2001 DODGE RAM Heat

CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
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) Using a new gasket, install the intake manifold
cover.
(2) Install the cover-to-cylinder head bolts that do
not hold down the high pressure fuel line support
brackets. Tighten the bolts to 24 N´m (18 ft. lbs.)
torque.
(3) Install the high pressure fuel lines (Refer to 14
- FUEL SYSTEM/FUEL DELIVERY/FUEL LINES -
INSTALLATION).(4) Install the high pressure fuel line support
bracket-to-intake manifold cover bolts and tighten to
24 N´m (18 ft. lbs.) torque.
Fig. 167 Charge Air Cooler Air Tube
1 - FRONT WIRING CLIP
2 - GROUND CABLE
3 - TUBE BOLT
4 - ENGINE OIL DIPSTICK TUBE
5 - CLAMPS
6 - AIR TUBE (INT. MAN.-TO-INTERCOOLER)
7 - RUBBER HOSE
8 - AIR INTAKE HOUSING
9 - CABLE BRACKET HOUSING
Fig. 168 Air Inlet Housing
1 - GROUND STRAP
2 - AIR INTAKE HOUSING
3 - HEATER POWER CABLE MOUNTING STUDS
4 - FUEL LINE BRACKET BOLT
5 - HOUSING BOLTS (4)
Fig. 169 Intake Air Grid Heater
1 - AIR HEATER ELEMENTS
2 - LOWER GASKET
3 - BLOCK
4 - UPPER GASKET
9 - 302 ENGINE 5.9L DIESELBR/BE
INTAKE MANIFOLD (Continued)

(5) Using two (2) new gaskets, install the intake
air grid heater and air inlet housing (Fig. 168). Posi-
tion the ground cable and install and tighten the
bolts to 24 N´m (18 ft. lbs.) torque.
(6) Install and tighten the air intake heater power
supply nuts to 14 N´m (120 in. lbs.) torque.
(7) Install the engine oil dipstick tube and mount-
ing bolt (Fig. 167).
(8) Position the charge air cooler outlet tube onto
the air inlet housing (Fig. 167). Tighten the clamps
to 8 N´m (72 in. lbs.) torque.
(9) Perform the fuel system air bleed procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(10) Connect the battery negative cables.
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Disconnect the exhaust pipe from the turbo-
charger elbow (Fig. 170).
(4) Lower vehicle.
(5) Disconnect the turbocharger air inlet hose (Fig.
171).
(6) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger (Fig. 172).
(7) Disconnect the charge air cooler inlet pipe from
the turbocharger (Fig. 172).
(8) Remove the turbocharger and gasket from the
exhaust manifold.
(9) Remove the cab heater return pipe nut from
the exhaust manifold stud. Position the tube out of
the way.
Fig. 170 Exhaust Pipe
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
Fig. 171 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
Fig. 172 Oil Supply Line and Charge Air Cooler Inlet
Duct
1 - EXHAUST PIPE
2 - TURBOCHARGER
3 - AIR INLET TUBE
4 - INTERCOOLER INLET DUCT
5 - WASTE GATE ACTUATOR
BR/BEENGINE 5.9L DIESEL 9 - 303
INTAKE MANIFOLD (Continued)

(10) Remove the exhaust manifold-to-cylinder head
bolts and spacers (Fig. 173).
(11) Remove the exhaust manifold and gaskets
(Fig. 173).
CLEANING
Clean the cylinder head and exhaust manifold seal-
ing surfaces with a suitable scraper. Use a Scotch-
BriteŸ pad or equivalent.
INSPECTION
Inspect the exhaust manifold for cracks. Measure
the exhaust manifold for flatness. Place a ruler over
all of the exhaust ports and insert a feeler gauge
between the port flange and the ruler.
INSTALLATION
(1) Using new gaskets, install the exhaust mani-
fold and gaskets. Install the bolts and spacers and
tighten the bolts in the sequence shown in (Fig. 173)
to 43 N´m (32 ft. lbs.) torque.
(2) Install the cab heater return hose to the man-
ifold bolt stud. Tighten the nut to 24 N´m (18 ft. lbs.)
torque.
(3) Install the turbocharger. Apply anti-seize to the
studs and then tighten the turbocharger mounting
nuts to 32 N´m (24 ft. lbs.) torque.(4) Install the oil drain tube and oil supply line to
the turbocharger. Tighten the drain tube bolts to 24
N´m (18 ft. lbs.) torque.
(5)Pre-lube the turbocharger.Pour 50 to 60 cc
(2 to 3 oz.) clean engine oil in the oil supply line fit-
ting. Rotate the turbocharger impeller by hand to
distrubute the oil thoroughly.
(6) Install and tighten the oil supply line fitting
nut to 20 N´m (133 in. lbs.) torque.
(7) Position the charge air cooler inlet pipe to the
turbocharger. With the clamp in position, tighten the
clamp nut to 8 N´m (72 in. lbs.) torque.
(8) Position the air inlet hose to the turbocharger
(Fig. 171). Tighten the clamp to 8 N´m (72 in. lbs.)
torque.
(9) Raise vehicle on hoist.
(10) Connect the exhaust pipe to the turbocharger
(Fig. 170) and tighten the bolts to 34 N´m (25 ft. lbs.)
torque.
(11) Lower the vehicle.
(12) Connect the battery negative cables.
(13) Start the engine to check for leaks.
GEAR HOUSING
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove the oil pan and suction tube (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(4) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(5) Lower vehicle.
(6) Remove radiator upper hose.
(7) Disconnect coolant recovery bottle hose from
radiator filler neck and lift bottle off of fan shroud.
(8) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(9) Remove the fan shroud-to-radiator mounting
bolts.
(10) Remove viscous fan/drive assembly (Refer to 7
- COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(11) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove the cooling fan support/hub from the
front of the engine (Fig. 174).
(13) Raise the vehicle on hoist.
(14) Remove the crankshaft damper (Fig. 175)
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(15) Lower the vehicle.
Fig. 173 Exhaust Manifold and Gaskets
9 - 304 ENGINE 5.9L DIESELBR/BE
EXHAUST MANIFOLD (Continued)

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION............................1
DIAGNOSIS AND TESTING..................4
GAS ENGINE...........................4
DIESEL ENGINE........................4
SPECIFICATIONS.........................5
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L
DESCRIPTION............................5
OPERATION.............................5
REMOVAL...............................5
INSPECTION.............................5
INSTALLATION............................5
CATALYTIC CONVERTER - 5.9L HEAVY
DUTY/8.0L
DESCRIPTION............................6
OPERATION.............................6
REMOVAL...............................6
INSPECTION.............................7
INSTALLATION............................7
EXHAUST PIPE - 3.9L/5.2L/5.9L
REMOVAL...............................7
INSPECTION.............................7
INSTALLATION............................7
EXHAUST PIPE - 5.9L HEAVY DUTY/8.0L
REMOVAL...............................8
INSPECTION.............................9
INSTALLATION............................9
EXHAUST PIPE - 5.9L DIESEL
REMOVAL...............................9
INSPECTION.............................9
INSTALLATION...........................10
HEAT SHIELDS
DESCRIPTION...........................10
REMOVAL..............................10
INSTALLATION...........................10MUFFLER - 3.9L/5.2L/5.9L/8.0L
REMOVAL..............................10
INSTALLATION...........................11
MUFFLER - 5.9L DIESEL
REMOVAL..............................11
INSTALLATION...........................11
TAILPIPE - 3.9L/5.2L/5.9L
REMOVAL..............................11
INSPECTION............................11
INSTALLATION...........................12
TAILPIPE - 5.9L HEAVY DUTY/8.0L
REMOVAL..............................12
INSPECTION............................12
INSTALLATION...........................12
TAILPIPE - 5.9L DIESEL
REMOVAL..............................12
INSPECTION............................12
INSTALLATION...........................12
RESONATOR
REMOVAL..............................13
INSTALLATION...........................13
TURBOCHARGER
DESCRIPTION...........................13
OPERATION.............................13
REMOVAL..............................15
CLEANING..............................16
INSPECTION............................16
INSTALLATION...........................16
CHARGE AIR COOLER AND PLUMBING
DESCRIPTION...........................17
OPERATION.............................17
REMOVAL..............................17
CLEANING..............................18
INSPECTION............................18
INSTALLATION...........................18
EXHAUST SYSTEM
DESCRIPTIONÐ3.9L/5.2L/5.9/8.0L
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
BR/BEEXHAUST SYSTEM 11 - 1

The federal gasoline engine exhaust system (Fig. 1)
consists of engine exhaust manifolds, exhaust pipes,
catalytic converter(s), extension pipe (if needed),
exhaust heat shields, muffler and exhaust tailpipe.
The California emission vehicles exhaust system
also contains the above components as well as mini
catalytic converters added to the exhaust pipe (Fig.
2).The exhaust system must be properly aligned to
prevent stress, leakage and body contact. Minimum
clearance between any exhaust component and the
body or frame is 25.4 mm (1.0 in.). If the system con-
tacts any body panel, it may amplify objectionable
noises from the engine or body.
Fig. 1 Exhaust System Gasoline EnginesÐFederal Emissions (Typical)
1 - CATALYTIC CONVERTER
2 - TAILPIPE
3 - MUFFLER
4 - CATALYTIC CONVERTERS5 - AIR INDUCTION LINES
6 - EXHAUST PIPE
11 - 2 EXHAUST SYSTEMBR/BE
EXHAUST SYSTEM (Continued)

DESCRIPTIONÐ5.9L DIESEL
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
The diesel engine exhaust system consists of an
engine exhaust manifold, turbocharger, exhaust pipe,
resonator, extension pipe (if needed), muffler and
exhaust tailpipe.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. The
exhaust components should be kept a minimum of
25.4 mm (1.0 in.) away from the body and frame. If
the system contacts any body panel, it may amplify
objectionable noises from the engine or body.
Fig. 2 Catalytic Converter with Pipes and Mini
Catalytic Converters
1 - BOLT
2 - RETAINER
3 - EXHAUST MANIFOLD
4 - NUT
5 - MINI CATALYTIC CONVERTER
6 - CATALYTIC CONVERTER WITH PIPES
BR/BEEXHAUST SYSTEM 11 - 3
EXHAUST SYSTEM (Continued)

SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Adjusting StrapÐBolt 23 Ð 200
Air Heater Power SupplyÐ
Nuts14 Ð 124
Air Inlet HousingÐBolts 24 18 Ð
Cab Heater Supply/Return
LineÐNuts24 18 Ð
Exhaust ClampÐNuts 48 35 Ð
Exhaust Manifold to Cylinder
HeadÐBolts
(Diesel Engine) 43 32 Ð
Exhaust Manifold to Cylinder
HeadÐBolts
(3.9L/5.2L/5.9L) 31 23 Ð
Exhaust Manifold to Cylinder
HeadÐBolts
(8.0L) 22 Ð 195
Exhaust Pipe to ManifoldÐ
Bolts31 23 Ð
Generator MountingÐBolts 41 30 Ð
Charge Air Cooler
MountingÐBolts2Ð17
Charge Air Cooler DuctÐ
Nuts8Ð72
Heat ShieldÐNuts and Bolts 11 Ð 100
Turbocharger MountingÐ
Nuts32 24 Ð
Turbocharger Oil Drain
TubeÐBolts24 18 Ð
Turbocharger Oil Supply
LineÐFitting15 Ð 133
Turbocharger V-Band
ClampÐNut9Ð75
CATALYTIC CONVERTER -
3.9L/5.2L/5.9L
DESCRIPTION
The stainless steel catalytic converter is located
under the vehicle, integral to the exhaust pipe(s).
OPERATION
The catalytic converter captures and burns any
unburned fuel mixture exiting the combustion cham-
bers during the exhaust stroke of the engine. This
process aids in reducing emissions output.
REMOVAL
(1) Raise and support vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove clamps and nuts (Fig. 3) (Fig. 4).
(4) Remove the catalytic converter.
INSPECTION
Look at the stainless steel body of the converter,
inspect for bulging or other distortion that could be a
result of overheating. If the converter has a heat
shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tap-
ping the bottom of the catalyst with a rubber mallet
may indicate a damaged core.
INSTALLATION
(1) Assemble converter and clamps loosely in
place.
Fig. 3 Catalytic Converter and Exhaust Pipe 3.9L,
5.2L and 5.9L Light Duty ( Federal )
1 - BOLT
2 - EXHAUST PIPE W/CONVERTER
3 - NUT
4 - RETAINER
BR/BEEXHAUST SYSTEM 11 - 5

(2) Install the exhaust pipe onto exhaust mani-
folds, tighten 31 N´m (23 ft. lbs.).
(3) Tighten all 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.
CATALYTIC CONVERTER - 5.9L
HEAVY DUTY/8.0L
DESCRIPTION
The stainless steel catalytic converter is located
under the vehicle, attached to the exhaust pipe(s).
OPERATION
The catalytic converter captures and burns any
unburned fuel mixture exiting the combustion cham-
bers during the exhaust stroke of the engine. This
process aids in reducing emissions output.
REMOVAL
(1) Raise and support vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove clamps and nuts (Fig. 5) (Fig. 6).
(4) Remove the catalytic converter.
Fig. 4 Catalytic Converter and Exhaust Pipe 3.9L,
5.2L and 5.9L Light Duty ( California )
1 - BOLT
2 - RETAINER
3 - EXHAUST MANIFOLD
4 - NUT
5 - MINI CATALYTIC CONVERTER
6 - CATALYTIC CONVERTER WITH PIPES
Fig. 5 Catalytic Converter 5.9L Heavy Duty
1 - DOWN PIPE RIGHT
2 - CLAMP
3 - CLAMP
4 - HANGER ASSY. DUAL CLAMP
5 - MUFFLER
6 - EXTENSION PIPE
7 - CATALYTIC CONVERTER
8 - DOWN PIPE LEFT
Fig. 6 Catalytic Converter 8.0L
1 - CLAMPS
2 - CATALYTIC CONVERTERS
3 - MUFFLER
4 - HANGER ASSY. DUAL CLAMP
5 - EXTENSION PIPES
6 - DOWN PIPE
11 - 6 EXHAUST SYSTEMBR/BE
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L (Continued)