Exhaust System: Removal & Installation RAM Pickup 2500

REMOVAL

Scheme 10

Scheme 11

Scheme 12

1. Disconnect both negative battery cables.
2. Raise vehicle.
3. If equipped, remove skid plates.
4. Disconnect the temperature and NOx sensors.
5. Saturate bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. NOTE: Do not remove the cooling lines (2) or the Urea supply line (1) to the Diesel Exhaust Fluid injector unless replacing the injector.
6. Remove the DEF injector (3) from the SCR catalyst (1) and position aside.
7. Remove the tailpipe assembly. Refer to «TAILPIPE, Exhaust , Removal»(ref-457794-S33552551762012030200000) .
8. Remove the isolators (1).
9. Remove the flange nuts (3).
10. Remove the SCR (2).
11. Remove and discard flange gaskets.

Scheme 13

1. Install new exhaust flange gasket between the Selective Catalytic Reduction Catalyst (SCR) (2) and the extension pipe.
2. Position the SCR (2) onto flange.
3. Install flange nuts (3). Hand tighten only.
4. Install the isolators (1).
5. Install the tail pipe assembly. Refer to «TAILPIPE, Exhaust , Installation»(ref-457794-S22794608362012030200000) .
6. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.
7. Tighten flange nuts (5) to 54 N.m (40 ft. lbs.).
8. Install the DEF injector. Refer to «INJECTOR, Diesel Exhaust Fluid , Installation»(ref-457800-S08130437002012030200000) .
9. Connect temperature and NOx sensors.
10. If equipped, install skid plates.
11. Lower vehicle.
12. Connect negative battery cables.
13. Using a scan tool, perform RESET REGENERATIVE FILTER TIMERS function found under ENGINE MISC. FUNCTIONS.

Scheme 14

1. Raise and support the vehicle.
2. Saturate the clamp nuts with spray lubricant. Allow 5 minutes for penetration.
3. Remove the tailpipe assembly. Refer to «TAILPIPE, Exhaust, Removal»(ref-457794-S33552551762012030200000).
4. Loosen clamps and nuts from muffler assembly (3).
5. Remove the muffler assembly (3) from the isolators (1, 2 and 4). (Scheme 13)

Scheme 15

1. Raise and support the vehicle.
2. Remove the tailpipe assembly. Refer to «TAILPIPE, Exhaust , Removal»(ref-457794-S33552551762012030200000) .
3. Saturate the muffler exhaust clamp nut (1) located on the front of the muffler assembly (2) with spray lubricant.
4. Loosen the muffler exhaust clamp (1).
5. Remove the muffler (2) from the isolators (4) and remove from the exhaust pipe (3).

Scheme 16

1. Disconnect the battery negative cables.
2. Raise and support the vehicle.
3. Remove the muffler to tail pipe and extension pipe clamps.
4. Disconnect the muffler from the hanger isolators.
5. Disconnect the muffler from the tailpipe.
6. Disconnect the muffler from the extension pipe and remove from the vehicle.

INSTALLATION

Scheme 17

1. Install differential pressure tubing, if removed. Tighten fittings to 30 N.m (22 ft. lbs.). 1 - DIFFERENTIAL PRESSURE SENSOR 2 - REAR HOSE 3 - FRONT HOSE 4 - MOUNTING NUT 5 - MOUNTING BRACKET 6 - ELECTRICAL CONNECTOR
2. Position differential pressure sensor (1).
3. Install mounting nuts (5) and bolts. Tighten to 10 N.m (89 in. lbs.) . NOTE: Before installing, inspect both pressure hoses and make sure there is not any dip across the hoses. In cases where water is frozen, a dip across the hoses can cause condensation which can set a MIL.
4. Install hose (2) to the rear DPF tubing.
5. Install hose (3) to the front DPF tubing.
6. Connect electrical connector (6).
7. Lower vehicle.

Scheme 18

The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value.

1. Raise and support vehicle.
2. Disconnect diesel exhaust temperature sensor electrical connector (1).
3. Remove diesel exhaust temperature sensor (2).

1. Install the diesel exhaust temperature sensor (2). Tighten sensor to 30 N.m (22 ft. lbs.) .
2. Connect diesel exhaust temperature sensor electrical connector (1)
3. Lower vehicle.

1. Position the exhaust heat shield (1) to the floor pan, crossmember or bracket and install the nuts (2) or bolts. 1 - HEAT SHIELD 2 - FASTENER 3 - NUT 4 - HEAT SHIELD
2. Tighten the nuts (3) and bolts (2) to 11 N.m (97 in. lbs.). 1 - HEAT SHIELD 2 - FASTENER 3 - NUT 4 - HEAT SHIELD
3. Lower the vehicle.

Scheme 19

1. Raise and support the vehicle.
2. Saturate the clamp (3) nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Remove clamps and nuts.
4. Disconnect the exhaust tailpipe (2) from the isolator (1).
5. Remove the exhaust tailpipe (2).

Scheme 20

Scheme 21

1. Raise and support the vehicle.
2. Saturate the tailpipe tip clamp nuts (3) with spray lubricant.
3. Loosen the exhaust tailpipe tip clamp nuts (3) and remove the exhaust tailpipe tips (1).
4. Saturate the muffler exhaust clamp nuts located on the muffler assembly (3) with spray lubricant.
5. Loosen the muffler exhaust clamp nuts located on the rear muffler assembly (3).
6. Pull the exhaust tailpipes off the isolators (2) and remove the exhaust tailpipes (1) from the dual outlet muffler assembly (3).

Scheme 22

1. Disconnect the battery negative cables.
2. Raise and support the vehicle.
3. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration.
4. Disconnect the exhaust tailpipe support hanger isolators.
5. Remove the muffler-to-tailpipe clamps.
6. Remove the tailpipe from the vehicle.