1993 DODGE TRUCK Service Repair Manual

11
- 10
EXHAUST SYSTEM
AND
INTAKE MANIFOLD
EXHAUST
PIPE

BRACE

MANUAL
TRANS. EXHAUST

PIPE

BRACE

AUTO
TRANS.

BRACKET
ISOLATORS

MUFFLER
PIPE
FRAMERAIL

131
"
WHEELBASE
135"
WHEELBASE
FRAMERAIL


135"
WHEELBASE

131"
WHEELBASE
ISOLATORS

159"
WHEELBASE
MUFFLER

PIPE
131
"
& 135"
WHEELBASE
FRAMERAIL
BRACKET
CONVERTER PIPE
FRAMERAIL
TIGHTENING
TORQUE

23 N-m (200 IN.
LBS.)

14 N-m (125 IN.
LBS.)

28
N-m (250 IN.
LBS.)
J9211-20

Fig. 5 Dual Exhaust System (5.9L Engines)—Heavy Duty Trucks (2 of 2)

EXHAUST
SYSTEM
AND
INTAKE
MANIFOLD
11-11

RETAINER
CATALYTIC

CONVERTER
PIPE
HEAT

SHIELD

FRAMERAIL
J9211-22
Fig. 6 Sport
Utility
Exhaust System (1 of 3)

11-12 EXHAUST SYSTEM AND INTAKE MANIFOLD
•
Fig. 7
Sport
Utility
Exhaust
System (2 of 3)

•

EXHAUST SYSTEM
AND

INTAKE MANIFOLD
11-13
TIGHTENING
TORQUE

23
N-m
(200
IN. LBS.)

7
N-m
(65
IN. LBS.)
5 N-m
(40
IN. LBS.)
HEAT
SHIELD CATALYTIC
CONVERTER
LOWER HEAT SHIELD HEAT
SHIELD UPPER

HEAT
SHIELD
CROSSMEMBER

SKID
PLATE
UPPER HEAT SHIELD
(6 IN.
RAIL) CONED WASHER
UPPER HEAT SHIELD
(7 IN.
RAIL)
J9211-21

Fig.
8
Sport
Utility
Exhaust
System—Exhaust
Heat
Shields
(3 of 3)

INTAKE MANIFOLD
The aluminum intake manifold is a single plane
design with equal length runners. The manifold is sealed by flange side gaskets with front and rear
cross-over gaskets. The intake manifold has internal
EGR.

REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (refer to Group 7,
Cooling System for the proper procedures).
(3) Remove the generator.
(4) Remove the air cleaner.
(5) Disconnect the fuel lines.
(6) Disconnect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(7) Remove the return spring.
(8) Remove the distributor cap and wires.
(9) Disconnect the coil wires.
(10) Disconnect the heat indicator sending unit

wire.
(11) Disconnect the heater hoses and bypass hose.
(12) Remove the closed crankcase ventilation and
evaporation control systems. (13) Remove intake manifold bolts.
(14) Lift the intake manifold and throttle body out
of the engine compartment as an assembly. (15) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.
(16) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 9). Discard
the gasket. (17) Remove the plenum pan as follows:
THROTTLE

BODY
(MPI)

J9209-68

Fig.
9
Throttle
Body Assembly—MPI

(a) Turn the intake manifold upside down. Sup­
port the manifold.
(b) Remove the bolts and lift the pan off the
manifold. Discard the gasket.

CLEANING
Clean manifold in solvent and blow dry with com­
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.

11-14
EXHAUST
SYSTEM
AND
INTAKE
MANIFOLD

• The plenum pan rail must be clean and dry (free of
all foreign material).

INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.

INSTALLATION
(1) Install the plenum pan, if removed, as follows: (a) Turn the intake manifold upside down. Sup­
port the manifold.
(b) Place a new plenum pan gasket onto the seal
rail of the intake manifold. Position the pan over
the gasket. Align all the gasket and pan holes with
the intake manifold. (c) Hand start all bolts.
(d) Tighten the bolts, in sequence (Fig. 10), as
follows:

V-6
V-8

Fig.
10
Plenum
Pan
Bolt
Tightening
Sequence

• Step
1-Tighten
bolts to 2.7 N*m (24 in. lbs.)
torque.
• Step 2-Tighten bolts to 5.4 N«m (48 in. lbs.)
torque.
• Step 3-Tighten bolts to 9.5 Nnn (84 in. lbs.)
torque.
• Step 4—Check that all bolts are tighten to 9.5 N®m (84 in. lbs.) torque.
(2) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23
Nun (200 in. lbs.) torque. (3) Place the 4 plastic locator dowels into the holes
in the block Fig. 11).
(4) Apply MOPAR Silicone Rubber Adhesive Seal­
ant, or equivalent, to the four corner joints. An ex­ cessive amount of sealant is not required to ensure a
leak proof seal. However, an excessive amount of
sealant may reduce the effectiveness of the flange
gasket. The sealant should be slightly higher than
the cross-over gaskets, approx. 5 mm (0.2 in).
(5) Install the front and rear cross-over gaskets
onto the dowels (Fig. 11).

FRONT
CROSS-OVER
GASKET



REAR
CROSS-OVER
GASKET
J9209-99

Fig
11
Cross-Over
Gaskets
and Locator
Dowels

(6) Install the flange gaskets. Ensure that the ver­
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must
be in position with the mating cylinder head gasket
tabs (Fig. 12). The words MANIFOLD SIDE should
be visible on the center of each flange gasket.
(7) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. Use the alignment dowels in the cross-over gaskets to posi­
tion the intake manifold. After intake manifold is in
place, inspect to make sure seals are in place.
(8) Install the intake manifold bolts and tighten as
follows:
V-6 ENGINE—(Fig. 13)
• Step
1-Tighten
bolts 1 and 2 to 8 Nun (72 in. lbs.)
torque. Tighten in alternating steps 1.4 Nun (12 in. lbs.) torque at a time.
• Step 2—Tighten bolts 3 through 12, in sequence,
to 8 Nun (72 in. lbs.) torque.
• Step 3—Check that all bolts are tighten to 8 Nun (72 in. lbs.) torque.
• Step 4—Tighten all bolts, in sequence, to 16 Nun (12 ft. lbs.) torque.
• Step 5—Check that all bolts are tighten to 16 Nun (12 ft. lbs.) torque.

EXHAUST SYSTEM
AND
INTAKE MANIFOLD
11-15

FLANGE GASKET

o

o
CYLINDER

HEAD GASKET
J9209-101

Fig. 12 Intake Manifold Flange Gasket Alignment

®— INTAKE

MANIFOLD
FRONT OF
ENGINE
J9209-59

Fig. 13 Intake Manifold Bolt Tightening Sequence—3.9L Engines
V-8 ENGINE—(Fig* 14)
• Step
1—Tighten
bolts 1 through 4, in sequence, to 8 Nun (72 in. lbs.) torque. Tighten in alternating
steps 1.4 Nun (12 in. lbs.) torque at a time.
FRONT
OF ENGINE
J9209-60

Fig. 14 Intake Manifold Bolt Tightening Sequence—5.2L Engines
• Step 2—Tighten bolts 5 through 12, in sequence,
to 8 Nun (72 in. lbs.) torque. • Step 3—Check that all bolts are tighten to 8 Nun (72 in. lbs.) torque.
• Step 4—Tighten all bolts, in sequence, to 16 Nun (12 ft. lbs.) torque.
• Step 5—Check that all bolts are tighten to 16 Nun (12 ft. lbs.) torque.
(9) Install closed crankcase ventilation and evapo­
ration control systems. (10) Connect the coil wires.
(11) Connect the heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Hook up the return spring.
(15) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables. (16) Install the fuel lines,
(17) Install the generator and drive belt. Tighten
generator mounting bolt to 41 Nun (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 Nun (200 in. lbs.) torque. Refer to Group 7, Cooling Sys­
tem for the proper adjusting of belt tension. (18) Install the air cleaner. (19) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure). (20) Connect the negative cable to the battery.

ENGINE EXHAUST MANIFOLD
Engine exhaust manifolds are LOG type with port­
ing for air injection into the LOG.
REMOVAL (1) Disconnect the negative cable from the battery.
(2) Raise and support the vehicle.
(3) Remove the bolts and nuts attaching the ex­
haust pipe to the engine exhaust manifold. (4) Lower the vehicle. (5) Remove the exhaust heat shields.

11-16
EXHAUST
SYSTEM
AND
INTAKE
MANIFOLD

• (6) Remove bolts, nuts and washers attaching
manifold to cylinder head. (7) Remove manifold from the cylinder head.
CLEANING Clean mating surfaces on cylinder head and mani­
fold. Wash with solvent and blow dry with com­
pressed 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).
INSTALLATION

CAUTION:
If the studs came out
with
the nuts when removing the engine exhaust
manifold,
install
new

studs.
Apply sealer on the coarse
thread
ends.
Wa­
ter leaks may develop at the studs if
this
precaution
is
not taken.
(1) Position the engine exhaust manifolds on the
two studs located on the cylinder head. Install coni­ cal washers and nuts on these studs (Fig. 15 or 16). (2) Install two bolts and conical washers at the in­
ner ends of the engine exhaust manifold outboard
arms.
Install two bolts WITHOUT washers on the
center arm of engine exhaust manifold (Fig. 15 or
16).
Starting at the center arm and working outward,
tighten the bolts and nuts to 34
Nth
(25 ft. lbs.) torque.
(3) Install the exhaust heat shields.
(4) Raise and support the vehicle.
(5) Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and nuts to 26
N-m
(19 ft. lbs.) torque.
(6) Lower the vehicle.
(7) Connect the negative cable to the battery.
Fig.
15
Engine
Exhaust
Manifold Installation—3.9L

Engine

J9311-11

Fig.
16
Engine
Exhaust
Manifold Installation—5.2U 5.9L
Engines

•
EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 17 8ERY1CE PROCEDURES
(DIESEL ENGINES)

INDEX

page

Charge
Air
Cooler
(Intercooler)
25
Engine
Exhaust
Manifold
18

Exhaust
Pipe
17

Exhaust
Tailpipe
18
EXHAUST PIPE

REMOVAL

(1) Remove the clamp that holds the front exhaust
pipe clamp to the turbocharger (Fig. 1).

Fig.
1
Exhaust
Pipe to Turbocharger
Clamp

(2)
Raise and support the vehicle on a hoist.
(3)
Remove the bolt from the exhaust pipe support
strap (Fig. 2).

(4)
Remove the clamp nuts (Fig. 2).

(5)
Separate the exhaust pipe from the front ex­
haust extension pipe (Fig. 2).
TURBOCHARGER WELD
FRONT
EXHAUST
CLAMP
JOINT
PIPE
SUPPORT STRAP
PIPE
J911M

Fig.
2 Front
Exhaust
Pipe
Mounting
and
Clamps
page

Intake
Manifold
Cover
/ Air
Intake
Heater
19

Muffler
and
Extension
Pipes
17

Turbocharger
21

INSTALLATION
(1)
Align the front exhaust pipe with the front ex­
haust extension pipe and the turbocharger exhaust outlet.

(2)
Install the exhaust pipe support strap. Tighten
the nut to 41 Nun (30 ft. lbs.) torque.

(3)
Install the exhaust pipe support clamps and

nuts.
Tighten the nuts to 54 Nun (40 ft. lbs.) torque.
(4)
Lower the vehicle.

(5)
Install the turbocharger clamp and tighten the
screw to 8 Nun (74 in. lbs.) torque (Fig. 2). (6) Start the engine and check for leaks.
MUFFLER AND EXTENSION PIPES Rear extension pipes are used on the 135 inch, 149
inch and 159 inch wheelbase vehicles.

REMOVAL
(1)
Raise and support the vehicle.

(2)
Remove the clamps and nuts from the front ex­
tension pipe. Remove the clamps and nuts from the rear extension pipe or from the muffler rear exten­sion pipe (Fig. 3).
Fig.
3 Muffler and Extension Pipe(s)