Chrysler RAM TRUCK 2500 1994 Service Manual page 904

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EXHAUST SYSTEM AND INTAKE MANIFOLD . 1 1 - 1 5
INSPECTION
Discard rusted clamps, broken or worn hangers,
supports and attaching parts. Replace a component
with original equipment parts, or equivalent. This
will assure proper alignment with other parts in the
system and provide acceptable exhaust noise levels.
INSTALLATION
(1) Loosely assemble exhaust tailpipe and exten­
sion pipe, if used, to permit proper alignment of all
parts.
(2) Connect the support hangers (Fig. 4 and 5).
(3) Position the exhaust tailpipe and extension
pipe, if used, for proper clearance with the underbody
parts.
(4) Tighten all clamp nuts to 43 N-m (32 ft. lbs.)
torque.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
EXHAUST HEAT SHIELDS
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the nuts or bolts holding the exhaust
heat shield to the floor pan, crossmember or bracket.
(3) Slide the shield out around the exhaust system.
INSTALLATION
(1) Position the exhaust heat shield to the floor
pan, crossmember or bracket and install the nuts or
bolts.
(2) Tighten the nuts and bolts.
(3) Lower the vehicle.
ENGINE EXHAUST MANIFOLD
REMOVAL
(1) Disconnect the air intake and exhaust pipes
(Fig. 6).
(2) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger (Fig. 7).
(3) Disconnect the charge air cooler (intercooler)
inlet duct from the turbocharger (Fig. 7).
(4) Remove the turbocharger and gasket.
(5) Remove the cab heater supply and return lines.
(6) Remove the engine exhaust manifold and gas­
kets (Fig. 8).
(7) Clean the sealing surfaces.
INSTALLATION
(1) Install the engine exhaust manifold and gas­
kets. Tighten the exhaust manifold bolts in sequence
to 43 N-m (32 ft. lbs.) torque (Fig. 9).
(2) Install the turbocharger. Tighten the turbo­
charger mounting nuts to 32 N-m (24 ft. lbs.) torque.
Fig. 6 Air Intake Pipe, Exhaust Pipe and
Turbocharger
Fig. 7 Oil Supply Line and Charge Air Cooler
(Intercooler) Inlet Duct
(3) Position the charge air cooler (intercooler) inlet
duct to the turbocharger. With the clamp in position,
tighten the clamp nut to 8 N-m (72 in. lbs.) torque.
(4) Position the air intake pipe and the exhaust
pipe onto the turbocharger. Tighten the clamps to 8
N-m (74 in. lbs.) torque.
(5) Install the oil drain tube and oil supply line to
the turbocharger. Tighten the drain tube bolts to 24