2002 DODGE RAM Service Repair Manual

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Page 1273 of 2255

DODGE RAM 2002 Service Repair Manual 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

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.
(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
HD/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.
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.
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
11 - 6 EXHAUST SYSTEMBR/BE
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L (Continued)

Page 1274 of 2255

DODGE RAM 2002 Service Repair Manual INSTALLATION
(1) Assemble converter and clamps loosely in
place.
(2) Tighten all clamp nuts to 48 N´m (35 ft. lbs.)
torque.
(3) Lower the vehicle.
(4) Start the engine and inspect for exhaust leaks
a

INSTALLATION
(1) Assemble converter and clamps loosely in
place.
(2) Tighten all clamp nuts to 48 N´m (35 ft. lbs.)
torque.
(3) Lower the vehicle.
(4) 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.
EXHAUST PIPE - 3.9L/5.2L/
5.9L
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove exhaust pipe to manifold bolts, retain-
ers and nuts (Fig. 7).
(4) Remove the clamp nuts (Fig. 7).
(5) Remove the exhaust pipe.
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) Position the exhaust pipe for proper clearance
with the frame and underbody parts. A minimum
clearance of 25.4 mm (1.0 in.) is required.
(2) Position the exhaust pipe to manifold. Install
the bolts, retainers and nuts. Tighten the nuts to 31
N´m (23 ft. lbs.) torque.
(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.
Adjust the alignment, if needed.
EXHAUST PIPE - 5.9L HD/8.0L
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove exhaust pipe to manifold bolts, retain-
ers and nuts (Fig. 8).
(4) Remove the clamp nuts (Fig. 9) (Fig. 10).
(5) Disconnect the exhaust pipe from the support
hangers on the 5.9L (Heavy Duty) and the 8.0L
engines (Fig. 8).
(6) Remove the exhaust pipe.
Fig. 6 Catalytic Converter 8.0L
1 - CLAMPS
2 - CATALYTIC CONVERTERS
3 - MUFFLER
4 - HANGER ASSY. DUAL CLAMP
5 - EXTENSION PIPES
6 - DOWN PIPEFig. 7 Exhaust Pipe 3.9L,5.2L, 5.9L Light Duty
1 - EXHAUST PIPE WITH CATALYTIC CONVERTER
2 - CLAMP
3 - MUFFLER
BR/BEEXHAUST SYSTEM 11 - 7
CATALYTIC CONVERTER - 5.9L HD/8.0L (Continued)

Page 1275 of 2255

DODGE RAM 2002 Service Repair Manual 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

Page 1276 of 2255

DODGE RAM 2002 Service Repair Manual EXHAUST PIPE - 5.9L DIESEL
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise and support the vehicle on a hoist.
(3) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes

Page 1277 of 2255

DODGE RAM 2002 Service Repair Manual HEAT SHIELDS
DESCRIPTION
There are two types of heat shields used. One is
stamped steel the other is molded foil sheets. The
shields attach to the vehicle around the exhaust sys-
tem to prevent heat f

Page 1278 of 2255

DODGE RAM 2002 Service Repair Manual 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 - 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-
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.
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 1279 of 2255

DODGE RAM 2002 Service Repair Manual (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
part

(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 HD/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.
Fig. 15 TAILPIPE 8.0L AND 5.9L HEAVY DUTY
1 - HANGER
2 - TAILPIPE
3 - CLAMP
4 - MUFFLER
5 - INSULATOR
Fig. 16 Tailpipe Removal/Installation
1 - HANGER BRACKETS
2 - ISOLATOR
3 - TAILPIPE
4 - MUFFLER
11 - 12 EXHAUST SYSTEMBR/BE
TAILPIPE - 3.9L/5.2L/5.9L (Continued)

Page 1280 of 2255

DODGE RAM 2002 Service Repair Manual 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 cl

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.
(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 SYSTEM
DIAGNOSIS AND TESTING - TURBOCHARGER
BOOST PRESSURE
NOTE: This diagnostic procedure is to be used with
the DRBIIITwhile test driving the vehicle under nor-
mal load and driving conditions.
Low turbocharger boost pressure can cause poor
engine proformance 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. 18).
(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.
Fig. 17 Resonator Removal/Installation
1 - EXTENSION PIPE
2 - RESONATOR
3 - EXTENSION PIPE
4 - CLAMP
Fig. 18 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
BR/BEEXHAUST SYSTEM 11 - 13
TAILPIPE - 5.9L DIESEL (Continued)

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