1998 DODGE RAM 1500 Engine Installation

MUFFLER
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
(3) Disconnect the muffler hangers (Fig. 9).
(4) Remove clamps and nuts.
(5) Remove the muffler.
INSTALLATION
(1) Assemble muffler and clamps loosely to permit
proper alignment of all parts.
(2) Connect the muffler hangers.
(3) Tighten the clamp nuts to 54.2 N´m (40 ft. lbs.)
torque.
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks.
Reair exhaust leaks as necessary.
(6) Check the exhaust system for contact with the
body panels. A minimum of 25.4 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjust-
ments, if needed..
Fig. 7 HEAT SHIELDS - RH - QUAD CAB
1 - HEAT SHIELD
2 - FASTENER
3 - NUT
4 - HEAT SHIELD
Fig. 8 HEAT SHIELD LH
1 - HEAT SHIELD
2 - NUT
Fig. 9 MUFFLER
1 - INSULATOR
2 - INSULATOR
3 - MUFFLER
4 - INSULATOR
DREXHAUST SYSTEM 11 - 9
HEAT SHIELDS (Continued)

MUFFLER - 5.9L DIESEL
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise and support the vehicle.
(3) Remove the muffler to tail pipe and extension
pipe clamps (Fig. 10).
(4) Disconnect the muffler from the hanger isola-
tors (Fig. 10).
(5) Disconnect the muffler from the tailpipe.
(6) Disconnect the muffler from the extension pipe
and remove from the vehicle.
INSTALLATION
(1) Install the muffler hanger rods into the isola-
tors (Fig. 10).
(2) Install the muffler into the extension pipe.
(3) Install the muffler into the tail pipe.
(4) Install the exhaust clamps, align the exhaust
system, and tighten the exhaust clamps to 54.2 N´m
(40 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Connect the battery negative cables.
(7) Start the engine and inspect for exhaust leaks.
Reair exhaust leaks as necessary.(8) Check the exhaust system for contact with the
body panels. A minimum of 25.4 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjust-
ments, if needed..
TAILPIPE - 5.9L DIESEL
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise and support the vehicle.
(3) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
(4) Disconnect the exhaust tailpipe support hanger
isolators (Fig. 11).
(5) Remove the muffler-to-tailpipe clamps (Fig. 11).
(6) Remove the tailpipe from the vehicle.
INSPECTION
Discard rusted clamps, broken or worn supports
and attaching parts. Replace a component with orig-
inal equipment parts, or equivalent. This will assure
proper alignment with other parts in the system and
provide acceptable exhaust noise levels.
Fig. 10 Muffler Removal/Installation
1 - INSULATOR
2 - ISOLATOR
3 - TAILPIPE
4 - CLAMP
5 - MUFFLER
6 - CLAMP
7 - EXTENSION PIPE
Fig. 11 Tailpipe Removal/Installation
1 - ISOLATOR
2 - TAILPIPRE
3 - CLAMP
4 - MUFFLER
11 - 10 EXHAUST SYSTEMDR

INSTALLATION
(1) Install the tailpipe into the muffler.
(2) Install the tailpipe hanger rods into the isola-
tors (Fig. 11)
(3) Install the exhaust clamp, align the exhaust
system, and tighten the clamp 48 N´m (35 ft. lbs.)
torque.
(4) Lower the vehicle.
(5) Connect the battery negative cables.
(6) Start the engine and inspect for exhaust leaks.
Reair exhaust leaks as necessary.
(7) Check the exhaust system for contact with the
body panels. A minimum of 25.4 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjust-
ments, if needed..
TAILPIPE
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
(3) Disconnect the exhaust tailpipe support hanger
(Fig. 12).(4) Remove clamps and nuts.
(5) Remove the exhaust tailpipe.
INSPECTION
Discard rusted clamps, broken or worn supports
and attaching parts. Replace a component with orig-
inal equipment parts, or equivalent. This will assure
proper alignment with other parts in the system and
provide acceptable exhaust noise levels.
INSTALLATION
(1) Loosely assemble exhaust tailpipe to permit
proper alignment of all parts.
(2) Connect the support hangers.
(3) Position the exhaust tailpipe for proper clear-
ance with the underbody parts.
(4) Tighten all clamp nuts to 54.2 N´m (40 ft. lbs.)
torque.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks.
Reair exhaust leaks as necessary.
(7) Check the exhaust system for contact with the
body panels. A minimum of 25.4 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjust-
ments, if needed..
TURBOCHARGER SYSTEM
DIAGNOSIS AND TESTING - TURBOCHARGER
BOOST PRESSURE
NOTE: This diagnostic procedure is to be used with
the DRB IIITwhile test driving the vehicle under
normal load and driving conditions.
Low turbocharger boost pressure can cause poor
engine performance and driveability concerns. The
following procedure will test the turbocharger boost
pressure.
(1) Loosen clamps holding air inlet duct rubber
sleeve to the intake manifold and air inlet duct.
Remove rubber sleeve (Fig. 13).
(2) Position Special Tool 8462 onto air inlet duct
and intake manifold. Using the existing clamps
tighten to 8 N´m (72 in. lbs.).
(3) Install the 3447.5 kPa 500 psi (gray) Pressure
Transducer (part of OT-CH8520 Transducer Kit) into
Special Tool 8462.
(4) Connect the DRB IIItto the pressure trans-
ducer following the instructions supplied with the
DRB IIIt.
(5) Enter DRB IIItinto pressure reading mode
and test drive vehicle.
Fig. 12 TAILPIPE
1 - INSULATOR
2 - TAILPIPE
3 - CLAMP
4 - MUFFLER
5 - CLAMP
6 - INSULATOR
7 - INSULATOR
8 - INSULATOR
DREXHAUST SYSTEM 11 - 11
TAILPIPE - 5.9L DIESEL (Continued)

(9) Remove the turbocharger and gasket from the
exhaust manifold.
(10) If the turbocharger is not to be installed
immediately, cover the opening to prevent material
from entering into the manifold.
(11) If replacing the turbocharger, transfer the tur-
bocharger oil supply fitting to the new assembly.
Tighten fitting to 36 N´m (27 ft. lbs.).
(12) Clean and inspect the sealing surface.
CAUTION: The turbocharger is only serviced as an
assembly. Do not attempt to repair the turbocharger
as turbocharger and/or engine damage can result.
CLEANING
WARNING: To prevent damage or personal injury,
do not use a combustable cleaner to clean the tur-
bocharger.
Clean the turbocharger and exhaust manifold
mounting surfaces with a suitable scraper.
INSPECTION
Visually inspect the turbocharger and exhaust
manifold gasket surfaces. Replace stripped or eroded
mounting studs.
(1) Visually inspect the turbocharger for cracks.
The following cracks are NOT acceptable:
²Cracks in the turbine and compressor housing
that go completely through.
²Cracks in the mounting flange that are longer
than 15 mm (0.6 in.).
²Cracks in the mounting flange that intersect
bolt through-holes.
²Two (2) Cracks in the mounting flange that are
closer than 6.4 mm (0.25 in.) together.
(2) Visually inspect the impeller and compressor
wheel fins for nicks, cracks, or chips. Note: Some
impellers may have a factory placed paint mark
which, after normal operation, appears to be a crack.
Remove this mark with a suitable solvent to verify
that it is not a crack.
(3) Visually inspect the turbocharger compressor
housing for an impeller rubbing condition (Fig. 20).
Replace the turbocharger if the condition exists.
(4) Measure the turbocharger axial end play:
(a) Install a dial indicator as shown in (Fig. 21).
Zero the indicator at one end of travel.
(b) Move the impeller shaft fore and aft and
record the measurement. Allowable end play is
0.026 mm (0.0001 in.) MIN. and 0.127 mm (0.005
in.) MAX. If the recorded measurement falls out-
side these parameters, replace the turbocharger
assembly.(5) Measure the turbocharger bearing radial clear-
ance:
(a) Insert a narrow blade or wire style feeler
gauge between the compressor wheel and the hous-
ing (Fig. 22).
(b) Gently push the compressor wheel toward
the housing and record the clearance.
(c) With the feeler gauge in the same location,
gently push the compressor wheel away from the
housing and again record the clearance.
(d) Subtract the smaller clearance from the
larger clearance. This is the radial bearing clear-
ance.
(e) Allowable radial bearing clearance is 0.33
mm (0.013 in.) MIN. and 0.50 mm (0.020 in.) MAX.
If the recorded measurement falls outside these
specifications, replace the turbocharger assembly.
INSTALLATION
(1) Install the turbocharger. Apply anti-seize to the
studs and then tighten the turbocharger mounting
nuts to 43 N´m (32 ft. lbs.) torque.
Fig. 20 Inspect Compressor Housing for Impeller
Rubbing Condition
Fig. 21 Measure Turbocharger Axial End Play
DREXHAUST SYSTEM 11 - 15
TURBOCHARGER (Continued)

CAUTION: Do not apply more than 138 kPa (20 psi)
air pressure to the charge air cooler system, sever
damage to the charge air cooler system may occur.
(3) Connect a regulated air supply to air fitting on
Tool 9022 Adapter. Set air pressure to a Maximum of
138 kPa (20 psi).
(4) Using soapy water check the rubber sleeves,
charge air cooler and intake manifold for leaks.
REMOVAL
WARNING: IF THE ENGINE WAS JUST TURNED
OFF, THE AIR INTAKE SYSTEM TUBES MAY BE
HOT.
(1) Disconnect the battery negative cables.
(2) Discharge the A/C system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE) and remove the A/C condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - REMOVAL) (if A/C
equipped).
(3) Remove the transmission auxiliary cooler
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - REMOVAL).
(4) Remove the boost tubes from the charge air
cooler (Fig. 24).
(5) Remove the charge air cooler bolts. Pivot the
charge air cooler forward and up to remove.
CLEANING
CAUTION: Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air cooler
will result.
NOTE: If internal debris cannot be removed from
the cooler, the charge air cooler MUST be replaced.
(1) If the engine experiences a turbocharger failure
or any other situation where oil or debris get into the
charge air cooler, the charge air cooler must be
cleaned internally.
(2) Position the charge air cooler so the inlet and
outlet tubes are vertical.
(3) Flush the cooler internally with solvent in the
direction opposite of normal air flow.
(4) Shake the cooler and lightly tap on the end
tanks with a rubber mallet to dislodge trapped
debris.
(5) Continue flushing until all debris or oil are
removed.
(6) Rinse the cooler with hot soapy water to
remove any remaining solvent.
(7) Rinse thoroughly with clean water and blow
dry with compressed air.
INSPECTION
Visually inspect the charge air cooler for cracks,
holes, or damage. Inspect the tubes, fins, and welds
for tears, breaks, or other damage. Replace the
charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge
Air Cooler Tester Kit #3824556. This kit is available
through CumminstService Products. Instructions
are provided with the kit.
INSTALLATION
(1) Position the charge air cooler. Install the bolts
and tighten to 2 N´m (17 in. lbs.) torque.
(2) Install the air intake system tubes to the
charge air cooler. With the clamps in position, tighten
the clamps to 11 N´m (95 in. lbs.) torque.
(3) Install the transmission auxiliary cooler (if
equipped) (Refer to 7 - COOLING/TRANSMISSION/
TRANS COOLER - INSTALLATION).
(4) Install the A/C condenser (if A/C equipped)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - INSTALLATION).
Recharge A/C system (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE).
(5) Connect the battery negative cables.
(6) Start engine and check for boost system leaks.
Fig. 24 Air Intake System Tubes
1 - BOLT
2 - CHARGE AIR COOLER
3 - CLAMP
4 - BOOST TUBE
DREXHAUST SYSTEM 11 - 17
CHARGE AIR COOLER AND PLUMBING (Continued)

(14) Remove the bolts attaching the lower radiator
crossmember to the hydroform fender rail. (Fig. 18)
CAUTION: Do not use any flame or plasma cutting
equipment to cut the frame in this procedure. The
inaccurate and high temperatures achieved during
flame or plasma cutting will change the metal char-
acteristics and may weaken the frame and/or repair
location.
(15) Using a reciprocating saw or equivalent, cut
the fender rail and shotgun at a straight and square
section of the hydroform and remove.
(16) Smooth and square the cut edges.
(17) Using the damaged structure as a reference
cut the service part at the same location as the first
cut. Smooth and square the cut edges.
NOTE: The repair structure should butt up to the
remaining structure and provide the same overall
vehicle geometry.
(18) Fabricate 51 mm (2.0 in.) long repair inserts
using scrap from the old structure or the replacement
part. It will be necessary to split the inserts on each
of their four sides to fit into the hydroform.
(19) Remove any paint or e-coat from the inserts
and also to the interior and exterior of the hydro-
forms.
(20) Cut plug weld holes as described below.
²On the upper rail, cut one 13 mm (0.5 in.) hole
on each side of the rail, 25 mm (1.0 in.) from the butt
joint of the tubes.
²On the lower rail, cut one 13 mm (0.5 in.) hole
on the top and bottom sides of the rail 25 mm (1.0
in.) from the butt joint of the tube.
²On the lower rail, cut two 13 mm (0.5 in.) holes
on the inner and outer sides of the rail 25 mm (1.0
in.) from the butt joint of the tube.
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.
(21) Install the insert 1º into the replacement part
and tack into place with a weld. (Refer to 13 -
FRAME & BUMPERS/FRAME - SPECIFICATIONS -
WELDING)
(22) Insert the service part into place and using
the appropriate measuring equipment, verify the
front end sheet metal bracket's location in all three
(X,Y, and Z) planes of space. (Fig. 19)
(23) Complete all 360É plug welds.
NOTE: Before the final welding, use three dimen-
sional measuring equipment to ensure the part is in
the correct location. Verify that tap plate extrusion
at the bottom of the vertical post lines up with theisolator and hole in the frame perch mount. Also
ensure the lower radiator closure tube is bolted into
the forward shotgun ends.
(24) Complete welding by making a 360É butt weld
around the fender rails.
(25) Metal finish the exposed welds on the hydro-
forms.
(26) Dress the welded area and apply corrosion
resistant coatings inside and out.
(a) Inside the rail, inject a creeping wax based
rust inhibitor compound to the inside of the hydro-
forms ensuring 100% coverage including the mat-
ing face between the fender rail sections and insert
such that corrosion protection is restored in the
internal cavity.
(b) Apply a durable top coat to the outside of the
repair area.
(27) Install the front cab mount bolt if previously
removed and tighten to 81 N´m (60 ft. lbs.).
(28) Install the lower radiator crossmember bolts
and tighten to 28 N´m (21 ft. lbs.).
(29) Install the headlamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - INSTALLATION)
(30) Install the upper radiator crossmember. (Refer
to 23 - BODY/EXTERIOR/UPPER RADIATOR
CROSSMEMBER - INSTALLATION)
(31) Install the wire harness and ground if previ-
ously removed and install the bolts.
(32) Install the integrated power module, if previ-
ously removed. (Refer to 8 - ELECTRICAL/POWER
DISTRIBUTION/INTEGRATED POWER MODULE -
INSTALLATION)
(33) Install the air cleaner bracket and air cleaner,
if previously removed. (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
INSTALLATION)
(34) Install the radiator assembly. (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION)
(35) Install the A/C lines, if previously removed.
Refer to the Heating and Air Conditioning section of
the manual for the recommended procedures.
(36) Install the A/C condenser, if previously
removed. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C CONDENSER - INSTAL-
LATION)
(37) Install the fender. (Refer to 23 - BODY/EXTE-
RIOR/FRONT FENDER - INSTALLATION)
(38) Install the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION)
(39) Reconnect the battery ground.
13 - 12 FRAMES & BUMPERSDR
FRAME (Continued)

(26) Install the lower shock absorber bolts. (Refer
to 2 - SUSPENSION/REAR/SHOCK - INSTALLA-
TION)
(27) Install the trailer hitch. (Refer to 13 - FRAME
& BUMPERS/FRAME/TRAILER HITCH - INSTAL-
LATION)(28) Install the cargo box. (Refer to 23 - BODY/EX-
TERIOR/CARGO BOX - INSTALLATION)
(29) Reconnect the battery ground.
SPECIFICATIONS
SPECIFICATIONS - WELD PROCESS
CAUTION: All welds should conform to
DaimlerChrysler vehicle engineering process stan-
dard ªps 9472º.
WELDING PROCESS FLUX CORED ARC GAS METAL ARC (MIG)* SHIELDED METAL ARC
(STICK)
Material Thickness3.7 mm to 4.2 mm 3.7 mm to 4.2 mm 3.7 mm to 4.2 mm
Electrode TypeLincoln Electrical Co.
Product #: NR-211 MP
(Do Not Substitute)AWS ER70S-3
(Do Not Substitute)** AWS E 7018
Electrodes Size Inches.045 Tubular .035 Solid 3/329
Electrode Stick Out3/89- 1/291/29- 5/89N/A
PolarityElectrode9-9
Work Piece9+9Electrode9+9
Work Piece9-9Electrode9+9
Work Piece9-9
Shielding GasSelf Shielded 75% Ar
25% CO2Self Shielded
Gas Flow RateN/A 25 - 35 CFM N/A
Wire Feed Speed
(inches per minute)110 - 130 Vertical Down
70 - 90 Flat & Overhead245 - 250 Vertical Down
210 - 225 Flat &
OverheadN/A
Approximate Amperage
Vertical110 - 130 175 85 (3/329Diameter)
Flat & Overhead70 - 90 155 90 (3/329Diameter)
Voltage15-18 19-20 N/A
Direction of Welding
VerticalVertical Down Hill (only) Vertical Down Hill (only) Vertical - Up Hill (only)
Flat & OverheadFlat - Push or Drag Flat - Push or Drag Flat - Drag
*First choice - Gas Metal Arc Welding Process:Butt joints - apply two layers (passes) of weld metal. First pass
should only fill approximately
1¤2the thickness. Vertical position welds - maintain electrode wire at leading edge of
weld puddle while traveling down hill to produce maximum penetration into the sleeve. These techniques work for
FCAW as well.
**E7018new electrodes may be exposed to the atmosphere for up to ten hours with no harmful effect.
Reconditioning schedules should come from the manufacturer.
DRFRAMES & BUMPERS 13 - 15
FRAME (Continued)

REMOVAL
The fuel level sending unit (fuel level sensor) and
float assembly is located on the side of the fuel pump
module (Fig. 3).
(1) Remove fuel pump module from fuel tank.
Refer to Fuel Pump Module Removal/Installation.
(2) To remove sending unit from pump module, lift
on plastic locking tab (Fig. 4) while sliding sending
unit tracks.
(3) Disconnect 4±wire electrical connector (Fig. 3)
from fuel pump module. Separate necessary sending
unit wiring from connector using terminal pick /
removal tool. Refer to Special Tools in 8W Wiring for
tool part numbers.
INSTALLATION
(1) Connect necessary wiring into electrical con-
nectors. Connect 4±wire electrical connector to pump
module.
(2) Position sending unit to pump module. Slide
and snap into place.
(3) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
FUEL LINES
DESCRIPTION
Also refer to Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM MAY BE UNDER A
CONSTANT PRESSURE (EVEN WITH THE ENGINE
OFF). BEFORE SERVICING ANY FUEL SYSTEM
HOSES, FITTINGS, LINES, OR MOST COMPO-
NENTS, FUEL SYSTEM PRESSURE MUST BE
RELEASED. REFER TO THE FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
The lines/tubes/hoses used on fuel injected vehicles
are of a special construction. This is due to the
higher fuel pressures and the possibility of contami-
nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, only those marked EFM/EFI
may be used.
If equipped:The hose clamps used to secure rub-
ber hoses on fuel injected vehicles are of a special
rolled edge construction. This construction is used to
prevent the edge of the clamp from cutting into the
hose. Only these rolled edge type clamps may be
used in this system. All other types of clamps may
cut into the hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
Fig. 3 LOCATION - FUEL GAUGE SENDING UNIT
1 - FUEL FILTER / FUEL PRESSURE REGULATOR
2 - FUEL PUMP MODULE ASSEMBLY
3 - 4-WAY ELEC. CONNECT.
4 - FLOAT ARM
5 - ELEC. FUEL PUMP
6 - INLET FILTER
7 - FUEL GAUGE SENDING UNIT
8 - GASKET (SEAL)
Fig. 4 FUEL GAUGE SENDING UNIT - R/I
1 - SENDING UNIT
2 - LOCK TAB
3 - TRACKS
4 - NOTCH
DRFUEL DELIVERY - GAS 14 - 7
FUEL LEVEL SENDING UNIT / SENSOR (Continued)