Dodge ram truck 3500 1996 Service Manual page 1220

11 - 18 EXHAUST SYSTEM AND INTAKE MANIFOLD
BR
R E M O V A L AND I N S T A L L A T I O N (Continued)
denser and sealing plate assembly away from the
charge air cooler (intercooler).
Fig. 41 Condenser and Charge Air Cooier—
intercooler
(4) Remove the inlet and outlet ducts from the
charge air cooler (intercooler) (Fig. 42).
(5) Remove the charge air cooler (intercooler) bolts.
Pivot the charge air cooler (intercooler) forward and
up to remove.
J9509-53
Fig. 42 Charge Air Cooler Intercooler Ducts
INSTALLATION
(1) Position the charge air cooler (intercooler).
Install the bolts and tighten to 2 N-m (17 in. lbs.)
torque.
(2) Install the inlet and outlet ducts to the charge
air cooler (intercooler). With the clamps in position,
tighten the clamp nut to 8 N-m (72 in. lbs.) torque.
(3) I f the vehicle is equipped with air conditioning,
install the condenser as follows:
(a) Position the condenser and sealing plate
assembly onto the charge air cooler (intercooler)
studs. Install the nuts and tighten.
(b) Connect the halves of the sealing plate.
Install the bolt and tighten.
(c) Charge the air conditioning system (refer to
Group 24, Heating and Air Conditioning for the
proper procedures).
(4) Install the front support bracket. Install and
tighten the bolts.
(5) Install the grille (refer to Group 23, Body for
the proper procedure).
C L E A N I N G A N D I N S P E C T I O N
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.
CLEANING
Clean ends of pipes to assure mating of all parts.
INTAKE MANIFOLD
CLEANING INTAKE
Clean manifold in solvent and blow dry with com­
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
mSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
EXHAUST MANIFOLD
CLEANING
Clean mating surfaces on cylinder head and mani­
fold. Wash with solvent and blow dry with com­
pressed air.
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straight edge. Gasket surfaces must be flat
within 0.2 mm per 300 mm (0.008 inch per foot).