Dodge ram truck 3500 1996 Service Manual page 1203

EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1
EXHAUST
S Y S T E M
AND
H N T A K E
MANIFOLD
C O N T E N T S
page
GENERAL INFORMATION
CATALYTIC CONVERTER
1
EXHAUST HEAT SHIELDS
2
EXHAUST SYSTEM 1.
DESCRIPTION AND OPERATION
ENGINE EXHAUST MANIFOLD—V-6 and V-8
ENGINES 3
EXHAUST MANIFOLD—V-10 ENGINE 3
INTAKE MANIFOLD—V-10 ENGINE 3
INTAKE MANIFOLD—V-6 and V-8 ENGINES . . . 3
INTERCOOLER—CHARGE AIR COOLER 3
TURBOCHARGER—5.9L DIESEL ENGINE 3
DIAGNOSIS AND TESTING
EXHAUST SYSTEM DIAGNOSIS 4
INTAKE MANIFOLD DIAGNOSIS 4
REMOVAL AND INSTALLATION
CATALYTIC CONVERTERS 5
CATALYTIC CONVERTERS—DIESEL
1 2
ENGINE EXHAUST MANIFOLD—V-6 and V-8
ENGINES 1 1
EXHAUST HEAT SHIELDS 6
EXHAUST MANIFOLD V-10 11
EXHAUST MANIFOLD—DIESEL 13
EXHAUST PIPE 4
G E N E R A L I N F O R M A T I O N
EXHAUST SYSTEM
The gasoline engine exhaust system consists of
engine exhaust manifolds, exhaust pipes, catalytic
converter(s), extension pipe (if needed), exhaust heat
shields, muffler and exhaust tailpipe (Fig. 1).
The diesel engine exhaust system consists of an
engine exhaust manifold, turbocharger, exhaust pipe,
catalytic converter, extension pipe (if needed), muffler
and exhaust tailpipe (Fig. 2).
The engine exhaust manifolds on gasoline engines
are equipped with ball flange outlets to assure a
tight seal and strain free connections.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. I f the sys­
tem contacts any body panel, it may amplify objec­
tionable noises from the engine or body.
When inspecting an exhaust system, critically
inspect for cracked or loose joints, stripped screw or
page
EXHAUST PIPE—DIESEL 12
EXHAUST TAILPIPE 6
EXHAUST TAILPIPE—DIESEL 13
HEAT SHIELDS—DIESEL 13
INTAKE MANIFOLD COVER—AIR INTAKE
HEATER 15
INTAKE MANIFOLD V-10 9
INTAKE MANIFOLD—V-6 and V-8 ENGINES . . . 7
INTERCOOLER—DIESEL 17
MUFFLERS 5
MUFFLER—DIESEL 13
TURBOCHARGER DIESEL 16
CLEANING AND INSPECTION
CATALYTIC CONVERTOR 19
EXHAUST MANIFOLD 18
EXHAUST PIPE 18
INTAKE MANIFOLD 18
INTERCOOLER—CHARGE AIR COOLER 19
ADJUSTMENTS
WASTEGATE ADJUSTMENT 19
SPECIFICATIONS
TORQUE SPECIFICATIONS 21
TURBOCHARGER SPECIFICATIONS 21
bolt threads, corrosion damage and worn, cracked or
broken hangers. Replace all components that are
badly corroded or damaged. DO NOT attempt to
repair.
When replacement is required, use original equip­
ment parts (or their equivalent). This will assure
proper alignment and provide acceptable exhaust
noise levels.
CAUTION: Avoid application of rust prevention
compounds or undercoating materials to exhaust
system floor pan exhaust heat shields. Light over-
spray near the edges is permitted. Application of
coating will result in excessive floor pan tempera­
tures and objectionable fumes.
CATALYTIC CONVERTER
There is no regularly scheduled maintenance on
any Mopar® stainless steel catalytic converter body.