Ram Truck 1500, 2500 & 3500 (2006-2008)

Exhaust Manifold

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Removal & Installation



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.  

5.7L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Raise the vehicle.
  6.  
  7. Remove exhaust pipe to manifold bolts.
  8.  
  9. Lower the vehicle.
  10.  
  11. Install engine support fixture special tool number 8534.
  12.  
  13. Raise the engine enough to remove manifolds.
    WARNING
    Do not damage the engine harness while raising the engine.

  14.  
  15. Remove heat shield.
  16.  
  17. Remove manifold bolts using sequence provided.
  18.  
  19. Remove the manifold and gasket.
  20.  

To install:

  1. Install manifold gasket and manifold.
  2.  
  3. Install manifold bolts and tighten using sequence provided to 18 ft. lbs. (25 Nm).

    Click image to see an enlarged view

    Fig. Left exhaust manifold tighten sequence-5.7L engine



    Click image to see an enlarged view

    Fig. Right exhaust manifold tighten sequence-5.7L engine

  4.  
  5. Install heat shield and tighten nuts to 11 ft. lbs. (15 Nm).
  6.  
  7. Lower the engine.
    WARNING
    Do not damage the engine harness while lowering the engine.

  8.  
  9. Remove engine support fixture from engine.
  10.  
  11. Raise the vehicle.
  12.  
  13. Tighten right and left side engine mount through bolts.
  14.  
  15. Install exhaust flange to pipe bolts.
  16.  
  17. Lower the vehicle.
  18.  
  19. Connect negative battery cable.
  20.  

5.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery negative cables.
  4.  
  5. Raise vehicle on hoist.
  6.  
  7. Disconnect the exhaust pipe from the turbocharger elbow.
  8.  
  9. Disconnect oil drain tube from turbocharger.
  10.  
  11. Lower the vehicle.
  12.  
  13. Disconnect the electronic wastegate command valve from harness.
  14.  
  15. Disconnect the turbocharger air inlet hose.
  16.  
  17. Remove air cleaner assembly.
  18.  
  19. Disconnect the turbocharger oil supply line.
  20.  
  21. Disconnect the charge air cooler inlet pipe from the turbocharger.
  22.  
  23. Remove the turbocharger and gasket from the exhaust manifold.
  24.  
  25. Remove the cab heater return pipe nut from the exhaust manifold stud. Position the tube out of the way.
  26.  
  27. Remove heat shield.
  28.  
  29. Remove exhaust manifold bolt lockplates.
  30.  
  31. Remove the exhaust manifold-to-cylinder head bolts and spacers.
  32.  
  33. Remove the exhaust manifold and gaskets.
  34.  

To install:

Click image to see an enlarged view

Fig. Manifold tightening sequence

  1. Using new exhaust manifold gaskets, install the exhaust manifold. Install the bolts and spacers and tighten the bolts in the sequence shown in to 32 ft. lbs. (43 Nm).
  2.  
  3. Retighten the four center bolts.
  4.  
  5. Install heat shield and torque nuts to 18 ft. lbs. (24 Nm).
  6.  
  7. Install cab heater tube.
  8.  
  9. Install exhaust manifold bolt retention straps.
  10.  
  11. Install the cab heater return tube brace to the manifold bolt stud. Tighten the nut to 18 ft. lbs. (24 Nm).
  12.  
  13. Install the turbocharger and a new gasket. Tighten the turbocharger mounting nuts to 32 ft. lbs. (43 Nm).
  14.  
  15. Raise vehicle on hoist.
  16.  
  17. Install the oil drain tube and a new gasket to the turbocharger. Tighten the drain tube bolts to 18 ft. lbs. (24 Nm).
    NOTE
    A new exhaust pipe to turbocharger elbow must be used. Do not reuse clamp.

  18.  
  19. Connect the exhaust pipe to the turbocharger and tighten the bolts to 100 ft. lbs. (11 Nm).
  20.  
  21. Connect the wastegate command valve connector.
  22.  
  23. Lower the vehicle.
  24.  
  25. Pre-lube the turbocharger . Pour 2-3 oz. (50-60 cc) clean engine oil in the oil supply line fitting on the turbo. Rotate the turbocharger impeller by hand to distribute the oil thoroughly.
  26.  
  27. Install and tighten the oil supply line fitting nut to18 ft. lbs. (24Nm).
  28.  
  29. Position the charge air cooler inlet pipe to the turbocharger. With the clamp in position, tighten the clamp nut to 95 inch lbs. (11 Nm).
  30.  
  31. Position the air inlet hose to the turbocharger. Tighten the clamp to 35 in. lbs. (4 Nm).
  32.  
  33. Connect the battery negative cables.
  34.  
  35. Start the engine to check for leaks.
  36.  

6.7L Engine
  1. Disconnect the battery negative cables.
  2.  
  3. Drain the coolant.
  4.  
  5. Raise the vehicle on hoist.
  6.  
  7. Remove the EGR cooler.
  8.  
  9. Remove the air filter housing.
  10.  
  11. Remove the air filter inlet hose from the turbo inlet.
  12.  
  13. Remove the delta P line bracket cap screw nuts and remove the delta P line from the exhaust manifold and thermostat housing.
  14.  
  15. Remove the heat shield and noise panel (if equipped) from the exhaust manifold.
  16.  
  17. Remove the four turbo to exhaust manifold nuts (15 mm).
  18.  
  19. Remove the two rear exhaust manifold cap screw lock plates.
  20.  
  21. Remove the Cab Heater tubing/bracket from the exhaust manifold stud (15 mm).
  22.  
  23. Remove the exhaust manifold.

    Click image to see an enlarged view

    Fig. Exhaust manifold and related parts 6.7L diesel engine

  24.  

To install:

  1. Clean the exhaust manifold gasket surfaces.
  2.  
  3. Clean the cylinder head exhaust port gasket surfaces.
  4.  
  5. Clean the turbo mounting flange on the exhaust manifold.
  6.  
  7. Clean the turbo mounting flange on the turbocharger.
  8.  
  9. Install the exhaust manifold to turbocharger gasket and cap screws.
  10.  
  11. Install the exhaust manifold gasket.
    NOTE
    The five exhaust manifold cap screws with studs are used at the number 1 and number 2 cylinder locations for the heat shield mounting and one on the rear lower corner of the manifold for the cabin heater tube bracket.

  12.  
  13. Install the exhaust manifold spacers and cap screws.
  14.  
  15. Starting from the center and moving in a pattern outward, torque the exhaust manifold bolts to 32 ft. lbs. (43 Nm).
  16.  
  17. Install the exhaust manifold cap screw lock plates.
  18.  
  19. Install the exhaust manifold heat shields/noise panels. Torque the mounting nuts to 18 ft. lbs. (24 Nm).
  20.  
  21. Torque the turbocharger mounting nuts to 32 ft. lbs. (43 Nm).
  22.  
  23. Attach the mounting tabs and start the delta-P tube to exhaust manifold and thermostat cap screws.
  24.  
  25. Torque the delta-P tube 15 mm nut to 18 ft. lbs. (24 Nm).
  26.  
  27. Torque the delta-P tube 6 mm nut to 89 in. lbs. (10 Nm).
  28.  
  29. Torque the delta-P flare nuts to 89 ft. lbs. (10 Nm).
  30.  
  31. Install the EGR cooler.
  32.  
  33. Install the air filter housing.
  34.  
  35. Fill the coolant.
  36.  
  37. Connect the battery negative cables.
  38.  
  39. Start the engine to check for leaks.
  40.  

 
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