapes and
abrasions. This procedure covers either the left or
right exhaust manifold.

1. Disconnect negative battery cable.

NOTE: When servicing the right exhaust manifold
it is necessary to remove the upper oil dip stick
tube fastener and position the tube aside.

2. Raise vehicle on hoist.

3. Loosen and remove the fasteners from the exhaust

pipe to exhaust manifold.

4. Separate exhaust pipe from the exhaust manifold.

5. Lower the vehicle.

6. Disconnect the spark plug wires from the spark

plugs and set aside.

7. Remove manifold heat shield from exhaust mani-

fold ,.

NOTE: Note the location of exhaust manifold studs
and bolts for proper installation.

8.

Remove studs and bolts attaching manifold to cyl-

inder head and remove manifold ,.

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INSPECTION

Inspect exhaust manifolds for damage or cracks.
Check for distortion of the cylinder head mounting sur-
faces with a straightedge and feeler gauge.

INSTALLATION

NOTE: Care must be taken to protect the cylinder
head covers powder coating from scrapes and
abrasions. This procedure covers either the left or
right exhaust manifold.

1. Install new gasket and install exhaust manifold

Tighten attaching fasteners to 23 N·m (200 in. lbs.)
,.

NOTE: When installing right exhaust manifold,
properly position the oil level indicator tube,
install fastener and tighten to the cylinder head
cover specification.

2. Install manifold heat shield and tighten attaching

fasteners to 6 N·m (50 in. lbs.) ,.

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3. Install the spark plug wires.

4. Raise vehicle on hoist.

5. Connect exhaust pipe to exhaust manifold. Tighten

fasteners to 34 N·m (25 ft.lbs.).

6. Lower vehicle.

7. Connect negative battery cable.

HEAD(S)-CYLINDER

REMOVAL - CYLINDER HEAD(S)

NOTE: Care must be taken to protect the intake
manifold and cylinder head covers powder coating
from scrapes and abrasions. This procedure cov-
ers either the left or right cylinder head.

The aluminum alloy cylinder head shown in is held in
place by 12,

1

⁄

2

inch bolts (5) and 8,

1

⁄

4

inch bolts (4).

1. Release the fuel pressure (Refer to 14 - FUEL

SYSTEM/FUEL DELIVERY - STANDARD PROCE-
DURE).

2. Disconnect negative battery cable.

3. Disconnect the throttle body air inlet duct, IAT sen-

sor, CCV hose and remove the air cleaner cover
(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR
CLEANER HOUSING - REMOVAL).

4. Drain the cooling system (Refer to 7 - COOLING/

ENGINE - STANDARD PROCEDURE - DRAINING
COOLING SYSTEM).

5. Raise and support the vehicle.

6. Disconnect the front exhaust pipe to exhaust man-

ifold connection.

7. Lower the vehicle.

8. Remove intake manifold (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL).

9. Disconnect the spark plug wires by pulling on the boot straight out in line with the spark plug. Dislodge spark

plug retainers from the cylinder head cover studs and position the spark plug wires aside.

10. Disconnect the oil level indicator tube and set aside.

11. Disconnect CCV hoses from cylinder head covers.

12. Remove the cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS - REMOVAL).

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13. Remove exhaust manifold heat shields.

14. Remove exhaust manifold(s) and gasket(s) (Refer to 9 - ENGINE/MANIFOLDS/EXHAUST MANIFOLD -

REMOVAL).

NOTE: If rocker arms and push rods are to be reused, identify each component to ensure installation in
original locations.

15. Remove the rocker arm and pedestal assemblies (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -

REMOVAL).

16. Remove push rods.

17. Remove the 12 head bolts and 8 cylinder head tappet gallery bolts from cylinder head(s).

18. Remove cylinder head(s) and gasket(s).

CLEANING

CLEANING / INSPECTION

1. Before cleaning, check for leaks, damage and

cracks.

2. Clean cylinder head and oil passages.

3. Check cylinder head for flatness.

4. Inspect all surfaces with a straightedge (2) if there

is any reason to suspect leakage. If out-of-flatness
exceeds 0.019 mm (0.00075 in.) times the span
length in inches in any direction, either replace
head or lightly machine the head surface. As an
example, if a 12.0 inch span is 1.0 mm (0.004 in.)
out-of-flat, allowable is 12 x 0.019 mm (0.00075 in.)
equals 0.22 mm (0.009 in.). This amount of out-of-
flat is acceptable. *Maximum of 0.2 mm (0.008 in.)
for grinding is permitted.

CAUTION: This is a combined total dimension of
stock removal from cylinder head surface.

INSTALLATION - CYLINDER HEAD(S)

NOTE: This procedure covers either the left or
right cylinder head.

1. Clean all surfaces of engine block and cylinder

heads (Refer to 9 - ENGINE - STANDARD PRO-
CEDURE - ENGINE GASKET SURFACE PREPA-
RATION).

CAUTION: Remove all gasket material from cylin-
der head and block using a plastic scraper only.
DO NOT use a metal scraper, as damage to seal-
ing surface may occur.

NOTE: A multi-layer steel head gasket is used.

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