Chrysler RAM TRUCK 2500 1994 Service Manual page 900

• EXHAUST SYSTEM AND INTAKE MANIFOLD 11 11
block and heads. After intake manifold is i n place, in­
spect to make sure seals and gaskets are i n place.
(5) Tighten the lower intake manifold bolts i n se­
quence to 54 N-m (40 ft. lbs.) torque (Fig. 10).
(6) Using a new gasket, position the upper intake
manifold onto the lower intake manifold.
(7) Tighten upper intake manifold bolts i n se­
quence to 22 N-m (16 ft. lbs.) torque (Fig. 9).
(8) Using a new gasket, install the throttle body
onto the upper intake manifold. Tighten the bolts to
23 N-m (200 in. lbs.) torque.
(9) Install closed crankcase ventilation and evapo­
ration control systems.
(10) Connect the heater hoses and bypass hose.
(11) Connect the vacuum lines.
(12) Install the coil assemblies and the ignition ca­
bles.
(13) Connect the accelerator linkage and i f so
equipped, the speed control and transmission kick-
down cables.
(14) Install the fuel lines.
(15) . Using a new gasket, install the air cleaner
housing. Tighten the nuts to 11 N-m (96 in. lbs.)
torque. Install the air cleaner filter and cover.
(16) Install the A/C compressor. Position the com­
pressor brace and install the bolts. Tighten the brace
bolts to 41 N-m (30 ft. lbs.) torque.
(17) Install the generator. Position the generator
brace and install the bolts. Tighten the brace bolts to
41 N-m (30 ft. lbs.) torque.
(18) Install the accessory drive belt (refer to Group
7, Cooling System).
(19) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure).
(20) Connect the negative cable to the battery.
ENGINE EXHAUST MANIFOLD—V-6 and V-8
ENGINES
Engine exhaust manifolds are LOG type with port­
ing for air injection into the LOG.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise and support the vehicle.
(3) Remove the bolts and nuts attaching the ex­
haust pipe to the engine exhaust manifold.
(4) Lower the vehicle. .
(5) Remove the exhaust heat shields.
(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold from the cylinder head.
CLEANING
Clean mating surfaces on cylinder head and mani­
fold. Wash with solvent and blow dry with com­
pressed air.
I N S P E C T I O N
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).
INSTALLATION
CAUTION: If the studs came out with the nuts when
removing the engine exhaust manifold, install new
studs. Apply sealer on the coarse thread ends. Wa­
ter leaks may develop at the studs if this precaution
is not taken..
(1) Position the engine exhaust manifolds on the
two studs located on the cylinder head. Install coni­
cal washers and nuts on these studs (Fig. 14 or 15).
(2) Install two bolts and conical washers at the in­
ner ends of the engine exhaust manifold outboard
arms. Install two bolts WITHOUT washers on the
center arm of engine exhaust manifold (Fig. 14 or
15). Starting at the center arm and working outward,
tighten the bolts and nuts to 34 N-m (25 ft. lbs.)
torque.
(3) Install the exhaust heat shields.
(4) Raise and support the vehicle.
(5) Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and
nuts to 26 N-m (19 ft. lbs.) torque.
(6) Lower the vehicle.
(7) Connect the negative cable to the battery.
Fig. 14 Engine Exhaust Manifold Installation—3.9L
Engine
ENGINE EXHAUST MANIFOLD—V-10 ENGINE
Engine exhaust manifolds are made of high molyb­
denum ductile cast iron. A special ribbed design helps
control permanent dimensional changes during heat
cycles.