Ram B1500, B2500, B3500, 1999-2003

Exhaust Manifold

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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

     

  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

     

  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

  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

  4.  

3.9L, 5.2L, 5.9L Gasoline Engines
  1. Perform the "Common Steps" above.
  2.  
  3. Remove the exhaust pipe to manifold nuts.
  4.  
  5. Remove the nuts and bolts securing the manifold to the head.
  6.  
  7. Installation is the reverse of removal. Tighten cylinder head hardware to 18 ft. lbs. (24 Nm). Tighten exhaust pipe nuts to 20 ft. lbs. (27 Nm).
  8.  



Click image to see an enlarged view

Fig. Disconnecting the manifold-to-exhaust pipe nuts-typical



Click image to see an enlarged view

Fig. Exhaust manifold and mounting hardware-5.2L shown

4.7L Engine
  1. Perform the "Common Steps" above.
  2.  
  3. Remove the left side manifold by undoing the exhaust pipe nuts and the manifold bolts on the cylinder head.
  4.  
  5. For the right side manifold:
    1. Remove the air cleaner and resonator assemblies and the air inlet hose.
    2.  
    3. Remove the accessory drive belt.
    4.  
    5. Remove the A/C compressor and set it to one side.
    6.  
    7. Remove the A/C accumulator support bracket fastener.
    8.  
    9. Drain the radiator and remove the heater hoses at the engine.
    10.  
    11. Remove the heat shield.
    12.  
    13. Remove the upper exhaust manifold fasteners.
    14.  
    15. Disconnect the exhaust pipe.
    16.  
    17. Remove the starter.
    18.  
    19. Remove the lower exhaust manifold fasteners. Remove the manifold.
    20.  

  6.  
  7. Installation is the reverse of removal. Tighten manifold hardware to 18 ft. lbs. (25 Nm).
  8.  
  9. Tighten the heat shield fasteners to 72 inch lbs. (8 Nm), then loosen 45-.
  10.  



Click image to see an enlarged view

Fig. Exhaust manifold and heat shield assembly-4.7L

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

  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

  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

  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.  

  1. Perform the "Common Steps" above.
  2.  
  3. Remove the exhaust pipe to manifold nuts and bolts.
  4.  
  5. Remove the dipstick bracket (right side).
  6.  
  7. Remove the bolts securing the manifold to the head.
  8.  
  9. Installation is the reverse of removal. Tighten hardware to 16 ft. lbs. (22 Nm).
  10.  

Common Steps

NOTE
The following steps are common to all models. Read this information before beginning the specific procedures for your vehicle.

  1. New gaskets are required on installation. Purchase these before beginning.
  2.  
  3. Access to exhaust manifold components is easier if the vehicle is raised.
  4.  


CAUTION
Obey all applicable safety procedures for jacking, supporting, and working beneath the vehicle.

  1. Disconnect the battery negative cable(s).
  2.  
  3. Check manifolds and header pipes for any sensor(s) which may be fitted to them and disconnect the wiring if it interferes with removal.
  4.  
  5. Remove the heat shield(s), if fitted.
  6.  
  7. Disconnecting the header(s) from the exhaust pipe(s) may be easier from beneath the vehicle.
  8.  
  9. Wire brush the threads of any accessible fasteners. Apply penetrating fluid to fasteners to ease disassembly.
  10.  
  11. Do NOT strike the manifold or exhaust pipe with a hammer. Use a plastic mallet to prevent damage.
  12.  
  13. Clean all mating surfaces before installation.
  14.  
  15. Anti-seize compound applied to the threads of nuts and bolts will make future removal easier.
  16.  
  17. Tighten all hardware evenly and to the proper torque. Manifold nuts and bolts should be tightened from the center outwards. Do NOT attempt to drive the manifold home by running down the nuts or bolts.
  18.  
  19. After installation is complete, start the engine and check for leaks.
  20.  


NOTE
If the studs come out of the block when the nuts are loosened, the use of new studs is recommended. Coat the threads of the new studs with an adhesive/sealer. This will help prevent oil leaks.



Click image to see an enlarged view

Fig. Spray hardware with penetrating fluid. Brittle metal may snap if the fastener is forced

Diesel Engines
  1. Perform the "Common Steps" above.
  2.  
  3. Disconnect the exhaust pipe from the turbocharger.
  4.  
  5. Remove the turbocharger. See "Turbocharger" for procedures.
  6.  
  7. Remove the cab heater return pipe nut from the exhaust manifold stud. Position tube out of the way.
  8.  
  9. Remove the fasteners and separate the exhaust manifold from the head.
  10.  
  11. Installation is the reverse of removal. Tighten the manifold hardware evenly and in a cross pattern starting in the center and working outwards. Proper torque is 32 ft. lbs. (43 Nm).
  12.  
  13. Install the turbocharger. See "Turbocharger" for procedures.
  14.  



Click image to see an enlarged view

Fig. Exhaust manifold assembly and tightening sequence-Diesel

 
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