Chrysler RAM TRUCK 2500 1994 Service Manual page 901

11 - 12 EXHAUST SYSTEM AND INTAKE MANIFOLD
•
J9311-11
Fig. 15 Engine Exhaust Manifold Installation—5.2U
5.9L Engines
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 (Figs. 16 ajid
17).
(6) Right exhaust manifold—Remove the EGR tube
and gasket (Fig. 16). Discard the gasket.
EXHAUST
HEAT
SHIELD J9411-13
Fig. 16 Right Engine Exhaust Manifold and EGR
Tube
(7) Right exhaust manifold—Remove the dipstick
bracket from the manifold.
(8) Remove bolts attaching manifold to cylinder
head.
SHIELD J 9 4 1 H 4
Fig. 17 Left Engine Exhaust Manifold
(9) Remove manifold from the cylinder head. Dis­
card the gasket.
CLEANING
Clean mating surfaces on cylinder head and manifold.
Wash with solvent and blow dry with compressed 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).
INSTALLATION
(1) Using a new gasket position the engine exhaust
manifold onto the cylinder head. Refer to Figs. 16 and
17 to install bolts and stud bolts in the proper position.
Tighten the bolts to 22 N-m (16 ft. lbs.) torque.
(2) Right side exhaust manifold—Install the EGR
tube using a new gasket (Fig. 16). Tighten the tube
assembly nut to 34 N-m (25 ft. lbs.) torque. Tighten
the two EGR nuts to 20 N-m (175 in. lbs.) torque.
(3) Right exhaust manifold—Install the dipstick
bracket to the manifold.
(4) Position washers and exhaust heat shields onto
the manifold stud bolts (Figs. 16 and 17). Be sure the
tabs on the heat shields align with slots i n the gas­
ket. Install the nuts and tighten to 20 N-m (175 in.
lbs.) torque.
(5) Raise and support the vehicle.
(6) Assemble exhaust pipe to manifold and secure with
bolts. Tighten the bolts to 34 N-m (25 ft. lbs.) torque.
(7) Lower the vehicle.
(8) Connect the negative cable to the battery.