Ram 1500, 2500, 3500, 2WD and 4WD, 2001-2005

Exhaust Manifold

Print

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cables
     
    Turbocharger
     
    Exhaust Gas Recirculation (EGR) tube
     
    Cab heater supply and return lines
     
    Exhaust manifold

    Click image to see an enlarged view

    Fig. Exhaust manifold torque sequence-5.9L diesel engine

    Exhaust manifold torque sequence-5.9L diesel engine
     

  4.  

To install:


NOTE
Use anti-seize compound on the exhaust manifold bolts.

  1. Install or connect the following:

    Exhaust manifold. Tighten the bolts in sequence to 32 ft. lbs. (43 Nm).
     
    Cab heater supply and return lines
     
    EGR tube. Tighten the bolts to 18 ft. lbs. (24 Nm).
     
    Turbocharger
     
    Negative battery cables
     

  2.  
  3. Start the engine and check for leaks.
  4.  

3.7L & 4.7L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Battery
     
    Power distribution center
     
    Battery tray
     
    Windshield washer fluid bottle
     
    Air cleaner assembly
     
    Accessory drive belt
     
    A/C compressor
     
    A/C accumulator bracket
     
    Heater hoses
     
    Exhaust manifold heat shields
     
    Exhaust Y-pipe
     
    Starter motor
     
    Exhaust manifolds

    Click image to see an enlarged view

    Fig. Right side exhaust manifold-4.7L engine, left side and 3.7L engine similar

    Right side exhaust manifold-4.7L engine, left side and 3.7L engine similar
     

  6.  

To install:

  1. Install or connect the following:

    Exhaust manifolds, using new gaskets. Tighten the bolts to 18 ft. lbs. (25 Nm), starting with the inner bolts and work out to the ends.
     
    Starter motor
     
    Exhaust Y-pipe
     
    Exhaust manifold heat shields
     
    Heater hoses
     
    A/C accumulator bracket
     
    A/C compressor
     
    Accessory drive belt
     
    Air cleaner assembly
     
    Windshield washer fluid bottle
     
    Battery tray
     
    Power distribution center
     
    Battery
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

3.9L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Exhaust manifold heat shields
     
    Exhaust front pipe
     
    Exhaust manifolds
     

  4.  

To install:


NOTE
If the exhaust manifold studs came out with the nuts when removing the exhaust manifolds, replace them with new studs.

  1. Install or connect the following:

    Exhaust manifolds. Tighten the fasteners to 25 ft. lbs. (34 Nm), starting with the center fasteners and working out to the ends.
     
    Exhaust front pipe
     
    Exhaust manifold heat shields
     
    HO 2 S sensor connectors
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Stud and bolt locations-3.9L engine

    Stud and bolt locations-3.9L engine
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heated Oxygen (HO 2 ) sensor connectors
     
    Exhaust manifold heat shields
     
    Exhaust front pipe
     
    Exhaust manifolds
     

  4.  

To install:


NOTE
If the exhaust manifold studs came out with the nuts when removing the exhaust manifolds, replace them with new studs.

  1. Install or connect the following:

    Exhaust manifolds. Tighten the fasteners to 25 ft. lbs. (34 Nm), starting with the center fasteners and working out to the ends.
     
    Exhaust front pipe
     
    Exhaust manifold heat shields
     
    HO 2 S sensor connectors
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Stud and bolt locations-3.9L engine

    Stud and bolt locations-3.9L engine
  4.  

5.2L & 5.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold heat shields
     
    Exhaust Gas Recirculation (EGR) tube
     
    Exhaust Y-pipe
     
    Exhaust manifolds
     

  4.  

To install:


NOTE
If the exhaust manifold studs came out with the nuts when removing the exhaust manifolds, replace them with new studs.



Click image to see an enlarged view

Fig. Exhaust manifold fastener locations-5.2L and 5.9L engines

Exhaust manifold fastener locations-5.2L and 5.9L engines
  1. Install or connect the following:

    Exhaust manifolds. Tighten the fasteners to 25 ft. lbs. (27 Nm), starting with the center nuts and work out to the ends.
     
    Exhaust Y-pipe
     
    EGR tube
     
    Exhaust manifold heat shields
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold heat shields
     
    Exhaust Gas Recirculation (EGR) tube
     
    Exhaust Y-pipe
     
    Exhaust manifolds
     

  4.  

To install:


NOTE
If the exhaust manifold studs came out with the nuts when removing the exhaust manifolds, replace them with new studs.



Click image to see an enlarged view

Fig. Exhaust manifold fastener locations-5.2L and 5.9L engines

Exhaust manifold fastener locations-5.2L and 5.9L engines
  1. Install or connect the following:

    Exhaust manifolds. Tighten the fasteners to 25 ft. lbs. (27 Nm), starting with the center nuts and work out to the ends.
     
    Exhaust Y-pipe
     
    EGR tube
     
    Exhaust manifold heat shields
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

5.7L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Battery
     
    Exhaust pipe-to-manifold bolts
     

  6.  
  7. Install an engine crane. Remove the right and left mount through bolts. Raise the engine just enough to provide clearance for manifold removal.
  8.  
  9. Remove or disconnect the following:

    Exhaust manifold heat shields
     
    Exhaust manifolds
     

  10.  

To install:

  1. Install or connect the following:

    Exhaust manifolds, using new gaskets. Tighten the bolts to 18 ft. lbs. (25 Nm), starting with the inner bolts and work out to the ends.
     
    Exhaust manifold heat shields
     

  2.  
  3. Install the right and left mount through bolts. Remove the crane.
  4.  
  5. Install or connect the following:

    Exhaust pipe-to-manifold bolts
     
    Battery
     

  6.  

8.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust front pipe
     
    Exhaust manifold heat shields
     
    Exhaust Gas Recirculation (EGR) tube
     
    Oil dipstick tube bracket
     
    Exhaust manifolds
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exhaust manifold fastener locations-8.0L engine

Exhaust manifold fastener locations-8.0L engine

  1. Install or connect the following:

    Exhaust manifolds. Tighten the fasteners to 16 ft. lbs. (22 Nm).
     
    Oil dipstick tube bracket
     
    EGR tube
     
    Exhaust manifold heat shields
     
    Exhaust front pipe
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

 
label.common.footer.alt.autozoneLogo