Description: Removal & Installation RAM Cab & Chassis 3500 HD

INSTALLATION

Note. Apply Mopar® Thread Sealant with PTFE to the sensor threads before installing into the engine block.

1. Install the oil temperature sensor (1).
2. Connect the oil temperature sensor electrical connector (1).
3. Connect the negative battery cable.

Scheme 162

Scheme 163

Scheme 164

Scheme 165

1. Disconnect the intake air temperature (IAT) sensor electrical connector (3).
2. Remove the clean air hose (2).
3. Remove the air cleaner housing (4).
4. Remove the engine cover (1).
5. Disconnect the negative battery cable (1).
6. Install Engine Support Fixture (special tool #8534B, Fixture, Driveline Support) (1).
7. Raise and support the vehicle. CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
8. Disconnect the oxygen sensor electrical connectors (2).
9. Saturate the front exhaust pipe/catalytic converter retaining bolts and nuts with Mopar® Rust Penetrant or equivalent and allow 5 minutes for penetration. NOTE: If separating the exhaust pipe/catalytic converter at the exhaust manifold flange. New bolts will be required.
10. Remove the right and left exhaust pipe/catalytic converter assembly at the exhaust manifold and discard the bolts. Right side shown in illustration, left side similar.
11. Remove the right and left engine mount through bolts (3).
12. Lower the vehicle. CAUTION: Do not damage engine harness while raising the engine.
13. Using the Engine Support Fixture (special tool #8534B, Fixture, Driveline Support), raise the engine enough to gain access to the exhaust manifold retaining bolts.
14. Remove the exhaust manifold heat shield. NOTE: The bolts used to secure the exhaust manifold are stainless steel at locations 7 and 8. All bolts removed must be installed in the same location were they were removed from.
15. Right Side: Using the sequence shown in illustration, remove the exhaust manifold retaining bolts. NOTE: The bolts used to secure the exhaust manifold are stainless steel at locations 5 and 6. All bolts removed must be installed in the same location were they were removed from.
16. Left Side: Using the sequence shown in illustration, remove the exhaust manifold retaining bolts. Left side shown in illustration, right similar.
17. Remove the exhaust manifold (2) and gasket.
18. Inspect the exhaust manifold for any damage. Refer to «Engine/Manifolds/MANIFOLD, Exhaust - Inspection»(ref-476518-S03956052332012060400000) .
19. Clean the mating surfaces.

Left side shown in illustration, right similar.

1. Prior to installation, make sure all gasket mating surfaces (1, 2) are clean and free of any debris.
2. Position the exhaust manifold gasket and manifold. NOTE: The bolts used to secure the exhaust manifold are stainless steel at locations 6 and 9. All bolts removed must be installed in the same location were they were removed from.
3. Left Side: Using the sequence shown in illustration, Install the exhaust manifold retaining bolts and pre-tighten to 25 N.m (18 ft. lbs.) allowing the gasket to seat to the exhaust manifold and cylinder head.
4. Re-check the torque at 25 N.m (18 ft. lbs.) using the sequence shown in illustration.
5. Install the heat shield and tighten nuts to 8 N.m (70 in. lbs.). NOTE: The bolts used to secure the exhaust manifold are stainless steel at locations 7 and 8. All bolts removed must be installed in the same location were they were removed from.
6. Right Side: Using the sequence shown in illustration, install the exhaust manifold retaining bolts and tighten to 25 N.m (18 ft. lbs.) allowing the gasket to seat to the exhaust manifold and cylinder head.
7. Re-check the torque at 25 N.m (18 ft. lbs.) using the sequence shown in illustration.
8. Install the heat shield and tighten nuts to 8 N.m (70 in. lbs.). CAUTION: Do not damage engine harness while lowering the engine.
9. Using the Engine Support Fixture (special tool #8534B, Fixture, Driveline Support), lower the engine into position.
10. Raise and support the vehicle. Right side shown in illustration, left side similar.
11. Install the right and left engine mount through bolts (3) and tighten to 100 N.m (74 ft. lbs.). NOTE: If separating the exhaust pipe/catalytic converter at the exhaust manifold flange. New bolts will be required.
12. Position the right and left exhaust pipe/catalytic converter assembly to the exhaust manifold flange. Install new bolts.
13. Connect the oxygen sensor electrical connectors (2).
14. Lower the vehicle.
15. Remove Engine Support Fixture (special tool #8534B, Fixture, Driveline Support).
16. Install the air cleaner housing (4).
17. Install the clean air hose (2).
18. Connect the intake air temperature (IAT) sensor electrical connector (3).
19. Install the engine cover (1).
20. Connect the negative battery cable (1).
21. Start the engine and check for leaks.

Scheme 166

The intake manifold is made of a composite material and features a dual shaft Short Runner Valve (SRV) system to maximize both low end torque and peak power. The SRV is bolted to the rear of the intake manifold and can be service separately from the manifold. The manifold uses a single plane sealing system with individual port seals and a separate PCV port seal to prevent leaks.