2003 DODGE RAM frame

VIBRATION DAMPER
REMOVAL
(1) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove the four (4) damper to crankshaft bolts
and remove damper and speed indicator ring.
INSPECTION
(1) Inspect the damper hub for cracks and replace
if any are found.
(2) Inspect the index lines on the damper hub and
the inertia member (Fig. 104). If the lines are more
than 1.59 mm (1/16 in.) out of alignment, replace the
damper.
(3) Inspect the rubber member for deterioration or
missing segments (Fig. 105).
INSTALLATION
(1) Install speed indicator ring.
NOTE: The speed indicator ring is located over a
dowel pin.
(2) Install the crankshaft damper and bolts.
Tighten bolts to 40 N´m (30 ft. lbs.) torque, plus an
additional 60É.
NOTE: The damper must be installed so the hole is
located over the dowel pin.
(3) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
FRONT MOUNT
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the viscous fan/drive assembly (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(3) Raise vehicle on hoist.
(4) Install engine support fixture tool# 8534 and
steel bracket tool # 8534A
(5) Loosen the thru-bolt and nut.
(6) Lift the engine SLIGHTLY and remove the
insulator to block bolts (Fig. 107) (Fig. 106).
(7) Remove the insulator from the vehicle.
INSTALLATION
(1) With engine raised SLIGHTLY, position the
insualtor to the mount (Fig. 108) (Fig. 109). Install
the bolts and torque to specification.
(2)
(3) Lower the engine using tool # 8534, while guid-
ing the mount and thru-bolt into the frame mounted
support cushion brackets.
(4) Install the thru-bolt nut and tighten the nut to
88 N´m (65 ft. lbs.) torque.
(5) Remove the engine support fixture tool #8534.
(6) Lower the vehicle.
(7) Install the viscous fan/drive assembly (Refer to
7 - COOLING/ENGINE/RADIATOR FAN - INSTAL-
LATION).
(8) Connect the battery negative cables.
Fig. 104 Inspect Index Lines for Alignment
1 - INDEX LINES
2 - HUB
3 - INERTIA MEMBER
Fig. 105 Inspect Damper Rubber Member
DRENGINE 5.9L DIESEL 9 - 335

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION
DESCRIPTION........................1
DESCRIPTION ± 5.9L DIESEL.............2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - GAS ENGINE . . . 2
DIAGNOSIS AND TESTING - DIESEL
ENGINE..............................3
SPECIFICATIONS - TORQUE...............4
SPECIAL TOOLS........................4
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER.....4
OPERATION............................4
REMOVAL
REMOVAL............................5
REMOVAL............................5
INSPECTION...........................5
INSTALLATION
INSTALLATION........................5
INSTALLATION........................5
EXHAUST PIPE
REMOVAL
REMOVAL Ð 5.9L......................5
REMOVAL............................5
INSPECTION...........................6
INSTALLATION
INSTALLATION Ð 5.9L..................6
INSTALLATION........................7
EXHAUST PIPE
REMOVAL.............................7
INSPECTION...........................7
INSTALLATION..........................7
HEAT SHIELDS
DESCRIPTION..........................7
REMOVAL.............................7INSTALLATION..........................8
MUFFLER
REMOVAL.............................8
INSTALLATION..........................8
MUFFLER - 5.9L DIESEL
REMOVAL.............................9
INSTALLATION..........................9
TAILPIPE - 5.9L DIESEL
REMOVAL.............................9
INSPECTION...........................9
INSTALLATION..........................9
TAILPIPE
REMOVAL.............................10
INSPECTION..........................10
INSTALLATION.........................10
TURBOCHARGER SYSTEM
DIAGNOSIS AND TESTING -
TURBOCHARGER BOOST PRESSURE.....10
TURBOCHARGER
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................13
CLEANING............................14
INSPECTION..........................14
INSTALLATION.........................14
CHARGE AIR COOLER AND PLUMBING
DESCRIPTION.........................15
OPERATION...........................15
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS..............15
REMOVAL.............................15
CLEANING............................16
INSPECTION..........................16
INSTALLATION.........................16
EXHAUST SYSTEM
DESCRIPTION
DESCRIPTION
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 federal gasoline engine exhaust system con-
sists of engine exhaust manifolds, exhaust pipes, cat-
alytic 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.
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.
DREXHAUST SYSTEM 11 - 1

DESCRIPTION ± 5.9L 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.
California emission vehicales include a catalytic
converter.
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.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - GAS ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.6. Tighten exhaust manifold to
cylinder head bolts.
7. Catalytic converter rusted or
blown out.7. Replace catalytic converter assy.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
CAUTION:
When servicing and replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing
the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
11 - 2 EXHAUST SYSTEMDR
EXHAUST SYSTEM (Continued)

REMOVAL
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove the bolts from the crossover pipe to the
catalytic converter connection.
(4) Disconnect oxygen sensor wiring.
(5) Loosen the nuts from the clamp that hold the
catalytic converter to the exhaust pipe flange connec-
tion.
NOTE: Do not remove nut from T-Bolt. Only remove
nut far enough, so that the T end can be removed
from the clamp.
(6) Remove the T bolt end of the fastener, from the
clamp.
(7) Spread the clamp, and remove the catalytic
converter from the vehicle.
(8) Discard the clamp.
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.
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.
(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
INSTALLATION
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.(1) Position the catalytic converter onto the
exhaust pipe flange connection. Tighten the nuts to
28 N´m (250 in. lbs.) torque.
(2) Install the muffler onto the catalytic converter
until the alignment tab is inserted into the align-
ment slot.
(3) Install the exhaust clamp at the muffler and
catalytic converter connection. Tighten the clamp
nuts to 47 N´m (35 ft. lbs.) torque.
(4) Connect oxygen sensor wiring.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
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.
EXHAUST PIPE
REMOVAL
REMOVAL Ð 5.9L
(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.
(4) Remove the clamp nuts.
(5) Remove the exhaust pipe (Fig. 1).
REMOVAL
CAUTION: When servicing or replacing exhaust
system components, disconnect the oxygen sensor
connector(s). Allowing the exhaust to hang by the
oxygen sensor wires will damage the harness
and/or sensor.
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with MopartRust
Penetrant. Allow 5 minutes for penetration.
(3) Disconnect the oxygen sensor(s).
DREXHAUST SYSTEM 11 - 5
CATALYTIC CONVERTER (Continued)

(4) Remove the exhaust manifold-to-exhaust pipe
nuts (Fig. 2).
(5) Remove exhaust pipe to converter exhaust
clamp.
(6) Disconnect the exhaust pipe from the catalytic
converter front flange.
(7) 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
INSTALLATION Ð 5.9L
(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 (Fig. 1) and (Fig. 3).
Fig. 1 Exhaust Pipe to Manifold Connection ± 5.9L
1 - BOLT
2 - RETAINER
3 - EXHAUST MANIFOLD
4 - NUT
5 - EXHAUST PIPE
Fig. 2 Exhaust Pipe(s) to Manifold Connection
1 - BOLT
2 - RETAINER
3 - EXHAUST MANIFOLD
4 - NUT
5 - EXHAUST PIPE
Fig. 3 Exhaust Pipe-to-Catalytic Converter Flange
Alignment Ð Typical
1 - 7.874±17.526 mm (0.31±0.69 in.)
2 - CATALYTIC CONVERTER FLANGE
3 - 20 mm (0.79 in.) MIN.
4 - CROSSMEMBER
5 - EXHAUST PIPE
6 - EXHAUST PIPE
11 - 6 EXHAUST SYSTEMDR
EXHAUST PIPE (Continued)

(3) Slide the shield out around the exhaust system.
INSTALLATION
(1) Position the exhaust heat shield to the floor
pan, crossmember or bracket and install the nuts or
bolts.
(2) Tighten the nuts and bolts 11 N´m (100 in.
lbs.).
(3) Lower the vehicle.
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 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.
Fig. 6 HEAT SHIELDS - RH - REG CAB
1 - HEAT SHIELD
2 - FASTENER
3 - NUT
4 - HEAT SHIELD
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
11 - 8 EXHAUST SYSTEMDR
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 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 - 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.
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.
Fig. 9 MUFFLER
1 - INSULATOR
2 - INSULATOR
3 - MUFFLER
4 - INSULATOR
Fig. 10 Muffler Removal/Installation
1 - INSULATOR
2 - ISOLATOR
3 - TAILPIPE
4 - CLAMP
5 - MUFFLER
6 - CLAMP
7 - EXTENSION PIPE
DREXHAUST SYSTEM 11 - 9
MUFFLER (Continued)

(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.
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 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.
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.
Fig. 11 Tailpipe Removal/Installation
1 - ISOLATOR
2 - TAILPIPRE
3 - CLAMP
4 - MUFFLER
Fig. 12 TAILPIPE
1 - INSULATOR
2 - TAILPIPE
3 - CLAMP
4 - MUFFLER
5 - CLAMP
6 - INSULATOR
7 - INSULATOR
8 - INSULATOR
11 - 10 EXHAUST SYSTEMDR
TAILPIPE - 5.9L DIESEL (Continued)