2001 DODGE RAM Service Repair Manual

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Page 1465 of 2889

DODGE RAM 2001 Service Repair Manual proper alignment with other parts in the system and
provide acceptable exhaust noise levels.
INSTALLATION
(1) Install the exhaust pipe into the transmission
support and onto the turbocharger flange (F

Page 1466 of 2889

DODGE RAM 2001 Service Repair Manual INSTALLATION
(1) Assemble muffler and clamps loosely to permit
proper alignment of all parts.
(2) Connect the muffler hanger.
(3) Tighten the clamp nuts to 48 N´m (35 ft. lbs.)
torque.
(4) Lower the

INSTALLATION
(1) Assemble muffler and clamps loosely to permit
proper alignment of all parts.
(2) Connect the muffler hanger.
(3) Tighten the clamp nuts to 48 N´m (35 ft. lbs.)
torque.
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels. A
minimum of 25.4 mm (1.0 in.) is required between
exhaust system components and body/frame parts.
Adjust the alignment, if needed.
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. 14).
(4) Disconnect the muffler from the hanger isola-
tors (Fig. 14).
(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. 14).(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 48 N´m
(35 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Connect the battery negative cables.
(7) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels. A
minimum of 25.4 mm (1.0 in.) is required between
exhaust system components and body/frame parts.
Adjust the alignment, if needed.
TAILPIPE - 3.9L/5.2L/5.9L
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.
(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-
Fig. 13 Muffler for 5.9L Heavy Duty and 8.0L
1 - HANGER
2 - TAILPIPE
3 - CLAMP
4 - MUFFLER
5 - INSULATOR
Fig. 14 Muffler Removal/Installation
1 - HANGER BRACKETS
2 - ISOLATOR
3 - TAILPIPE
4 - CLAMP
5 - MUFFLER
6 - EXTENSION PIPE
7 - HANGER W/CLAMP
BR/BEEXHAUST SYSTEM 11 - 11
MUFFLER - 3.9L/5.2L/5.9L/8.0L (Continued)

Page 1467 of 2889

DODGE RAM 2001 Service Repair Manual 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

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 48 N´m (35 ft. lbs.)
torque.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and exhaust system 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. Adjust the alignment, if needed.
TAILPIPE - 5.9L HEAVY
DUTY/8.0L
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with MopartRust
Penetrant. Allow 5 minutes for penetration.
(3) Disconnect the exhaust tailpipe support hang-
ers (Fig. 15).
(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 (Fig. 15).
(2) Connect the support hangers (Fig. 15).
(3) Position the exhaust tailpipe for proper clear-
ance with the underbody parts.
(4) Tighten all clamp nuts to 48 N´m (35 ft. lbs.)
torque.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and exhaust system 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. Adjust the alignment, 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. 16).
(5) Remove the muffler-to-tailpipe clamps (Fig. 16).
(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.
INSTALLATION
(1) Install the tailpipe into the muffler.
(2) Install the tailpipe hanger rods into the isola-
tors (Fig. 16)
(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.
Fig. 15 TAILPIPE 8.0L AND 5.9L HEAVY DUTY
1 - HANGER
2 - TAILPIPE
3 - CLAMP
4 - MUFFLER
5 - INSULATOR
11 - 12 EXHAUST SYSTEMBR/BE
TAILPIPE - 3.9L/5.2L/5.9L (Continued)

Page 1468 of 2889

DODGE RAM 2001 Service Repair Manual (6) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
RESONATOR
REMOVAL
(1) Disconnect the battery negative cables.
(2) R

(6) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
RESONATOR
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove the exhaust clamps from the resonator
to extension pipes (Fig. 17).
(4) Separate the resonator from the front and rear
extension pipes (Fig. 17) and remove the resonator
from the vehicle.
INSTALLATION
(1) Assemble the resonator to the front and rear
extension pipes (Fig. 17).
(2) Install new exhaust clamps, align the exhaust
system, and tighten the exhaust clamps to 48 N´m
(35 ft. lbs.) torque.
(3) Lower the vehicle.
(4) Connect the battery negative cables.
(5) Start the engine and inspect for exhaust leaks.
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. 18) (Fig. 19):
²Turbine section
²Compressor section
²Bearing housing
²Wastegate
OPERATION
Exhaust gas pressure and energy drive the tur-
bine, which in turn drives a centrifugal compressor
that compresses the inlet air, and forces the air into
the engine through the charge air cooler and plumb-
ing. Since heat is a by-product of this compression,
the air must pass through a charge air cooler to cool
the incoming air and maintain power and efficiency.
Increasing air flow to the engine provides:
²Improved engine performance
²Lower exhaust smoke density
²Improved operating economy
²Altitude compensation
²Noise reduction.
Fig. 16 Tailpipe Removal/Installation
1 - HANGER BRACKETS
2 - ISOLATOR
3 - TAILPIPE
4 - MUFFLER
Fig. 17 Resonator Removal/Installation
1 - EXTENSION PIPE
2 - RESONATOR
3 - EXTENSION PIPE
4 - CLAMP
BR/BEEXHAUST SYSTEM 11 - 13
TAILPIPE - 5.9L DIESEL (Continued)

Page 1469 of 2889

DODGE RAM 2001 Service Repair Manual The turbocharger also uses a wastegate (Fig. 20),
which regulates intake manifold air pressure andprevents over boosting at high engine speeds. When
the wastegate valve is closed, all of the exhaust g

Page 1470 of 2889

DODGE RAM 2001 Service Repair Manual bearing housing, routes the engine oil back to the
crankcase.
The most common turbocharger failure is bearing
failure related to repeated hot shutdowns with inad-
equate ªcool-downº periods. A sudde

bearing housing, routes the engine oil back to the
crankcase.
The most common turbocharger failure is bearing
failure related to repeated hot shutdowns with inad-
equate ªcool-downº periods. A sudden engine shut
down after prolonged operation will result in the
transfer of heat from the turbine section of the tur-
bocharger to the bearing housing. This causes the oil
to overheat and break down, which causes bearing
and shaft damage the next time the vehicle is
started.
Letting the engine idle after extended operation
allows the turbine housing to cool to normal operat-
ing temperature. The following chart should be used
as a guide in determining the amount of engine idle
time required to sufficiently cool down the turbo-
charger before shut down, depending upon the type
of driving and the amount of cargo.
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Disconnect the exhaust pipe from the turbo-
charger elbow (Fig. 22).
(4) Lower vehicle.
(5) Disconnect the turbocharger air inlet hose (Fig.
23).
(6) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger (Fig. 24).
(7) Disconnect the charge air cooler inlet pipe from
the turbocharger (Fig. 24).(8) Remove the turbocharger and gasket from the
exhaust manifold.
(9) If the turbocharger is not to be installed imme-
diately, cover the opening to prevent material from
entering into the manifold.
(10) If replacing the turbocharger, transfer the dis-
charge elbow and clamp to the new assembly.
(11) Clean and inspect the sealing surface.
Fig. 21 Turbocharger Oil Supply and Drain
1 - BEARINGS
2 - OIL SUPPLY (FROM FILTER HEAD)
3 - OIL RETURN (TO SUMP)
Fig. 22 Exhaust Pipe Removal/Installation
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
Fig. 23 Turbocharger Air Inlet Hose
1 - AIR FILTER HOUSING COVER
2 - TURBOCHARGER
3 - AIR INLET TUBE
4 - HOSE CLAMP
5 - HINGE TABS
6 - FILTER MINDER
7 - CLIPS (4)
8 - TUBE ALIGNMENT NOTCHES
BR/BEEXHAUST SYSTEM 11 - 15
TURBOCHARGER (Continued)

Page 1471 of 2889

DODGE RAM 2001 Service Repair Manual 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
Clean the turbocharger and exhaust manifo

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
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. 25).
Replace the turbocharger if the condition exists.
(4) Measure the turbocharger axial end play:
(a) Install a dial indicator as shown in (Fig. 26).
Zero the indicator at one end of travel.
(b) Move the impeller shaft fore and aft and
record the measurement. Allowable end play is
0.038 mm (0.0015 in.) MIN. and 0.089 mm (0.0035
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. 27).
(b) Gently push the compresser 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 0.326
mm (0.0128 in.) MIN. and 0.496 mm (0.0195 in.)
MAX. If the recorded measurement falls outside
these specifications, replace the turbocharger assy.
INSTALLATION
(1) Install the turbocharger. Apply anti-seize to the
studs and then tighten the turbocharger mounting
nuts to 32 N´m (24 ft. lbs.) torque.
(2) Install the oil drain tube and oil supply line to
the turbocharger (Fig. 24). Tighten the drain tube
bolts to 24 N´m (18 ft. lbs.) torque.
Fig. 24 Oil Supply Line and Charge Air Cooler Inlet
Duct
1 - EXHAUST PIPE
2 - TURBOCHARGER
3 - AIR INLET TUBE
4 - COOLER INLET DUCT
Fig. 25 Inspect Compressor Housing for Impeller
Rubbing Condition
11 - 16 EXHAUST SYSTEMBR/BE
TURBOCHARGER (Continued)

Page 1472 of 2889

DODGE RAM 2001 Service Repair Manual (3)Pre-lube the turbocharger.Pour 50 to 60 cc
(2 to 3 oz.) clean engine oil in the oil supply line fit-
ting. Carefully rotate the turbocharger impeller by
hand to distribute the oil thoroughly.
(4) I

(3)Pre-lube the turbocharger.Pour 50 to 60 cc
(2 to 3 oz.) clean engine oil in the oil supply line fit-
ting. Carefully rotate the turbocharger impeller by
hand to distribute the oil thoroughly.
(4) Install and tighten the oil supply line fitting
nut to 20 N´m (133 in. lbs.) torque.
(5) Position the charge air cooler inlet pipe to the
turbocharger. With the clamp in position, tighten the
clamp nut to 11 N´m (95 in. lbs.) torque.
(6) Position the air inlet hose to the turbocharger
(Fig. 23). Tighten the clamp to 11 N´m (95 in. lbs.)
torque.
(7) Raise vehicle on hoist.
(8) Connect the exhaust pipe to the turbocharger
(Fig. 22) and tighten the bolts to 34 N´m (25 ft. lbs.)
torque.
(9) Lower the vehicle.
(10) Connect the battery negative cables.
(11) Start the engine to check for leaks.
CHARGE AIR COOLER AND
PLUMBING
DESCRIPTION
The charge air system (Fig. 28) consists of the
charge air cooler piping, charge air cooler and intake
air grid heater.
The charge air cooler is a heat exchanger that uses
air flow from vehicle motion to dissipate heat from
the intake air. As the turbocharger increases air
pressure, the air temperature increases. Lowering
the intake air temperature increases engine effi-
ciency and power.
OPERATION
Intake air is drawn through the air cleaner and
into the turbocharger compressor housing. Pressur-
ized air from the turbocharger then flows forward
through the charge air cooler located in front of the
radiator. From the charge air cooler the air flows
back into the intake manifold.
REMOVAL
WARNING: IF THE ENGINE WAS JUST TURNED
OFF, THE AIR INTAKE SYSTEM TUBES MAY BE
HOT.
(1) Disconnect the battery negative cables.
(2) Remove the front bumper (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT
BUMPER - REMOVAL).
Fig. 26 Measure Turbocharger Axial End Play
Fig. 27 Measure Turbocharger Bearing Radial
Clearance
1 - FEELER GAUGE
Fig. 28 Intake Air Circulation
1 - CHARGE AIR COOLER
2 - AIRFILTER
3 - TURBOCHARGER
BR/BEEXHAUST SYSTEM 11 - 17
TURBOCHARGER (Continued)

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