
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)

(6) Full load boost pressure at rated speed will be
158 - 186 kPa (23 - 27 psi.) depending on engine hp
rating.. If pressure readings are are not within this
range inspect for the following:
²Restricted air inlet system
²Leak in the charge air cooler system (Refer to 11
- EXHAUST SYSTEM/TURBOCHARGER SYSTEM/
CHARGE AIR COOLER AND PLUMBING - DIAG-
NOSIS AND TESTING)
²Turbocharger wastegate broken or misadjusted
²Restricted/high pressure drop across charge air
cooler
²Turbocharger damaged (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER SYSTEM/TURBO-
CHARGER - INSPECTION)
TURBOCHARGER
DESCRIPTION
The turbocharger is an exhaust-driven super-
charger which increases the pressure and density of
the air entering the engine. With the increase of air
entering the engine, more fuel can be injected into
the cylinders, which creates more power during com-
bustion.
The turbocharger assembly consists of four (4)
major component systems (Fig. 14) (Fig. 15) :²Turbine section
²Compressor section
²Bearing housing
²Wastegate
Fig. 13 INTAKE MANIFOLD TO AIR INLET DUCT
RUBBER SLEEVE
1 - INTAKE MANIFOLD AIR INLET
2 - CLAMPS
3 - AIR INLET DUCT
4 - AIR INLET DUCT RUBBER SLEEVE
Fig. 14 Turbocharger Operation
1 - TURBINE SECTION
2 - EXHAUST GAS
3 - BEARING HOUSING
4 - COMPRESSOR SECTION
5 - INLET AIR
6 - COMPRESSED AIR TO ENGINE
7 - EXHAUST GAS
8 - EXHAUST GAS TO EXHAUST PIPE
Fig. 15 Turbocharger Wastegate Actuator
1 - TURBOCHARGER
2 - DIAPHRAGM
3 - WASTE GATE ACTUATOR
11 - 12 EXHAUST SYSTEMDR
TURBOCHARGER SYSTEM (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)

INSTALLATION
(1) Align the holes in the bumpers to the trailer
hitch pins and install the bumper.
(2) Install the support bracket to the hitch bolts,
loosely.
(3) Install the front upper edge to the trailer hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(4) Install the license plate reinforcement to hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(5) Tighten the left bumper bracket bolts to 54
N´m (40 ft. lbs.).
(6) Tighten the right bumper bracket bolts to 54
N´m (40 ft. lbs.).
(7) Connect the trailer light connector electrical
connection, if equipped.
(8) Connect the license plate light electrical con-
nectors.
(9) Install the license plate.
FRAME
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
²BEFORE PROCEEDING WITH FRAME REPAIR
INVOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
²DO NOT ALLOW OPEN FLAME OR HEAT AND
METAL SPATTER FROM ARC WELDING, TO CON-
TACT PLASTIC BODY PANELS. FIRE OR EXPLO-
SION CAN RESULT.
²WHEN WELDED FRAME COMPONENTS ARE
REPLACED, ENSURE COMPLETE PENETRATION
WELD IS ACHIEVED DURING INSTALLATION. IF
NOT, DANGEROUS OPERATING CONDITIONS CAN
RESULT.
²STAND CLEAR OF CABLES OR CHAINS ON
PULLING EQUIPMENT DURING FRAME STRAIGHT-
ENING OPERATIONS, PERSONAL INJURY CAN
RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT SUPPORTED ON SAFETY
STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: 1500 series Dodge Ram Trucks (2002 and
later) are not designed for snow plow equipment.The front collision repair tips must not be installed
on any truck equipped with a snow plow, or even
intended to be equipped with a snow plow.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Failure to use only pro-
duction fasteners or fasteners of equivalent hard-
ness can result in loosening or failure. Do not drill
any holes in the frame that are not specifically out-
lined in this or other, DaimlerChrysler procedure as
frame rail failure can result. When using heat to
straighten frame components do not exceed 566ÉC
(1050ÉF), metal fatigue can result.
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY FRONT
FRAME RAIL TIP REPLACEMENT
CAUTION: This procedure is designed to replace
the front frame rail tips that have been damaged in
the crush initiator zones. Prior to any cutting, the
vehicle must be mounted on the appropriate frame
repair equipment (ªframe rackº), checked with three
dimensional measuring equipment, and the neces-
sary pull corrections made. If damage remains in
the frame beyond the area covered by this service
part after the pull, the frame must be replaced in its
entirety.
NOTE: Procedures for 4X2 and 4X4 are common
except as noted in this procedure.
(1) Before proceding with this repair procedure
review the required service warnings and precau-
tions. (Refer to 13 - FRAME & BUMPERS/FRAME -
WARNING)
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - REMOVAL)
(4) Remove the bolts and position aside the wire
harness and grounds, if required.
(5) Remove the front bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- REMOVAL)
(6) Loosen and lower the stabilizer bar mount and
bar. (Refer to 2 - SUSPENSION/FRONT/STABI-
LIZER BAR - REMOVAL)
13 - 4 FRAMES & BUMPERSDR
REAR BUMPER (Continued)

(25) Confirm alignment of the replacement frame
rail tip. (Fig. 14)
(26) Final welding should be performed in a skip
(stitch) type method to minimize the heat buildup
and frame distortion, utilizing the Weld Process
Specifications at the end of this section. The pre-
ferred method is GMAW (MIG). (Refer to 13 -
FRAME & BUMPERS/FRAME - SPECIFICATIONS -
WELDING)
(a) Apply root pass welds to the root joint one
quadrant at a time, switching to the opposite side
of the frame for each quadrant. (Fig. 8)
(b) Clean the welds of any flux and other impu-
rities before proceeding with the cover pass welds.
(c) Apply the cover pass welds in the same man-
ner as described above.
(27) Confirm alignment of the replacement frame
rail tip. (Fig. 14)
NOTE: Any burned surface coatings will need to be
removed prior to application of corrosion preventa-
tive coatings.
(28) Dress the welded area and apply corrosion
resistant coatings inside and out.
(a) Apply etch-primer to the inside of the frame
rail repair area.
(b) Inside the rail, inject a creeping wax based
rust inhibitor compound through the existing holes
in the frame ensuring 100% coverage including the
space between the original frame rail and the rein-
forcing sleeve.
(c) Apply a durable top coat to the outside of the
repair area.
(29) Tighten the front cab mounting bolt to the
FESM bracket to 81 N´m (60 ft. lbs.).(30) Install the stabilizer bar. (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER BAR - INSTALLA-
TION)
(31) Install the front bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- INSTALLATION)
(32) Install the wire harness and ground strap if
previously removed and install the bolt.
(a) If necessary, re-drill and tap the ground
strap mounting hole
(33) Install the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION)
Fig. 13 RING FILLET WELD
1 - WELD START LOCATION
2 - WELD END LOCATION
3 - RING-FILLET WELD
Fig. 14 FRAME TIP DIMENSIONS
1 - PLP POINT
2 - FRAME
3 - PLP POINT
4 - REPLACEMENT FRAME TIP
DRFRAMES & BUMPERS 13 - 9
FRAME (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)

(9) Remove the clip and remove the spare tire
winch tube. (Fig. 21)
(10) Remove the bolts and remove the spare tire
winch. (Fig. 22)
(11) Position the wire harness forward of the work
area.
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.(12) Carefully remove the H-section welds using a
grinder or equivalent tool.
(13) Remove the H-section and clean any remain-
ing welds from the frame.
(14) Trial fit the replacement part.
(15) Remove all e-coat from within 25 mm (1.0 in.)
of the weld area.
(16) Using the appropriate measuring equipment,
position the replacement part and verify correct posi-
tioning in all three (X,Y, and Z) planes of space.
(Refer to 13 - FRAME & BUMPERS/FRAME - SPEC-
IFICATIONS - FRAME DIMENSIONS)
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.
(17) Weld the replacement H-section into position.
The welding should be performed in a skip (stitch)
type method to minimize the heat buildup following
I-CAR or the American Welding Society welding pro-
cedures and utilizing the process specifications at the
end of this section. (Refer to 13 - FRAME &
BUMPERS/FRAME - SPECIFICATIONS - WELD-
ING)
(18) Dress the welded area and apply corrosion
resistant coatings inside and out.
(a) Inside the rail, inject a creeping wax based
rust inhibitor compound through the existing holes
in the frame ensuring 100% coverage including the
mating face between the frame and replacement
H-section.
(b) Apply a durable top coat to the outside of the
repair area.
(19) Position the wiring harness back.
CAUTION: Inspect the tire winch assembly for dam-
age. If any one or more of the following are evident,
replace the winch assembly.
²Indications of cracked or bulging plastic.
²Housing flanges are bent or cracked.
²If winch was loose before repair.
(20) Install the spare tire winch and install the
bolts. (Fig. 22)
(21) Tighten the bolts to 41 N´m (30 ft. lbs.).
(22) Install the spare tire winch tube and install
the clip. (Fig. 21)
(23) Install the spare tire.
CAUTION: Check operation of the spare tire winch
by manipulating it up and down. If the winch binds
or jambs, replace the winch assembly.
(24) Lift the axle into position and install the rear
shackle bolts. (Fig. 20)
(25) Tighten the bolts to 163 N´m (120 ft. lbs.).
Fig. 21 SPARE TIRE WINCH TUBE
1 - SPARE TIRE WINCH ASSEMBLY
2 - HAIR PIN CLIP
3 - WINCH TUBE
4 - H-SECTION/SPARE WHEEL SUPPORT
Fig. 22 SPARE TIRE WINCH ASSEMBLY
1 - SPARE TIRE WINCH ASSEMBLY
2 - BOLTS
3 - RETAINER BRACKET
4 - H-SECTION/SPARE WHEEL SUPPORT
13 - 14 FRAMES & BUMPERSDR
FRAME (Continued)

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY - GAS....................1
FUEL INJECTION - GAS...................21FUEL DELIVERY - DIESEL.................44
FUEL INJECTION - DIESEL................68
FUEL DELIVERY - GAS
TABLE OF CONTENTS
page page
FUEL DELIVERY - GAS
DESCRIPTION..........................1
OPERATION............................2
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE...................2
SPECIFICATIONS
FUEL SYSTEM PRESSURE..............3
TORQUE - FUEL SYSTEM - EXCEPT
DIESEL..............................3
SPECIAL TOOLS
FUEL SYSTEM........................5
FUEL FILTER/PRESSURE REGULATOR
DESCRIPTION..........................5
OPERATION............................6
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................7
INSTALLATION..........................7
FUEL LINES
DESCRIPTION..........................7
QUICK CONNECT FITTING
DESCRIPTION..........................8STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS............................8
FUEL PUMP
DESCRIPTION.........................11
OPERATION...........................11
FUEL PUMP MODULE
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................12
INSTALLATION.........................12
FUEL RAIL
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL.............................13
INSTALLATION.........................15
FUEL TANK
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL- EXCEPT DIESEL..............17
INSTALLATION - EXCEPT DIESEL..........19
INLET FILTER
REMOVAL.............................20
INSTALLATION.........................20
FUEL DELIVERY - GAS
DESCRIPTION
The fuel delivery system consists of:
²a fuel pump module containing the electric fuel
pump, fuel filter/fuel pressure regulator, fuel gauge
sending unit (fuel level sensor) and a secondary fuel
filter located at the bottom of the pump module
²fuel tubes/lines/hoses
²a combination fuel filter/fuel pressure regulator
²quick-connect fittings²fuel injector rail
²fuel tank
²fuel tank filler/vent tube assembly
²fuel tank filler tube cap
²accelerator pedal
²throttle cable
Certain fuel delivery components can be found in
(Fig. 1).
DRFUEL SYSTEM 14 - 1